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The synthesis of bimetallic and trimetallic platinum-based octahedral catalysts for the cathode of proton exchange membrane fuel cells (PEMFCs) is a particularly active area aimed at meeting technological requirements in terms of durability and cost. The electrocatalytic activity and stability of these shaped catalysts were tested at relatively high potentials (@0.9 V vs RHE) and at lower current densities using the rotating disk electrode, which is less suitable for assessing their behavior under the operating conditions of PEMFCs. In this work, we use a gas diffusion electrode (GDE) half-cell setup to test the performance of the catalysts under application-oriented conditions, relatively higher current densities, and a square-wave stability test. After the stability test, we analyzed the GDE catalytic layer to study the agglomeration and dissolution of the transition metal under these conditions by using high-resolution scanning electron microscopy and energy-dispersive X-ray spectroscopy. The present results provide valuable guidance for developing next-generation active and durable catalysts for PEMFCs.
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With high current density, the intense near-electrode CO2 reduction reaction (CO2RR) will cause the concentration gradients of bicarbonate (HCO3-) and hydroxyl (OH-) ions, which affect the selectivity of high-value C2+ products of the CO2RR. In this work, we simulated the near-electrode concentration gradients of electrolyte species with different porous Cu-based CLs (catalyst layers) of GDE (gas diffusion electrode) by COMSOL Multiphysics. The higher porosity CL exhibits a better buffer ability of local alkalinity while ensuring a sufficient supply of H+ and local CO2 concentration. Subsequently, the different porosity CLs were prepared by vacuum-thermal evaporation with different evaporation rate. Structural characterizations and liquid permeability tests confirm the role of the porous CL structure in optimizing concentration gradients. As a result, the high-porosity CL (Cu-HP) exhibits a higher C2+ Faraday efficiency (FE) of â¼79.61% at 500 mA cm-2 under 1 M KHCO3, far more than the FEC2+ ≈ 38.20% with the low-porosity sample (Cu-LP).
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The high cost and often complex synthesis procedure of new highly selective electrocatalysts (particularly those based on noble metals) for H2O2 production are daunting obstacles to penetration of this technology into the wastewater treatment market. In this work, a simple direct thermal method has been employed to synthesize Sn-doped carbon electrocatalysts, which showed an electron transfer number of 2.04 and outstanding two-electron oxygen reduction reaction (ORR) selectivity of up to 98.0%. Physicochemical characterization revealed that this material contains 1.53% pyrrolic nitrogen, which is beneficial for the production of H2O2, and -C≡N functional group, which is advantageous for H+ transport. Moreover, the high volume ratio of mesopores to micropores is known to favor the quick escape of H2O2 from the electrode surface, thus minimizing its further oxidation. A purpose-made gas-diffusion electrode (GDE) was prepared, yielding 20.4 mM H2O2 under optimal electrolysis conditions. The drug diphenhydramine was selected for the first time as model organic pollutant to evaluate the performance of an electrochemical advanced oxidation process. In conventional electro-Fenton process (pH 3), complete degradation was achieved in only 15 min at 10 mA cm-2, whereas at natural pH 5.9 and 33.3 mA cm-2, almost overall drug removal was reached in 120 min.
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The gas diffusion layer (GDL), as the bridge to reactants and electrons in PEMFC, is a carbon-based porous component and would be deformed under compression to induce changes in the distributions of reactants and the corresponding performances of PEMFC; therefore, unmasking the impacts of assembly pressure on the distribution of the reactants in GDL is significant to improve the performance of PEMFC. In the present article, the structural response of GDL to assembly pressure was first studied; the variations in transport properties of GDL and the reactant distributions induced by assembly pressure were then discussed; the impacts on the dynamic performances of PEMFC were finally investigated. From the results, assembly pressure was found to have different effects on the regions of GDL under the rib and channel, significant gaps in GDL porosity and/or GDL permeability existed near the rib/channel transition region to worsen the inhomogeneity of reactants. Suffering assembly pressure, the distribution of current density became uneven, and the current density near the rib-channel border seriously rose to the aggravated risk of MEA thermal damage. Furthermore, the power density at specific efficiencies was raised under certain assembly pressures, which meant suitable assembly pressure(s) existed for better output performances of PEMFC.
