Stability of iron species in heat-treated polyaniline–iron–carbon polymer electrolyte fuel cell cathode catalysts

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.

Deactivation Mechanism and Mitigation Strategies of Single-Atom Site Electrocatalysts

Single-atom site electrocatalysts (SACs), with maximum atom efficiency, fine-tuned coordination structure, and exceptional reactivity toward catalysis, energy, and environmental purification, have become the emerging frontier in recent decade. Along with significant breakthroughs in activity and selectivity, the limited stability and durability of SACs are often underemphasized, posing a grand challenge in meeting the practical requirements. One pivotal obstacle to the construction of highly stable SACs is the heavy reliance on empirical rather than rational design methods. A comprehensive review is urgently needed to offer a concise overview of the recent progress in SACs stability/durability, encompassing both deactivation mechanism and mitigation strategies. Herein, this review first critically summarizes the SACs degradation mechanism and induction factors at the atomic-, meso- and nanoscale, mainly based on but not limited to oxygen reduction reaction. Subsequently, potential stability/durability improvement strategies by tuning catalyst composition, structure, morphology and surface are delineated, including construction of robust substrate and metal-support interaction, optimization of active site stability, fabrication of porosity and surface modification. Finally, the challenges and prospects for robust SACs are discussed. This review facilitates the fundamental understanding of catalyst degradation mechanism and provides efficient design principles aimed at overcoming deactivation difficulties for SACs and beyond.

Activating the Mn Single Atomic Center for an Efficient Actual Active Site of the Oxygen Reduction Reaction by Spin-State Regulation

The ligand engineering for single-atom catalysts (SACs) is considered a cutting-edge strategy to tailor their electrocatalytic activity. However, the fundamental reasons underlying the reaction mechanism and the contemplation for which the actual active site for the catalytic reaction depends on the pyrrolic and pyridinic N ligand structure remain to be fully understood. Herein, we first reveal the relationship between the oxygen reduction reaction (ORR) activity and the N ligand structure for the manganese (Mn) single atomic site by the precisely regulated pyrrolic and pyridinic N4 coordination environment. Experimental and theoretical analyses reveal that the long Mn-N distance in Mn-pyrrolic N4 enables a high spin state of the Mn center, which is beneficial to reduce the adsorption strength of oxygen intermediates by the high filling state in antibond orbitals, thereby activating the Mn single atomic site to achieve a half-wave potential of 0.896 V vs RHE with outstanding stability in acidic media. This work provides a new fundamental insight into understanding the ORR catalytic origin of Mn SACs and the rational design strategy of SACs for various electrocatalytic reactions.

Operando Fe dissolution in Fe-N-C electrocatalysts during acidic oxygen reduction: impact of local pH change

Atomic Fe in N-doped C (Fe-N-C) catalysts provide the most promising non-precious metal O2 reduction activity at the cathodes of proton exchange membrane fuel cells. However, one of the biggest remaining challenges to address towards their implementation in fuel cells is their limited durability. Fe demetallation has been suggested as the primary initial degradation mechanism. However, the fate of Fe under different operating conditions varies. Here, we monitor operando Fe dissolution of a highly porous and >50% FeN x electrochemical utilization Fe-N-C catalyst in 0.1 M HClO4, under O2 and Ar at different temperatures, in both flow cell and gas diffusion electrode (GDE) half-cell coupled to inductively coupled plasma mass spectrometry (ICP-MS). By combining these results with pre- and post-mortem analyses, we demonstrate that in the absence of oxygen, Fe cations diffuse away within the liquid phase. Conversely, at -15 mA cm-2 geo and more negative O2 reduction currents, the Fe cations reprecipitate as Fe-oxides. We support our conclusions with a microkinetic model, revealing that the local pH in the catalyst layer predominantly accounts for the observed trend. Even at a moderate O2 reduction current density of -15 mA cm-2 geo at 25 °C, a significant H+ consumption and therefore pH increase (pH = 8-9) within the bulk Fe-N-C layer facilitate precipitation of Fe cations. This work provides a unified view on the Fe dissolution degradation mechanism for a model Fe-N-C in both high-throughput flow cell and practical operating GDE conditions, underscoring the crucial role of local pH in regulating the stability of the active sites.

