Efficient catalysis for acidic methanol oxidation: Exploration of a Low-Platinum quaternary alloy catalyst via a Two-Step method

•Two-step synthesis method prepares the quaternary alloy catalyst for enhancing efficiency and reproducibility.•A significant reduction in platinum content to approximately 10% in catalysts without compromising catalytic performance.•PtCoSnCu/N-C catalyst with mass activity and specific activity up to 9.73 and 9.75 times higher than commercial Pt/C.•DFT calculations reveal the optimization of electronic structure and the synergistic effect of atoms on the catalyst surface. The quest for platinum-based catalysts with enhanced catalytic efficacy and durability during the methanol oxidation reaction (MOR) has been a focal point in energy conversion science. Traditional platinum-based catalysts are often constrained by their high platinum content, which escalates economic costs and complicates experimental protocols. In this study, we introduce a low-platinum-loaded catalyst synthesized via a two-step method, which incorporates a four-component alloy. This innovative approach significantly reduces platinum content while maintaining superior catalytic performance through precise control over the alloy’s composition and structure. The two-step synthesis methodology streamlines the conventional multi-step processes, enhancing the catalyst preparation’s efficiency and reproducibility. The resulting PtCoSnCu/N-C alloy catalyst exhibits remarkable catalytic activity in methanol solution, with mass activity and specific activity that are 9.73 and 9.75 times higher, respectively, than those of commercial platinum on carbon (Pt/C) catalysts. Notably, the optimized PtCoSnCu/N-C alloy catalyst demonstrates exceptional long-term stability, outperforming Pt/C in aging and extended stability tests. Density functional theory (DFT) calculations elucidate the optimization of the electronic structure and the synergistic effect of surface atoms in the PtCoSnCu/N-C catalyst, which mitigates the adsorption energy of CO molecules and enhances the utilization rate of active sites during the oxidation process. This research presents a paradigm-shifting low-platinum catalyst strategy for methanol fuel cells, establishing a theoretical foundation for catalyst design and optimization.