Chemical vapour deposition of Fe-N-C oxygen reduction catalysts with full utilization of dense Fe-N4 sites.

Replacing scarce and expensive platinum (Pt) with metal-nitrogen-carbon (M-N-C) catalysts for the oxygen reduction reaction in proton exchange membrane fuel cells has largely been impeded by the low oxygen reduction reaction activity of M-N-C due to low active site density and site utilization. Herein, we overcome these limits by implementing chemical vapour deposition to synthesize Fe-N-C by flowing iron chloride vapour over a Zn-N-C substrate at 750 °C, leading to high-temperature trans-metalation of Zn-N4 sites into Fe-N4 sites. Characterization by multiple techniques shows that all Fe-N4 sites formed via this approach are gas-phase and electrochemically accessible. As a result, the Fe-N-C catalyst has an active site density of 1.92 × 1020 sites per gram with 100% site utilization. This catalyst delivers an unprecedented oxygen reduction reaction activity of 33 mA cm-2 at 0.90 V (iR-corrected; i, current; R, resistance) in a H2-O2 proton exchange membrane fuel cell at 1.0 bar and 80 °C.

Alkaline Anion-Exchange Membrane Fuel Cells: Challenges in Electrocatalysis and Interfacial Charge Transfer.

Alkaline anion-exchange membrane (AAEM) fuel cells have attracted significant interest in the past decade, thanks to the recent developments in hydroxide-anion conductive membranes. In this article, we compare the performance of current state of the art AAEM fuel cells to proton-exchange membrane (PEM) fuel cells and elucidate the sources of various overpotentials. While the continued development of highly conductive and thermally stable anion-exchange membranes is unambiguously a principal requirement, we attempt to put the focus on the challenges in electrocatalysis and interfacial charge transfer at an alkaline electrode/electrolyte interface. Specifically, a critical analysis presented here details the (i) fundamental causes for higher overpotential in hydrogen oxidation reaction, (ii) mechanistic aspects of oxygen reduction reaction, (iii) carbonate anion poisoning, (iv) unique challenges arising from the specific adsorption of alkaline ionomer cation-exchange head groups on electrocatalysts surfaces, and (v) the potential of alternative small molecule fuel oxidation. This review and analysis encompasses both the precious and nonprecious group metal based electrocatalysts from the perspective of various interfacial charge-transfer phenomena and reaction mechanisms. Finally, a research roadmap for further improvement in AAEM fuel cell performance is delineated here within the purview of electrocatalysis and interfacial charge transfer.

Evolution Pathway from Iron Compounds to Fe1(II)-N4 Sites through Gas-Phase Iron during Pyrolysis.

Pyrolysis is indispensable for synthesizing highly active Fe-N-C catalysts for the oxygen reduction reaction (ORR) in acid, but how Fe, N, and C precursors transform to ORR-active sites during pyrolysis remains unclear. This knowledge gap obscures the connections between the input precursors and the output products, clouding the pathway toward Fe-N-C catalyst improvement. Herein, we unravel the evolution pathway of precursors to ORR-active catalyst comprised exclusively of single-atom Fe1(II)-N4 sites via in-temperature X-ray absorption spectroscopy. The Fe precursor transforms to Fe oxides below 300 °C and then to tetrahedral Fe1(II)-O4 via a crystal-to-melt-like transformation below 600 °C. The Fe1(II)-O4 releases a single Fe atom that diffuses into the N-doped carbon defect forming Fe1(II)-N4 above 600 °C. This vapor-phase single Fe atom transport mechanism is verified by synthesizing Fe1(II)-N4 sites via "noncontact pyrolysis" wherein the Fe precursor is not in physical contact with the N and C precursors during pyrolysis.

Unifying the Hydrogen Evolution and Oxidation Reactions Kinetics in Base by Identifying the Catalytic Roles of Hydroxyl-Water-Cation Adducts.

