Designing the next generation of proton-exchange membrane fuel cells

The Recent Progresses of Electrodes and Electrolysers for Seawater Electrolysis

The utilization of renewable energy for hydrogen production presents a promising pathway towards achieving carbon neutrality in energy consumption. Water electrolysis, utilizing pure water, has proven to be a robust technology for clean hydrogen production. Recently, seawater electrolysis has emerged as an attractive alternative due to the limitations of deep-sea regions imposed by the transmission capacity of long-distance undersea cables. However, seawater electrolysis faces several challenges, including the slow kinetics of the oxygen evolution reaction (OER), the competing chlorine evolution reaction (CER) processes, electrode degradation caused by chloride ions, and the formation of precipitates on the cathode. The electrode and catalyst materials are corroded by the Cl- under long-term operations. Numerous efforts have been made to address these issues arising from impurities in the seawater. This review focuses on recent progress in developing high-performance electrodes and electrolyser designs for efficient seawater electrolysis. Its aim is to provide a systematic and insightful introduction and discussion on seawater electrolysers and electrodes with the hope of promoting the utilization of offshore renewable energy sources through seawater electrolysis.

Elastic and Conductive Cross-linked Anion Exchange Membranes Based on Polyphenylene Oxide and Poly(vinyl alcohol) for H2 -O2 Fuel Cells

A series of cross-linked AEMs (c-DQPPO/PVA) are synthesized by using rigid polyphenylene oxide and flexible poly(vinyl alcohol) as the backbones. Dual cations are grafted on the PPO backbone to improve the ion exchange capacity (IEC), while glutaraldehyde is introduced to enhance compatibility and reduce swelling ratio of AEMs. In addition to the enhanced mechanical properties resulting from the rigid-flexible cross-linked network, c-DQPPO/PVA AEMs also exhibit impressive ionic conductivity, which can be attributed to their high IEC, good hydrophilicity of PVA, and well-defined micro-morphology. Additionally, due to confined dimension behavior and ordered micro-morphology, c-DQPPO/PVA AEMs demonstrate excellent chemical stability. Specifically, c-DQPPO/PVA-7.5 exhibits a wet-state tensile strength of 12.5 MPa and an elongation at break of 53.0 % at 25 °C. Its OH- conductivity and swelling degree at 80 °C are measured to be 125.7 mS cm-1 and 8.2 %, respectively, with an IEC of 3.05 mmol g-1 . After 30 days in a 1 M NaOH solution at 80 °C, c-DQPPO/PVA-7.5 experiences degradation rates of 12.8 % for tensile strength, 27.4 % for elongation at break, 14.7 % for IEC, and 19.2 % for ion conductivity. With its excellent properties, c-DQPPO/PVA-7.5 exhibits a peak power density of 0.751 W cm-2 at 60 °C in an H2 -O2 fuel cell.

Identification of a Durability Descriptor for Molecular Oxygen Reduction Reaction Catalysts

The development of durable platinum-group-metal-free oxygen reduction reaction (ORR) catalysts is a key research direction for enabling the wide use of fuel cells. Here, we use a combination of experimental measurements and density functional theory calculations to study the activity and durability of seven iron-based metallophthalocyanine (MPc) ORR catalysts that differ only in the identity of the substituent groups on the MPcs. While the MPcs show similar ORR activity, their durabilities as measured by the current decay half-life differ greatly. We find that the energy difference between the hydrogenated intermediate structure and the final demetalated structure (ΔEdemetalation) of the MPcs is linearly related to the degradation reaction barrier energy. Comparison to the degradation data for the previously studied metallocorrole systems suggested that ΔEdemetalation also serves as a descriptor for the corrole systems and that the high availability of protons at the active site due to the COOH group of the o-corrole decreases the durability.

Unraveling the Effects of Carbon Corrosion on Oxygen Transport Resistance in Low Pt Loading Proton Exchange Membrane Fuel Cells

Cost and durability have become crucial hurdles for the commercialization of proton exchange membrane fuel cells (PEMFCs). Although a continuous reduction of Pt loading within the cathode catalyst layers (CCLs) can lead to cost savings, it also increases the oxygen transport resistance, which is further compounded by key material degradation. Hence, a further understanding of the mechanism of significant performance loss due to oxygen transport limitations at the triple phase boundaries (TPBs) during the degradation process is critical to the development of low Pt loading PEMFCs. The present study systematically investigates the impact of carbon corrosion in CCLs on the performance and oxygen transport process of low Pt loading PEMFCs through accelerated stress tests (ASTs) that simulate start-up/shutdown cycling. A decline in peak power density from 484.3 to 251.6 mW cm-2 after 1500 AST cycles demonstrates an apparent performance loss, especially at high current densities. The bulk and local oxygen transport resistances (rbulk and Rlocal) of the pristine cell and after 200, 600, 1000, and 1500 AST cycles are quantified by combining the limiting current method with a dual-layer CCL design. The results show that rbulk increased from 1527 to 1679 s cm-2, Rlocal increased from 0.38 to 0.99 s cm-1, and the local oxygen transport resistance with the normalized Pt surface area (rlocal) exhibited an increase from 18.5 to 32.0 s cm-1, indicating a crucial impact on the structure collapse and changes in the chemical properties of the carbon supports in the CCLs. Further, the interaction between the ionomer and carbon supports during the carbon corrosion process is deeply studied via electrochemical quartz crystal microbalance and molecular dynamics simulations. It is concluded that the oxygen-containing functional groups on the carbon surface could impede the adsorption of ionomers on carbon supports by creating an excessively water-rich layer, which in turn aggravates the formation of ionomer agglomerations within the CCLs. This process ultimately leads to the destruction of the TPBs and hinders the transport of oxygen through the ionomer.

Nanotechnologies in ceramic electrochemical cells

Although they are emerging technologies for achieving high-efficiency and green and eco-friendly energy conversion, ceramic electrochemical cells (CECs), i.e. solid oxide electrolysis cells (SOECs) and fuel cells (SOFCs), are still fundamentally limited by their inferior catalytic activities at low temperature, poor thermo-mechanical stability, high material cost, etc. The materials used in electrolytes and electrodes, which are the most important components in CECs, are highly associated with the cell performances. Therefore, rational design of electrolytes and electrodes with excellent catalytic activities and high stabilities at relatively low cost is a meaningful and valuable approach for the development of CECs. Nanotechnology is a powerful tool for improving the material performances in CECs owing to the favourable effects induced by the nanocrystallization of electrolytes and electrodes. Herein, a relatively comprehensive review on the nanotechnologies implemented in CECs is conducted. The working principles of CECs and the corresponding challenges were first presented, followed by the comprehensive insights into the working mechanisms of nanocrystalline materials in CECs. Then, systematic summarization and analyses of the commonly used nano-engineering strategies in the fabrication of CEC materials, including physical and chemical methods, were provided. In addition, the frontiers in the research of advanced electrolyte and electrode materials were discussed with a special emphasis on the modified electrochemical properties derived from nanotechnologies. Finally, the bottlenecks and the promising breakthroughs in nanotechnologies were highlighted in the direction of providing useful references for rational design of nanomaterials for CECs.

Covalent organic frameworks with flexible side chains in hybrid PEMs enable highly efficient proton conductivity

Electrochemical hydrogen compression (EHC) is an emerging energy conversion technology. Proton exchange membranes (PEMs) with high proton conductivity and high mechanical strength are highly required to meet the practical requirements of EHC. Herein, ionic covalent organic frameworks (iCOFs) with tunable side chains were synthesized and introduced into the sulfonated poly (ether ether ketone) (SPEEK) matrix to fabricate hybrid PEMs. In our membranes, the rigid iCOFs afford ordered proton conduction channels, whereas the flexible side chains on iCOFs afford abundant proton conduction sites, adaptive hydrogen bonding networks, and high local density short hydrogen bonds for highly efficient proton transport. Moreover, the hydrogen bond interactions between the side chains on iCOFs and the SPEEK matrix enhance the mechanical stability of membranes. As a result, the hybrid PEM acquires an enhanced proton conductivity of 540.4 mS cm-1 (80 °C, 100%RH), a high mechanical strength of 120.41 MPa, and a superior performance (2.3 MPa at 30 °C, 100%RH) in EHC applications.

