PGM-Free Fe/N/C and Ultralow Loading Pt/C Hybrid Cathode Catalysts with Enhanced Stability and Activity in PEM Fuel Cells

Towards the Reduction of Pt Loading in High Temperature Proton Exchange Membrane Fuel Cells - Effect of Fe-N-C in Pt-Alloy Cathodes

Pt poisoning by phosphate in high temperature proton exchange membrane fuel cells (HT-PEMFC) leads to loadings up to 1 mg_Pt  cm^-2 per electrode of costly materials. While cheaper Fe-N-C catalysts are unaffected by phosphate deactivation and contribute to the catalysis of the oxygen reduction reaction, their volumetric activity is substantially lower. In this study, the effect of Pt-loading reduced hybrid cathodes for HT-PEMFC is investigated using commercial Celtec®-P-based assembling. A promising effect of Fe-N-C incorporation in terms of acid attraction and activity retention is found. A longer activation (230 h, 0.3 A cm^-2 ) for the hybrid membrane electrode assembly (MEA) is necessary, due to the slower acid distribution within Fe-N-Cs. This study shows the potential of Pt-content reduction by up to 25 % compared to standard MEA using hybrid electrodes. Moreover, important insights for future strategies of cell activation are revealed for these hybrid MEAs.

Generalized Encapsulations of ZIF-Based Fe-N-C Catalysts with Controllable Nitrogen-Doped Carbon for Significantly-Improved Stability Toward Oxygen Reduction Reaction

The vigorous development of efficient platinum group metal-free catalysts is considerably important to facilitate the universal application of proton exchange membrane fuel cells. Although nitrogen-coordinated atomic iron intercalated in carbon matrix (Fe-N-C) catalysts exhibit promising catalytic activity, the performance in fuel cells, especially the short lifetime, remains an obstacle. Herein, a highly-active Fe-N-C catalyst with a power density of >1 w cm^-2 and prolonged discharge stability with a current density of 357 mA cm^-2 after 40 h of constant voltage discharge at 0.7 V in H₂ -O₂ fuel cells using a controllable and efficient N-C coating strategy is developed. It is clarified that a thicker N-C coating may be more favorable to enhance the stability of Fe-N-C catalysts at the expense of their catalytic activity. The stability enhancement mechanism of the N-C coating strategy is proven to be the synergistic effect of reduced carbon corrosion and iron loss. It is believed that these findings can contribute to the development of Fe-N-C catalysts with high activity and long lifetimes.

Effective Approaches for Designing Stable M-Nx /C Oxygen-Reduction Catalysts for Proton-Exchange-Membrane Fuel Cells

The large-scale commercialization of proton-exchange-membrane fuel cells (PEMFCs) is extremely limited by their costly platinum-group metals (PGMs) catalysts, which are used for catalyzing the sluggish oxygen reduction reaction (ORR) kinetics at the cathode. Among the reported PGM-free catalysts so far, metal-nitrogen-carbon (M-N_x /C) catalysts hold a great potential to replace PGMs catalysts for the ORR due to their excellent initial activity and low cost. However, despite tremendous progress in this field in the past decade, their further applications are restricted by fast degradation under practical conditions. Herein, the theoretical fundamentals of the stability of the M-N_x /C catalysts are first introduced in terms of thermodynamics and kinetics. The primary degradation mechanisms of M-N_x /C catalysts and the corresponding mitigating strategies are discussed in detail. Finally, the current challenges and the prospects for designing highly stable M-N_x /C catalysts are outlined.

Engineering Atomic Single Metal-FeN4Cl Sites with Enhanced Oxygen-Reduction Activity for High-Performance Proton Exchange Membrane Fuel Cells

Fe-N-C single-atomic metal site catalysts (SACs) have garnered tremendous interest in the oxygen reduction reaction (ORR) to substitute Pt-based catalysts in proton exchange membrane fuel cells. Nowadays, efforts have been devoted to modulating the electronic structure of metal single-atomic sites for enhancing the catalytic activities of Fe-N-C SACs, like doping heteroatoms to modulate the electronic structure of the Fe-N_x active center. However, most strategies use uncontrolled long-range interactions with heteroatoms on the Fe-N_x substrate, and thus the effect may not precisely control near-range coordinated interactions. Herein, the chlorine (Cl) is used to adjust the Fe-N_x active center via a near-range coordinated interaction. The synthesized FeN₄Cl SAC likely contains the FeN₄Cl active sites in the carbon matrix. The additional Fe-Cl coordination improves the instrinsic ORR activity compared with normal FeN_x SAC, evidenced by density functional theory calculations, the measured ORR half-wave potential (E_1/2, 0.818 V), and excellent membrane electrode assembly performance.

