Highly Active NiRu/C Cathode Catalyst Synthesized by Displacement Reaction for Anion Exchange Membrane Water Electrolysis

Anion exchange membrane water electrolysis (AEMWE) is highly promising for cost-effective green hydrogen production due to its basic operating conditions facilitating the use of non-noble catalysts. While non-noble Ni/Fe-based catalysts are utilized at the anode, its cathode catalyst still requires precious Pt. Due to the high cost of Pt and the sluggish hydrogen evolution reaction (HER) at the cathode in basic conditions, developing alternative catalysts to replace Pt is highly important. Here, a synthesis procedure for a Ru-based catalyst is reported and its high activity toward the HER in alkaline media is demonstrated in both half-cell and single-cell tests. The catalyst is synthesized in a two-step approach. A highly dispersed Ni catalyst is prepared on carbon support in the first step. In the second step, Ru is deposited on its surface using a galvanic displacement reaction. The uniqueness of this method is that Ru is deposited over the entire electrically conductive surface, resulting in an isotropic and homogeneous Ru distribution within the catalyst powder. It is demonstrated that this material remarkably outperforms state-of-the-art Pt/C catalysts in half-cell and single-cell tests. The single cell only requires 1.73 V at 1 A cm^-2 with an overall PGM content of 0.05 mg cm^-2.