Constructing Nanoporous Ir/Ta2 O5 Interfaces on Metallic Glass for Durable Acidic Water Oxidation

Although proton exchange membrane water electrolyzers (PEMWE) are considered as a promising technique for green hydrogen production, it remains crucial to develop intrinsically effective oxygen evolution reaction (OER) electrocatalysts with high activity and durability. Here, a flexible self-supporting electrode with nanoporous Ir/Ta2O5 electroactive surface is reported for acidic OER via dealloying IrTaCoB metallic glass ribbons. The catalyst exhibits excellent electrocatalytic OER performance with an overpotential of 218 mV for a current density of 10 mA cm-2 and a small Tafel slope of 46.1 mV dec-1 in acidic media, superior to most electrocatalysts. More impressively, the assembled PEMWE with nanoporous Ir/Ta2 O5 as an anode shows exceptional performance of electrocatalytic hydrogen production and can operate steadily for 260 h at 100 mA cm-2 . In situ spectroscopy characterizations and density functional theory calculations reveal that the modest adsorption of OOH* intermediates to active Ir sites lower the OER energy barrier, while the electron donation behavior of Ta2 O5 to stabilize the high-valence states of Ir during the OER process extended catalyst's durability.

Bimetallic-MOF Derived Carbon with Single Pt Anchored C4 Atomic Group Constructing Super Fuel Cell with Ultrahigh Power Density And Self-Change Ability

Pursuing high power density with low platinum catalysts loading is a huge challenge for developing high-performance fuel cells (FCs). Herein, a new super fuel cell (SFC) is proposed with ultrahigh output power via specific electric double-layer capacitance (EDLC) + oxygen reduction reaction (ORR) parallel discharge, which is achieved using the newly prepared catalyst, single-atomic platinum on bimetallic metal-organic framework (MOF)-derived hollow porous carbon nanorods (PtSA /HPCNR). The PtSA-1.74 /HPCNR-based SFC has a 3.4-time higher transient specific power density and 13.3-time longer discharge time with unique in situ self-charge and energy storage ability than 20% Pt/C-based FCs. X-ray absorption fine structure, aberration-corrected high-angle annular dark-field scanning transmission electron microscope, and density functional theory calculations demonstrate that the synergistic effect of Pt single-atoms anchored on carbon defects significantly boosts its electron transfer, ORR catalytic activity, durability, and rate performance, realizing rapid " ORR+EDLC" parallel discharge mechanism to overcome the sluggish ORR process of traditional FCs. The promising SFC leads to a new pathway to boost the power density of FCs with extra-low Pt loading.

A dual-functional cuprum coordination framework for high proton conduction and electrochemical dopamine detection

The present study selected 5, 5'-((6-(ethylamino)-1, 3, 5-triazine-2, 4-diyl) bis(azanediyl))diisophthalic acid (H4EATDIA) as ligand and an amino-functionalized cuprum-based MOF (EA-JUC-1000), successfully synthesized by microwave-assisted method, for proton conduction and dopamine sensing applications. In order to enhance the proton-conducting potential of EA-JUC-1000, the Brönsted acid (BA) encapsulated composites (BA@EA-JUC-1000) are dopped into chitosan (CS) to form a series of hybrid membranes (BA@EA-JUC-1000/CS). The impedance results display that the best proton conductivity of CF3SO3H@EA-JUC-1000/CS-8% reaches up to 1.23 × 10-3 S∙cm-1 at 338 K and ~ 98% RH, 2.6-fold than that of CS. Moreover, the EA-JUC-1000 is in-situ combined with reduced graphene oxide (rGO) (rGO/EA-JUC-1000), which makes EA-JUC-1000 have a wide detection range (0.1 ~ 500 μM) and a low limit of detection (50 nM), together with good anti-interference performance, reproducibility and repeatability. In addition, the electrochemical sensing method has been successfully applied to detect DA in bovine serum samples. The dual-functional MOF-based hybrid membrane and composites including proton conduction and DA sensing would provide an example of practical application for MOFs.

Enhancing Polymer Electrolyte Membrane Fuel Cells with Ionic Liquids: A Review

Polymer electrolyte membrane fuel cells (PEMFCs) represent a promising clean energy solution. However, their widespread adoption faces hurdles related to component optimization. This review explores the pivotal role of ionic liquids (ILs) in enhancing PEMFC performance, focusing on their role in polymer electrolyte membranes, catalyst modification, and other components. By addressing key obstacles, including proton conductivity, catalyst stability, and fuel crossover, ILs provide a pathway towards the widespread commercialization of PEMFCs. In the realm of PEMFC membranes, ILs have shown great potential in improving proton conductivity, mechanical strength, and thermal stability. Additionally, the utilization of ILs as catalyst modifiers has shown promise in enhancing the electrocatalytic activity of electrodes by serving as an effective stabilizer to promote the dispersion of metal nanoparticles, and reduce their agglomeration, thereby augmenting catalytic performance. Furthermore, ILs can be tailored to optimize the catalyst-support interaction, ultimately enhancing the overall fuel cell efficiency. Their unique properties, such as high oxygen solubility and low volatility, offer advantages in terms of reducing mass transport and water management issues. This review not only underscores the promising advancements achieved thus far but also outlines the challenges that must be addressed to unlock the full potential of ILs in PEMFC technology, offering a valuable resource for researchers and engineers working toward the realization of efficient and durable PEMFCs.

Porous Polyethylene Supports in Reinforcement of Multiblock Hydrocarbon Ionomers for Proton Exchange Membranes

Hydrocarbon (HC)-based block copolymers have been recognized as promising candidates for proton exchange membranes (PEMs) due to their distinct hydrophilic-hydrophobic separation, which results in improved proton transport compared to that of random copolymers. However, most PEMs derived from HC-based ionomers, including block copolymers, encounter challenges related to durability in electrochemical cells due to their low mechanical and chemical properties. One method for reinforcing HC-based ionomers involves incorporating the ionomers into commercially available low surface tension PTFE porous substrates. Nevertheless, the high interfacial energy between the hydrocarbon-based ionomer solution and PTFE remains a challenge in this reinforcement process, which necessitates the application of surface energy treatment to PTFE. Here, multiblock sulfonated poly(arylene ether sulfone) (SPAES) ionomers are being reinforced using untreated PE on the surface, and this is compared to reinforcement using surface-treated porous PTFE. The PE support layer exhibits a lower surface energy barrier compared to the surface-treated PTFE layer for the infiltration of the multiblock SPAES solution. This is characterized by the absence of noticeable voids, high translucency, gas impermeability, and a physical and chemical stability. By utilizing a high surface tension PE support with a comparable value to the multiblock SPAES, effective reinforcement of the multiblock SPAES ionomers is achieved for a PEM, which is potentially applicable to various hydrogen energy-based electrochemical cells.

