Fuel cell is a device that can directly convert chemical energy into electrical energy. For low-temperature fuel cells, catalysts are required. Fuel cells using Pt-based or other non-biological materials as catalysts are known as conventional fuel cells. Inspired from Nature, enzymes can be used as catalysts in fuel cells known as enzyme-based fuel cells. The conventional and enzymatic fuel cells share the same underlying electrochemical principles, while enzyme-based fuel cells have their intrinsic advantages and disadvantages due to enzyme properties. The objective of this thesis is to investigate the current/voltage/ power/stability capabilities of enzyme-based membrane-less H2 fuel cells in order to design the enzymatic fuel cells with improved performance. This thesis presents a facile, effective method for the construction of 3D porous carbon electrodes. The 3D porous carbon electrodes are constructed by compacting suitable carbon nanomaterials into discs. The 3D porous carbon electrodes, with large roughness, high specific surface area, and optimized pore size distribution, are able to increase the loading density of enzymes, that is, reaction sites per unit geometric electrode area. The high loading density of enzymes can result in the high current/power density of the enzyme-based membrane-less H2 fuel cells. Moreover, the large enzyme loading can bring about the improvement in fuel cell stability because current becomes limited by mass transport of dissolved gases rather than enzyme immobilization so that neither inactivation nor desorption of enzymes would influence the current output. Based on one type of 3D porous carbon electrodes, the maximum power density of enzyme-based membrane-less H2 fuel cells has increased to the mW•cm2 level by at least one order of magnitude and the half-life has also increased from several hours to one week. This thesis presents a method for the increase in power density otherwise limited by low cathodic currents due to meagre O2 in non-explosive H2-rich H2-air mixtures. The power density of enzyme-based membrane-less H2 fuel cells can be increased by re-proportioning cathode/anode geometric area ratio to balance the cathodic and anodic currents under such an unusual H2-air mixture. This thesis also demonstrates that the 3D porous carbon electrode can improve the apparent O2 tolerance of anodic catalysts – hydrogenases, which are very important for the fuel cell performance. The degrees of apparent O2 tolerance for both O2-tolerant and O2-sensitive [NiFe]-hydrogenases are greatly increased based on the 3D porous carbon electrodes, so that even an O2-sensitive [NiFe]-hydrogenase can be used as an anodic catalyst in the enzyme-based membrane-less H2 fuel cell under a non-explosive H2-rich H2-air mixture. This thesis presents a design of a test bed in which series and parallel connections of sandwich-like electrode stacks can be varied. The fuel cell test bed has demonstrated low-loss interconnects and efficient stack configuration. Operated under a non-explosive H2-air mixture containing only 4.6% O2 at 20 °C, the maximum volume power density of the fuel cell test bed exceeds 2 mW•cm3, capable of powering electronic gadgets, which is a good demonstration of electricity that originates from the buried active sites of enzymes and is transmitted by long-range electron hopping in accordance with Marcus theory.

The work in this Thesis addresses the challenges associated with using redox enzymes for chemical synthesis. The use of enzymes as catalysts in the synthesis of fine chemicals is becoming more wide spread, in part due their ability to catalyse reactions with incredible selectivity under relatively mild conditions. In particular, enzymes are useful for selective reduction of ketones to enantiomerically pure alcohols or amines, and partial oxidations of alkanes to alcohols. However, a key limitation to exploiting redox enzymes in these reaction pathways is the requirement for a specialised electron source, usually the expensive nicotinamide cofactors NADH or NADPH. Existing cofactor regeneration methods use a second enzyme with a sacrificial substrate which is oxidised to generate a stoichiometric waste product; this complicates isolation of the desired product and prevents the environmental benefits of biocatalysis from being fully realised. In order to provide clean and efficient biocatalytic routes, improved recycling methods for these cofactors are crucial. This Thesis develops two novel methods for in situ cofactor recycling. The first is an electro-enzymatic system; an NAD⁺-reductase enzyme is shown to use electrons directly from an electrode for supply of NADH to a co-immobilised cofactor-dependent enzyme. The second uses a hydrogenase, NAD⁺ reductase and cofactor-dependent enzyme immobilised on conducting particles for H₂-driven NADH regeneration. This relies on the thermodynamically favourable reduction of NAD⁺ by H₂ when the hydrogenase and NAD⁺-reductase are in electronic contact, provided by the conducting particle. The electro-enzymatic approach to NAD⁺ reduction is then adapted for electrochemical devices; an enzyme catalysed fuel cell and a self-powered biosensor were considered.