Yuta
Nabae
*a,
Mayu
Sonoda
a,
Chiharu
Yamauchi
a,
Yo
Hosaka
a,
Ayano
Isoda
b and
Tsutomu
Aoki
b
aDepartment of Organic and Polymeric Materials, Tokyo Institute of Technology, 2-12-1 S8-26 Ookayama, Meguro-ku, Tokyo 152-8552, Japan. E-mail: nabae.y.aa@m.titech.ac.jp; Fax: +81 3 5734 2433; Tel: +81 3 5734 2429
bToshiba Fuel Cell Power Systems Corporation, 4-1, Ukishima-cho, Kawasaki-ku, Kawasaki-shi, Kanagawa 210-0862, Japan
First published on 13th February 2014
Pt-free cathode catalysts for polymer electrolyte membrane fuel cells have been developed by multi-step pyrolysis of Fe phthalocyanine (FePc) and phenolic resin (PhRs), the best of which shows a promising fuel cell performance: 1.0 A cm−2 at 0.38 V with 0.2 MPa of H2 and O2 at 80 °C. Durability tests over 800 h have been completed and they suggest good stability of the catalyst. This promising fuel cell performance and durability can be achieved because the multi-step pyrolysis of FePc and PhRs can overcome the trade-off between the heat treatment temperature and catalytic activity by combining the stepwise heat treatments and acid washing.
Since Jasinski discovered the catalytic property of Co phthalocyanine1 and Jahnke reported the heat treatment of Co TAA (Co dibenzotetraazaannulene),2 numerous attempts have been made to develop precious-metal-free cathode catalysts by pyrolyzing precursors containing transition metals (mainly Fe or Co), a nitrogen source and a carbon source.3–15 Although some of these precious-metal-free cathode catalysts show quite promising fuel cell performances,9,14 their durability needs to be much improved if they are to be considered for commercial applications.
While the majority of this class of catalysts contain transition metal species (mainly Fe or Co), the role of this transition metal is still much debated. One convincing model for the active sites is the catalytic center based on metal–N coordination.3 However, it has been pointed out that this metal–N coordination is no longer stable in the catalysts treated at high temperature (over 800 °C).8,15 In contrast, several research groups have focused on the nature of nitrogen-containing carbon itself.16,17 Regardless of whether the actual catalytically active sites contain Fe species or not, we assume that sufficient nitrogen content is essential to obtain highly active carbon-based ORR catalysts, and that Fe species are important to enhance the growth of the carbon network, although we do not eliminate the possibility of catalysis by the transition metal species during the ORR.
Our research group has been developing precious-metal-free cathode catalysts based on pyrolysis of polymer precursors such as phenolic resin18–20 and nitrogen containing polymers.21 Our catalyst materials are prepared by pyrolyzing these mixtures rather than surface modification of ready-made carbon supports, such as carbon blacks. This approach could result in high density of active sites and high durability of the resulting catalysts, since the chemical structure of the active sites can be produced both in the bulk and on the surface of the carbon. In the catalyst preparation from such polymer based precursors, the pyrolysis protocol is quite important to obtain highly active and highly durable ORR catalysts.
This study focuses on how the durability of carbon-based ORR catalysts can be improved without losing catalytically active sites. We hereby report a multi-step pyrolysis of Fe phthalocyanine (FePc) and phenolic resin (PhRs) to prepare highly active and highly stable ORR catalysts, the concept of which is shown in Fig. 1. The hypothesis is based on the conclusion of our previous work: Fe species are important at up to 600 °C for the growth of the carbon network, but Fe nanoparticles kill the active sites at over 700 °C.20 If one assumes that the chemical structure of the active sites has been formed at around 600 °C, the post-treatment of the catalysts prepared at 600 °C could be effective to improve the stability after removing the Fe species that kill the active sites. The current paper describes the properties of the FePc/PhRs derived cathode catalysts prepared by different pyrolysis protocols and the fuel cell performances using the prepared catalyst.