Selective Etching of Metal-Organic Frameworks for Open Porous Structures: Mass-Efficient Catalysts with Enhanced Oxygen Reduction Reaction for Fuel Cells

Fe-Nx-C-based single-atom (SA-Fe-N-C) catalysts have shown favorable oxygen reduction reaction (ORR) activity. However, their application in proton exchange membrane fuel cells is hindered by reduced performance owing to the thick catalyst layer, restricting mass transfer and the O2 supply. Metal-organic frameworks (MOFs) are a promising class of crystal materials, but their narrow pores exacerbate the sluggish mass-transport properties within the catalyst layer. This study developed an approach for constructing an open-pore structure in MOFs via chelation-assisted selective etching, resulting in atomically dispersed Fe atoms anchored on an N, S co-doped carbon framework. The open-pore structure reduces oxygen transport resistance in the membrane electrode assembly (MEA) with unprecedented ORR activity and stability, as evidenced by finite element simulations. In an acidic electrolyte, the OP-Fe-NC catalyst shows a half-wave potential of 0.89 V vs RHE, surpassing Pt/C by 20 mV, and a current density of 29 mA cm-2 at 0.9 ViR-free in the MEA. This study provides an effective structural strategy for fabricating electrocatalysts with high mass efficiency and atomic precision for energy storage and conversion devices.

3D microprinting of inorganic porous materials by chemical linking-induced solidification of nanocrystals

Three-dimensional (3D) microprinting is considered a next-generation manufacturing process for the production of microscale components; however, the narrow range of suitable materials, which include mainly polymers, is a critical issue that limits the application of this process to functional inorganic materials. Herein, we develop a generalised microscale 3D printing method for the production of purely inorganic nanocrystal-based porous materials. Our process is designed to solidify all-inorganic nanocrystals via immediate dispersibility control and surface linking-induced interconnection in the nonsolvent linker bath and thereby creates multibranched gel networks. The process works with various inorganic materials, including metals, semiconductors, magnets, oxides, and multi-materials, not requiring organic binders or stereolithographic equipment. Filaments with a diameter of sub-10 μm are printed into designed complex 3D microarchitectures, which exhibit full nanocrystal functionality and high specific surface areas as well as hierarchical porous structures. This approach provides the platform technology for designing functional inorganics-based porous materials.

Surface-structure tailoring of Dendritic PtCo nanowires for efficient oxygen reduction reaction

Platinum-based alloy nanowire catalysts demonstrates great promise as electrocatalysts to facilitate the cathodic oxygen reduction reaction (ORR) of proton exchange membrane fuel cells (PEMFCs). However, it is still challenge to further improve the Pt atom utilization of Pt based nanowires featuring inherent structural stability. Herein, a new structure of PtCo nanowire with nanodendrites was developed using CO-assistance solvent thermal method. The dendrite structure with an average length of about 7 nm are characterized by a Pt-rich surface and the high-index facets of {533}, {331} and {311}, and grows from the ultra-fine wire structure with an average diameter of about 3 nm. PtCo nanowires with nanodendrites developed in this work shows outstanding performance for ORR, in which its mass activity of 1.036 A/mgPt is 5.76 times, 1.74 times higher than that of commercial Pt/C (0.180 A/mgPt) and PtCo nanowires without nanodendrites (0.595 A/mgPt), and its mass activity loss is only 18% under the accelerated durability tests (ADTs) for 5k cycles. The significant improvement is attributed to high exposure of active sites induced by the dendrite structure with Pt-rich surface with the high-index facets and Pt-rich surface. This structure may provide a new idea for developing novel 1D Pt based electrocatalysts.

Crystallizing Self-Standing Covalent Organic Framework Membranes for Ultrafast Proton Transport in Flow Batteries

Covalent organic frameworks (COFs) display great potential to be assembled into proton conductive membranes for their uniform and controllable pore structure, yet constructing self-standing COF membrane with high crystallinity to fully exploit their ordered crystalline channels for efficient ionic conduction remains a great challenge. Here, a macromolecular-mediated crystallization strategy is designed to manipulate the crystallization of self-standing COF membrane, where the -SO3 H groups in introduced sulfonated macromolecule chains function as the sites to interact with the precursors of COF and thus offer long-range ordered template for membrane crystallization. The optimized self-standing COF membrane composed of highly-ordered nanopores exhibits high proton conductivity (75 mS cm-1 at 100 % relative humidity and 20 °C) and excellent flow battery performance, outperforming Nafion 212 and reported membranes. Meanwhile, the long-term run of membrane is achieved with the help of the anchoring effect of flexible macromolecule chains. Our work provides inspiration to design self-standing COF membranes with ordered channels for permselective application.

S-Block Potassium Single-atom Electrocatalyst with K-N4 Configuration Derived from K+ /Polydopamine for Efficient Oxygen Reduction

Currently, single-atom catalysts (SACs) research mainly focuses on transition metal atoms as active centers. Due to their delocalized s/p-bands, the s-block main group metal elements are typically regarded as catalytically inert. Herein, an s-block potassium SAC (K-N-C) with K-N4 configuration is reported for the first time, which exhibits excellent oxygen reduction reaction (ORR) activity and stability under alkaline conditions. Specifically, the half-wave potential (E1/2 ) is up to 0.908 V, and negligible changes in E1/2 are observed after 10,000 cycles. In addition, the K-N-C offers an exceptional power density of 158.1 mW cm-2 and remarkable durability up to 420 h in a Zn-air battery. Density functional theory (DFT) simulations show that K-N-C has bifunctional active K and C sites, can optimize the free energy of ORR reaction intermediates, and adjust the rate-determining steps. The crystal orbital Hamilton population (COHP) results showed that the s orbitals of K played a major role in the adsorption of intermediates, which was different from the d orbitals in transition metals. This work significantly guides the rational design and catalytic mechanism research of s-block SACs with high ORR activity.

A Review of Potential Electrochemical Applications in Buildings for Energy Capture and Storage

The integration of distributed renewable energy technologies (such as building-integrated photovoltaics (BIPV)) into buildings, especially in space-constrained urban areas, offers sustainable energy and helps offset fossil-fuel-related carbon emissions. However, the intermittent nature of these distributed renewable energy sources can negatively impact the larger power grids. Efficient onsite energy storage solutions capable of providing energy continuously can address this challenge. Traditional large-scale energy storage methods like pumped hydro and compressed air energy have limitations due to geography and the need for significant space to be economically viable. In contrast, electrochemical storage methods like batteries offer more space-efficient options, making them well suited for urban contexts. This literature review aims to explore potential substitutes for batteries in the context of solar energy. This review article presents insights and case studies on the integration of electrochemical energy harvesting and storage into buildings. The seamless integration can provide a space-efficient source of renewable energy for new buildings or existing structures that often have limited physical space for retrofitting. This work offers a comprehensive examination of existing research by reviewing the strengths and drawbacks of various technologies for electrochemical energy harvesting and storage, identifying those with the potential to integrate into building skins, and highlighting areas for future research and development.

Overcoming the Electrode Challenges of High-Temperature Proton Exchange Membrane Fuel Cells

Proton exchange membrane fuel cells (PEMFCs) are becoming a major part of a greener and more sustainable future. However, the costs of high-purity hydrogen and noble metal catalysts alongside the complexity of the PEMFC system severely hamper their commercialization. Operating PEMFCs at high temperatures (HT-PEMFCs, above 120 °C) brings several advantages, such as increased tolerance to contaminants, more affordable catalysts, and operations without liquid water, hence considerably simplifying the system. While recent progresses in proton exchange membranes for HT-PEMFCs have made this technology more viable, the HT-PEMFC viscous acid electrolyte lowers the active site utilization by unevenly diffusing into the catalyst layer while it acutely poisons the catalytic sites. In recent years, the synthesis of platinum group metal (PGM) and PGM-free catalysts with higher acid tolerance and phosphate-promoted oxygen reduction reaction, in conjunction with the design of catalyst layers with improved acid distribution and more triple-phase boundaries, has provided great opportunities for more efficient HT-PEMFCs. The progress in these two interconnected fields is reviewed here, with recommendations for the most promising routes worthy of further investigation. Using these approaches, the performance and durability of HT-PEMFCs will be significantly improved.

