Expert assessments of the cost and expected future performance of proton exchange membrane fuel cells for vehicles

Real-time investigation of reactive oxygen species and radicals evolved from operating Fe-N-C electrocatalysts during the ORR: potential dependence, impact on degradation, and structural comparisons

Improving the stability of platinum-group-metal-free (PGM-free) catalysts is a critical roadblock to the development of economically feasible energy storage and conversion technologies. Fe-N-C catalysts, the most promising class of PGM-free catalysts, suffer from rapid degradation. The generation of reactive oxygen species (ROS) during the oxygen reduction reaction (ORR) has been proposed as a central cause of this loss of activity. However, there is insufficient understanding of the generation and dynamics of ROS under catalytic conditions due to the difficulty of detecting and quantifying short-lived ROS such as the hydroxyl radical, OH˙. To accomplish this, we use operando scanning electrochemical microscopy (SECM) to probe the production of radicals by a commercial pyrolyzed Fe-N-C catalyst in real-time using a redox-active spin trap methodology. SECM showed the monotonic production of OH˙ which followed the ORR activity. Our results were thoroughly backed using electron spin resonance confirmation to show that the hydroxyl radical is the dominant radical species produced. Furthermore, OH˙ and H2O2 production followed distinct trends. ROS studied as a function of catalyst degradation also showed a decreased production, suggesting its relation to the catalytic activity of the sample. The structural origins of ROS production were also probed using model systems such as iron phthalocyanine (FePc) and Fe3O4 nanoparticles, both of which showed significant generation of OH˙ during the ORR. These results provide a comprehensive insight into the critical, yet under-studied, aspects of the production and effects of ROS on electrocatalytic systems and open the door for further mechanistic and kinetic investigation using SECM.

Bypassing Formation of Oxide Intermediate via Chemical Vapor Deposition for the Synthesis of an Mn-N-C Catalyst with Improved ORR Activity

A significant barrier to the commercialization of proton exchange membrane fuel cells (PEMFCs) is the high cost of the platinum-based oxygen reduction reaction (ORR) cathode electrocatalysts. One viable solution is to replace platinum with a platinum-group metal (PGM) free catalyst with comparable activity and durability. However, PGM-free catalyst development is burdened by a lack of understanding of the active site formation mechanism during the requisite high-temperature synthesis step, thus making rational catalyst design challenging. Herein we demonstrate in-temperature X-ray absorption spectroscopy (XAS) to unravel the mechanism of site evolution during pyrolysis for a manganese-based catalyst. We show the transformation from an initial state of manganese oxides (MnOx) at room temperature, to the emergence of manganese-nitrogen (MnN4) site beginning at 750 °C, with its continued evolution up to the maximum temperature of 1000 °C. The competition between the MnOx and MnN4 is identified as the primary factor governing the formation of MnN4 sites during pyrolysis. This knowledge led us to use a chemical vapor deposition (CVD) method to produce MnN4 sites to bypass the evolution route involving the MnOx intermediates. The Mn-N-C catalyst synthesized via CVD shows improved ORR activity over the Mn-N-C synthesized via traditional synthesis by the pyrolysis of a mixture of Mn, N, and C precursors.

Effective single web-structured electrode for high membrane electrode assembly performance in polymer electrolyte membrane fuel cell

To achieve a sustainable society, CO₂ emissions must be reduced and efficiency of energy systems must be enhanced. The polymer electrolyte membrane fuel cell (PEMFC) has zero CO₂ emissions and high effectiveness for various applications. A well-designed membrane electrolyte assembly (MEA) composed of electrode layers of effective materials and structure can alter the performance and durability of PEMFC. We demonstrate an efficient electrode deposition method through a well-designed carbon single web with a porous 3D web structure that can be commercially adopted. To achieve excellent electrochemical properties, active Pt nanoparticles are controlled by a nanoglue effect on a highly graphitized carbon surface. The developed MEA exhibits a notable maximum power density of 1082 mW/cm² at 80°C, H₂/air, 50% RH, and 1.8 atm; low cathode loading of 0.1 mg_Pt/cm²; and catalytic performance decays of only 23.18 and 13.42% under commercial-based durability protocols, respectively, thereby achieving all desirables for commercial applications.

