Cited by 3Electrocatalysts for Energy ConversionFuel Cells and Related MaterialsCatalytic Processes in Materials Science

Scalable Preparation of Intermetallic PtCo Fuel Cell Catalysts from Commercial Pt/C Catalysts

Open access
Zhang, Le, Tong, Lei, Li, Zi‐Rui, Xu, Xiao‐Chu, Li, Shuai, Ma, Chang‐Song, Song, Tian‐Wei, Shao, Ru‐Yang +2 more·2025·ChemCatChem

Abstract

Abstract Carbon‐supported intermetallic PtCo nanoparticles are among the most promising low‐platinum catalysts for proton exchange membrane fuel cells (PEMFCs). However, achieving the synthesis of this catalyst with high performance in a simple and scalable manner remains a challenge. In this work, we achieve the scalable synthesis of high‐performance intermetallic PtCo/C catalysts from commercially available Pt/C catalysts through the straightforward optimization of synthesis parameters, including the deposition method of Co salts, the annealing atmosphere, and the direction of gas flow during annealing. Under optimized synthesis conditions, we prepared the intermetallic PtCo/C catalysts at a five‐gram scale with an average particle size of 3.9 ± 1.4 nm and a high ordering degree of 50%. With a 0.1 mg Pt cm −2 cathode loading, the resulting catalyst exhibits superior performance in H 2 ‐air PEMFCs showing power densities of 0.34 and 0.96 W cm − 2 at 0.8 and 0.67 V, respectively.

Integrity signals

Registry

Crossref · 10.1002/cctc.202500007

Cites

51 of 51 references verified0 citation errors · 0 not checkable

Statistics

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Claims the paper makes

0 of 19 cited sources checked · 0 supported · 0 flagged

  • Findingown data

    Increasing the synthesis scale from 0.1 to 1 g resulted in a broader particle size distribution.

    “Large particles with diameters exceeding 10 nm were observed in all of these catalysts, which were rarely seen in the previously obtained SR-PtCo/C, suggesting that the increase in synthesis scale from 0.1 to 1 g resulted in a broader particle size distribution.”
    Quote in the paperNot a substantial claim
  • Findingown data

    With a 0.1 mg Pt cm-2 cathode loading, the optimized catalyst exhibits a power density of 0.34 W cm-2 at 0.8 V in H2-air PEMFCs.

    “With a 0.1 mg Pt cm -2 cathode loading, the resulting catalyst exhibits superior performance in H 2 -air PEMFCs showing power densities of 0.34 and 0.96 W cm -2 at 0.8 and 0.67 V, respectively.”
    • Also stated in: § 2.2. Electrochemical Testing · hedged
      “As shown in Figure 6D, Vertical-SR-PtCo/C and SR-PtCo/C exhibited nearly identical power densities at 0.8 V (∼0.34 W cm -2 ) with the power density of Vertical-SR-PtCo/C at 0.67 V (0.96 W cm -2 ) being only slightly lower than that of SR-PtCo/C (1.04 W cm -2 ).”
    Quote in the paperSubstantial claim
  • Findingown data

    Vertical-SR-PtCo/C has a smaller average particle size (3.9 ± 1.4 nm) compared to Horizontal-SR-PtCo/C (5.0 ± 1.8 nm).

    “Further statistical results verified that Vertical-SR-PtCo/C has a smaller average particle size (3.9 ± 1.4 nm) compared to Horizontal-SR-PtCo/C (5.0 ± 1.8 nm) (Figure 4D).”
    Quote in the paperSubstantial claim
  • Findingown data

    Horizontal-SR-PtCo/C prepared at a 5 g scale exhibited lower power densities at both 0.8 V (0.30 W cm-2) and 0.67 V (0.85 W cm-2) compared to Vertical-SR-PtCo/C.

    “It is worth highlighting that Horizontal-SR-PtCo/C also prepared at a 5 g scale exhibited lower power densities at both 0.8 V (0.30 W cm -2 ) and 0.67 V (0.85 W cm -2 ) compared to vertical-SR-PtCo/C.”
    Quote in the paperSubstantial claim
  • Findingown data

    The optimized catalyst has an average particle size of 3.9 ± 1.4 nm.

    “Under optimized synthesis conditions, we prepared the intermetallic PtCo/C catalysts at a five-gram scale with an average particle size of 3.9 ± 1.4 nm and a high ordering degree of 50%.”
    • Also stated in: § 2.1. Synthesis and Characterization of Catalysts · plain
      “Further statistical results verified that Vertical-SR-PtCo/C has a smaller average particle size (3.9 ± 1.4 nm) compared to Horizontal-SR-PtCo/C (5.0 ± 1.8 nm) (Figure 4D).”
    Quote in the paperSubstantial claim
  • May combine two claims. 13
  • Classified as probably not a substantial claim. 6
  • May combine two claims.

