Oxygen evolution catalyst compositions, forms, and manufacturing of the same

Abstract

A catalyst for an electrode of an electrolytic cell, comprising a metal-containing substance having at least two of the three elements Nickel (Ni), Iron (Fe), and Chromium (Cr).

1 . A catalyst for an electrode of an electrolytic cell, comprising:
 a metal containing substance having at least two of the three elements Nickel (Ni), Iron (Fe), and Chromium (Cr).   
     
     
         2 . The catalyst of  claim 1 ,
 wherein the metal containing substance comprises 50-90 wt % Ni, 0-40 wt % Fe, 10-50 wt % Cr,   wherein weight percentages (wt %) of Ni, Fe, and Cr in the metal containing substance are defined relative to one another and are independent of the presence or concentration of other elements or materials in the metal containing substance.   
     
     
         3 . The catalyst of  claim 1 ,
 wherein the metal containing substance comprises 0-45 wt % Ni, and 40-85 wt % Fe, 15-60 wt % Cr,   wherein weight percentages (wt %) of Ni, Fe, and Cr in the metal containing substance are defined relative to one another and are independent of the presence or concentration of other elements or materials in the metal containing substance.   
     
     
         4 . The catalyst of  claim 2 ,
 wherein the metal containing substance is contained within a region in the NiFeCr parameter space bounded by a triangular perimeter having vertices at (90 wt % Ni, 0 wt % Fe, 10 wt % Cr), (50 wt % Ni, 0 wt % Fe, 50 wt % Cr), and (50 wt % Ni, 40 wt % Fe, 10 wt % Cr),   wherein weight percentages (wt %) of Ni, Fe, and Cr in the metal containing substance are defined relative to one another and are independent of the presence or concentration of other elements or materials in the metal containing substance.   
     
     
         5 . The catalyst of  claim 3 ,
 wherein the metal containing substance is contained within a region in the NiFeCr parameter space bounded by a triangular perimeter having vertices at (45 wt % Ni, 40 wt % Fe, 15 wt % Cr), (0 wt % Ni, 40 wt % Fe, 60 wt % Cr), and (0 wt % Ni, 85 wt % Fe, 15 wt % Cr).   
     
     
         6 . The catalyst of  claim 1 ,
 wherein the catalyst comprises 51-100 wt % the metal containing substance.   
     
     
         7 . An electrode for an electrolytic cell, comprising the catalyst of  claim 1 . 
     
     
         8 . The electrode of  claim 7 ,
 wherein the electrode comprises a substrate layer and a catalyst layer, wherein the catalyst layer comprises the catalyst for an electrode of an electrolytic cell, comprising a metal containing substance having at least two of the three elements Nickel (Ni), Iron (Fe), and Chromium (Cr).   
     
     
         9 . The electrode of  claim 8 ,
 wherein the substrate layer comprises an electrically conductive and porous media.   
     
     
         10 . The electrode of  claim 9 ,
 wherein the substrate layer comprises a metallic felt, woven mesh, sintered plate, foam, or expanded metal.   
     
     
         11 . The electrode of  claim 8 ,
 wherein the catalyst layer comprises an ink comprising a catalyst powder having the catalyst for an electrode of an electrolytic cell, comprising a metal containing substance having at least two of the three elements Nickel (Ni), Iron (Fe), and Chromium (Cr), and optionally contains ionomers and binders.   
     
     
         12 . The electrode of  claim 8 ,
 wherein the catalyst layer comprises an electroplated layer containing the catalyst for an electrode of an electrolytic cell, comprising a metal containing substance having at least two of the three elements Nickel (Ni), Iron (Fe), and Chromium (Cr).   
     
     
         13 . The electrode of  claim 8 ,
 wherein the catalyst layer comprises a layer of the substrate containing the catalyst for an electrode of an electrolytic cell, comprising a metal containing substance having at least two of the three elements Nickel (Ni), Iron (Fe), and Chromium (Cr), which has been impregnated via a chemical bath.   
     
     
         14 . The electrode of  claim 8 ,
 wherein the catalyst layer comprises a layer of the substrate containing the catalyst for an electrode of an electrolytic cell, comprising a metal containing substance having at least two of the three elements Nickel (Ni), Iron (Fe), and Chromium (Cr), which has been grown on the substrate via thermochemical growth.   
     
