High-Efficiency Synthesis of High-Index Facet Nanocatalysts for Fuel Cell Applications

NU 2018-121

INVENTORS

Chad Mirkin*
Haixin Lin
Liliang Huang

SHORT DESCRIPTION

For fuel cell applications, this method uses a ligand-free, solid-state synthesis technique to produce high-index facet catalysts with superior activity.

BACKGROUND

Conventional synthesis methods for nanocatalysts face several challenges. Conventional synthesis techniques often yield nanoparticles dominated by less active low-index facets. Additionally, ligand-dependent processes hinder performance by blocking active sites and require extensive post-synthesis cleaning. These limitations lead to higher production costs and reduced catalyst efficiency, presenting a significant gap in current technologies.

ABSTRACT

This invention uses a dealloying-based synthesis approach to form tetrahexahedron-shaped Pt, Pd, and Rh nanoparticles. The process employs trace amounts of shape-regulating elements (Sb, Bi, Pb, Te) in a ligand-free, solid-state thermolysis method. Laboratory studies demonstrate that the synthesized nanocatalysts achieve up to 63 times the activity of standard Pt/C catalysts in formic acid oxidation. The method provides a scalable and rapid route for producing high-performance nanocatalysts, with additional potential for recycling waste catalysts.

MARKET OPPORTUNITY

The global nanocatalyst market was valued at approximately $7.5 billion in 2023 and is anticipated to expand at a compound annual growth rate (CAGR) of 8.9% from 2024 to 2030 (Source: Grand View Research, 2024).

DEVELOPMENT STAGE

TRL-4 - Prototype Validated in Lab: Key functions have been demonstrated using a laboratory-scale prototype under simulated fuel cell conditions.

APPLICATIONS

Nanocatalyst design for fuel cells: Produces high-index facet nanoparticles for enhanced electrocatalysis.
Waste catalyst recycling: Transforms irregular waste catalysts into high-activity tetrahexahedral forms.
Electrocatalysis: Improves formic acid oxidation reactions in fuel cell systems.
Catalyst performance optimization: Enhances activity for Pt, Pd, and Rh-based catalysts in industrial applications.

ADVANTAGES

One-step process: Simplifies production with a single, ligand-free synthesis step.
Superior catalytic performance: Achieves up to 63 times higher activity compared to commercial catalysts.
Scalable industrial method: Employs established thermolysis techniques for mass production.
Cost-effective catalyst recycling: Converts waste catalysts into valuable, high-performance nanocatalysts.

PUBLICATIONS