Preparation of a Graphitized-Carbon-Supported PtNi Octahedral Catalyst and Application in a Proton-Exchange Membrane Fuel Cell

Multiscale Architectured Membranes, Electrodes, and Transport Layers for Next-Generation Polymer Electrolyte Membrane Fuel Cells

Over the past few decades, considerable advances have been achieved in polymer electrolyte membrane fuel cells (PEMFCs) based on the development of material technology. Recently, an emerging multiscale architecturing technology covering nanometer, micrometer, and millimeter scales has been regarded as an alternative strategy to overcome the hindrance to achieving high-performance and reliable PEMFCs. This review summarizes the recent progress in the key components of PEMFCs based on a novel architecture strategy. In the first section, diverse architectural methods for patterning the membrane surface with random, single-scale, and multiscale structures as well as their efficacy for improving catalyst utilization, charge transport, and water management are discussed. In the subsequent section, the electrode structures designed with 1D and 3D multiscale structures to enable low Pt usage, improve oxygen transport, and achieve high electrode durability are elucidated. Finally, recent advances in the architectured transport layer for improving mass transportation including pore gradient, perforation, and patterned wettability for gas diffusion layer and 3D structured/engineered flow fields are described.

An elegant 3D-ordered hierarchically porous framework to anchor Pt nanocrystals for durable oxygen reduction reaction

While Platinum (Pt)-based electrocatalysts have been extensively studied for the oxygen reduction reaction (ORR), improving their durability remains a challenge. One promising approach is to design structure-defined carbon supports that can uniformly immobilize Pt nanocrystals (NCs). In this study, we present an innovative strategy for constructing three-dimensional ordered, hierarchically porous carbon polyhedrons (3D-OHPCs) as an efficient support for immobilizing Pt NCs. We achieved this by template-confined pyrolysis of a zinc-based zeolite imidazolate framework (ZIF-8) grown within the voids of polystyrene templates, followed by carbonizing the native oleylamine ligands on Pt NCs to produce graphitic carbon shells. This hierarchical structure enables the uniform anchorage of Pt NCs, while enhancing facile mass transfer and local accessibility of active sites. The optimal material with graphitic carbon armor shells on the surface of Pt NCs (CA-Pt), named CA-Pt@3D-OHPCs-1600, shows comparable activities to commercial Pt/C catalysts. Furthermore, it can withstand over 30,000 cycles of accelerated durability tests, owing to the protective carbon shells and hierarchically ordered porous carbon supports. Our study presents a promising approach for designing highly efficient and durable electrocatalysts for energy-based applications and beyond.

The effect of supporting carbons on the gas phase synthesis of octahedral Pt3Ni electrocatalysts with various H2:CO ratios

The gas phase synthesis of octahedral Pt₃Ni/C electrocatalysts using several carbon substrates (Ketjen black, Graphene, and Vulcan XC-72R) was investigated. Different carbon substrates altered the morphology and alloy of Pt₃Ni nanoparticles, with octahedral morphology and alloy metal preferentially developing on Ketjen black and Graphene, while spherical shape and bimetallic metal preferentially developing on Vulcan. Furthermore, the shape was shown to be regulated throughout the reduction process, with the H₂:CO ratio playing a crucial role in controlling octahedral morphology and carrying out the ORR activity. At a 1:3 H₂:CO ratio, the Pt₃Ni/Ketjen black exhibited the highest ORR activity for both mass activity (1.02 A mgPt⁻¹) and specific activity (5.09 mA cm⁻²) that were 16.5 and 66.1 times larger than commercial Pt/C catalysts, respectively (0.062 A mgPt⁻¹ and 0.077 mA cm⁻²). The best ORR activity of Pt₃Ni onto Graphene and Vulcan XC-72R was exhibited with a 1:1 H₂:CO mixture. The catalysts were tested using a 4000-voltage-cycle accelerated durability test, and the Pt₃Ni/Ketjen catalyst fared the best in terms of ORR stability and durability.

Controlled Synthesis of Carbon-Supported Pt-Based Electrocatalysts for Proton Exchange Membrane Fuel Cells

