Synthetic multiscale design of nanostructured Ni single atom catalyst for superior CO2 electroreduction

[Display omitted] •Hierarchical structures with atomically dispersed Ni sites were fabricated.•Maximizing accessible active sites promotes mass transport of CO2 reactants.•Conductive substrates enhance charge transfer and intrinsic catalytic activity.•Ni-SAC-CNT achieved 400 mA cm−2 with a cathodic energetic efficiency of 83.4%.•A turnover frequency of 188,000 h−1 was attained at a low overpotential of 0.24 V. Rational design of nanoscale structures can greatly strengthen heterogeneous catalysis with the maximal utilization of active sites. Single atom catalysts (SACs) are recently emerging but a systematic design of nanostructured SAC has rarely been demonstrated yet. Here, distinct architectural structure-dependence of electrochemical CO2 reduction (CO2RR) on Ni-based SACs is presented. Starting from Ni-imidazolate coordination polymers (Ni-Im) and their supported counterparts with a carbon nanotube (CNT) and a zeolite imidazolate framework (ZIF-8), the respective derivatives, i.e. Ni-SAC, Ni-SAC-CNT, and Ni-SAC-ZIF8, are obtained after pyrolysis. The presence of substrates ultimately results in large surface porous N-doped carbon nanostructures, which facilitate the diffusion of etchants to remove undesired Ni nanoparticles effectively. The dense Ni single atomic sites contained within the nanostructure are easily accessible to CO2 reactants during CO2RR, thus promoting high utilization of active sites even at large current densities. Electro-conductive CNT substrates mediate fluent charge transfer and stimulates the intrinsic activity of catalytic sites. Consequently, operating at 400 mA cm−2, Ni-SAC-CNT attains a high faradaic efficiency of 99% toward CO at a low overpotential of 0.24 V, equivalent to a record cathodic energetic efficiency and turnover frequency of 83.4% and 439,000 h−1, respectively.