This thesis examines using electrophoretic deposition (EPD) to coat 3D graphite felt with cobalt ferrite nanoparticles. The objectives are to improve the kinetically slow anodic reaction in the solar sulfur-ammonia thermochemical cycle for hydrogen production. Experiments include EPD with different suspensions, adhesion testing of deposits, penetration analysis via SEM, and electrochemical studies. Results show EPD fully penetrates the felt and maximum monolayer coverage is achieved. Deposits on 3 mm felt have the highest current density increase compared to the blank substrate.
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M.S.ThesisDefense
1. Electrophoretic Deposition of Cobalt
Ferrite Nanoparticles into 3D Felt
Nicole Shellhammer Pacheco
M.S. Thesis Defense
Chemical Engineering
Committee Members:
Professor Jan B. Talbot, Chair
Professor Joanna M. McKittrick
Professor Justin P. Opatkiewicz
1
3. Hydrogen as a fuel
• Uses of hydrogen
– Burning hydrogen
– Hydrogen fuel cells
• Advantages of hydrogen as a fuel
– Safe
– Environmentally-friendly
– Can replace fossil fuels used in
transportation systems
• Challenge: 86 % of hydrogen is
produced from burning fossil fuels1
Motivation and Objectives
1Steinfeld, A. International Journal of Hydrogen Energy 2002, 27, 611–619.
Image source: http://www.zmescience.com/science/hydrogen-car-fuel-04042013/ 3
4. Objective
• Produce hydrogen from clean
and sustainable method
– Solar sulfur-ammonia (SA)
thermochemical cycle
Goals
• Penetrate and coat nanoparticles
into 3D felt with EPD
• Improve kinetically slow anodic
reaction for SA cycle with EPD
deposits of electrocatalysts
– Determine EPD conditions and
suspension properties
Motivation and Objectives
Image source: http://www.baseofengineering.com/index.php/2015/06/12/engineers-develop-
state-by-state-plan-to-convert-us-to-100-clean-renewable-energy-by-2050/ 4
7. • Advantages of EPD:
– Simple apparatus
– Short deposition time
– Allows various substrate shapes
Background Electrophoretic Deposition
Image source: Siracuse et al. J. Electrochem. Soc., 137 (1990)
Hamaker equation:
m
Et
Electrophoretic mobility:
7
• Bath properties:
• Dielectric constant of liquid ( ), and
viscosity of liquid ( )
• Surface charge of the particle: zeta
potential ( ) measured
• C is concentration and A is
area of EPD deposit
8. • Filling pores
– Silica nanoparticles into porous
anodic aluminum oxide film
• Penetrate and coat 3D material
– EPD deposited nickel oxide film
into 3D porous nickel foam
Background EPD of 3D Substrates
Fori, B.; Taberna, P.; Arurault, L.; Bonino, J. Journal of Colloid and Interface Science 2014, 413, 31–36.
Gonzalez, Z.; Ferrari, B.; Sanchez-Herencia, A.; Caballero, A.; Morales, J.; Hernan, L. In
Electrophoretic Deposition: Fundamentals and Applications V, Oct. 2015.
