Publications

Novel catalysts for hydrogen fuel cell applications:Final report (FY03-FY05)

Thornberg, Steven M.; Coker, Eric N.; Steen, William A.; Jarek, Russell L.

The goal of this project was to develop novel hydrogen-oxidation electrocatalyst materials that contain reduced platinum content compared to traditional catalysts by developing flexible synthesis techniques to fabricate supported catalyst structures, and by verifying electrochemical performance in half cells and ultimately laboratory fuel cells. Synthesis methods were developed for making small, well-defined platinum clusters using zeolite hosts, ion exchange, and controlled calcination/reduction processes. Several factors influence cluster size, and clusters below 1 nm with narrow size distribution have been prepared. To enable electrochemical application, the zeolite pores were filled with electrically-conductive carbon via infiltration with carbon precursors, polymerization/cross-linking, and pyrolysis under inert conditions. The zeolite host was then removed by acid washing, to leave a Pt/C electrocatalyst possessing quasi-zeolitic porosity and Pt clusters of well-controlled size. Plotting electrochemical activity versus pyrolysis temperature typically produces a Gaussian curve, with a peak at ca. 800 C. The poorer relative performances at low and high temperature are due to low electrical conductivity of the carbon matrix, and loss of zeolitic structure combined with Pt sintering, respectively. Cluster sizes measured via adsorption-based methods were consistently larger than those observed by TEM and EXAFS, suggesting , that a fraction of the clusters were inaccessible to the fluid phase. Detailed EXAFS analysis has been performed on selected catalysts and catalyst precursors to monitor trends in cluster size evolution, as well as oxidation states of Pt. Experiments were conducted to probe the electroactive surface area of the Pt clusters. These Pt/C materials had as much as 110 m{sup 2}/g{sub pt} electroactive surface area, an almost 30% improvement over what is commercially (mfg. by ETEK) available (86 m{sup 2}/g{sub pt}). These Pt/C materials also perform qualitatively as well as the ETEK material for the ORR, a non-trivial achievement. A fuel cell test showed that Pt/C outperformed the ETEK material by an average of 50% for a 300 hour test. Increasing surface area decreases the amount of Pt needed in a fuel cell, which translates into cost savings. Furthermore, the increased performance realized in the fuel cell test might ultimately mean less Pt is needed in a fuel cell; this again translates into cost savings. Finally, enhanced long-term stability is a key driver within the fuel cell community as improvements in this area must be realized before fuel cells find their way into the marketplace; these Pt/C materials hold great promise of enhanced stability over time. An external laser desorption ion source was successfully installed on the existing Fourier transform ion-cyclotron resonance (FT-ICR) mass spectrometer. However, operation of this laser ablation source has only generated metal atom ions, no clusters have been found to date. It is believed that this is due to the design of the pulsed-nozzle/laser vaporization chamber. The final experimental configuration and design of the two source housings are described.