Recent developments of nanocarbon based supports for PEMFCs electrocatalysts

Optimization of Hot Embossing Condition Using Taguchi Method and Evaluation of Microchannels for Flexible On-Chip Proton-Exchange Membrane Fuel Cell

Hot embossing is a manufacturing technique used to create microchannels on polymer substrates. In recent years, microchannel fabrication technology based on hot embossing has attracted considerable attention due to its convenience and low cost. A new evaluation method of microchannels, as well as an approach to obtaining optimal hot embossing conditions based on the Taguchi method, is proposed in this paper to fabricate precise microchannels for a flexible proton-exchange membrane fuel cell (PEMFC). Our self-made hot embossing system can be used to fabricate assorted types of micro-channel structures on polymer substrates according to various applications, whose bottom width, top width, height and cross-sectional area vary in the aims of different situations. In order to obtain a high effective filling ratio, a new evaluation method is presented based on the four parameters of channel structures, and the Taguchi method is utilized to arrange three main factors (temperature, force and time) affecting the hot embossing in orthogonal arrays, quickly finding the optimal condition for the embossing process. The evaluation method for microchannels proposed in this paper, compared to traditional evaluation methods, incorporates the area factor, providing a more comprehensive assessment of the fabrication completeness of the microchannels. Additionally, it allows for the quick and simple identification of optimal conditions. The experimental results indicate that after determining the optimal embossing temperature, pressure and time using the Taguchi method, the effective filling rate remains above 95%, thereby enhancing the power density. Through variance analysis, it was found that temperature is the most significant factor affecting the hot embossing of microchannels. The high filling rate makes the process suitable for PEMFCs. The results demonstrate that under optimized process conditions, a self-made hot embossing system can effectively fabricate columnar structure microchannels for PEMFCs.

Nano-metal diborides-supported anode catalyst with strongly coupled TaOx/IrO2 catalytic layer for low-iridium-loading proton exchange membrane electrolyzer

The sluggish kinetics of oxygen evolution reaction (OER) and high iridium loading in catalyst coated membrane (CCM) are the key challenges for practical proton exchange membrane water electrolyzer (PEMWE). Herein, we demonstrate high-surface-area nano-metal diborides as promising supports of iridium-based OER nanocatalysts for realizing efficient, low-iridium-loading PEMWE. Nano-metal diborides are prepared by a novel disulphide-to-diboride transition route, in which the entropy contribution to the Gibbs free energy by generation of gaseous sulfur-containing products plays a crucial role. The nano-metal diborides, TaB2 in particular, are investigated as the support of IrO2 nanocatalysts, which finally forms a TaOx/IrO2 heterojunction catalytic layer on TaB2 surface. Multiple advantageous properties are achieved simultaneously by the resulting composite material (denoted as IrO2@TaB2), including high electrical conductivity, improved iridium mass activity and enhanced corrosion resistance. As a consequence, the IrO2@TaB2 can be used to fabricate the membrane electrode with a low iridium loading of 0.15 mg cm-2, and to give an excellent catalytic performance (3.06 A cm-2@2.0 V@80 oC) in PEMWE-the one that is usually inaccessible by unsupported Ir-based nanocatalysts and the vast majority of existing supported Ir-based catalysts at such a low iridium loading.

Engineering carbon semi-tubes supported platinum catalyst for efficient oxygen reduction electrocatalysis

Innovation of catalyst structure is extremely important to develop the high-performance electrocatalysts for oxygen-reduction reaction (ORR). Herein, nitrogen-doped carbon semi-tube (N-CST) is used as a functional support for stabilizing the microwave-reduced Pt nanoparticles with an average size of ∼2.8 nm to synthesize the semi-tubular Pt/N-CST catalyst. The contribution of interfacial Pt-N bond between N-CST support and Pt nanoparticles with electrons transfer from N-CST support to Pt nanoparticles is found by electron paramagnetic resonance (EPR) and X-ray absorption fine structure (XAFS) spectroscopy. This bridged Pt-N coordination can simultaneously help ORR electrocatalysis and promote electrochemical stability. As a result, the innovative Pt/N-CST catalyst exhibits excellent catalytic performance, realizing ORR activity and electrochemical stability superior to the commercial Pt/C catalyst. Furthermore, density functional theoretical (DFT) calculations suggest that the interfacial Pt-N-C site with unique affinity of O∗ + OH∗ can provide new active routes for the enhanced electrocatalytic ORR capacity.

