Thesis (M.S.)--Mississippi State University. Department of Chemistry. / Title from title screen. Includes bibliographical references.

Thesis (Ph. D.)--Institute of Paper Chemistry, 1968. / Includes bibliographical references (p. 91-96).

Thesis (M.S.)--Mississippi State University. Department of Chemical Engineering. / Title from title screen. Includes bibliographical references.

Fuel cells are electrochemical energy conversion devices that convert chemical energy to electrical energy efficiently. Bipolar plates form an integral part of a fuel cell and their high manufacturing cost and low production rate have hindered the commercialization of fuel cells. Bipolar plates require high electrical conductivity, strength, chemical resistance and thermal conductivity. This thesis presents efforts to manufacture bipolar plates which meet these requirements using compression or injection molding. Compression or injection molding processes allow cost-effective, large-scale manufacturing of bipolar plates. A variety of material systems for the fabrication of bipolar plates are processed, molded and characterized. / text

Proton exchange membrane fuel cells (PEMFCs) and direct methanol fuel cells (DMFCs) are two types of low-temperature fuel cells (LTFCs) that operate at temperatures less than 100 °C and are appealing for portable, transportation, and stationary applications. However, commercialization has been hampered by several problems such as cost, efficiency, and durability. New electrocatalysts must be developed that have higher oxygen reduction reaction (ORR) activity, lower precious metal loadings, and improved durability to become commercially viable. This dissertation investigates the development and use of new electrocatalysts for the ORR. Core-shell (shell@core) Pt@Pd[subscript x]Cu[subscript y]/C electrocatalysts, with a range of initial compositions, were synthesized to result in a Pt-rich shell atop a Pd[subscript x]C[subscript y]-rich core. The interaction between core and shell resulted in a delay in the onset of Pt-OH formation, accounting in a 3.5-fold increase in Pt-mass activity compared to Pt/C. The methanol tolerance of the core-shell Pt@PdCu₅/C was found to decrease with increasing Pt-shell coverage due to the negative potential shift in the CO oxidation peak. It was discovered that Cu leached out from the cathode has a detrimental effect on membrane-electrode assembly performance. A spray-assisted impregnation method was developed to reduce particle size and increase dispersion on the support in a consistent manner for a Pd₈₈W₁₂/C electrocatalyst. The spray-assisted method resulted in decreased particle size, improved dispersion and more uniform drying compared to a conventional method. These differences resulted in greater performance during operation of a single DMFC and PEMFC. Additionally, Pd₈₈W₁₂/C prepared by spray-assisted impregnation showed DMFC performance similar to Pt/C with similar particle size in the kinetic region while offering improved methanol tolerance. Pd₈₈W₁₂/C also showed comparable maximum power densities and activities normalized by cost in a PEMFC. Lastly, the activation of aluminum as an effective reducing agent for the wet- chemical synthesis of metallic particles by pitting corrosion was explored along with the control of particle morphology. It was found that atomic hydrogen, an intermediate, was the actual reducing agent, and a wide array of metals could be produced. The particle size and dispersion of Pd/C produced using Al was controlled using PVP and FeCl₂ as stabilizers. The intermetallic Cu₂Sb was similarly prepared with a 20 nm crystallite size for potential use in lithium-ion battery anodes. Lastly, it was found that the shape of Pd produced with Al as a reducing agent could be controlled to prepare 10 nm cubes enclosed by (100) facets with potentially high activity for the ORR. / text

