Rapid hydrogen evolution from NaBH₄ methanolysis using Co–Fe LDH: catalytic efficiency, kinetic modeling, and recyclability

This work explores the catalytic performance of Co–Fe layered double hydroxide (LDH) in the methanolysis of sodium borohydride (NaBH₄) for hydrogen production. A systematic investigation was carried out to assess the influence of temperature (20–50 °C), catalyst loading (133–1333 ppm), methanol volume (5–20 mL), and NaBH₄ concentration (0.176–0.881 M) on the hydrogen generation rate (HGR). The Co–Fe LDH catalyst was synthesized through co-precipitation and thoroughly characterized via X-ray diffraction (XRD), scanning electron microscopy with energy-dispersive X-ray spectroscopy (SEM–EDX), elemental mapping, Fourier-transform infrared spectroscopy (FT-IR), and Brunauer–Emmett–Teller (BET) techniques. Kinetic evolutions revealed a power-law rate model with a reaction order of 2.25 and an activation energy of 8.47 kJ mol⁻¹. Additional kinetic modeling using Michaelis–Menten and Langmuir–Hinshelwood approaches yielded activation energies of 10.61 and 10.08 kJ mol⁻¹, respectively. Thermodynamic analysis indicated favorable reaction conditions, with calculated enthalpy and entropy values of 14.20 kJ mol⁻¹ and 39.45 kJ mol⁻¹ K⁻¹, and a progressive decrease in Gibbs free energy from − 11,543.6 to − 12,727.0 J mol⁻¹. The optimum HGR value of 584.43 L min⁻¹ gcat⁻¹ was achieved at 30 °C using 133 ppm catalyst, 0.528 M NaBH₄, and 15 mL methanol. Under identical conditions, except for a higher NaBH₄ concentration of 0.881 M, the maximum HGR increased to 776.40 L min⁻¹ gcat⁻¹. After five successive reaction cycles, the catalyst preserved 91% of its initial activity, confirming its reusability and structural stability. These results underscore the potential of Co–Fe LDH as a low-cost, eco-friendly catalyst for rapid hydrogen generation, with promising implications for future enhancements.