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This study utilises computational fluid dynamics simulations with the OpenFOAM computational framework to investigate and compare the in-plane and through-plane permeability properties of four different gas diffusion layers (GDLs). Also the through-plane water and air relative permeability values and water saturations at different rates were simulated. Permeability analysis enhances our understanding of fluid flow, ways to decrease pressure loss in the GDL, and methods to enhance oxygen concentration at the catalyst layer interface through convection. The analysis reveals that the investigated GDL materials have spatial heterogeneity of porosity and permeability, especially in the Sigracet SGL 25 BA GDL. However, the porosity and permeability of the Toray TGP-H 060 and AvCarb 370 MGL GDLs exhibit less variations. The two-phase flow studies on GDL saturation show that at the same water injection flowrate, the AvCarb 370 MGL GDL has the largest remaining water saturation, with Sigracet SGL 25 BA GDL being the less saturated GDL among the four investigated GDLs. The compression from the ribs significantly affected the in-plane permeabilities of both Toray TGP-H 060 and especially impacted Sigracet SGL 25 BA GDL. This impact was expected as the pore size distribution varied significantly in the areas under the ribs versus the channel.
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The electrochemical regeneration of reduced nicotinamide adenine dinucleotide (NADH) using [Rh(Cp*)(bpy)Cl]+ holds significant promise for the industrial synthesis of chiral chemicals. However, challenges persist due to the high consumption of NADH and the limited efficiency of its cyclic regeneration, which currently hinder widespread application. To address these obstacles, based on in-situ growth of 3D ordered metal-organic framework (NU-1000) on the surface of graphite felt, [Rh(Cp*)(bpy)Cl]+ were immobilized on the Zr6 nodes of NU-1000 by solvent-assisted ligand incorporation (SALI), and applied in a flow bioreactor. Moreover, we employ a gas diffusion electrode (GDE) to oxidize H2, providing a clean proton source for the electrochemical regeneration of NADH. Consequently, highly efficient enzymatic electrocatalytic synthesis of L-lactate was achieved when coupled with L-lactate dehydrogenases (LDH) as a model reaction, and the total turnover number (TTN) reached 19600 and 1750 for [Rh(Cp*)(bpy)Cl]+ and NAD+ after 48 h, corresponding to a high turnover frequency (TOF) of 2350 h-1 and 210 h-1 for [Rh(Cp*)(bpy)Cl]+ and NAD+, respectively. This work provides new insights for the construction of efficient enzymatic electrosynthesis systems in industrial production.
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The very high theoretical specific energy of the lithium-air (Li-O2) battery (3500 Wh kg-1) compared with other batteries makes it potentially attractive, especially for the electrification of flight. While progress has been made in realizing the Li-air battery, several challenges remain. One such challenge is achieving a high capacity to store charge at the positive electrode at practical current densities, without which Li-air batteries will not outperform lithium-ion. The capacity is limited by the mass transport of O2 throughout the porous carbon positive electrode. Here it is shown that by replacing the binder in the electrode by a polymer with the intrinsic ability to transport O2, it is possible to reach capacities as high as 31 mAh cm-2 at 1 mA cm-2 in a 300 µm thick electrode. This corresponds to a positive electrode energy density of 2650 Wh L-1 and specific energy of 1716 Wh kg-1, exceeding significantly Li-ion batteries and previously reported Li-O2 cells. Due to the enhanced oxygen diffusion imparted by the gas diffusion polymer, Li2O2 (the product of O2 reduction on discharge) fills a greater volume fraction of the electrode and is more homogeneously distributed.
