Studies of oxygen reduction reaction active sites and stability of nitrogen-modified carbon composite catalysts for PEM fuel cells

Breaking the Activity and Stability Trade-Off of Platinum-Free Catalysts for the Oxygen Reduction Reaction in Hydrogen Fuel Cells

Hydrogen fuel cells, which use hydrogen as fuel to generate electricity, hold great promises as future energy conversion devices for heavy-duty transport, due to their zero CO2 emissions, high energy conversion efficiency, and high power density. However, the adoption of hydrogen fuel cells has been slow due to their reliance on large amounts of costly and scarce platinum (Pt) for the oxygen reduction reaction. The replacement of Pt with Earth-abundant transition metals such as Fe, Co, Mn, and Sn with oxygen reduction reaction affinity has thus been a holy grail of electrocatalysis research. Pt-free catalysts must combine both high power density and high stability in hydrogen fuel cells to be considered viable alternatives to Pt. Despite promising progress on both fronts, a trade-off has emerged: Pt-free catalysts either achieve high power densities (≥1.5 W cm-2) but suffer from low stabilities (≥70% loss after 25 h) or more recently demonstrate improved stability (≤25% loss after 150 h), while delivering considerably lower power densities (<1 W cm-2) in hydrogen fuel cells. Herein, we summarize the recent progress in the synthesis of high power density M-N-C catalysts for hydrogen fuel cells and highlight the critical importance of uncovering the underlying mechanisms using operando methods. We then discuss the primary causes of catalyst degradation in hydrogen fuel cells and the most promising strategies to enhance the stability of the M-N-C catalysts. Finally, a roadmap is proposed to overcome the activity stability trade-off for Pt-free catalysts in hydrogen fuel cells.

Why Does the Performance of Nitrogen-Doped Carbon Electrocatalysts Decrease in Acidic Conditions?

Nitrogen-doped carbon has emerged as a promising low-cost and durable alternative to platinum catalysts for the oxygen reduction reaction (ORR) in fuel cells. However, its catalytic activity decreases significantly in acidic electrolytes, limiting the practical applications. Here, we report the degradation mechanisms of nitrogen-doped carbon catalysts, focusing on the acid-base equilibrium of pyridinic nitrogen (pyri-N), which serves the primary active site. We found that the electrochemical hydrogenation of pyri-N to pyri-NH, coupled with oxygen adsorption, is a critical process. Although this reaction occurs at higher potentials in basic electrolytes, it shifts to lower potentials in acidic environments due to the protonation and stabilization of pyri-N. These results demonstrate that the decrease of the catalytic activity in acidic electrolytes is tied to the basicity of pyri-N. By controlling the basicity of pyri-N, specifically its pKa, a guideline for enhancing the ORR and other electrode reactions has been established.

Nanostructure Engineering of Cathode Layers in Proton Exchange Membrane Fuel Cells: From Catalysts to Membrane Electrode Assembly

The membrane electrode assembly (MEA) is the core component of proton exchange membrane fuel cells (PEMFCs), which is the place where the reaction occurrence, the multiphase material transfer and the energy conversion, and the development of MEA with high activity and long stability are crucial for the practical application of PEMFCs. Currently, efforts are devoted to developing the regulation of MEA nanostructure engineering, which is believed to have advantages in improving catalyst utilization, maximizing three-phase boundaries, enhancing mass transport, and improving operational stability. This work reviews recent research progress on platinum group metal (PGM) and PGM-free catalysts with multidimensional nanostructures, catalyst layers (CLs), and nano-MEAs for PEMFCs, emphasizing the importance of structure-function relationships, aiming to guide the further development of the performance for PEMFCs. Then the design strategy of the MEA interface is summarized systematically. In addition, the application of in situ and operational characterization techniques to adequately identify current density distributions, hot spots, and water management visualization of MEAs is also discussed. Finally, the limitations of nanostructured MEA research are discussed and future promising research directions are proposed. This paper aims to provide valuable insights into the fundamental science and technical engineering of efficient MEA interfaces for PEMFCs.

