CATALYST SYSTEM, ELECTRODE AND FUEL CELL OR ELECTROLYZER
20220006103 · 2022-01-06
Assignee
Inventors
- Moritz WEGENER (Erlangen, DE)
- Yahsar MUSAYEV (Nurnberg, DE)
- Jeevanthi VIVEKANANTHAN (Herzogenaurach, DE)
- Detlev REPENNING (Reinbeck, DE)
- Ladislaus Dobrenizki (Hochstadt, DE)
Cpc classification
Y02E60/50
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H01M4/9075
ELECTRICITY
International classification
H01M4/86
ELECTRICITY
Abstract
The invention relates to a catalyst system (9), an electrode (1) which comprises the catalyst system (9), and a fuel cell (10) or an electrolyzer having at least one such electrode (1). The catalyst system (9) comprises an electrically conductive carrier metal oxide and an electrically conductive, metal oxide catalyst material. A near-surface pH value, called pzzp value (pzzp=point of zero zeta potential), of the carrier metal oxide and the catalyst material differ. The catalyst material and the carrier metal oxide form an at least two-phase disperse oxide composite. The carrier metal oxide has a first crystal lattice structure comprising first oxygen lattice sites and first metal lattice sites, wherein the carrier metal oxide on the first oxygen lattice sites is preferably doped with at least one element from the group comprising nitrogen, carbon, and boron, and is optionally additionally doped with hydrogen. The carrier metal oxide has a second crystal lattice structure comprising second oxygen lattice sites and second metal lattice sites, wherein the catalyst material on the second oxygen lattice sites is preferably doped with fluorine and at least one element from the group comprising nitrogen, carbon and boron, and optionally additionally doped with hydrogen.
Claims
1. A catalyst system comprising, an electrically conductive carrier metal oxide having an electrical conductivity λ.sub.1 of at least 10 S/cm, the carrier metal oxide having at least two first metallic elements selected from the group of non-precious metals and having a structure comprising oxide grains with a grain size of at least 30 nm; an electrically conductive, metal oxide catalyst material having an electrical conductivity λ.sub.2 of at least 10 S/cm, the catalyst material having at least one second metallic element from the group of non-precious metals, the at least two first metallic elements in the carrier metal oxide and the at least one second metallic element in the catalyst material each being present in a solid stoichiometric compound or solid homogeneous solution; the carrier metal oxide having a first crystal lattice structure comprising first oxygen lattice sites and first metal lattice sites, the carrier metal oxide on the first oxygen lattice sites being doped with at least one of fluorine or at least one element from the group comprising nitrogen, carbon, or boron; the catalyst material having a second crystal lattice structure comprising second oxygen lattice sites and second metal lattice sites, wherein the catalyst material on the second oxygen lattice sites is doped with fluorine and at least one element from the group comprising nitrogen, carbon, or boron; and the carrier metal oxide and the catalyst material differing in a composition thereof, a near-surface pH, called pzzp value (pzzp=point of zero zeta potential), of the carrier metal oxide and the catalyst material differ, and the catalyst material and the carrier metal oxide at least forming a two-phase disperse oxide composite.
2. The catalyst system according to claim 1, wherein the carrier metal oxide and the catalyst material differ in a surface energy thereof, wherein a first phase of the at least two-phase disperse oxide composite has a more hydrophobic surface than a further surface of at least one further phase.
3. The catalyst system according to claim 2, wherein the surface energy of the more hydrophobic surface of the first phase is <30 Nm/mm.sup.2.
4. The catalyst system according to claim 2, wherein a surface energy of the further surface of the at least one further phase is greater than 35 Nm/mm.sup.2.
5. The catalyst system according to claim 1, wherein the first metallic elements are formed by at least two metals from the group consisting of tin, tantalum, niobium, titanium, hafnium, and zirconium.
6. The catalyst system according to claim 5, wherein the first metallic elements are formed by tin and by at least one metal from the group consisting of tantalum, niobium, titanium, hafnium, and zirconium.
7. The catalyst system according to claim 1, wherein the at least one second metallic element is formed by at least one metal from the group comprising tantalum, niobium, hafnium, zirconium, iron, tungsten, and molybdenum.
8. The catalyst system according to claim 1, wherein the catalyst material has a structure comprising oxide grains with a grain size in a range from 1 nm to 50 nm.
9. The catalyst system according to claim 1, wherein the carrier metal oxide is doped on the first metal lattice sites with at least one element from the group comprising iridium and ruthenium.
