Performance of laboratory polymer electrolyte membrane hydrogen generator with sputtered iridium oxide anode

The continuous improvement of the anode materials constitutes a major challenge for the future commercial use of polymer electrolyte membranes (PEM) electrolyzers for hydrogen production. In accordance to this direction, iridium/titanium films deposited directly on carbon substrates via magnetron sputtering are operated as electrodes for the oxygen evolution reaction interfaced with Nafion 115 electrolyte in a laboratory single cell PEM hydrogen generator. The anode with 0.2 mg cm⁻² Ir catalyst loading was electrochemically activated by cycling its potential value between 0 and 1.2 V (vs. RHE). The water electrolysis cell was operated at 90 °C with current density 1 A cm⁻² at 1.51 V without the ohmic contribution. The corresponding current density per mgr of Ir catalyst is 5 A mg⁻¹. The achieved high efficiency is combined with sufficient electrode stability since the oxidation of the carbon substrate during the anodic polarization is almost negligible.     

Synthesis and characterization of carbon nanotubes supported platinum nanocatalyst for proton exchange membrane fuel cells

Multi-walled carbon nanotubes (MWCNTs) were used as catalyst support for depositing platinum nanoparticles by a wet chemistry route. MWCNTs were initially surface modified by citric acid to introduce functional groups which act as anchors for metallic clusters. A two-phase (water-toluene) method was used to transfer PtCl₆²⁻ from aqueous to organic phase and the subsequent sodium formate solution reduction step yielded Pt nanoparticles on MWCNTs. High-resolution TEM images showed that the platinum particles in the size range of 1-3 nm are homogeneously distributed on the surface of MWCNTs. The Pt/MWCNTs nanocatalyst was evaluated in the proton exchange membrane (PEM) single cell using H₂/O₂ at 80 °C with Nafion-212 electrolyte. The single PEM fuel cell exhibited a peak power density of about 1100 mW cm⁻² with a total catalyst loading of 0.6 mg Pt cm⁻² (anode: 0.2 mg Pt cm⁻² and cathode: 0.4 mg Pt cm⁻²). The durability of Pt/MWCNTs nanocatalyst was evaluated for 100 h at 80 °C at ambient pressure and the performance (current density at 0.4 V) remained stable throughout. The electrochemically active surface area (64 m² g⁻¹) as estimated by cyclic voltammetry (CV) was also similar before and after the durability test.     

Electrode structure optimization combined with water feeding modes for Bi-Functional Unitized Regenerative Fuel Cells

Bi-functional Unitized Regenerative Fuel Cells (URFCs) based on proton-exchange membrane (PEM) electrolyte are promising in the field of energy storage. Their performance was investigated with catalyst loadings, carbon paper hydrophobicity and water feeding modes in both fuel cell (FC) and water electrolysis (WE) operations. The optimum membrane electrode assembly (MEA) is with 0.20 mg cm⁻² Pt (in 50% Pt/C catalyst) for the hydrogen electrode (HE), and a total catalyst loading of 0.80 mg cm⁻² for the oxygen electrode (OE). And its performance can reach 2.18 A cm⁻² at 1.80 V in WE test and 0.64 A cm⁻² at 0.60 V in FC test with air oxidant. Comparison of different carbon papers reveals that suitable hydrophobicity of OE carbon papers is obtained when the PTFE content accounts for 26.95 wt.%. Choice of water feeding modes, which has an influence on URFC performance in WE mode, is proven to have relations with current density and carbon paper hydrophobicity in a sophisticated way.     

Effect of Ti sublayer on the ORR catalytic efficiency of dc magnetron sputtered thin Pt films

A series of thin Pt films were deposited by dc magnetron sputtering directly on a commercial hydrophobic carbon paper substrate having a thin microporous Vulcan-XC72 layer or upon a thin Ti sublayer sputtered on the top of the microporous carbon film. The electrocatalytic properties of the sputtered Pt films toward the oxygen reduction reaction were investigated in 0.5 M H₂SO₄ solution and in a hydrogen PEM fuel cell. The catalyst with ultralow Pt loading of 22 μg cm⁻² deposited on a 33 Å thick Ti sublayer is robust, mechanically stable, possesses highly developed surface area and improved catalytic efficiency. Its performance as a MEA cathode in a single hydrogen PEM fuel cell (577 mA cm⁻² at 0.4 V cell voltages and a maximum power of 0.954 W) proved to be much superior compared to that of MEA with the same cathode Pt loading but without Ti sublayer (173 mA cm⁻² at 0.4 V, 0.231 W, respectively).     