Second-Shell N Dopants Regulate Acidic O2 Reduction Pathways on Isolated Pt Sites

Pt is a well-known benchmark catalyst in the acidic oxygen reduction reaction (ORR) that drives electrochemical O2-to-H2O conversion with maximum chemical energy-to-electricity efficiency. Once dispersing bulk Pt into isolated single atoms, however, the preferential ORR pathway remains a long-standing controversy due to their complex local coordination environment and diverse site density over substrates. Herein, using a set of carbon nanotube supported Pt-N-C single-atom catalysts, we demonstrate how the neighboring N dopants regulate the electronic structure of the Pt central atom and thus steer the ORR selectivity; that is, the O2-to-H2O2 conversion selectivity can be tailored from 10% to 85% at 0.3 V versus reversible hydrogen electrode. Moreover, via a comprehensive X-ray-radiated spectroscopy and shell-isolated nanoparticle-enhanced Raman spectroscopy analysis coupled with theoretical modeling, we reveal that a dominant pyridinic- and pyrrolic-N coordination within the first shell of Pt-N-C motifs favors the 4e- ORR, whereas the introduction of a second-shell graphitic-N dopant weakens *OOH binding on neighboring Pt sites and gives rise to a dominant 2e- ORR. These findings underscore the importance of the chemical environment effect for steering the electrochemical performance of single-atom catalysts.

Recent Progress on Durable Metal-N-C Catalysts for Proton Exchange Membrane Fuel Cells

It is essential for the widespread application of proton exchange membrane fuel cells (PEMFCs) to investigate low-cost, extremely active, and long-lasting oxygen reduction catalysts. Initial performance of PGM-free metal-nitrogen-carbon (M-N-C) catalysts for oxygen reduction reaction (ORR) has advanced significantly, particularly for Fe-N-C-based catalysts. However, the insufficient stability of M-N-C catalysts still impedes their use in practical fuel cells. In this review, we focus on the understanding of the structure-stability relationship of M-N-C ORR catalysts and summarize valuable guidance for the rational design of durable M-N-C catalysts. In the first section of this review, we discuss the inherent degrading mechanisms of M-N-C catalysts, such as carbon corrosion, demetallation, H2 O2 attack, etc. As we gain a thorough comprehension of these deterioration mechanisms, we shift our attention to the investigation of strategies that can mitigate catalyst deterioration and increase its stability. These strategies include enhancing the anti-oxidation of carbon, fortifying M-N bonds, and maximizing the effectiveness of free radical scavengers. This review offers a prospective view on the enhancement of the stability of non-noble metal catalysts.

Effective Approaches for Designing Stable M-Nx /C Oxygen-Reduction Catalysts for Proton-Exchange-Membrane Fuel Cells

The large-scale commercialization of proton-exchange-membrane fuel cells (PEMFCs) is extremely limited by their costly platinum-group metals (PGMs) catalysts, which are used for catalyzing the sluggish oxygen reduction reaction (ORR) kinetics at the cathode. Among the reported PGM-free catalysts so far, metal-nitrogen-carbon (M-N_x /C) catalysts hold a great potential to replace PGMs catalysts for the ORR due to their excellent initial activity and low cost. However, despite tremendous progress in this field in the past decade, their further applications are restricted by fast degradation under practical conditions. Herein, the theoretical fundamentals of the stability of the M-N_x /C catalysts are first introduced in terms of thermodynamics and kinetics. The primary degradation mechanisms of M-N_x /C catalysts and the corresponding mitigating strategies are discussed in detail. Finally, the current challenges and the prospects for designing highly stable M-N_x /C catalysts are outlined.

