This thesis focuses on developing support materials for direct methanol fuel cell (DMFC) catalysts. The approach involves using graphene based materials including reduced graphene oxide (rGO), reduced graphene oxide-activated carbon (rGO-AC) hybrid and reduced graphene oxide-silicon carbide (rGO-SiC) hybrid as a support for Pt and Pt-Ru nanoparticles. Pt/rGO and Pt-Ru/rGO catalysts were synthesized by three chemical reduction methods: (1) modified polyol, (2) ethylene glycol (EG) reduction and (3) mixed reducing agents (EG + NaBH4) methods. The synthesized catalysts were characterized by physical and electrochemical techniques. The results demonstrated that Pt/rGO-3 and Pt-Ru/rGO-3 catalyst synthesized with Method-3 exhibit higher electrochemical active surface area (ECSA) than the other rGO supported and Vulcan supported commercial electrocatalysts. In addition, Pt/rGO-3 and Pt-Ru/rGO-3 catalysts showed better oxygen reduction reaction (ORR) and methanol oxidation reaction (MOR) activities, respectively. The DMFC tests under different cell temperature (30, 50 and 70°C) and methanol concentration (1, 2 and 4 M) conditions further demonstrated the higher catalytic activity of the catalysts. The peak power density obtained with Pt/rGO-3 cathode and Pt-Ru/rGO-3 anode catalysts at 70°C with 1 M methanol was 63.3 mW/cm2 which is about 59 % higher than that of commercial Pt/C and Pt-Ru/C catalysts. The enhanced performance was attributed to the highly accessible and uniformly dispersed nanoparticles on rGO support with large surface area and high conductivity. Pt/rGO-AC (reduced graphene oxide-activated carbon) and Pt-Ru/rGO-AC catalysts were synthesized with various rGO:AC support ratios by using biomass derived AC. The results showed that the catalysts with content of 20 wt. % AC support (Pt/rGO-AC20 and Pt-Ru/rGO-AC20) exhibited higher ECSA, better catalytic activity and stability among all the tested catalysts. With 1 M methanol and 70°C cell temperature, the MEA with Pt/rGO-AC20 cathode and Pt-Ru/rGO-AC anode catalysts gave 19.3 % higher peak power density (75.5 mW/cm2), than that of Pt/rGO-3 and Pt-Ru/rGO-3 catalysts. The better DMFC performance was due to the incorporation of AC particles into rGO structure which builds electron-conductive paths between rGO sheets, facilitates the transport of reactant and products and provides higher specific surface area for the uniform distribution of nanoparticles. Pt/rGO-SiC catalysts were synthesized with variable silicon carbide (SiC) content in the hybrid support. Pt/rGO-SiC10 (10 wt. % of SiC support) catalyst showed higher ECSA and better catalytic activity compared to the Pt/SiC, Pt/rGO-3 and Pt/rGO-SiC20 catalysts. In addition, the Pt/rGO-SiC10 gave 14.2 % higher DMFC performance than the Pt/rGO-3 catalyst in terms of power density. The high performance can be attributed to the insertion of the SiC nanoparticles into rGO structure that improves the conductivity and stability of the catalyst by playing a spacer role between rGO layers. In summary, the overall results showed that the catalytic performance of the catalysts followed the trend in terms of support material: rGO-AC20 > rGO-SiC10 > rGO > Vulcan. The study demonstrated that the novel rGO-AC and rGO-SiC hybrids are promising catalyst supports for direct methanol fuel cell applications.

