Upcycled Polystyrene-Derived Carbon-Bound Platinum Alloy Catalysts for Enhanced Durability in Fuel Cells

Proton exchange membrane fuel cell (PEMFC) technology demands the development of highly active and durable catalysts while minimizing platinum (Pt) usage to lower costs. In this study, we present a scalable method for synthesizing carbon-bound catalysts by upcycling polystyrene (PS) polymer. Our technique employs solvent-based hyper-crosslinking to create a hierarchically porous structure in a single-step process. The resulting PS-derived carbon support, loaded with Pt, features a mesoporous structure that enhances mass transport within PEMFCs, even at a low Pt loading of 0.05 mg_Pt cm^-2. This catalyst demonstrates exceptional durability, maintaining 92.1% of its initial power density after 30,000 cycles, attributed to its carbon-bound structure and robust catalyst-support interactions. In comparison, commercial Pt/C retains only 35.8% of its power density after the same number of cycles. This method provides a cost-effective and sustainable way to convert PS polymer into durable cathode materials for PEMFCs.