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High-resolution porous structures of catalyst layers (CLs) including non-precious metal catalysts (NPMCs) or Pt for proton exchange membrane fuel cells are reconstructed using the quartet structure generation set. The nanoscale structures are analyzed in terms of pore size distribution, specific surface area, and phase connectivity. Pore-scale simulation methods based on the lattice Boltzmann method are developed to predict the macroscopic transport properties in CLs. The non-uniform distribution of ionomer in CL generates more tortuous pathways for reactant transport, greatly reducing the effective diffusivity. The tortuosity of CLs is much higher than that adopted by the Bruggeman equation. Knudsen diffusion plays a significant role in oxygen diffusion and significantly reduces the effective diffusivity. Reactive transport inside the CLs is also investigated. Although the reactive surface area of the non-precious …