Bioinspired and Bioderived Aqueous Electrocatalysis

The development of efficient and sustainable electrochemical systems able to provide clean-energy fuels and chemicals is one of the main current challenges of materials science and engineering. Over the last decades, significant advances have been made in the development of robust electrocatalysts for different reactions, with fundamental insights from both computational and experimental work. Some of the most promising systems in the literature are based on expensive and scarce platinum-group metals; however, natural enzymes show the highest per-site catalytic activities, while their active sites are based exclusively on earth-abundant metals. Additionally, natural biomass provides a valuable feedstock for producing advanced carbonaceous materials with porous hierarchical structures. Utilizing resources and design inspiration from nature can help create more sustainable and cost-effective strategies for manufacturing cost-effective, sustainable, and robust electrochemical materials and devices. This review spans from materials to device engineering; we initially discuss the design of carbon-based materials with bioinspired features (such as enzyme active sites), the utilization of biomass resources to construct tailored carbon materials, and their activity in aqueous electrocatalysis for water splitting, oxygen reduction, and CO₂ reduction. We then delve in the applicability of bioinspired features in electrochemical devices, such as the engineering of bioinspired mass transport and electrode interfaces. Finally, we address remaining challenges, such as the stability of bioinspired active sites or the activity of metal-free carbon materials, and discuss new potential research directions that can open the gates to the implementation of bioinspired sustainable materials in electrochemical devices.

Enhancement of oxygen reduction reactivity on TiN by tuning the work function via metal doping

Oxide layers on conductive TiN have recently been investigated to catalyse the oxygen reduction reaction (ORR) in acidic media. The ORR reactivity, i.e., activity and selectivity, has been correlated with the surface nitrogen atoms. A new strategy, optimising the work function via the doping of foreign metals, is revealed herein to enhance the reactivity.

Enhanced Performance of Sn@Pt Core-Shell Nanocatalysts Supported on Two Different Carbon Structures for the Hydrogen Oxidation Reaction in Acid Media

Sn@Pt core-shell nanocatalysts, supported on Vulcan XC-72 and home-developed nitrogen-doped graphene (Sn@Pt/C and Sn@Pt/NG, respectively), were evaluated for the hydrogen oxidation reaction (HOR) in acid electrolyte. The nanocatalysts were synthesized by the bromide anion exchange (BAE) method. TEM characterization confirmed the nanosize nature of Sn@Pt/C and Sn@Pt/NG, with an average particle size of 2.1 and 2.3 nm, respectively. Sn@Pt/C delivered a similar mass limiting current density (jl, m) of the HOR compared to Sn@Pt/NG, which was higher than those of Pt/C and Pt/NG (ca. 2 and 2.3-fold increase, respectively). Moreover, the Sn@Pt/C and Sn@Pt/NG core-shell nanocatalysts demonstrated a higher specific activity related to Pt/C and Pt/NG. Mass and specific Tafel slopes further demonstrated the improved catalytic activity of Sn@Pt/C for the HOR, followed by Sn@Pt/NG. The application of the nanocatalysts was proposed for polymer electrolyte membrane fuel cells (PEMFC).

A Review on the Long-Term Performance of Proton Exchange Membrane Fuel Cells: From Degradation Modeling to the Effects of Bipolar Plates, Sealings, and Contaminants

Proton-exchange membrane fuel cells (PEMFCs) are regarded as promising alternatives to internal combustion engines (ICEs) to reduce pollution. Recent research on PEMFCs focuses on achieving higher power densities, reducing the refueling time, mitigating the final price, and decreasing the degradations, to facilitate the commercialization of hydrogen mobility. The design of bipolar plates and compression kits, in addition to their coating, can effectively improve performance, increase durability, and support water/thermal management. Past reviews usually focused on the specific aspect, which can hardly provide readers with a complete picture of the key challenges facing and advances in the long-term performance of PEMFCs. This paper aims to deliver a comprehensive source to review, from both experimental, analytical and numerical viewpoints, design challenges, degradation modeling, protective coatings for bipolar plates, and key operational challenges facing and solutions to the stack to prevent contamination. The significant research gaps in the long-term performance of PEMFCs are identified as (1) improved bipolar-plate design and coating, (2) the optimization of the design of sealing and compression kits to reduce mechanical stresses, and (3) stack degradation regarding fuel contamination and dynamic operation.

Controlling Hydronium Diffusivity in Model Proton Exchange Membranes

Fuel-cell-based proton exchange membranes (PEMs) show great potential as cost-effective and clean energy conversion devices. In our recent work, we found that for the low-hydrated model PEMs with a inhomogeneous water distribution and a sulfonate anionic functional end group (SO₃^-), the H₃O⁺ reacts with SO₃^- according to SO₃^- + H₃O⁺ ↔ SO₃H + H₂O, indicating that the anions in PEMs become active participants in the hydronium diffusion. In this work, we use fully atomistic ab initio molecular dynamics simulations to elucidate the optimal conditions that would promote the participation of SO₃^- in the hydronium diffusion mechanism by increasing the H₃O⁺/SO₃^- reactivity, thus increasing the hydronium diffusivity along the cell. The results presented in this work allow us to suggest a set of design rules for creating novel, highly conductive PEMs operating at high temperatures under a nonuniform water distribution using a linker/anion with a relatively high pK_a such as (CH₂)₂SO₃. We expect that the discovery of these key design principles will play an important role in the synthesis of high-performing materials for emerging PEM-based fuel cell technologies.