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We introduced a new class of gas diffusion electrodes (GDEs) with adjustable pore morphology. We fabricated intrinsically conductive polymer-composite membranes containing carbon filler, enabling a pore structure variation through film casting cum phase separation protocols. We further selectively functionalized specific pore regions of the membranes with Cu by a NaBH4-facilitated coating strategy. The as-obtained GDEs can facilitate the electrochemical CO2 reduction reaction (CO2RR) at Cu active sites that are presented inside a defined and electrically conductive pore system. When employing them as free-standing cathodes in a CO2 flow electrolyzer, we achieved >70% Faradaic efficiencies for CO2RR products at up to 200 mA/cm2. We further demonstrated that deposition of a dense Cu layer on top of the membrane leads to obstruction of the underlying pore openings, inhibiting an excessive wetting of the pore pathways that transport gaseous CO2. However, the presentation of Cu inside the pore system of our novel membrane electrodes increased the C2H4/CO selectivity by a factor of up to 3 compared to Cu presented in the dense layer on top of the membrane. Additionally, we found that gaseous CO2 could still access Cu in macropores after wetting with electrolyte, while CO2RR was completely suppressed in wetted nm-scale pores.
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Efficient electrochemical CO2 reduction reaction (CO2RR) requires advanced gas-diffusion electrodes (GDEs) with tunned microenvironment to overcome low CO2 availability in the vicinity of catalyst layer. Herein, for the first time, pyridine-containing microgels-augmented CO2 availability is presented in Cu2O-based GDE for high-rate CO2 reduction to ethylene, owing to the presence of CO2-phil microgels with amine moieties. Microgels as three-dimensional polymer networks act as CO2 micro-reservoirs to engineer the GDE microenvironment and boost local CO2 availability. The superior ethylene production performance of the GDE modified by 4-vinyl pyridine microgels, as compared with the GDE with diethylaminoethyl methacrylate microgels, indicates the bifunctional effect of pyridine-based microgels to enhance CO2 availability, and electrocatalytic CO2 reduction. While the Faradaic efficiency (FE) of ethylene without microgels was capped at 43% at 300 mA cm-2, GDE with the pyridine microgels showed 56% FE of ethylene at 700 mA cm-2. A similar trend was observed in zero-gap design, and GDEs showed 58% FE of ethylene at -4.0 cell voltage (>350 mA cm-2 current density), resulting in over 2-fold improvement in ethylene production. This study showcases the use of CO2-phil microgels for a higher rate of CO2RR-to-C2+, opening an avenue for several other microgels for more selective and efficient CO2 electrolysis.
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Oxygen reduction reaction (ORR) performance of porous electrode is critical for solid oxide fuel cells (SOFCs). However, the effects of gas diffusion on the ORR in porous media need further investigation, although some issues, such as nonthermal surface oxygen exchange, have been attributed to gas diffusion. Herein, La0.6Sr0.4Co0.2Fe0.8O3-δ (LSCF) with various porosity, pore radii and gas permeability were investigated via the electrical conductivity relaxation method and analysed using the distributed of characteristic time (DCT) model. The ORR is revealed with three characteristic times, which are gas diffusion, oxygen exchange via the surface corresponding to small pores, and oxygen exchange to large pores. Gas diffusion delays the oxygen surface exchange reaction, resulting in very low chemical oxygen surface exchange coefficient compared with that obtained with dense sample under the assumption that all the surfaces are active for the ORR. Reduced surface area is thus defined to quantitatively represent the gas diffusion effects. The reduced surface area increases with increasing gas permeability, demonstrating the importance of electrode engineering for fast gas transport. Moreover, reduced surface area is suggested for replacing the specific surface area to calculate the electrode polarization resistance using the ALS model.