General Carbon-Supporting Strategy to Boost the Oxygen Reduction Activity of Zeolitic-Imidazolate-Framework-Derived Fe/N/Carbon Catalysts in Proton Exchange Membrane Fuel Cells

The oxygen reduction reaction (ORR) activity of the Fe/N/Carbon catalysts derived from the pyrolysis of zeolitic-imidazolate-framework-8 (ZIF-8) has been still lower than that of commercial Pt-based catalysts utilized in the proton exchange membrane fuel cells (PEMFCs) due to low density of accessible active sites. In this study, an efficient carbon-supporting strategy is developed to enhance the ORR efficiency of the ZIF-derived Fe/N/Carbon catalysts by increasing the accessible active site density. The enhancement lies in (i) improving the accessibility of active sites via converting dodecahedral particles to graphene-like layered materials and (ii) enhancing the density of FeN_x active sites via suppressing the formation of nanoparticles as well as providing extra spaces to host active sites. The optimized and efficient Fe/N/Carbon catalyst shows a half-wave potential (E_1/2) of 0.834 V versus reversible hydrogen electrode in acidic media and produces a peak power density of 0.66 W cm^-2 in an air-fed PEMFC at 2 bar backpressure, outperforming most previously reported Pt-free ORR catalysts. Finally, the general applicability of the carbon-supporting strategy is confirmed using five different commercial carbon blacks. This work provides an effective route to derive Fe/N/Carbon catalysts exhibiting a higher power density in PEMFCs.

Electrified Hydrogen Production from Methane for PEM Fuel Cells Feeding: A Review

The greatest challenge of our times is to identify low cost and environmentally friendly alternative energy sources to fossil fuels. From this point of view, the decarbonization of industrial chemical processes is fundamental and the use of hydrogen as an energy vector, usable by fuel cells, is strategic. It is possible to tackle the decarbonization of industrial chemical processes with the electrification of systems. The purpose of this review is to provide an overview of the latest research on the electrification of endothermic industrial chemical processes aimed at the production of H2 from methane and its use for energy production through proton exchange membrane fuel cells (PEMFC). In particular, two main electrification methods are examined, microwave heating (MW) and resistive heating (Joule), aimed at transferring heat directly on the surface of the catalyst. For cases, the catalyst formulation and reactor configuration were analyzed and compared. The key aspects of the use of H2 through PEM were also analyzed, highlighting the most used catalysts and their performance. With the information contained in this review, we want to give scientists and researchers the opportunity to compare, both in terms of reactor and energy efficiency, the different solutions proposed for the electrification of chemical processes available in the recent literature. In particular, through this review it is possible to identify the solutions that allow a possible scale-up of the electrified chemical process, imagining a distributed production of hydrogen and its consequent use with PEMs. As for PEMs, in the review it is possible to find interesting alternative solutions to platinum with the PGM (Platinum Group Metal) free-based catalysts, proposing the use of Fe or Co for PEM application.

Stabilizing Fe-N-C Catalysts as Model for Oxygen Reduction Reaction

The highly efficient energy conversion of the polymer-electrolyte-membrane fuel cell (PEMFC) is extremely limited by the sluggish oxygen reduction reaction (ORR) kinetics and poor electrochemical stability of catalysts. Hitherto, to replace costly Pt-based catalysts, non-noble-metal ORR catalysts are developed, among which transition metal-heteroatoms-carbon (TM-H-C) materials present great potential for industrial applications due to their outstanding catalytic activity and low expense. However, their poor stability during testing in a two-electrode system and their high complexity have become a big barrier for commercial applications. Thus, herein, to simplify the research, the typical Fe-N-C material with the relatively simple constitution and structure, is selected as a model catalyst for TM-H-C to explore and improve the stability of such a kind of catalysts. Then, different types of active sites (centers) and coordination in Fe-N-C are systematically summarized and discussed, and the possible attenuation mechanism and strategies are analyzed. Finally, some challenges faced by such catalysts and their prospects are proposed to shed some light on the future development trend of TM-H-C materials for advanced ORR catalysis.