Superior Proton Exchange Membrane Fuel Cell (PEMFC) Performance Using Short-Side-Chain Perfluorosulfonic Acid (PFSA) Membrane and Ionomer

Optimization of the ionomer materials in catalyst layers (CLs) which sometimes is overlooked has been equally crucial as selection of the membranes in membrane electrode assembly (MEA) for achieving a superior performance in proton exchange membrane fuel cells (PEMFCs). Four combinations of the MEAs composed of short-side-chain (SSC) and long-side-chain (LSC) perfluorosulfonic acid (PFSA) polymers as membrane and ionomer materials have been prepared and tested under various temperatures and humidity conditions, aiming to investigate the effects of different side chain polymer in membranes and CLs on fuel cell performance. It is discovered that SSC PFSA polymer used as membrane and ionomer in CL yields better fuel cell performance than LSC PFSA polymer, especially at high temperature and low RH conditions. The MEA with the SSC PFSA employed both as a membrane and as an ionomer in cathode CL demonstrates the best cell performance amongst the investigated MEAs. Furthermore, various electrochemical diagnoses have been applied to fundamentally understand the contributions of the different resistances to the overall cell performance. It is illustrated that the charge transfer resistance (R_ct) made the greatest contribution to the overall cell resistance and then membrane resistance (R_m), implying that the use of the advanced ionomer in CL could lead to more noticeable improvement in cell performance than only the substitution as the membrane.

Inexpensive gram scale synthesis of porous Ti4O7 for high performance polymer electrolyte fuel cell electrodes

As a fuel cell catalyst support, more than 2 g of Magnéli phase Ti₄O₇ fine-particles were synthesized in a single reaction via an inexpensive route. The single-cell performance reached that of commercial carbon-supported platinum, with an excellent load cycle durability, one of the highest ever reported for oxide-supported platinum catalysts.

Investigation on the Microscopic/Macroscopic Mechanical Properties of a Thermally Annealed Nafion® Membrane

The Nafion® electrolyte membrane, which provides a proton pathway, is an essential element in fuel cell systems. Thermal treatment without additional additives is widely used to modify the mechanical properties of the membrane, to construct reliable and durable electrolyte membranes in the fuel cell. We measured the microscopic mechanical properties of thermally annealed membranes using atomic force microscopy with the two-point method. Furthermore, the macroscopic property was investigated through tensile tests. The microscopic modulus exceeded the macroscopic modulus over all annealing temperature ranges. Additionally, the measured microscopic modulus increased rapidly near 150 °C and was saturated over that temperature, whereas the macroscopic modulus continuously increased until 250 °C. This mismatched micro/macroscopic reinforcement trend indicates that the internal reinforcement of the clusters is induced first until 150 °C. In contrast, the reinforcement among the clusters, which requires more thermal energy, probably progresses even at a temperature of 250 °C. The results showed that the annealing process is effective for the surface smoothing and leveling of the Nafion® membrane until 200 °C.

Slot-die-coating operability windows for polymer electrolyte membrane fuel cell cathode catalyst layers

Roll-to-roll (R2R) slot-die coating of polymer electrolyte membrane fuel cell (PEMFC) catalyst layers represents a scalable deposition method for producing 10-20 m²·min^-1 of catalyst-coated gas diffusion layers (GDLs). This high-throughput production technique will help lower the cost of PEMFC catalyst layers. The uniformity of the wet layer applied by slot die deposition is affected by process parameters such as substrate speed, vacuum pressure applied at the upstream meniscus, gap between the slot die lips and substrate, ink rheology, and other ink and substrate properties. The set of conditions for producing a defect-free coating with a dilute ink typically requires little to no upstream vacuum pressure, so suitable operating conditions can be found easily through trial and error and operator intuition. However, the higher viscosity of more concentrated inks dramatically shifts the range of settings that result in a homogeneous coating to higher vacuum levels, which are harder to find through hit or miss. A predictive model showing the range of operable conditions decreases material wastage inherent in experimentally searching for suitable parameters. In this study, the defect-free coating parameter window is explored experimentally and theoretically for two concentrations of PEFC cathode inks. Both a full capillary hydrodynamic model and a computationally cheaper viscocapillary model successfully predict the experimentally determined coating window within the experimental and model uncertainty limits for inks with 5.3 wt% and 12.0 wt% solids ink while maintaining the 0.1 mg_Pt·cm^-2Pt areal loading target. This paper demonstrates a viable pathway for meeting the $30/kW_net ultimate cost target of the United States Department of Energy (U.S. DOE) Hydrogen Fuel Cells Technologies Office (HFTO). The concentrated ink lowers the thermal energy and capital expenditure (CapEx) budget of the coating process by decreasing the amount of time, energy, and floorspace required for drying the coating.