Identification of the active triple-phase boundary of a non-Pt catalyst layer in fuel cells

The rational design of non-Pt oxygen reduction reaction (ORR) catalysts and catalyst layers in fuel cells is largely impeded by insufficient knowledge of triple-phase boundaries (TPBs) in the micropore and mesopore ranges. Here, we developed a size-sensitive molecular probe method to resolve the TPB of Fe/N/C catalyst layers in these size ranges. More than 70% of the ORR activity was found to be contributed by the 0.8- to 2.0-nanometer micropores of Fe/N/C catalysts, even at a low micropore area fraction of 29%. Acid-alkaline interactions at the catalyst-polyelectrolyte interface deactivate the active sites in mesopores and macropores, resulting in inactive TPBs, leaving micropores without the interaction as the active TPBs. The concept of active and inactive TPBs provides a previously unidentified design principle for non-Pt catalyst and catalyst layers in fuel cells.

A Top-Down Templating Strategy toward Functional Porous Carbons

Nanostructured carbon materials with high porosity and desired chemical functionalities are of immense interest because of their wide application potentials in catalysis, environment, and energy storage. Herein, a top-down templating strategy is presented for the facile synthesis of functional porous carbons, based on the direct carbonization of diverse organic precursors with commercially available metal oxide powders. During the carbonization, the metal oxide powders can evolve into nanoparticles that serve as in situ templates to introduce nanopores in carbons. The porosity and heteroatom doping of the prepared carbon materials can be engineered by varying the organic precursors and/or the metal oxides. It is further demonstrated that the top-down templating strategy is applicable to prepare carbon-based single-atom catalysts with iron-nitrogen sites, which exhibit a high power density of 545 mW cm^-2 in a H₂ -air proton exchange membrane fuel cell.

Recent Advances in Electrocatalysts for Proton Exchange Membrane Fuel Cells and Alkaline Membrane Fuel Cells

The rapid progress of proton exchange membrane fuel cells (PEMFCs) and alkaline exchange membrane fuel cells (AMFCs) has boosted the hydrogen economy concept via diverse energy applications in the past decades. For a holistic understanding of the development status of PEMFCs and AMFCs, recent advancements in electrocatalyst design and catalyst layer optimization, along with cell performance in terms of activity and durability in PEMFCs and AMFCs, are summarized here. The activity, stability, and fuel cell performance of different types of electrocatalysts for both oxygen reduction reaction and hydrogen oxidation reaction are discussed and compared. Research directions on the further development of active, stable, and low-cost electrocatalysts to meet the ultimate commercialization of PEMFCs and AMFCs are also discussed.

Enhanced Performance of Pt Nanoparticles on Ni-N Co-Doped Graphitized Carbon for Oxygen Reduction Reaction in Polymer Electrolyte Membrane Fuel Cells

Since the reaction rate and cost for cathodic catalyst in polymer electrolyte membrane fuel cells are obstacles for commercialization, the high-performance catalyst for oxygen reduction reaction is necessary. The Ni encapsulated with N-doped graphitic carbon (Ni@NGC) prepared with ethylenediamine and carbon black is employed as an efficient support for the oxygen reduction reaction. Characterizations show that the Ni@NGC has a large surface area and mesoporous structure that is suitable to the support for the Pt catalyst. The catalyst structure is identified and the size of Pt nanoparticles distributed in the narrow range of 2–3 nm. Four different nitrogen species are doped properly into graphitic carbon structure. The Pt/Ni@NGC shows higher performance than the commercial Pt/C catalyst in an acidic electrolyte. The mass activity of the Pt/Ni@NGC in fuel cell tests exhibits over 1.5 times higher than that of commercial Pt/C catalyst. The Pt/Ni@NGC catalyst at low Pt loading exhibits 47% higher maximum power density than the Pt/C catalyst under H2-air atmosphere. These results indicate that the Ni@NGC as a support is significantly beneficial to improving activity.

