Membrane electrode assembly with Pt/SiO2/C anode catalyst for proton exchange membrane fuel cell operation under low humidity conditions

In this work, a novel self-humidifying membrane electrode assembly (MEA) with Pt/SiO₂/C as anode catalyst was developed to improve the performance of proton exchange membrane fuel cell (PEMFC) operating at low humidity conditions. The characteristics of the composite catalysts were investigated by XRD, TEM and water uptake measurement. The optimal performance of the MEA was obtained with the 10 wt.% of silica in the composite catalyst by single cell tests under both high and low humidity conditions. The low humidity performance of the novel self-humidifying MEA was evaluated in a H₂/air PEMFC at ambient pressure under different relative humidity (RH) and cell temperature conditions. The results show that the MEA performance was hardly changed even if the RHs of both the anode and cathode decreased from 100% to 28%. However, the low humidity performance of the MEA was quite susceptible to the cell temperature, which decreased steeply as the cell temperature increased. At a cell temperature of 50 °C, the MEA shows good stability for low humidity operating: the current density remained at 0.65 A cm⁻² at a usual work voltage of 0.6 V without any degradation after 120 h operation under 28% RH for both the anode and cathode.     

Influence of ionomer content on the structure and performance of PEFC membrane electrode assemblies

Nafion^® ionomer content of the cathode catalyst-layer of a polymer electrolyte fuel cell (PEFC), made by the “decal” hot pressing method, has been investigated for its effect on performance and structure of the membrane electrode assembly (MEA). Varying Nafion^® content was shown to have an effect on performance within the entire range of polarization curves (i.e. kinetic, ohmic, and mass-transport regions) as well as on the structure. AFM analysis shows the effect of Nafion on the dispersion of carbon aggregates. Further analysis using TEM demonstrates the effect of Nafion on both the dispersion of carbon aggregates and the distribution and thickness of the Nafion ionomer films surrounding the catalyst/carbon aggregates. The MEA structure change correlates well with the MEA performance on both kinetics and mass-transport region. The determining factors on the performance of MEA are the interfacial zone (between the ionomer and catalyst particle), the dispersion of catalyst/carbon aggregates and the distribution/thickness of Nafion films. An optimized Nafion^® content in the range of 27 ± 6 wt.% for the cathode was determined for an E-TEK 20% Pt₃Cr/C catalyst at a loading of 0.20 mg Pt/cm².     

Characterization of proton exchange membranes based on SPSEBS/SPSU blends

Proton-conducting polymer membranes are used as an electrolytes in proton exchange membrane fuel cells (PEMFCs). The most widely used commercially available membrane electrolytes are perfluorosulfonic acid polymers, an expensive class of ionomers. In this study, the potential of polymer blends derived from sulfonated polystyrene ethylene butylene polystyrene (SPSEBS) and sulfonated polysulfone (SPSU) for use in electrolyte applications was examined. Although SPSEBS by itself exhibits good conductivity, flexibility, and chemical stability, it has poor mechanical stability. So, in an effort to improve the mechanical properties of SPSEBS while maintaining its good conductivity, it was blended with SPSU. SPSEBS/SPSU blends were therefore prepared by a solvent evaporation method, and the resulting blend membranes were characterized in terms of conductivity, ionic exchange capacity, and water uptake. Sulfonation was confirmed and the crystallinity of the blend membranes was studied by FTIR spectroscopy and X-ray diffraction. The morphologies of the membranes were studied by scanning electron microscope (SEM), and their thermal stabilities by TGA and DSC. Finally, the mechanical strength of SPSEBS was studied using a UTM (universal testing machine). This paper presents the results of recent investigations aimed at developing an optimized in-house membrane electrode assembly (MEA) preparation technique combining catalyst ink spraying and assembly hot pressing. Easy steps were chosen for this preparation technique in order to simplify the method, thus minimizing costs. The influence of MEA fabrication parameters like electrode pressing or annealing on the performance of the hydrogen fuel cell was studied by performing single cell measurements during H₂/O₂ operation. Carbon cloth was used as a gas diffusion layer (GDL), and the composition of the electrode ink was optimized to maximize fuel cell performance. A commercial E-TEK catalyst was used for the anode and cathode, with Pt loadings of 0.125 and 0.37 mg/cm², respectively. The MEA with the best performance delivered approximately 0.50 W/cm² at room temperature. The methanol permeability and the selectivity ratio strongly influenced DMFC performance. Both direct methanol fuel cells (DMFCs) and PEMFCs are discussed in this paper.     