8
9. • Penetration equation:
– EPD of 10 nm ceramic dielectric particles
between carbon nanotubes on stainless steel
electrode (50 nm diameter, 20 µm length)
– Ratio of Peclet number to Damköhler number
(electrophoretic velocity (v) to local
deposition rate (k))
Background Penetration by EPD
>1000
Bakhoum, E.; Cheng, M. Journal of Applied Physics 2009, 105, 1–6. 9
a = average pore radius, D = diffusion coefficient, gamma = experimental coefficient
10. Objective: Penetrate and coat 3D felt
and enhance anodic reaction rate for
hydrogen subcycle for SA
thermochemical cycle
– Electrophoretic Deposition (EPD)
– Adhesion Tests
– EPD Penetration
– Electrochemical Study
Experiments
10
11. • Baths: 2 g/L cobalt ferrite
nanoparticles in
– 100 % ethanol (E)
– 100 % acetylacetone with 0.2 wt. %
polyethylenimine (AA-PEI)
– 90/10 % water/isopropanol (IPA)
with 0.05 mM or 1 mM CTAB
(hexadecyltrimethlyammonium
bromide)
Experiments Electrophoretic Deposition (EPD)
11
Desired: Positive zeta
potential > 25 mV
Image: Zi et al., Journal of Magnetism and Magnetic Materials, 321(2009)1251–1255
12. • Substrates:
– 3.14 cm2 of aluminum foil and
graphite paper
– 1 cm2 of 3 mm carbon, 6 mm
graphite felt
• E bath EPD conditions:
– 20 V - 63 V for 1 or 2 min
• AA-PEI bath EPD conditions:
– 60 V - 128 V for 1-13 min
Experiments Electrophoretic Deposition (EPD)
12
13. • Dry adhesion
– Important for removing and drying deposit from
bath
– Tape test: place on film and remove scotch tape
• Wet adhesion
– Important for electrochemical tests of deposits
– Soak test: 24 hour soak of deposits in de-ionized
water
Experiments Adhesion Tests
13
Adhesion of EPD deposits from ethanol bath on
aluminum foil (weight of sample before & after test)
14. • Penetration calculation into porous carbon
– Ratio values based on EPD conditions and suspension properties
– Ratio > 1000 means deep penetration can occur into felt
• Phillips XL30 ESEM scanning electron microscope
(SEM) imaging of EPD deposits (Neil Verma)
– Image analysis of top and middle of the 3D felt deposits
Experiments EPD Penetration
Image source: http://sirius.mtm.kuleuven.be/Research/Equipment/fiches/xl30-esem-feg.html
14
15. • Linear sweep voltammetry of EPD deposits
– Oxidation of 2 M ammonium sulfite to ammonium sulfate
– Deposits soaked in 2 M ammonium sulfite before (24 or 72 hr)
– Princeton Applied Research VersaSTAT 3 potentiostat
• Scanned from 0.0 to 1.0 V vs. standard calomel electrode (SCE)
• Sweep rate of 50 mV/s
• Standard three-compartment electrode cell
Experiments Electrochemical Study
15
Image source: http://electronicstructure.wikidot.com/oxygen-reduction-reaction-
on-platinum-using-dft
8 cm2 graphite cloth
1 cm2 deposit on 3 mm or 6 mm felt
Standard calomel
electrode (SCE)
16. • Calculation of monolayer deposit density: 10.2 μg/cm2
– Assume hexagonal close packing (91 % area filled)
– 20 nm cobalt ferrite particles into 4.91 cm2 area
• EPD from ethanol bath: 5 V for 55 s on aluminum foil
Results Electrophoretic Deposition (EPD)
0
2.5
5
7.5
10
12.5
15
0 10 20 30 40 50 60
DepositDensity(µg/cm2)
Time (s)
1 monolayer
16
500 nm
17. • Dry adhesion test (Tape test)
– 0 to 25 % of the particles were removed
– Error: ± 0.01 mg
• Wet adhesion test (24 hour soak test)
– No particles were removed
Results Adhesion Tests
17
18. • EPD on graphite paper (GP) follows Hamaker equation
• 3 mm and 6 mm felt may have adsorption of nanoparticles
with no electric field (not verified experimentally)
• Deposit density greater for 6mm > 3mm > GP
Results EPD from Ethanol bath
0.00
0.20
0.40
0.60
0.80
1.00
1.20
1.40
0 10 20 30 40 50 60 70
DepsoitDensity(mg/cm2)
Voltage*Time (V*min)
GP
3 mm felt
6 mm felt
Slope ratios:
3 mm to GP: 1.3
6 mm to GP: 1.7
6 mm to 3 mm: 1.4
18
19. EPD follows Hamaker equation
Deposit density greater for Al, GP > 6mm > 3mm
Results EPD from AA-PEI bath
Slope ratios:
Al to 3 mm: 5.6
GP to 3 mm: 5.6
Al to 6 mm: 2.2
GP to 6 mm: 2.2
6 mm to 3 mm: 2.6
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
0 500 1000 1500 2000
Depsoitdensity(mg/cm2)
Voltage*Time (V*min)
Al
GP
3 mm felt
6 mm felt
19
20. • Electrophoretic velocity to local deposition rate into 6 mm
felt:
– EPD conditions: E, 40 V, 1 min (41 mA, 1.17 mg)
– EPD conditions: AA-PEI, 127 V, 4 min (6 mA, 0.79 mg)
Results EPD Penetration
20Bakhoum, E.; Cheng, M. Journal of Applied Physics 2009, 105, 1–6.
