Gram-Scale Synthesis of Well-Dispersed Shape-Controlled Pt-Ni/C as High-Performance Catalysts for the Oxygen Reduction Reaction

Effects of Electrostatic Force and Network Structure on the Stability of Proton-Exchange Membrane Fuel Cell Catalyst Ink

The stability of the catalyst slurry of a proton-exchange membrane fuel cell (PEMFC) is of great significance to its large-scale production and commercialization. In this study, three kinds of slurries with different stabilities were prepared using different probe ultrasonic powers. The influence of electrostatic force and network structure on slurry stability was also studied. In addition, the catalyst layer (CL) and membrane electrode assembly (MEA) were further tested to determine the relationship between slurry stability, CL, and MEA performance. The results showed that the slurry prepared with 600 W dispersion power had the least agglomeration on day 12, which is due to the clusters in the slurry having the smallest average particle size and the largest surface area, thereby allowing them to absorb the most Nafion and have the largest electrostatic force to inhibit agglomeration. However, the slurry with 1200 W dispersion power had the least sedimentation after 9.4 days because the strength of the network structure in the slurry strengthened the most, resulting in a significant increase in viscosity and inhibition of sedimentation. Electrochemical tests showed that the MEA gradually exhibited worse electrical performance and higher impedance due to the agglomeration of catalyst particles caused by the standing process. Altogether, this study provides insights to better understand and regulate the stability of catalyst slurries.

Alternative and facile production pathway towards obtaining high surface area PtCo/C intermetallic catalysts for improved PEM fuel cell performance

The design of catalysts with stable and finely dispersed platinum or platinum alloy nanoparticles on the carbon support is key in controlling the performance of proton exchange membrane (PEM) fuel cells. In the present work, an intermetallic PtCo/C catalyst is synthesized via double-passivation galvanic displacement. TEM and XRD confirm a significantly narrowed particle size distribution for the catalyst particles compared to commercial benchmark catalysts (Umicore PtCo/C). Only about 10% of the mass fraction of PtCo particles show a diameter larger than 8 nm, whereas this is up to or even more than 35% for the reference systems. This directly results in a considerable increase in electrochemically active surface area (96 m² g^-1 vs. >70 m² g^-1), which confirms the more efficient usage of precious catalyst metal in the novel catalyst. Single-cell tests validate this finding by improved PEM fuel cell performance. Reducing the cathode catalyst loading from 0.4 mg cm^-2 to 0.25 mg cm^-2 resulted in a power density drop at an application-relevant 0.7 V of only 4% for the novel catalyst, compared to the 10% and 20% for the commercial benchmarks reference catalysts.

Electrochemical Activation and Its Prolonged Effect on the Durability of Bimetallic Pt-Based Electrocatalysts for PEMFCs

The present study, concerned with high-performance ORR catalysts, may be a valuable resource for a wide range of researchers within the fields of nanomaterials, electrocatalysis, and hydrogen energy. The objects of the research are electrocatalysts based on platinum–copper nanoparticles with onion-like and solid-solution structures. To evaluate the functional characteristics of the catalysts, the XRD, XRF, TEM, HAADF-STEM, and EDX methods, as well as the voltammetry method on a rotating disk electrode have been used. This work draws the attention of researchers to the significance of applying a protocol of electrochemically activating bimetallic catalysts in terms of the study of their functional characteristics on the rotating disk electrode. The choice of the potential range during the pre-cycling stage has been shown to play a crucial role in maintaining the durability of the catalysts. The activation of the PtCu/C catalyst during cycling of up to 1.0 V allows for an increase in the durability of the catalysts with onion-like and solid-solution structures of nanoparticles by 28% and 23%, respectively, as compared with activation of up to 1.2 V.

Batch synthesis of high activity and durability carbon supported platinum catalysts for oxygen reduction reaction using a new facile continuous microwave pipeline technology

Traditional synthesis methodologies for fuel cell catalyst production involve long reactions and uncontrollable reaction processes. Synthesis methods for the production of catalysts typically have difficulties to achieve catalysts materials with consistency, high activity, and durability. In this study, a fast, simple, and suitable continuous pipeline microwave method for catalyst mass production was developed, with the carbon carrier being treated at different temperatures simultaneously. The method herein developed resulted in carbon-supported platinum (Pt) catalysts with high activity and high durability. In addition, the half-wave potential of the catalyst exceeded 0.9 V, the electrochemical active surface area reached 85.7 m²-g_Pt^-1, and the mass specific activity reached 171.1 mA-mg^-1. Remarkably, after 30,000 cycles of Pt attenuation tests and 30,000 cycles of carbon carrier attenuation tests, the retention rate of the annealed carbon carrier catalyst reached 80 %. As a membrane electrode, the catalyst generated a single cell maximum power density of 1.4 W-cm^-2, and the Pt content reached 0.286 g_Pt-kW^-1. The work provides an effective and practical method for the mass production of high-performance and high-durability catalysts, which guiding significance for mass production of catalysts.