Heteroatom-doped carbon-based oxygen reduction electrocatalysts with tailored four-electron and two-electron selectivity

Oxygen reduction reaction (ORR) plays a pivotal role in electrochemical energy conversion and commodity chemical production. Oxygen reduction involving a complete four-electron (4e-) transfer is important for the efficient operation of polymer electrolyte fuel cells, whereas the ORR with a partial 2e- transfer can serve as a versatile method for producing industrially important hydrogen peroxide (H2O2). For both the 4e- and 2e- pathway ORR, platinum-group metals (PGMs) have been materials of prevalent choice owing to their high intrinsic activity, but they are costly and scarce. Hence, the development of highly active and selective non-precious metal catalysts is of crucial importance for advancing electrocatalysis of the ORR. Heteroatom-doped carbon-based electrocatalysts have emerged as promising alternatives to PGM catalysts owing to their appreciable activity, tunable selectivity, and facile preparation. This review provides an overview of the design of heteroatom-doped carbon ORR catalysts with tailored 4e- or 2e- selectivities. We highlight catalyst design strategies that promote 4e- or 2e- ORR activity. We also summarise the major active sites and activity descriptors of the respective ORR pathways and describe the catalyst properties controlling the ORR mechanisms. We conclude the review with a summary and suggestions for future research.

Unveiling the Axial Hydroxyl Ligand on Fe-N4-C Electrocatalysts and Its Impact on the pH-Dependent Oxygen Reduction Activities and Poisoning Kinetics

Fe-N-C materials have shown a promising nonprecious oxygen reduction reaction (ORR) electrocatalyst yet their active site structure remains elusive. Several previous works suggest the existence of a mysterious axial ligand on the Fe center, which, however, is still unclarified. In this study, the mysterious axial ligand is identified as a hydroxyl ligand on the Fe centers and selectively promotes the ORR activities depending on different Fe-N4-C configurations, on which the adsorption free energy of the hydroxyl ligand also differs greatly. The selective formation of hydroxyl ligand on specific Fe-N-C configurations can resolve contradictories between previous theoretical and experimental results regarding the ORR activities and associated active configurations of Fe-N-C catalysts. It also explains the pH-dependent ORR activities and, moreover, a previously unreported pH-dependent poisoning kinetics of the Fe-N-C catalysts.

Study of M(iii)-cyclam (M = Rh, Ru; cyclam = 1,4,8,11-tetraazacyclotetradecane) complexes as novel methanol resistant electrocatalysts for the oxygen reduction reaction

Ru(iii)- and Rh(iii)-cyclam macrocyclic complexes as selective oxygen electroreduction catalysts: no ligand μ-bonds or complex heating treatments are needed.

Synergistic effect on BCN nanomaterials for the oxygen reduction reaction – a kinetic and mechanistic analysis to explore the active sites

The rGO doped with boron and nitrogen reduce the oxygen via the dissociative four-electron pathway whereas the two-electron oxygen reduction reaction is more predominant on the rGO doped with either of the two individual heteroatoms.

High-Energy Efficiency Membraneless Flowless Zn-Br Battery: Utilizing the Electrochemical-Chemical Growth of Polybromides

Aqueous Zn-Br batteries (ZBBs) offer promising next-generation high-density energy storage for energy storage systems, along with distinctive cost effectiveness particularly in membraneless and flowless (MLFL) form. Unfortunately, they generally suffer from uncontrolled diffusion of corrosive bromine components, which cause serious self-discharge and capacity fade. An MLFL-ZBB is presented that fundamentally tackles the problem of bromine crossover by converting bromine to the polybromide anion using protonated pyridinic nitrogen doped microporous carbon decorated on graphite felt (NGF). The NGF electrodes efficiently capture bromine and polybromide anions at the abundant protonated nitrogen dopant sites within micropores and facilitate effective conversion of bromine into polybromides through electrochemical-chemical growth mechanism. The MLFL-ZBBs with NGF exhibit an extraordinary stability over 1000 charge/discharge cycles, with an energy efficiency over 80%, the highest value ever reported among membraneless Zn-Br batteries. Judicious engineering of an atomistically designed nanostructured electrode offers a novel design platform for low cost, high voltage, long-life cycle aqueous hybrid Zn-Br batteries.

