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.