Direct alkaline fuel cell for multiple liquid fuels: Anode electrode studies

A direct alkaline fuel cell with a liquid potassium hydroxide solution as an electrolyte is developed for the direct use of methanol, ethanol or sodium borohydride as fuel. Three different catalysts, e.g., Pt-black or Pt/Ru (40 wt.%:20 wt.%)/C or Pt/C (40 wt.%), with varying loads at the anode against a MnO₂ cathode are studied. The electrodes are prepared by spreading the catalyst slurry on a carbon paper substrate. Nickel mesh is used as a current-collector. The Pt–Ru/C produces the best cell performance for methanol, ethanol and sodium borohydride fuels. The performance improves with increase in anode catalyst loading, but beyond 1 mg cm⁻² does not change appreciably except in case of ethanol for which there is a slight improvement when using Pt–Ru/C at 1.5 mA cm⁻². The power density achieved with the Pt–Ru catalyst at 1 mg cm⁻² is 15.8 mW cm⁻² at 26.5 mA cm⁻² for methanol and 16 mW cm⁻² at 26 mA cm⁻² for ethanol. The power density achieved for NaBH₄ is 20 mW cm⁻² at 30 mA cm⁻² using Pt-black.     

Experimental study of commercial size proton exchange membrane fuel cell performance

Commercial sized (16 × 16 cm² active surface area) proton exchange membrane (PEM) fuel cells with serpentine flow chambers are fabricated. The GORE-TEX® PRIMEA 5621 was used with a 35-μm-thick PEM with an anode catalyst layer with 0.45 mg cm⁻² Pt and cathode catalyst layer with 0.6 mg cm⁻² Pt and Ru or GORE-TEX® PRIMEA 57 was used with an 18-μm-thick PEM with an anode catalyst layer at 0.2 mg cm⁻² Pt and cathode catalyst layer at 0.4 mg cm⁻² of Pt and Ru. At the specified cell and humidification temperatures, the thin PRIMEA 57 membrane yields better cell performance than the thick PRIMEA 5621 membrane, since hydration of the former is more easily maintained with the limited amount of produced water. Sufficient humidification at both the cathode and anode sides is essential to achieve high cell performance with a thick membrane, like the PRIMEA 5621. The optimal cell temperature to produce the best cell performance with PRIMEA 5621 is close to the humidification temperature. For PRIMEA 57, however, optimal cell temperature exceeds the humidification temperature.     

Power source research at USC: Development of advanced electrocatalysts for polymer electrolyte membrane fuel cells

This paper provides an overview on the development of advanced fuel cell cathode catalysts at University of South Carolina (USC) with the emphasis on the stability of non-precious metal and Pt alloy catalysts. Nitrogen-modified carbon composite (NMCC) catalysts were developed for the oxygen reduction reaction (ORR) through the pyrolysis of cobalt (iron)-nitrogen chelate followed by the treatment combination of pyrolysis, acid leaching, and re-pyrolysis. A promising stability was observed for 1050 h fuel cell operation under current density of 200 mA cm⁻² as evidenced by a potential decay rate as low as 40 μV h⁻¹. The performance degradation mechanism of the NMCC-based fuel cell is discussed. Pt and PtPd hybrid catalysts are developed that use a NMCC, which is itself active for the ORR, instead of a conventional carbon black support. The stability test at 1 A cm⁻² indicated that the Pt/NMCC hybrid catalyst (new Pt-Co/C) is more stable than the conventional Pt-Co/C without the Co leaching out. The PEM fuel cell accelerated stress test (AST) for supports and catalysts demonstrated that their stability changes in the order: Pt₃Pd₁/NMCC hybrid catalyst > Pt/NMCC hybrid catalyst > conventional Pt/C catalyst. Moreover, the hybrid catalysts exhibit higher mass activity than the Pt/C catalysts.     