10. The catalyst system according to claim 1, wherein the pzzp value of the catalyst material is lower than the pzzp value of the carrier metal oxide.
11. The catalyst system according to claim 1, further comprising platinum applied to a surface of the catalyst system in an amount of at most 0.1 mg/cm.sup.2.
12. An electrode comprising a catalyst system (9) according to claim 1.
13. The electrode according to claim 12, further comprising platinum applied to a free surface of the electrode in an amount of at most 0.2 mg/cm.sup.2.
14. A fuel cell or electrolyzer, comprising at least one electrode according to claim 12 and at least one polymer electrolyte membrane.
15. The fuel cell or electrolyzer according to claim 14, wherein the electrode includes an ionomer, and the polymer electrolyte membrane and the ionomer contained in the electrode are formed from identical materials.
16. The catalyst system according to claim 1, wherein the carrier metal oxide on the first oxygen lattice sites is additionally doped with hydrogen.
17. The catalyst system according to claim 1, wherein the catalyst material on the second oxygen lattice sites is additionally doped with hydrogen.
18. The catalyst system according to claim 3, wherein the surface energy of the more hydrophobic surface of the first phase is in a range from 22 to 28 Nm/mm.sup.2.
19. The fuel cell of claim 14, wherein the fuel cell is oxygen-hydrogen fuel cell.
20. A catalyst system comprising: an electrically conductive carrier metal oxide having an electrical conductivity λ.sub.1 of at least 10 S/cm, the carrier metal oxide having at least two first metallic elements selected from the group of non-precious metals and having a structure comprising oxide grains; an electrically conductive, metal oxide catalyst material having an electrical conductivity λ.sub.2 of at least 10 S/cm, the catalyst material having at least one second metallic element from the group of non-precious metals, the at least two first metallic elements in the carrier metal oxide and the at least one second metallic element in the catalyst material each being present in a solid stoichiometric compound or solid homogeneous solution; the carrier metal oxide having a first crystal lattice structure comprising first oxygen lattice sites and first metal lattice sites, the carrier metal oxide on the first oxygen lattice sites being doped with at least one of fluorine or at least one element from the group comprising nitrogen, carbon, or boron; the catalyst material having a second crystal lattice structure comprising second oxygen lattice sites and second metal lattice sites, wherein the catalyst material on the second oxygen lattice sites is doped with fluorine and at least one element from the group comprising nitrogen, carbon, or boron; and the carrier metal oxide and the catalyst material differing in a composition thereof, such that a near-surface pH, called pzzp value (pzzp=point of zero zeta potential), of the carrier metal oxide and the catalyst material differ, and the catalyst material and the carrier metal oxide at least forming a two-phase disperse oxide composite.
Description
BRIEF DESCRIPTION FO THE DRAWINGS
[0043]
[0044] In the figures:
[0045]
[0046]
[0047]
[0048]
[0049]
[0050]
DETAILED DESCRIPTION
[0051]
[0052]
[0053]
[0054]
[0055] In the following, a catalyst system 9 is presented using the example of the quasi-binary oxide phase diagram Ta.sub.2O.sub.5—SnO.sub.2.
[0056]
[0057] The activity profile of the two oxides at 1500° C. in the respective mixed phases is as shown in
[0058] The increase in electrical conductivity rises steadily with the concentration of the solution up to the aforementioned phase boundary and then decreases again. When the solubility limit according to the phase diagram shown in
[0059] The electrically highly conductive tin dioxide phase Sn.sub.0.99Ta.sub.0.01O.sub.2 forms the carrier metal oxide and the thoreaulite phase SnTa.sub.2O.sub.7 forms the catalyst material which is finely dispersed in the grain of the carrier metal oxide. The precipitation conditions are determined on the one hand by the grain size produced and on the other hand by the temperature-time diagram for setting the structure. By varying the composition, the proportions of the two phases of the oxide composite are changed.
[0060] However, the chemical activities of the first and second metallic elements in the oxides remain unchanged in the two-phase region, as do the respective basic electrical and chemical-physical properties. For catalysis, the triple phase boundary lengths as well as the energetic surface states of the carrier metal oxide can be set via the quantity and size ratios. Since the two phases, i.e., the carrier metal oxide and the catalyst material, are present in crystallographic structures that differ from one another, they are inherently dissolved with one another, i.e., the catalyst material is present as inherently dissolved dispersoids in the carrier metal oxide.