Insight into Oxygen Transport in Solid and High-Surface-Area Carbon Supports of Proton Exchange Membrane Fuel Cells

Understanding the oxygen transport mechanism through an ionomer film that covered the catalyst surface is essential for reducing local oxygen transport resistance and improving the low Pt-loading proton exchange membrane fuel cell performance. Besides the ionomer material, the carbon supports, upon which ionomers and catalyst particles are dispersed, also play a crucial role in local oxygen transport. Increasing attention has been paid to the effects of carbon supports on local transport, but the detailed mechanism is still unclear. Herein, the local oxygen transports based on conventional solid carbon (SC) and high-surface-area carbon (HSC) supports are investigated by molecular dynamics simulations. It is found that oxygen diffuses through the ionomer film that covered the SC supports via "effective diffusion" and "ineffective diffusion". The former denotes the process by which oxygen diffuses directly from the ionomer surface to the Pt upper surface through small and concentrated regions. In contrast, ineffective diffusion suffers more restrictions by both carbon- and Pt-dense layers, and thus, the oxygen pathways are long and tortuous. The HSC supports exhibit larger transport resistance relative to SC supports due to the existence of micropores. Also, the major transport resistance originates from the carbon-dense layer as it inhibits oxygen from diffusing downward and migrating toward the pore opening, while the oxygen transport inside the pore is facile along the pore's inner surface, which leads to a specific and short diffusion pathway. This work provides insight into oxygen transport behavior with SC and HSC supports, which is the basis for the development of high-performance electrodes with low local transport resistance.

A facile strategy to prepare FeNx decorated PtFe intermetallic with excellent acidic oxygen reduction reaction activity and stability

The construction of low-Pt-content intermetallic on carbon supports has been verified as a promising method to promote the activity of the oxygen reduction reaction (ORR). In this study, we have developed a simple and effective strategy to obtain a well-designed CNT-PtFe-PPy precursor. This precursor contains modulated Pt- and Fe-based content dispersed in polypyrrole (PPy) chain segments, which are in-situ generated on the templates of carbon nanotubes (CNTs). Subsequent pyrolysis of the CNT-PtFe-PPy precursor produces a CNT-PtFe@FeNC catalyst, which contains both Fe-N_x and PtFe intermetallic active sites. Due to the highly efficient dispersion of active species, the CNT-PtFe@FeNC electrocatalyst displays a 9.5 times higher specific activity (SA) and 8.5 times higher mass activity (MA) than those of a commercial Pt/C catalyst in a 0.1 M HClO₄ solution. Additionally, these results, combined with excellent durability (the SA and MA maintained 94 % and 91 % of initial activity after a 10-k cycle accelerated durability test), represent among the best performance achieved so far for Pt-based ORR electrocatalysts. Furthermore, density functional theory (DFT) calculations revealed that the presence of Fe-N₄ species reduces the adsorption energy between the PtFe intermetallic compound and OH*, accelerating the ORR process.

Electrocatalytic oxygen reduction with cobalt corroles bearing cationic substituents

Recent decades have seen increasing interest in developing highly active and selective electrocatalysts for the oxygen reduction reaction (ORR). The active site environment of cytochrome c oxidases (CcOs), including electrostatic and hydrogen-bonding interactions, plays an important role in promoting the selective conversion of dioxygen to water. Herein, we report the synthesis of three Co^III corroles, namely 1 (with a 10-phenyl ortho-trimethylammonium cationic group), 2 (with a 10-phenyl ortho-dimethylamine group) and 3 (with a 10-phenyl para-trimethylammonium cationic group) as well as their electrocatalytic ORR activities in both acidic and neutral solutions. We discovered that 1 is much more active and selective than 2 and 3 for the electrocatalytic four-electron ORR. Importantly, 1 showed ORR activities with half-wave potentials at E_1/2 = 0.75 V versus RHE in 0.5 M H₂SO₄ solutions and at E_1/2 = 0.70 V versus RHE in neutral 0.1 M phosphate buffer solutions. This work is significant for outlining a strategy to increase both the activity and selectivity of metal corroles for the electrocatalytic ORR by introducing cationic units.