= 8 x 104 >1000
Deep penetration of 3D felt up to 6 mm thick should occur
= 5 x 106 >1000
>1000
22. 3 mm carbon felt
EPD deposit conditions: E, 40 V, 1 min, (42 mA, 0.68 mg)
Top of the deposit Middle of the deposit
Results EPD Penetration
22
23. 6 mm graphite felt
EPD deposit conditions: E, 40 V, 1 min (41 mA, 1.17 mg)
Top of the deposit Middle of the deposit
Results EPD Penetration
23
24. • Deposit weight and number of monolayers
– E and AA-PEI bath
• Maximum monolayers: 27 on graphite paper, 1 on 3 mm felt
• Maximum surface coverage of 6 mm felt: ~31 %
Results Comparison of EPD baths
24
25. • Linear sweep voltammetry (LSV) from 0 to 1.0 V vs. SCE
with scan rate of 50 mV/s in 2 M ammonium sulfite
– As reaction increases, i proportional exp(V)
– Deposit from ethanol bath into 6 mm graphite felt
– EPD conditions: 40 V, 1 min, (41 mA, 1.17 mg)
Results Electrochemical Study
25
i
iblank
26. • Extrapolated current density of platinum electrode at 0.8 V
vs. NHE for 50 mV/s in 2 M ammonium sulfite solution1
imax = 190 mA/cm2
Results Electrochemical Study
261Skavas, E.; Hemmingsen, T. Electrochimica Acta 2007, 52, 3510–3517.
• EPD conditions into 6 mm felt with highest electrochemical activity
• AA-PEI bath: 127 V for 4 min
• E bath: 40 V for 1 min
27. EPD Deposits from Ethanol bath
• Ratio current density of deposit compared to blank
substrate vs. deposit density
– i/iblank for graphite paper and 6 mm felt is ~1.6
– i/iblank for 3 mm felt ranges between 4-8
Results Electrochemical
0
1
2
3
4
5
6
7
8
9
0.00 0.20 0.40 0.60 0.80 1.00 1.20 1.40
i/iblank
Deposit Density (mg/cm2)
GP
3 mm felt
6 mm felt
27
28. EPD deposits from AA-PEI bath
• Ratio current density of deposit compared to blank
substrate vs. deposit density
– i/iblank for aluminum foil, graphite paper and 6 mm felt is ~1.9
– i/iblank for 3 mm felt ranges between 9-14
Results Electrochemical
28
0
2
4
6
8
10
12
14
16
0.0 1.0 2.0 3.0 4.0 5.0
i/iblank
Deposit density (mg/cm2)
Al
GP
3 mm felt
6 mm felt
29. • Full penetration and coating of 3 mm and 6 mm felt
• Maximum number of monolayers deposited
– Graphite paper: 27
– 3 mm carbon felt: 1
– 6 mm graphite felt: < 1
• Current density of EPD deposit into 6 mm felt compared to
platinum electrode
– 32 % imax from AA-PEI bath (127 V for 4 min)
– 20 % imax from ethanol bath (40 V for 1 min)
• Ratio of current density of deposit to blank substrate
– Highest magnitude for 3 mm carbon felt
Conclusions
29
30. • Wet adhesion on graphite paper, 3 mm, and 6 mm felt
• Determine EPD conditions for 1 monolayer of
particles into 6 mm graphite felt
• Determine how number of monolayers affect
electrochemical activity of EPD deposits (Neil Verma
M.S. thesis)
Future work
30
31. • Professor Jan B. Talbot (UCSD)
• Neil Verma for SEM image analysis (UCSD)
• Dr. Richard Herz (UCSD)
• Dr. Dave Genders and Dr. Peter Symons
(Electrosynthesis Inc.)
• Dr. Lloyd Brown (Thermochemical Solutions LLC.)
• Roger Davenport and Robin Taylor (Leidos)
This work was funded by the Department of Energy,
Grant DE-FG36-07GO17002.
Acknowledgements
31
EPD is a method that deposits suspended particles in a liquid medium under an applied electric field into a substrate
Zeta potential measures the potential difference of the diffusion layer, which is between the shear plane and the surrounding liquid
Vacuum permittivity constant
Peclet # study of transport through a medium expressed as the rate of advection by the rate of diffusion
The Damköhler number is defined as the reaction rate by the diffusive mass transfer rate
a is average pore radius, D is diffusion coefficient
Slope ratio: rate of deposition
Driving force (voltage), rate of reaction I proportional exp(V)