[0061] With RDE investigations (RDE=ring disc electrode) it was found that both the tantalum-rich β phase and the thoreaulite phase SnTa.sub.2O.sub.7 have a comparatively good catalytic activity for oxygen reduction. This was verified with experiments in which the catalyst system was treated with a solution containing 2-[1-[difluoro[(trifluoroethenyl)oxy]methyl]-1,2,2,2-tetrafluoroethoxy]-1,1,2,2-tetrafluoroethanesulfonic acid as a polymer electrolyte material or ionomer, also known under the trade names Nation or Flemion, was applied to a carbon substrate (glassy carbon) to form an electrode. The onset voltages U were in the range of those for platinum. However, the specific currents i found were low: i<0.1 A/cm.sup.2 at U=0.65 V.
[0062] In the next step, the individual phases were eliminated from the two-substance mixture. As stated above, the carrier metal oxide used was SnO.sub.2 with about 1 mol % Ta.sub.2O.sub.5, wherein the mass fraction of this phase was in the range from 70 to 95% by weight.
[0063] Table 1 below shows the results of the catalyst systems of this type. The results were determined by means of a single cell consisting of two end plates, two graphite plates, two bipolar plates 2, 2′ made of graphite, two gas diffusion layers 6, 6′, the electrode 1 (cathode side) according to the invention, a standard Pt/C catalyst (anode side) and a polymer electrolyte membrane 7 made from Nation. The process gases, here air and hydrogen, were humidified differently on the cathode side and the anode side.
[0064] The electrode 1 had an electrode area of 30 mm×30 mm. The cell was operated at T=85° C. with p=2.5 bar. The settings used were λ=1.5 on the hydrogen side and λ=2 on the air side. A reference humidification temperature T.sub.B was set at 80° C.
[0065] The prepared coating thicknesses of the electrode 1 were in the range of from 1 to 5 μm.
TABLE-US-00001 TABLE 1 Ratio of carrier (metal Grain size of Onset oxide)/catalyst Carrier (metal the carrier I (A/cm.sup.2) & voltage material in oxide)/catalyst metal oxide 0.7 V in V wt. % material in nm (T = 85° C.) NHE 80/20 C/Pt 2-4 1.1 0.95 50/7 SnO.sub.2—1%Ta.sub.2O.sub.5/Ta.sub.2O.sub.5—dop. 100-125 0.65 1.05 35/15 SnO.sub.2—1%Ta.sub.2O.sub.5/Ta.sub.2O.sub.5—dop. 100-125 0.75 1.1 35/15 SnO.sub.2—1%Ta.sub.2O.sub.5/Ta.sub.2O.sub.5—dop.0.1%Pt 100-125 1.4 1.1 50/7 SnO.sub.2—2.5%Nb.sub.2O.sub.5/Ta.sub.2O.sub.5—dop. 80-100 0.5 1.15 35/15 SnO.sub.2—2.5%Nb.sub.2O.sub.5/Ta.sub.2O.sub.5—dop. 80-100 0.8 1.2 35/15 SnO.sub.2—2.5%Nb.sub.2O.sub.5/Ta.sub.2O.sub.5—dop.—0.1%Pt 100-125 1.35 1.2 30/10 SnO.sub.2—2.5%Nb.sub.2O.sub.5/(Ti90Nb10)O.sub.2—0.1%Pt 80-100 0.95 0.85
[0066] According to Table 1, the current densities for catalyst systems according to the disclosure are 5-8 times higher than in experiments in which individual oxidic phases were deposited on a carbon substrate. The results in Table 1 impressively show that it is possible to produce platinum-free or significantly platinum-reduced and carbon-free electrodes with similarly good activities as in the conventional system of “platinum on carbon carriers”.
[0067] The Triple Phase Boundary (TPB) length, the nanodisperse precipitated electrocatalytically active thoreaulite phase (=catalyst material), as well as the size of the individual grains in the microstructure can be optimized via the precipitation conditions from the Sn—Ta—O system. In this way, the electrolytic activity of the catalyst system for oxygen reduction can also be optimized.
