2.1 Electrode material screening and electrode preparation
The catalytic behavior of six metal eletrodes (Cu, Pb, Ni, Fe, Sn and Ti) was investigated by LSV in 1.0 M KOH solution (Fig. 1a). We note that when the voltage is 0.7 V vs. Hg/HgO, the oxidation current of Cu and Fe electrodes increases significantly, while Pb and Ni demonstrate the same onset potentials of 0.8 V vs. Hg/HgO. However, no oxygen evolution peak is found when Sn and Ti are used as anodes, indicating that the two electrodes are inert in electro-oxidation oxygen evolution. After addition of FF, the onset potential can be seen to be shifted to the positive direction distinctly for Cu, Ni and Fe electrodes (Fig. 1b), indicating that FF is more easily oxidated than water. A distinctive waves was observed on Ni electrode, which suggests a better performance of Ni in the oxidation of FF than Cu and Fe electrodes. In view of this, Ni was chosen as the basic catalysts in this work.
According to the above results and good electrocatalytic activity and stability for the oxides of nickel and cobalt in alkaline solution [17], a mixture of x M Ni(NO3)2 and (0.1-x) M Co(NO3)2 was used as the electrolyte and nickel foam as the anode to prepare NixCo1−xOy electrode by electrodeposition. Figure 2a shows the relationship between the ratio of Ni2+/(Ni2++Co2+) in the electrolyte and the content of Ni (x) on the surface of the prepared electrode material (determined by EDS). It can be seen that the Ni atom content on NixCo1−xOy electrode considerably increases with the rise in Ni2+ ratio. In addition, the ratio of Ni2+ to Co2+ in the electrolyte is different from that of the corresponding elements on the surface of the prepared electrode, which is mainly caused by the difference in the rate of formation of Co(OH)2 and Ni(OH)2 during the deposition process.
The Faraday efficiency and selectivity of the product were obtained after electrooxidation for 40 min using the Ni-Co oxide electrode (NixCo1−xOy) prepared by electrodeposition method in 1 M KOH containing 20 mM FF at 50oC and 1.0 V vs. Hg/HgO and the results were showed in Fig. 2b. It shows that when only Co2+ is contained in the electrolyte, the effect of the oxide electrode Ni0Co1Oy on the electrooxidation of FF is relatively poor (FE 68.2% and selectivity 71.5%). FE and selectivity of FA then increased significantly to 95.4% and 99.6% with the increase of Ni content from 0 to 0.48, then declined at Ni content of 1. Therefore, the electrode sample with Ni content of 0.48 was chosed as the anode.
2.3 Characterization of electrode structure of NixCo1−xOy
The XRD measurements of NixCo1−xOy were performed and the diffractograms are depicted in Fig. 3a. Intense Ni diffraction peaks at 44.5°(111), 51.8°(200) and 76.4°(220) (PDF 65-2865) can be observed in all NixCo1−xOy electrodes. When the content of Ni x < 0.48, only Co3O4 diffraction patterns (PDF 43-1003) can be observed, which is consistent with the literature report [18]. Meanwhile slight phase offset of Co3O4 diffraction patterns can be attributed to slight changes in lattice parameters during the formation of Ni and Co oxides [19]. The intensity of diffraction peaks of Co3O4 decrease and gradually disappeare with increase of Ni content, even only NiO cubic structure (PDF 65-2901) exist on the electrode surface when the Ni content is higher than 65.0%.
The surface chemical states of NixCo1−xOy (sample 0.48) was investigated with XPS analysis, and the results are displayed in Fig. 3. The general XPS survey (Fig. 3b) of the bimetallic oxide electrode demonstrates that elements the element in electrode are mainly composed of Co, Ni, O and C. Figure 3c demonstrates the Ni 2p3/2 and Ni 2p1/2 spin-orbital splitting at binding energy of 856.2 eV and 873.6 eV, meanwhile two vibrational satellite peaks appeared at 862.8 eV and 880.3 eV, proving the existence of Ni2+ [20]. The result of high-resolution Co 2p spectra at 781.3 eV and 797.1 eV in combination of the satellite peaks at 785.1 eV and 802.1 eV can be attributed to the presence of Co2+ (Fig. 3d). The broad peak at 775.4 eV indicates the presence of Co3+ [21]. The O1s spectrum at 524.9 eV and 531.6 eV in Fig. 3e can be attributed to the typical metal oxygen bond and the binding of oxygen to nearby O vacancies, respectively [22]. From the above analysis, we can conclude that NiO and Co3O4 coexist on the surface of NixCo1−xOy (sample 0.48), which is consistent with the results of XRD.
