Fe/N/C non-precious catalysts for PEM fuel cells: Influence of the structural parameters of pristine commercial carbon blacks on their activity for oxygen reduction

Fifteen commercial SRCC furnace carbon blacks of various grades, ranging from N1 to N9, were used as carbon supports in the preparation of Fe/N/C type electrocatalysts for the oxygen reduction reaction (ORR) in PEM fuel cell conditions. All catalysts were prepared by loading the various carbon grades with 0.2 wt.% Fe as iron acetate and heat-treating the resulting material at 950 °C in pure NH₃. This reaction provides the nitrogen content and the microporosity necessary to synthesize and host the Fe/N/C catalytic sites that perform ORR. The maximum catalytic activity (V_pr max) for each carbon grade was determined by optimizing pyrolysis time. The aim of this study is to determine which structural characteristics of the pristine carbon black are important for maximizing catalytic activity. Three structural parameters that influenced the catalytic site density on the carbon support were identified. They are: (i) the average particle diameter of the pristine carbon black, d_particle, available from BET area measurements; (ii) the amount of disordered phase which is proportional to W_D, the width at half maximum of the D peak in the Raman spectrum of the pristine carbon; and (iii) the mean size of the graphene layers characterizing the graphitic crystallites in the carbon black, L_a. The latter is available by Rietveld analysis of the XRD spectra of the pristine carbons. The best catalytic activities are obtained for the smallest d_particle, the largest W_D, and the largest L_a. Optimizing these three parameters maximizes the fraction of the pristine carbon black that becomes microporous upon reaction with NH₃ and, therefore, enables the formation of Fe/N/C catalytic sites. A FeN₂₊₂/C structure bridging two adjacent graphitic crystallites is proposed as a potential model for most of the catalytic sites present in such Fe/N/C type catalysts.     

Fe-based catalysts for the reduction of oxygen in polymer electrolyte membrane fuel cell conditions: determination of the amount of peroxide released during electroreduction and its influence on the stability of the catalysts

Fe-based catalysts have been prepared by pyrolyzing ClFeTMPP (Cl-Fe tetramethoxyphenyl porphyrin) or Fe acetate adsorbed on PTCDA (perylene tetracarboxylic dianhydride) or on prepyrolyzed PTCDA (p-PTCDA). The catalysts which were already well characterized in terms of active FeN₄/C and FeN₂/C catalytic sites (J. Phys. Chem. B 106 (2002) 8705) are now characterized by RRDE experiments to determine the values of the apparent number of electron transferred (n) and the percentage of peroxide (%H₂O₂) released during the oxygen reduction reaction (ORR) in H₂SO₄ at pH 1. A direct correlation is found between the relative abundance of the FeN₂/C catalytic site in these materials, their catalytic activity and the value of n. The correlation is inverse for %H₂O₂. The best catalysts at their maximum catalytic activity are characterized by n>3.9 and %H₂O₂<5%, equivalent to a value of %H₂O₂ released by a 2 wt.% Pt/C catalyst. It is shown that even low peroxide levels of the order of 5 vol% in H₂SO₄ are able to decompose the catalytic sites releasing iron ions in the H₂SO₄ solution. The loss of catalytic activity correlates directly with the loss of iron ions by these catalysts. All the catalysts have been tested at the cathode of single membrane electrode assemblies (MEAs). The slow decrease in performance in fuel cell stability tests is interpreted as the result of the detrimental effect that has H₂O₂, released during ORR, on the chemical integrity of the nonnoble metal catalytic sites at work at the fuel cell cathodes.     

