Enhancing CO Tolerance in PEMFC Anodes via Thermal Oxidation Induced RuO2 Blocking Shell on a PtRu/C Catalyst.

CO poisoning in Pt-based anode catalysts significantly hampers the proton exchange membrane fuel cell (PEMFC) performance. Despite great advances in CO-tolerant catalysts, their effectiveness is often limited to fundamental three-electrode systems, which is inadequate for practical PEMFC applications. Herein, we present a straightforward thermal oxidation strategy for constructing a Ru oxide blocking layer on commercial PtRu/C through a one-step Ru-segregation-and-oxidation process. The resulting 0.7 nm thick Ru oxide layer effectively inhibits CO adsorption while maintaining hydrogen oxidation activity. PtRu@RuO2/C demonstrates exceptional CO tolerance, enduring 1% CO in rotating disk electrode tests, an ∼10-fold improvement compared to that of PtRu/C. Crucially, it retains high HOR activity and CO tolerance in PEMFC, with negligible polarization curve loss in the presence of 100 ppm CO. Notably, 85% HOR activity is retained after a 4 h stability test. This enhancement contributes to the Ru oxide layer decelerating CO adsorption kinetics, rather than promoting CO oxidation via the classic bifunctional mechanism.

Simultaneously Geometrical and Electronic Modulation of L10-PtZn by Trace Ge Boosts High-performance Oxygen Reduction Reaction.

Developing a highly active, durable, and low-platinum-based electrocatalyst for the cathodic oxygen reduction reaction (ORR) is for breaking the bottleneck of large-scale applications of proton exchange membrane fuel cells (PEMFCs). Herein, ultrafine PtZn intermetallic nanoparticles with low Pt-loading and trace germanium (Ge) involvement confined in the nitrogen-doped porous carbon (Ge-L10-PtZn@N-C) are reported. The Ge-L10-PtZn@N-C exhibit superior ORR activity with a mass activity of 3.04 A mg-1 Pt and specific activity of 4.69 mA cm-2, ≈12.2- and 10.2-times improvement compared to the commercial Pt/C (20%) at 0.90 V in 0.1 m KOH. The cathodic catalyst Ge-L10-PtZn@N-C assembled in the PEMFC shows encouraging peak power densities of 316.5 (at 0.86 V) and 417.2 mW cm-2 (at 0.91 V) in alkaline and acidic fuel-cell, respectively. The combination of experiment and density functional theory calculations (DFT) results robustly reveal that the participation of trace Ge can not only trigger a "growth site locking effect" to effectively inhibit nanoparticle growth, bring miniature nanoparticles, enhance dispersion uniformity, and achieve the exposure of the more electrochemical active site, but also effectively modulates the electronic structure, hence optimizing the adsorption/desorption of the oxygen intermediates.

Coupling Single-Atom Sites and Ordered Intermetallic PtM Nanoparticles for Efficient Catalysis in Fuel Cells.

The design of an efficient catalytic system with low Pt loading and excellent stability for the acidic oxygen reduction reaction is still a challenge for the extensive application of proton-exchange membrane fuel cells. Here, a gas-phase ordered alloying strategy is proposed to construct an effective synergistic catalytic system that blends PtM intermetallic compounds (PtM IMC, M = Fe, Cu, and Ni) and dense isolated transition metal sites (M-N4 ) on nitrogen-doped carbon (NC). This strategy enables Pt nanoparticles and defects on the NC support to timely trap flowing metal salt without partial aggregation, which is attributed to the good diffusivity of gaseous transition metal salts with low boiling points. In particular, the resulting Pt1 Fe1 IMC cooperating with Fe-N4 sites achieves cooperative oxygen reduction with a half-wave potential up to 0.94 V and leads to a high mass activity of 0.51 A  mgPt -1 and only 23.5% decay after 30 k cycles, both of which exceed DOE 2025 targets. This strategy provides a method for reducing Pt loading in fuel cells by integrating Pt-based intermetallics and single transition metal sites to produce an efficient synergistic catalytic system.

Ultrathin Ultralow-Platinum Catalyst Coated Membrane for Proton Exchange Membrane Fuel Cells.