SEM images of Ni-Co oxide electrode with Ni content of 0.48 (Ni0.48Co0.36O0.16), obtained by electrodeposition in 0.6 M Ni (NO3)2 and 0.4 M Co(NO3)2, are showed in Fig. 4. A porous and smooth skeleton structure can be seen in commercially available nickel foam (Fig. 4a). After electrodeposition, a flower-like porous structure (Fig. 4b) was covered on a nickel foam. This special morphology is beneficial for increasing surface area of the oxide electrode and maintains good electrical continuity between the Ni atom and the Co3O4 and NiO crystals. The elemental distribution of this oxide electrode is studied with EDS and element mapping analysis. The result in Fig. 4c indicates that Co and O contents are 0.35 and 0.16, respectively.
2.4 Electrochemical characteristics of Ni0.48Co0.36O0.16 electrode
The electrochemical performance of Ni0.48Co0.36O0.16 electrode for the oxidation of FF was investigated by LSV in an H-type electrolytic cell. For electrochemical oxidation of most organic compounds in water, the oxygen evolution reaction is the major competing reaction [23]. Therefore, it is necessary to check the oxidation current in the absence of organic matter. The current at the prepared Ni0.48Co0.36O0.16 in the electrolysis of water was recorded in the absence of FF, which can be attributed to the generation of O2 (Fig. 5a). It was found that the current density of Ni0.48Co0.36O0.16 electrode at 0.7 V vs Hg/HgO increases and violent O2 bubbles can be observed on the electrode surface. The onset potential in Fig. 5b can be seen to be shifted to the positive direction (0.6 V vs Hg/HgO for Ni0.48Co0.36O0.16 electrode after the addition of FF, indicating that FF is more easily oxidized than water. A distinctive cathodic curve was observed, which suggests that Ni0.48Co0.36O0.16 electrode exhibits excellent catalytic performance in the oxidation reaction of FF.
A semi-circular Nyquist diagram in the high frequency region for Ni0.48Co0.36O0.16 electrode compared with the Ni foam in Fig. 5b, indicating that the prepared electrode material has a smaller contact resistance (Rct). The EIS values of Ni and Ni0.48Co0.36O0.16 electrodes were 13.1Ω and 6.6Ω, respectively. It can be attributed to the flower-like porous structure of Ni-Co oxides, which enhances the exchange of electrons and accelerates the electrochemical reaction process, agreeing with the results of electrooxidation (Fig. 2b). The smaller Rct of Ni0.48Co0.36O0.16 electrode can be attributed to the intrinsic metal properties reflected by the continuous cross-linking of Ni-Co or Ni-Ni bonds in the Ni-Co oxide, which means that the bimetallic oxide has higher conductivity.
2.5 Electrooxidation of FF to FA over Ni0.48Co0.36O0.16 electrode
FF oxidation was performed at 50 oC using Ni0.48Co0.36O0.16 electrode as the anode in 1 M KOH solution containing 20 mM FF. The region of potential used in this work is chosen based on the results of LSVs from 0.8 V to 1.2 V vs. Hg/HgO. As shown in Fig. 6a, FE of product FA are 82.3% at 0.8 V vs. Hg/HgO, then increased to 95.4% at 1.0 V vs. Hg/HgO and declined to 65.1% at 1.2 V vs. Hg/HgO, while the selectivity of FA remained basically unchanged. This is mainly due to the poor Oads on the electrode surface when less than optimal potential, leading to the reduced binding probability between FF and Oads and then low FF conversion. The higher potential, the more Oads on electrode surface. However, the competitive oxygen evolution reaction (OER) will become more advantageous when the potential is further increased [24].
The effect of reaction temperature on electrooxidation of FF was studied at 1.0 V vs. Hg/HgO for 40 min and the results were shown in Fig. 6b. When the temperature is relatively low (such as 30oC), the oxidation reaction rate is low, resulting in low FF conversion, FA selectivity and FE, which are 42.7%, 75.8% and 85.9%, respectively. With the increase of reaction temperature, FF conversion was accelerated and the selectivity and FE of FA were gradually reduced. However, when the temperature exceeded 50 oC, FE and selectivity of FA were decreased, indicating that OER rate on the anode surface was elevated and more by-products were produced when the temperature was high [24].