Direct borohydride fuel cell using Ni-based composite anodes

In this study, nickel-based composite anode catalysts consisting of Ni with either Pd on carbon or Pt on carbon (the ratio of Ni:Pd or Ni:Pt being 25:1) were prepared for use in direct borohydride fuel cells (DBFCs). Cathode catalysts used were 1 mg cm⁻² Pt/C or Pd electrodeposited on activated carbon cloth. The oxidants were oxygen, oxygen in air, or acidified hydrogen peroxide. Alkaline solution of sodium borohydride was used as fuel in the cell. High power performance has been achieved by DBFC using non-precious metal, Ni-based composite anodes with relatively low anodic loading (e.g., 270 mW cm⁻² for NaBH₄/O₂ fuel cell at 60 °C, 665 mW cm⁻² for NaBH₄/H₂O₂ fuel cell at 60 °C). Effects of temperature, oxidant, and anode catalyst loading on the DBFC performance were investigated. The cell was operated for about 100 h and its performance stability was recorded.     

Electrochemical characterization of single cell and short stack PEM electrolyzers based on a nanosized IrO2 anode electrocatalyst

A nanosized IrO₂ anode electrocatalyst was prepared by a sulfite-complex route for application in a proton exchange membrane (PEM) water electrolyzer. The physico-chemical properties of the IrO₂ catalyst were studied by termogravimetry–differential scanning calorimetry (TG–DSC), X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS) and transmission electron microscopy (TEM). The electrochemical activity of this catalyst for oxygen evolution was investigated in a single cell PEM electrolyzer consisting of a Pt/C cathode and a Nafion^® membrane. A current density of 1.26 A cm⁻² was obtained at 1.8 V and a stable behavior during steady-state operation at 80 °C was recorded. The Tafel plots for the overall electrochemical process indicated a slope of about 80 mV dec⁻¹ in a temperature range from 25 °C to 80 °C. The kinetic and ohmic activation energies for the electrochemical process were 70.46 kJ mol⁻¹ and 13.45 kJ mol⁻¹, respectively. A short stack (3 cells of 100 cm² geometrical area) PEM electrolyzer was investigated by linear voltammetry, impedance spectroscopy and chrono-amperometric measurements. The amount of H₂ produced was 80 l h⁻¹ at 60 A under 330 W of applied electrical power. The stack electrical efficiency at 60 A and 75 °C was 70% and 81% with respect to the low and high heating value of hydrogen, respectively.     

Preparation of a high performance Pt–Co/C electrocatalyst for oxygen reduction in PEM fuel cell via a combined process of impregnation and seeding

The preparation of a Pt–Co/C electrocatalyst for the oxygen reduction reaction in PEM fuel cells was achieved via a combined process of impregnation and seeding. The effects of initial pH of the precursor solution and Pt loading were all found to have a significant effect on both the electrocatalyst morphology and the cell performance when tested in a single PEM fuel cell. The optimum condition found for preparing the Pt–Co/C electrocatalyst was from an initial precursor solution pH of 2 at the metal loading of 23.6–30.3% (w/w). The Pt–Co/C electrocatalysts, formed under these optimal conditions, tested in a single PEM fuel cell with the carbon sub-layer, gave a cell performance of 772 mA/cm² or 460 mW/cm² at 0.6 V in a H₂/O₂ system. An electron pathway of oxygen reduction on the prepared Pt–Co/C electrocatalyst was also determined using a rotating disk electrode.     