Synthesis of Pt nanocatalyst with micelle-encapsulated multi-walled carbon nanotubes as support for proton exchange membrane fuel cells

Micelle-encapsulated multi-walled carbon nanotubes (MWCNTs) with sodium dodecyl sulfate (SDS) were used as catalyst support to deposit platinum nanoparticles. High resolution transmission electron microscopy (HRTEM) images reveal the crystalline nature of Pt nanoparticles with a diameter of ∼4 nm on the surface of MWCNTs. A single proton exchange membrane fuel cell (PEMFC) with total catalyst loading of 0.2 mg Pt cm⁻² (anode 0.1 and cathode 0.1 mg Pt cm⁻², respectively) has been evaluated at 80 °C with H₂ and O₂ gases using Nafion-212 electrolyte. Pt/MWCNTs synthesized by using modified SDS-MWCNTs with high temperature treatment (250 °C) showed a peak power density of 950 mW cm⁻². Accelerated durability evaluation was carried out by conducting 1500 potential cycles between 0.1 and 1.2 V with 50 mV s⁻¹ scan rate, H₂/N₂ at 80 °C. The membrane electrode assembly (MEA) with Pt/MWCNTs showed superior performance stability with a power density degradation of only ∼30% compared to commercial Pt/C (70%) after potential cycles.     

Microscopic characterizations of membrane electrode assemblies prepared under different hot-pressing conditions

The durability of the membrane electrode assembly (MEA) for direct methanol fuel cells (DMFCs) is one of the most critical issues to be addressed before widespread commercialization of the DMFC technology. In this work, we investigated the effect of the hot-pressing duration on the performance and durability of the MEA prepared by hot-pressing technique. It was found that the 60-min hot pressing at 135 °C under the pressure of 4.0 MPa yielded a significantly improved MEA durability than did the 3-min hot pressing (a typical duration in practice) under the same condition, but no substantial difference was found in the cell performance of the MEAs prepared with the two different hot-pressing durations. The reason why the hot-pressing duration had no significant effect on cell performance is explained based on X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), and Fourier transform infrared spectroscopy (FT-IR) characterizations of the changes in the physiochemical properties of MEAs and their constituent components, including the anode, cathode and Nafion membrane, before and after hot pressing with different durations.     

The improved methanol tolerance using Pt/C in cathode of direct methanol fuel cell

Membrane electrode assemblies (MEA) were prepared using PtRu black and 60 wt.% carbon-supported platinum (Pt/C) as their anode and cathode catalysts, respectively. The cathode catalyst layers were fabricated using various amounts of Pt (0.5 mg cm⁻², 1.0 mg cm⁻², 2.0 mg cm⁻², and 3.0 mg cm⁻²). To study the effect of carbon support on performance, a MEA in which Pt black was used as the cathode catalyst was fabricated. In addition, the effect of methanol crossover on the Pt/C on the cathode side of a direct methanol fuel cell (DMFC) was investigated. The performance of the single cell that used Pt/C as the cathode catalyst was higher than single cell that used Pt black and this result was pronounced when highly concentrated methanol (above 2.0 M) was used as the fuel.     