     
         15 . The electrode of  claim 8 ,
 wherein the catalyst layer is a naturally forming surface layer of the substrate layer.   
     
     
         16 . The electrode of  claim 15 ,
 wherein the substrate layer comprises a material having 50-90 wt % Ni, 0-40 wt % Fe, 10-50 wt % Cr,   wherein weight percentages (wt %) of Ni, Fe, and Cr in the metal containing substance are defined relative to one another and are independent of the presence or concentration of other elements or materials in the metal containing substance.   
     
     
         17 . The electrode of  claim 15 ,
 wherein the substrate layer comprises a material having 0-45 wt % Ni, and 40-85 wt % Fe, 15-60 wt % Cr,   wherein weight percentages (wt %) of Ni, Fe, and Cr in the metal containing substance are defined relative to one another and are independent of the presence or concentration of other elements or materials in the metal containing substance.   
     
     
         18 . The electrode of  claim 16 ,
 wherein the substrate layer comprises a material within a region in the NiFeCr parameter space bounded by a triangular perimeter having vertices at (90 wt % Ni, 0 wt % Fe, 10 wt % Cr), (50 wt % Ni, 0 wt % Fe, 50 wt % Cr), and (50 wt % Ni, 40 wt % Fe, 10 wt % Cr),   wherein weight percentages (wt %) of Ni, Fe, and Cr in the metal containing substance are defined relative to one another and are independent of the presence or concentration of other elements or materials in the metal containing substance.   
     
     
         19 . The electrode of  claim 17 ,
 wherein the substrate layer comprises a material within a region in the NiFeCr parameter space bounded by a triangular perimeter having vertices at (45 wt % Ni, 40 wt % Fe, 15 wt % Cr), (0 wt % Ni, 40 wt % Fe, 60 wt % Cr), and (0 wt % Ni, 85 wt % Fe, 15 wt % Cr),   wherein weight percentages (wt %) of Ni, Fe, and Cr in the metal containing substance are defined relative to one another and are independent of the presence or concentration of other elements or materials in the metal containing substance.   
     
     
         20 . The electrode of  claim 15 ,
 wherein the substrate layer comprises a material selected from the group consisting of Inconel 601, Inconel 625, Hastelloy C-267, Hastelloy C-2000, Nichrome80, Nichrome60, a Fe (72%)Cr(28%) alloy, and Incoloy 25-6Mo.   
     
     
         21 . An electrolytic cell comprising an electrode of  claim 7 . 
     
     
         22 . The electrolytic cell of  claim 21 , wherein the cell performs the oxygen evolution reaction at one of its electrodes. 
     
     
         23 . The electrolytic cell of  claim 21 , wherein the cell performs water electrolysis. 
     
     
         24 . An electrolysis stack comprising an electrolytic cell of  claim 21 . 
     
     
         25 . A method for preparing a catalyst composition for an electrode of an electrolytic cell, comprising:
 forming a catalyst ink by preparing a solvent, adding a powder comprising the catalyst of  claim 1 , and optionally adding ionomers and/or binders,   applying the catalyst ink to an electrode.   
     
     
         26 . The method of  claim 25 ,
 wherein the catalyst ink is applied to the electrode via a slot-die coating operation.   
     
     
         27 . The method of  claim 25 ,
 wherein the catalyst ink is applied to the electrode via a spray coating operation.   
     
     
         28 . A method for preparing a catalyst composition for an electrode of an electrolytic cell, comprising:
 preparing an aqueous or non-aqueous metal ion solution containing the catalyst of  claim 1 ,   applying the catalyst via chemical bath impregnation, electroplating, or thermochemical growth.   
     
     
         29 . A method for preparing a catalyst composition for an electrode of an electrolytic cell, comprising:
 providing an electrode substrate having a naturally occurring catalyst layer.   
     
     
         30 . The method of  claim 29 , wherein the electrode substrate comprises a material having (a) 50-90 wt % Ni, 0-40 wt % Fe, 10-50 wt % Cr, or (b) 0-45 wt % Ni, and 40-85 wt % Fe, 15-60 wt % Cr,
 wherein weight percentages (wt %) of Ni, Fe, and Cr in the metal containing substance are defined relative to one another and are independent of the presence or concentration of other elements or materials in the metal containing substance.