Ultra-low Pt loading catalyst layers prepared by pulse electrochemical deposition for PEM fuel cells

Electrospray Deposition of Catalyst Layers with Ultralow Pt Loading for Cost-Effective H2 Production by SO2 Electrolysis

The hybrid sulfur (HyS) thermochemical cycle has been considered as a promising approach for the massive production of clean hydrogen without CO2 emissions. The key to advance this technology and to enhance the cycle efficiency is to improve the electrocatalytic oxidation of SO2, which is the pivotal reaction within this process. Hence, this paper investigates, for the first time, the effect of electrospray and air gun deposition techniques and the influence of very low Pt loadings (<0.3 mg Pt/cm2) on catalyst durability and activity. The variation of electrochemical active surface area (ECSA) with the number of cycles demonstrates the significant impact of the electrode fabrication method and catalyst loading on the catalyst durability with considerable ECSA values for electrosprayed electrodes. Electrodes prepared with low platinum loadings (0.05 mg Pt/cm2) exhibit elevated catalyst activity and stability under sulfuric acid conditions and maintain a crucial current density after 5 h of electrolysis. This work extends the understanding of the SO2-depolarized electrolysis (SDE) process and gives suggestions for further improvements in the catalyst layer fabrication, which provides potential support for the large-scale research and application of the HyS cycle.

Preparation, Performance and Challenges of Catalyst Layer for Proton Exchange Membrane Fuel Cell

In this paper, the composition, function and structure of the catalyst layer (CL) of a proton exchange membrane fuel cell (PEMFC) are summarized. The hydrogen reduction reaction (HOR) and oxygen reduction reaction (ORR) processes and their mechanisms and the main interfaces of CL (PEM|CL and CL|MPL) are described briefly. The process of mass transfer (hydrogen, oxygen and water), proton and electron transfer in MEA are described in detail, including their influencing factors. The failure mechanism of CL (Pt particles, CL crack, CL flooding, etc.) and the degradation mechanism of the main components in CL are studied. On the basis of the existing problems, a structure optimization strategy for a high-performance CL is proposed. The commonly used preparation processes of CL are introduced. Based on the classical drying theory, the drying process of a wet CL is explained. Finally, the research direction and future challenges of CL are pointed out, hoping to provide a new perspective for the design and selection of CL materials and preparation equipment.

A Facile and Scalable Route to the Preparation of Catalytic Membranes with in Situ Synthesized Supramolecular Dendrimer Particle Hosts for Pt(0) Nanoparticles Using a Low-Generation PAMAM Dendrimer (G1-NH2) as Precursor

Since the first reports of Cu dendrimer-encapsulated nanoparticles (DENs) published in 1998, the dendrimer-templating method has become the best and most versatile method for preparing ultrafine metallic and bimetallic nanoparticles (1-3 nm) with well-defined compositions, high catalytic activity, and tunable selectivity. However, DENs have remained for the most part model systems with limited prospects for scale up and integration into high-performance and reusable catalytic modules and systems for industrial-scale applications. Here, we describe a facile and scalable route to the preparation of catalytic polyvinylidene fluoride (PVDF) membranes with in situ synthesized supramolecular dendrimer particles (SDPs) that can serve as hosts and containers for Pt(0) nanoparticles (2-3 nm). These new catalytic membranes were prepared using a reactive encapsulation process similar to that utilized to prepare Pt DENs by addition of a reducing agent (sodium borohydride) to aqueous complexes of Pt(II) + G4-OH/G6-OH polyamidoamine (PAMAM) dendrimers. However, the SDPs (2.4 μm average diameter) of our new mixed matrix PVDF-PAMAM membranes were synthesized in the dope dispersion without purification prior to film casting using (i) a low-generation PAMAM dendrimer (G1-NH₂) as particle precursor and (ii) epichlorohydrin, an inexpensive functional reagent, as cross-linker. In addition, the membrane PAMAM particles contain secondary amine groups (∼1.9 mequiv per gram of dry membrane), which are more basic and thus have higher Pt binding affinity than the tertiary amine groups of the G4-OH and G6-OH PAMAM dendrimers. Proof-of-concept experiments show that our new PVDF-PAMAM-G1-Pt/membranes can serve as highly active and reusable catalysts for the hydrogenation of alkenes and alkynes to the corresponding alkanes using (i) H₂ at room temperature and a pressure of 1 bar and (ii) low catalyst loadings of ∼1.4-1.6 mg of Pt. Using cyclohexene as model substrate, we observed near quantitative conversion to cyclohexane (∼98%). The regeneration studies showed that our new Pt/membrane catalysts are stable and can be reused for five consecutive reaction cycles for a total duration of 120 h including 60 h of heating at 100 °C under vacuum for substrate, product, and solvent removal with no detectable loss of cyclohexene hydrogenation activity. The overall results of our study point to a promising, versatile, and scalable path for the integration of catalytic membranes with in situ synthesized SDP hosts for Pt(0) nanoparticles into high-throughput modules and systems for heterogeneous catalytic hydrogenations, an important class of reactions that are widely utilized in industry to produce pharmaceuticals, agrochemicals, and specialty chemicals.