Enhanced performance and improved interfacial properties of polymer electrolyte membrane fuel cells fabricated using sputter-deposited Pt thin layers

For this study, catalyst layers for polymer electrolyte membrane fuel cells (PEMFC) were prepared by spraying and sputtering to deposit Pt amount of 0.1 and 0.01 mg cm⁻², respectively. These Pt layers were then assembled to fabricate membrane electrode assemblies (MEA) having either single- or double-layered catalysts. The PEM fuel cell with double layers showed a current density of 777 mA cm⁻² at a cell voltage of 0.6 V, which is a higher current density than state-of-the-art fuel cells at 643 mA cm⁻². These results indicate that Pt loading in state-of-the-art PEMFCs could be reduced by approximately 50% with no performance loss by using both spraying and sputtering method in the MEA fabrication process.     

PEM fuel cell reaction kinetics in the temperature range of 23-120 °C

The performance of a Nafion 112 based proton exchange membrane (PEM) fuel cell was tested at a temperature range from 23 °C to 120 °C. The fuel cell polarization curves were divided into two different ranges based on current density, namely, <0.4 A/cm² and >0.4 A/cm², respectively. These two ranges were treated separately with respect to electrode kinetics and mass transfer. In the high current density range, a linear increase in membrane electrode assembly (MEA) power density with increasing temperature was observed, indicating the advantages of high temperature operation.Simulation based on electrode reaction kinetic theory, experimental polarization curves, and measured cathodic apparent exchange current densities all gave temperature dependent apparent exchange current densities. Both the calculated partial pressures of O₂ and H₂ gas in the feed streams and the measured electrochemical Pt surface areas (EPSAs) decrease with increasing temperature. They were also used to obtain the intrinsic exchange current densities. A monotonic increase of the intrinsic exchange current densities with increasing temperature in the range of 23-120 °C was observed, suggesting that increasing the temperature does promote intrinsic kinetics of fuel cell reactions.There are two sets of cathode apparent exchange current densities obtained, one set is for the low current density range, and the other is for the high current density range. The different values of cathode current densities in the two current density ranges can be attributed to the different states of the cathode Pt catalyst surface. In the low current density range, the cathode catalyst surface is a Pt/PtO, and in the high current density range, the catalyst surface becomes pure Pt.     

Characterization of catalysts and membrane in DMFC lifetime testing

The lifetime and performance of a direct methanol fuel cell (DMFC) were investigated to understand the correlation between the structure of catalysts/membrane and cell performance versus time. The cell polarization and performance curves were obtained during the DMFC operation with the time. The catalysts and Nafion^® membrane of the membrane electrode assembly (MEA) from the lifetime test were comprehensively examined by XRD, HRTEM, FTIR and Raman spectroscopy techniques. The results revealed that there was significant performance degradation during the first 200 h operation; while the degradation was slowing down between 200 and 704 h operation. The degradation became worse after 1002 h operation. The increases of the catalyst particle size from both anode and cathode catalysts were observed after the DMFC lifetime test. The changes of microstructure, surface composition, the interfacial structure of the MEA, and the aging of Nafion^® under the DMFC lifetime tests were also observed.     

Novel approach to membraneless direct methanol fuel cells using advanced 3D anodes

A conventional membrane electrode assembly (MEA) for a direct methanol fuel cell (DMFC) consists of a polymer electrolyte membrane (PEM) compressed between an anode and cathode electrode. Limitations with this conventional design include: cost, fuel crossover, membrane degradation or contamination, ohmic losses and reduced active triple phase boundary (TPB) sites for catalyst located away from the electrode/membrane interface. In this work, ex situ and in situ characterization of a novel electrode assembly based on a membraneless architecture and advanced 3D anodes was investigated. The approach was shown to be fuel independent and scaleable to a conventional bi-polar fuel cell arrangement. The membraneless configuration exhibits comparable performance to a conventional ambient (25 °C, 1 atm) air-breathing DMFC. However, it has the additional advantages of a simplified design, the elimination of the membrane (a significant component expense) and enhanced fuel and catalyst utilization through the extension of the active catalyst zone.     

