A team of researchers from Tianjin University has developed a novel tree-like nitrogen-doped carbon (T-NC) support structure that addresses key challenges in fuel cell technology—cost, performance, and durability. Published in
Front. Energy, this innovation enables low-platinum (Pt) loaded fuel cells to deliver superior efficiency and longer lifespan, bringing the widespread commercialization of hydrogen-powered vehicles one step closer.
A Game-Changer for Low-Platinum Fuel Cells
Fuel cells are hailed as clean, efficient energy converters for the hydrogen economy, but high costs and limited durability have hindered their mass adoption. Platinum, a critical catalyst in fuel cells, accounts for nearly 40% of the total cost of fuel cell systems. Reducing platinum loading while maintaining performance has long been a major technical barrier.
The T-NC support developed by the Tianjin University team offers a clever solution. It combines multi-walled carbon nanotubes (MWCNTs) as a conductive "backbone" with ZIF-8-derived carbon (synthesized from 2-methylimidazole zinc salt) as "branches." This tree-like structure provides abundant attachment sites for platinum group metals (PGMs), creates ordered mass transfer pathways, and enhances corrosion resistance through high graphitization.
Key Performance Leaps
In tests with a cathode platinum loading of just 0.1 mg
Pt/cm², the Pt/T-NC electrode outperformed conventional Pt/C electrodes by significant margins:
- A 12.7% increase in peak power density, reaching 0.93 W/cm².
- A 30% reduction in concentration loss at 2.0 A/cm², a critical improvement for high-power operation.
- A 21.6% decrease in pressure-independent oxygen transport resistance, optimizing reactant delivery.
Even at high platinum loadings (>50 wt.%), the T-NC support maintains uniform dispersion of Pt nanoparticles (around 3.73 nm in size), avoiding particle agglomeration that degrades performance. This versatility makes it compatible with various advanced PGM catalysts.
Durability That Meets Industrial Demands
Durability is another make-or-break factor for fuel cell applications—especially for heavy-duty vehicles, which require over 25,000 hours of stable operation by 2030 (per U.S. Department of Energy targets). The T-NC support’s high graphitization ensures exceptional corrosion resistance.
After 5000 cycles of accelerated durability testing (ADT) simulating carbon corrosion, the Pt/T-NC fuel cell retained 50.8% of its original performance, compared to only 38% for conventional Pt/C fuel cells. The electrochemically active surface area (ECSA) retention of the Pt/T-NC electrode was 2.2 times higher than that of Pt/C after testing, and Pt particle growth was limited to just 6.7% (vs. 14.1% for Pt/C).
How the T-NC Structure Works
The T-NC support is synthesized via a simple, low-energy process:
- MWCNTs are pre-treated to create surface defects and oxygen-containing groups, providing nucleation sites.
- ZIF-8 crystals grow on the MWCNTs to form a core-shell precursor.
- High-temperature calcination evaporates zinc, creating porosity and forming the final tree-like structure with nitrogen coordination.
This design addresses two critical flaws of traditional carbon supports: random, tortuous mass transfer paths and poor corrosion resistance. The ordered architecture facilitates efficient gas and water transport, while nitrogen doping strengthens the bond between Pt particles and the support.
Toward Commercialization of Hydrogen Vehicles
"Our T-NC support bridges the gap between theoretical catalytic activity and practical fuel cell performance," said Kui Jiao, corresponding author of the study and professor at Tianjin University. "It enables low-platinum fuel cells to meet both cost and durability targets for automotive applications, from light-duty cars to heavy-duty trucks."
The T-NC structure is broadly applicable, compatible with existing fuel cell manufacturing processes and scalable with low-cost raw materials. This breakthrough not only advances fuel cell technology but also supports the global transition to low-carbon transportation and renewable energy systems.
DOI:
10.1007/s11708-025-1042-0