The Effect of Pretreatment on a PtCu/C Catalyst's Structure and Functional Characteristics

This research focuses on studying the effects of various pretreatment types on a PtCu/C catalyst synthesized by the co-deposition of metal precursors. The treatment in a 1 M HNO₃ solution for 1 h is shown to result in a slight increase in activity in the oxygen electroreduction reaction (both the mass activity and specific activity calculated for the value of the electrochemically active surface area). The sample obtained after the thermal treatment, which is carried out at 350 °C under an argon atmosphere for 1 h, demonstrates 1.7 times higher specific activity than the sample before the treatment. The durability testing results obtained by the stress testing method in a potential range of 0.6-1.4 V during 2000 cycles show that the PtCu/C catalysts after both the acid treatment and the thermal treatment are characterized by higher residual activity than the sample in the "as-prepared" state.

In Situ S-Doping Strategy of Promoting Iron Coordinated by Nitrogen-Doped Carbon Nanosheets for Efficient Oxygen Reduction Reaction

Improving transition metal-nitrogen-carbon (M-N-C) as a noble-metal-free catalyst for the oxygen reduction reaction (ORR) is critical to achieve low-cost electrochemical energy conversion. Herein, an in situ S doping strategy of enhancing Fe-N-C activity for ORR was developed by newly designed Fe(II) ion coordinated S-containing bis(imino)-pyridine-based polymers as precursors, which were synthesized through copolymerizing three monomers of 2, 6-diacetylpyridine (DAP), triamterene (TIT), and 2,5-dithiobiurea (DTB) as both N and S sources. All samples derived from various molar ratios of the three monomers possess a self-supporting structure of nanosheets. Additionally, incorporating DTB into the copolymer can not only strongly affect the derived coordinative species of N dopants to Fe atom but also effectively induce the synergistic effect between S dopants and FeNx moieties, resulting a significant improvement for ORR. The S-doped Fe-N-C nansheets with Fe coordinated by 4 pyrrolic N dopants exhibit the highest ORR activity and stability in alkaline media with a higher power output of Zn-air battery than that of the same loading of Pt/C. Theoretical calculation identifies that the thiophenic S dopant adjacent to Fe-pyrrolic N moiety can decrease the d band center of Fe atom, greatly weakening the energy profiles of oxygenated intermediates and thus enhancing ORR. In addition, because of the designability of transition metal coordinated S-containing bis(imino)-pyridine based polymers in the work, therefore, it is believable that this strategy would open a wide space to explore the structural relationship between precursors and MNx active sites with S dopants for the purpose of achieving highly efficient and robust M-N-C catalysts for energy-related electrocatalysis.

Electronic Metal-Support Interaction Triggering Interfacial Charge Polarization over CuPd/N-Doped-C Nanohybrids Drives Selectively Electrocatalytic Conversion of Nitrate to Ammonia

Selective electrocatalytic nitrate-to-ammonia conversion holds significant potential in treatment of nitrate wastewater and simultaneously produces high-value-added ammonia. However, today's development of nitrate-to-ammonia technology remains hindered by the lack of electrocatalysts with high activity and selectivity. In this work, metal-organic framework-derived CuPd bimetallic nanoparticles/nitrogen-doped carbon (CuPd/CN) hybrid nanoarrays for efficient ammonia electrosynthesis from nitrate are designed and synthesized. Systematic characterization reveals that the electronic metal-support interaction between the CuPd nanoparticles and N-doped nanocarbon matrix could trigger interfacial charge polarization over the CuPd/CN composite and make Cu sites electron deficient, which is conducive to the adsorption of nitrate ions. Moreover, the Pd atom sites separate by Cu atoms and could catalyze the dissociation of H₂ O molecules to form adsorbed H species, which evolves into hydrogen radicals and behaves as the dominant reactive species in accelerating nitrate-to-ammonia electrocatalysis. These advantages endow the CuPd/CN nanoarrays with high faradaic efficiency (96.16%), selectivity (92.08%) as well as excellent catalytic stability for electroreduction of nitrate to ammonia.