Influence of Ionomer Content in the Catalytic Layer of MEAs Based on Aquivion® Ionomer

Perfluorinated sulfonic acid (PFSA) polymers such as Nafion^® are widely used for both electrolyte membranes and ionomers in the catalytic layer of membrane-electrode assemblies (MEAs) because of their high protonic conductivity, σ_H, as well as chemical and thermal stability. The use of PFSA polymers with shorter side chains and lower equivalent weight (EW) than Nafion^®, such as Aquivion^® PFSA ionomers, is a valid approach to improve fuel cell performance and stability under drastic operative conditions such as those related to automotive applications. In this context, it is necessary to optimize the composition of the catalytic ink, according to the different ionomer characteristics. In this work, the influence of the ionomer amount in the catalytic layer was studied, considering the dispersing agent used to prepare the electrode (water or ethanol). Electrochemical studies were carried out in a single cell in the presence of H₂-air, at intermediate temperatures (80-95 °C), low pressure, and reduced humidity ((50% RH). %). The best fuel cell performance was found for 26 wt.% Aquivion^® at the electrodes using ethanol for the ink preparation, associated to a maximum catalyst utilization.

Synthesis of Tailored Perfluoro Unsaturated Monomers for Potential Applications in Proton Exchange Membrane Preparation

The aim of the present work is the synthesis and characterization of new perfluorinated monomers bearing, similarly to Nafion^®, acidic groups for proton transport for potential and future applications in proton exchange membrane (PEM) fuel cells. To this end, we focused our attention on the synthesis of various molecules with (i) sufficient volatility to be used in vacuum polymerization techniques (e.g., PECVD)), (ii) sulfonic, phosphonic, or carboxylic acid functionalities for proton transport capacity of the resulting membrane, (iii) both aliphatic and aromatic perfluorinated tags to diversify the membrane polarity with respect to Nafion^®, and (iv) a double bond to facilitate the polymerization under vacuum giving a preferential way for the chain growth of the polymer. A retrosynthetic approach persuaded us to attempt three main synthetic strategies: (a) organometallic Heck-type cross-coupling, (b) nucleophilic displacement, and (c) Wittig–Horner reaction (carbanion approach). Preliminary results on the plasma deposition of a polymeric film are also presented. The variation of plasma conditions allowed us to point out that the film prepared in the mildest settings (20 W) shows the maximum monomer retention in its structure. In this condition, plasma polymerization likely occurs mainly by rupture of the π bond in the monomer molecule.

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.

Subsize Pt-based intermetallic compound enables long-term cyclic mass activity for fuel-cell oxygen reduction

Pt-based alloy catalysts may promise considerable mass activity (MA) for oxygen reduction but are generally unsustainable over long-term cycles, particularly in practical proton exchange membrane fuel cells (PEMFCs). Herein, we report a series of Pt-based intermetallic compounds (Pt₃Co, PtCo, and Pt₃Ti) enclosed by ultrathin Pt skin with an average particle size down to about 2.3 nm, which deliver outstanding cyclic MA and durability for oxygen reduction. By breaking size limitation during ordered atomic transformation in Pt alloy systems, the MA and durability of subsize Pt-based intermetallic compounds can be simultaneously optimized. The subsize scale was also found to enhance the stability of the membrane electrode through preventing the poisoning of catalysts by ionomers in humid fuel-cell conditions. We anticipate that subsize Pt-based intermetallic compounds set a good example for the rational design of high-performance oxygen reduction electrocatalysts for PEMFCs. Furthermore, the prevention of ionomer poisoning was identified as the critical parameter for assembling robust commercial membrane electrodes in PEMFCs.