Nanostructured palladium-silver coated nickel foam cathode for magnesium-hydrogen peroxide fuel cells

A novel multiscale Pd-Ag catalyzed porous cathode for the magnesium-hydrogen peroxide fuel cell was prepared by electrodeposition of Pd onto Ag coated nickel foam surface from an aqueous solution of palladium chloride. The structure, morphology and composition of the electrodeposited catalyst layer were characterized using SEM, EDS and XPS analysis. Magnesium-hydrogen peroxide fuel cell tests with the Pd-Ag deposited cathode were carried out and compared with the Ag-deposited electrode. The effects of temperature, H₂O₂ flow rate and H₂O₂ concentration on cell performance were investigated, and the electrode stability test was carried out. The Pd-Ag deposited electrode showed higher catalytic activity for the reduction of hydrogen peroxide than that of the Ag-deposited Ni foam cathode, and gave much improved fuel cell performance. The magnesium-hydrogen peroxide fuel cell with nanostructured Pd-Ag coated nickel foam cathode presented a maximum power density of 140 mW cm⁻², but the Mg-H₂O₂ fuel cell with Ag coated Ni foam cathode gave only 110 mW cm⁻² under the same operation condition.     

Characterization and performances of cobalt-tungsten and molybdenum-tungsten carbides as anode catalyst for PEFC

The preparation of carbon-supported cobalt-tungsten and molybdenum-tungsten carbides and their activity as an anode catalyst for a polymer electrolyte fuel cell were investigated. The electrocatalytic activity for the hydrogen oxidation reaction over the catalysts was evaluated using a single-stack fuel cell and a rotating disk electrode. The characterization of the catalysts was performed by XRD, temperature-programmed carburization, temperature-programmed reduction and X-ray photoelectron spectroscopy. The maximum power densities of the 30 wt% 873 K-carburized cobalt-tungsten and molybdenum-tungsten mixed with Ketjen carbon (cobalt-tungsten carbide (CoWC)/Ketjen black (KB) and molybdenum-tungsten carbide (MoWC)/KB) were 15.7 and 12.0 mW cm⁻², respectively, which were 14 and 11%, compared to the in-house membrane electrode assembly (MEA) prepared from a 20 wt% Pt/C catalyst. The CoWC/KB catalyst exhibited the highest maximum power density compared to the MoWC/KB and WC/KB catalysts. The 873 K-carburized CoW/KB catalyst formed the oxycarbided and/or carbided CoW that are responsible for the excellent hydrogen oxygen reaction.     

A study on the dissymmetrical microporous layer structure of a direct methanol fuel cell

The effect of carbon type, carbon loading and microporous layer structure in the microporous layer on the performance of a direct methanol fuel cell (DMFC) at low temperature was investigated using electrochemical polarization techniques, electrochemical impedance spectroscopy, scanning electron microscope and other methods. Vulcan XC-72 carbon was found to be most suitable as a microporous layer for low temperature DMFC. Maximum fuel cell performance was obtained utilizing a microporous layer with carbon loading of 1.0 mg cm⁻² when air was used as an oxidant. A membrane electrode assembly with 1.0 mg cm⁻² Vulcan XC-72 carbon with 20 wt.% Teflon in the cathode and no microporous layer in the anode showed a maximum power density of 36.7 mW cm⁻² at 35 °C under atmospheric pressure. The AC impedance study proved that a cell with a dissymmetrical microporous layer structure had lower internal resistance and mass transfer resistance, thus obtaining better performance.     

Development and characterization of a silicon-based micro direct methanol fuel cell

A silicon-based micro direct methanol fuel cell (μDMFC) for portable applications has been developed and its electrochemical characterization carried out in this study. Anode and cathode flowfields with channel and rib width of 750 μm and channel depth of 400 μm were fabricated on Si wafers using the microelectromechanical system (MEMS) technology. A membrane-electrode assembly (MEA) was specially fabricated to mitigate methanol crossover. This MEA features a modified anode backing structure in which a compact microporous layer is added to create an additional barrier to methanol transport thereby reducing the rate of methanol crossing over the polymer membrane. The cell with the active area of 1.625 cm² was assembled by sandwiching the MEA between two micro-fabricated Si wafers. Extensive cell polarization testing demonstrated a maximum power density of 50 mW/cm² using 2 M methanol feed at 60 °C. When the cell was operated at room temperature, the maximum power density was shown to be about 16 mW/cm² with both 2 and 4 M methanol feed. It was further found that the present μDMFC still produced reasonable performance under 8 M methanol solution at room temperature.     