The MEA performance was tested at 80 °C by flowing fully humidified hydrogen (300 mL min−1) into the anode side and fully humidified oxygen or air into the cathode side (300 mL min−1). The absolute pressures of the anode and cathode compartments were maintained at 0.2 MPa. I–V polarization curves were measured by recording the cell voltages after holding the current density using an Electronic Load (Kikusui, PLZ164WA) for 5 min at each value. Durability tests were carried out by holding the current density at 200 mA cm−2 and recording the cell voltage.
Sample name | Elemental analysis (wt%) | EPMA Fe (wt%) | Specific surface area (m2 g−1) | |||
---|---|---|---|---|---|---|
C | H | N | ||||
A BET | A meso | |||||
600-I-N2-g | 74.9 | 1.3 | 3.1 | 1.4 | 517 | 94 |
800-I-N2-g | 92.1 | Trace | 0.7 | 0.5 | 484 | 284 |
800-II-N2-g | 87.0 | 0.1 | 2.6 | 1.2 | 488 | 80 |
800-II-NH3-g | 78.7 | 1.3 | 4.7 | 0.8 | 655 | 110 |
1000-III-NH3-g | 84.3 | 0.8 | 1.9 | 1.6 | 918 | 220 |
1000-III-NH3-guw | 77.5 | 1.8 | 2.0 | 2.3 | 860 | 219 |
1000-III-NH3 | 84.7 | 0.2 | 1.4 | 1.0 | 739 | 166 |
Fig. 2 shows the XRD patterns of the catalysts prepared by different pyrolysis protocols. 600-I-N2-g shows small diffraction peaks due to metallic Fe and Fe3C. This suggests that the phthalocyanine structure has started decomposing at around this temperature. The degree of graphitization is probably one of the most important properties to achieve the high stability of the carbon based cathode catalysts. In the 600-I-N2 and 800-II-N2-g samples, broad diffraction peaks spreading over 15–30° due to amorphous carbon were observed. In contrast, the 1000-III-NH3-g sample shows a relatively sharp peak at 25.8° due to turbostratic carbon.23
Fig. 3 shows the XPS spectra of the catalysts prepared by different pyrolysis protocols. The C 1s spectrum of 600-I-N2-g can be deconvoluted into four peaks: aromatic carbon at 284.6 eV, ether (C*OC) species at 285.5 eV, ester (C*OCO) species at 286.8 eV and carboxyl (C*(
O)O) species at 289.2 eV.22 Three other samples prepared by the multi-step pyrolysis show more aromatic carbon, suggesting a well grown carbon network as evidenced by XRD patterns (Fig. 2). The N 1s spectra can be deconvoluted into three peaks: pyridinic (398.4–398.5 eV), pyrrolic (399.9–400.0 eV) and graphitic (401.0–401.2 eV).24 Apart from 600-I-N2-g, the majority of N 1s signals can be assigned to pyridinic and graphitic nitrogens which have been proposed as catalytically active nitrogen species.14,25 The Fe 2p spectra were also measured under similar scanning conditions but only trace signals can be detected, suggesting that the concentration of Fe species on the catalyst surface is extremely low, whereas the bulk analysis (EPMA and XRD) detected considerable intensity of Fe signals. Our previous work suggests that the majority of FePc have decomposed and formed Fe nanoparticles at around 600 °C.20 The residual Fe in the prepared carbon is probably in the form of nanoparticles fully encapsulated by carbon layers, and therefore can be detected by the bulk analysis whereas the acid washing removes most of the Fe species on the catalyst surface. This assumption is evidenced by TEM as shown in Fig. 4. The 1000-III-NH3 sample shows Fe particles covered by layered carbon even after the acid washing.
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Fig. 3 (a) C 1s, (b) N 1s and (c) Fe 2p XPS spectra of the prepared carbon materials, dots: measured data; lines: fitted curves. |
The EPMA, XRD, XPS and TEM analyses suggest that the majority of Fe species observed in the 1000-III-NH3-g sample are in metallic Fe or Fe3C form and the concentration of Fe species on the catalyst surface is extremely low. These Fe particles presumably catalyze the formation of the layered structure.26 Note that 800-I-N2-g resulted in lower nitrogen content with a higher degree of graphitization. This is because the high temperature treatment with too much Fe species enhances the growth of carbon and the elimination of nitrogen species. These results suggest that controlling the catalysis of the Fe species is quite important to raise the heat treatment temperature without losing nitrogen species.
