Polymer electrolyte fuel cells have shown great potential in providing clean energy with no emissions. The kinetics of the cathode reaction, i.e. the oxygen reduction reaction (ORR) are sluggish necessitating high loadings of the catalyst metal, i.e. platinum. Platinum is a limited resource and expensive. Its price has been one of the major drawbacks in wide scale commercialisation of fuel cells. In an effort to improve the activity of the catalyst and therefore reduce Pt loadings on the catalyst, Pt can be alloyed with transition metal elements (e.g. Ni, Co and Fe) to form bimetallic catalysts. Alloying has been known to improve the activity and stability of a catalyst for the ORR. The enhanced activity of the alloys originates from the modified electronic structures of the Pt in these alloy catalysts which reduces the adsorption of spectator species therefore increasing the number of active sites for the ORR (Wang et al., 2012 (2)). The aim of this study was to gain a better understanding of the influence of Pt alloy particle size and active surface morphology on the ORR activity. The Pt alloy that was investigated was Pt₃Co/C. The surface morphology was modified by varying the Pt/Pt₃Co loading on a carbon support. The catalysts were prepared using thermally induced chemical deposition. The support used was Vulcan-XC-72R. The effects of varying the metal loadings on the ORR was investigated. The loadings that were investigated were 20, 40, 60 and 80 wt. % Pt and Pt₃Co. The alloy catalysts were subjected to annealing at 900 °C and acid leaching. The catalysts were analysed using electrochemical characterisation techniques such as cyclic voltammetry, CO stripping voltammetry, rotating disk electrode and rotating ring disk electrode. Physical characterisation of the catalysts was also implemented. The techniques used were x-ray diffraction, thermogravimetric analysis and transmission electron microscopy. The Pt particles on the carbon support were found not to agglomerate significantly despite the loading being increased. This trend was also observed for the Pt₃Co/C catalysts even after heat treatment and leaching. The lack of agglomeration was credited to a new reactor system developed in this work. The particle growth increased from low loadings to high loadings for both the Pt/C and Pt₃Co/C catalysts. Particle growth was more significant for the Pt₃Co/C catalysts at high loadings. At lower loadings (20 and 40 wt. %) the particle sizes between the Pt/C and Pt₃Co/C catalysts were comparable despite the Pt₃Co/C catalysts undergoing annealing and leaching. The mass specific activity of the Pt/C catalysts was not improved by alloying with the exception of the 20 wt. % catalyst which saw an enhancement factor of 1.66. The surface specific activity of the Pt/C catalysts was improved significantly with factors of 2.40 and 3.11 being recorded for the 20 and 80 wt. % Pt₃Co/C catalysts respectively. The enhancement factors of the intermediate loadings (40 and 60 wt. %) were lower and fairly similar at 1.30 and 1.35 respectively.

Proton exchange membrane fuel cell (PEMFC) has been reported as clean and efficient energy technology from conversion of H₂. However, one of the main challenges remains the storage and transport of hydrogen. The promising alternative is to produce H₂ on site by a reformer using a H₂-dense liquid as a fuel, a technology known as fuel processing. Methanol is an attractive source of H₂ compared to other fuels as it presents several advantages, i.e. it is obtained sulphur-free, has a high H to C ratio and therefore produces a H₂-rich reformate, can be reformed at low temperatures (200 - 300°C) and is a liquid at ambient conditions so that it can be easily handled. Typically, Cu-based catalysts are used for steam reforming of methanol due to their high activity (i.e. H₂ production) and high selectivity towards CO₂. As CO poisons anodic catalyst of PEMFC, high selectivity towards CO₂ is crucial so as to eliminate or at least minimize CO removal load downstream a fuel processor. However, Cubased catalysts are thermally unstable and suffer deactivation due to sintering at high temperatures (> 250°C). Moreover, Cu-based catalysts are pyrophoric and therefore difficult to handle. Recent studies show that PdZn catalysts are very promising as they exhibit comparable activity and selectivity to Cu-based ones. Furthermore, PdZn catalysts are thermally stable in the typically methanol steam reforming temperature range (200 - 300°C). Most literature attributes high CO₂ selectivity of PdZn catalysts to formation of PdZn alloy. It is generally agreed that PdZn alloy is formed when PdZn catalysts are reduced in H₂ at high temperatures (> 250°C). In this work, a Pd/ZnO catalyst aimed at 2.5 wt% Pd was successfully prepared via incipient wetness impregnation and the duplicate preparation of the catalyst was successful. Both impregnation catalysts were confirmed by ICP-OES to contain similar weight Pd loadings i.e. 2.8 and 2.7 wt%, respectively. The actual Pd loading (ICP-OES) was slightly higher than the target loading (2.5 wt%) due to Pd content of Pd salt underestimated during catalyst preparation. Furthermore, crystallite size distribution, i.e. PdO crystallites on ZnO support, was similar (i.e. 6.7 ± 2.4 nm and 6.3 ± 1.9 nm) for both impregnation catalysts.