Despite the fundamental and practical significance of the hydrogen evolution and oxidation reactions (HER/HOR), their kinetics in base remain unclear. Herein, we show that the alkaline HER/HOR kinetics can be unified by the catalytic roles of the adsorbed hydroxyl (OHad)-water-alkali metal cation (AM+) adducts, on the basis of the observations that enriching the OHad abundance via surface Ni benefits the HER/HOR; increasing the AM+ concentration only promotes the HER, while varying the identity of AM+ affects both HER/HOR. The presence of OHad-(H2O) x-AM+ in the double-layer region facilitates the OHad removal into the bulk, forming OH--(H2O) x-AM+ as per the hard-soft acid-base theory, thereby selectively promoting the HER. It can be detrimental to the HOR as per the bifunctional mechanism, as the AM+ destabilizes the OHad, which is further supported by the CO oxidation results. This new notion may be important for alkaline electrochemistry.

Roles of Mo Surface Dopants in Enhancing the ORR Performance of Octahedral PtNi Nanoparticles.

Doping with a transition metal was recently shown to greatly boost the activity and durability of PtNi/C octahedral nanoparticles (NPs) for the oxygen reduction reaction (ORR), but its specific roles remain unclear. By combining electrochemistry, ex situ and in situ spectroscopic techniques, density functional theory calculations, and a newly developed kinetic Monte Carlo model, we showed that Mo atoms are preferentially located on the vertex and edge sites of Mo-PtNi/C in the form of oxides, which are stable within the wide potential window of the electrochemical cycle. These surface Mo oxides stabilize adjacent Pt sites, hereby stabilizing the octahedral shape enriched with (111) facets, and lead to increased concentration of Ni in subsurface layers where they are protected against acid dissolution. Consequently, the favorable Pt3Ni(111) structure for the ORR is stabilized on the surface of PtNi/C NPs in acid against voltage cycling. Significantly, the unusual potential-dependent oxygen coverage trend on Mo-doped PtNi/C NPs as revealed by the surface-sensitive Δµ analysis suggests that the Mo dopants may also improve the ORR kinetics by modifying the coordination environments of Pt atoms on the surface. Our studies point out a possible way to stabilize the favorable shape and composition established on conceptual catalytic models in practical nanoscale catalysts.

Asymmetric Volcano Trend in Oxygen Reduction Activity of Pt and Non-Pt Catalysts: In Situ Identification of the Site-Blocking Effect.

Proper understanding of the major limitations of current catalysts for oxygen reduction reaction (ORR) is essential for further advancement. Herein by studying representative Pt and non-Pt ORR catalysts with a wide range of redox potential (Eredox) via combined electrochemical, theoretical, and in situ spectroscopic methods, we demonstrate that the role of the site-blocking effect in limiting the ORR varies drastically depending on the Eredox of active sites; and the intrinsic activity of active sites with low Eredox have been markedly underestimated owing to the overlook of this effect. Accordingly, we establish a general asymmetric volcano trend in the ORR activity: the ORR of the catalysts on the overly high Eredox side of the volcano is limited by the intrinsic activity; whereas the ORR of the catalysts on the low Eredox side is limited by either the site-blocking effect and/or intrinsic activity depending on the Eredox.

Metal and Metal Oxide Interactions and Their Catalytic Consequences for Oxygen Reduction Reaction.

Many industrial catalysts are composed of metal particles supported on metal oxides (MMO). It is known that the catalytic activity of MMO materials is governed by metal and metal oxide interactions (MMOI), but how to optimize MMO systems via manipulation of MMOI remains unclear, due primarily to the ambiguous nature of MMOI. Herein, we develop a Pt/NbOx/C system with tunable structural and electronic properties via a modified arc plasma deposition method. We unravel the nature of MMOI by characterizing this system under reactive conditions utilizing combined electrochemical, microscopy, and in situ spectroscopy. We show that Pt interacts with the Nb in unsaturated NbOx owing to the oxygen deficiency in the MMO interface, whereas Pt interacts with the O in nearly saturated NbOx, and further interacts with Nb when the oxygen atoms penetrate into the Pt cluster at elevated potentials. While the Pt-Nb interactions do not benefit the inherent activity of Pt toward oxygen reduction reaction (ORR), the Pt-O interactions improve the ORR activity by shortening the Pt-Pt bond distance. Pt donates electrons to NbOx in both Pt-Nb and Pt-O cases. The resultant electron eficiency stabilizes low-coordinated Pt sites, hereby stabilizing small Pt particles. This determines the two characteristic features of MMO systems: dispersion of small metal particles and high catalytic durability. These findings contribute to our understandings of MMO catalytic systems.