Comprehensive Review on Fuel Cell Technology for Stationary Applications as Sustainable and Efficient Poly-Generation Energy Systems

Fuel cell technologies have several applications in stationary power production, such as units for primary power generation, grid stabilization, systems adopted to generate backup power, and combined-heat-and-power configurations (CHP). The main sectors where stationary fuel cells have been employed are (a) micro-CHP, (b) large stationary applications, (c) UPS, and IPS. The fuel cell size for stationary applications is strongly related to the power needed from the load. Since this sector ranges from simple backup systems to large facilities, the stationary fuel cell market includes few kWs and less (micro-generation) to larger sizes of MWs. The design parameters for the stationary fuel cell system differ for fuel cell technology (PEM, AFC, PAFC, MCFC, and SOFC), as well as the fuel type and supply. This paper aims to present a comprehensive review of two main trends of research on fuel-cell-based poly-generation systems: tracking the market trends and performance analysis. In deeper detail, the present review will list a potential breakdown of the current costs of PEM/SOFC production for building applications over a range of production scales and at representative specifications, as well as broken down by component/material. Inherent to the technical performance, a concise estimation of FC system durability, efficiency, production, maintenance, and capital cost will be presented.

Hydrogen-Mediated Thin Pt Layer Formation on Ni3N Nanoparticles for the Oxygen Reduction Reaction

A simple wet-chemical route for the preparation of core-shell-structured catalysts was developed to achieve high oxygen reduction reaction (ORR) activity with a low Pt loading amount. Nickel nitride (Ni₃N) nanoparticles were used as earth-abundant metal-based cores to support thin Pt layers. To realize the site-selective formation of Pt layers on the Ni₃N core, hydrogen molecules (H₂) were used as a mild reducing agent. As H₂ oxidation is catalyzed by the surface of Ni₃N, the redox reaction between H₂ and Pt(IV) in solution was facilitated on the Ni₃N surface, which resulted in the selective deposition of Pt on Ni₃N. The controlled Pt formation led to a subnanometer (0.5-1 nm)-thick Pt shell on the Ni₃N core. By adopting the core-shell structure, higher ORR activity than the commercial Pt/C was achieved. Electrochemical measurements showed that the thin Pt layer on Ni₃N nanoparticle exhibits 5 times higher mass activity and specific activity than that of commercial Pt/C. Furthermore, it is expected that the proposed simple wet-chemical method can be utilized to prepare various transition-metal-based core-shell nanocatalysts for a wide range of energy conversion reactions.

Drivers and Barriers to the Adoption of Fuel Cell Passenger Vehicles and Buses in Germany

As policymakers and automotive stakeholders around the world seek to accelerate the electrification of road transport with hydrogen, this study focuses on the experiences of Germany, a world leader in fuel cell technology. Specifically, it identifies and compares the drivers and barriers influencing the production and market penetration of privately-owned fuel cell electric passenger vehicles (FCEVs) and fuel cell electric buses (FCEBs) in public transit fleets. Using original data collected via a survey and 17 interviews, we elicited the opinions of experts to examine opportunities and obstacles in Germany from four perspectives: (i) the supply of vehicles (ii) refuelling infrastructure, (iii) demand for vehicles, and (iv) cross-cutting institutional issues. Findings indicate that despite multiple drivers, there are significant challenges hampering the growth of the hydrogen mobility market. Several are more pronounced in the passenger FCEV market. These include the supply and cost of production, the lack of German automakers producing FCEVs, the profitability and availability of refuelling stations, and low demand for vehicles. In light of these findings, we extract implications for international policymakers and future studies. This study provides a timely update on efforts to spur the deployment of hydrogen mobility in Germany and addresses the underrepresentation of studies examining both buses and passenger vehicles in tandem.

Proton Conductivity via Trapped Water in Phosphonate-Based Metal-Organic Frameworks Synthesized in Aqueous Media

Metal-organic frameworks (MOFs) are promising candidates for proton-conducting applications. Herein, we report the aqueous synthesis of two new phosphonate-based MOFs comprising glyphosate linkers, [Mg(dpmp)]·2H₂O (Mg-NU-225) and [Fe(dpmp)]·2H₂O (Fe-NU-225), (dpmp = N,N'-diphosphonomethyl-2,5-piperazinedione), and explore their proton conductivities. Single crystal X-ray diffraction measurements revealed that both frameworks display a two-dimensional layered structure with a cyclic ring ligand which forms in situ from the condensation of two glyphosate molecules. Under humid conditions and over a wide temperature range, water molecules are trapped between adjacent layers and facilitate rapid proton conduction. Mg-NU-225 and Fe-NU-225 recorded proton conductivities of 1.5 × 10^-5 and 1.7 × 10^-5 S cm^-1, respectively, along the plane direction and 1.6 × 10^-3 and 9.1 × 10^-5 S cm^-1 perpendicular to the plane direction at 55 °C and 95% relative humidity, as confirmed by two-contact probe impedance methods. The mechanism of proton transport was found to be that of the Grotthuss model from the low activation energy for proton hopping.