The preferential oxidation (PROX) reaction is an effective process for the removal of trace amounts of carbon monoxide from a reformate stream. Tricobalt tetraoxide (Co₃O₄) is the candidate for CO-PROX in a H₂ rich gas and could be an alternative to the rare and expensive PGMs. This study investigates the effect of different Co₃O₄ morphologies in the preferential oxidation of carbon monoxide in H₂ rich gas. Reports have shown morphology dependency in CO oxidation in the absence of hydrogen, no study has investigated the morphology dependency in H₂ rich atmospheres. Different morphologies of nanocubes, nanosheets and nanobelts were prepared using hydrothermal mn and precipitation. Conventional spherical nanoparticles from our group were included to compare the activity of conventional nanoparticles with nanoparticles of different morphology. The model catalysts were supported on silica spheres which were also prepared. The CO-PROX experiments were conducted in the in situ UCT-developed magnetometer and PXRD capillary cell instruments by induced reduction at temperatures between 50 and 450°C. Catalyst tests showed two distinct temperature regions with maximum activity. In the range of 150 – 175ᵒC, activity decreased from nanoparticles > amine nanosheets > nanobelts. However, the surface area specific rate of CO₂ formation displayed an inverse trend. In the region of 225 – 250ᵒC, nanocubes > NaOH nanosheet > HCl nanocubes showed maximum activity. The surface area specific rate was the same for amine nanocubes and NaOH nanosheets. None of the model catalysts retained their morphology after the temperature was ramped from 50ᵒC to 450ᵒC, and back to 50ᵒC. The catalysts were partially reduced to metallic Coo (other phase being CoO). Figure 1: In situ PXRD analysis and kinetics of CH4, CO and CO₂ showing the behaviour of Co₃O₄/SiO₂ (amine nanocubes) under CO-PROX conditions

Supported nano-catalyst technologies are key for increasing the catalyst utilisation and achieving economically feasible platinum metal loadings in hydrogen polymer electrolyte fuel cells (PEFCs). High surface area carbons are commonly utilised as support materials for platinum due to low cost, large surface areas and high conductivity. However, PEFCs using this technology undergo oxidation of carbon supports, significantly reducing the lifetime of the fuel cell. In this work, silicon carbide and boron carbide are investigated as alternative catalyst support materials to carbon, for the oxygen reduction reaction for low temperature fuel cells. Electrochemical testing, accelerated degradation studies as well as advanced characterisation techniques were used to clarify the structure-property relationships between catalyst morphology, metal-support interaction, ORR activity and surface adsorption onto the Pt nanoparticles. Extended X-ray Absorption Fine Structure (EXAFS) analysis gave insights into the shape of the clustered nanoparticles while X-ray Photoelectron Spectroscopy (XPS) and in-situ X-ray Absorption Near-Edge Spectroscopy (XANES) analysis provided information into how the metal-support interaction influences surface adsorption of intermediate species. Electronic metal-support interactions between platinum and the carbide supports were observed which influenced the electrochemical characteristics of the catalyst, in some cases increasing the oxygen reduction reaction activity, hydrogen oxidation reaction activity and Pt stability on the surface of the support.

