Microwave-assisted synthesis of palladium-based ferroalloy electrocatalysts for application in alkaline direct alcohol fuel cells

Abstract

This research work describes the study of Pd-based ferro-electrocatalysts for application towards direct ethanol fuel cells (DEFCs), direct ethylene glycol fuel cells (DEGFCs), direct glycerol fuel cells (DGFCs) and oxygen reduction reaction (ORR) operated in a basic environment. The initial part of the research was to explore the Pd-based monometallic and bimetallic (Pd/C and PdFe/C) by utilising varied methods such as the conventional sodium borohydride (NaBH4) and microwave-assisted technique (MW) towards the oxidation of glycerol (gly), intending to choose the best method viable for these catalysts. This study revealed that MW techniques tuned the physicochemical properties of Pd/C and PdFe/C by augmenting their crystallinity and defect. These led to improved electrocatalytic activities towards glycerol oxidation reaction (GOR) over NaBH4 technique. MW process as a powerful tool was further used in the entire study to synthesise bimetallic and trimetallic electrocatalysts in ethanol (EtOH), ethylene glycol (EG) and glycerol (Gly) oxidation reaction in an alkaline environment. The synthesised bimetallic catalysts studied in this research work were (PdFe/C, PdCo/C, and PdMn/C) at varied ratios of Pd: M (Pd2M/C (2:1) and PdM/C (1:1)). Amongst them all, Pd2Fe/C and PdFe/C were observed to be the most favourable catalysts towards all the alcohols, with the excellent specific activity of about, for EtOH (11.59 and 4.15 mA cm-2), EG (9.82 and 5.51 mA cm-2) and Gly (8.94 and 4.73 mA cm-2), respectively. The satisfactory performance exhibited by the PdFe/C electrocatalyst prompted the exploration of the second 3d transition metal (PdFeMn/C and PdFeCo/C), intending to investigate the synergistic behaviour between the non-noble metals and Pd. The XRD confirmed that these electrocatalysts are in a crystalline nature with a decrease in d spacing (from 0.2247 nm, PdFe/C to 0.2236 nm (PdFeMn/C)) after the insertion of Mn into PdFe/C. This was supported by the TEM images obtained for the PdFeMn/C catalyst with a particle size of sub 10 nm. The comparison studies towards EtOH, EG and Gly were investigated for all the electrocatalysts and there was a remarkable observation, which is dissimilar from the theoretical studies (DFT). Density Functional Theory (DFT) revealed that PdFeCo performed better in terms of Gibbs free energy, binding energy, and energy band gap than PdFeMn; however, the experimental studies favoring the performance of PdFeMn. The PdFeMn/C delivered the best electrochemical activities, including a superior electrochemical active surface area (ECSA), larger current densities and mass activity response, and less susceptibility to poisoning and high conductivity as compared to PdFe/C and PdFeCo/C electrocatalysts. Furthermore, the PdFeMn/C electrocatalyst exhibited remarkable electrochemical properties during the ORR (basic medium). Ultimately, the best two anode electrocatalysts (PdFe/C & PdFeMn/C) were explored and tested for the proof-of-concept in the two-electrode configuration with the micro-3D printed cell. The PdFeMn/C delivered improved µ-ethylene glycol fuel cell, µ-glycerol fuel cell, and µ-ethanol fuel cell activities with respective to high voltage and power density of 33.27 mW cm-2, 11.00 mW cm-2 and 45,80 mW cm-2 respectively, operated at 100 mV / s. These electrocatalysts have demonstrated promising results in advancing ADAFCs.