Tuning the Electrocatalytic Oxygen Reduction Reaction Activity of Pt-Co Nanocrystals by Cobalt Concentration with Atomic-Scale Understanding

A review of ordered PtCo3 catalyst with higher oxygen reduction reaction activity in proton exchange membrane fuel cells

This review is devoted to the potential advantages of ordered alloy catalysts in proton exchange membrane fuel cells (PEMFCs), specifically focusing on the development of the low Pt content, high activity, and durability ordered PtCo3 catalyst. Due to the sluggish oxygen reduction reaction (ORR) kinetics and poor durability, the overall performance of the fuel cell is affected, and its application and promotion are limited. To address this issue, researchers have explored various synthetic strategies, such as element doping, morphology adjusting, structure controlling, ordering and support/metal interaction enhancement. This article extensively discussed the Pt related ORR catalysts and follows an in-depth analysis of ordered PtCo3. The introduction briefly discusses the direction of development of fuel cell catalysts and frontier progress, including theoretical mechanism, practical preparation, and Pt-containing electrode structures, etc. The subsequent chapter focuses on the Pt-Co catalyst, the evolution process of Pt alloy to Pt-Co alloy and the improvement scheme are introduced. The next chapter describes the properties of PtCo3. Although the ordered PtCo3 catalyst has a wide range of applicability due to low cost and high activity catalyst. However, besides the common agglomeration and sintering problems of Pt-Co alloy, its commercial application still faces unique problems of oversized crystal size, phase segregation, ordering transformation and transition metal dissolution. Therefore, in Chapter 4, this overview provides some possible improvement methods for three specific functions: crystal refinement, enhancing the effect of support and active substances, and anti-dissolution.

Oxidation of Toluene over the Pt-Embedded Mesoporous CeO2 Hollow Nanospheres with Advanced Catalytic Performances

In this study, the novel Pt-embedded mesoporous CeO2 hollow nanospheres (Pt-MS-CeO2-H) with varying Pt contents (0.5-3.0 wt %) were facilely prepared. The Pt nanoparticles were one-pot embedded within the mesoporous shell of Pt-MS-CeO2-H and assisted with the reduction Ostwald ripening process. The traditional preparation methods often face challenges, such as the uneven distribution or aggregation of nanoparticles, as well as difficulty in maintaining high catalytic activity at low Pt content. Compared with the traditional supported Pt/MS-CeO2 catalyst, the embedding strategy facilitated precise control over the position, distribution, and uniformity of Pt nanoparticles within the CeO2 mesoporous shell. Additionally, the encapsulation process of Pt nanoparticles played a pivotal role in generating oxygen vacancies and activating surface chemical adsorption of oxygen. Resultantly, the toluene oxidation performances of 1Pt-MS-CeO2-H catalyst showed much lower T90 (171 °C) than 1Pt/MS-CeO2 (311 °C). To elucidate the underlying reasons, in situ diffuse reflectance infrared Fourier transform spectroscopy of toluene oxidation was employed to identify the reaction intermediates and pathways over these catalysts. In summary, the Pt-embedded mesoporous CeO2 hollow nanosphere catalysts were considered as potential candidates when designing high-performance toluene catalytic oxidation catalysts.

Pt3(CoNi) Ternary Intermetallic Nanoparticles Immobilized on N-Doped Carbon Derived from Zeolitic Imidazolate Frameworks for Oxygen Reduction

Pt-based intermetallic compound (IMC) nanoparticles have been considered the most promising catalysts for oxygen reduction reaction (ORR) in proton exchange membrane fuel cells (PEMFC). Herein, we propose a strategy for producing ordered Pt3(CoNi) ternary IMC nanoparticles supported on N-doped carbon materials. Particularly, the Co and Ni are originally embedded into ZIF-derived carbon, which diffuse into Pt nanocrystals to form Pt3(CoNi) nanoparticles. Moreover, a thin layer of carbon develops outside of Pt3(CoNi) nanoparticles during the cooling process, which contributes to stabilizing the Pt3(CoNi) on carbon supports. The optimal Pt3(CoNi) nanoparticle catalyst has achieved significantly enhanced activity and stability, exhibiting a half-wave potential of 0.885 V vs reversible hydrogen electrode (RHE) and losing only 16 mV after 10,000 potential cycles between 0.6 and 1.0 V. Unlike the direct-use commercial carbon (VXC-72) for depositing Pt, we utilized ZIF-derived carbon containing dispersed Co and Ni nanocluster or nanoparticles to prepare ordered Pt3(CoNi) intermetallic catalysts.