High throughput and combinatorial experimentation is becoming more and more used in catalysis research. The benefits of parallel experiments are not only limited to shorten the time - to - market, but also give opportunities to study the process in more depth by performing more experiments. The influence of a parameter, for example the amount of the active metal and/or promoter, to the process is better understood with a broader parameter space investigated. To study the parameter space, multiple experiments need to be performed. It is of paramount importance to understand the variability of the data between these experiments. This is not always defined, specifically when literature gives contradictory results, most often due to the time for duplicate experiments necessary. In this project the reproducibility and variance in high throughput catalyst preparation and testing was determined and the use of parallel experimentation was demonstrated within a catalyst development study. The high throughput equipment was used for catalyst development studies for fuel processing, the production of fuel cell - grade hydrogen from hydrocarbon fuels. Fuel processing consists of three catalytic reactions, namely reforming, water - gas shift and a CO clean - up through either selective methanation or preferential oxidation. Focus has been placed on the first two reactions, steam methane reforming (SMR) and medium temperature water - gas shift (WGS), using platinum group metals (PGM). All catalysts in this study (except for the commercial WGS catalyst) were prepared using automated synthesis robot (Chemspeed ISYNTH) and the activity testing was performed on the Avantium Flowrence. For both reactions two types of studies were performed, one - to - many and many - to - many; referring to one catalyst tested in many reactors or many prepared catalysts (same composition, different batches) tested in many reactors. For the WAGS one - to - many a commercial low temperature shift catalyst was selected and for SMR a single batch of Rh/Al 2 O 3 . The many - to - many experiments comprised of eight batches of prepared catalysts for both reactions. The WGS reaction was performed with 1 wt% Pt/Al 2 O 3 catalysts and for the reforming reaction batches of 0.5 wt% Rh/Al 2 O 3 was used. It was proven that in all these studies the experimental standard deviations in the data is 6%, from preparation to activity measurements. A study on the rhodium metal loading on alumina in the steam methane reforming catalyst was studied between 0.05 and 0.6 wt%. A 0.4 wt% Rh/Al 2 O 3 was found to have the highest activity per amount of rhodium. Lower Rh content would require decreased space velocity, whereas higher metal content does not increase the conversion due to larger crystals sizes. This study has been performed up to a metal loading of 0.6 wt% and it is recommended to follow - up with studying the range of 0.6 to ~2.5 wt% to investigate the optimal metal loading. It was shown that the use of automated experimentation (parallel preparation and evaluation under same condition) for catalyst development results in highly reproducible results with a relative standard deviation of ~6% activity. The high throughput equipment was demonstrate d to be a very powerful tool in catalyst research

Bibliography: p. 179-188. / Iron antimony oxide has been known to be an active and selective catalyst for the partial oxidation of propene to acrolein and the oxidative dehydrogenation of 1-butene to 1,3- butadiene. It has become the preferred catalyst for the industrial acrolein formation from propene. The main purpose of this work was to investigate the influence of catalyst parameters such as calcination temperature, Sb:Fe ratio, type of pre-treatment, absence or presence of gaseous oxygen on the activity and selectivity in the partial oxidation of propene. Furthermore the influence of the reaction parameters temperature, space time, partial pressure, time on stream and the carbon chain length of the olefin have been studied in partial oxidation reactions using a fixed bed U-tube glass reactor. Various models have been tested for the rate of formation of products in the range of C₂ to C₆ α-olefins. Increasing the calcination temperature from 500°C to 900°C resulted in an increase of the crystallite diameter and a simultaneous decrease of the surface area which might be ascribed to high temperature sintering of the catalyst. The activity decreased proportional to the decrease of surface area. At the same time the selectivity to acrolein increased with increasing calcination temperature.

Zeolites have found widespread applications as acid catalysts for decades. By introducing transition metal ions in the cation position, the zeolite is transformed into a redox catalyst. The nature of the trivalent heteroatom influences the properties of the zeolite. Contrary to Al-zeolites, Fe-containing zeolites show redox properties, since Fe can easily change its oxidation state (Fe²⁺, Fe³⁺, or Fe⁴⁺). Catalytic function of isolated redox sites within zeolite cavities (or channels) may result in a material with specific redox properties (Kiwi-Minsker et al., 2003). The properties of transition metal exchanged zeolites have been studied from the 1960's onwards and the conversion of N₂O over Fe-Y zeolites has been studied by Fu et al. (1981) in late 1970's. In this study, the preparation of iron ZSM-5 zeolite catalysts by mechanochemical means and thermally induced solid-state ion exchange was studied. After grinding the NH4-Zeolite and ferrous chloride, no x-ray reflections characteristic of ferrous chloride are detected. After heating the sample to 120 and 200 °C reflections characteristic of ferrous chloride are visible but disappear upon further heating to 300 °C. No porosity is observed after grinding and heating up to 200 °C as a result of pore mouth blocking. Moreover, upon heating up to 500 °C porosity starts to develop with pore volumes and pore sizes slightly lower than those of the parent zeolite. From the thermogravimetric analysis it is evident that the ion exchange takes place during calcination from 150 and 420 °C in agreement with the literature. In the second part of the study commercial Fe-ZSM-5 catalyst samples with different N₂O conversion activities (in the presence of H₂O and NO at 425 °C), ranging between 70 and 90 % (high, mid and low activity) are studied and characterised. The effect of temperature during calcination of the plant produced and laboratory calcined extrudate catalyst material was investigated. Panov et al. (1996) reported in the literature that the Fe²⁺ is oxidised to Fe³⁺ in the presence of N₂O forming what they called the α-oxygen, a form of active surface oxygen, with the evolution of molecular nitrogen. During the conversion, two surface α-oxygen atoms migrate, combine and desorbs as molecular oxygen from the surface. The α-oxygen forms between 200 and 350 °C and desorbs as molecular oxygen above 350 °C (Taboada et al., 2005). In this study, no correlation to N₂O conversion activity could be found for the α-oxygen content and correspondingly the concentrations of the respective iron oxides and iron hydroxides in the Fe-ZSM-5 samples.