Application of iron-based cathode catalysts in a microbial fuel cell

Catalysts for the oxygen reduction reaction (ORR) in a microbial fuel cell (MFC) were prepared by the impregnation on carbon black of Fe^II acetate (FeAc), Cl–Fe^III tetramethoxyphenyl porphyrin (ClFeTMPP), and Fe^II phthalocyanine (FePc). These materials were subsequently pyrolyzed at a high temperature. The ORR activity of all Fe-based catalysts was measured at pH 7 with a rotating disk electrode (RDE) and their performance for electricity production was then verified in a continuous flow MFC. Catalysts prepared with FeAc and pyrolyzed in NH₃ showed poor activity in RDE tests as well as a poor performance in a MFC. The ORR activity and fuel cell performance for catalysts prepared with ClFeTMPP and FePc and pyrolyzed in Ar were significantly higher and comparable for both precursors. The iron loading was optimized for FePc-based catalysts. With a constant catalyst load of 2 mg cm⁻² in a MFC, the highest power output (550–590 mW/m²) was observed when the Fe content was 0.5–0.8 wt%, corresponding to only 0.01–016 mg Fe/cm². A similar power output was observed using a Pt-based carbon cloth cathode containing 0.5 mg Pt/cm². Long-term stability of the Fe-based cathode (0.5 wt% Fe) was confirmed over 20 days of MFC testing.     

Efficient production of hydrogen and multi-walled carbon nanotubes from ethanol over Fe/Al2O3 catalysts

Fe/Al₂O₃ catalysts with different Fe loadings (10-90 mol%) were prepared by hydrothermal method. Ethanol decomposition was studied over these Fe/Al₂O₃ catalysts at temperatures between 500 and 800 °C to produce hydrogen and multi-walled carbon nanotubes (MWCNTs) at the same time. The results showed that the catalytic activity and stability of Fe/Al₂O₃ depended strongly on the Fe loading and reaction temperature. The Fe(30 mol%)/Al₂O₃ and Fe(40 mol%)/Al₂O₃ were both the effective catalyst for ethanol decomposition into hydrogen and MWCNTs at 600 °C. Several reaction pathways were proposed to explain ethanol decomposition to produce hydrogen and carbon (including nanotube) at the same time.     

Vapor phase synthesis of methylpyrazine using aqueous glycerol and ethylenediamine over ZnCr2O4 catalyst: Elucidation of reaction mechanism

A novel method has been developed for the synthesis of methylpyrazine (MP) by using aqueous glycerol and ethylenediamine (EDA) over Zn–Cr catalyst derived from hydrotalcite precursors. The X-ray diffraction analysis of the oven-dried Zn–Cr samples synthesized at various pH ranging from 7 to 11 showed hydrotalcite phase whereas the calcined catalysts displayed ZnO and ZnCr₂O₄ phases. The cyclisation activity of Zn–Cr catalyst prepared at pH ~ 9 demonstrated 99.4% conversion of EDA and 94% of glycerol with ~ 72% selectivity to MP at a reaction temperature of 400 °C. This process demonstrates direct utilization of bio-glycerol for the synthesis of MP.     

Preparation and electrochemical studies of metal–carbon composite catalysts for small-scale electrosynthesis of H2O2

Numerous transition metal–carbon composite catalysts (M = V, Zn, Ni, Sn, Ce, Ba, Fe, Cu) have been synthesized and tested for electroreduction of O₂ to H₂O₂, The activity and selectivity of all synthesized catalysts for electrosynthesis of H₂O₂ were determined by the rotating ring-disk electrode method in acidic and neutral electrolytes. The Co-based catalysts in general showed the highest activity towards H₂O₂ formation. Experiments with different loading contents of Co showed that the activation overpotential losses of oxygen reduction to H₂O₂ reduces as loading increases to about 4 wt% Co. Addition of Co beyond this level did not seem to impact the overpotential losses. The cobalt-based catalysts, were spray-coated onto 120 μm thick Toray^® graphite substrates, and were studied in bulk electrolysis cells for up to 100 h at potentiostatic conditions (0.25 V vs. RHE) in pH 0, 3, and 7 electrolytes. At (25 °C and 1 bar) with a catalysts loading of about and using dissolved O₂ in 0.5 M H₂SO₄, typical H₂O₂ electrosynthesis rates of about were reached with current efficiencies of about 85 ± 5% at 0.25 V (vs. RHE).     