    Findingown data

    Vertical-SR-PtCo/C exhibited better H2-air MEA performance than Horizontal-SR-PtCo/C, as evidenced by consistently higher cell voltages across the entire current density range.

    “As shown in Figure 6C, Vertical-SR-PtCo/C exhibited better H 2 -air MEA performance than Horizontal-SR-PtCo/C, as evidenced by its consistently higher cell voltages across the entire current density range.”
    Quote in the paperSubstantial claim
  • May combine two claims.

    Findingown data

    Among the PtCo/C catalysts, SR-PtCo/C exhibited the highest cell voltages across the entire tested current density range, followed by WI-PtCo/C, while FD-PtCo/C showed the lowest cell voltages.

    “Among the PtCo/C catalysts, SR-PtCo/C exhibited the highest cell voltages across the entire tested current density range, followed by WI-PtCo/C, while FD-PtCo/C showed the lowest cell voltages.”
    Quote in the paperSubstantial claim
  • May combine two claims.

    Findingown data

    The ECSA values of SR-PtCo/C, WI-PtCo/C, and FD-PtCo/C were 84.5, 81.0, and 74.3 m2 gPt-1, respectively.

    “The ECSA values of SR-PtCo/C, WI-PtCo/C, and FD-PtCo/C were determined to be 84.5, 81.0, and 74.3 m 2 g Pt -1 , respectively.”
    Quote in the paperSubstantial claim
  • May combine two claims.

    Findingown data

    H2-SR-PtCo/C exhibited a relatively narrow particle size distribution and a smaller average particle size (3.6 ± 1.2 nm) compared to N2-SR-PtCo/C and Ar-SR-PtCo/C.

    “Compared to N 2 -SR-PtCo/C and Ar-SR-PtCo/C, H 2 -SR-PtCo/C exhibited a relatively narrow particle size distribution and a smaller average particle size (3.6 ± 1.2 nm) suggesting that the reductive atmosphere is favorable for achieving better size control.[30]”
    Quote in the paperSubstantial claim
  • May combine two claims.

    Findingown data

    SR-PtCo/C exhibited the highest ordering degree (50%), greater than WI-PtCo/C (35%) and significantly higher than FD-PtCo/C (8%).

    “As shown in Figure 2F, SR-PtCo/C exhibited the highest ordering degree (50%), which was greater than that of WI-PtCo/C (35%) and significantly higher than FD-PtCo/C (8%).”
    Quote in the paperSubstantial claim
  • May combine two claims.

    Premisecitation

    Lowering the annealing temperature helps control particle size but often fails to achieve a high ordering degree.

    “In contrast, lowering the annealing temperature helps control particle size but often fails to achieve a high ordering degree.[3c]”
    Quote in the paperSubstantial claim0 of 1 sources checked
    • cites [3c]

      Couldn’t be matched to a paper in Crossref, so it can’t be checked.

  • May combine two claims.

    Premisecitation

    The ordered structure strengthens the metallic bonds between Pt and Co atoms, enhancing the resistance of Co atoms to leaching in the corrosive cathode environment and thus enhancing the catalyst's durability.

    “More importantly, the ordered structure strengthens the metallic bonds between Pt and Co atoms, enhancing the resistance of Co atoms to leaching in the corrosive cathode environment and thus enhancing the catalyst's durability.[5][6][7][8]”
    Quote in the paperSubstantial claim0 of 3 sources checked
    • cites [5] 5. E. Antolini, Appl. Catal., B 2017, 217, 201-213;

      Couldn’t be matched to a paper in Crossref, so it can’t be checked.

    • cites [6] 6. W. Xiao, W. Lei, M. Gong, H. L. Xin, D. Wang, ACS Catal. 2018, 8, 3237-3256;

      Couldn’t be matched to a paper in Crossref, so it can’t be checked.

    • cites [7] 7. J. Li, S. Sun, Acc. Chem. Res. 2019, 52, 2015-2025;

      Couldn’t be matched to a paper in Crossref, so it can’t be checked.

  • Classified as probably not a substantial claim.

    Premisecitation

    Power densities at 0.8 V and 0.67 V are commonly used in the literature as representative metrics for evaluating low and high current density performance.

    “Power densities at 0.8 V and 0.67 V were selected for comparison, as these are commonly used in the literature as representative metrics for evaluating low and high current density performance.[36]”
    Quote in the paperSubstantial claim0 of 1 sources checked
    • cites [36] 36. X. Han, Y. Zhou, X. Tai, G. Wu, C. Chen, X. Hong, L. Tong, F. Xu, H.-W. Liang, Y. Lin, Nat. Commun. 2024, 15, 7200.

