New evaluation method for the effectiveness of platinum/carbon electrocatalysts under operating conditions

Three-dimensional nanostructure analysis of non-stained Nafion in fuel-cell electrode by combined ADF-STEM tomography

The polymer electrolyte fuel cell (PEFC) is one of the strongest candidates for a next-generation power source for vehicles which do not emit CO2 gas as exhaust gas. The key factor in PEFCs is the nano-scaled electrochemical reactions that take place on the catalyst material and an ionomer supported by a carbon support. However, because the nano-scaled morphological features of the key materials in the catalyst compound cannot be observed clearly by transmission electron microscopy, improvement of PEFC performance had been approached by an imaginal schematic diagram based on an electrochemical analysis. In this study, we revealed the nano-scaled morphological features of the PEFC electrode in three dimensions and performed a quantitative analysis of the nanostructure by the newly developed 'Combined ADF-STEM tomography technique'. This method combines information from plural annular darkfield detectors with different electron collection angles and can emphasize the difference of the electron scattering intensity between the ionomer and carbon in the cross-sectional image of the reconstructed three-dimensional (3D) data. Therefore, this segmentation method utilizing image contrast does not require a high electron beam current like that used in energy dispersive X-ray analysis, and thus is suitable for electron beam damage-sensitive materials. By eliminating the process of manually determining the thresholds for obtaining classified component data from grayscale data, the obtained 3D structures have sufficient accuracy to allow quantitative analysis and specify the nano-scaled structural parameters directly related to power generation characteristics.

X-ray Photoelectron Spectroscopy Analysis of Nafion-Containing Samples: Pitfalls, Protocols, and Perceptions of Physicochemical Properties

X-ray photoelectron spectroscopy (XPS) is one of the most common techniques used to analyze the surface composition of catalysts and support materials used in polymer electrolyte membrane (PEM) fuel cells and electrolyzers, providing important insights for further improvement of their properties. Characterization of catalyst layers (CLs) is more challenging, which can be at least partially attributed to the instability of ionomer materials such as Nafion during measurements. This work explores the stability of Nafion during XPS measurements, illuminating and addressing Nafion degradation concerns. The extent of Nafion damage as a function of XPS instrumentation, measurement conditions, and sample properties was evaluated across multiple instruments. Results revealed that significant Nafion damage to the ion-conducting sulfonic acid species (>50% loss in sulfur signal) may occur in a relatively short time frame (tens of minutes) depending on the exact nature of the sample and XPS instrument. This motivated the development and validation of a multipoint XPS data acquisition protocol that minimizes Nafion damage, resulting in reliable data acquisition by avoiding significant artifacts from Nafion instability. The developed protocol was then used to analyze both thin film ionomer samples and Pt/C-based CLs. Comparison of PEM fuel cell CLs to Nafion thin films revealed several changes in Nafion spectral features attributed to charge transfer due to interaction with conductive catalyst and support species. This study provides a method to reliably characterize ionomer-containing samples, facilitating fundamental studies of the catalyst-ionomer interface and more applied investigations of structure-processing-performance correlations in PEM fuel cell and electrolyzer CLs.

Water Condensation in the Nanoscale Pores of Pt/C Catalyst Particles and Its Impact on Catalyst Utilization: A Simulation Based on a Reconstructed Structure from Nanoimaging

In polymer electrolyte membrane fuel cells, carbon-supported platinum (Pt/C) catalyst particles require sufficient water condensation within the nanoscale pores to effectively utilize the interior Pt catalysts. Since experimental visualizations with nanoscale precision of this phenomenon are not yet possible, we utilized a Pt/C catalyst particle reconstructed from segmented nanoimaging of a catalyst powder, which served as the computational domain for lattice density functional theory (LDFT) simulation of water condensation. Paired with experimental water uptake data, LDFT successfully simulated high-resolution water condensation, capturing both thin-film and capillary water condensation phenomena. Using a simple proton movement method within the water network, we reproduced the Pt utilization data from a CO stripping experiment. Our findings highlight that at low relative humidity (RH), Pt utilization is influenced by thin water film formations, mainly dictated by the wettability properties of surfaces within primary pores and the Pt/C catalyst particle's exterior. Conversely, at high RH, Pt utilization is attributed to capillary water condensation in medium-to-large sized pores. This approach contributes a qualitative and quantitative discussion on hypotheses regarding the mechanism of Pt utilization, supporting recent studies (e.g., Girod, R.; Nat. Catal. 2023, 6, (5), 383-391).

