A CuNi Alloy–Carbon Layer Core–Shell Catalyst for Highly Efficient Conversion of Aqueous Formaldehyde to Hydrogen at Room Temperature

A copper (Cu) material is catalytically active for formaldehyde (HCHO) dehydrogenation to produce H2, but the unsatisfactory efficiency and easy corrosion hinder its practical application. Alloying with other metals and coating a carbon layer outside are recognized as effective strategies to improve the catalytic activity and the long-term durability of nonprecious metal catalysts. Here, highly dispersed CuNi alloy–carbon layer core–shell nanoparticles (CuNi@C) have been developed as a robust catalyst for efficient H2 generation from HCHO aqueous solution at room temperature. Under the optimized reaction conditions, the CuNi@C catalyst exhibits a H2 evolution rate of 110.98 mmol·h–1·g–1, which is 1.5 and 4.9 times higher than those of Cu@C and Ni@C, respectively, which ranks top among the reported nonprecious metal catalysts for catalytic HCHO reforming at room temperature to date. Furthermore, CuNi@C also displays excellent stability toward the catalytic HCHO reforming into H2 in tap water owing to the well-constructed carbon sheath protecting CuNi nanocrystals from oxidation in an alkaline medium. Combined with density functional theory calculations, the superior catalytic efficiency of CuNi@C for H2 generation results from the synergistic contribution between the massive active species from HCHO decomposition on the Cu sites and the remarkable H2 evolution activity on Ni sites. The improved performance of CuNi@C highlights the enormous potential of advancing noble-metal-free nanoalloys as cost-effective and recyclable catalysts for energy recovery from industrial HCHO wastewater.