      Couldn’t be matched to a paper in Crossref, so it can’t be checked.

  • Classified as probably not a substantial claim.

    Study design and conductcitation

    The ordering degrees were calculated based on the ratio of the integrated area of the superlattice peaks to the total integrated area of all other diffraction peaks.

    “We further analyzed the differences in ordering degrees among these catalysts, which were calculated based on the ratio of the integrated area of the superlattice peaks to the total integrated area of all other diffraction peaks.[27,28]”
    Quote in the paperSubstantial claim0 of 2 sources checked
    • cites [27] 27. H. Chen, D. Wang, Y. Yu, K. A. Newton, D. A. Muller, H. Abruña, F. J. DiSalvo, J. Am. Chem. Soc. 2012, 134, 18453- 18459.

      Couldn’t be matched to a paper in Crossref, so it can’t be checked.

    • cites [28] 28. T.-W. Song, C. Xu, Z.-T. Sheng, H.-K. Yan, L. Tong, J. Liu, W.-J. Zeng, L.-J. Zuo, P. Yin, M. Zuo, S.-Q. Chu, P. Chen, H.-W. Liang, Nat. Commun. 2022, 13, 6521.

      Couldn’t be matched to a paper in Crossref, so it can’t be checked.

  • Classified as probably not a substantial claim. May combine two claims.

    Premisecitation

    Both alloying and ordering steps need annealing treatments to overcome the kinetic barriers for atomic diffusion and migration.

    “Both steps need annealing treatments to overcome the kinetic barriers for atomic diffusion and migration.[14]”
    Quote in the paperSubstantial claim0 of 1 sources checked
    • cites [14] 14. S. Li, J.-J. Li, C. Xu, L. Zhang, A. Li, T.-W. Song, W. Zhang, L. Tong, H.-W. Liang, ACS Mater. Lett. 2024, 6, 706-712.

      Couldn’t be matched to a paper in Crossref, so it can’t be checked.

  • May combine two claims.

    Interpretationown data

    The deposition method of Co salts and the annealing atmosphere are critical factors for the catalyst's ordering degree and particle size, respectively.

    “We found that the deposition method of Co salts and the annealing atmosphere are critical factors for the catalyst's ordering degree and particle size, respectively.”
    Quote in the paperSubstantial claim
  • May combine two claims.

    Premisecitation

    Raising the annealing temperature can enhance alloying and ordering kinetics and thereby favor affording highly ordered structures but this also promotes particle sintering.

    “Therefore, in principle raising the annealing temperature can enhance alloying and ordering kinetics and thereby favor affording highly ordered structures but this also promotes particle sintering. [15,16]”
    Quote in the paperSubstantial claim0 of 2 sources checked
    • cites [15] 15. L. Zhang, L. Tong, S. Li, C.-S. Ma, K.-Z. Xue, H.-W. Liang, J. Energy Chem. 2025, 101, 1-6.

      Couldn’t be matched to a paper in Crossref, so it can’t be checked.

    • cites [16] 16. X. Li, J. Zhao, D. Su, Small Struct. 2021, 2, 2100011.

      Couldn’t be matched to a paper in Crossref, so it can’t be checked.

  • May combine two claims.

    Interpretationown data

    The performance gain of Vertical-SR-PtCo/C can be attributed to the size effect, as it displayed an almost identical ordering degree compared to Horizontal-SR-PtCo/C, but with a higher ECSA.

    “The performance gain of Vertical-SR-PtCo/C can be also attributed to the size effect, as it displayed an almost identical ordering degree compared to Horizontal-SR-PtCo/C, but with a higher ECSA (Figure S6).”
    Quote in the paperSubstantial claim
  • Classified as probably not a substantial claim.

    Premisecitation

    The ordered atomic arrangement in intermetallic PtCo enhances the lattice strain effect induced by cobalt, further improving ORR activity.

    “The ordered atomic arrangement in intermetallic PtCo enhances the lattice strain effect induced by cobalt, further improving ORR activity.[4]”
    Quote in the paperSubstantial claim0 of 1 sources checked
    • cites [4] 4. H. A. Gasteiger, S. S. Kocha, B. Sompalli, F. T. Wagner, Appl. Catal., B 2005, 56, 9-35.

      Couldn’t be matched to a paper in Crossref, so it can’t be checked.

  • May combine two claims.

    Interpretationown data

    Scaling up the catalyst synthesis often leads to particle overgrowth, an issue that can be mitigated by optimizing the design of tube furnaces to enhance gas flow efficiency through the precursor-packed bed.

