Regulation Strategies for Fe-N-C and Co-N-C Catalysts for the Oxygen Reduction Reaction.

Proton exchange membrane fuel cells (PEMFCs) and alkaline membrane fuel cells (AEMFCs) have received great attention as energy devices of the next generation. Accelerating oxygen reduction reaction (ORR) kinetics is the key to improve PEMFC and AEMFC performance. Platinum-based catalysts are the most widely used catalysts for the ORR, but their high price and low abundance limit the commercialization of fuel cells. Non-noble metal-nitrogen-carbon (M-N-C) is considered to be the most likely material class to replace Pt-based catalysts, among which Fe-N-C and Co-N-C have been widely studied due to their excellent intrinsic ORR performance and have made great progress in the past decades. With the improvement of synthesis technology and a deeper understanding of the ORR mechanism, some reported Fe-N-C and Co-N-C catalysts have shown excellent ORR activity close to that of commercial Pt/C catalysts. Inspired by the progress, regulation strategies for Fe-N-C and Co-N-C catalysts are summarized in this Review from 5 perspectives: (1) coordinated atoms, (2) environmental heteroatoms and defects, (3) dual-metal active sites, (4) metal-based particle promoters, and (5) curved carbon layers. We also make suggestions on some challenges facing Fe-N-C and Co-N-C research.

Unveiling Low Temperature Assembly of Dense Fe-N4 Active Sites via Hydrogenation in Advanced Oxygen Reduction Catalysts.

The single-atom Fe-N-C is a prominent material with exceptional reactivity in areas of sustainable energy and catalysis research. It is challenging to obtain the dense Fe-N4 site without the Fe nanoparticles (NPs) sintering during the Fe-N-C synthesis via high-temperature pyrolysis. Thus, a novel approach is devised for the Fe-N-C synthesis at low temperatures. Taking FeCl2 as Fe source, a hydrogen environment can facilitate oxygen removal and dichlorination processes in the synthesis, efficiently favouring Fe-N4 site formation without Fe NPs clustering at as low as 360 °C. We shed light on the reaction mechanism about hydrogen promoting Fe-N4 formation in the synthesis. By adjusting the temperature and duration, the Fe-N4 structural evolution and site density can be precisely tuned to directly influence the catalytic behaviour of the Fe-N-C material. The FeNC-H2-360 catalyst demonstrates a remarkable Fe dispersion (8.3 wt %) and superior acid ORR activity with a half-wave potential of 0.85 V and a peak power density of 1.21 W cm-2 in fuel cell. This method also generally facilitates the synthesis of various high-performance M-N-C materials (M=Fe, Co, Mn, Ni, Zn, Ru) with elevated single-atom loadings.

Instantaneous Free Radical Scavenging by CeO2 Nanoparticles Adjacent to the Fe-N4 Active Sites for Durable Fuel Cells.

To achieve the Fe-N-C materials with both high activity and durability in proton exchange membrane fuel cells, the attack of free radicals on Fe-N4 sites must be overcome. Herein, we report a strategy to effectively eliminate radicals at the source to mitigate the degradation by anchoring CeO2 nanoparticles as radicals scavengers adjacent (Scaad-CeO2 ) to the Fe-N4 sites. Radicals such as ⋅OH and HO2 ⋅ that form at Fe-N4 sites can be instantaneously eliminated by adjacent CeO2 , which shortens the survival time of radicals and the regional space of their damage. As a result, the CeO2 scavengers in Fe-NC/Scaad-CeO2 achieved ∼80 % elimination of the radicals generated at the Fe-N4 sites. A fuel cell prepared with the Fe-NC/Scaad-CeO2 showed a smaller peak power density decay after 30,000 cycles determined with US DOE PGM-relevant AST, increasing the decay of Fe-NCPhen from 69 % to 28 % decay.

Construction of Highly Active Metal-Containing Nanoparticles and FeCo-N4 Composite Sites for the Acidic Oxygen Reduction Reaction.

Metal-containing nanoparticles (M-NPs) in metal/nitrogen-doped carbon (M-N-C) catalysts have been considered hostile to the acidic oxygen reduction reaction (ORR). The relation between M-NPs and the active sites of metal coordinated with nitrogen (MNx ) is hard to establish in acid medium owing to the poor stability of M-NPs. Herein, we develop a strategy to successfully construct a new FeCo-N-C catalyst containing highly active M-NPs and MN4 composite sites (M/FeCo-SAs-N-C). Enhanced catalytic activity and stability of M/FeCo-SAs-N-C is shown experimentally. Calculations reveal that there is a strong interaction between M-NPs and FeN4 sites, which can favor ORR by activating the O-O bond, thus facilitating a direct 4 e- process. Those findings firstly shed light on the highly active M-NPs and FeN4 composite sites for catalyzing acid oxygen reduction reaction, and the relevant reaction mechanism is suggested.

A Fe-NC electrocatalyst boosted by trace bromide ions with high performance in proton exchange membrane fuel cells.

Replacement of expensive and rare platinum with metal-nitrogen-carbon catalysts for oxygen reduction reactions in proton exchange membrane fuel cells is hindered by their inferior activity. Herein, we report a highly active iron-nitrogen-carbon catalyst by optimizing the carbon structure and coordination environments of Fe-N4 sites. A critical high-temperature treatment with ammonium chloride and ammonium bromide not only enhances the intrinsic activity and density of Fe-N4 sites, but also introduces numerous defects, trace Br ions and creates mesopores in the carbon framework. Notably, surface Br ions significantly improve the interaction between the ionomer and catalyst particles, promoting ionomer infiltration and optimizing the O2 transport and charge transfer at triple-phase boundary. This catalyst delivers a high peak power density of 1.86 W cm-2 and 54 mA cm-2 at 0.9 ViR-free in a H2-O2 fuel cells at 80 °C. Our findings highlight the critical role of interface microenvironment regulation.