Hydrogen Storage for Fuel Cell Electric Vehicles: Expert Elicitation and a Levelized Cost of Driving Model

A cost-effective and compact hydrogen storage system could advance fuel cell electric vehicles (FCEVs). Today's commercial FCEVs incorporate storage that is projected to be heavier, larger, and costlier than targets set by the U.S. Driving Research and Innovation for Vehicle efficiency and Energy sustainability Partnership (U.S. DRIVE). To inform research and development (R&D), we elicited 31 experts' assessments of expected future costs and capacities of storage systems. Experts suggested that systems would approach U.S. DRIVE's ultimate capacity targets but fall short of cost targets at a high production volume. The 2035 and 2050 median costs anticipated by experts were $13.5 and $10.53/kWh_H2, gravimetric capacities of 5.2 and 5.6 wt %, and volumetric capacities of 0.93 and 1.33 kWh_H2/L, respectively. To meet U.S. DRIVE's targets, experts recommended allocating the majority of government hydrogen storage R&D funding to materials development. Furthermore, we incorporated experts' cost assessments into a levelized cost of driving model. Given technical and fuel price uncertainty, FCEV costs ranged from $0.38 to $0.45/mile ($0.24-$0.28/km) in 2020, $0.30 to $0.33/mile ($0.19-$0.21/km) in 2035-2050, and $0.27 to $0.31/mile ($0.17-$0.19/km) in 2050. Depending on fuel, electricity, and battery prices, our findings suggest that FCEVs could compete with conventional and alternative fuel vehicles by 2035.

Strategies to enhance the electrochemical performances of Pt-based intermetallic catalysts

The need for improving the energy conversion efficiency of proton exchange membrane fuel cells (PEMFCs) has motivated the development of advanced electrocatalysts with desirable activity and durability. Pt-Based intermetallic compounds, featuring atomically ordered structures, have long been considered to be very promising alternatives to widely employed Pt and Pt alloy (solid solutions) catalysts. To facilitate the practical application of Pt-based intermetallics in PEMFCs, effective strategies have been developed to further improve their catalytic activity and durability over the last decade. This feature article overviews the recent advances on the strategies for enhancing the electrochemical performances of Pt-based intermetallic catalysts, which include size control, surface engineering, and composition tuning. Thermodynamic and kinetic perspectives on the formation of the intermetallic phases are summarized to better design the synthesis conditions and realize the size control. After this, the size-control approaches (e.g. coating protection, matrix protection) are illustrated and discussed. We highlight the positive effect of surface engineering and discuss the recently developed methods for surface engineering. Finally, we discuss the thermodynamic feasibility of composition tuning and recent work based on composition-tunable intermetallic electrocatalysts.

Local probe investigation of electrocatalytic activity

As the world energy crisis remains a long-term challenge, development and access to renewable energy sources are crucial for a sustainable modern society. Electrochemical energy conversion devices are a promising option for green energy supply, although the challenge associated with electrocatalysis have caused increasing complexity in the materials and systems, demanding further research and insights. In this field, scanning probe microscopy (SPM) represents a specific source of knowledge and understanding. Thus, our aim is to present recent findings on electrocatalysts for electrolysers and fuel cells, acquired mainly through scanning electrochemical microscopy (SECM) and other related scanning probe techniques. This review begins with an introduction to the principles of several SPM techniques and then proceeds to the research done on various energy-related reactions, by emphasizing the progress on non-noble electrocatalytic materials.

Water electrolysers with closed and open electrochemical systems

Green hydrogen production using renewables-powered, low-temperature water electrolysers is crucial for rapidly decarbonizing the industrial sector and with it many chemical transformation processes. However, despite decades of research, advances at laboratory scale in terms of catalyst design and insights into underlying processes have not resulted in urgently needed improvements in water electrolyser performance or higher deployment rates. In light of recent developments in water electrolyser devices with modified architectures and designs integrating concepts from Li-ion or redox flow batteries, we discuss practical challenges hampering the scaling-up and large-scale deployment of water electrolysers. We highlight the role of device architectures and designs, and how engineering concepts deserve to be integrated into fundamental research to accelerate synergies between materials science and engineering, and also to achieve industry-scale deployment. New devices require benchmarking and assessment in terms of not only their performance metrics, but also their scalability and deployment potential.