Catalysts for Oxygen Reduction Reaction in the Polymer Electrolyte Membrane Fuel Cells: A Brief Review

This mini-review presents a short account of materials with exceptional activity towards oxygen reduction reaction. Two main classes of catalytic materials are described, namely platinum group metal (PGM) catalyst and Non-precious metal catalyst. The classes are discussed in terms of possible application in low-temperature hydrogen fuel cells with proton exchange membrane and further commercialization of these devices. A short description of perspective approaches is provided and challenging issues associated with developed catalytic materials are discussed.

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.

Proton Exchange Membrane (PEM) Fuel Cells with Platinum Group Metal (PGM)-Free Cathode

Proton exchange membrane (PEM) fuel cells have gained increasing interest from academia and industry, due to its remarkable advantages including high efficiency, high energy density, high power density, and fast refueling, also because of the urgent demand for clean and renewable energy. One of the biggest challenges for PEM fuel cell technology is the high cost, attributed to the use of precious platinum group metals (PGM), e.g., Pt, particularly at cathodes where sluggish oxygen reduction reaction takes place. Two primary ways have been paved to address this cost challenge: one named low-loading PGM-based catalysts and another one is non-precious metal-based or PGM-free catalysts. Particularly for the PGM-free catalysts, tremendous efforts have been made to improve the performance and durability-milestones have been achieved in the corresponding PEM fuel cells. Even though the current status is still far from meeting the expectations. More efforts are thus required to further research and develop the desired PGM-free catalysts for cathodes in PEM fuel cells. Herein, this paper discusses the most recent progress of PGM-free catalysts and their applications in the practical membrane electrolyte assembly and PEM fuel cells. The most promising directions for future research and development are pointed out in terms of enhancing the intrinsic activity, reducing the degradation, as well as the study at the level of fuel cell stacks.

Molecular Level Design of Nitrogen-Doped Well-Defined Microporous Carbon Spheres for Selective Adsorption and Electrocatalysis

Nitrogen-doped porous carbon spheres have attracted great interest in diversified fields owing to their unique physical and chemical properties. However, the synthesis of nitrogen-doped porous carbon spheres with hierarchical superstructures and refined micropore structures is still a challenge. Herein, we develop a molecular-scale silica templating strategy to prepare nitrogen-doped microporous carbon spheres (MCSSs) with high porosity and a well-defined micropore structure. Octa(aminophenyl) polyhedral oligomeric silsesquioxane is used as a building block in MCSS precursors to provide precise molecular-scale templating and nitrogen doping. The morphology of MCSSs can be easily tuned by choosing the proper solvent. The as-synthesized MCSS with a large surface area (2036 m² g^-1), narrow micropore size distribution, nitrogen doping, and hierarchical geometry can serve as an efficient selective adsorbent for CO₂ and organic pollutants. Furthermore, the MCSS decorated with Fe-N-C active sites (MCSS-Fe) shows enhanced electrocatalytic ORR activity in alkaline solution. This novel approach may open a new avenue for controllable fabrication of porous carbon spheres with desired geometry and well-designed pore structure and show potential applications in selective adsorption and catalysis.