Proton exchange membrane fuel cells (PEMFC) and direct methanol fuel cells (DMFC) are drawing much attention as alternative power sources for transportation, stationary, and portable applications. Nafion membranes are presently used in both PEMFC and DMFC as electrolytes, but are confronted with a few difficulties: (i) high cost, (ii) limited operating temperature of < 100 °C, and (iii) high methanol permeability. With an aim to overcome some of the problems encountered with the Nafion membranes, this dissertation focuses on the design and development of a few materials systems for use in PEMFC and/or DMFC. The incorporation of hydrous Ta₂O₅·nH₂O into Nafion membrane as well as the electrodes is shown to help the cell to retain water to higher temperatures. Membrane-electrode assembly (MEA) consisting of the composite membrane shows better cell performance at 100 and 110 °C than that with plain Nafion membrane, and a high power density of ~ 650 mW/cm² at 100 °C is obtained with H₂ - CO mixture as the fuel due to a significant alleviation of the CO poisoning of the catalysts. Sulfonated poly(etheretherketone) (SPEEK) membranes with various sulfonation levels are prepared and investigated in DMFC. With a sulfonation level of ~ 50 %, the SPEEK membranes exhibit low methanol permeability and electrochemical performance comparable to that of Nafion at around 60 °C, making it an attractive low-cost alternative to Nafion. From a comparative study of the structural evolutions with temperature in 2 M methanol solution, it is found that the lower methanol permeability of SPEEK membranes is related to the less connected and narrower pathways for water/methanol permeation. The dry proton conductor CsHSO₄ shows a high proton conductivity of ~ 10⁻³ S/cm at temperatures > 140 °C and water is not needed for proton conduction. However, it is found that CsHSO₄ decomposes to Cs₂SO₄ and H₂S at 150 °C in H₂ atmosphere in contact with the Pt/C catalyst. Thus, new catalyst materials need to be explored for CsHSO₄ to be used in practical high temperature PEMFC. Thin self-humidifying Nafion membranes with dispersed Pt/C catalyst powder are prepared and tested in PEMFC with dry H₂ and O₂. The Pt/C particles provide sites for catalytic recombination of H₂ and O₂ permeating from the anode and cathode, and the water produced at these sites directly humidifies the membrane. The performance of the cell with the self-humidifying membrane operated with dry reactants is ~ 90 % of that obtained with well humidified H₂ and O₂. / text

Direct alcohol fuel cells (DAFC) are attracting considerable interest to meet a variety of energy needs as they offer higher efficiency with less pollution compared to other conventional energy-conversion devices. However, the sluggish alcohol oxidation reaction kinetics and durability problems of the conventional Pt-Ru anode catalyst hamper the commercialization of the DAFC systems. With an aim to overcome these problems, there have been intensive efforts to alloy Pt-Ru with other metals. Although such strategies have led to some enhancement in activity, the durability problem caused by the instability of Ru could still not be alleviated. In this regard, this dissertation focuses on the development of non-Ru electrocatalysts with high activity and durability for DAFC applications. First, Ru-free, Pt-based bimetallic electrocatalysts for methanol oxidation reaction (MOR) were studied. Particularly, Pt-Sn and Pt-CeO₂ catalysts were synthesized, respectively, by a polyol method and a one-step reverse microemulsion (RME) method. The prepared samples are investigated for phase and morphological evaluations by various material-characterization techniques. Cyclic voltammetry and accelerated durability tests revealed that these alternative catalysts have much higher stability with a catalytic activity for MOR comparable to that of Pt-Ru. In the case of Pt-CeO₂, an improved particle morphology is obtained by the RME synthesis, and the advantage of the RME method is reflected by a higher catalytic activity in comparison to that of Pt-CeO₂ synthesized by the conventional synthesis method. It has been known that Pt-Sn is better than Pt-Ru for ethanol oxidation reaction (EOR), and the direct ethanol fuel cells (DEFC) employing Pt-Sn as the anode catalyst have better durability than the DMFC system employing a Pt-Ru anode catalyst. Therefore, this dissertation then focused on the enhancement of the catalytic activity for EOR by incorporating a third metal M to the Pt-Sn catalyst. Following the synthesis and characterization of the Pt-Sn-M (M = Mo and Pd) alloys, the effect of M on the enhanced catalytic activity of Pt-Sn-M is presented. The activity enhancement of the above catalysts is based on the promoting effect of the second or third elements added to Pt. However, in the final chapter of this dissertation, the activity enhancement of Pt nanoparticle itself through the formation of low energy surfaces is investigated. Carbon-supported Pt nanoparticles are synthesized in mixed water-ethylene glycol solvent, and the positive effect of the mixed solvent on both the morphology and surface structure of the Pt nanoparticles for COad oxidation is discussed. / text

