Development of low-loading, carbon monoxide tolerant PEM fuel cell electrodes

This work discusses the problems of, and potential solutions to, high catalyst cost of and carbon monoxide (CO) poisoning of the proton-exchange membrane fuel cell (PEMFC). As this is a comprehensive work, background on fuel cells and specifically PEMFCs is first presented.{09}A discussion of the current status of PEMFCs is presented showing ongoing work for stationary, transportation, portable and military applications. This leads into two of the more significant problems preventing widespread commercialization of PEMFC technology: poisoning of the catalyst by CO and the cost of the catalyst. A thorough examination of CO poisoning of the PEMFC anode is presented from how CO comes to be present in the feed stream of the PEMFC anode to how it then poisons the PEMFC anode. The first work presented here describes the development of a novel CO tolerant anode (the Ruthenium filter). It shows that by placing a layer of carbon-supported Ruthenium catalyst between the Pt catalyst and the anode flow field to form a filter, tolerance to CO will be increased relative to a Pt:Ru alloy when oxygen is added to the anode fuel stream. Secondly, after an introduction to catalyst preparation techniques used today and a brief discussion of catalyst-cost in PEMFCs, it is shown how sputter-deposition technology may be used to create more kinetically active PEMFC catalyst electrodes versus standard ink-based techniques. The technologies of the Ru filter and sputter-deposition are then combined to create a low-loading, CO tolerant anode for the PEMFC. In the final work, the effect of the airbleed on CO oxidation is then modeled.; In the concluding chapter, it is shown how the work presented can lead the PEMFC closer to large-scale commercialization. The Appendix A provides a detailed method by which PEMFC MEAs were manufactured using catalyst inks. This method served as the basis for all original works presented. Appendix B–F provide further background and information on the mathematical model developed, including a printout of the Fortran code used to generate the model results.