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The diffusion and adsorption properties of the O2/H2O corpuscles at active sites play a crucial role in the fast photo-electrocatalytic reaction of hydrogen peroxide (H2O2) production. Herein, SnS2 nanosheets with abundant interfacial boundaries and large specific areas are encapsulated into hollow mesoporous carbon spheres (CSs) with flexibility, producing a yolk-shell SnS2@CSs Z-scheme photocatalyst. The nanoconfined microenvironment of SnS2@CSs could enrich O2/H2O in catalyst cavities, which allows sufficient internal O2 transfer, improving the surface chemistry of catalytic O2 to O2- conversion and increasing reaction kinetics. By shaping the mixture of SnS2@CSs and polytetrafluoroethylene (PTFE) on carbon felt (CF) using the vacuum filtration method, the natural air-breathing gas diffusion photoelectrode (AGPE) was prepared, and it can achieve an accumulated concentration of H2O2 about 12 mM after a 10 h stability test from pure water at natural pH without using electrolyte and sacrificial agents. The H2O2 product is upgraded through one downstream route of conversion of H2O2 to sodium perborate. The improved H2O2 production performance could be ascribed to the combination of the confinement effect of SnS2@CSs and the rich triple phase interfaces with the continuous hydrophobic layer and hydrophilic layer to synergistically modulate the photoelectron catalytic microenvironment, which enhanced the transfer of O2 mass and offered a stronger affinity to oxygen bubbles. The strategy of combining the confined material with the air-breathing gas diffusion electrode equips a wide practical range of applications for the synthesis of high-yield hydrogen peroxide.
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In polymer electrolyte fuel cells (PEFCs), the gas diffusion layer (GDL) is crucial for managing the flooding tolerance, which is the ability to remove the water produced during power generation from the assembled cell. However, an improved understanding of the properties of GDLs is required to develop effective waterproofing strategies. This study investigated the influence of the polytetrafluoroethylene (PTFE) content on the pore diameter, porosity, wettability, water saturation, and flooding tolerance of waterproofed carbon papers as cathode GDLs in PEFCs. The addition of minimal PTFE (â¼6 wt %) to carbon paper provided external waterproofing, whereas internal waterproofing was achieved at a higher PTFE content (â¼13 wt %). However, excessive PTFE (â¼37 wt %) led to macropore collapse within the carbon paper, reducing fuel cell performance. Although PTFE addition was expected to improve the flooding tolerance, operando synchrotron X-ray radiography revealed that the water saturation level in carbon paper increased with increasing PTFE content. These findings provide a benchmark for assessing whether GDLs meet the flooding tolerance requirements of PEFCs and may be applicable to waterproofed GDLs in electrochemical devices for water and CO2 electrolysis.
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Converting hierarchical biomass structure into cutting-edge architecture of electrocatalysts can effectively relieve the extreme dependency of nonrenewable fossil-fuel-resources typically suffering from low cost-effectiveness, scarce supplies, and adverse environmental impacts. A cost-effective cobalt-coordinated nanocellulose (CNF) strategy is reported for realizing a high-performance 2e-ORR electrocatalysts through molecular engineering of hybrid ZIFs-CNF architecture. By a coordination and pyrolysis process, it generates substantial oxygen-capturing active sites within the typically oxygen-insulating cellulose, promoting O2 mass and electron transfer efficiency along the nanostructured Co3O4 anchored with CNF-based biochar. The Co-CNF electrocatalyst exhibits an exceptional H2O2 electrosynthesis efficiency of ≈510.58 mg L-1 cm-2 h-1 with an exceptional superiority over the existing biochar-, or fossil-fuel-derived electrocatalysts. The combination of the electrocatalysts with stainless steel mesh serving as a dual cathode can strongly decompose regular organic pollutants (up to 99.43% removal efficiency by 30 min), showing to be a desirable approach for clean environmental remediation with sustainability, ecological safety, and high-performance.
