On-chip catalytic combustion of hydrogen using Pt and Ru quantum-crystallites on functionalized SiO2 aerogels

Abstract Hydrogen offers a high-energy, carbon-free fuel alternative; however, conventional flame-based hydrogen combustion poses challenges, including NO x emissions and the risk of flame flashback. Catalytic combustion provides a safer, low-temperature approach to hydrogen utilization, but realizing it within compact, integrated systems have remained a significant challenge. This study introduces an innovative approach to hydrogen catalytic combustion by directly integrating noble metal single quantum-crystallites of Pt and Ru within a porous silica aerogel matrix embedded in a silicon chip. This configuration enables deep nanoparticle ( np ) penetration throughout the aerogel network, maximizing the catalytic surface area and providing efficient on-chip hydrogen combustion. The np @aerogel systems are systematically synthesized and incorporated within silicon chips equipped with a polyimide membrane and Pt thermal structures. This unique setup allows for direct, real-time characterization of hydrogen catalytic combustion by measuring resistance changes in an embedded thermistor. The Pt@SiO₂ system demonstrates a rapid and substantial temperature increase of up to 40 K upon hydrogen exposure, independent of both preheating and Pt concentration, underscoring its robustness and adaptability for micro-scale hydrogen combustion. This on-chip integration of np @aerogel catalysts marks a significant advancement for hydrogen-based energy applications, offering a compact, scalable platform for efficient catalytic combustion. This approach opens pathways for applications in thermoelectric generators and other micro-reactor technologies where controlled, localized energy generation is critical.