Carbon-supported Ir–V nanoparticle as novel platinum-free anodic catalysts in proton exchange membrane fuel cell

The active, carbon-supported Ir–V nanoparticle catalysts were successfully synthesized using IrCl₃ and NH₄VO₃ as the Ir and V precursors in ethylene glycol refluxing at 120 °C with varying pH values, then further reduction under hydrogen atmosphere at 200 °C. The nanostructured catalysts were characterized by X-ray diffraction (XRD) and high resolution transmission electron microscopy (TEM). These carbon-supported catalysts give a good dispersion of Ir–V/C electrocatalysts with mean particle size of 2–3 nm, thus leading to a marked promotion of hydrogen oxidation reaction. Electrochemical impedance spectroscopy (EIS) and cyclic voltammetry techniques (CV) were used to characterize on-line the performance of the proton exchange membrane fuel cell (PEMFC) using several anode catalysts at different pH values. It was found that the pH value for the synthesis of catalysts affects the performance of electrocatalysts significantly, based on the discharge characteristics of the fuel cell. High cell performance on the anode was achieved with a loading of 0.4 mg cm⁻² 40%Ir–10%V/C catalyst synthesized at pH 12, which results in a maximum a power density of 1008 mW cm⁻² at 0.6 V and 70 °C. This is 50% higher performance than that for commercial available Pt/C catalyst. Fuel cell life test at a constant current density of 1000 mA cm⁻² demonstrated an initial stability up to 100 h generating a cell voltage of 0.6 V, which strongly suggests that the novel Ir–V/C nanoparticle catalysts proposed in this work could be promising for PEMFC.     

Biocatalyzed hydrogen production in a continuous flow microbial fuel cell with a gas phase cathode

A single liquid chamber microbial fuel cell (MFC) with a gas-collection compartment was continuously operated under electrically assisted conditions for hydrogen production. Graphite felt was used for anode construction, while the cathode was made of Pd/Pt coated Toray carbon fiber paper with a catalyst loading of 0.5 mg cm⁻². To achieve hydrogen production, the MFC was connected to a power supply and operated at voltages in a range of 0.5–1.3 V. Either acetate or glucose was used as a source of carbon. At an acetate load of 1.67 g (L_A d)⁻¹, the volumetric rate of hydrogen production reached 0.98 L_STP (L_A d)⁻¹ when a voltage of 1.16 V was applied. This corresponded to a hydrogen yield of 2 mol (mol-acetate)⁻¹ with a 50% conversion efficiency. Throughout the experiment, MFC efficiency was adversely affected by the metabolic activity of methanogenic microorganisms, which competed with exoelectrogenic microorganisms for the carbon source and consumed part of the hydrogen produced at the cathode.     

Performance of a miniaturized silicon reformer-PrOx-fuel cell system

A fuel cell made with silicon is operated with hydrogen supplied by a reformer and a preferential oxidation (PrOx) reactor those are also made with silicon. The performance and durability of the fuel cell is analyzed and tested, then compared with the results obtained with pure hydrogen. Three components of the system are made using silicon technologies and micro electro-mechanical system (MEMS) technology. The commercial Cu-ZnO-Al₂O₃ catalyst for the reformer and the Pt-Al₂O₃ catalyst for the PrOx reactor are coated by means of a fill-and-dry method. A conventional membrane electrode assembly composed of a 0.375 mg cm⁻² PtRu/C catalyst for the anode, a 0.4 mg cm⁻² Pt/C catalyst for the cathode, and a Nafion™ 112 membrane is introduced to the fuel cell. The reformer gives a 27 cm³ min⁻¹ gas production rate with 3177 ppm CO concentration at a 1 cm³ h⁻¹ methanol feed rate and the PrOx reactor shows almost 100% CO conversion under the experimental conditions. Fuel cells operated with this fuel-processing system produce 230 mW cm⁻² at 0.6 V, which is similar to that obtained with pure hydrogen.     

Preparation and characterization of carbonaceous materials containing nitrogen as electrochemical capacitor

Carbonaceous materials containing nitrogen (C/N materials) were prepared by a pyrolysis of 2,3,6,7-tetracyano-1,4,5,8-tetraazanaphthalene (CAN). A C/N material prepared by the pyrolysis of CAN at 1070 K (CAN-1070 K) had a C/N atomic ratio of 3.0 and a non-crystalline carbonaceous structure with a BET surface area of 880 m² g⁻¹. The material CAN-1070 K showed large capacitances of 160–180 F g⁻¹ and 110–120 F cm⁻³ in case of current density of 10 mA cm⁻² (2 A g⁻¹) by using three-electrode cell in 1 M H₂SO₄ aqueous solution, in comparison with that of activated carbon (160 F g⁻¹ and 55 F cm⁻³) having BET surface area of 2300 m² g⁻¹. ESCA study indicated that pyridinic and quarternary nitrogen atoms existed in the C/N materials, which could result in producing a pseudo-capacitance in addition to the electric double layer capacitance. Also introduction of nitrogen into the carbonaceous material could enhance the wettability of material, which might also improve the capacitance.     