Highly Active and Stable Fe-N-C Catalyst for Oxygen Depolarized Cathode Applications.

Anion immunity toward the oxygen reduction reaction (ORR) has tremendous implications in electrocatalysis with applications for fuel cells, metal-air batteries, and oxygen depolarized cathodes (ODCs) in the anodic evolution of chlorine. The necessity of exploring ORR catalysts with immunity to anion adsorption is particularly significant considering that platinum group metal (PGM) catalysts are costly and highly vulnerable to impurities such as halides. Herein, we report a metal organic framework (MOF)-derived Fe-N-C catalyst that exhibits a dramatically improved half-wave potential of 240 mV compared to the state-of-the-art RhxSy/C catalyst in a rotating disk electrode in the presence of Cl-. The Fe-N4 active sites in Fe-N-C are intrinsically immune to Cl- poisoning, in contrast to Pt/C, which is severely susceptible to Cl- poisoning. As a result, the activity of Fe-N-C decreases only marginally in the presence of Cl-, far exceeding that of Pt/C. The viability of this catalyst as ODCs is further demonstrated in real-life hydrochloric acid electrolyzers using highly concentrated HCl solution saturated with Cl2 gas as the electrolyte. The introduction of Fe-N-C materials as ODC catalysts here overcomes the limitations of (i) the low intrinsic ORR activity of RhxSy/C as the state-of-the-art ODC catalyst; (ii) the vulnerability to Cl- poisoning of Pt/C as the state-of-the-art ORR catalyst; and (iii) the high cost of precious metals in these two materials, resulting in a cost-effective ODC catalyst with the overall performance exceeding that of all previously reported materials.

Experimental Proof of the Bifunctional Mechanism for the Hydrogen Oxidation in Alkaline Media.

Realization of the hydrogen economy relies on effective hydrogen production, storage, and utilization. The slow kinetics of hydrogen evolution and oxidation reaction (HER/HOR) in alkaline media limits many practical applications involving hydrogen generation and utilization, and how to overcome this fundamental limitation remains debatable. Here we present a kinetic study of the HOR on representative catalytic systems in alkaline media. Electrochemical measurements show that the HOR rate of Pt-Ru/C and Ru/C systems is decoupled to their hydrogen binding energy (HBE), challenging the current prevailing HBE mechanism. The alternative bifunctional mechanism is verified by combined electrochemical and in situ spectroscopic data, which provide convincing evidence for the presence of hydroxy groups on surface Ru sites in the HOR potential region and its key role in promoting the rate-determining Volmer step. The conclusion presents important references for design and selection of HOR catalysts.

Unraveling the Nature of Sites Active toward Hydrogen Peroxide Reduction in Fe-N-C Catalysts.

Fe-N-C catalysts with high O2 reduction performance are crucial for displacing Pt in low-temperature fuel cells. However, insufficient understanding of which reaction steps are catalyzed by what sites limits their progress. The nature of sites were investigated that are active toward H2 O2 reduction, a key intermediate during indirect O2 reduction and a source of deactivation in fuel cells. Catalysts comprising different relative contents of FeNx Cy moieties and Fe particles encapsulated in N-doped carbon layers (0-100 %) show that both types of sites are active, although moderately, toward H2 O2 reduction. In contrast, N-doped carbons free of Fe and Fe particles exposed to the electrolyte are inactive. When catalyzing the ORR, FeNx Cy moieties are more selective than Fe particles encapsulated in N-doped carbon. These novel insights offer rational approaches for more selective and therefore more durable Fe-N-C catalysts.

A Search for the Optimum Lithium Rich Layered Metal Oxide Cathode Material for Li-Ion Batteries.