Metal-Support Interaction between Titanium Oxynitride and Pt Nanoparticles Enables Efficient Low-Pt-Loaded High-Performance Electrodes at Relevant Oxygen Reduction Reaction Current Densities

In the present work, we report on a synergistic relationship between platinum nanoparticles and a titanium oxynitride support (TiOxNy/C) in the context of oxygen reduction reaction (ORR) catalysis. As demonstrated herein, this composite configuration results in significantly improved electrocatalytic activity toward the ORR relative to platinum dispersed on carbon support (Pt/C) at high overpotentials. Specifically, the ORR performance was assessed under an elevated mass transport regime using the modified floating electrode configuration, which enabled us to pursue the reaction closer to PEMFC-relevant current densities. A comprehensive investigation attributes the ORR performance increase to a strong interaction between platinum and the TiOxNy/C support. In particular, according to the generated strain maps obtained via scanning transmission electron microscopy (STEM), the Pt-TiOxNy/C analogue exhibits a more localized strain in Pt nanoparticles in comparison to that in the Pt/C sample. The altered Pt structure could explain the measured ORR activity trend via the d-band theory, which lowers the platinum surface coverage with ORR intermediates. In terms of the Pt particle size effect, our observation presents an anomaly as the Pt-TiOxNy/C analogue, despite having almost two times smaller nanoparticles (2.9 nm) compared to the Pt/C benchmark (4.8 nm), manifests higher specific activity. This provides a promising strategy to further lower the Pt loading and increase the ECSA without sacrificing the catalytic activity under fuel cell-relevant potentials. Apart from the ORR, the platinum-TiOxNy/C interaction is of a sufficient magnitude not to follow the typical particle size effect also in the context of other reactions such as CO stripping, hydrogen oxidation reaction, and water discharge. The trend for the latter is ascribed to the lower oxophilicity of Pt-based on electrochemical surface coverage analysis. Namely, a lower surface coverage with oxygenated species is found for the Pt-TiOxNy/C analogue. Further insights were provided by performing a detailed STEM characterization via the identical location mode (IL-STEM) in particular, via 4DSTEM acquisition. This disclosed that Pt particles are partially encapsulated within a thin layer of TiOxNy origin.

Structure and conductivity of ionomer in PEM fuel cell catalyst layers: a model-based analysis

Efforts in design and optimization of catalyst layers for polymer electrolyte fuel cells hinge on mathematical models that link electrode composition and microstructure with effective physico-chemical properties. A pivotal property of these layers and the focus of this work is the proton conductivity, which is largely determined by the morphology of the ionomer. However, available relations between catalyst layer composition and proton conductivity are often adopted from general theories for random heterogeneous media and ignore specific features of the microstructure, e.g., agglomerates, film-like structures, or the hierarchical porous network. To establish a comprehensive understanding of the peculiar structure-property relations, we generated synthetic volumetric images of the catalyst layer microstructure. In a mesoscopic volume element, we modeled the electrolyte phase and calculated the proton conductivity using numerical tools. Varying the ionomer morphology in terms of ionomer film coverage and thickness revealed two limiting cases: the ionomer can either form a thin film with high coverage on the catalyst agglomerates; or the ionomer exists as voluminous chunks that connect across the inter-agglomerate space. Both cases were modeled analytically, adapting relations from percolation theory. Based on the simulated data, a novel relation is proposed, which links the catalyst layer microstructure to the proton conductivity over a wide range of morphologies. The presented analytical approach is a versatile tool for the interpretation of experimental trends and it provides valuable guidance for catalyst layer design. The proposed model was used to analyze the formation of the catalyst layer microstructure during the ink stage. A parameter study of the initial ionomer film thickness and the ionomer dispersion parameter revealed that the ionomer morphology should be tweaked towards well-defined films with high coverage of catalyst agglomerates. These implications match current efforts in the experimental literature and they may thus provide direction in electrode materials research for polymer electrolyte fuel cells.