    “Moreover, our results indicated that scaling up the catalyst synthesis often leads to particle overgrowth, an issue that can be mitigated by optimizing the design of tube furnaces to enhance gas flow efficiency through the precursor-packed bed.”
    Quote in the paperSubstantial claim
  • Probably not a substantial claim: may not pass S3 (load-bearing).

    Premisecitation

    The formation of the intermetallic structure consists of two sequential steps: alloying and ordering.

    “Specifically, the formation of the inter-metallic structure consists of two sequential steps: alloying and ordering.[12,13]”
    Quote in the paperNot a substantial claim0 of 2 sources checked
    • cites [12] 12. D. Wang, H. L. Xin, R. Hovden, H. Wang, Y. Yu, D. A. Muller, F. J. DiSalvo, H. D. Abruña, Nat. Mater. 2012, 12, 81-87.

      Couldn’t be matched to a paper in Crossref, so it can’t be checked.

    • cites [13] 13. J. Li, S. Sharma, X. Liu, Y.-T. Pan, J. S. Spendelow, M. Chi, Y. Jia, P. Zhang, D. A. Cullen, Z. Xi, H. Lin, Z. Yin, B. Shen, M. Muzzio, C. Yu, Y. S. Kim, A. A. Peterson, K. L. More, H. Zhu, S. Sun, Joule 2019, 3, 124- 135.

      Couldn’t be matched to a paper in Crossref, so it can’t be checked.

  • Probably not a substantial claim: may not pass S3 (load-bearing).

    Study design and conductown data

    The particle size distributions were obtained by measuring the diameters of over 300 particles for each catalyst.

    “We measured the diameters of over 300 particles for each catalyst to obtain the particle size distribution, which was presented as violin plots in Figure 2D.”
    Quote in the paperNot a substantial claim
  • May combine two claims.

    Interpretationcitation

    The power densities of Vertical-SR-PtCo/C at both 0.8 and 0.67 V are comparable to those of the most advanced alloy catalysts reported in the literature, even though these catalysts are typically fabricated at smaller scales.

    “Note that the power densities of Vertical-SR-PtCo/C at both 0.8 and 0.67 V are comparable to those of the most advanced alloy catalysts reported in the literature, even though these catalysts are typically fabricated at smaller scales (Table S2).”
    Quote in the paperSubstantial claim0 of 1 sources checked
    • cites Table S2

      Couldn’t be matched to a paper in Crossref, so it can’t be checked.

    • Rests on an assumption: The literature-reported power densities in Table S2 are comparable to the present measurements despite potential differences in testing conditions.
18 of 18
  • The paper relies on this without support.

    The literature-reported power densities in Table S2 are comparable to the present measurements despite potential differences in testing conditions.

    “Note that the power densities of Vertical-SR-PtCo/C at both 0.8 and 0.67 V are comparable to those of the most advanced alloy catalysts reported in the literature, even though these catalysts are typically fabricated at smaller scales (Table S2).”
  • The paper relies on this without support.

    The single commercial Pt/C catalyst TEC10E30E is representative of commercially available Pt/C catalysts for the scalable synthesis.

    “a commercial Pt/C catalyst from Tanaka Kikinzoku Kogyo with a Pt content of approximately 30 wt% (TEC10E30E, referred to as TKK-Pt/C) was used as the starting material.”
2 of 2

Cites

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Authors
Zhang, L., Tong, L., Li, Z., Xu, X., Li, S., Ma, C., Song, T., Shao, R., Zhang, W., & Liang, H.
Affiliations
  • University of Science and Technology of China (CN)
  • Hefei National Research Center for Physical Sciences at the Microscale Department of Chemistry University of Science and Technology of China Hefei Anhui 230026 China
Corresponding author
  • Tong, Lei
  • Liang, Hai‐Wei
Venue
ChemCatChem
Publisher
Wiley
Published
2025-04-28
Volume
17
Issue
11
ISSN
  • 1867-3880 (ISSN-L)
  • 1867-3899
OpenAlex
W4409074061
Cited by
3
References
51
Citations by year
2026: 3
FWCI
0.42
Type
journal article
Language
en
Open access
Locations
ChemCatChem (publishedVersion)
Funders
  • National Natural Science Foundation of China (22325903, 22221003)
  • University of Science and Technology of China (YD2060002032)
  • Major Science and Technology Projects in Anhui Province (202203a0520013)
Topics
  • Physical Sciences › Energy › Renewable Energy, Sustainability and the Environment › Electrocatalysts for Energy Conversion
  • Physical Sciences › Engineering › Electrical and Electronic Engineering › Fuel Cells and Related Materials
  • Physical Sciences › Materials Science › Materials Chemistry › Catalytic Processes in Materials Science
Keywords
proton exchange membrane fuel cells, low platinum catalysts, scalable catalyst synthesis, annealing atmosphere, gas flow direction

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