Zeolitic Imidazolate Framework-Derived Pt-Co in Nanofibrous Networks as Stable Oxygen Reduction Electrocatalysts with Low Pt Loading

Proton-exchange membrane fuel cell technology is a key component in the future zero-carbon energy system, generating power from carbon-free fuels, such as green hydrogen. However, the high Pt loading in conventional fuel cell electrodes to maintain electrocatalytic activity and durability, especially on the cathode for oxygen reduction, is the Achilles heel for the worldwide deployment of fuel cell technologies. To minimize Pt consumption for oxygen reduction, we synthesized Pt-Co-based electrocatalysts with meticulous structuring from micrometer to the atomic scale based on reaction pathways. The resulting Pt-Co-based electrocatalysts contain only 1.9 wt% Pt, which is 20 times lower than the conventional Pt-C catalysts for fuel cells. By utilizing electrospinning and in situ synthesis, we anchored three-dimensionally structured zeolitic imidazolate frameworks on continuously connected nanofibrous electrospun mats. The Pt-Co@Pt-free nanowire (PC@PFN) electrocatalysts contain Pt-Co nanoparticles (NPs) and non-Pt elements, Co-containing sites comprising NPs, nanoclusters, and N-coordinated Co single atoms. Despite the ultralow Pt loading in PC@PFN, the mass activity exceeds the U.S. Department of Energy 2025 target by 2.8 times and retains 85.5% of the initial activity after 80,000 durability test cycles, possibly owing to synergistic reaction pathways between Pt and non-Pt sites.

Intermetallic Nanocrystals for Fuel-Cells-Based Electrocatalysis

Electrocatalysis underpins the renewable electrochemical conversions for sustainability, which further replies on metallic nanocrystals as vital electrocatalysts. Intermetallic nanocrystals have been known to show distinct properties compared to their disordered counterparts, and been long explored for functional improvements. Tremendous progresses have been made in the past few years, with notable trend of more precise engineering down to an atomic level and the investigation transferring into more practical membrane electrode assembly (MEA), which motivates this timely review. After addressing the basic thermodynamic and kinetic fundamentals, we discuss classic and latest synthetic strategies that enable not only the formation of intermetallic phase but also the rational control of other catalysis-determinant structural parameters, such as size and morphology. We also demonstrate the emerging intermetallic nanomaterials for potentially further advancement in energy electrocatalysis. Then, we discuss the state-of-the-art characterizations and representative intermetallic electrocatalysts with emphasis on oxygen reduction reaction evaluated in a MEA setup. We summarize this review by laying out existing challenges and offering perspective on future research directions toward practicing intermetallic electrocatalysts for energy conversions.

Microporous 3D-Structured Hierarchically Entangled Graphene-Supported Pt3Co Alloy Catalyst for PEMFC Application with Process-Friendly Features