This thesis is an investigation of the anode of a direct methanol fuel cell (DMFC) through numerical modeling and simulation. This model attempts to help better understand the two phase flow phenomena in the anode as well as to explain some of the many problems on the anode side of a DMFC and show how changing some of the anode side properties could alleviate these problems. This type of modeling is important for designing and optimizing the DMFC for specific applications like portable electronics. Understanding the losses within the DMFC like removable of carbon dioxide, conversion losses, and methanol crossover from the anode to the cathode will help the DMFC become more commercially viable. The model is based on two phase flow in porous media combined with equilibrium between phases in a porous media with contributions from a capillary pressure difference. The effect of the physical parameters of the fuel cell like the thickness, permeability, and contact angle as well as the operating conditions like the temperature and methanol feed concentration, have on the performance of the DMFC during operation will be investigated. This will show how to remove the gas phase from the anode while enabling methanol to reach the catalyst layer and minimizing methanol crossover. / text

Direct methanol fuel cells (DMFC) are being investigated for use as low-power electrochemical energy conversion devices. These types of fuel cells can be useful for portable electronics. The polymer electrolyte membrane plays a critical role in the overall performance of DMFC. The commercially available membrane, Nafion, suffers from high methanol permeability and a resulting methanol crossover from the anode to the cathode; it is also expensive. Accordingly, alternative membrane materials, such as sulfonated hydrocarbons, are intensively pursued for DMFC. For example, sulfonated poly (ether ether ketone) (SPEEK) and sulfonated polysulfone (SPsf) are two such candidates. This thesis focuses first on a simple synthesis method for a cross-linked sulfonated polysulfone membrane. Sulfonated polysulfone (Psf) membranes, with high IEC (1.4 - 2.2 meq/g), were characterized by nuclear magnetic resonance spectroscopy (NMR), proton conductivity, and water uptake. The degree of sulfonation was calculated by NMR and verified by acid-base titration analysis. Although the membranes showed good proton conductivity, they suffered from excessive swelling at high temperatures. Furthermore, the post-sulfonation of a carboxyl-substituted polysulfone (Psf-COOH) was carried out with trimethylsilyl chlorosulfonate, and solubility issues of the Psf-COOH in chlorinated solvents led to difficulty in controlling the degree of sulfonation (DS) and in purification. Accordingly, this approach to cross-linking sulfonated polysulfone was rejected as a viable method. This thesis then focused on the investigation of the mechanical properties of acid-base blend membranes based on SPEEK and heterocycle-tethered Psf and cross-linked membranes based on SPEEK that were previously reported by our group; these membranes were known to exhibit good performance in DMFC. However, the assessment of the mechanical stability of any new membranes developed is critical for their practical viability in DMFC. Accordingly, the mechanical strength and ductility of these membranes were investigated and compared for various membrane compositions. The acid-base blend membranes investigated consisted of SPEEK (acidic polymer) and a heterocycle-tethered Psf (basic polymer); for example, blends consisting of SPEEK and amino-benzimidazole-tethered Psf (SPEEK/Psf-ABIm) and SPEEK and benzotriazole tethered Psf (SPEEK/Psf-Btraz) were investigated. The cross-linked SPEEK was made by Friedel-Craft acylation with Psf-COOH (DS = 1 or 2). The two blend membranes showed superior mechanical properties compared to Nafion 115 and comparable to plain SPEEK. The crosslinked membranes showed good mechanical properties and better strength than Nafion 115, but they were more brittle than both Nafion 115 and plain SPEEK. Further optimization of cross-linking conditions is necessary to produce the best performing membrane. / text

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