Optimization of catalyst preparation conditions for direct sodium borohydride fuel cell using response surface methodology

•RSM was used to determine the optimum catalyst preparation parameters.•Nonlinear quadratic equation in terms of independent parameters was obtained.•ANOVA results of the quadratic model were presented.•Optimum maximum power density and minimum hydrogen production rate were obtained.

The aim of this work is to determine the optimum operating conditions for the process of preparing anode electrocatalysts for direct sodium borohydride fuel cell (DSBHFC). Pt–Au/C electrocatalysts were studied as the anode catalysts while Pt/C were chosen as a cathode catalyst. Anode electrocatalysts were produced by the precipitation method. In this work, pH, temperature, drying time and Pt/Au ratio were selected as independent process parameters and their effects on dependent parameters, such as power density and hydrogen production rate, were investigated using response surface methodology (RSM). Based on this methodology, it was found that the maximum power density and the minimum hydrogen production rate were 354.4 mW cm−2 and 30 ml min−1 respectively. These findings were obtained at 90 °C, 9.27 pH, 61.07 h of drying time, and 93.54% Au ratio to total metal ratio.