N-Doped Carbon NanoWalls for Power Sources

Cycling stability and specific capacitance are the most critical features of energy sources. Nitrogen incorporation in crystalline carbon lattice allows to increase the capacitance without increasing the mass of electrodes. Despite the fact that many studies demonstrate the increase in the capacitance of energy sources after nitrogen incorporation, the mechanism capacitance increase is still unclear. Herein, we demonstrate the simple approach of plasma treatment of carbon structures, which leads to incorporation of 3 at.% nitrogen into Carbon NanoWalls. These structures have huge specific surface area and can be used for supercapacitor fabrication. After plasma treatment, the specific capacitance of Carbon NanoWalls increased and reached 600 F g-1. Moreover, we made a novel DFT simulation which explains the mechanism of nitrogen incorporation into the carbon lattice. This work paves the way to develop flexible thin film supercapacitors based on carbon nanowalls.

Carbon-Based Metal-Free ORR Electrocatalysts for Fuel Cells: Past, Present, and Future

Replacing precious platinum with earth-abundant materials for the oxygen reduction reaction (ORR) in fuel cells has been the objective worldwide for several decades. In the last 10 years, the fastest-growing branch in this area has been carbon-based metal-free ORR electrocatalysts. Great progress has been made in promoting the performance and understanding the underlying fundamentals. Here, a comprehensive review of this field is presented by emphasizing the emerging issues including the predictive design and controllable construction of porous structures and doping configurations, mechanistic understanding from the model catalysts, integrated experimental and theoretical studies, and performance evaluation in full cells. Centering on these topics, the most up-to-date results are presented, along with remarks and perspectives for the future development of carbon-based metal-free ORR electrocatalysts.

Transition Metal–Nitrogen–Carbon (M–N–C) Catalysts for Oxygen Reduction Reaction. Insights on Synthesis and Performance in Polymer Electrolyte Fuel Cells

Platinum group metal (PGM)-free catalysts for oxygen reduction reaction (ORR) have attracted increasing interest as potential candidates to replace Pt, in the view of a future widespread commercialization of polymer electrolyte fuel cell (PEFC) devices, especially for automotive applications. Among different types of PGM-free catalysts, M–N–C materials appear to be the most promising ones in terms of activity. These catalysts can be produced using a wide variety of precursors containing C, N, and one (or more) active transition metal (mostly Fe or Co). The catalysts synthesis methods can be very different, even though they usually involve at least one pyrolysis step. In this review, five different synthesis methods are proposed, and described in detail. Several catalysts, produced approximately in the last decade, were analyzed in terms of performance in rotating disc electrode (RDE), and in H2/O2 or H2/air PEFC. The catalysts are subdivided in five different categories corresponding to the five synthesis methods described, and the RDE and PEFC performance is put in relation with the synthesis method.

Doping of Carbon Materials for Metal-Free Electrocatalysis

Carbon atoms in the graphitic carbon skeleton can be replaced by heteroatoms with different electronegative from that of the carbon atom (i.e., heteroatom doping) to modulate the charge distribution over the carbon network. The charge modulation can be achieved via direct charge transfer with an electron acceptor/donor (i.e., charge transfer doping) or through introduction of defects (i.e., defective doping). Various doping strategies, including heteroatom doping, charge-transfer doping, and defective doping, have now been devised for modulating the charge distribution of numerous graphite carbon materials to impart new properties to carbon materials. Consequently, carbon nanomaterials with defined doping have recently become prominent members in the carbon family, promising for a variety of applications, including catalysis, energy conversion and storage, environmental remediation, and important chemical production and industrial processes. The purpose of this review is to present an overview on the doping of carbon materials for metal-free electrocatalysis, especially the development of doping strategies and doping-induced structure and property changes for potential catalytic applications. Current challenges and future perspectives in the doped carbon-based metal-free catalyst field are also discussed.

The stability limits of highly active nitrogen doped carbon ORR nano-catalysts: a mechanistic study of degradation reactions

A new approach in electrode catalysis bearing immense potential for electrochemical technologies is the prospect of carbon-based electrodes. Pristine carbon nanostructures are relatively inert and modifications like nitrogen doping are known for their beneficial effects on the electrochemical activity of carbon nanomaterials in both alkaline and acidic media. However, the long-term stability of these materials, especially in an acidic environment, is rarely mentioned. Here, we evaluate the stability and long-term degradation of nitrogen doped graphene flakes as an oxygen reduction electrocatalyst with theoretical and experimental techniques. We assume that nitrogen dopants in the graphene sheet interact with e- and H+ at the electrode-electrolyte interface, leading to NH3 scission and continuous catalyst deactivation. With Density Functional Theory calculations, NH3 scission pathways of pyridinic, graphitic and pyrrolic nitrogen species were analyzed and compared under different operating conditions which are relevant for low and intermediate temperature fuel cells. The computational results are correlated with electrochemical measurements in solid acid fuel cells in a humidified oxygen environment at 240 °C.