Study on Self-Humidification in PEMFC with Crossed Flow Channels and an Ultra-Thin Membrane

In this study, a 3D model of a proton exchange membrane fuel cell (PEMFC) with crossed channels and an ultra-thin membrane is developed to investigate the feasibility of self-humidification; experiments utilizing a PEMFC stack with identical configurations are conducted to validate the simulation results and further investigate the effects of various operating conditions (OCs) on self-humidification. The results indicate that the crossed flow channel leads to enhanced uniformity of water distribution, resulting in improved cell performance under low/no humidification conditions. External humidifiers for the anode can be removed since the performance difference is negligible (≤3%) between RHa = 0% and 100%. Self-humidification can be achieved in the stack at 90 °C or below with an appropriate back pressure among 100-200 kPa. As the current density increases, there is a gradual convergence and crossing of the voltage at low RH with that at high RH, and the crossover points are observed at 60-80 °C with suitable pressure when successful self-humidification is achieved. Below the current density of the point, the stack's performance is inferior at lower RH due to membrane unsaturation, and conversely, the performance is inferior at higher RH due to flooding; this current density decreases with higher pressure and lower temperature.

Symmetry-Induced Regulation of Pt Strain Derived from Pt3 Ga Intermetallic for Boosting Oxygen Reduction Reaction

Pt-based fuel cell catalysts with excellent activity and stability for proton-exchange membrane fuel cells (PEMFCs) have been developed through strain regulation in recent years. Herein, this work demonstrates that symmetry-induced strain regulation of Pt surface of PtGa intermetallic compounds can greatly enhance the catalytic performance of the oxygen reduction reaction (ORR). With the strain environment varies derived from the lattice mismatch of analogous PtGa core but different symmetry, the Pt surface of the PtGa alloy and the Pt3 Ga (Pm3 ¯ $\bar{3}$ m) precisely realize 0.58% and 2.7% compressive strain compared to the Pt3 Ga (P4/mmm). Experimental and theoretical results reveal that when the compressive stress of the Pt lattice increases, the desorption process of O* intermediates becomes accelerated, which is conducive to oxygen reduction. The Pt3 Ga (Pm3 ¯ $\bar{3}$ m) with high symmetry and compressive Pt surface exhibit the highest mass and specific activities of 2.18 A mgPt -1 and 5.36 mA cm-2 , respectively, which are more than one order of magnitude higher than those of commercial Pt/C catalysts. This work demonstrates that material symmetry can be used to precisely modulate Pt surface stress to enhance the ORR, as well as provide a distinct platform to investigate the relationship between Pt compressibility and catalytic activity.

High proton conductivity within the 'Norby gap' by stabilizing a perovskite with disordered intrinsic oxygen vacancies

Proton conductors are attractive materials with a wide range of potential applications such as proton-conducting fuel cells (PCFCs). The conventional strategy to enhance the proton conductivity is acceptor doping into oxides without oxygen vacancies. However, the acceptor doping results in proton trapping near dopants, leading to the high apparent activation energy and low proton conductivity at intermediate and low temperatures. The hypothetical cubic perovskite BaScO2.5 may have intrinsic oxygen vacancies without the acceptor doping. Herein, we report that the cubic perovskite-type BaSc0.8Mo0.2O2.8 stabilized by Mo donor-doing into BaScO2.5 exhibits high proton conductivity within the 'Norby gap' (e.g., 0.01 S cm-1 at 320 °C) and high chemical stability under oxidizing, reducing and CO2 atmospheres. The high proton conductivity of BaSc0.8Mo0.2O2.8 at intermediate and low temperatures is attributable to high proton concentration, high proton mobility due to reduced proton trapping, and three-dimensional proton diffusion in the cubic perovskite stabilized by the Mo-doping into BaScO2.5. The donor doping into the perovskite with disordered intrinsic oxygen vacancies would be a viable strategy towards high proton conductivity at intermediate and low temperatures.

Simultaneous multimaterial operando tomography of electrochemical devices

The performance of electrochemical energy devices, such as fuel cells and batteries, is dictated by intricate physiochemical processes within. To better understand and rationally engineer these processes, we need robust operando characterization tools that detect and distinguish multiple interacting components/interfaces in high contrast. Here, we uniquely combine dual-modality tomography (simultaneous neutron and x-ray tomography) and advanced image processing (iterative reconstruction and metal artifact reduction) for high-contrast multimaterial imaging, with signal and contrast enhancements of up to 10 and 48 times, respectively, compared to conventional single-modality imaging. Targeted development and application of these methods to electrochemical devices allow us to resolve operando distributions of six interacting fuel cell components (including void space) with the highest reported pairwise contrast for simultaneous yet decoupled spatiotemporal characterization of component morphology and hydration. Such high-contrast tomography ushers in key gold standards for operando electrochemical characterization, with broader applicability to numerous multimaterial systems.

Targeted Spin-State Regulation to Boost Oxygen Reduction Reaction

Catalytic reactions are known to be significantly affected by spin states and their variations during reaction processes, yet the mechanisms behind them remain not fully understood, thus preventing the rational optimization of catalysis. Here, we explore the relationship between the spin states of active sites and their catalytic performance, taking the oxygen reduction reaction as an example. We demonstrate that the catalytic performance is spin-state-dependent and can be improved by adjusting spin states during the catalytic process. To this end, we further investigate the possibility of altering the spin states of transition metals through the application of external fields, such as adsorbed species. By studying the influence of the strength of adsorbed ligands on spin states and its impact on catalytic performance, our results show that optimal catalytic performance is achieved when the strength of the external field is neither too strong nor too weak, forming a volcano-like relationship between the catalytic performance and the external field strength. Our findings can have far-reaching implications for the rational design of high-performance catalysis.

Developing high-affinity, oxygen-insensitive [NiFe]-hydrogenases as biocatalysts for energy conversion

The splitting of hydrogen (H2) is an energy-yielding process, which is important for both biological systems and as a means of providing green energy. In biology, this reaction is mediated by enzymes called hydrogenases, which utilise complex nickel and iron cofactors to split H2 and transfer the resulting electrons to an electron-acceptor. These [NiFe]-hydrogenases have received considerable attention as catalysts in fuel cells, which utilise H2 to produce electrical current. [NiFe]-hydrogenases are a promising alternative to the platinum-based catalysts that currently predominate in fuel cells due to the abundance of nickel and iron, and the resistance of some family members to inhibition by gases, including carbon monoxide, which rapidly poison platinum-based catalysts. However, the majority of characterised [NiFe]-hydrogenases are inhibited by oxygen (O2), limiting their activity and stability. We recently reported the isolation and characterisation of the [NiFe]-hydrogenase Huc from Mycobacterium smegmatis, which is insensitive to inhibition by O2 and has an extremely high affinity, making it capable of oxidising H2 in air to below atmospheric concentrations. These properties make Huc a promising candidate for the development of enzyme-based fuel cells (EBFCs), which utilise H2 at low concentrations and in impure gas mixtures. In this review, we aim to provide context for the use of Huc for this purpose by discussing the advantages of [NiFe]-hydrogenases as catalysts and their deployment in fuel cells. We also address the challenges associated with using [NiFe]-hydrogenases for this purpose, and how these might be overcome to develop EBFCs that can be deployed at scale.

