Enhanced hydrogen peroxide electrosynthesis and prolonged lifespan by preparing gas diffusion electrode via electrodeposition of CB on Ni foam

In-situ hydrogen peroxide (H2O2) production is pivotal for the effective implementation of the electro-Fenton reaction. However, challenges such as low H2O2 yields and a short electrode lifespan have hindered its application. This study introduced a novel gas diffusion electrode (GDE), the CB(E)-Ni foam(GDE), fabricated through a combination of carbon black (CB) electrodeposition and polytetrafluoroethylene (PTFE) impregnation techniques. Comprehensive physicochemical characterizations and electrochemical evaluations indicated that CB was more uniformly dispersed across the Ni foam, enhancing its electrochemical activity. When employed as a cathode, the CB(E)-Ni foam(GDE) demonstrated superior two-electron oxygen reduction reaction (2e- ORR) capabilities, marked by increased oxygen utilization and reduced energy demands, achieving a remarkable H2O2 concentration of 897.73 mg/L after 120 min. This performance significantly outpaces that of traditional GDEs. The unique structure of the CB(E)-Ni foam(GDE) not only prolonged electrode life by preventing rapid deactivation but also boosted H2O2 production and oxygen efficiency by 31.78% and 31.79%, respectively, when compared to a standard non-GDE configuration. In practical applications, the CB(E)-Ni foam(GDE) demonstrated utility by facilitating an 84.1% degradation rate of fulvic acid over 120 min within a homogeneous electro-Fenton system, highlighting its potential for environmental remediation.