Energy-saving and product-oriented hydrogen peroxide electrosynthesis enabled by electrochemistry pairing and product engineering

Hydrogen peroxide (H2O2) electrosynthesis through oxygen reduction reaction (ORR) is drawing worldwide attention, whereas suffering seriously from the sluggish oxygen evolution reaction (OER) and the difficult extraction of thermodynamically unstable H2O2. Herein, we present an electrosynthesis protocol involving coupling ORR-to-H2O2 with waste polyethylene terephthalate (PET) upcycling and the first H2O2 conversion strategy. Ni-Mn bimetal- and onion carbon-based catalysts are designed to catalyze ORR-to-H2O2 and ethylene glycol electrooxidation with the Faradaic efficiency of 97.5% (H2O2) and 93.0% (formate). This electrolysis system runs successfully at only 0.927 V to achieve an industrial-scale current density of 400 mA cm−2, surpassing all reported H2O2 electrosynthesis systems. H2O2 product is upgraded through two downstream routes of converting H2O2 into sodium perborate and dibenzoyl peroxide. Techno-economic evolution highlights the high gross profit of the ORR || PET upcycling protocol over HER || PET upcycling and ORR || OER. This work provides an energy-saving methodology for the electrosynthesis of H2O2 and other chemicals. The development of robust catalysts that could work under industrial-scale current densities bring promise but also a challenge for hydrogen production. Here, the authors report an in situ activation method to produce ferromagnetic ruthenium clusters that can catalyze the hydrogen evolution reaction at high current densities.