To improve the oxygen reduction reaction (ORR) performance in a proton-exchange membrane fuel cell (PEMFC) cathode with respect to mass activity and durability, a suitable electrocatalyst design strategy is essentially needed. Here, we have prepared a sub-three nm-sized platinum (Pt)-cobalt (Co) alloy (Pt₃Co)-supported N-doped microporous 3D graphene (Pt₃Co/pNEGF) by using the polyol synthesis method. A microwave-assisted synthesis method was employed to prepare the catalyst based on the 3D porous carbon support with a large pore volume and dense micro-/mesoporous surfaces. The ORR performance of Pt₃Co/pNEGF closely matches with the state-of-the-art commercial Pt/C catalyst in 0.1 M HClO₄, with a small overpotential of 10 mV. The 3D microporous structure of the N-doped graphene significantly improves the mass transport of the reactant and thus the overall ORR performance. As a result of the lower loading of Pt in Pt₃Co/pNEGF as compared to that in Pt/C, the alloy catalyst achieved 1.5 times higher mass activity than Pt/C. After 10,000 cycles, the difference in the electrochemically active surface area (ECSA) and half-wave potential (E_1/2) of Pt₃Co/pNEGF is found to be 5 m² g_Pt^-1 (ΔECSA) and 24 mV (ΔE_1/2), whereas, for Pt/C, these values are 9 m² g_Pt^-1 and 32 mV, respectively. Finally, in a realistic perspective, single-cell testing of a membrane electrode assembly (MEA) was made by sandwiching the Pt₃Co/pNEGF-coated gas diffusion layers as the cathode displayed a maximum power density of 800 mW cm^-2 under H₂-O₂ feed conditions with a clear indication of helping the system in the mass-transfer region (i.e., the high current dragging condition). The nature of the I-V polarization shows a progressively lower slope in this region of the polarization plot compared to a similar system made from its Pt/C counterpart and a significantly improved performance throughout the polarization region in the case of the system made from the Pt₃Co/NEGF catalyst (without the microwave treatment) counterpart. These results validate the better process friendliness of Pt₃Co/pNEGF as a PEMFC electrode-specific catalyst owing to its unique texture with 3D architecture and well-defined porosity with better structural endurance.

Dilute Alloys Based on Au, Ag, or Cu for Efficient Catalysis: From Synthesis to Active Sites

The development of new catalyst materials for energy-efficient chemical synthesis is critical as over 80% of industrial processes rely on catalysts, with many of the most energy-intensive processes specifically using heterogeneous catalysis. Catalytic performance is a complex interplay of phenomena involving temperature, pressure, gas composition, surface composition, and structure over multiple length and time scales. In response to this complexity, the integrated approach to heterogeneous dilute alloy catalysis reviewed here brings together materials synthesis, mechanistic surface chemistry, reaction kinetics, in situ and operando characterization, and theoretical calculations in a coordinated effort to develop design principles to predict and improve catalytic selectivity. Dilute alloy catalysts─in which isolated atoms or small ensembles of the minority metal on the host metal lead to enhanced reactivity while retaining selectivity─are particularly promising as selective catalysts. Several dilute alloy materials using Au, Ag, and Cu as the majority host element, including more recently introduced support-free nanoporous metals and oxide-supported nanoparticle "raspberry colloid templated (RCT)" materials, are reviewed for selective oxidation and hydrogenation reactions. Progress in understanding how such dilute alloy catalysts can be used to enhance selectivity of key synthetic reactions is reviewed, including quantitative scaling from model studies to catalytic conditions. The dynamic evolution of catalyst structure and composition studied in surface science and catalytic conditions and their relationship to catalytic function are also discussed, followed by advanced characterization and theoretical modeling that have been developed to determine the distribution of minority metal atoms at or near the surface. The integrated approach demonstrates the success of bridging the divide between fundamental knowledge and design of catalytic processes in complex catalytic systems, which can accelerate the development of new and efficient catalytic processes.

Structural and Valence State Modification of Cobalt in CoPt Nanocatalysts in Redox Conditions

Platinum is the primary catalyst for many chemical reactions in the field of heterogeneous catalysis. However, platinum is both expensive and rare. Therefore, it is advantageous to combine Pt with another metal to reduce cost while also enhancing stability. To that end, Pt is often combined with Co to form Co-Pt nanocrystals. However, dynamical restructuring effects that occur during reaction in Co-Pt ensembles can impact catalytic properties. In this study, model Co₂Pt₃ nanoparticles supported on carbon were characterized during a redox cycle with two in situ approaches, namely, X-ray absorption spectroscopy (XAS) and scanning transmission electron microscopy (STEM) using a multimodal microreactor. The sample was exposed to temperatures up to 500 °C under H₂, and then to O₂ at 300 °C. Irreversible segregation of Co in the Co₂Pt₃ particles was seen during redox cycling, and substantial changes of the oxidation state of Co were observed. After H₂ treatment, a fraction of Co could not be fully reduced and incorporated into a mixed Co-Pt phase. Reoxidation of the sample increased Co segregation, and the segregated material had a different valence state than in the fresh, oxidized sample. This in situ study describes dynamical restructuring effects in CoPt nanocatalysts at the atomic scale that are crucial to understand in order to improve the design of catalysts used in major chemical processes.