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Water electrolysis is increasingly considered a viable solution for meeting the world's growing energy demands and mitigating environmental issues. An inventive strategy to mitigate the energy requirements involves substituting the energy-intensive oxygen evolution reaction (OER) with biomass-derived glycerol electrooxidation. Nonetheless, the synthesis of electrocatalysts for controlling the selectivity towards added-value chemicals at the anode and efficient H2 generation at the cathode remains a critical bottleneck. Herein, we implemented a galvanostatic electroshock synthesis approach to control the reduction kinetics of Au(III) and Pt(IV) to grow ultra-low amount of gold-platinum alloys on a gas diffusion electrode (12-26 µgmetal cmâ2) for glycerol-fed hydroxide anion exchange membrane based electrolyzer. The symmetric GDE-Au100-xPtx||GDE-Au100-xPtx systems showed a notable improvement in electrolyzer performance (GDE-Au64Pt36 = 201 mA cm-2) as compared to monometallic versions (GDE-Au100Pt0 = 18 mA cm-2, GDE-Au0Pt100 = 81 mA cm-2). Chromatography (HPLC) analysis underscores the critical importance of bulk electrolysis methodology (galvanostatic vs potentiostatic) for the efficient conversion of glycerol into high-value-added products. Regarding the electrical energy required to produce 1 kg of H2 for such an electrolyzer fed at the anode with glycerol, our results confirm a drastic decrease by a factor of at least two compared with conventional water electrolysis.
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Electrochemical CO2 reduction to value-added chemicals by renewable energy sources is a promising way to implement the artificial carbon cycle. During the reaction, especially at high current densities for practical applications, the complex interaction between the key intermediates and the active sites would affect the selectivity, while the reconfiguration of electrocatalysts could restrict the stability. This paper describes the fabrication of Ag/C catalysts with a well-engineered interfacial structure, in which Ag nanoparticles are partially encapsulated by C supports. The obtained electrocatalyst exhibits CO Faradaic efficiencies (FEs) of over 90 % at current densities even as high as 1.1â A/cm2. The strong interfacial interaction between Ag and C leads to highly localized electron density that promotes the rate-determining electron transfer step by enhancing the adsorption and the stabilization of the key *COO- intermediate. In addition, the partially encapsulated structure prevents the reconfiguration of Ag during the reaction. Stable performance for over 600â h at 500â mA/cm2 is achieved with CO FE maintaining over 95 %, which is among the best stability with such a high selectivity and current density. This work provides a novel catalyst design showing the potential for the practical application of electrochemical reduction of CO2.
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As ammonia continues to gain more and more interest as a promising hydrogen carrier compound, so does the electrochemical ammonia oxidation reaction (AmOR). To avoid the liberation of H2 in a reverse Haber-Bosch reaction under release of the energetically more favorable N2, we propose the oxidation of ammonia to value-added nitrite (NO2 -), which is usually obtained during the Ostwald process. We investigated the anodic oxidation of gaseous ammonia directly supplied to a gas diffusion electrode (GDE) using a variety of compositionally different multi-metal catalysts coated on Ni foam under the simultaneous formation of H2 at the cathode. This will double the amount of H2 per ammonia molecule while applying a lower overpotential than that required for water electrolysis (1.4-1.8â V vs. RHE at 50â mA â cm-2). A selectivity study demonstrated that some of the catalyst compositions were able to produce significant amounts of NO2 -, and further investigations using the most promising catalyst composition Nif_AlCoCrCuFe integrated within a GDE demonstrated up to 88 % Faradaic efficiency for NO2 - at the anode coupled to close to 100 % Faradaic efficiency for the cathodic H2 production.