Includes bibliographical references (pages 99-107). / Two deposition-precipitation style methods of preparing zinc oxide supported dispersed gold materials for use as water-gas shift catalysts were examined, with some of the better formulated materials being tested for catalytic activity, and compared to World Gold Council Au/TiO₂ reference material and a commercial copper-based WGS catalyst (Cu/ZnO/AlO₃ - C 18-7 from Sud-Chemie). Materials Synthesis: The classical deposition-precipitation synthesis from the group of Haruta (Tsubota et al., 1995) - where the support is added to a pH adjusted solution of HAuCl₄ and the system aged at constant pH and temperature - was examined, using ZnO as the support. Gold uptake by the support was confirmed to decrease with ageing pH, tending to zero as the IEPS of ZnO (~ 9) is approached. Such behaviour is both qualitatively and quantitatively consistent with theory, which proposes that the magnitude and polarity of the charge on the support surface will determine the effective carrying capacity of that surface for an (an)ionic solution phase gold species. Decreasing post-calcination (120°C) gold crystallite size with increasing ageing pH [as reported by Haruta (1997)] was also observed (figure 11.2) - but it is not clear whether this resulted from pH dependent crystallization dynamics, from crystallite size being simply determined by the amount of deposited gold (which clearly decreases with increasing pH), or from chloride induced sintering during heat treatment (with chloride uptake by the support decreasing with increasing pH [Kung et al., 2003)). Nevertheless, gold deposition at pH 8 produced highly dispersed gold crystallites around 3.5 nm in diameter. It emerged that an inherent trade-off exists with this, the classical depositionprecipitation method, in that acidic ageing pH promotes a high degree of gold uptake by the support, but produces large gold crystallites, and vice versa. To overcome this, a modified method - where HAuCI₄ and the base (ammonium carbonate) were simultaneously added dropwise to a slurry of the support, maintaining a constant pH of 8 (Fu et al., 2003b) - was investigated. This method was attractive because it is claimed to simultaneously achieve total gold uptake and post-calcination Au crystallite size in the range 5 - 6 nm. Since it was not clear from the published description whether a constant pH was maintained across the ageing period (practiced here as MDP1 ), or if the pH was rather allowed to drift (practiced here as MDP2), both alternatives were investigated. When a constant pH was maintained across the ageing period (MDP1 ), gold uptake by the support was found to reach a maximum (of ~ 60 %) when operating at a pH of ~ 8. The degree of gold uptake was found to be independent of both gold loading and support surface area. Furthermore, the degree of gold uptake achieved using this variation was increased to unity by allowing the pH to drift during the ageing period (after being initially held constant at 8 during HAuCI₄ addition) [= MDP2], instead of being maintained at a constant value via addition of nitric acid (as is done in MDP1). In terms of the size of the gold crystallites produced, after calcination in air at 400°C, a mean diameter of 3.8 ± 1.5 nm was observed for a sample 1.9 wt % in Au, increasing slightly with increasing gold loading [to 4.6 ± 1. 7 nm by 5.1 wt %Au].