Sulfur-anchoring synthesis of platinum intermetallic nanoparticle catalysts for fuel cells

[Figure: see text].

Unlocking synergy in bimetallic catalysts by core-shell design

Extending the toolbox from mono- to bimetallic catalysts is key in realizing efficient chemical processes¹. Traditionally, the performance of bimetallic catalysts featuring one active and one selective metal is optimized by varying the metal composition^1-3, often resulting in a compromise between the catalytic properties of the two metals^4-6. Here we show that by designing the atomic distribution of bimetallic Au-Pd nanocatalysts, we obtain a synergistic catalytic performance in the industrially relevant selective hydrogenation of butadiene. Our single-crystalline Au-core Pd-shell nanorods were up to 50 times more active than their alloyed and monometallic counterparts, while retaining high selectivity. We find a shell-thickness-dependent catalytic activity, indicating that not only the nature of the surface but also several subsurface layers play a crucial role in the catalytic performance, and rationalize this finding using density functional theory calculations. Our results open up an alternative avenue for the structural design of bimetallic catalysts.

Strain and ligand effects in Pt-Ni alloys studied by valence-to-core X-ray emission spectroscopy

Experimental detection of the Pt 5d densities of states in the valence band is conducted on a series of Pt-Ni alloys by high energy resolution valence-to-core X-ray emission spectroscopy (VTC-XES) at the Pt L₃-edge. VTC-XES measurements reveal that the Pt d-band centroid shifts away from the Fermi level upon dilution, accompanied by concentration-dependent Pt d-band width. The competition between the strain effect and ligand effect is observed experimentally for the first time. It is found that the d-band widths in Pt₃Ni and PtNi are broader than that of Pt metal due to compressive strain which overcompensates the effect of dilution, while it is narrower in PtNi₃ where the ligand effect dominates. VTC-XES is demonstrated to be a powerful tool to study the Pt d-band contribution to the valence band of Pt-based bimetallic. The implication for the enhanced activity of Pt-Ni catalysts in oxygen reduction reaction is discussed.

Substituents and the induced partial charge effects on cobalt porphyrins catalytic oxygen reduction reactions in acidic medium

Charge states at the catalytic interface can intensely alter the charge transfer mechanism and thus the oxygen reduction performance. Two symmetric cobalt porphyrins with electron deficient 2,1,3-benzothiadiazole (BTD) and electron-donating propeller-like triphenylamine (TPA) derivatives have been designed firstly, to rationally generate intramolecular partial charges, and secondly, to utilize the more exposed molecular orbitals on TPA for enhancing the charge transfer kinetics. The catalytic performance of the two electrocatalysts was examined for oxygen reduction reactions (ORR) in acidic electrolyte. It was found that BCP1/C with two BTD groups showed greater reduction potential but less limiting current density as compared to BCP2/C bearing BTD-TPA units. The reduced potential of BCP2/C was proposed to the introduction of the electron-donating ability of TPA, which may decrease the adsorption affinity of oxygen to the cobalt center. Both dipole-induced partial charge effect and the more exposed cation orbitals of the 3D structural TPA were proposed to contribute to the increased response current of BCP2/C. In addition, BCP2/C attained more than 80% of H₂O₂ generation in acidic solution, which may also relate to the structural effect. These findings may provide new insight into the structural design of organic electrocatalysts and deep understanding on the interfacial charge transfer mechanism for ORR.