Reducing Irreversible Performance Losses via a Graphene Oxide Buffer Layer for Proton-Exchange Membrane Fuel Cells

Alloy catalysts are promising for proton-exchange membrane fuel cells but are difficult to realize high-durability operation because the dissolution of Pt-M (M = Co, Ni, etc.) metals inevitably accelerates irreversible performance degradation. Here, we propose a buffer layer solution that inserts a trace layer of a graphene oxide (GO) film between the PEM and the alloy catalyst layer to mitigate the poison effect. To distinguish the irreversible and reversible losses, two typical recovery procedures (shutdown and JRC-based protocols) being part of a fuel cell dynamic load cycle durability test are characterized. The electrochemical evaluation reveals that GO-1 μg/cm² enables a higher initial performance and stability. Furthermore, the GO buffer layer design allows the realization of membrane electrode assemblies with a highly homogeneous current density distribution and a low accessible mass transport resistance. Thanks to the ion sieving effect in the GO buffer layer, high anti-poisoning and stability during the accelerated stress test process are ensured.

Architecture Evolution of Different Nanoparticles Types: Relationship between the Structure and Functional Properties of Catalysts for PEMFC

This review considers the features of the catalysts with different nanoparticle structures architecture transformation under the various pre-treatment types. Based on the results of the publications analysis, it can be concluded that the chemical or electrochemical activation of bimetallic catalysts has a significant effect on their composition, microstructure, and catalytic activity in the oxygen reduction reaction. The stage of electrochemical activation is recommended for use as a mandatory catalyst pre-treatment to obtain highly active de-alloyed materials. The literature is studied, which covers possible variants of the structural modification under the influence of thermal treatment under different processing conditions. Additionally, based on the literature data analysis, recommendations are given for the thermal treatment of catalysts alloyed with various d-metals.

Well entrapped platinum-iron nanoparticles on three-dimensional nitrogen-doped ordered mesoporous carbon as highly efficient and durable catalyst for oxygen reduction and zinc-air battery

The high-performance and durable oxygen reduction reaction (ORR) catalyst on air cathode is a key component in assembly of Zn-air batteries. Herein, three-dimensional N-doped ordered mesoporous carbon (3D N-OMC) was first prepared with silica as a template via pyrolysis with assistance of dicyandiamide as a N-doping agent, combined by full adsorption of platinum (II) acetylacetonate (Pt(acac)₂) and iron (II) phthalocyanine (FePc) via π-π interactions. After further pyrolysis of the resulting mixture, many PtFe nanoparticles were efficiently incorporated in 3D N-OMC (termed as PtFe@3D N-OMC for simplicity). Control experiments were certificated the important role of the pyrolysis temperature played in this synthesis. The resultant composite synergistically combines advantages of hierarchically accessible surfaces, highly open structure, and well-dispersed PtFe particles, which endow the PtFe@3D N-OMC with onset and half-wave potentials of 0.98 and 0.86 V in alkaline media, respectively, showing appealing catalytic activity for the ORR. Most significantly, the PtFe@3D N-OMC based Zn-air battery has a high power density of 80.57 mW cm^-2 and long-term durability (220 h, 660 cycles). This work opens a new avenue for design of high-efficiency and durable ORR electrocatalysts in energy conversion and storage systems.

Electrocatalytic performance of sonochemically synthesized Pt–Ni/C nanoparticles in fuel cell application

Developing high-performance electrocatalysts using simple and controllable methods is of interest to reduce the cost of polymer electrolyte membrane fuel cells. In this study, platinum is alloyed with nickel and supported on carbon (Pt–Ni/C) via an ultrasound-assisted route. The crystallite and particle sizes of the obtained nanoparticles were smaller than the commercial carbon-supported Pt nanoparticles. The sonochemically synthesized Pt–Ni/C nanoparticles exhibited superior electrocatalytic properties than the commercial Pt/C nanoparticles in the fuel cell operation. Electrochemical measurements performed with Pt–Ni/C electrocatalyst displayed excellent oxygen reduction and higher electrochemical active surface area (EASA). Optimum fuel cell performance based on peak power density using Pt–Ni/C electrocatalyst was observed as 0.28 W/cm2 at 0.39 V.