Electrochemical performance of gel-cast NiO-SDC composite anodes in low-temperature SOFCs

NiO-Ce_0.8Sm_0.2O_1.9 (SDC) composites were synthesized using gel-casting technique. The electrochemical performance of the gel-cast (GC) Ni-SDC cermet as anode was investigated contrast with that fabricated from traditional mechanical mixing (MM) technique using fuel cells with about 35 μm-thick SDC electrolyte and Sm_0.5Sr_0.5CoO₃-SDC cathode. Maximum power density of the cell with GC anode achieved 491 mW cm⁻² at 600 °C, over 100 mW cm⁻² larger than that with MM anode, inferring high catalytic activity of the GC anode. Impedance measurements on the fuel cell at open circuit showed that the anodic interfacial polarization resistance of the GC anode was 0.1 Ω cm² lower than that of the MM anode. Long-term stability of the cell with GC anode in hydrogen was also performed, which showed that it can stabilize at least 7 days.     

A Study on Process Parameters of Direct Ethanol Fuel Cell

Ethanol is one of the promising future fuels of Direct Alcohol Fuel Cells (DAFC). The electro‐oxidation of ethanol fuel on anode made of carbon‐supported Pt‐Ru electrode catalysts was carried out in a lab scale direct ethanol fuel cell (DEFC). Cathode used was Pt‐black high surface area. The membrane electrode assembly (MEA) was prepared by sandwiching the solid polymer electrolyte membrane, prepared from Nafion^® (SE‐5112, DuPont USA) dispersion, between the anode and cathode. The DEFC was fabricated using the MEA and tested at different catalyst loadings at the electrodes, temperatures and ethanol concentrations. The maximum power density of DEFC for optimized value of ethanol concentration, catalyst loading and temperature were determined. The maximum open circuit voltage (OCV) of 0.815 V, short circuit current density (SCCD) of 27.90 mA/cm² and power density of 10.30 mW/cm² were obtained for anode (Pt‐Ru/C) and cathode (Pt‐black) loading of 1 mg/cm² at a temperature of 90°C anode and 60°C cathode for 2M ethanol.     

High performance electrode for electrochemical oxygen generator cell based on solid electrolyte ion transport membrane

A double-layer composite electrode based on Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3−δ + Sm_0.2Ce_0.8O_1.9 (BSCF + SDC) and BSCF + SDC + Ag was investigated to be a promising cathode and also anode for the electrochemical oxygen generator based on samaria doped ceria electrolyte. The Ag particles in the second layer were not only the current collector but also the improver for the oxygen adsorption at the electrode. a.c. impedance results indicated that the electrode polarization resistance, as low as 0.0058 Ω cm² was reached at 800 °C under air. In oxygen generator cell performance test, the electrode resistance dropped to half of the value at zero current density under an applied current density of 2.34 A cm⁻² at 700 °C, and on the same conditions the oxygen generator cell was continual working for more than 900 min with a Faradic efficiency of ∼100%.     

Platinum nanopaticles supported on stacked-cup carbon nanofibers as electrocatalysts for proton exchange membrane fuel cell