Ni–Pt/C as anode electrocatalyst for a direct borohydride fuel cell

In this study, a series of Ni–Pt/C and Ni/C catalysts, which were employed as anode catalysts for a direct borohydride fuel cell (DBFC), were prepared and investigated by XRD, TEM, cyclic voltammetry, chronopotentiometry and fuel cell test. The particle size of Ni₃₇–Pt₃/C (mass ratio, Ni:Pt = 37:3) catalyst was sharply reduced by the addition of ultra low amount of Pt. And the electrochemical measurements showed that the electro-catalytic activity and stability of the Ni₃₇–Pt₃/C catalysts were improved compared with Ni/C catalyst. The DBFC employing Ni₃₇–Pt₃/C catalyst on the anode (metal loading, 1 mg cm⁻²) showed a maximum power density of 221.0 mW cm⁻² at 60 °C, while under identical condition the maximum power density was 150.6 mW cm⁻² for Ni/C. Furthermore, the polarization curves and hydrogen evolution behaviors on all the catalysts were investigated on the working conditions of the DBFC.     

Scale-up of a high temperature polymer electrolyte membrane fuel cell based on polybenzimidazole

A high temperature PEM fuel cell stack with a total active area 150 cm² has been studied. The PEM technology is based on a polybenzimidazole (PBI) membrane. Cast from a PBI polymer synthesised in our lab, the performance of a three-cell stack was analysed in static and dynamic modes. In static mode, operating at high constant oxygen flow rate (QO₂>1105 ml O₂/min) produces a small decrease on the stack performance. High constant oxygen stoichiometry (λO₂>3) does not produce a decrease on the performance of the stack. There are not differences between operating at constant flow rate of oxygen and constant stoichiometry of oxygen in the stack performance. The effect of operating at high temperature with a pressurization system and operating at higher temperatures are beneficial since the performance of the fuel cell is enhanced. A large shut-down stage produces important performance losses due to the loss of catalyst activity and the loss of membrane conductivity. After 150 h of operation at 0.2 A cm⁻², it is observed a very high voltage drop. The phosphoric acid leached from the stack was also evaluated and did not exceed 2% (w/w). This fact suggests that the main degradation mechanism of a fuel cell stack based on polybenzimidazole is not the electrolyte loss. In dynamic test mode, it was observed a rapid response of power and current output even at the lower step-time (10 s). In the static mode at 125 °C and 1 atm, the stack reached a power density peak of 0.29 W cm⁻² (43.5 W) at 1 V.     

Pyrolyzed CoN4-chelate as an electrocatalyst for oxygen reduction reaction in acid media

A novel platinum-free electrocatalyst CoTETA/C for oxygen reduction reaction (ORR) was prepared from pyrolysis of carbon-supported cobalt triethylenetetramine chelate under an inert atmosphere. X-ray diffraction (XRD) measurement showed that nanometallic face-centered cubic (fcc) crystalline α-Co phase embedded in graphitic carbon was present on the pore surface of this catalyst. Cyclic voltammogram experiment showed that the ORR peak potential appears at 710 mV (vs. NHE) in oxygen-saturated acidic media (0.5 M H₂SO₄). The Koutecky–Levich analysis indicated that the ORR follows the first-order kinetic reaction and the ORR proceeds via both the two-electron reduction and the four-electron reduction, while the latter is the main process. The actual performance of a single cell with the obtained CoTETA/C electrocatalyst was examined under a hydrogen-oxygen fuel cell system, and the maximal output power density reached 135 mW cm⁻² at 25 °C.     