Fig. 5 shows the RDE voltammograms of the catalysts from various pyrolysis protocols. 800-I-N2-g shows quite poor ORR activity reflecting poor nitrogen content. The samples from the multi-step pyrolysis, 800-II-N2-g, 800-II-NH3-g and 1000-III-NH3-g show good catalytic activities even after the high-temperature treatment. This is probably because the multi-step pyrolysis can minimize the loss of nitrogen species since extraordinary Fe species has been washed out. 800-III-NH3-g shows even higher nitrogen content than 600-I-N2-g and a good ORR current. The nitrogen content of 1000-III-NH3-g is lower than that of 800-II-NH3 but also shows a quite good catalytic performance. This is probably because this sample has a high surface area due to the etching effect by NH3.
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Fig. 5 ORR voltammograms of the catalysts prepared by various pyrolysis protocols. Temperature: RT, catalyst loading: 0.2 mg cm−2, electrolyte: 0.5 M H2SO4, rotation: 1500 rpm. |
One might wonder if the different catalytic performances derive from the difference in the nature of Fe species among the samples. Fig. 6 compares the ORR voltammograms of 1000-III-NH3-g and 1000-III-NH3-guw. Indeed, the ORR activity slightly decreases by the acid washing, and 1000-III-NH3-g is still much active as a precious-metal-free catalyst. We do not eliminate the possibility of catalysis by Fe species during the ORR; however, the catalysts after the acid washing contain very little amount of Fe species on the surfaces (see Fig. 3) and it is quite difficult to discuss the correlation between the amount of Fe species and the catalytic activity. We assume that the different catalytic activities by different pyrolysis protocols mainly derive from the different nitrogen contents and specific surface areas.
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Fig. 6 ORR voltammograms of the 1000-III-NH3-g and 1000-III-NH3-guw catalysts. Temperature: RT, catalyst loading: 0.2 mg cm−2, electrolyte: 0.5 M H2SO4, rotation: 1500 rpm. |
Fig. 8 shows the RDE voltammograms of the 1000-III-NH3 and 1000-III-NH3-g samples. Reflecting the fine morphology, the ball milled sample (1000-III-NH3-g) shows higher current density. This higher catalytic performance is probably due to an increased three phase boundary by the fine particle size or the increased BET surface area and nitrogen content. It is concluded that mechanical grinding on the pyrolysis protocol is effective to improve the catalytic performance of the prepared carbon.
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Fig. 8 ORR voltammograms of the 1000-III-NH3 and 1000-III-NH3-g catalysts. Temperature: RT, catalyst loading: 0.2 mg cm−2, electrolyte: 0.5 M H2SO4, rotation: 1500 rpm. |
The durability tests of these fuel cells were carried out by introducing air into the cathode compartment and keeping the current density at 200 mA cm−2 (Fig. 10). Although the cell voltage gradually decreases, the performance loss after 500 h is less than 20%. To our knowledge, most of the state-of-art Pt-free catalysts significantly degrade within 100 h under the real fuel cell conditions;14 therefore, it can be concluded that the carbon based catalysts prepared by the multi-step pyrolysis have extremely good durability as Pt-free catalysts. It can be presumed that there are two main reasons for the extremely high durability of this catalyst: (a) the catalyst is well tolerant against corrosion under the electrochemical conditions because the materials have been well carbonized due to the multi-step pyrolysis, and (b) this material can retain the catalytic activity even if some degree of corrosion occurs on the material surface because active sites exist both in the bulk and on the surface of the carbon.
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Fig. 10 Durability test of the MEA using the 1000-III-NH3-g catalyst. Cathode: air (0.2 MPa). Anode: H2 (0.2 MPa). Current density: 200 mA cm−2. |
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