abstract: Proton exchange membrane fuel cells have attracted immense research activities from the inception of the technology due to its high stability and performance capabilities. The major obstacle from commercialization is the cost of the catalyst material in manufacturing the fuel cell. In the present study, the major focus in PEMFCs has been in reduction of the cost of the catalyst material using graphene, thin film coated and Organometallic Molecular catalysts. The present research is focused on improving the durability and active surface area of the catalyst materials with low platinum loading using nanomaterials to reduce the effective cost of the fuel cells. Performance, Electrochemical impedance spectroscopy, oxygen reduction and surface morphology studies were performed on each manufactured material. Alkaline fuel cells with anion exchange membrane get immense attention due to very attractive opportunity of using non-noble metal catalyst materials. In the present study, cathodes with various organometallic cathode materials were prepared and investigated for alkaline membrane fuel cells for oxygen reduction and performance studies. Co and Fe Phthalocyanine catalyst materials were deposited on multi-walled carbon nanotubes (MWCNTs) support materials. Membrane Electrode Assemblies (MEAs) were fabricated using Tokuyama Membrane (#A901) with cathodes containing Co and Fe Phthalocyanine/MWCNTs and Pt/C anodes. Fuel cell performance of the MEAs was examined. / Dissertation/Thesis / Masters Thesis Technology 2014

In this work, carbonaceous deposits on spent HTFT catalysts were investigated. This research was required in order to better understand the observed loss in productivity observed in the industrial reactors, with the aim of improving the economy of the HTFT process. A host of complementary techniques were employed to systematically determine the composition of a typical catalyst recovered from a reactor. Spent HTFT catalysts are comprised of magnetite and a mixture of iron carbides as well as adsorbed hydrocarbon products (soft carbon) and hard carbon. Reaction initiates at the particle surface and along the promoter-rich grain boundaries toward the core of the grains. A partially reacted particle would therefore have a core-shell structure, with magnetite representing the unreacted region of the catalyst. The reacted region consists of a porous carbonaceous matrix with soft carbon and carbide crystallites nestled in this matrix. The hard carbonaceous species is a mixture of polymeric carbon and polycyclic aromatic hydrocarbons. The particle structure is linked to the sample preparation method and an alternative method yielding catalyst particle with uniformly distributed promoter elements could be beneficial. Investigating carbonaceous species is a complex process, and development of a fresh methodology would aid in the quest for insight into the nature of carbonaceous species in various systems. A new approach which entails a combination of the traditional techniques combined with MALDI-TOF MS enabled a deeper investigation. Additional aspects such as the molecular weight distributions along with known information about crystallinity and morphology of the catalyst provide a comprehensive study of carbonaceous material. Polymeric carbon and very large polycyclic aromatic hydrocarbons constitute hard carbon and can be observed with minimal sample preparation procedures. The evolution of the HTFT catalysts was investigated as a function of time-on-stream. This enabled us to study the effects of increasing amounts of hard carbon on the activity and the chemical and physical properties of the catalysts. The catalyst activity was found to decrease with increasing hard carbon content, although the effect of carbon deposition cannot be distinguished from phase transformation (oxidation) which occurs simultaneously. A method to quantify the amount of hard carbon, which progressively builds up on the catalyst, was demonstrated. This required a great deal of method development, which provides a platform for future investigations of these catalysts. Importantly, it allows predictions of the amounts of carbon that will be deposited after a certain reaction time. This allows more efficient regulation of catalyst replacement. The production of fine carbon-rich particles in the industrial reactor poses a major problem in the process. Carbon deposition leads to an increase in particle diameter with time on-stream. Permissible levels of hard carbon were identified, beyond which the mechanical strength of the catalyst particles deteriorate. This leads to break-up of the particles and therefore fines formation. The surface area and pore volume generally increase with progressive deposition of hard carbon, while the bulk density of the catalyst material exhibits a linear decrease with carbon build-up. A mechanism is proposed for hard carbon formation which apparently occurs through the dissociative adsorption of CO to form a carbon monolayer. This is followed by polymerisation of the carbon atoms. Meta-stable interstitial carbides are formed at the iron-carbon interface. Owing to a carbon concentration gradient between the top of the surface and the bottom of the metal or carbide particle, carbon diffusion across the crystal (carbide decomposition) and grows as a PAH molecule lifting the iron carbide away from the particle. As this corrosion process is intrinsic to iron-based catalysts, a catalyst that contains sulphur is proposed for future development.