Proton Exchange Membrane Fuel Cells (PEMFCs): Advances and Challenges

The study of the electrochemical catalyst conversion of renewable electricity and carbon oxides into chemical fuels attracts a great deal of attention by different researchers. The main role of this process is in mitigating the worldwide energy crisis through a closed technological carbon cycle, where chemical fuels, such as hydrogen, are stored and reconverted to electricity via electrochemical reaction processes in fuel cells. The scientific community focuses its efforts on the development of high-performance polymeric membranes together with nanomaterials with high catalytic activity and stability in order to reduce the platinum group metal applied as a cathode to build stacks of proton exchange membrane fuel cells (PEMFCs) to work at low and moderate temperatures. The design of new conductive membranes and nanoparticles (NPs) whose morphology directly affects their catalytic properties is of utmost importance. Nanoparticle morphologies, like cubes, octahedrons, icosahedrons, bipyramids, plates, and polyhedrons, among others, are widely studied for catalysis applications. The recent progress around the high catalytic activity has focused on the stabilizing agents and their potential impact on nanomaterial synthesis to induce changes in the morphology of NPs.

Anchored Pt-Co Nanoparticles on Honeycombed Graphene as Highly Durable Catalysts for the Oxygen Reduction Reaction

Durability is an important factor in evaluating the performance of a catalyst. In this work, the spatial protection of the carrier to nanoparticles was considered to improve the durability of the catalyst. It is found that a honeycombed graphene with a three-dimensional (3D)-hierarchical porous structure (3D HPG) can help to reduce the shedding of Pt-Co nanoparticles (Pt-Co NPs) because 3D HPG can form a protective layer to reduce the direct erosion of Pt-Co NPs on the interface by an electrolyte. Then, appropriate oxygen groups were introduced on the 3D reduced hierarchical porous graphene oxide (3D rHPGO) to improve the dispersion of Pt-Co NPs on the surface of the carrier. It was found that the Pt d-band of the catalyst was anchored by π sites of carbonyl of an oxygen group. After optimization, the catalyst (referred to as Pt-Co/3D rHPGO) achieved a 2-fold enhancement in mass activity than that of a commercial Pt/C catalyst. More importantly, after the accelerated durability test (ADT) of 20 000 cycles, the Pt-Co/3D rHPGO catalyst can almost sustain this level of performance, whereas other catalysts showed a comparatively large loss of activity. According to the results, the high durability of Pt-Co/3D rHPGO was attributed to spatial protection of Pt-Co NPs and the defects on the surface allowed the electrolyte to enter. In addition, oxygen groups provided an anchoring effect on nanoparticles. Thus, the Pt-Co/3D rHPGO electrocatalyst exhibited splendid durability, holding a potential to be applied in PEMFC for long-term work.

Temperature-Controlled Structural Variations of Meticulous Fibrous Networks of NiFe-Polymeric Zeolite Imidazolate Frameworks for Enhanced Performance in Electrocatalytic Water-Splitting Reactions

Developing non-noble, earth-ample, and stable electrocatalysts are highly anticipated in oxygen-evolution reaction (OER) and hydrogen-evolution reaction (HER) at unique pH conditions. Herein, we have synthesized bimetallic (nickel and iron) zeolite imidazolate framework (ZIF)-based nanofibrous materials via a simple electrospinning (ES) process. The structural stability of the fibrous material is subjected to various calcination conditions. We have elaborated the structural importance of the one-dimensional (1D) fibrous materials in electrocatalytic water-splitting reactions. As a result, NiFe-ZIF-NFs (Nanofibers)-RT (Room Temperature) have delivered a small overpotential of 241 mV at 10 mA cm^-2 current density in OER and 290 mV at a fixed current density of 50 mA cm^-2 in HER at two different pH conditions with 1 M KOH and 0.5 M H₂SO₄, respectively. Furthermore, it exposes the actual surface area of 27.270 m² g^-1 and a high electrochemical active surface area (ECSA) of 50 μF in OER and 55 μF in HER, which is responsible for the electrochemical performance with better stability. This exceptional activity of the materials is mainly attributed to the structural dependency of the fibrous network through the polymeric architecture.