[0068] The conductivity of the tin oxide, in which the tantalum oxide is dissolved up to the maximum limit solubility (approx. 1.1 mol %), depends heavily on the sintering temperature. It is important to ensure that the oxygen partial pressure above the powder is always high enough that the fully oxidized compounds are established. Otherwise, post-oxidation during cell operation and loss of activity can be expected. It is currently unclear whether the thoreaulite phase or the tantalum-rich β phase actually occurs under the oxidative test conditions chosen. According to the test results, this is not decisive for the effectiveness of the catalyst system.
[0069] Furthermore, a sintering temperature must be set so high that later grain agglomeration is not to be expected and, on the other hand, the catalyst system is sufficiently stable even for use at lower temperatures. This risk would exist if the mutual solubilities in the α and β phases were to change significantly. This is why the temperature program was chosen in such a way that initially sintering was carried out at higher temperatures of up to T=900° C. and the grain was adapted as closely as possible to the conditions in cell operation in the cooling program. Accordingly, a holding phase at T=250° C. over a period of 60 minutes is preferably set in the cooling program.
[0070] Embodiments of the catalyst system according to the disclosure are presented below. For this purpose, the powders were fluorinated with a nitrogen treatment and/or a carbon treatment (in particular with C.sub.2H.sub.2) and/or with the aid of CF.sub.4. Exceptionally good results were already achieved with the samples treated with carbon or nitrogen. On the one hand, the onset voltage for oxygen reduction was positively shifted by approx. 50-100 mV compared to the Pt/C platinum standard and the area-specific current densities are comparable to platinum catalysts or higher.
TABLE-US-00002 TABLE 2 D.sub.50, d.sub.50 = mean particle size in nm; a = surface energy in mN/m; I (A/cm.sup.2) measured with RDE at 2400 rpm and at 600 mV vs. NHE; x = 0 to 0.3; y = 0 to 0.2; w = 0.01 to 0.1 Ratio of Grain Grain Surface carrier (metal size of size of treatment of I (A/cm.sup.2) Onset oxide)/catalyst carrier catalyst carrier (metal & 0.7 V voltage OT/K Catalyst material in (metal oxide) material oxide)/catalyst with T = in V in system wt. % Carrier (metal oxide)/catalyst material D.sub.50 in nm d.sub.50 in nm material 85° C. NHE (mN/m) 1 50/10 SnO.sub.2—1%Ta.sub.2O.sub.5−xFx/Ta.sub.2O.sub.4.8N.sub.0.19F.sub.0.01 100-125 3-5 Fluorinated/ 0.75 1.08 25-28 nitrided & fluorinated 2 35/14 SnO.sub.2—1%Ta.sub.2O.sub.5−xN.sub.yF.sub.xy/Ta.sub.2O.sub.4.9C.sub.0.09F.sub.0.01 100-125 3-5 Nitrided & 0.8 1.03 22-25 fluorinated/ carburized & fluorinated 3 35/15 SnO.sub.2—1%Ta.sub.2O.sub.5−xC.sub.yF.sub.xy/Ta.sub.2O.sub.5−xyN.sub.xF.sub.y 100-125 3-5 Carburized & 0.73 1.12 22-25 fluorinated/ nitrided & fluorinated 4 50/7 SnO.sub.2—1%Ta.sub.2O.sub.5−xF.sub.x/Ta.sub.2O.sub.5−xyC.sub.xF.sub.y 100-125 3-5 Fluorinated/ 1.4 1.11 25-28 coated with 0.1% Pt carburized & fluorinated 5 35/15 (Ti, Zr)O.sub.2−xN.sub.yF.sub.xy/Ta.sub.2O.sub.4C.sub.0.9F.sub.0.1—1%SnO.sub.2 50-70 3-10 Nitrided & 0.4 0.8 25-28 fluorinated/ carburized & fluorinated 6 80/20 C/Pt — 2-5 Hydrophobized 1.1 0.95 — 7 65/35 Ti.sub.2ZrO.sub.6−xN.sub.x/(Ti, Nb)O.sub.2−xC.sub.x 75-90 3-5 Nitrided/ 0.9 0.85 45 coated with 0.1% Pt carburized 8 65/35 Ti.sub.2ZrO.sub.6−xN.sub.xF.sub.y/(Ti.sub.90Nb.sub.10)O.sub.2−xC.sub.x 75-90 3-5 Nitrided & 0.98 0.98 22-28 coated with 0.1% Pt fluorinated/ carburized 9 65/35 SnO.sub.2—1%Ta.sub.2O.sub.5−xFx/Ta.sub.2−wW.sub.wO.sub.4.8N.sub.0.19F.sub.0.01 100-125 3-5 Fluorinated/ 0.9 1.08 24-28 nitrided & fluorinated 10 65/35 SnO.sub.2—1%Ta.sub.2O.sub.5−xF.sub.x/Ta.sub.2−wM.sub.owO.sub.4.8N.sub.0.19F.sub.0.01 100-125 3-5 Fluorinated/ 0.9 1.08 24-28 coated with 0.05% Pt nitrided & fluorinated
[0071] Before the samples were actually measured in small cells, they were each subjected to a CV stress test, namely a repeated exposure between −100 mV to 2000 mV vs. NHE. With these “rapid examinations”, on the one hand, the hydrogen sensitivity thereof and the oxidation resistance thereof can be reliably determined. It was found that the samples without CF.sub.4 treatment increasingly passivate during operation. The samples with CF.sub.4 treatment (compare Tab. 2) remained stable even after more than 50 repeated cycles under the rigid conditions.
