Premium Power (October 1998)

Preparation and Fundamental Evaluation of Catalytic Materials for Energy Applications

Sponsor: Cabot Superior MicroPowders (formerly Superior MicroPowders)

• Project Performance Period: 11/1/1998 - 10/31/2001
• Total project (est.): $3,842,811.00
• Requested ATP funds: $2,000,000.00

Superior MicroPowders (SMP) proposes to develop a novel manufacturing process for producing high-purity, well-characterized electrocatalysts for use in batteries and fuel cells. If successful, their project will remove a major barrier to the development of two potentially important electric power technologies: metal/air batteries and proton exchange membrane (PEM) fuel cells. Rechargeable zinc/air batteries could threaten the dominant lithium-ion batteries of foreign competitors for the premium notebook computer and mobile communications markets, but at present they are in limited use. PEM fuel cells also have a limited market now, but with improved cost, power, and life expectancy would appeal widely to homes, businesses, and eventually electric vehicle manufacturers. Both the batteries and the cells rely on electrocatalysts that are primarily precious metal/carbon composite powders, but the performance of these catalysts has fallen far short of ideal. This is blamed on the properties of the constituent particles. Performance could be maximized if the uniformity in size (on the order of microns--millionths of a meter), shape, composition, and other characteristics of the particles could be better controlled at these particle sizes. SMP plans to develop a novel processing method, determine the suitability of the resulting powders for battery and fuel-cell applications, and determine how to control the powder properties as manufacturing capacity increases to satisfy demand. This processing method allows control over two features of electrocatalyst powder structure that are critical to their performance: control over the macrostructure --particle size, morphology, and particle-size distribution-- that is expected to enable more advanced deposition methods and electrode architecture; and better control over the microstructure by improved dispersion of the catalyst (typically a precious metal) within each particle to achieve improved electrochemical performance. A small company, SMP does not have the resources to pursue this technology without ATP support. Success, however, would broadly enable other technologies powered by the improved batteries and fuel cells. The advances from a successful project, and even knowledge gained from partial success, would benefit many kinds of batteries and fuel cells and could lead to molecularly engineered powders for other applications.

For project information:

Mark Hampden-Smith, (505) 342-1492
mhs@flash.net

ATP Project Manager

Richard Bartholomew, (301) 975-4786
richard.bartholomew@nist.gov