We report the results of a comprehensive study of the relationship between electrochemical performance in Li cells and chemical composition of a series of Li rich layered metal oxides of the general formula xLi2MnO3 · (1-x)LiMn0.33Ni0.33Co0.33O2 in which x = 0,1, 0.2, 0,3, 0.5 or 0.7, synthesized using the same method. In order to identify the cathode material having the optimum Li cell performance we first varied the ratio between Li2MnO3 and LiMO2 segments of the composite oxides while maintaining the same metal ratio residing within their LiMO2 portions. The materials with the overall composition 0.5Li2MnO3 · 0.5LiMO2 containing 0.5 mole of Li2MnO3 per mole of the composite metal oxide were found to be the optimum in terms of electrochemical performance. The electrochemical properties of these materials were further tuned by changing the relative amounts of Mn, Ni and Co in the LiMO2 segment to produce xLi2MnO3 · (1-x)LiMn0.50Ni0.35Co0.15O2 with enhanced capacities and rate capabilities. The rate capability of the lithium rich compound in which x = 0.3 was further increased by preparing electrodes with about 2 weight-percent multiwall carbon nanotube in the electrode. Lithium cells prepared with such electrodes were cycled at the 4C rate with little fade in capacity for over one hundred cycles.

The Role of OOH Binding Site and Pt Surface Structure on ORR Activities.

We present experimentally observed molecular adsorbate coverages (e.g., O(H), OOH and HOOH) on real operating dealloyed bimetallic PtMx (M = Ni or Co) catalysts under oxygen reduction reaction (ORR) conditions obtained using X-ray absorption near edge spectroscopy (XANES). The results reveal a complex Sabatier catalysis behavior and indicate the active ORR mechanism changes with Pt-O bond weakening from the O2 dissociative mechanism, to the peroxyl mechanism, and finally to the hydrogen peroxide mechanism. An important rearrangement of the OOH binding site, an intermediate in the ORR, enables facile H addition to OOH and faster O-O bond breaking on 111 faces at optimal Pt-O bonding strength, such as that occurring in dealloyed PtM core-shell nanoparticles. This rearrangement is identified by previous DFT calculations and confirmed from in situ measured OOH adsorption coverages during the ORR. The importance of surface structural effects and 111 ordered faces is confirmed by the higher specific ORR rates on solid core vs porous multi-core nanoparticles.

Exploring the Role of an Electrolyte Additive in Suppressing Surface Reconstruction of a Ni-Rich NMC Cathode at Ultrahigh Voltage via Enhanced In Situ and Operando Characterization Methods.

Vinylene carbonate (VC) is a widely used electrolyte additive in lithium-ion batteries for enhanced solid electrolyte interphase formation on the anode side. However, the cathode electrolyte interphase (CEI) formation with VC has received a lot less attention. This study presents a comprehensive investigation employing advanced in situ/operando-based Raman and X-ray absorption spectroscopy (XAS) to explore the effect of electrolyte composition on the CEI formation and suppression of surface reconstruction of LixNiyMnzCo1-y-zO2 (NMC) cathodes. A novel chemical pathway via VC polymerization is proposed based on experimental results. In situ Raman spectra revealed a new peak at 995 cm-1, indicating the presence of C-O semi-carbonates resulting from the radical polymerization of VC. Operando Raman analysis unveiled the formation of NiO at 490 cm-1 in the baseline system under ultrahigh voltage (up to 5.2 V). However, this peak was conspicuously absent in the VC electrolyte, signifying the effectiveness of VC in suppressing surface reconstruction. Further investigation was carried out utilizing in situ XAS compared X-ray absorption near edge structure spectra from cells of 3 and 20 cycles in both electrolytes at different operating voltages. The observed shift at the Ni K-edge confirmed a more substantial reduction of Ni in the baseline electrolyte compared to that in the VC electrolyte, thus indicating less CEI protection in the former. A sophisticated extended X-ray absorption fine structure analysis quantitatively confirmed the effective suppression of rock-salt formation with the VC electrolyte during the charging process, consistent with the operando Raman results. The in situ XAS results thus provided additional support for the key findings of this study, establishing the crucial role of VC polymerization in enhancing CEI stability and mitigating surface reconstruction on NMC cathodes. This work clarifies the relationship between the enhanced CEI layer and NMC degradation and inspires rational electrolyte design for long-cycling NMC cathodes.