Investigating Degradation Mechanisms in PtCo Alloy Catalysts: The Role of Co Content and a Pt-Rich Shell Using Operando High-Energy Resolution Fluorescence Detection X-ray Absorption Spectroscopy

Low Pt-based alloy catalysts are regarded as an efficient strategy in achieving high activity for the oxygen reduction reaction (ORR) in proton-exchange membrane fuel cells (PEMFCs). However, the desired durability for the low Pt-based catalysts, such as the Pt1Co3 catalyst, has still been considered a great challenge for PEMFCs. In this study, we investigate sub-2.5 nm PtxCoy alloy catalysts with varying Co content and Pt1Co3@Pt core-shell (CS) nanostructure catalysts obtained through a simple displacement reaction. The Pt1Co3@Pt_H catalysts showed a high mass activity (MA) of 1.46 A/mgPt at 0.9 V and 14% MA loss after 10k accelerated degradation test (ADT) cycles, which suggested the improved stability compared with Pt1Co3 catalysts (52% MA loss). To clarify the degradation mechanism, operando high-energy resolution fluorescence detection X-ray absorption spectroscopy (XAS) was applied in addition to conventional advanced measurement techniques, including operando conventional XAS, to analyze the electronic state and structure changes during operation potentials. We found that introducing Co improves the catalysts' activity mainly from the strain effect, but an excessive amount of Co leads to increased Pt-oxidation, which accelerates the degradation of the catalysts. The Pt1Co3@Pt_H catalyst shows high tolerance to Pt-oxidation, benefiting both the stability and activity. Our findings demonstrate an in-depth understanding of the degradation mechanism and the importance of designing PtCo CS nanostructures with optimal Co content for enhanced performance in PEMFCs.

Au Doping PtNi Nanodendrites for Enhanced Electrocatalytic Methanol Oxidation Reaction

To boost the electrocatalytic methanol oxidation reaction (MOR) of Platinum (Pt), making binary PtM (M = transition metals, for example, Fe, Cu, and Ni) with specific morphology is known as a promising method. Although great progress has been made in the synthesis of shaped PtM catalysts toward MOR, enhancing the catalytic performance of the PtM to enable it to be commercialized is still a hotspot. In this work, the Au-doped PtNi dendritic nanoparticles (Au-PtNi DNPs) were obtained by doping a small amount of gold (Au) into initially prepared PtNi DNPs, greatly improving their MOR catalytic activity and durability. The energy-dispersive X-ray spectroscopy mapping (EDXS) indicates that the surface of DNPs is mainly composed of Au dopant and PtNi, while the core is mainly Pt, indicating the formation of Au-doped PtNi/Pt core-shell-like DNP structures. The electrocatalytic performance of the prepared Au-PtNi DNPs with different compositions for the MOR was evaluated using cyclic voltammetry, chronoamperometry, and CO-stripping tests. The experimental findings indicate that the Au-PtNi DNPs showed better MOR performance in comparison with PtNi DNPs and commercial Pt catalysts. Among all the catalysts, 6% Au-PtNi DNPs showed 4.3 times improved mass catalytic activity for the MOR in comparison with commercial Pt catalysts. In addition, all the prepared Au-PtNi DNPs display a remarkable CO tolerance compared to that of PtNi DNPs and commercial Pt catalysts. The dendritic structure of Au-PtNi DNPs can effectively enhance catalytic performance, combined with the electronic effect of Au, Pt, and Ni.

Single-Atom-Based Oxygen Reduction Reaction Catalysts for Proton Exchange Membrane Fuel Cells: Progress and Perspective

Single-atom catalysts (SACs) are regarded as promising non-noble-metal alternatives for the oxygen reduction reaction (ORR) in proton exchange membrane fuel cells due to their high atom utilization efficiency and excellent catalytic properties. However, the insufficient long-term stability issues of SACs under the working conditions seriously hinder their practical application. In this perspective, the recent progress of SACs with optimized ORR catalytic activity is first reviewed. Then, the possible degradation mechanisms of SACs in the ORR process and effective strategies for improving their ORR durability are summarized. Finally, some challenges and opportunities are proposed to develop stable single-atom-based ORR electrocatalysts in the future.

Recent Progress in Using Mesoporous Carbon Materials as Catalyst Support for Proton Exchange Membrane Fuel Cells

Developing durable oxygen reduction reaction (ORR) electrocatalysts is essential to step up the large-scale applications of proton exchange membrane fuel cells (PEMFCs). Traditional ORR electrocatalysts provide satisfactory activity, yet their poor durability limits the long-term applications of PEMFCs. Porous carbon used as catalyst support in Pt/C is vulnerable to oxidation under high potential conditions, leading to Pt nanoparticle dissolution and carbon corrosion. Thus, integrating Pt nanoparticles into highly graphitic mesoporous carbons could provide long-term stability. This Perspective seeks to reframe the existing approaches to employing Pt alloys and mesoporous carbon-integrated ORR electrocatalysts to improve the activity and stability of PEMFCs. The unusual porous structure of mesoporous carbons promotes oxygen transport, and graphitization provides balanced stability. Furthermore, the synergistic effect between Pt alloys and heteroatom doping in mesoporous carbons not only provides a great anchoring surface for catalyst nanoparticles but also improves the intrinsic activity. Furthermore, the addition of Pt alloys into mesoporous carbon optimizes the available surface area and creates an effective electron transfer channel, reducing the mass transport resistance. The long-term goals for fuel-cell-powered cars, especially those designed for heavy-duty use, are well aligned with the results shown when this hybrid material is used in PEMFCs to improve performance and durability.

Simulation and optimization of the impacts of metal-organic frameworks on the hydrogen adsorption using computational fluid dynamics and artificial neural networks

One of the barriers to further commercialization of the proton exchange membrane fuel cell (PEMFC) is hydrogen storage. Conventional methods are based on pressurizing the hydrogen up to 700 bar. The focus of this study is to characterize the hydrogen storage capacity of hydrogen tanks filled with MOF-5 at low pressures. Thus, Computational Fluid Dynamic (CFD) was used in a transient condition to analyze the hydrogen storage. Benefiting from the CFD model, three input parameters of the MOF-5, namely, density, specific heat, and conductivity, were utilized to develop an artificial neural network (ANN) model to find the highest mass of adsorption at the lowest required pressure. The optimum possible MOF among 729220 different possibilities, which enables the adsorption of 0.0099 kg at 139 bar, was found using a newly defined parameter called Pressure Adsorption Parameter (PAP).

Advanced Architectures of Air Electrodes in Zinc-Air Batteries and Hydrogen Fuel Cells

The air electrode is an essential component of air-demanding energy storage/conversion devices, such as zinc-air batteries (ZABs) and hydrogen fuel cells (HFCs), which determines the output power and stability of the devices. Despite atom-level modulation in catalyst design being recently achieved, the air electrodes have received much less attention, causing a stagnation in the development of air-demanding equipment. Herein, the evolution of air electrodes for ZABs and HFCs from the early stages to current requirements is reviewed. In addition, the operation mechanism and the corresponding electrocatalytic mechanisms of ZABs are summarized. In particular, by clarifying the air electrode interfaces of ZABs at different scales, several approaches to improve the air electrode in rechargeable ZABs are reviewed, including innovative electrode structures and bifunctional oxygen catalysts. Afterward, the operating mechanisms of proton-exchange-membrane fuel cells (PEMFCs) and anion-exchange-membrane fuel cells (AEMFCs) are explained. Subsequently, the strategies employed to enhance the efficiency of the membrane electrode assembly (MEA) in PEMFCs and AEMFCs, respectively, are highlighted and discussed in detail. Last, the prospects for air electrodes in ZABs and HFCs are considered by discussing the main challenges. The aim of this review is to facilitate the industrialization of ZABs and HFCs.