Catalyst coated membrane (CCM) is the core component of proton exchange membrane fuel cells and is routinely fabricated by spraying Pt/C slurries onto membrane, resulting in low activity and thick catalyst layer (CL, 5-10 µm) with an unaffordable Pt loading of 0.2-0.4 mg cm-2 and a large mass transfer resistance at cathode. Highly active ultrathin ultralow-Pt CL (UUCL) is urgently required, but remains rare. Herein, wet-chemical direct growth of UUCLs on both sides of membrane to achieve integrated ultrathin ultralow-Pt catalyst coated membranes (UUCCMs) with a cathodic CL thickness of 79.7 ± 15.0 nm and a Pt loading of 20.2 ± 1.6 µg cm-2 is reported. The key to this unique fabrication is the release of proton from membrane to regioselectively initiate the growth of interconnected Pd nanoneedle clusters array on membrane, followed by high-density deposition of Pt nanoparticles on Pd (Pt/Pd UUCLs). The single cell of UUCCMs exhibits the highest mass peak power density of 59.9 W mgPt,Cathode -1 in the literature. The exceptional activity originates from high electrochemically active surface area, remarkable oxygen reduction reaction activity closely correlated with strain, and electronic effect at Pt/Pd interface, as well as improved mass transfer and optimal water management.

Super Proton Conductivity Through Control of Hydrogen-Bonding Networks in Flexible Metal-Organic Frameworks.

Metal-organic frameworks (MOFs) have received much attention as a solid-state electrolyte in proton exchange membrane fuel cells. The introduction of proton carriers and functional groups into MOFs can improve the proton conductivity attributed to the formation of hydrogen-bonding networks, while the underlying synergistic mechanism is still unclear. Here, a series of flexible MOFs (MIL-88B, [Fe3 O(OH)(H2 O)2 (O2 C-C6 H4 -CO2 )3 ] with imidazole) is designed to modify the hydrogen-bonding networks and investigate the resulting proton-conducting characteristics by controlling the breathing behaviors. The breathing behavior is tuned by varying the amount of adsorbed imidazole into pore (small breathing (SB) and large breathing (LB)) and introducing functional groups onto ligands (-NH2 , -SO3 H), resulting in four kinds of imidazole-loaded MOFs-Im@MIL-88B-SB, Im@MIL-88B-LB, Im@MIL-88B-NH2 , and Im@MIL-88B-SO3 H. Im@MIL-88B-LB without functional groups exhibits the highest proton conductivity of 8.93 × 10-2  S cm-1 at 60 °C and 95% relative humidity among imidazole-loaded proton conductors despite the mild condition, indicating that functional groups may not be always required to enhance proton conductivity. The elaborately controlled pore size and host-guest interaction in flexible MOFs through imidazole-dependent structural transformation are translated into the high proton concentration without the limitation of proton mobility, contributing to the formation of effective hydrogen-bonding networks in imidazole conducting media.

Defect-Engineered ZIF-Derived Non-Pt Cathode Catalyst at 1.5 mg cm-2 Loading for Proton Exchange Membrane Fuel Cells.

Due to the sluggish kinetics of the oxygen reduction reaction (ORR) by non-Pt based catalyst, high loading of catalyst is required to achieve satisfactory fuel cell performance, which inevitably leads to the increase of the catalyst layer thickness with serious mass transport resistance. Herein, a defective zeolitic imidazolate framework (ZIF) derived Co/Fe-N-C catalyst with small mesopores (2-4 nm) and high density of CoFe atomic active sites are prepared by regulating the Fe dosage and pyrolysis temperature. Molecular dynamics simulation and electrochemical tests indicate that > 2 nm mesopores show insignificant influence on the diffusion process of O2 and H2 O molecules, leading to the high utilization of active sites and low mass transport resistance. The proton exchange membrane fuel cell (PEMFC) shows a high-power density of 755 mW cm-2 with only 1.5 mg cm-2 of non-Pt catalyst in the cathode. No apparent performance loss caused by concentration difference can be observed, in particular in the high current density region (1 A cm-2 ). This work emphasizes the importance of small mesopore design in the Co/Fe-N-C catalyst, which is anticipated to provide essential guidance for the application of non-Pt catalysts.