Suppression of Membrane Degradation Accompanied with Increased Output Performance in Fuel Cells by Use of Silica-Containing Anode Catalyst Layers

Polymer electrolyte membranes (PEMs) for fuel cells are chemically degraded by the attack of ·OH radicals generated from the decomposition of H2O2, which is predominantly produced at the Pt/C hydrogen anode. The incorporation of conventional radical scavengers into the PEM suffers from a decrease in the output performance. We, for the first time, demonstrate that the addition of hygroscopic silica nanoparticles (NPs) to the Pt/C anode catalyst layer provides a remarkably prolonged (ca. 4 times) lifetime of a Nafion membrane in an accelerated stress test and open circuit voltage (OCV) holding at 90 °C, accompanied by improved output (I-E) performances at low relative humidity. It has been found that the use of silica NPs decreases H2O2 formation rate from the OCV to a practical H2 oxidation potential in a half-cell using 0.1 M HClO4 at 90 °C and provides reduced ohmic resistance (increase in water content) and effective utilization of Pt cathode catalyst in a single cell, by which the improvement of the durability of the PEM and increased output performance are explained rationally.

Optimization of a Perovskite Oxide-Based Cathode Catalyst Layer on Performance of Direct Ammonia Fuel Cells

To maximize fuel cell performance, transport pathways for electrons, ions, and reactants should be connected well. This demands a well-constructed microstructure in the catalyst layer (CL). Herein we design and optimize a cathode CL for a direct ammonia fuel cell (DAFC) using a perovskite oxide as the catalyst to reduce reliance on platinum group metals (PGMs). The effects of tailoring carbon, ionomer, and polytetrafluoroethylene (PTFE) content in cathode CLs (CCLs) were explored, and several DAFCs were tested. Using the same catalyst and operating conditions, the lowest maximum current density and peak power density obtained were 85.3 mA cm^-2 and 5.92 mW cm^-2, respectively, which substantially increased to 317 mA cm^-2 and 30.1 mW cm^-2 through proper carbon, ionomer, and PTFE optimization, illustrating the importance of an effective three-phase interface. The findings reveal that despite employment of an active catalyst for oxygen reduction at the cathode site, the true performance of the catalyst cannot be reflected unless it is supported by proper design of the CCL. The study also reveals that by optimizing the CCL, similar performances to those of Pt/C-based CCLs in literature can be obtained at a cost reduction.

Differences in the Electrochemical Performance of Pt-Based Catalysts Used for Polymer Electrolyte Membrane Fuel Cells in Liquid Half- and Full-Cells

A substantial amount of research effort has been directed toward the development of Pt-based catalysts with higher performance and durability than conventional polycrystalline Pt nanoparticles to achieve high-power and innovative energy conversion systems. Currently, attention has been paid toward expanding the electrochemically active surface area (ECSA) of catalysts and increase their intrinsic activity in the oxygen reduction reaction (ORR). However, despite innumerable efforts having been carried out to explore this possibility, most of these achievements have focused on the rotating disk electrode (RDE) in half-cells, and relatively few results have been adaptable to membrane electrode assemblies (MEAs) in full-cells, which is the actual operating condition of fuel cells. Thus, it is uncertain whether these advanced catalysts can be used as a substitute in practical fuel cell applications, and an improvement in the catalytic performance in real-life fuel cells is still necessary. Therefore, from a more practical and industrial point of view, the goal of this review is to compare the ORR catalyst performance and durability in half- and full-cells, providing a differentiated approach to the durability concerns in half- and full-cells, and share new perspectives for strategic designs used to induce additional performance in full-cell devices.