Extending conducting channels in Fe-N-C by interfacial growth of CNTs with minimal metal loss for efficient ORR electrocatalysis

Achieving a high electrocatalytic performance using a completely metal-free electrocatalyst, preferably based on only carbonaceous materials, remains a challenge. Alternatively, an efficient composite of a carbon nanostructure and a non-noble metal with minimum dependence on a metal holds immense potential. Although single-atom catalysis brings superior performance, its complex synthetic strategy limits its large-scale implementation. Previous investigation has shown that atomic dispersion (Fe-Nx-C) is accompanied by higher metal-loss compared to nanoparticle formation (Fe-NPs-N-C). Therefore, to achieve minimum metal loss, we first incorporated iron nanoparticles (Fe NPs) to N-doped carbon (N-C) and then exposed them to a cheap carbon source, melamine at high temperature, resulting in the growth of carbon nanotubes (CNTs) catalysed by those Fe NPs loaded on N-C (Fe-NPs-N-C). Thermogravimetric analysis showed that the metal-retention in the composite is higher than that in the bare carbon nanotube and even the atomically dispersed Fe-active sites on N-C. The composite material (Fe-NPs-N-C/CNT) shows a high half-wave potential (0.89 V vs. RHE) which is superior to that of commercial Pt/C towards the oxygen reduction reaction (ORR). The enhanced activity is attributed to the synergistic effect of high conductivity of CNTs and active Fe-sites as the composite exceeds the individual electrocatalytic performance shown by Fe-CNTs & Fe-NPs-N-C, and even that of atomically dispersed Fe-active sites on N-C.

Local environmental engineering for highly stable single-atom Pt1/CeO2catalysts: first-principles insights

Single-atom Pt1/CeO2catalysts may cope with the high cost and durability issues of fuel cell electrocatalysts. In the present study, the stability and underlying interaction mechanisms of the Pt1/CeO2system are systematically investigated using first-principles calculations. The Pt adsorption energy on CeO2surfaces can be divided into chemical interaction and surface deformation parts. The interaction energy, mainly associated with the local chemical environment, i.e. the number of Pt-O bonds, plays a major role in Pt1/CeO2stability. When forming a Pt-4O configuration, the catalytic system has the highest stability and Pt is oxidized to Pt2+. An electronic metal-support interaction mechanism is proposed for understanding Pt1/CeO2stability. In addition, our calculations show that the Pt1/CeO2(100) system is dynamically stable, and the external O environment can promote the further oxidation of Pt to Ptn+(2 ≤n< 4). The present study provides useful guidance for the experimental development of highly stable and efficient electrocatalysts for fuel cell applications.

Immobilizing ultrasmall Pt nanocrystals on 3D interweaving BCN nanosheet-graphene networks enables efficient methanol oxidation reaction

Currently, the state-of-the-art anode catalysts employed in direct methanol fuel cells (DMFCs) consist of nanosize Pt dispersed on a carbonaceous support; however, the relatively weak Pt-carbon interfacial interactions severely affect their overall electrocatalytic activity and service life. Herein, we demonstrate a convenient and robust stereo-assembly strategy for the efficient immobilization of ultrasmall Pt nanocrystals on 3D interweaving porous B-doped g-C3N4 nanosheet-graphene networks (Pt/BCN-G) by combining thermal annealing and solvothermal processes. This delicate configuration endowed the resulting hybrid nanoarchitecture with unusual textural merits, including 3D crosslinked porous skeletons, well-separated ultrathin nanosheets, rich B and N species, homogeneous Pt dispersion, stable heterointerface, and high electrical conductivity. Consequently, the 3D Pt/BCN-G nanoarchitecture with an optimized composition exhibited a large electrochemically active surface area of up to 121.2 m2 g-1, high mass activity of 1782.2 mA mg-1, superior poison tolerance, and excellent cycling stability towards the electrooxidation of methanol, all of which exceeded that of the reference Pt/graphene, Pt/BCN, Pt/carbon nanotube, Pt/carbon black, and Pt/g-C3N4 catalysts.

Rational Materials and Structure Design for Improving the Performance and Durability of High Temperature Proton Exchange Membranes (HT-PEMs)

Hydrogen energy as the next-generation clean energy carrier has attracted the attention of both academic and industrial fields. A key limit in the current stage is the operation temperature of hydrogen fuel cells, which lies in the slow development of high-temperature and high-efficiency proton exchange membranes. Currently, much research effort has been devoted to this field, and very innovative material systems have been developed. The authors think it is the right time to make a short summary of the high-temperature proton exchange membranes (HT-PEMs), the fundamentals, and developments, which can help the researchers to clearly and efficiently gain the key information. In this paper, the development of key materials and optimization strategies, the degradation mechanism and possible solutions, and the most common morphology characterization techniques as well as correlations between morphology and overall properties have been systematically summarized.

A New Integrated GDL with Wavy Channel and Tunneled Rib for High Power Density PEMFC at Low Back Pressure and Wide Humidity

Proton exchange membrane fuel cells (PEMFCs) have garnered significant attention due to their high efficiency and low emissions. However, PEMFC always suffers mass transfer and water management in performance improvement. Herein, an integrated gas diffusion layer (GDL) with wavy channel and micro-tunneled rib is designed and prepared to achieve faster and gentler mass transfer and excellent water management capability by laser engraving. Outstandingly, the new integrated GDL can use the back pressure of air as low as 0 and 50 kPa to respectively achieve 80% and 90% of fuel cell performance realized under pure oxygen. Such high performance is mainly due to the turbulent flow caused by wavy channel and express removing pathway of liquid water provided by micro-tunneled rib. Moreover, the new integrated GDL also shows wide humidity tolerance from 40% to 100% and a very high specific volume power density of 16,300 W L-1 due to the thin thickness of new integrated GDL. This new integrated GDL is expected to be widely used in PEMFC and other energy conversion devices.

Recent progress, trends, and new challenges in the electrochemical production of green hydrogen coupled to selective electrooxidation of 5-hydroxymethylfurfural (HMF)

The production of clean electrical energy and the correct use of waste materials are two topics that currently concern humanity. In order to face both problems, extensive work has been done on the electrolytic production of green H2 coupled with the electrooxidative upgrading of biomass platform molecules. 5-Hydroxymethylfurfural (HMF) is obtained from forest waste biomass and can be selectively oxidized to 2,5-furandicarboxylic acid (FDCA) by electrochemical pathways. FDCA is an attractive precursor to polyethylene furanoate (PEF), with the potential to replace petroleum-based polyethylene terephthalate (PET). An integrated electrochemical system can simultaneously produce H2 and FDCA at a lower energy cost than that required for electrolytic water splitting. Here, the benefits of the electrochemical production of H2 and FDCA over other production methods are presented, as well as the innovative applications of each reaction product and the advantages of carrying out both reactions in a coupled system. The recently reported progress is disclosed, through an exploration of electrocatalyst materials used in simultaneous production, including the use of nickel foams (NF) as modification substrates, noble and non-noble metals, metal non-oxides, metal oxides, spinel oxides and the introduction of oxygen vacancies. Based on the latest trends, the next challenges associated with its large-scale production are proposed for its implementation in the industrial world. This work can offer a guideline for the detailed understanding of the electrooxidation of HMF towards FDCA with the production of H2, as well as the design of advanced electrocatalysts for the sustainable use of renewable resources.

Slip-Enhanced Transport by Graphene in the Microporous Layer for High Power Density Proton-Exchange Membrane Fuel Cells

Proton exchange membrane (PEM) fuel cells are a promising and environmentally friendly device to directly convert hydrogen energy into electric energy. However, water flooding and gas transport losses degrade its power density owing to structural issues (cracks, roughness, etc.) of the microporous layer (MPL). Here, we introduce a green material, supercritical fluid exfoliated graphene (s-Gr), to act as a network to effectively improve gas transport and water management. The assembled PEM fuel cell achieves a power density of 1.12 W cm-2. This improved performance is attributed to the reduction of cracks and the slip of water and gas on the s-Gr surface, in great contrast to the nonslip behavior on carbon black (CB). These findings open up an avenue to solve the water and gas transport problem in porous media by materials design with low friction and provide a new opportunity to boost high power density PEM fuel cells.