Advances in Low Pt Loading Membrane Electrode Assembly for Proton Exchange Membrane Fuel Cells.

Hydrogen has the potential to be one of the solutions that can address environmental pollution and greenhouse emissions from traditional fossil fuels. However, high costs hinder its large-scale commercialization, particularly for enabling devices such as proton exchange membrane fuel cells (PEMFCs). The precious metal Pt is indispensable in boosting the oxygen reduction reaction (ORR) in cathode electrocatalysts from the most crucial component, i.e., the membrane electrode assembly (MEA). MEAs account for a considerable amount of the entire cost of PEMFCs. To address these bottlenecks, researchers either increase Pt utilization efficiency or produce MEAs with enhanced performance but less Pt. Only a few reviews that explain the approaches are available. This review summarizes advances in designing nanocatalysts and optimizing the catalyst layer structure to achieve low-Pt loading MEAs. Different strategies and their corresponding effectiveness, e.g., performance in half-cells or MEA, are summarized and compared. Finally, future directions are discussed and proposed, aiming at affordable, highly active, and durable PEMFCs.

Recent advances in process engineering and upcoming applications of metal-organic frameworks.

Progress in metal-organic frameworks (MOFs) has advanced from fundamental chemistry to engineering processes and applications, resulting in new industrial opportunities. The unique features of MOFs, such as their permanent porosity, high surface area, and structural flexibility, continue to draw industrial interest outside the traditional MOF field, both to solve existing challenges and to create new businesses. In this context, diverse research has been directed toward commercializing MOFs, but such studies have been performed according to a variety of individual goals. Therefore, there have been limited opportunities to share the challenges, goals, and findings with most of the MOF field. In this review, we examine the issues and demands for MOF commercialization and investigate recent advances in MOF process engineering and applications. Specifically, we discuss the criteria for MOF commercialization from the views of stability, producibility, regulations, and production cost. This review covers progress in the mass production and formation of MOFs along with future applications that are not currently well known but have high potential for new areas of MOF commercialization.

Constructing Co-N-C Catalyst via a Double Crosslinking Hydrogel Strategy for Enhanced Oxygen Reduction Catalysis in Fuel Cells.

Exploiting platinum-group-metal (PGM)-free electrocatalysts with remarkable activity and stability toward oxygen reduction reaction (ORR) is of significant importance to the large-scale commercialization of proton exchange membrane fuel cells (PEMFCs). Here, a high-performance and anti-Fenton reaction cobalt-nitrogen-carbon (Co-N-C) catalyst is reported via employing double crosslinking (DC) hydrogel strategy, which consists of the chemical crosslinking between acrylic acid (AA) and acrylamide (AM) copolymerization and metal coordinated crosslinking between Co2+ and P(AA-AM) copolymer. The resultant DC hydrogel can benefit the Co2+ dispersion via chelated Co-N/O bonds and relieve metal agglomeration during the subsequent pyrolysis, resulting in the atomically dispersed Co-Nx/C active sites. By optimizing the ratio of AA/AM, the optimal P(AA-AM)(5-1)-Co-N catalyst exhibits a high content of nitrogen doping (12.36 at%) and specific surface area (1397 m2 g-1 ), significantly larger than that of the PAA-Co-N catalyst (10.59 at%/746 m2 g-1 ) derived from single crosslinking (SC) hydrogel. The electrochemical measurements reveal that P(AA-AM)(5-1)-Co-N possesses enhanced ORR activity (half-wave potential (E1/2 ) ≈0.820 V versus the reversible hydrogen electrode (RHE)) and stability (≈4 mV shift in E1/2 after 5000 potential cycles in 0.5 m H2 SO4 at 60 ºC) relative to PAA-Co-N, which is higher than most Co-N-C catalysts reported so far.

Scaling Up Studies on PEMFC Using a Modified Serpentine Flow Field Incorporating Porous Sponge Inserts to Observe Water Molecules.