Inexpensive stacked-cup carbon nanofibers (SC-CNFs) supported Pt nanoparticles with a loading from 5 to 30 wt.% were prepared through a modified ethylene glycol method. XRD and TEM characterizations show that the average Pt particle sizes increase with increasing metal loading, and they can be controlled <5 nm with a uniform dispersion. A self-developed filtration process was employed to fabricate Pt/SC-CNFs film-based membrane electrode assembly (MEA), and the catalyst transfer efficiency can reach nearly 100% using a super-hydrophobic polycarbonate filter. The thickness of catalyst layer can be accurately controlled through altering Pt loadings of the catalyst and electrode, this is in good agreement with our theoretical calculation. For Pt/SC-CNFs-based-MEAs, Pt cathode loading was found more critical than Pt anode loading on proton exchange membrane fuel cell (PEMFC) performance. The Pt/SC-CNFs-based MEA with an optimized 50 wt.% Nafion content demonstrates higher PEMFC performance than the carbon black-based MEA with an optimized 30 wt.% Nafion content. SC-CNFs possess much larger length-to-diameter ratio than carbon black particles, it makes Pt/SC-CNFs more easily form continuously conductive networks in the Nafion matrix than carbon black. Therefore, the Pt/SC-CNFs-based MEA demonstrates higher Pt utilization than carbon black-based MEA, which implies possible reduction in Pt loading of MEA.     

Kinetics and electrocatalytic activity of nanostructured Ir-V/C for oxygen reduction reaction

Active, carbon-supported Ir-V nanoparticle catalysts have been synthesized by an ethylene glycol reduction method under controlled conditions at pH 10-13 and 120 °C, then further reduced at elevated temperature from 150 to 500 °C using IrCl₃ and NH₄VO₃ as the Ir and V precursors. The nanostructured catalysts have been characterized by X-ray diffraction (XRD) and high-resolution transmission electron microscopy (TEM). Ir nanoparticles, after modification with V, show a narrow particle size distribution in the range 0.5-4.5 nm, centered at 1.8 nm, and are uniformly dispersed on Vulcan XC-72. No particle agglomeration was observed, not even at high V loadings (V:Ir = 4:1 in atomic ratio). Investigation of the catalytic activity of the Ir-V/C by means of cyclic voltammetry (CV) and linear sweep voltammetry (LSV) employing a rotating disk electrode (RDE) has revealed that the presence of V may suppress the electrochemical oxidation of Ir and stabilize the Ir active centers. About six times higher kinetic current density was obtained for Ir-V/C compared to that of the pure Ir/C catalyst at 0.8 V versus RHE for the oxygen reduction reaction (ORR). The ORR in acid solution proceeds by an approximately four-electron pathway, through which molecular oxygen is directly reduced to water. The performance of a membrane electrode assembly (MEA) prepared with the most active 40% Ir-10% V/C as the cathode catalyst in a single proton-exchange membrane fuel cell (PEMFC) generated a maximum power density of 517 mW cm⁻² at 0.431 V and 70 °C, and 100 h of stable cell operation due to no loss of catalyst sites on the cathode.     

Improved gas diffusion electrodes for hybrid polymer electrolyte fuel cells

In this study, the performance of the anionic electrodes for hybrid polymer electrolyte fuel cells was improved. The anion exchange membrane (AEM) electrodes were initially characterized as the cathode on a proton exchange membrane (PEM) anode/membrane half-assembly (i.e. hybrid polymer electrolyte fuel cell). The electrode performance was improved by tailoring the ionomer distribution within the electrode structure so as to better balance the electronic, ionic, and reactant transport within the catalyst layer. An ionomer impregnation method was used to achieve a non-uniform ionomer distribution and higher performance. Traditional electrode fabrication methods (i.e. thin-film method) lead to a uniform ionomer distribution. The peak power density at 70 °C for a H₂/O₂ hybrid fuel cell was 44 mW cm⁻² using the thin-film electrode, and 120 mW cm⁻² using the ionomer impregnated electrode. A hydrophobic additive used in the catalyst layer further improved the electrode performance, giving a peak power density of 315 mW cm⁻² for H₂/O₂ at 70 °C. Electrochemical impedance spectroscopy was used as an in situ diagnostic tool to help understand the origin of the electrode improvements. The increase in performance was attributed to improved catalyst utilization due to the creation of facile gas transport domains in the AEM electrode structure. Similarly, the AEM anode prepared by ionomer impregnation with polytetrafluoroethylene resulted in a three-fold increase in the peak power density compared to ones made by the thin-film method, which has no polytetrafluoroethylene.