Is the H2 economy realizable in the foreseeable future? Part III: H2 usage technologies, applications, and challenges and opportunities

Energy enthusiasts in developed countries explore sustainable and efficient pathways for accomplishing zero carbon footprint through the H₂ economy. The major objective of the H₂ economy review series is to bring out the status, major issues, and opportunities associated with the key components such as H₂ production, storage, transportation, distribution, and applications in various energy sectors. Specifically, Part I discussed H₂ production methods including the futuristic ones such as photoelectrochemical for small, medium, and large-scale applications, while Part II dealt with the challenges and developments in H₂ storage, transportation, and distribution with national and international initiatives. Part III of the H₂ economy review discusses the developments and challenges in the areas of H₂ application in chemical/metallurgical industries, combustion, and fuel cells. Currently, the majority of H₂ is being utilized by a few chemical industries with >60% in the oil refineries sector, by producing grey H₂ by steam methane reforming on a large scale. In addition, the review also presents the challenges in various technologies for establishing greener and sustainable H₂ society.

Is the H2 economy realizable in the foreseeable future? Part III: H2 usage technologies, applications, and challenges and opportunities

Energy enthusiasts in developed countries explore sustainable and efficient pathways for accomplishing zero carbon footprint through the H₂ economy. The major objective of the H₂ economy review series is to bring out the status, major issues, and opportunities associated with the key components such as H₂ production, storage, transportation, distribution, and applications in various energy sectors. Specifically, Part I discussed H₂ production methods including the futuristic ones such as photoelectrochemical for small, medium, and large-scale applications, while Part II dealt with the challenges and developments in H₂ storage, transportation, and distribution with national and international initiatives. Part III of the H₂ economy review discusses the developments and challenges in the areas of H₂ application in chemical/metallurgical industries, combustion, and fuel cells. Currently, the majority of H₂ is being utilized by a few chemical industries with >60% in the oil refineries sector, by producing grey H₂ by steam methane reforming on a large scale. In addition, the review also presents the challenges in various technologies for establishing greener and sustainable H₂ society.

Is the H2 economy realizable in the foreseeable future? Part III: H2 usage technologies, applications, and challenges and opportunities

Energy enthusiasts in developed countries explore sustainable and efficient pathways for accomplishing zero carbon footprint through the H₂ economy. The major objective of the H₂ economy review series is to bring out the status, major issues, and opportunities associated with the key components such as H₂ production, storage, transportation, distribution, and applications in various energy sectors. Specifically, Part I discussed H₂ production methods including the futuristic ones such as photoelectrochemical for small, medium, and large-scale applications, while Part II dealt with the challenges and developments in H₂ storage, transportation, and distribution with national and international initiatives. Part III of the H₂ economy review discusses the developments and challenges in the areas of H₂ application in chemical/metallurgical industries, combustion, and fuel cells. Currently, the majority of H₂ is being utilized by a few chemical industries with >60% in the oil refineries sector, by producing grey H₂ by steam methane reforming on a large scale. In addition, the review also presents the challenges in various technologies for establishing greener and sustainable H₂ society.

Recovery of expensive Pt/C catalysts from the end-of-life membrane electrode assembly of proton exchange membrane fuel cells

A simple and economical route using an environmental friendly solvent is reported for recovering catalyst from the end-of-life membrane electrode assembly. This precious component is recovered in the form of Pt/C and ionomer powder. The catalyst exhibited an electrochemical surface area of 42 m² g⁻¹ and remarkable stability, showcasing its potential for second life applications.

A sustainable approach for the recovery of EoL MEAs and possibility of pushing the recovered products back into the supply chain.

Self-Humidifying Proton Exchange Membranes for Fuel Cell Applications: Advances and Challenges

Polymer electrolyte fuel cells (PEFCs) provide efficient and carbon-free power by converting the hydrogen chemical energy. The PEFCs can reach their greatest performance in humidified condition, as proton exchange membranes (PEMs) should be humidified for their proton transportation function. Thus, external humidifiers are commonly employed to increase the water content of reactants. However, being burdened with external humidifiers can make the control of PEFCs complicated and costly, in particular for transportation application. To overcome this issue, self-humidifying PEMs have been introduced, with which PEFC can be fed by dry reactants. In fact, internal humidification is accomplished by produced water from the recombination of permeated hydrogen and oxygen gases on the incorporated platinum catalysts within the PEM. While the water production agent remains constant, there is a broad range of additives that are utilized to retain the generated water and facilitate the proton conduction path in the PEM. This review paper has classified the aforementioned additives in three categories: inorganic materials, proton-conductive materials, and carbon-based additives. Moreover, synthesis methods, preparation procedures, and characterization tests are overviewed. Eventually, self-humidifying PEMs endowed with platinum and different additives are compared from performance and stability perspectives, such as water uptake, proton conductivity, fuel cell performance, gas cross-over, and the overall durability. In addition, their challenges and possible solutions are reviewed. Considering the concerns regarding the long-term durability of such PEMs, it seems that further investigations can be beneficial to confirm their reliability for prolonged PEFC operation.