Proton exchange membrane fuel cells are playing an increasing role in postpandemic economic recovery and climate action plans. However, their performance, cost, and durability are significantly related to Pt-based electrocatalysts, hampering their large-scale commercial application. Hence, considerable efforts have been devoted to improving the activity and durability of Pt-based electrocatalysts by controlled synthesis in recent years as an effective method for decreasing Pt use, and consequently, the cost. Therefore, this review article focuses on the synthesis processes of carbon-supported Pt-based electrocatalysts, which significantly affect the nanoparticle size, shape, and dispersion on supports and thus the activity and durability of the prepared electrocatalysts. The reviewed processes include (i) the functionalization of a commercial carbon support for enhanced catalyst–support interaction and additional catalytic effects, (ii) the methods for loading Pt-based electrocatalysts onto a carbon support that impact the manufacturing costs of electrocatalysts, (iii) the preparation of spherical and nonspherical Pt-based electrocatalysts (polyhedrons, nanocages, nanoframes, one- and two-dimensional nanostructures), and (iv) the postsynthesis treatments of supported electrocatalysts. The influences of the supports, key experimental parameters, and postsynthesis treatments on Pt-based electrocatalysts are scrutinized in detail. Future research directions are outlined, including (i) the full exploitation of the potential functionalization of commercial carbon supports, (ii) scaled-up one-pot synthesis of carbon-supported Pt-based electrocatalysts, and (iii) simplification of postsynthesis treatments. One-pot synthesis in aqueous instead of organic reaction systems and the minimal use of organic ligands are preferred to simplify the synthesis and postsynthesis treatment processes and to promote the mass production of commercial carbon-supported Pt-based electrocatalysts.

Graphical Abstract

This review focuses on the synthesis process of Pt-based electrocatalysts/C to develop aqueous one-pot synthesis at large-scale production for PEMFC stack application.

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.

A High-Durability Graphitic Black Pearl Supported Pt Catalyst for a Proton Exchange Membrane Fuel Cell Stack

Graphitized black pearl (GBP) 2000 supported Pt nanoparticle catalysts is synthesized by a formic acid reduction method. The results of a half-cell accelerated degradation test (ADT) of two protocols and a single-cell ADT show that, Pt/GBP catalyst has excellent stability and durability compared with commercial Pt/C. Especially, the survival time of Pt/GBP-membrane electrode assembly (MEA) reaches 205 min, indicating that it has better reversal tolerance. After the 1003-hour durability test, the proton exchange membrane fuel cell (PEMFC) stack with Pt/GBP presents a slow voltage degradation rate of 5.19% and 36 μV h-1 at 1000 mA cm-2. The durability of the stack is improved because of the durability and stability of the catalyst. In addition, the post morphology characterizations indicate that the structure and particle size of the Pt/GBP catalyst remain unchanged during the dynamic testing protocol, implying its better stability under dynamic load cycles. Therefore, Pt/GBP is a valuable and promising catalyst for PEMFC, and considered as an alternative to classical Pt/C.

Effect of Dispersion Solvents and Ionomers on the Rheology of Catalyst Inks and Catalyst Layer Structure for Proton Exchange Membrane Fuel Cells

This study investigated the effects of the dielectric constant (ε) of a dispersion solvent and ionomer content on the rheology of graphitized carbon (GC)-supported Pt catalyst ink and the structure of catalyst layers (CLs). The ionomer dispersions and catalyst inks were tested using rheological techniques, zeta (ξ) potential, and dynamic light scattering measurements. Results showed that increases in the solvent ε or ionomer content increased the ξ-potential of catalyst particles in the ink, which reduced the catalyst agglomerate size. Steady-state and oscillation scans showed that the Pt/GC catalyst ink had shear-thinning properties and gel-like behavior. The ink with a solvent ε of 40 tended to be more Newtonian fluid, with low yield stress (σ_y). The ionomer content altered the rheology of the ink by changing the internal interaction of inks. Solvents with ε of 70 and 55 enhanced the adsorption of ionomers onto catalysts, thereby increasing the adhesion between ink particles and reducing the risk of CL cracking. As the ionomer content increased, the catalyst absorbed more ionomers in inks, increasing the fracture toughness of CLs, which reduced the crack width.

Enhanced PEMFC durability with graphitized carbon black cathode catalyst supports under accelerated stress testing

The anti-corrosion properties of the carbon substrates of cathode catalysts play a vital role in the commercialization of fuel cell vehicles. Our report reveals the enhanced durability of graphitized carbon black catalyst substrates in polymer electrolyte membrane fuel cells (PEMFCs), tested under simulated start-stop cycling and high potential holding conditions. Graphitized carbon treated at various temperatures is used as the support for Pt catalysts. The catalyst utilizing graphitized carbon treated at 1800 °C demonstrates superior antioxidation properties and the inhibition of Pt particle coarsening. The decay ratio of the potential at 1000 mA cm-2 has been reduced from 34.9% (commercial Pt/C) to 0.5% during high potential holding accelerated stress testing. Correspondingly, the growth of Pt particles is reduced from 0.95 nm (commercial Pt/C) to 0.08 nm; that is, the coalescence of Pt particles is effectively alleviated upon using graphitized carbon black.