Advances in anodic alumina membranes thin film fuel cell: CsH2PO4 pore-filler as proton conductor at room temperature

Anodic alumina membranes (AAM) filled with cesium hydrogen phosphate proton conductor have been tested as inorganic composite electrolyte for hydrogen–oxygen thin film (≤50 μm) fuel cell (TFFC) working at low temperatures (25 °C), low humidity (T_gas = 25 °C) and low Pt loading (1 mg cm⁻²). Single module TFFC delivering a peak power of around 15–27 mW cm⁻², with open circuit voltage (OCV) of about 0.9 V and short circuit current density in the range 80–160 mA cm⁻² have been fabricated. At variance with pure solid acid electrolytes showing reproducibility problems due to the scarce mechanical resistance, the presence of porous alumina support allowed to replicate similar fuel cell performances over numerous AAM/CsH₂PO₄ assemblies. A scale-up process of the electrodic area has been optimized in order to increase the delivered peak power of AAM thin film fuel cell. Morphological, chemical and electrochemical studies on the alumina composite electrolyte have been carried out by means of scanning electron microscopy, X-ray diffractometry, Micro-Raman spectroscopy, DTA/DTG analysis, ac impedance spectroscopy and single fuel cell tests.     

Optimization of Nafion content in Nafion–polyaniline nano-composite modified cathodes for PEMFC application

In this research several Nafion–Polyaniline nano-composite modified cathodes have been fabricated and evaluated in oxygen reduction reaction (ORR) in order to use in proton exchange membrane fuel cell (PEMFC). Modified cathodes made by the wide range of Nafion content (from 0 to 1.6 mg cm⁻²) and investigated in the acidic solution by different electrochemical techniques at 25 °C. The results indicate the activity of the modified electrodes is increased by employing of Nafion–Polyaniline nano-composite in the reaction layer, but there is an optimum value for Nafion content in the catalyst layer. The modified electrode impregnated by 0.4 mg cm⁻² of Nafion shows the highest activity. Analysis of the surface morphology of the Nafion–polyaniline modified electrodes by scanning electron microscopy and electrochemical data reveal that the existence of polyaniline (PANI) nanofibers in the catalyst layer before adding Nafion solution, improves the homogeneity distribution of the ionomer in catalyst layer, change the morphology of electrode and increase the performance of gas diffusion electrodes (GDEs) in oxygen reduction reaction.     

(Titanium,chromium) nitride coatings for bipolar plate of polymer electrolyte membrane fuel cell

(Titanium, chromium) nitride [(Ti,Cr)N] coatings are synthesized on a 316L stainless-steel substrate by inductively-coupled, plasma-assisted, reactive direct current magnetron sputtering. The chemical and electrical properties of the coating are investigated from the viewpoint of it application to bipolar plates. Nanocrystallized Cr–Ti films are formed in the absence of nitrogen gas, while a hexagonal β-(Ti,Cr)₂N phase is observed at N₂ = 1.2 sccm. Well-crystallized (Ti,Cr)N films are obtained at N₂ > 2.0 sccm. The corrosion resistance of the coating is examined by potentiodynamic and potentiostatic tests in 0.05 M H₂SO₄ + 0.2 ppm HF solution at 80 °C, which simulates the operation conditions of a polymer electrolyte membrane fuel cell. The Davies method is used to measure the interfacial contact resistance between the sample and carbon paper. The (Ti,Cr)N coating exhibits the highest corrosion potential and lowest current density. In a cathode environment, the corrosion potential and current density are 0.33 V (vs. SCE) and <5 × 10⁻⁷ A cm⁻² (at 0.6 V), respectively. In an anode environment the corresponding values are 0.16 V and <−5 × 10⁻⁸ A cm⁻² at −0.1 V. The (Ti,Cr)N coatings exhibit excellent stability during potentiostatic polarization tests in both anode and cathode environments. The interfacial contact resistance decreases with deposition of the (Ti,Cr)N film, and a minimum value of 4.5 mΩ cm² is obtained at a compaction force of 150 N cm⁻², which indicates that the formation of oxide films can be successfully prevented by the (Ti,Cr)N film. Analysis with Auger electron spectroscopy reveals that the oxygen content at the surface decreases with increase in the nitrogen content.