Palladium-Functionalized Nanostructured Nickel–Cobalt Oxide as Alternative Catalyst for Hydrogen Sensing Using Pellistors

To meet today’s requirements, new active catalysts with reduced noble metal content are needed for hydrogen sensing. A palladium-functionalized nanostructured Ni0.5Co2.5O4 catalyst with a total Pd content of 4.2 wt% was synthesized by coprecipitation to obtain catalysts with an advantageous sheet-like morphology and surface defects. Due to the synthesis method and the reducible nature of Ni0.5Co2.5O4 enabling strong metal-metal oxide interactions, the palladium was highly distributed over the metal oxide surface, as determined using scanning transmission electron microscopy and energy-dispersive X-ray investigations. The catalyst tested in planar pellistor sensors showed high sensitivity to hydrogen in the concentration range below the lower flammability limit (LFL). At 400 °C and in dry air, a sensor response of 109 mV/10,000 ppm hydrogen (25% of LFL) was achieved. The sensor signal was 4.6-times higher than the signal of pristine Ni0.5Co2.5O4 (24.6 mV/10,000 ppm). Under humid conditions, the sensor responses were reduced by ~10% for Pd-functionalized Ni0.5Co2.5O4 and by ~27% for Ni0.5Co2.5O4. The different cross-sensitivities of both catalysts to water are attributed to different activation mechanisms of hydrogen. The combination of high sensor sensitivity to hydrogen and high signal stability over time, as well as low cross-sensitivity to humidity, make the catalyst promising for further development steps.