The higher substrate concentration is usually the better for commercialized process when considering the energy consumption and efficiency. The effect of substrate concentration on the electrooxidation of FF was investigated at 1.0 V vs. Hg/HgO and 50 oC. As can be seen in Fig. 6c that FE of FA reached the maximum when the initial concentration of FF was 20 mM. Due to the limited active sites of the electrode, the proportion of electrooxidation reactions decreases, leading to a gradually depressed conversion when the FF concentration is high.
2.6 Discussion on Electrooxidation mechanism of Ni0.48Co0.36O0.16 electrode
According to the above observations, the possible mechanism of electrooxidation of FF to FA over Ni0.48Co0.36O0.16 electrode is proposed. It can be seen from Fig. 5a that O2 evolution on the Ni-Co oxide electrode did not initiate until 0.7 V vs. Hg/HgO. Therefore, in the potential region of 0.6 V vs. Hg/HgO < E < 0.7 V vs. Hg/HgO, the oxidation of FF have little to do with OER. However, FE of the catalytic oxidation of FF to FA in this region is slightly lower, indicating that the oxidation reaction of OH− may occur on the electrode surface, which leading to the formation of little amount of OH radicals or other oxide species and then causing current consumption. For 0.7 V vs. Hg/HgO ≤ E < 1.0 V vs. Hg/HgO, the adsorption of OH− on the electrode surface improved greatly due to the increase of potential, so that FF adsorbed on the electrode surface was rapidly oxidized into FA. The mechanism of electrooxidation of FF on Ni-Co oxide electrode is shown in Fig. 6d.
G.G. Botte and coworkers studied the electrooxidation of urea on NiOOH by in-situ surface-enhanced Raman spectroscopy and found that NiOOH was reduced to Ni(OH)2 during electrooxidation process [25]. A plausible mechanism can be understood according to the electro-oxidation of urea on NiCo2O4 electrode. First, after adsorption of OH−, both Ni2+ and Co2+ are oxidized to Ni3+ and Co3+, respectively. At high potential, Co3+ is further oxidized to Co4+. The reaction process is as follows:
$$\text{N}\text{i}\text{O}+{\text{O}\text{H}}^{-}\rightleftharpoons \text{N}\text{i}\text{O}\text{O}\text{H}+{e}^{-}$$
1
$$\text{C}\text{o}\text{O}+{\text{O}\text{H}}^{-}\rightleftharpoons \text{C}\text{o}\text{O}\text{O}\text{H}+{e}^{-}$$
2
$$\text{C}\text{o}\text{O}\text{O}\text{H}+{\text{O}\text{H}}^{-}\rightleftharpoons \text{C}\text{o}{\text{O}}_{2}+{\text{H}}_{2}\text{O}+{e}^{-}$$
3
$${ \text{C}\text{o}}_{2}{\text{O}}_{3}+{2\text{O}\text{H}}^{-}\rightleftharpoons 2\text{C}\text{o}{\text{O}}_{2}+{\text{H}}_{2}\text{O}+2{e}^{-}$$
4
Ni3+ on the surface of electrode adsorbs OH− by electrooxidation process, which is reduced to Ni2+ and meanwhile HO• is formed. Afterward, Ni2+ on the electrode could be oxidized to form Ni3+ again. The formed HO• is further added to the aldehyde group on FF molecule to form alkoxy radical I, and then α-hydroxyl carbon radical II is obtained by 1, 2-hydrogen migration reaction (1, 2-HAT). After that, the α-hydroxyl carbon radical II on Ni3+ undergoes a single electron transfer to form product III, which further is removed a molecule of water under alkaline conditions to obtain product FA. During the conversion of intermediate II into III, Ni3+ was reduced to Ni2+, which then was oxidized to re-form Ni3+, realizing the cyclic regeneration of the electrode. Similarly, Co ions are also involved in the electrooxidation of FF in the form of Co4+/Co3+ [26]. The difference is that Co has a better affinity with oxygen, so this process can be strengthened.
In higher voltage range (≥ 1.0 V vs. Hg/HgO), OER is highly competitive with the FF electrooxidation on surface of electrode, resulting in the declining of FE for FA (Fig. 6a). However, the selectivity for FA remains high since there is few side reactions in the conversion process of FF.