Activity descriptor identification for oxygen reduction on nonprecious electrocatalysts: linking surface science to coordination chemistry.

Developing nonprecious group metal based electrocatalysts for oxygen reduction is crucial for the commercial success of environmentally friendly energy conversion devices such as fuel cells and metal-air batteries. Despite recent progress, elegant bottom-up synthesis of nonprecious electrocatalysts (typically Fe-N(x)/C) is unavailable due to lack of fundamental understanding of molecular governing factors. Here, we elucidate the mechanistic origin of oxygen reduction on pyrolyzed nonprecious catalysts and identify an activity descriptor based on principles of surface science and coordination chemistry. A linear relationship, depicting the ascending portion of a volcano curve, is established between oxygen-reduction turnover number and the Lewis basicity of graphitic carbon support (accessed via C 1s photoemission spectroscopy). Tuning electron donating/withdrawing capability of the carbon basal plane, conferred upon it by the delocalized π-electrons, (i) causes a downshift of e(g)-orbitals (d(z(2))) thereby anodically shifting the metal ion's redox potential and (ii) optimizes the bond strength between the metal ion and adsorbed reaction intermediates thereby maximizing oxygen-reduction activity.

Bypassing Formation of Oxide Intermediate via Chemical Vapor Deposition for the Synthesis of an Mn-N-C Catalyst with Improved ORR Activity.

A significant barrier to the commercialization of proton exchange membrane fuel cells (PEMFCs) is the high cost of the platinum-based oxygen reduction reaction (ORR) cathode electrocatalysts. One viable solution is to replace platinum with a platinum-group metal (PGM) free catalyst with comparable activity and durability. However, PGM-free catalyst development is burdened by a lack of understanding of the active site formation mechanism during the requisite high-temperature synthesis step, thus making rational catalyst design challenging. Herein we demonstrate in-temperature X-ray absorption spectroscopy (XAS) to unravel the mechanism of site evolution during pyrolysis for a manganese-based catalyst. We show the transformation from an initial state of manganese oxides (MnOx) at room temperature, to the emergence of manganese-nitrogen (MnN4) site beginning at 750 °C, with its continued evolution up to the maximum temperature of 1000 °C. The competition between the MnOx and MnN4 is identified as the primary factor governing the formation of MnN4 sites during pyrolysis. This knowledge led us to use a chemical vapor deposition (CVD) method to produce MnN4 sites to bypass the evolution route involving the MnOx intermediates. The Mn-N-C catalyst synthesized via CVD shows improved ORR activity over the Mn-N-C synthesized via traditional synthesis by the pyrolysis of a mixture of Mn, N, and C precursors.

Dramatically enhanced cleavage of the C-C bond using an electrocatalytically coupled reaction.

This paper describes a generalized approach for the selective electrocatalytic C-C bond splitting in aliphatic alcohols at low temperature in aqueous state, with ethanol as an example. We show that selective C-C bond cleavage, leading to carbon dioxide, is possible in high pH aqueous media at low overpotentials. This improved selectivity and activity is achieved using a solution-born co-catalyst based on Pb(IV) acetate, which controls the mode of the ethanol adsorption so as to facilitate direct activation of the C-C bond. The simultaneously formed under-potentially deposited (UPD) Pb and surface lead hydroxide change the functionality of the catalyst surface for efficient promotion of CO oxidation. The resulting catalyst retains an unprecedented ability to sustain the full oxidation reaction pathway on an extended time scale of hours as opposed to minutes without addition of Pb(IV) acetate.

Structure of the catalytic sites in Fe/N/C-catalysts for O2-reduction in PEM fuel cells.