[0072] Furthermore, a study was made of how further deposition of nanodisperse platinum particles affects the electrocatalytic effectiveness of the catalyst system. The platinum was deposited on the surface of the catalyst system no. 4 according to Table 2 by means of sputtering technology with an area coverage of <0.1 mg/cm.sup.2. In the case of this catalyst system no. 4 with platinum, surprisingly high activities for oxygen reduction were found.
[0073] Overall, it can be stated that surprisingly high activities for oxygen reduction are found in the embodiments according to the disclosure of the catalyst system according to Table 2 both without platinum and with platinum. Using extremely loaded electrochemical investigations with CV measurements up to anodic potentials of 2000 mV NHE in sulfuric acid solution at pH=3 and T=85° C., it was also possible to demonstrate the high oxidation stability in 30-fold repeated cycles. It could even be shown that even up to 3000 mV NHE, especially in the phases rich in thoreaulite or β phase, the samples show very good resistance to passivation and dissolution. The samples additionally loaded with platinum (see Tab. 1 and Tab. 2) changed with the cycles, however, towards lower specific currents.
[0074] Similar results were achieved with the same type of niobium-containing tin oxide composites. Niobium oxide has a slightly higher solubility in tin oxide than tantalum oxide. The limit solubility for niobium oxide is 2.5 at. %. With niobium oxide, stable stoichiometric phases SnNb.sub.2O.sub.7 (“froodite”) similar to the thoreaulite phase are formed. The activities measured are lower than with the tantalum-based catalyst systems, which can be explained by, among other things, the different pzzp values set. However, it should be noted at this point that the activities depend very heavily on the manufacturing conditions.
[0075] The use of the catalyst system according to the disclosure for future fuel cells brings with it considerable advantages, both economically and in terms of long-term stability and increased catalytic activity.
[0076] The temperature treatment of the catalyst system has a great influence in several respects on the desired results with regard to the activity and electrical conductivity of the catalyst system. On the one hand, the density of the carrier metal oxide, for example the stoichiometric tin oxide, is set by means of the temperature treatment, taking into account the decomposition pressure of the compound at sintering temperatures above 950° C. On the other hand, the temperature treatment determines the precipitation conditions of the dispersoids, i.e., the catalyst material. For example, if the oxide is treated appropriately, pure Ta.sub.2O.sub.5 is precipitated at the grain boundaries of the tin oxide. It follows from this that the temperature treatment, as described above, must take place in such a way that the phases that are stable for fuel cell operation are established. For example, the SnO.sub.2— Ta.sub.2O.sub.5 carrier material is produced in such a way that the starting materials are intimately mixed in the desired ratio in a ball mill and tempered at a temperature in the range of 700-800° C. under oxygen for a period of t.sub.1=30 min. It is then cooled to a temperature of 250° C. and this temperature is maintained for a period of time t.sub.2=1 h. Finally, the catalyst system is cooled to room temperature.
LIST OF REFERENCE SYMBOLS
[0077] 1, 1′ Electrode (cathode side) [0078] 2, 2′ Bipolar plate [0079] 2a, 2a′ Carrier plate [0080] 3a Inflow region [0081] 3b Outlet region [0082] 4, 4′ Opening [0083] 5 Gas distribution structure [0084] 6, 6′ Gas diffusion layer [0085] 7 Polymer electrolyte membrane [0086] 8 Coating (anode side) [0087] 9 Catalyst system [0088] 10 Fuel cell [0089] 100 Fuel cell system