A mass-producible integrative structure Pt alloy oxygen reduction catalyst synthesized with atomically dispersive metal-organic framework precursors

Oxygen reduction reaction (ORR) catalyst is one of the most significant influential factors for the application of proton exchange membrane fuel cells. This work introduces a mass-producible high-performance PtZn alloy integrative structure ORR catalyst, synthesized with the atomically dispersive metal-organic framework precursors. This PtZn catalyst displays excellent catalytic activity with the onset reduction potential of 1.0 V_RHE@ 0.16 mA cm^-2 (Reversible hydrogen electrode; RHE) and the half-wave potential of 0.934 V_RHE for the ORR catalysis. The calculated specific activity and mass activity at 0.9 V are 9.44 A m^-2 and 544 A g_Pt^-1, respectively, which are 5.62 times and 5.77 times as high as the commercial Pt/C. The mass activity is remarkably higher than the target put forward by the Department of Energy (DOE; 440 A g_Pt^-1). Furthermore, this PtZn catalyst also exhibits outstanding stability after the 10,000 potential cyclic degeneration test. The ORR current is much higher than Pt/C in the whole potential range not only before but also after the 10,000 potential cycles with identical Pt loading. This catalyst has a multifarious active-site catalytic structure with PtZn alloyed particles and atomically dispersive metal-N active sites on the N-doped graphited carbon matrix, exhibiting appealing ORR catalytic activity and sound stability for the application and scalable production of fuel cell catalysts.

Multifunctional Nafion/CeO2 Dendritic Structures for Enhanced Durability and Performance of Polymer Electrolyte Membrane Fuel Cells

The development of a novel approach to achieve high-performance and durable fuel cells is imperative for the further commercialization of proton-exchange (or polymer electrolyte) membrane fuel cells (PEMFCs). In this work, multifunctional dendritic Nafion/CeO₂ structures were introduced onto the cathode side of the interface between a membrane and a catalyst layer through electrospray deposition. The dendritic structures enlarged the interfacial contact area between the membrane and the catalyst layer and formed microscale voids between the catalyst layer and gas diffusion medium. This improved the PEMFC performance through the effective utilization of the catalyst and enhanced mass transport of the reactant. Especially, under low-humidity conditions, the hygroscopic effect of CeO₂ nanoparticles also boosted the power density of PEMFCs. In addition to the beneficial effects on the efficiency of the PEMFC, the incorporation of CeO₂, widely known as a radical scavenger, effectively mitigated the free-radical attack on the outer surface of the membrane, where chemical degradation is initiated by radicals formed during PEMFC operation. These multifunctional effects of the dendritic Nafion/CeO₂ structures on PEMFC performance and durability were investigated using various in situ and ex situ measurement techniques.

Rational design of a Fe/S/N/C catalyst from ZIF-8 for efficient oxygen reduction reaction

Fe/N/C catalysts have been regarded as prospective electrocatalysts for oxygen reduction reactions (ORR). As reported, doping S into the Fe/N/C catalyst is an effective strategy to further enhance its ORR performance. Herein, a rational design is demonstrated to synthesize Fe/S/N/C catalysts with a flexible ratio of the doped Fe and S. Through atomic substitution and molecular confinement methods, Fe and S were incorporated into the ZIF-8 precursor, respectively. After further pyrolysis, the Fe/S/N/C catalyst was obtained with uniformly dispersed Fe-N_x, C-S-C active sites and high specific surface area. The Fe/S/N/C catalyst shows a high half-wave potential in alkaline medium, nearly 32 mV higher than the commercial Pt/C, owing to the strong synergistic effect from Fe-N_x and C-S-C active sites. Additionally, the Fe/S/N/C catalyst exhibits good long-term electrocatalytic durability and high endurance to methanol crossover, implying it is a suitable candidate to take the place of conventional Pt or Pt-based catalysts in electrochemical devices.

Metal Organic Frameworks Modified Proton Exchange Membranes for Fuel Cells

Proton exchange membrane fuel cells (PEMFCs) have received considerable interest due to their low operating temperature and high energy conversion rate. However, their practical implement suffers from significant performance challenge. In particular, proton exchange membrane (PEM) as the core component of PEMFCs, have shown a strong correlation between its properties (e.g., proton conductivity, dimensional stability) and the performance of fuel cells. Metal-organic frameworks (MOFs) as porous inorganic-organic hybrid materials have attracted extensive attention in gas storage, gas separation and reaction catalysis. Recently, the MOFs-modified PEMs have shown outstanding performance, which have great merit in commercial application. This manuscript presents an overview of the recent progress in the modification of PEMs with MOFs, with a special focus on the modification mechanism of MOFs on the properties of composite membranes. The characteristics of different types of MOFs in modified application were summarized.