Flooding of the cathode flow channel is a major hindrance in achieving maximum performance from Proton Exchange Membrane Fuel Cells (PEMFC) during the scaling up process. Water accumulated between the interface region of Gas Diffusion Layer (GDL) and rib of the cathode flow field can be removed by the use of Porous Sponge Inserts (PSI) on the ribs. In the present work, the experimental investigations are carried out on PEMFC for the various reaction areas, namely 25, 50 and 100 cm2. Stoichiometry value of 2 is maintained for all experiments to avoid variations in power density obtained due to differences in fuel utilization. The experiments include two flow fields, namely Serpentine Flow Field (SFF) and Modified Serpentine with Staggered provisions of 4 mm PSI (4 mm × 2 mm × 2 mm) Flow Field (MSSFF). The peak power densities obtained on MSSFF are 0.420 W/cm2, 0.298 W/cm2 and 0.232 W/cm2 compared to SFF which yields 0.242 W/cm2, 0.213 W/cm2 and 0.171 W/cm2 for reaction areas of 25, 50 and 100 cm2 respectively. Further, the reliability of experimental results is verified for SFF and MSSFF on 25 cm2 PEMFC by using Electrochemical Impedance Spectroscopy (EIS). The use of 4 mm PSI is found to improve the performance of PEMFC through the better water management.

Impact of the Cathode Pt Loading on PEMFC Contamination by Several Airborne Contaminants.

Proton exchange membrane fuel cells (PEMFCs) with 0.1 and 0.4 mg Pt cm-2 cathode catalyst loadings were separately contaminated with seven organic species: Acetonitrile, acetylene, bromomethane, iso-propanol, methyl methacrylate, naphthalene, and propene. The lower catalyst loading led to larger cell voltage losses at the steady state. Three closely related electrical equivalent circuits were used to fit impedance spectra obtained before, during, and after contamination, which revealed that the cell voltage loss was due to higher kinetic and mass transfer resistances. A significant correlation was not found between the steady-state cell voltage loss and the sum of the kinetic and mass transfer resistance changes. Major increases in research program costs and efforts would be required to find a predictive correlation, which suggests a focus on contamination prevention and recovery measures rather than contamination mechanisms.

Automotive Subzero Cold-Start Quasi-Adiabatic Proton Exchange Membrane Fuel Cell Fixture: Design and Validation.

Subzero automotive cold-starts of proton exchange membrane fuel cell (PEMFC) stacks require accelerated thermal rises to achieve nominal operating conditions and close-to-instantaneous usable output power. Advances in the material, structure and operational dependence on the balance between the maximum power output and the electrochemical conversion of hydrogen and oxygen into water requires validation with subzero cold-starts. Herein are presented the design and validation of a quasi-adiabatic PEMFC to enable single-cell evaluation, which would provide a more cost-effective option than stack-level testing. At -20 °C, the operational dependence of the preconditioned water content (3.2 verse 6.2) for a galvanic cold-start (<600 mA cm-2) was counter to that of a laboratory-scale isothermal water fill test (10 mA cm-2). The higher water content resulted in a faster startup to appreciable power output within 0.39 min versus 0.65 min. The water storage capacity, as determined from the isothermal water fill test, was greater, for the lower initial water content of 3.2, than 6.2, 17.4 ± 0.3 mg versus 12.8 ± 0.4 mg, respectively. Potentiostatic cold-starts produced usable power in 0.09 min. The versatility and reproducibility of the single cell quasi-adiabatic fixture avail it to future universal cold-start stack relevant analyzes involving operational parameters and advanced materials, including: applied load, preconditioning, interchanging flow field structures, diffusion media, and catalyst coated membranes.

Designing AI-Aided Analysis and Prediction Models for Nonprecious Metal Electrocatalyst-Based Proton-Exchange Membrane Fuel Cells.