Electrocatalyst Performance at the Gas/Electrolyte Interface under High-Mass-Transport Conditions: Optimization of the "Floating Electrode" Method

The thin-film rotating disk electrode (TF-RDE) is a well-developed, conventional ex situ electrochemical method that is limited by poor mass transport in the dissolved phase and hence can only measure the kinetic response for Pt-based catalysts in a narrow overpotential range. Thus, the applicability of TF-RDE results in assessing how catalysts perform in fuel cells has been questioned. To address this problem, we use the floating electrode (FE) technique, which can facilitate high-mass transport to a catalyst layer composed of an ultralow loading of catalyst (1-15 μg_Pt cm_geo^-2) at the gas/electrolyte interface. In this paper, the aspects that have critical effects on the performance of the FE system are measured and parametrized. We find that, in order to obtain reproducible results with high performance, the following factors need to be taken into account: system cleanliness, break-in procedure, hydrophobic agent, ionomer type, and the measurements of catalyst surface area and loading. For some of these parameters, we examined a range of different approaches/materials and determined the optimum configuration. We find that the gas permeability of the hydrophobic agent is an important factor for improving the hydrogen oxidation reaction (HOR) and oxygen reduction reaction (ORR) performance. We provide evidence that the suppression of the HOR and ORR introduced by the Nafion ionomers is more than a local mass transport barrier but that a mechanism involving the adsorption of the sulfonate on Pt also plays a significant role. The work provides intriguing insights into how to manufacture and optimize electrocatalyst systems that must function at the gas/electrolyte interface.

Construction and Regulation of a Surface Protophilic Environment to Enhance Oxygen Reduction Reaction Electrocatalytic Activity

Pyrolytic transition metal nitrogen-carbon (M-N/C) materials are considered as the most promising alternatives for platinum-based catalysts toward oxygen reduction reaction (ORR). As the proton-coupled electron transfer step in ORR has been proven to be a rate-determining step in the M-N/C catalysts, we envisaged that building a protophilic surface might be helpful to enhance the ORR activity. Herein, a polyaniline decoration strategy was put forward and realized to confer the Fe-N/C catalyst with a surface protophilic environment. A 20 mV positive shift in half-wave potential was observed owing to the enriched interfacial proton concentration, corresponding to a tripled turnover frequency under acidic conditions (from 0.46 to 1.28 e·s^-1·sites^-1). Our work blazed a new path toward the design of M-N/C ORR catalysts, commencing via the ORR kinetics.

Effect of Dispersion Solvents in Catalyst Inks on the Performance and Durability of Catalyst Layers in Proton Exchange Membrane Fuel Cells

Five different ionomer dispersions using water–isopropanol (IPA) and N-methylpyrrolidone (NMP) were investigated as ionomer binders for catalyst layers in proton exchange membrane fuel cells. The distribution of ionomer plays an important role in the design of high-performance porous electrode catalyst layers since the transport of species, such as oxygen and protons, is controlled by the thickness of the ionomer on the catalyst surface and the continuity of the ionomer and gas networks in the catalyst layer, with the transport of electrons being related to the continuity of the carbon particle network. In this study, the effect of solvents in ionomer dispersions on the performance and durability of catalyst layers (CLs) is investigated. Five different types of catalyst inks were used: (i) ionomer dispersed in NMP; (ii) ionomer dispersed in water–IPA; (iii) ionomer dispersed in NMP, followed by adding water–IPA; (iv) ionomer dispersed in water–IPA, followed by adding NMP; and (v) a mixture of ionomer dispersed in NMP and ionomer dispersed in water–IPA. Dynamic light scattering of the five dispersions showed different average particles sizes: ~0.40 μm for NMP, 0.91–1.75 μm for the mixture, and ~2.02 μm for water–IPA. The membrane-electrode assembly prepared from an ionomer dispersion with a larger particle size (i.e., water–IPA) showed better performance, while that prepared from a dispersion with a smaller particle size (i.e., NMP) showed better durability.

Effect of Electronic Conductivities of Iridium Oxide/Doped SnO2 Oxygen-Evolving Catalysts on the Polarization Properties in Proton Exchange Membrane Water Electrolysis