N-Doped and Sulfonated Reduced Graphene Oxide Supported PtNi Nanoparticles as Highly Efficient Electrocatalysts for Oxygen Reduction Reaction

N-doping and sulfonation is prepared on the reduced graphene oxide (rGO) support for PtNi nanoparticles (PtNi/S-(N)rGO) by a simple method of hydrothermal synthesis and thermal decomposition. The specific surface area increases from 180.7 m2/g of PtNi/rGo to 293.5 m2/g of PtNi/S-(N)rGO. The surface morphology shows wrinkles sites, which are separated by the sulfonated groups. The catalytic stability and efficiency are improved by the anchoring effect of sulfonated groups and evenly distribution of nanoparticles, respectively. The synergistic effect of N-doping and sulfonation can be in favor of catalytic efficiency by the increase of number of electron transfer. The half-wave potential of the PtNi/S-(N)rGO catalyst is up to 0.632 V, a small positive shift compared to the Pt/C catalyst. The durability of the PtNi/S-(N)rGO is 2.6 times higher than of the Pt/C catalyst after 5000 repeated cycles. The peak power of the PtNi/S-(N)rGO catalyst increased 37.5% compared to the Pt/C catalyst. Therefore, the stability and catalytic efficiency are improved by the PtNi/S-(N)rGO catalyst applied in proton exchange membrane fuel cell (PEMFC) compared to the commercial Pt/C catalyst.

Catalytic Decomposition of Methane to Hydrogen over Al2O3 Supported Mono- and Bimetallic Catalysts

This article discusses the decomposition of methane in the temperature range 550–800 °C on low-percentage   monometallic (Ni/g-Al2O3, Co/g-Al2O3) and bimetallic (Ni-Co/g-Al2O3) catalysts. It is shown that the bimetallic catalyst is more active in the decomposition of methane to hydrogen than monometallic ones. At a reaction temperature of 600 °C, the highest methane conversion is 81%, and the highest hydrogen yield of 51% is formed on Ni-Co/g-Al2O3. A complex of physicochemical methods (Scanning Electron Microscope (SEM), X-ray Diffraction (XRD), Temperature Programmed Reduction (TPR-H2), etc.) established that the addition of cobalt oxide to the composition of Ni/g-Al2O3 leads to the formation of surface bimetallic Ni-Co alloys, while the dispersion of particles increases and the reducibility of the catalyst is facilitated, which provides an increase in the concentration of metal particles - active centers, which can be the reason for an increase in the catalytic properties of a bimetallic catalyst in comparison with monometallic ones. Copyright © 2021 by Authors, Published by BCREC Group. This is an open access article under the CC BY-SA License  (https://creativecommons.org/licenses/by-sa/4.0). 

Deep learning for the automation of particle analysis in catalyst layers for polymer electrolyte fuel cells

The rapidly growing use of imaging infrastructure in the energy materials domain drives significant data accumulation in terms of their amount and complexity. The applications of routine techniques for image processing in materials research are often ad hoc, indiscriminate, and empirical, which renders the crucial task of obtaining reliable metrics for quantifications obscure. Moreover, these techniques are expensive, slow, and often involve several preprocessing steps. This paper presents a novel deep learning-based approach for the high-throughput analysis of the particle size distributions from transmission electron microscopy (TEM) images of carbon-supported catalysts for polymer electrolyte fuel cells. A dataset of 40 high-resolution TEM images at different magnification levels, from 10 to 100 nm scales, was annotated manually. This dataset was used to train the U-Net model, with the StarDist formulation for the loss function, for the nanoparticle segmentation task. StarDist reached a precision of 86%, recall of 85%, and an F1-score of 85% by training on datasets as small as thirty images. The segmentation maps outperform models reported in the literature for a similar problem, and the results on particle size analyses agree well with manual particle size measurements, albeit at a significantly lower cost.