In Situ Exsolved Metal Nanoparticles: A Smart Approach for Optimization of Catalysts

Because of the generally lower activation energy associated with proton conduction in oxides compared to oxygen ion conduction, protonic ceramic fuel cells (PCFCs) should be able to operate at lower temperatures than solid oxide fuel cells (250° to 550°C versus ≥600°C) on hydrogen and hydrocarbon fuels if fabrication challenges and suitable cathodes can be developed. We fabricated the complete sandwich structure of PCFCs directly from raw precursor oxides with only one moderate-temperature processing step through the use of sintering agents such as copper oxide. We also developed a proton-, oxygen-ion-, and electron-hole-conducting PCFC-compatible cathode material, BaCo(0.4)Fe(0.4)Zr(0.1)Y(0.1)O(3-δ) (BCFZY0.1), that greatly improved oxygen reduction reaction kinetics at intermediate to low temperatures. We demonstrated high performance from five different types of PCFC button cells without degradation after 1400 hours. Power densities as high as 455 milliwatts per square centimeter at 500°C on H2 and 142 milliwatts per square centimeter on CH4 were achieved, and operation was possible even at 350°C.

Surfaces decorated with uniformly dispersed catalytically active nanoparticles play a key role in many fields, including renewable energy and catalysis. Typically, these structures are prepared by deposition techniques, but alternatively they could be made by growing the nanoparticles in situ directly from the (porous) backbone support. Here we demonstrate that growing nano-size phases from perovskites can be controlled through judicious choice of composition, particularly by tuning deviations from the ideal ABO3 stoichiometry. This non-stoichiometry facilitates a change in equilibrium position to make particle exsolution much more dynamic, enabling the preparation of compositionally diverse nanoparticles (that is, metallic, oxides or mixtures) and seems to afford unprecedented control over particle size, distribution and surface anchorage. The phenomenon is also shown to be influenced strongly by surface reorganization characteristics. The concept exemplified here may serve in the design and development of more sophisticated oxide materials with advanced functionality across a range of possible domains of application.