We have developed IrOx/M-SnO2 (M = Nb, Ta, and Sb) anode catalysts, IrOx nanoparticles uniformly dispersed on M-SnO2 supports with fused-aggregate structures, which make it possible to evolve oxygen efficiently, even with a reduced amount of noble metal (Ir) in proton exchange membrane water electrolysis. Polarization properties of IrOx/M-SnO2 catalysts for the oxygen evolution reaction (OER) were examined at 80 °C in both 0.1 M HClO4 solution (half cell) and a single cell with a Nafion® membrane (thickness = 50 μm). While all catalysts exhibited similar OER activities in the half cell, the cell potential (Ecell) of the single cell was found to decrease with the increasing apparent conductivities (σapp, catalyst) of these catalysts: an Ecell of 1.61 V (voltage efficiency of 92%) at 1 A cm−2 was achieved in a single cell by the use of an IrOx/Sb-SnO2 anode (highest σapp, catalyst) with a low Ir-metal loading of 0.11 mg cm−2 and Pt supported on graphitized carbon black (Pt/GCB) as the cathode with 0.35 mg cm−2 of Pt loading. In addition to the reduction of the ohmic loss in the anode catalyst layer, the increased electronic conductivity contributed to decreasing the OER overpotential due to the effective utilization of the IrOx nanocatalysts on the M-SnO2 supports, which is an essential factor in improving the performance with low noble metal loadings.

Tuning the Ionomer Distribution in the Fuel Cell Catalyst Layer with Scaling the Ionomer Aggregate Size in Dispersion

With the demands for better performance of polymer electrolyte membrane fuel cells, studies on controlling the distribution of ionomers have recently gained interest. Here, we present a tunable ionomer distribution in the catalyst layer (CL) with dipropylene glycol (DPG) and water mixtures as the ionomer dispersion medium. Dynamic light scattering and molecular dynamics simulation demonstrate that, by increasing the DPG content in the dispersion, the size of the ionomer aggregates in the dispersion is exponentially reduced because of the higher affinity of DPG for Nafion ionomers. The ionomer distribution of the resulting CLs dictates the dimensional feature of the ionomer dispersion. Although the ionomer distribution becomes more uniform with increasing the DPG content, an optimal power performance is obtained at a DPG content of 50 wt % regardless of feed humidity because of balanced proton and mass transports. As a guide for tuning the ionomer distribution, we suggest that the ionomer aggregates in the dispersion with a size close to that of the Pt/C aggregates form a highly connected ionomer network and maintain a porosity in the catalyst/ionomer aggregate, resulting in high power performance.

Durability Improvement of Pt/RGO Catalysts for PEMFC by Low-Temperature Self-Catalyzed Reduction

Pt/C catalyst used for polymer electrolyte membrane fuel cells (PEMFCs) displays excellent initial performance, but it does not last long because of the lack of durability. In this study, a Pt/reduced graphene oxide (RGO) catalyst was synthesized by the polyol method using ethylene glycol (EG) as the reducing agent, and then low-temperature hydrogen bubbling (LTHB) treatment was introduced to enhance the durability of the Pt/RGO catalyst. The cyclic voltammetry (CV), oxygen reduction reaction (ORR) analysis, and transmittance electron microscopy (TEM) results suggested that the loss of the oxygen functional groups, because of the hydrogen spillover and self-catalyzed dehydration reaction during LTHB, reduced the carbon corrosion and Pt agglomeration and thus enhanced the durability of the electrocatalyst.

Three-dimensional analysis of Nafion layers in fuel cell electrodes

Proton exchange membrane fuel cell is one of the most promising zero-emission power sources for automotive or stationary applications. However, their cost and lifetime remain the two major key issues for a widespread commercialization. Consequently, much attention has been devoted to optimizing the membrane/electrode assembly that constitute the fuel cell core. The electrodes consist of carbon black supporting Pt nanoparticles and Nafion as the ionomer binder. Although the ionomer plays a crucial role as ionic conductor through the electrode, little is known about its distribution inside the electrode. Here we report the three-dimensional morphology of the Nafion thin layer surrounding the carbon particles, which is imaged using electron tomography. The analyses reveal that doubling the amount of Nafion in the electrode leads to a twofold increase in its degree of coverage of the carbon, while the thickness of the layer, around 7 nm, is unchanged.

Double-layer ionomer membrane for improving fuel cell performance

A double-layer ionomer membrane, thin-layer Nafion (perfluorinated sulfonic acid polymer) on a sulfonated aromatic block copolymer (SPK-bl-1), was prepared for improving fuel cell performance. Each component of the double-layer membrane showed similar phase-separated morphologies to those of the original membranes. A fuel cell with the double-layer membrane exhibited lower ohmic resistance and higher cathode performance than those with the original SPK-bl-1 membrane despite their comparable water uptake and proton conductivity. Detailed electrochemical analyses of fuel cell data suggested that the thin Nafion interlayer contributed to improving the interfacial contact between the SPK-bl-1 membrane and the cathode catalyst layer and to mitigating excessive drying of the membrane. The results provide new insight on designing high-performance fuel cells with nonfluorinated ionomer membranes such as sulfonated aromatic polymers.