Influence of Electrochemical Pretreatment Conditions of PtCu/C Alloy Electrocatalyst on Its Activity

A carbon supported PtCu_x/C catalyst, which demonstrates high activity in the oxygen electroreduction and methanol electrooxidation reactions in acidic media, has been obtained using a method of chemical reduction of Pt (IV) and Cu (2+) in the liquid phase. It has been found that the potential range of the preliminary voltammetric activation of the PtCu_x/C catalyst has a significant effect on the de-alloyed material activity in the oxygen electroreduction reaction (ORR). High-resolution transmission electron microscopy (HRTEM) demonstrates that there are differences in the structures of the as-prepared material and the materials activated in different potential ranges. In this case, there is practically no difference in the composition of the PtCu_x-y/C materials obtained after activation in different conditions. The main reason for the established effect, apparently, is the reorganized features of the bimetallic nanoparticles’ surface structure, which depend on the value of the limiting anodic potential in the activation process. The effect of the activation conditions on the catalyst’s activity in the methanol electrooxidation reaction is less pronounced.

Ultrafine Pt-Ni nanoparticles in hollow porous carbon spheres for remarkable oxygen reduction reaction catalysis

Ultrafine bimetallic Pt-Ni nanoparticles, which catalyze the oxygen reduction reaction (ORR) efficiently, were successfully prepared in hollow porous carbon spheres (HPCSs) under the assistance of organic molecules. 2,2'-Dipyridylamine (dpa) was found to be most effective in preparing homogeneous small Pt-Ni nanoparticles (2.0 ± 0.4 nm) without the phase separation of Pt and Ni during synthesis, and the assistance of the organic molecules was investigated for the alloy nanoparticle formation. The Pt-Ni nanoparticle/HPCS catalyst synthesized in the presence of dpa exhibited remarkable electrochemical performance in the ORR showing a high mass activity of 3.25 ± 0.14 A mg-1Pt at 0.9 VRHE (13.5-fold higher relative to a commercial Pt/C catalyst), a large electrochemical surface area of 105 ± 8 m2 g-1Pt, and high durability. After 60 000 cycles of accelerated durability testing, the mass activity was still 12.3 times higher than that of the commercial Pt/C catalyst.

Catalytic Nanoframes and Beyond

The ever-increasing need for the production and expenditure of sustainable energy is a result of the astonishing rate of consumption of fossil fuels and the accompanying environmental problems. Emphasis is being directed to the generation of sustainable energy by the fuel cell and water splitting technologies. Accordingly, the development of highly efficient electrocatalysts has attracted significant interest, as the fuel cell and water splitting technologies are critically dependent on their performance. Among numerous catalyst designs under investigation, nanoframe catalysts have an intrinsically large surface area per volume and a tunable composition, which impacts the number of catalytically active sites and their intrinsic catalytic activity, respectively. Nevertheless, the structural integrity of the nanoframe during electrochemical operation is an ongoing concern. Some significant advances in the field of nanoframe catalysts have been recently accomplished, specifically geared to resolving the catalytic stability concerns and significantly boosting the intrinsic catalytic activity of the active sites. Herein, general synthetic concepts of nanoframe structures and their structure-dependent catalytic performance are summarized, along with recent notable advances in this field. A discussion on the remaining challenges and future directions, addressing the limitations of nanoframe catalysts, are also provided.

Topological transformation of LDH nanosheets to highly dispersed PtNiFe nanoalloys enhancing CO oxidation performance

Highly dispersed nanoalloys with a tailored metal-oxide interface are pivotal in developing advanced catalysts with superior performance for applications. Herein, a series of highly dispersed Pt/NiFeAl nanoalloys on amorphous supports were successfully fabricated by a topological transformation of layered-double-hydroxide nanosheets. With increasing reduction temperature, samples Pt/NiFeAl-x (x = reduction temperature) showed a progressive transformation from Pt/NiFeAl-LDH to a mixture (Pt, NiFe alloys, FeOy, and NiOy) supported on amorphous Al2O3, which eventually transformed to atomically dispersed PtNiFe alloys supported on amorphous Al2O3. Systematic sample characterization demonstrates that amorphous alumina-supported PtNiFe nanoalloys are merited by excellent redox ability, outstanding O2 activation ability, and moderate CO adsorption strength. When tested as catalysts for CO oxidation, all samples have demonstrated an apparent interfacial effect on catalytic performance, among which Pt/NiFeAl-600 shows a strikingly high CO oxidation activity at low-temperatures coupled with a broader operation temperature window (i.e. CO conversion >99.0%, 100-400 °C). Such a topological transformation strategy has proven applicable for generating atomically dispersed nanoalloys on amorphous supports for catalytic applications.