Hydrogen production by oxidative steam reforming of methanol using ceria promoted copper–alumina catalysts

The performance of different Cu/CeO₂/Al₂O₃ catalysts of varying compositions is investigated for the oxidative steam reforming of methanol (OSRM) in order to produce the hydrogen selectively for polymer electrolyte membrane (PEM) fuel cell applications. All the catalysts were prepared by co-precipitation method and characterized for their surface area, pore volume and oxidation–reduction behavior. The effect of various operating parameters studied are as follows: reaction temperature (200–300 °C), contact-time (W/F = 3–15 kg_cat s mol^− 1) and oxygen to methanol (O/M) molar ratio (0–0.5). The steam to methanol (S/M) molar ratio = 1.5 and pressure = 1 atm were kept constant. Among all the catalysts studied, catalyst Cu–Ce–Al:30–20–50 exhibited 100% methanol conversion and 179 mmol s^− 1 kg_cat^− 1 hydrogen production rate at 280 °C with carbon monoxide formation as low as 0.19%. The high catalytic activity and hydrogen selectivity shown by ceria promoted Cu/Al₂O₃ catalysts is attributed to the improved specific surface area, dispersion and reducibility of copper which were confirmed by characterizing the catalysts through temperature programmed reduction (TPR), CO chemisorption, X-ray diffraction (XRD) and N₂ adsorption–desorption studies. Reaction parameters were optimized in order to produce hydrogen with carbon monoxide formation as low as possible. The time-on-stream stability test showed that the Cu/CeO₂/Al₂O₃ catalysts were quite stable.     

Highly active and selective Cu/SiO2 catalysts prepared by the urea hydrolysis method in dimethyl oxalate hydrogenation

Cu/SiO₂ catalysts have been successfully prepared via urea hydrolysis method. The catalysts have been systematically characterized by X-ray diffraction, high-resolution transmission electron microscopy, N₂-physisorption and H₂ temperature-programmed reduction. The results demonstrated the presence of copper nanoparticles and their high dispersion on the SiO₂ support. Catalysts with different copper loadings were prepared, and their performances in the hydrogenation of dimethyl oxalate to ethylene glycol were studied. A 100% conversion of dimethyl oxalate and maximum 98% selectivity of ethylene glycol were reached with 15.6 wt.% copper loading at 200 °C and 2 MPa. Furthermore, under the same reaction conditions, the catalyst can maintain the selectivity of 90% when the reduction temperature reduced from 350 °C to 200 °C. The high activity and selectivity over the catalyst may be ascribed to the homogenously distribution of copper nanoparticles on the large surface.     

Preparation of nanocrystalline Sr3Al2O6 powders via citric acid precursor

Sr₃Al₂O₆ was synthesized via citric acid precursor. The effects of the molar ratio of citric acid to total metal cations concentration (CA/M) on the formation of Sr₃Al₂O₆ were investigated. Increasing the CA/M promoted the formation of Sr₃Al₂O₆. Single-phase and well-crystallized Sr₃Al₂O₆ was obtained from the CA/M = 1, CA/M = 2 and CA/M = 4 precursor at temperature 1200 °C, 1100 °C and 900 °C, respectively. Differential thermal analysis and thermogravimetric (DTA/TG), X-ray diffractometry (XRD) and field emission scanning electron microscopy (FESEM) were used to characterize the precursors and the derived oxide powders. Sr₃Al₂O₆ nanoparticles with a diameter of about 50-70 nm were obtained.     

Comparison of product selectivity during hydroprocessing of bitumen derived gas oil in the presence of NiMo/Al2O3 catalyst containing boron and phosphorus

A detailed experimental study was performed in a trickle-bed reactor using bitumen derived gas oil. The objective of this work was to compare the activity of NiMo/Al₂O₃ catalyst containing boron or phosphorus for the hydrotreating and mild hydrocracking of bitumen derived gas oil. Experiments were performed at the temperature and LHSV of 340-420 °C and 0.5-2 h⁻¹, respectively, using NiMo/Al₂O₃ catalysts containing 1.7 wt% boron or 2.7 wt% phosphorus. In the temperature range of 340-390 °C, higher nitrogen conversion was observed from boron containing catalyst than that from phosphorus containing catalyst whereas in the same temperature range, phosphorus containing catalyst gave higher relative removal of sulfur than boron containing catalyst. Phosphorus containing catalyst showed excellent hydrocracking and mild hydrocracking activities at all operating conditions. Higher naphtha yield and selectivity were obtained using phosphorus containing catalyst at all operating conditions. Maximum gasoline selectivity of ∼45 wt% was obtained at the temperature, pressure, and LHSV of 400 °C, 9.4 MPa and 0.5 h⁻¹, respectively, using catalyst containing 2.7 wt% phosphorus.     

