Integrating PGM-Free Catalysts into Catalyst Layers and Proton Exchange Membrane Fuel Cell Devices

While proton exchange membrane fuel cells (PEMFCs) continue to expand into commercial markets, there is still pressure to decrease cost. One of the largest opportunities to reducing cost is to reduce the amount of platinum-group metal (PGM) catalysts used in the electrodes (particularly the cathode). Over the past decade, exciting advances in the Fe/N/C family of PGM-free oxygen reduction reaction (ORR) catalysts has provided great optimism that not only can PGMs at the cathode be reduced but possibly be completely eliminated. In fact, in September 2017, Ballard Power Systems announced the commercialization of the world's first PEMFC product to utilize a PGM-free catalyst at the cathode (FCgen-micro (non-precious-metal catalyst, NPMC)). However, for these catalysts to be used in more demanding applications, an improved understanding and new design approaches for PGM-free catalyst layers will be required. Herein, some of the latest research on both modeling and experimental studies in the field of PGM-free catalyst layer research are discussed. In addition, a short discussion on Ballard's new NPMC is provided.