Optimization of Sulfurization Process of Cobalt Sulfide and Nitrogen Doped Carbon Material for Boosting the Oxygen Reduction Reaction Catalytic Activity in Alkaline Medium

In order to reduce fuel cell material cost and promote its application, it is urgent to develop non-noble metal materials to replace platinum as the cathode catalysts in fuel cells. The cobalt sulfide and nitrogen co-doped carbon (S-Co-N/C) materials with metal-organic frameworks as precursors have shown good oxygen reduction reaction (ORR) catalytic activity. Benefiting from the protection of catalytic active sites by sulfur atoms, the stability and alcohol-tolerance of the S-Co-N/C catalyst can be significantly improved. In order to fully understand the effect of the sulfurization process on the properties of the material, zeolite imidazole frameworks (ZIF)-8, and ZIF-67 are used as precursors to prepare a novel material of S-Co-N/C by using a sulfurization-pyrolysis method. Another S-Co-N/C material by using a pyrolysis- sulfurization method is prepared for comparison. The effects of the sulfurization process in the preparation on the morphology, chemical structure, specific surface area, and ORR catalytic activity of the final material are investigated. The experimental results show that the surface of the S-Co-N/C material tends to be rough due to the sulfurization reaction of the metal elements. The porosity of the material is reduced to some extent due to the remaining Zn elements in the final product. Interestingly, some carbon nanotubes are found to be generated on the surface of the S-Co-N/C material because of the synergistic effect of Zn and Co on the carbon material during the pyrolysis process, which is beneficial to accelerate the adsorption of oxygen on the S-Co-N/C surface and the electron transportation during the oxygen reduction reaction. In addition, the generated CoS during the sulfurization process can further protect the Co elements from agglomeration, which can effectively increase the ORR catalytic active sites in the final material. The S-Co-N/C material prepared by the sulfurization-pyrolysis method performs a superior ORR catalytic activity to the one synthesized by the pyrolysis-sulfurization method.

Kinetic separation of CO2/CH4 mixtures with Ni-MOF-74@Al2O3 core–shell composites

A novel core–shell species for the adsorption-based separation of carbon dioxide (CO2) from methane (CH4) is introduced by hydrothermal synthesis of Ni-MOF-74 on mesoporous spherical Al2O3 carrier substrate. The material was characterized and the shell thickness determined by means of optical and scanning electron microscopy as well as volumetric adsorption and fluid displacement experiments. Kinetic experiments with Ni-MOF-74@Al2O3 core–shell composites carried out at 303.15 K and at pressures up to 10 bar expose remarkably dominating uptake rates for CO2 over CH4. In the contrary Ni-MOF-74@Al2O3 appears to be unselective according to equilibrium data at the same conditions. Dynamic breakthrough experiments of binary CH4/CO2-mixtures (at 303.15 K and 5 bar) prove the prevailing effect of adsorption kinetics and the storage function of the mesoporous core. This statement is supported by a considerable boost in CO2-selectivity and capacity compared to adsorption equilibria measured on pure Ni-MOF-74 by the factor of 55.02 and up to 2.42, respectively.

High Power Density Platinum Group Metal-free Cathodes for Polymer Electrolyte Fuel Cells

Low cost and high-performing platinum group metal-free (PGM-free) cathodes have the potential to transform the economics of polymer electrolyte fuel cell (PEFC) commercialization. Significant advancements have been made recently in terms of PGM-free catalyst activity and stability. However, before PGM-free catalysts become viable in PEFCs, several technical challenges must be addressed including cathode's fabrication, ionomer integration, and transport losses. Here, we present an integrated optimization of cathode performance that was achieved by simultaneously optimizing the catalyst morphology and electrode structure for high power density. The chemically doped metal-organic framework derived Fe-N-C catalyst we used allows precise tuning of the particle size over a wide range, enabling this unique study. Our results demonstrate the careful interplay between the catalyst primary particle size and the polymer electrolyte ionomer integration. The primary particles must be sufficiently large to permit uniform ionomer thin films throughout the surrounding pores, but not so large as to impact intraparticle transport to the active sites. The content of ionomer must be carefully balanced between sufficient loading for the complete catalyst coverage and adequate proton conductivity, while not being excessive and inducing large oxygen transport losses and liquid water flooding. With the optimal 100 nm size catalyst and ionomer loading, we achieved a high power density of 410 mW/cm² at a rated voltage and a peak power density of 610 mW/cm² in an automotive-relevant operating condition.