Correlating 3D Surface Atomic Structure and Catalytic Activities of Pt Nanocrystals

Active sites and catalytic activity of heterogeneous catalysts is determined by their surface atomic structures. However, probing the surface structure at an atomic resolution is difficult, especially for solution ensembles of catalytic nanocrystals, which consist of heterogeneous particles with irregular shapes and surfaces. Here, we constructed 3D maps of the coordination number (CN) and generalized CN (CN_) for individual surface atoms of sub-3 nm Pt nanocrystals. Our results reveal that the synthesized Pt nanocrystals are enclosed by islands of atoms with nonuniform shapes that lead to complex surface structures, including a high ratio of low-coordination surface atoms, reduced domain size of low-index facets, and various types of exposed high-index facets. 3D maps of CN_ are directly correlated to catalytic activities assigned to individual surface atoms with distinct local coordination structures, which explains the origin of high catalytic performance of small Pt nanocrystals in important reactions such as oxygen reduction reactions and CO electro-oxidation.

Three-step method with self-sacrificial Co to prepare a uniform 5 nm-scale Pt catalyst for the oxygen reduction reaction

Simple and rapid preparation method for a highly dispersed and small-sized CoPt catalyst.

Atomic-Level Manipulations in Oxides and Alloys for Electrocatalysis of Oxygen Evolution and Reduction

As chemical reactions and charge-transfer simultaneously occur on the catalyst surface during electrocatalysis, numerous studies have been carried out to attain an in-depth understanding on the correlation among the surface structure and composition, the electrical transport, and the overall catalytic activity. Compared with other catalysis reactions, a relatively larger activation barrier for oxygen evolution/reduction reactions (OER/ORR), where multiple electron transfers are involved, is noted. Many works over the past decade thus have been focused on the atomic-scale control of the surface structure and the precise identification of surface composition change in catalyst materials to achieve better conversion efficiency. In particular, recent advances in various analytical tools have enabled noteworthy findings of unexpected catalytic features at atomic resolution, providing significant insights toward reducing the activation barriers and subsequently improving the catalytic performance. In addition to summarizing important surface issues, including lattice defects, related to the OER and ORR in this Review, we present the current status and discuss future perspectives of oxide- and alloy-based catalysts in terms of atomic-scale observation and manipulation.

Structurally ordered Pt3Co for oxygen reduction reaction prepared using polyvinylpyrrolidone as auxiliary dispersant

Structurally ordered Pt₃Co/C nanoparticles (NPs) were obtained via a spray paint drying method with an annealing treatment. The addition of a suitable dose of polyvinylpyrrolidone resulted in a narrow size distribution of the Pt₃Co/C-600-1 NPs, an average particle size of ca. 4.6 nm, which may be due to the enhanced dispersion in aqueous solution resulting from the carbon support. The sample denoted as Pt₃Co/C-600-1 NPs performs high activity for oxygen reduction reaction with the mass activity (MA) ca. 3 times higher than that of a commercial Pt/C catalyst at 0.9 V. Accelerated durability tests (ADTs) showed that Pt₃Co/C-600-1 NPs exhibit superior stability with a minimal loss of 17.5% in MA at 0.9 V after 5000 cycles, while Pt/C catalysts show loss of 44.4%. This simple two-step strategy provides an effective way to prepare Pt-based catalysts for industrial application.

Cobalt and nitrogen codoped carbon nanotubes derived from a graphitic C3N4 template as an electrocatalyst for the oxygen reduction reaction

Sluggish oxygen reduction reaction kinetics have been a main obstacle for commercial application of fuel cells. To replace Pt-based noble metal electrocatalysts, it is crucial to develop economical materials as electrocatalysts. Herein, we provide a strategy to prepare Co and N codoped carbon nanotubes for efficient oxygen reduction reaction. The composites are synthesized by hydrothermal reaction followed by calcination at 900 °C. Graphitic carbon nitride is used as a template and nitrogen source, and citric acid and cobalt nitrate hexahydrate are used as carbon and cobalt sources, respectively. Due to the synergistic effect of Co and N codoping and increased specific surface area, the resulting Co and N codoped carbon nanotubes exhibit excellent catalytic performance. The present results provide experimental support for further development of electrocatalysts.