Biomass to hydrogen via catalytic steam reforming of bio-oil over Ni-supported alumina catalysts

Production of hydrogen (H₂) from catalytic steam reforming of bio-oil was investigated in a fixed bed tubular flow reactor over nickel/alumina (Ni/Al₂O₃) supported catalysts at different conditions. The features of the steam reforming of bio-oil, including the effects of metal content, reaction temperature, W_bHSV (defined as the mass flow rate of bio-oil per mass of catalyst) and S/C ratio (the molar ratio of steam to carbon fed) on the hydrogen yield were investigated. Carbon conversion (moles of carbon in the outlet gases to moles of the carbon feed) was also studied, and the outlet gas distributions were obtained. It was revealed that the Al₂O₃ with 14.1% Ni content gave the highest yield of hydrogen (73%) among the catalysts tested, and the best carbon conversion was 79% under the steam reforming conditions of S/C = 5, W_bHSV = 13 1/h and temperature = 950 °C. The H₂ yield increased with increasing temperature and decreasing W_bHSV; whereas the effect of the S/C ratio was less pronounced. In the S/C ratio range of 1 to 2, the hydrogen yield was slightly increased, but when the S/C ratio was increased further, it did not have an effect on the H₂ production yield.     

Influence of temperature on pyrolysis of recycled organic matter from municipal solid waste using an activated olivine fluidized bed

Pyrolysis of an organic concentrate from municipal solid waste was carried out using a bench-scale fluidized bed reactor at 350-540 °C comparing Al₂O₃ with activated olivine sand as bed materials. A maximum oil yield of 50 wt.% was obtained using the activated olivine sand at 400 °C while only 45 wt.% was obtained at 500 °C using Al₂O₃. The bio-oils using activated olivine sand at 400 °C had an H/C ratio of 1.50 and O/C ratio of 0.37 and were less aromatic and less nitrogenous compare to the oils obtained using Al₂O₃ at 400 °C where the H/C ratio was 1.32 and the O/C ratio was 0.44. The aromatic compounds were found to be reduced while the aliphatic compounds increased in the oils generated using activated olivine sand. The calorific value of the bio-oil at 500 °C was 29 MJ/kg using activated olivine sand while the bio-oil using Al₂O₃ was 23 MJ/kg. The presence of iron, magnesium and other oxides probably promotes the removal of oxygen, which indicates that the activation energy of C―O bond breakage is reduced compared to the C―C bonds, thus promoting dehydration, decarboxylation and alkalation reactions to produce aliphatic fatty acid at lower temperatures.     

Ethanol electrooxidation on novel carbon supported Pt/SnOx/C catalysts with varied Pt:Sn ratio

Novel carbon supported Pt/SnO_x/C catalysts with Pt:Sn atomic ratios of 5:5, 6:4, 7:3 and 8:2 were prepared by a modified polyol method and characterized with respect to their structural properties (X-ray diffraction (XRD) and transmission electron microscopy (TEM)), chemical composition (XPS), their electrochemical properties (base voltammetry, CO_ad stripping) and their electrocatalytic activity and selectivity for ethanol oxidation (ethanol oxidation reaction (EOR)). The data show that the Pt/SnO_x/C catalysts are composed of Pt and tin oxide nanoparticles with an average Pt particle diameter of about 2 nm. The steady-state activity of the Pt/SnO_x/C catalysts towards the EOR decreases with tin content at room temperature, but increases at 80 °C. On all Pt/SnO_x/C catalysts, acetic acid and acetaldehyde represent dominant products, CO₂ formation contributes 1-3% for both potentiostatic and potentiodynamic reaction conditions. With increasing potential, the acetaldehyde yield decreases and the acetic acid yield increases. The apparent activation energies of the EOR increase with tin content (19-29 kJ mol⁻¹), but are lower than on Pt/C (32 kJ mol⁻¹). The somewhat better performance of the Pt/SnO_x/C catalysts compared to alloyed PtSn_x/C catalysts is attributed to the presence of both sufficiently large Pt ensembles for ethanol dehydrogenation and C-C bond splitting and of tin oxide for OH generation. Fuel cell measurements performed for comparison largely confirm the results obtained in model studies.     

