Electrosynthesis of Hydrogen Peroxide at Industrial‐Level Current Density in Flow‐Cell System: Interfacial Microenvironment Regulation and Catalyst Design

TL;DR

Scientists developed a new method to efficiently produce hydrogen peroxide using electricity, which could replace traditional chemical processes.

Contribution

A surfactant-based microenvironment strategy and a boron-doped carbon catalyst enable industrial-level hydrogen peroxide electrosynthesis.

Findings

Cetyltrimethylammonium bromide surfactant improves H2O2 production rate by 1.58-fold in flow-cell reactors.

Boron-doped mesoporous carbon achieves 100% Faradic efficiency and 1.80-fold higher H2O2 production rate.

Modified interfacial microenvironment enhances 2e− ORR current density by 1.40-fold.

Abstract

Electrosynthesis of hydrogen peroxide via two‐electron oxygen reduction (2e− ORR) provides a green, sustainable, and cost‐effective alternative to anthraquinone processes. However, scaling up from laboratory evaluations to practical applications remains challenging. Herein, an interfacial microenvironment regulation strategy using cetyltrimethylammonium bromide cationic surfactant is reported to boost the hydrogen peroxide (H2O2) production rate of commercial carbon black catalysts in alkaline flow‐cell reactors. The modified interfacial microenvironment creates an ideal environment for H2O2 production, resulting in a 1.40‐fold improvement in 2e− ORR current density (from 227.0 to 320.0 mA cm−2) and a 1.58‐fold improvement in H2O2 production rate (from 137.0 to 217.8 mM L−1 h−1). Additionally, a boron‐doped mesoporous carbon catalyst is developed, demonstrating superior catalytic performance, achieving a 1.80‐fold improvement in H2O2 production rate (246.7 mM L−1 h−1) comparing with commercial carbon black. These results highlight the potential of microenvironment regulation and catalyst design for developing highly efficient and scalable H2O2 electrosynthesis system.

The present study highlights the underlying mechanism behind cationic surfactant‐modified interfacial microenvironment engineering strategy for enhanced two‐electron oxygen reduction process. The kinetic analysis demonstrates that the strengthened electric field stabilizes HO2
− intermediates, promoting efficient H2O2 production. Furthermore, a novel boron‐doped mesoporous carbon with a unique tailored porous structure is developed, achieving industrial‐level H2O2 production with 100% Faradic efficiency.© 2025 WILEY‐VCH GmbH

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