Rational Design and Synthesis of Low-Temperature Fuel Cell Electrocatalysts

Abstract

Recent progresses in proton exchange membrane fuel cell electrocatalysts are reviewed in this article in terms of cathodic and anodic reactions with a focus on rational design. These designs are based around gaining active sites using model surface studies and include high-index faceted Pt and Pt-alloy nanocrystals for anodic electrooxidation reactions as well as Pt-based alloy/core–shell structures and carbon-based non-precious metal catalysts for cathodic oxygen reduction reactions (ORR). High-index nanocrystals, alloy nanoparticles, and support effects are highlighted for anodic catalysts, and current developments in ORR electrocatalysts with novel structures and different compositions are emphasized for cathodic catalysts. Active site structures, catalytic performances, and stability in fuel cells are also reviewed for carbon-based non-precious metal catalysts. In addition, further developmental perspectives and the current status of advanced fuel cell electrocatalysts are provided.

Graphical Abstract

Efficient degradation of organic phosphorus in glyphosate wastewater by catalytic wet oxidation using modified activated carbon as a catalyst

Glyphosate (PMG) wastewater, which is an organic phosphorus (OP) wastewater containing 200-3000 mg/L PMG, was treated via catalytic wet oxidation (CWO) to degrade PMG to orthophosphate ([Formula: see text]). The catalysts were activated carbons (ACs) modified by H2O2 oxidation and thermal treatment with ammonia or melamine. The catalysts were characterized using N2 adsorption/desorption, Boehm titration, and X-ray photoelectron spectroscopy. The CWO experiments were performed in a co-current upflow fixed-bed reactor at 110-130°C and under 1.0 MPa. The AC modified by H2O2 and melamine had the highest catalytic activity and had excellent stability in the continuous 55-day test: 100% PMG removal and over 93% OP removal for different samples of real PMG wastewater. More pyrrolic nitrogen, pyridinic nitrogen, and graphitic nitrogen along with quinone oxygen functional groups on the surface of the AC showed higher catalytic activity according to linear fitting results. The identification and quantification of critical reaction intermediaries and the main end products of PMG degradation were possible, and a degradation pathway was proposed.

Preparation of bacterial cellulose based nitrogen-doped carbon nanofibers and their applications in the oxygen reduction reaction and sodium–ion battery

3D N-doped carbon nanofibers were fabricated from low-cost biomass bacterial cellulose and used as electrodes for both ORR and SIBs.

Rapid Adsorption Enables Interface Engineering of PdMnCo Alloy/Nitrogen-Doped Carbon as Highly Efficient Electrocatalysts for Hydrogen Evolution Reaction

The catalytic performance of Pd-based catalysts has long been hindered by surface contamination, particle agglomeration, and lack of rational structural design. Here we report a simple adsorption method for rapid synthesis (∼90 s) of structure-optimized Pd alloy supported on nitrogen-doped carbon without the use of surfactants or extra reducing agents. The material shows much lower overpotential than 30 wt % Pd/C and 40 wt % Pt/C catalysts while exhibiting excellent durability (80 h). Moreover, unveiled by the density functional theory (DFT) calculation results, the underlying reason for the outstanding performance is that the PdMnCo alloy/pyridinic nitrogen-doped carbon interfaces weaken the hydrogen-adsorption energy on the catalyst and thus optimize the Gibbs free energy of the intermediate state (ΔG_H*), leading to a remarkable electrocatalytic activity. This work also opens up an avenue for quick synthesis of a highly efficient structure-optimized Pd-based catalyst.