Effect of calcination temperature on the oxidation of benzene with ozone at low temperature over mesoporous α-Mn2O3

Highly ordered mesoporous α-Mn₂O₃ was synthesized from cubic mesoporous silica (KIT-6) via nano-casting method. The mesoporous α-Mn₂O₃ thus obtained was calcined at 200-500 °C, and characterized using XRD, N₂ sorption and temperature-programmed reduction (TPR). The calcination temperature did not significantly affect the BET surface areas, mesopore sizes, pore structures and crystallinities of the mesoporous α-Mn₂O₃ materials. The mesoporous α-Mn₂O₃ calcined at 300 °C showed the highest catalytic activity due to its high reduction ability revealed from the TPR analysis. However, the catalytic activity was negligible without ozone. In addition, the selectivity to CO₂ was about 90% and this seems to be an advantage of mesoporous α-Mn₂O₃ for removing benzene using ozone.     

High-temperature close coupled catalysts Pd/Ce-Zr-M/Al2O3 (M = Y, Ca or Ba) used for the total oxidation of propane

A series of high-temperature close coupled catalysts Pd/Ce-Zr-M/Al₂O₃ (M = Y, Ca or Ba) were prepared by ultrasonic-assisted successive impregnation. The catalysts were subjected to a series of characterization measurements. The results of activity evaluation show that Y is the best promoter for propane total oxidation, especially at the calcination temperature of 1100 °C. It is interesting that although the BET specific surface areas and the dispersion of Pd species decrease, the Y-promoted catalyst calcined at 1100 °C shows higher catalytic activity than the corresponding one calcined at 900 °C and better sulfur-resisting performance. The results of TEM, TPHD and CO chemisorption indicate that Y can remarkably increase the dispersion of Pd species. However, the dispersion is hard to be connected with the activity increase as the calcination temperature is elevated from 900 to 1100 °C. The change of active phases and the interaction between Pd species and the supports may account for the activity enhancement. Combined with XRD, H₂-TPR and O₂-TPD results, it is deduced that the coexistence of metallic Pd and PdO species in the catalysts calcined at 1100 °C may be also favorable to C₃H₈ oxidation. In a word, Pd/Ce-Zr-Y/Al₂O₃ is indeed a promising high-temperature close coupled catalyst applicable to high temperature.     

Preparation, characterization and dielectric properties of CaCu3Ti4O12 ceramics

CaCu₃Ti₄O₁₂ nano-sized powders were successfully prepared by sol-gel technique and calcination at 600-900 °C. The thermal decomposition process, phase structures and morphology of synthesized powders were characterized by IR, DSC-TG, XRD, TEM, respectively. It was found that the main weight-loss and decomposition of precursors occurred below 450 °C and the complex perovskite phase appeared when the calcination temperature was higher than 700 °C. Using above synthesized powders as starting materials, CCTO-based ceramics with excellent dielectric properties (?₂₅ = 5.9 × 10⁴, tan δ = 0.06 at 1.0 kHz) were prepared by sintering at 1125 °C. According to the results, a conduction mechanism was proposed to explain the origin of giant dielectric constant in CCTO system.     