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Gas diffusion layers (GDLs) are usually coated with a hydrophobic agent to achieve a delicate balance between liquid and gas phases to maximize mass transport. Yet, most GDL numerical models to date have assumed an average contact angle for all materials, thereby eliminating the possibility of studying the role of the polytetrafluoroethylene (PTFE) content. This study introduces two mixed wettability algorithms to predict the mixed wetting behavior of GDLs composed of multiple materials. The algorithms employ contact angle and distance to solid materials to determine the critical capillary pressure for each pore voxel. The application of the algorithms to the estimation of capillary pressure vs saturation curves for two GDLs, namely, a micro-computed tomography (µ-CT) reconstructed SGL 39BA GDL and a stochastically reconstructed Toray 120C GDL, showed that, in agreement with experimental data, the addition of PTFE resulted in a decrease in saturation at a given capillary pressure. For Toray-120C, the mixed wettability model was capable of reproducing experimentally observed features in the intrusion curve at low saturation that could not be reproduced with a single wettability model, providing a clear link between PTFE coverage and intrusion at low saturation. Numerical results also predicted an increased breakthrough pressure and a decrease in saturation with increasing PTFE, in agreement with experimental observations. The decreased saturation at breakthrough improves gas transport through the layer while maintaining the layer's ability to remove water. Diffusivity simulations confirm the increase in diffusivity at breakthrough with increasing PTFE, thereby providing a rationale for the addition of PTFE, as well as for the optimal amount. This study emphasizes the importance of multimaterial wetting models and calls for more detailed investigations into PTFE and ionomer distributions in GDLs and catalyst layers, respectively.
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The typical commercial size of a Gas Diffusion Layer (GDL) for Proton Exchange Membrane Fuel Cell (PEMFC) application is around 180 µm up to 290 µm. GDL facilitates the diffusion of reactants to the catalyst layers and liquid removal from the membrane to the flow field. In this regard, GDL should be a porous region with conductive materials as thin as possible to reduce the size and the costs. Lowering the thickness of the GDL also results in better performance of the stack since it increases the speed of reactants to reach the catalysts. However, the main obstacle is the formation of ultra-thin porous GDL, which can be also named as standalone microporous layer (MPL). The novelty of this study is the manufacturing process and production of ultra-thin porous GDL with carbon and Polytetrafluoroethylene (PTFE) as the main materials. The produced GDL has the thickness of 28.9 µm, which has been measured using microscope imaging. This novel GDL can be used as the conductive diffusive region inside the PEM fuel cells, Alkaline fuel cells, and the cathode of PEM and Alkaline electrolyzers. Additionally, the novel invention can be considered as a 2D membrane for carbon capture purposes after being functionalized.
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Proton-exchange membrane fuel cells (PEMFCs) and water electrolysis (PEMWE) are rapidly developing hydrogen energy conversion devices. Catalyst layers and membranes have been studied extensively and reviewed. However, few studies have compared gas diffusion layers (GDLs) in PEMWE and PEMFC. This review compares the differences and similarities between the GDLs of PEMWE and PEMFC in terms of their material and mass transport characteristics. First, the GDL materials are selected based on their working conditions. Carbon materials are prone to rapid corrosion because of the high anode potential of PEMWEs. Consequently, metal materials have emerged as the primary choice for GDLs. Second, the mutual counter-reactions of the two devices result in differences in mass transport limitations. In particular, water flooding and the effects of bubbles are major drawbacks of PEMFCs and PEMWE, respectively; well-designed structures can solve these problems. Imaging techniques and simulations can provide a better understanding of the effects of materials and structures on mass transfer. Finally, it is anticipated that this review will assist research on GDLs of PEMWE and PEMFC.
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Presented here is an electrochemical three-electrode Gas Diffusion Electrode (GDE) cell tailored for operandoand in situ investigations of electrocatalytic processes, with a particular focus on X-ray scattering studies. The optimized cell is engineered to accommodate the minimal sample-detector distances requisite for comprehensive X-ray total scattering investigations. An in-depth understanding of catalytic processes requires their study under 'working' conditions. Configured as a flow-cell, the setup therefore enables the examination of electrocatalysts under high current densities and associated gas evolution phenomena, particularly pertinent for reactions like the oxygen evolution reaction (OER). Notably, its transparency simplifies cell alignment, troubleshooting, and facilitates scans through the catalyst layer, crucial for background corrections. Demonstrating its versatility, we showcase its utility through Small Angle X-ray Scattering (SAXS), X-ray Diffraction (XRD), and X-ray Pair Distribution Function (PDF) analyses of total scattering data.