Traditionally, a larger number of experiments are needed to optimize the performance of the membrane electrode assembly (MEA) in proton-exchange membrane fuel cells (PEMFCs) since it involves complex electrochemical, thermodynamic, and hydrodynamic processes. Herein, we introduce artificial intelligence (AI)-aided models for the first time to determine key parameters for nonprecious metal electrocatalyst-based PEMFCs, thus avoiding unnecessary experiments during MEA development. Among 16 competing algorithms widely applied in the AI field, decision tree and XGBoost showed good accuracy (86.7 % and 91.4 %) in determining key factors for high-performance MEA. Artificial neural network (ANN) shows the best accuracy (R2=0.9621) in terms of predictions of the maximum power density and a decent reproducibility (R2>0.99) on uncharted I-V polarization curves with 26 input features. Hence, machine learning is shown to be an excellent method for improving the efficiency of MEA design and experiments.

UIO-66-NH2 -Derived Mesoporous Carbon Catalyst Co-Doped with Fe/N/S as Highly Efficient Cathode Catalyst for PEMFCs.

Efficient, low-cost catalysts are desirable for the sluggish oxygen reduction reaction (ORR). Herein, UIO-66-NH2 -derived multi-element (Fe, S, N) co-doped porous carbon catalyst is reported, Fe/N/S-PC, with an octahedral morphology, a well-defined mesoporous structure, and highly dispersed doping elements, synthesized by a double-solvent diffusion-pyrolysis method (DSDPM). The morphology of the UIO-66-NH2 precursor is perfectly inherited by the derived carbon material, resulting in a high surface area, a well-defined mesoporous structure, and atomic-level dispersion of the doping elements. Fe/N/S-PC demonstrates outstanding catalytic activity and durability for the ORR in both alkaline and acidic solutions. In 0.1 m KOH, its half-potential reaches 0.87 V (vs reversible hydrogen electrode (RHE)), 30 mV more positive than that of a 20 wt% Pt/C catalyst. In 0.1 m HClO4 , it reaches 0.785 V (vs RHE), only 65 mV less than that of Pt/C. The catalyst also exhibits excellent performance in acidic hydrogen/oxygen proton exchange membrane fuel cells. A membrane electrode assembly (MEA) with the catalyst as the cathode reaches 700 mA·cm-2 at 0.6 V and a maximum power density of 553 mW·cm-2 , ranking it among the best MEAs with a nonprecious metal catalyst as the cathode.

Rational Design of Ultrathin Gas Barrier Layer via Reconstruction of Hexagonal Boron Nitride Nanoflakes to Enhance the Chemical Stability of Proton Exchange Membrane Fuel Cells.

Hexagonal boron nitride (hBN) has great potential as a promising gas barrier layer in proton exchange membrane fuel cells (PEMFCs) as it shows high proton conductivity as well as excellent gas-blocking capability. However, structural defects and mechanical damage during the transfer of the hBN layer and membrane swelling have limited the application of hBN sheets to PEMFCs. Here, an ultrathin gas barrier layer is successfully fabricated on a proton exchange membrane via reconstruction of mechanically exfoliated hBN nanoflakes using a direct spin-coating process. The hBN-coated layer effectively suppresses the gas crossover and inhibits the formation of reactive oxygen radicals in the electrodes without reducing the proton conductivity of the membrane. It is also demonstrated that the structural advantages of hBN-coated gas barrier layers promise high performance of a unit cell even after a open-circuit voltage (OCV) hold test for 100 h. Furthermore, through in-depth postmortem analyses, a time-dependent degradation mechanism of membrane electrode assembly under the OCV condition is rationally proposed.

Carbon Corrosion in Proton-Exchange Membrane Fuel Cells: Spectrometric Evidence for Pt-Catalysed Decarboxylation at Anode-Relevant Potentials.

The carbon oxidation reaction (COR) is a critical issue in proton-exchange membrane fuel cells (PEMFCs), as carbon in various forms is the most used electrocatalyst support material. The COR is thermodynamically possible above the C/CO2 standard potential, but its rate becomes significantly important only at high overpotential (e. g. PEMFC cathode potential). Herein, using on-line differential electrochemical mass spectrometry, we show that oxygen-containing carbon surface groups present on high-surface aera carbon, Vulcan XC72 or reinforced graphite are oxidized at PEMFC anode-relevant potential (E=0.1 V vs. the reversible hydrogen electrode, RHE), but not at E=0.4 V vs. RHE. We rationalized our findings by considering a Pt-catalysed decarboxylation mechanism in which Pt nanoparticles provide adsorbed hydrogen species to the oxygen-containing carbon surface groups, eventually leading to evolution of carbon dioxide and carbon monoxide. These results shed fundamental light on an unexpected degradation mechanism and facilitate the understanding of the long-term stability of PEMFC anode nanocatalysts.