Mechanochemical synthesis and characterisation of BaTa2O6 ceramic powders

Mechanochemical synthesis was used to prepare BaTa₂O₆ powders from BaCO₃ and Ta₂O₅ precursors in a planetary ball mill. Effect of milling time and heat treatment temperature on the formation of BaTa₂O₆ and on the microstructure was investigated. Intensive milling of starting materials resulted in crystallization of BaTa₂O₆ even after 1 h of milling time and single phase BaTa₂O₆ was obtained after 10 h of milling under optimal conditions. The powder derived from 10 h of mechanical activation had crystallite size of 22 nm. But the increase in milling time did not decrease the crystallite size further. High energy milling activated the powders that although 1 h of milling led to formation of single phase BaTa₂O₆ at 1200 °C, this temperature decreased to 900 °C after 5 h of milling. No significant grain growth was observed when the milled powders were heat treated below 900 °C. However, annealing at 1100 and 1200 °C gave an average BaTa₂O₆ grain size of 180 and 650 nm, respectively. An unidentified phase started to form at 1100 °C increasing to high amounts at 1200 °C and they had different shapes and sizes than BaTa₂O₆ grains. These elongated large grains were thought to be due to liquid phase formation caused by iron contamination.     

Methane reforming reaction with carbon dioxide over SBA-15 supported Ni-Mo bimetallic catalysts

A series of mesoporous molecular sieves SBA-15 supported Ni-Mo bimetallic catalysts (xMo1Ni, Ni = 12 wt.%, Mo/Ni atomic ratio = x, x = 0, 0.3, 0.5, 0.7) were prepared using co-impregnation method for carbon dioxide reforming of methane. The catalytic performance of these catalysts was investigated at 800 °C, atmospheric pressure, GHSV of 4000 ml·g_cat^− 1·h^− 1 and a V(CH₄)/(CO₂) ratio of 1 without dilute gas. The result indicated that the Ni-Mo bimetallic catalysts had a little lower initial activity compared with Ni monometallic catalyst, but it kept very stable performance under the reaction conditions. In addition, the Ni-Mo bimetallic catalyst with Mo/Ni atomic ratio of 0.5 showed high activity, superior stability and the lowest carbon deposition rate (0.00073g_c·g_cat^− 1·h^− 1) in 600-h time on stream. The catalysts were characterized by power X-ray diffraction, N₂-physisorption, H₂-TPR, CO₂-TPD, TG and TEM. The results indicate that the Ni-Mo bimetallic catalysts have smaller metal particle, higher metal dispersion, stronger basicity, metal-support interaction and Mo₂C species. It is concluded that Mo species in the Ni-Mo bimetallic catalysts play important roles in reducing effectively the amount of carbon deposition, especially the amount of shell-like carbon deposition.     

Phase diagram of the Al2O3-HfO2-Y2O3 system

The phase diagram of the Al₂O₃-HfO₂-Y₂O₃ system was first constructed in the temperature range 1200-2800 °C. The phase transformations in the system are completed in eutectic reactions. No ternary compounds or regions of appreciable solid solution were found in the components or binaries in this system. Four new ternary and three new quasibinary eutectics were found. The minimum melting temperature is 1755 °C and it corresponds to the ternary eutectic Al₂O₃ + HfO₂ + Y₃Al₅O₁₂. The solidus surface projection, the schematic of the alloy crystallization path and the vertical sections present the complete phase diagram of the Al₂O₃-HfO₂-Y₂O₃ system.     

Oxidative dehydrogenation of 1 -butene to butadiene on α-Fe2O3/ZnAl2O4 and ZnFexAl2-xO4 catalysts

The oxidative dehydrogenation of 1-butene to butadiene was studied over a series of catalysts of iron impregnated on ZnAl₂O₄ used as a support and also Fe coprecipitated with zinc and aluminum in order to obtain ZnFe_xAl_2-xO₄ type catalysts. Results were compared with bulk -Fe₂O₃, ZnAl₂O₄ and ZnFe₂O₄. X-ray diffraction (XRD) and Mössbauer spectroscopy suggest that in the impregnated catalysts, Fe ions are in strong interaction with the support. These samples have higher butadiene selectivity than coprecipitated ZnFe_xAl_2-xO₄ catalysts, in which iron is incorporated into the ZnAl₂O₄ spinel network. Results suggest also that iron content has a greater effect on butadiene selectivity than the zinc aluminate-iron oxide interaction.