High-performance NiCoP/NF electrocatalysts for coupled methanol upgrading and hydrogen production

•NiCoP/NF catalyst achieves 131 mV overpotential at 100 mA cm−2 for HER.•Methanol oxidation on NiCoP/NF shows high activity with 100 mA cm−2 at 1.36 V.•Coupled MOR||HER system requires only 1.52 V for 50 mA cm−2, saving 300 mV energy.•MOR||HER system offers a net profit of $159.4 kmol−1, over twice that of OER||HER.•Methanol addition enhances both energy efficiency and economic profitability. Hydrogen (H2) production is a promising clean energy solution, yet conventional methods remain costly and energy-intensive, with the challenge of developing efficient electrocatalysts. In this work, a bifunctional NiCoP catalyst was synthesized on nickel foam (NF) through a straightforward electrodeposition-phosphorization method, designed to lower energy consumption and increase profitability. The NiCoP/NF catalyst demonstrates remarkable efficiency in both the hydrogen evolution reaction (HER) and methanol oxidation reaction (MOR) in alkaline conditions. It achieves a low overpotential of 131 mV at 100 mA cm−2 for HER, while reaching a current density of 100 mA cm−2 at 1.36 V for MOR. Importantly, in the coupled MOR||HER system, the catalyst required only 1.52 V to deliver 50 mA cm−2, which is 300 mV lower than traditional OER||HER systems, translating to a 16.5 % reduction in energy consumption. From an economic perspective, the MOR combined with HER produces the high-value product formic acid, yielding a net profit of $725 per ton of H2, compared to a $128 loss for traditional OER||HER systems, demonstrating the significant economic benefit of the MOR||HER system. These findings suggest that the NiCoP/NF bifunctional catalyst not only enhances energy efficiency but also offers economic benefits by producing hydrogen and valuable chemicals, making it a promising candidate for sustainable energy applications.