FeN4 Active Sites Electronically Coupled with PtFe Alloys for Ultralow Pt Loading Hybrid Electrocatalysts in Proton Exchange Membrane Fuel Cells.

The exorbitant cost of Pt-based electrocatalysts and the poor durability of non-noble metal electrocatalysts for proton exchange membrane fuel cells limited their practical application. Here, FeN4 active sites electronically coupled with PtFe alloys (PtFe-FeNC) were successfully prepared by a vapor deposition strategy as an ultralow Pt loading (0.64 wt %) hybrid electrocatalyst. The FeN4 sites on the FeNC matrix are able to effectively anchor the PtFe alloys, thus inhibiting their aggregation during long-life cycling. These PtFe alloys, in turn, can efficiently restrain the leaching of the FeN4 sites from the FeNC matrix. Thus, the PtFe-FeNC demonstrated an improved Pt mass activity of 2.33 A mgPt-1 at 0.9 V toward oxygen reduction reaction, which is 12.9 times higher than that of commercial Pt/C (0.18 A mgPt-1). It demonstrated great stability, with the Pt mass activity decreasing by only 9.4% after 70,000 cycles. Importantly, the fuel cell with an ultralow Pt loading in the cathode (0.012 mgPt cm-2) displays a high Pt mass activity of 1.75 A mgPt-1 at 0.9 ViR-free, which is significantly better than commercial MEA (0.25 A mgPt-1). Interestingly, PtFe-FeNC catalysts possess enhanced durability, exhibiting a 12.5% decrease in peak power density compared to the 51.7% decrease of FeNC.

Strong Electronic Metal-Support Interactions Enable the Increased Spin State of Co-N4 Active Sites and Performance for Acidic Oxygen Reduction Reaction.

Nonprecious metal catalysts, particularly M-N-C catalysts, are widely recognized as promising contenders for the oxygen reduction reaction (ORR). However, a notable performance gap persists between M-N-C catalysts and Pt-based catalysts under acidic conditions. In this study, hybrid catalysts comprising single Co atoms and ultralow concentrations of Pt3Co intermetallic nanoparticles (NPs) are introduced to enhance ORR performance. Under acidic conditions, these hybrid catalysts demonstrate ORR efficiency with a half-wave potential of 0.895 V, negligible decay even after 80 000 cycles, and a high maximum power density of 1.34 W cm-2 in fuel cells. This performance surpasses those of Co-N-C and Pt/Co-N-C catalysts. Both experimental findings and theoretical computations suggest that the heightened ORR activity stems from an increase in the spin density of Co sites induced by noble metal NPs, facilitating the activation of O-O bonds via side-on overlapping and enabling a transition in the reaction pathway from associative to dissociative processes. This research offers a promising avenue for the systematic design of M-N-C cathodes with an enhanced performance for acidic fuel cells.

An in situ exploration of how Fe/N/C oxygen reduction catalysts evolve during synthesis under pyrolytic conditions.

In pursuing cheap and effective oxygen reduction catalysts, the Fe/N/C system emerges as a promising candidate. Nevertheless, the structural transformations of starting materials into Fe- and N-doped carbon catalysts remains poorly characterized under pyrolytic conditions. Here, we explore the evolution of Fe species and track the formation of Fe-N4 site development by employing diverse in-situ diagnostic techniques. In-situ heating microscopy reveals the initial formation of FeOx nanoparticles and subsequent internal migration within the carbon matrix, which stops once FeOx is fully reduced. The migration and decomposition of nanoparticles then leads to carbon layer reconstruction. Experimental and theoretical analysis reveals size-dependent behavior of FeOx where nanoparticles below 7 nm readily release Fe atoms to form Fe-N4 while nanoparticles with sizes >10 nm tend to coalesce and impede Fe-N4 site formation. The work visualizes the pyrolysis process of Fe/N/C materials, providing theoretical guidance for the rational design of catalysts.

A plasma-assisted approach to enhance density of accessible FeN4 sites for proton exchange membrane fuel cells.

Enhancing the density and utilization of FeN4 sites can serve as a viable approach to enhance the catalytic efficacy of iron nitrogen carbon (FeNC) catalysts for oxygen reduction reaction (ORR). Herein, we present a plasma-assisted method for enhancing the porosity of nitrogen-doped carbon. Our findings indicate that the ideal ratio of mesopore to micropore area is 0.463. This ratio not only promotes the diffusion of Fe3+ but also creates additional active sites for Fe3+ loading, leading to an increase in the number of available FeN4 sites in FeNC electrocatalysts during pyrolysis. The density (76.5 µmol g-1) and utilization (21.08 %) of d-FeNC-30 are significantly higher than those of FeNC without plasma treatment, with a 2.8-fold and 2-fold increase, respectively. Remarkably, it displays outstanding performance, evidenced by a half-wave potential of 0.835 V (vs. RHE) in a 0.1 M HClO4 solution and a power density of 0.860 W cm-2 in proton exchange membrane fuel cells (PEMFCs). The developed plasma-assisted approach for improving the site density (SD) and utilization of FeN4 provides a new perspective for high-performance ORR FeNC catalysts.