Electrochemical devices, such as fuel cells and electrolysers, are said to be at the forefront of a renewable energy technology revolution centred on hydrogen as an energy carrier. These devices rely on the chemical reactions of oxygen, namely the oxidation of water to evolve oxygen (oxygen evolution reaction, OER) and hydrogen , carried out in electrolyser applications or the reverse reaction, the reduction of oxygen to water (oxygen reduction reaction, ORR) producing electricity in the case of fuel cells . Th e reactions of oxygen are however still hindered by extremely slow reaction kinetics. The resultant low efficiencies and associated high cost of electrocatalysts required hinder the widespread commercial success of these devices. In addition, current state - of - the - art electrocatalyst technologies suffer from severe corrosion during operation, presenting an additional barrier to commercialisation and ultimately delaying the successful implementation of a sustainable hydrogen economy. One primary goal of electrocatalysis research is thus the rational design of new materials with higher efficiencies. The fundamental understanding of the behaviour of the electrocatalyst materials towards these reactions will enable greater strides to be achieved in this area. To date much research has been conducted towards this end, however further progress is still required. This thesis details work towards the understanding of a new generation of electrocatalyst technologies for the OER and ORR. This study particularly explore s the use metal oxide based electrocatalyst materials for the oxygen evolution and reduction r eactions as employed in electrolyser and fuel cell applications respectively. The thesis is divided in two parts focusing individually on the OER and ORR respectively. New theoretical and experimental insight into the understanding of oxide electrocataly sts for the OER are discussed in Part I. Part II explores the ORR by studying metal oxides as both catalysts and catalyst support materials in alkaline and acidic environments respectively. Here the emphasis is placed on activity and durability of oxide ma terials under fuel cell operating conditions. The study confirms the promise of oxide based materials and highlights some of the challenges still present in their development for fuel cell applications. The final chapter presents a summary of the thesis. This study provides important insight and contributes towards the further understanding of the use of metal oxides for the OER and ORR. From this study several interesting and promising results were also obtained which warrant further intensive research and investigation. Directions for future research are discussed. [Please note: the full text of this thesis has been deferred until January 2018]

The direct methanol fuel cell (DMFC) is identified as a promising fuel cell for portable and micro fuel cell applications. One of the major benefits is that methanol is an energy dense, inexpensively manufactured, easily stored and transported, liquid fuel (Hamann et al., 2007). However, the DMFC's current efficiency and power density is much lower than theoretically possible. This inefficiency is predominantly due to the crossover of methanol from the anode to the cathode, Ru dissolution and Ru crossover from the anode to the cathode. In addition, the DMFC has a high manufacturing cost due to expensive catalyst costs and other materials. Catalyst expenses are further increased by catalyst loading due to low activity at the anode of the DMFC (Zhang, 2008). Hence, with increasing activity and stability of the Pt-Ru/C catalyst, catalyst expenditure will decrease due to a decrease in catalyst loading. In addition, performance will increase due to a reduction in ruthenium dissolution and crossover. Therefore, increasing the activity and stability of the Pt-Ru/C catalyst is paramount to improving the current DMFC performance and viability as an alternative energy conversion device. Pt-Ru/C catalyst synthesis method, precursors, reduction time and temperature play a role in the activity for methanol electro-oxidation and stability since these conditions affect structure, morphology and dispersivity of the catalyst (Wang et al., 2005). Metal organic chemical deposition methods have shown promise in improving performance of electro-catalysts (Garcia & Goto, 2003). However, it is necessary to optimise deposition conditions such as deposition time and temperature for Pt(acac)₂ and Ru(acac)₃ precursors. This study focuses on a methodical approach to optimizing the chemical deposition synthesis method for Pt-Ru/C produced from Pt(acac)₂ and Ru(acac)₃ precursors. Organo-metallic chemical vapour deposition (OMCVD) involved the precursor's vapourisation before deposition and a newly developed method which involved the precursors melting before deposition. An investigation was conducted on the effects of precursor's phase before deposition. The second investigation was that of the furnace operating temperature, followed by an exploration of the furnace operating time influence on methanol electro-oxidation, CO tolerance and catalyst stability. Lastly, the exploration of the Pt:Ru metal ratio influence was completed. It was found that the catalyst produced via the liquid phase precursor displayed traits of a high oxide content. This led to an increased activity for methanol electro-oxidation, CO tolerance and catalyst stability despite the OMCVD catalyst producing smaller particles with a higher electrochemically active surface area (ECSA).