Fe-based catalytic sites for the reduction of oxygen in acidic medium have been identified by (57)Fe Mössbauer spectroscopy of Fe/N/C catalysts containing 0.03 to 1.55 wt% Fe, which were prepared by impregnation of iron acetate on carbon black followed by heat-treatment in NH(3) at 950 °C. Four different Fe-species were detected at all iron concentrations: three doublets assigned to molecular FeN(4)-like sites with their ferrous ions in a low (D1), intermediate (D2) or high (D3) spin state, and two other doublets assigned to a single Fe-species (D4 and D5) consisting of surface oxidized nitride nanoparticles (Fe(x)N, with x≤ 2.1). A fifth Fe-species appears only in those catalysts with Fe-contents ≥0.27 wt%. It is characterized by a very broad singlet, which has been assigned to incomplete FeN(4)-like sites that quickly dissolve in contact with an acid. Among the five Fe-species identified in these catalysts, only D1 and D3 display catalytic activity for the oxygen reduction reaction (ORR) in the acid medium, with D3 featuring a composite structure with a protonated neighbour basic nitrogen and being by far the most active species, with an estimated turn over frequency for the ORR of 11.4 e(-) per site per s at 0.8 V vs. RHE. Moreover, all D1 sites and between 1/2 and 2/3 of the D3 sites are acid-resistant. A scheme for the mechanism of site formation upon heat-treatment is also proposed. This identification of the ORR-active sites in these catalysts is of crucial importance to design strategies to improve the catalytic activity and stability of these materials.

Influence of phosphate anion adsorption on the kinetics of oxygen electroreduction on low index Pt(hkl) single crystals.

The detrimental effects of phosphate anion adsorption on the oxygen reduction reactions (ORR) on low index Pt single crystal electrodes were studied in 0.1 M perchloric acid by using a hanging meniscus rotating disk electrode in the presence of varied concentrations of H(3)PO(4). The kinetic current for ORR decreased dramatically on Pt(100), Pt(110), Pt(111), and PtSn(111) even with the addition of a small amount (1 mM) of H(3)PO(4) into the perchloric acid solution, most probably due to the adsorption of phosphate anions onto the Pt active sites that impeded the electroreduction of O(2). Remarkably, the extent of decline was found to vary with the specific single crystal surface, following the order of Pt(111) > PtSn(111) > Pt(110) ∼ Pt(100). Consistent behaviors were also observed in Tafel analysis and in electrochemical impedance spectroscopic measurements. Within the present experimental context, Pt(110) was found to be the optimal crystal surface for ORR in phosphoric acid fuel cells with the smallest charge transfer resistance, whereas the poisoning effects of phosphate anion adsorption were the most pronounced on Pt(111), most likely because the phosphate anions primarily adsorbed on the 3-fold sites on the Pt(111) faces, as manifested in in situ X-ray absorption spectroscopic measurements.

X-Ray Absorption Spectroscopy Characterizations on PGM-Free Electrocatalysts: Justification, Advantages, and Limitations.

Transition metals embedded in nitrogen-doped carbon matrices (denoted as M-N-C) are the leading platinum group metal (PGM)-free electrocatalysts for the oxygen reduction reaction (ORR) in acid, and are the most promising candidates for replacing platinum in practical devices such as fuel cells. Two of the long-standing puzzles in the field are the nature of active sites for the ORR and the reaction mechanism. Poor understanding of the structural and mechanistic basis for the exceptional ORR activity of M-N-C electrocatalysts impedes rational design for further improvements. Recently, synchrotron-based X-ray absorption spectroscopy (XAS) has been successfully implemented to shed some light on these two issues. In this context, a critical review is given to detail the contribution of XAS to the advancement of the M-N-C electrocatalysis to highlight its advantages and limitations.

Resolving the Iron Phthalocyanine Redox Transitions for ORR Catalysis in Aqueous Media.

Metal macrocycles are among the most important catalytic systems in electrocatalysis and biocatalysis owing to their rich redox chemistry. Precise understanding of the redox behavior of metal macrocycles in operando is essential for fundamental studies and practical applications of this catalytic system. Here we present electrochemical data for the representative iron phthalocyanine (FePc) in both aqueous and nonaqueous media coupled with in situ Raman and X-ray absorption analyses to challenge the traditional notion of the redox transition of FePc at the low potential end in aqueous media by showing that it arises from the redox transition of the ring. Our data unequivocally demonstrate that the electron is shuttled to the Pc ring via the Fe(II)/Fe(I) redox center. The Fe(II)/Fe(I) redox transition of FePc in aqueous media is indiscernible by normal spectroscopic methods owing to the lack of a suitable axial ligand to stabilize the Fe(I) state.