Intrinsic spin shielding effect in platinum-rare-earth alloy boosts oxygen reduction activity

Oxygen reduction reactions (ORRs) involve a multistep proton-coupled electron process accompanied by the conversion of the apodictic spin configuration. Understanding the role of spin configurations of metals in the adsorption and desorption of oxygen intermediates during ORRs is critical for the design of efficient ORR catalysts. Herein, a platinum-rare-earth-metal-based alloy catalyst, Pt2Gd, is introduced to reveal the role of spin configurations in the catalytic activity of materials. The catalyst exhibits a unique intrinsic spin reconfiguration because of interactions between the Gd-4f and Pt-5d orbitals. The adsorption and desorption of the oxygen species are optimized by modifying the spin symmetry and electronic structures of the material for increased ORR efficiency. The Pt2Gd alloy exhibits a half-wave potential of 0.95 V and a superior mass activity of 1.5 A·mgPt-1 in a 0.1 M HClO4 electrolyte, as well as higher durability than conventional Pt/C catalysts. Theoretical calculations have proven that the spin shielding effect of Gd pairs increases the spin symmetry of Pt-5d orbitals and adsorption preferences toward spin-polarized intermediates to facilitate ORR. This work clarifies the impact of modulating the intrinsic spin state of Pt through the interaction with the local high spin 4f orbital electrons in rare-earth metals, with the aim of boosting the spin-related oxygen reduction reaction, thus fundamentally contributing to the understanding of new descriptors that control ORR activity.

d-Orbital Electron Delocalization Realized by Axial Fe4 C Atomic Clusters Delivers High-Performance Fe-N-C Catalysts for Oxygen Reduction Reaction

Fe-N-C catalyst for oxygen reduction reaction (ORR) has been considered as the most promising nonprecious metal catalyst due to its comparable catalytic performance to Pt in proton exchange membrane fuel cells (PEMFCs). The active centers of Fe-pyrrolic N4 have been proven to be extremely active for ORR. However, forming a stable Fe-pyrrolic N4 structure is a huge challenge. Here, a Cyan-Fe-N-C catalyst with Fe-pyrrolic N4 as the intrinsic active center is constructed with the help of axial Fe4 C atomic clusters, which shows a half-wave potential of up to 0.836 V (vs. RHE) in the acid environment. More remarkably, it delivers a high power density of 870 and 478 mW cm-2 at 1.0 bar in H2 -O2 and H2 -Air fuel cells, respectively. According to theoretical calculation and in situ spectroscopy, the axial Fe4 C can provide strong electronic perturbation to Fe-N4 active centers, leading to the d-orbital electron delocalization of Fe and forming the Fe-pyrrolic N4 bond with high charge distribution, which stabilizes the Fe-pyrrolic N4 structure and optimizes the OH* adsorption during the catalytic process. This work proposes a new strategy to adjust the electronic structure of single-atom catalysts based on the strong interaction between single atoms and atomic clusters.

Lattice-Strain Engineering for Heterogenous Electrocatalytic Oxygen Evolution Reaction

The energy efficiency of metal-air batteries and water-splitting techniques is severely constrained by multiple electronic transfers in the heterogenous oxygen evolution reaction (OER), and the high overpotential induced by the sluggish kinetics has become an uppermost scientific challenge. Numerous attempts are devoted to enabling high activity, selectivity, and stability via tailoring the surface physicochemical properties of nanocatalysts. Lattice-strain engineering as a cutting-edge method for tuning the electronic and geometric configuration of metal sites plays a pivotal role in regulating the interaction of catalytic surfaces with adsorbate molecules. By defining the d-band center as a descriptor of the structure-activity relationship, the individual contribution of strain effects within state-of-the-art electrocatalysts can be systematically elucidated in the OER optimization mechanism. In this review, the fundamentals of the OER and the advancements of strain-catalysts are showcased and the innovative trigger strategies are enumerated, with particular emphasis on the feedback mechanism between the precise regulation of lattice-strain and optimal activity. Subsequently, the modulation of electrocatalysts with various attributes is categorized and the impediments encountered in the practicalization of strained effect are discussed, ending with an outlook on future research directions for this burgeoning field.

A Recyclable Standalone Microporous Layer with Interpenetrating Network for Sustainable Fuel Cells

The commercialization of fuel cells inevitably brings recycling problems. Therefore, achieving high recyclability of fuel cells is particularly important for their sustainable development. In this work, a recyclable standalone microporous layer (standalone MPL) with interpenetrating network that can significantly enhance the recyclability and sustainability of fuel cells is prepared. The interpenetrating network enables the standalone MPL to have high strength (17.7 MPa), gas permeability (1.55 × 10-13  m2 ), and fuel-cell performance (peak power density 1.35 W cm-2 ), providing the basic guarantee for its application in high-performance and highly recyclable fuel cells. Additionally, the standalone MPL is highly adaptable to various gas-diffusion backings (GDBs), providing high possibility to select highly recyclable GDBs. Outstandingly, anode standalone MPLs and GDBs can be easily detached from the spent membrane electrode assembly (MEA). This not only saves >90 vol% solvent in the recovery of the catalyst-coated membrane (CCM), but also extends the service life of the GDBs and the anode standalone MPL at least 138 times (2 760 000 h assuming 20 000 h of CCM) comparing to CCM. Therefore, the standalone MPL significantly enhances the recyclability and sustainability of fuel cells and is promising to be an indispensable component in the next-generation fuel cells.

PEMFCs Model-Based Fault Diagnosis: A Proposal Based on Virtual and Real Sensors Data Fusion

Proton Exchange Membrane Fuel Cells (PEMFCs) are critical components in renewable hybrid systems, demanding reliable fault diagnosis to ensure optimal performance and prevent costly damages. This study presents a novel model-based fault diagnosis algorithm for commercial hydrogen fuel cells using LabView. Our research focused on power generation and storage using hydrogen fuel cells. The proposed algorithm accurately detects and isolates the most common faults in PEMFCs by combining virtual and real sensor data fusion. The fault diagnosis process began with simulating faults using a validated mathematical model and manipulating selected input signals. A statistical analysis of 12 residues from each fault resulted in a comprehensive fault matrix, capturing the unique fault signatures. The algorithm successfully identified and isolated 14 distinct faults, demonstrating its effectiveness in enhancing reliability and preventing performance deterioration or system shutdown in hydrogen fuel cell-based power generation systems.

Carbon-Supported High-Loading Sub-4 nm PtCo Alloy Electrocatalysts for Superior Oxygen Reduction Reaction

Increasing the loading density of nanoparticles on carbon support is essential for making Pt-alloy/C catalysts practical in H2-air fuel cells. The challenge lies in increasing the loading while suppressing the sintering of Pt-alloy nanoparticles. This work presents a 40% Pt-weighted sub-4 nm PtCo/C alloy catalyst via a simple incipient wetness impregnation method. By carefully optimizing the synthetic conditions such as Pt/Co ratios, calcination temperature, and time, the size of supported PtCo alloy nanoparticles is successfully controlled below 4 nm, and a high electrochemical surface area of 93.8 m2/g is achieved, which is 3.4 times that of commercial PtCo/C-TKK catalysts. Demonstrated by electrochemical oxygen reduction reactions, PtCo/C alloy catalysts present an enhanced mass activity of 0.465 A/mg at 0.9 V vs. RHE, which is 2.0 times that of the PtCo/C-TKK catalyst. Therefore, the developed PtCo/C alloy catalyst has the potential to be a highly practical catalyst for H2-air fuel cells.