Thermally Driven Structure and Performance Evolution of Atomically Dispersed FeN4 Sites for Oxygen Reduction.

FeN4 moieties embedded in partially graphitized carbon are the most efficient platinum group metal free active sites for the oxygen reduction reaction in acidic proton-exchange membrane fuel cells. However, their formation mechanisms have remained elusive for decades because the Fe-N bond formation process always convolutes with uncontrolled carbonization and nitrogen doping during high-temperature treatment. Here, we elucidate the FeN4 site formation mechanisms through hosting Fe ions into a nitrogen-doped carbon followed by a controlled thermal activation. Among the studied hosts, the ZIF-8-derived nitrogen-doped carbon is an ideal model with well-defined nitrogen doping and porosity. This approach is able to deconvolute Fe-N bond formation from complex carbonization and nitrogen doping, which correlates Fe-N bond properties with the activity and stability of FeN4 sites as a function of the thermal activation temperature.

A Review on Recent Developments and Prospects for the Oxygen Reduction Reaction on Hollow Pt-alloy Nanoparticles.

Due to their interesting electrocatalytic properties for the oxygen reduction reaction (ORR), hollow Pt-alloy nanoparticles (NPs) supported on high-surface-area carbon attract growing interest. However, the suitable synthesis methods and associated mechanisms of formation, the reasons for their enhanced specific activity for the ORR, and the nature of adequate alloying elements and carbon supports for this type of nanocatalysts remain open questions. This Review aims at shedding light on these topics with a special emphasis on hollow PtNi NPs supported onto Vulcan C (PtNi/C). We first show how hollow Pt-alloy/C NPs can be synthesized by a mechanism involving galvanic replacement and the nanoscale Kirkendall effect. Nickel, cobalt, copper, zinc, and iron (Ni, Co, Cu, Zn, and Fe, respectively) were tested for the formation of Pt-alloy/C hollow nanostructures. Our results indicate that metals with standard potential -0.4

Using the IL-TEM Technique to Understand the Mechanism and Improve the Durability of Platinum Cathode Catalysts for Proton-Exchange Membrane Fuel Cells.

Proton-exchange membrane fuel cells are one of the most promising energy conversion technologies for both automotive and stationary applications. Scientists are testing a number of solutions to increase the durability of cells, especially catalysts, which are the most expensive component. These solutions include, among others, the modification of the composition and morphology of supported nanoparticles, the platinum-support interface, and the support itself. A detailed understanding of the mechanism of platinum degradation and the subsequent improvement of the durability of the entire cell requires the development of methods for effectively monitoring the behavior of catalytic nanoparticles under various cell operating conditions. The Identical-Location Transmission Electron Microscopy (IL-TEM) method makes it possible to visually track structural and morphological changes in the catalyst directly. Because the tests are performed with a liquid electrolyte imitating a membrane, they provide better control of the degradation conditions and, consequently, facilitate the understanding of nanoparticle degradation processes in various operating conditions. This review is primarily intended to disseminate knowledge about this technique to scientists using electron microscopy in the study of energy materials and to draw attention to issues related to the characterization of the structure of carbon supports.

The Lifetime of Hydroxyl Radical in Realistic Fuel Cell Catalyst Layer.

The lifetime of hydroxyl radicals (⋅OH) in the fuel cell catalyst layer remains uncertain, which hampers the comprehension of radical-induced degradation mechanisms and the development of longevity strategies for proton-exchange membrane fuel cells (PEMFCs). In this study, we have precisely determined that the lifetime of ⋅OH radicals can extend up to several seconds in realistic fuel cell catalyst layers. This finding reveals that ⋅OH radicals are capable of carrying out long-range attacks spanning at least a few centimeters during PEMFCs operation. Such insights hold great potential for enhancing our understanding of radical-mediated fuel cell degradation processes and promoting the development of durable fuel cell devices.