Ultra low loading of anode catalyst for direct methanol fuel cells with ZrO2/ pyrolysed (PANI-melamine) as catalyst support

• Pyrolysed PANI-melamine on ZrO2 as catalyst support for DMFC using electrodeposition method for the first time.
• Enhancement of catalyst utilization is observed due to increasing in surface area of catalyst and catalyst support.
• An ultra-low loading of 79 µg cm−2 anode catalyst is observed with the fuel cell performance of 68 mW cm−2.

A new electrochemical methodology is developed for coating ultra-low PtRu catalyst by depositing ZrO2/PANI/Melamine as a strong catalyst support for the electrode. Electrodeposition of PtRu alloy on the surface of pyrolysed ZrO2/PANI/ Melamine enhances the catalyst utilization (Pt: 78.4 µg/cm2, Ru: 0.57 µg/cm2) in the methanol fuel cell. Pyrolysis of PANI and melamine on ZrO2 forms high porous graphene like structure which is identified by XRD/SEM/TEM. The surface composition and chemical oxidation states of Pt, Ru, Zr, C, N, and O are examined by XPS spectra. The DMFC performance has reached a peak power density of 68 mW/cm2 in 5 M methanol concentration at 100 °C with ultra-low catalyst loading in the anode. Comparing with commercial catalyst, 98% of PtRu usage has been reduced in this method which is first of kind ever reported.