Physical Chemistry Research Toward Proton Exchange Membrane Fuel Cell Advancement

Hydrogen fuel cells, the most common type of which are proton exchange membrane fuel cells (PEMFCs), are on a rapid path to commercialization. We credit physical chemistry research in oxygen reduction electrocatalysis and theory with significant breakthroughs, enabling more cost-effective fuel cells. However, most of the physical chemistry has been restricted to studies of platinum and related alloys. More work is needed to better understand electrocatalysts generally in terms of properties and characterization. While the advent of such highly active catalysts will enable smaller, less expensive, and more powerful stacks, they will require better understanding and a complete restructuring of the diffusion media in PEMFCs to facilitate faster transport of the reactants (O2) and products (H2O). Even Ohmic losses between materials become more important at high power. Such lessons from PEMFC research are relevant to other electrochemical conversion systems, including Li-air batteries and flow batteries.

Temperature dependence of oxygen reduction reaction activity at stabilized Pt skin-PtCo alloy/graphitized carbon black catalysts prepared by a modified nanocapsule method

We have developed a new catalyst supported on graphitized carbon black (GCB), which exhibits higher resistance to carbon corrosion than a conventional carbon black (CB), in order to favor both high mass activity for the oxygen reduction reaction (ORR) and high durability. To protect the underlying Pt(X)Co alloy from corrosion and maintain the modified electronic structure, two monolayers of Pt-skin layer (Pt(2 ML)) were formed on the Pt(X)Co core-particles, which were of uniform size and composition. Characterization of the Pt(2 ML)-PtCo(X = 1)/GCB, both by a scanning transmission electron microscope (STEM) with an energy dispersive X-ray (EDX) analyzer and by X-ray diffraction (XRD), indicated the formation of the Pt(2 ML) on the PtCo alloy solid solution nanoparticles. The temperature dependence of the ORR activity of the Pt(2 ML)-PtCo((2 nm))/GCB catalyst was evaluated from the hydrodynamic voltammograms in O(2)-saturated 0.1 M HClO(4) solution at 30-90 °C by the channel flow double electrode (CFDE) technique. It was found that the Co dissolution from PtCo particles during the ORR was considerably suppressed by the stabilized Pt-skin structure. The kinetically controlled mass activity (MA(k)) for the ORR at the Pt(2 ML)-PtCo((2 nm))/GCB at E = 0.85 V vs reversible hydrogen electrode (RHE) was about two times larger than that for a standard commercial c-Pt/CB catalyst at 80-90 °C. The value of H(2)O(2) yield at the Pt(2 ML)-PtCo((2 nm))/GCB was found to be very low (0.2%), about one-half of that for c-Pt/CB, and it is thus better able to mitigate the degradation of the polymer electrolyte membrane and gasket material.

Preparation and fuel cell performance of catalyst layers using sulfonated polyimide ionomers

Sulfonated polyimide (SPI-8) ionomers were used as binders in the catalyst layers, and their fuel cell performance was evaluated. SPI-8 ionomers functioned well in the anode with only minor overpotential even at low humidity (50% relative humidity (RH)). In contrast, the cathode performance was significantly dependent on the content and molecular weight of the ionomers and humidity of the supplied gases. Higher molecular weight of the ionomer caused larger potential drop at high current density at 80 and 100% RH since oxygen supply and/or water discharge became insufficient due to higher water uptake (swelling) of the ionomer. Similar results were obtained at higher ionomer content, because of the increase of thickness in the catalyst layer. The mass transport was improved with decreasing humidity, however, proton conductivity became lower. While the maximum values of j(@0.70 V) for all membrane electrode assemblies (MEAs) were ca. 0.35 A/cm(2), each electrode could have the different appropriate operating conditions. The results suggest that the parameters such as oxygen supply, proton conductivity, and water uptake and discharge need to be carefully optimized in the catalyst layers for achieving reasonable cathode performance with hydrocarbon ionomers.