A study on solid state synthesis of electrocatalysts assisted by resonant acoustic mixing for electrochemical reactions

Abstract

Green and scalable synthesis techniques for producing highly dispersed supported metal nanocatalysts (SMNCs) are essential for industrial heterogeneous catalysis. Traditional liquid-phase methods to create nanosized SMNCs often rely on organic capping agents and low metal loading to prevent nanoparticle aggregation, yet these requirements hinder practical, large-scale production. Supported metal nanoparticles are highly sought after for their exceptional activity, stability, and reusability in electrochemical applications, making it critical to develop more efficient and scalable synthesis methods. Conventional material synthesis processes tend to consume substantial time and energy and generate waste solvents, posing environmental challenges. Mechanochemical synthesis provides a promising alternative as an environmentally friendly and scalable approach. This method, applied in fields such as metallurgy, mineral processing, and organic synthesis, has gained renewed interest in producing various nanomaterials, including organic, inorganic, and hybrid materials. Mechanochemistry proves particularly effective in creating highly porous carbons, metal-organic frameworks (MOFs), and covalent organic frameworks (COFs). Ball milling, a mechanochemical process, has also been used to produce ordered coordination polymers and mesoporous carbons. Today, mechanochemistry is recognized as a versatile and powerful tool for synthesizing a wide range of materials, particularly those used in adsorption, catalysis, and energy storage. However, there are still challenges for synthesis of SMNCs in that they have limitations; possibility of oxidation, time-consuming, aggregation of particles and limited elements, etc. To solve those limitations, this study introduces an innovative solid-state synthesis method utilizing resonant acoustic mixing (RAM) with ball, a technique that enables easy, eco-friendly metal nanoparticle production without organic solvents. RAM employs acoustic energy to facilitate substance mixing, using ultrasound waves to increase particle movement and enhance blending efficiency. Known for its adaptability and energy efficiency, RAM supports improved product quality, operational efficiency, and reduced manufacturing costs, making it highly suitable for sustainable, large-scale applications.