Effective Fuel Cell Electrocatalyst with Ultralow Pd Loading on Ni-N-Doped Graphene from Upcycled Water Bottle Waste

Environmental pollution due to the excessive consumption of fossil fuels for energy production is a critical global issue. Fuel cells convert chemical energy directly into electricity in a clean and silent electrochemical process, but face challenges related to hydrogen storage, handling, and transportation. The direct borohydride fuel cell (DBFC), utilizing sodium borohydride as a liquid fuel, is a promising alternative to overcome such issues but requires the design of cost-effective nanostructured electrocatalysts. In this study, we synthesized nitrogen-doped graphene anchoring Ni nanoparticles (Ni@NG) by thermal degradation of polyethylene terephthalate bottle waste with urea and metallic Ni, and evaluated it as a sustainable carbon support. Electrocatalysts were prepared by incorporating ultralow amounts (0.09 to 0.27 wt.%) of Pd into the Ni@NG support. The resulting PdNi@NG electrocatalysts were characterized using ICP-OES, XPS, TEM, N2-sorption analysis, XRD, and Raman and FTIR spectroscopy. Voltammetry assessed the materials’ electrocatalytic activity for oxygen reduction and borohydride oxidation reactions in alkaline media, corresponding to the anodic and cathodic reactions in DBFCs. The electrocatalyst with 0.27 wt.% Pd loading (PdNi_15@NG) exhibited the best performance for both reactions. Consequently, it was employed as an anodic and cathodic material in a lab-scale DBFC, achieving a specific power of 3.46 kW gPd−1.