Efficient NH3-Tolerant Nickel-Based Hydrogen Oxidation Catalyst for Anion Exchange Membrane Fuel Cells

Converting hydrogen chemical energy into electrical energy by fuel cells offers high efficiencies and environmental advantages, but ultrapure hydrogen (over 99.97%) is required; otherwise, the electrode catalysts, typically platinum on carbon (Pt/C), will be poisoned by impurity gases such as ammonia (NH3). Here we demonstrate remarkable NH3 resistivity over a nickel-molybdenum alloy (MoNi4) modulated by chromium (Cr) dopants. The resultant Cr-MoNi4 exhibits high activity toward alkaline hydrogen oxidation and can undergo 10,000 cycles without apparent activity decay in the presence of 2 ppm of NH3. Furthermore, a fuel cell assembled with this catalyst retains 95% of the initial peak power density even when NH3 (10 ppm)/H2 was fed, whereas the power output reduces to 61% of the initial value for the Pt/C catalyst. Experimental and theoretical studies reveal that the Cr modifier not only creates electron-rich states that restrain lone-pair electron donation but also downshifts the d-band center to suppress d-electron back-donation, synergistically weakening NH3 adsorption.

A Super Uniform Hydrophobic Gas Diffusion Layer for a Proton Exchange Membrane Fuel Cell

The design and optimization of the gas diffusion layer (GDL) play a crucial role in the improvement of proton exchange membrane fuel cell performance. Hydrophobic treatment of a GDL is an important method for facilitating mass transfer, while conventional Teflon treatment is not uniform and leads to an increase in ohmic and heat resistance. Herein, a homogeneous molecular hydrophobic GDL was prepared by liquid phase synthesis, and a two-dimensional non-isothermal model was developed to investigate the transfer mechanism. The peak power density of cells with the GDL described above was improved by 46% compared to that of the conventional GDL. The ohmic and mass transport resistance decreased by 15% and 52%, respectively, under a current density of 1 A cm-2 using the uniform hydrophobic GDL. The simulation results proved that the uniform hydrophobic GDL eliminates the hydrophilic dots, which prevents the formation of water pools and reduces the resistance to gas flow. The water saturation of the conventional GDL reaches 0.19 at a current density of 1 A cm-2, and the saturation of a modified GDL under the same conditions is only 0.13. A dimensionless parameter, Tf, is proposed to characterize the resistance of oxygen diffusion. In conclusion, molecular-level uniform hydrophobic treatment can effectively reduce the ohmic and mass transfer resistance of a GDL and effectively improve the performance of fuel cells.

High Density Single Fe Atoms on Mesoporous N-Doped Carbons: Noble Metal-Free Electrocatalysts for Oxygen Reduction Reaction in Acidic and Alkaline Media

It remains a challenge to develop efficient noble metal-free electrocatalysts for the oxygen reduction reaction (ORR) in various renewable energy systems. Single atom catalysts have recently drawn great attention as promising candidates both due to their high activity and their utmost atom utilization for electrocatalytic ORR. Herein, the synthesis of an efficient ORR electrocatalyst that is composed of N-doped mesoporous carbon and a high density (4.05 wt%) of single Fe atoms via pyrolysis Fe-conjugated polymer is reported. Benefiting from the abundant atomic Fe-N4 sites on its conductive, mesoporous carbon structures, this material exhibits an excellent electrocatalytic activity for ORR, with positive onset potentials of 0.93 and 0.98 V in acidic and alkaline media, respectively. Its electrocatalytic performance for ORR is also comparable to that of Pt/C (20 wt%) in both media. Furthermore, it electrocatalyzes the reaction almost fully to H2 O (or barely to H2 O2 ). Additionally, it is durable and tolerates the methanol crossover reaction well. Furthermore, a proton exchange membrane fuel cell and a zinc-air battery assembled using it on their cathode deliver high maximum power densities (320 and 91 mW cm-2 , respectively). Density functional theory calculation reveals that the material's decent electrocatalytic performance for ORR is due to its atomically dispersed Fe-N4 sites.

Hierarchically Porous Carbons with Highly Curved Surfaces for Hosting Single Metal FeN4 Sites as Outstanding Oxygen Reduction Catalysts

Iron-nitrogen-carbon (FeNC) materials have emerged as a promising alternative to platinum-group metals for catalyzing the oxygen reduction reaction (ORR) in proton-exchange-membrane fuel cells. However, their low intrinsic activity and stability are major impediments. Herein, an FeN-C electrocatalyst with dense FeN4 sites on hierarchically porous carbons with highly curved surfaces (denoted as FeN4 -hcC) is reported. The FeN4 -hcC catalyst displays exceptional ORR activity in acidic media, with a high half-wave potential of 0.85 V (versus reversible hydrogen electrode) in 0.5 m H2 SO4 . When integrated into a membrane electrode assembly, the corresponding cathode displays a high maximum peak power density of 0.592 W cm-2 and demonstrates operating durability over 30 000 cycles under harsh H2 /air conditions, outperforming previously reported Fe-NC electrocatalysts. These experimental and theoretical studies suggest that the curved carbon support fine-tunes the local coordination environment, lowers the energies of the Fe d-band centers, and inhibits the adsorption of oxygenated species, which can enhance the ORR activity and stability. This work provides new insight into the carbon nanostructure-activity correlation for ORR catalysis. It also offers a new approach to designing advanced single-metal-site catalysts for energy-conversion applications.

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.

Ice Formation during PEM Fuel Cell Cold Start: Acceptable or Not?

Proton exchange membrane (PEM) fuel cell faces the inevitable challenge of the cold start at a sub-freezing temperature. Understanding the underlying degradation mechanisms in the cold start and developing a better starting strategy to achieve a quick startup with no degradation are essential for the wide application of PEM fuel cells. In this study, the comprehensive in situ non-accelerated segmented techniques are developed to analyze the icing processes and obtain the degradation mechanisms under the conditions of freeze-thaw cycle, voltage reversal, and ice formation in different components of PEM fuel cells for different freezing time. A detailed degradation mechanism map in the cold start of PEM fuel cells is proposed to demonstrate how much degradation occurs under different conditions, whether the ice formation is acceptable under the actual operating conditions, and how to suppress the ice formation. Moreover, an ideal starting strategy is developed to achieve the cold start of PEM fuel cells without degradation. This map is highly valuable and useful for researchers to understand the underlying degradation mechanisms and develop the cold start strategy, thereby promoting the commercialization of PEM fuel cells.

Phosphonate poly(vinylbenzyl chloride)-Modified Sulfonated poly(aryl ether nitrile) for Blend Proton Exchange Membranes: Enhanced Mechanical and Electrochemical Properties

Blend proton exchange membranes (BPEMs) were prepared by blending sulfonated poly(aryl ether nitrile) (SPAEN) with phosphorylated poly(vinylbenzyl chloride) (PPVBC) and named as SPM-x%, where x refers to the proportion of PPVBC to the weight of SPAEN. The chemical complexation interaction between the phosphoric acid and sulfonic acid groups in the PPVBC-SPAEN system resulted in BPEMs with reduced water uptake and enhanced mechanical properties compared to SPAEN proton exchange membranes. Furthermore, the flame retardancy of the PPVBC improved the thermal stability of the BPEMs. Despite a decrease in ion exchange capacity, the proton conductivity of the BPEMs in the through-plane direction was significantly enhanced due to the introduction of phosphoric acid groups, especially in low relative humidity (RH) environments. The measured proton conductivity of SPM-8% was 147, 98, and 28 mS cm-1 under 95%, 70%, and 50% RH, respectively, which is higher than that of the unmodified SPAEN membrane and other SPM-x% membranes. Additionally, the morphology and anisotropy of the membrane proton conductivities were analyzed and discussed. Overall, the results indicated that PPVBC doping can effectively enhance the mechanical and electrochemical properties of SPAEN membranes.