Structural engineering of atomic catalysts for electrocatalysis

As a burgeoning category of heterogeneous catalysts, atomic catalysts have been extensively researched in the field of electrocatalysis. To satisfy different electrocatalytic reactions, single-atom catalysts (SACs), diatomic catalysts (DACs) and triatomic catalysts (TACs) have been successfully designed and synthesized, in which microenvironment structure regulation is the core to achieve high-efficiency catalytic activity and selectivity. In this review, the effect of the geometric and electronic structure of metal active centers on catalytic performance is systematically introduced, including substrates, central metal atoms, and the coordination environment. Then theoretical understanding of atomic catalysts for electrocatalysis is innovatively discussed, including synergistic effects, defect coupled spin state change and crystal field distortion spin state change. In addition, we propose the challenges to optimize atomic catalysts for electrocatalysis applications, including controlled synthesis, increasing the density of active sites, enhancing intrinsic activity, and improving the stability. Moreover, the structure-function relationships of atomic catalysts in the CO2 reduction reaction, nitrogen reduction reaction, oxygen reduction reaction, hydrogen evolution reaction, and oxygen evolution reaction are highlighted. To facilitate the development of high-performance atomic catalysts, several technical challenges and research orientations are put forward.

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.

Chemical Kinetic Method for Active-Site Quantification in Fe-N-C Catalysts and Correlation with Molecular Probe and Spectroscopic Site-Counting Methods

Mononuclear Fe ions ligated by nitrogen (FeNx) dispersed on nitrogen-doped carbon (Fe-N-C) serve as active centers for electrocatalytic O2 reduction and thermocatalytic aerobic oxidations. Despite their promise as replacements for precious metals in a variety of practical applications, such as fuel cells, the discovery of new Fe-N-C catalysts has relied primarily on empirical approaches. In this context, the development of quantitative structure-reactivity relationships and benchmarking of catalysts prepared by different synthetic routes and by different laboratories would be facilitated by the broader adoption of methods to quantify atomically dispersed FeNx active centers. In this study, we develop a kinetic probe reaction method that uses the aerobic oxidation of a model hydroquinone substrate to quantify the density of FeNx centers in Fe-N-C catalysts. The kinetic method is compared with low-temperature Mössbauer spectroscopy, CO pulse chemisorption, and electrochemical reductive stripping of NO derived from NO2- on a suite of Fe-N-C catalysts prepared by diverse routes and featuring either the exclusive presence of Fe as FeNx sites or the coexistence of aggregated Fe species in addition to FeNx. The FeNx site densities derived from the kinetic method correlate well with those obtained from CO pulse chemisorption and Mössbauer spectroscopy. The broad survey of Fe-N-C materials also reveals the presence of outliers and challenges associated with each site quantification approach. The kinetic method developed here does not require pretreatments that may alter active-site distributions or specialized equipment beyond reaction vessels and standard analytical instrumentation.

Coordination engineering of atomically dispersed zirconium on graphene for the oxygen reduction reaction

We study the effect of boron and sulfur doping on graphene with atomically dispersed zirconium as an electrocatalyst for the oxygen reduction reaction (ORR) by using density functional theory (DFT). The use of Zr as a metal center offers a highly stable catalyst due to the high electronegativity difference between Zr and its ligand. The origin of the ORR activity improvement has been investigated thoroughly. Here, we proposed a novel geometric descriptor for an atomically dispersed zirconium on a nitrogen-doped graphene catalyst with an axial oxygen ligand, which is the fractional coordination number of the Zr atom. We found that the fractional coordination number can successfully describe the shift of the dz2 band center in the doped compound, which is related to the binding energy of the Zr to the O ligand. We also found that the oxygen ligand is mobile during the adsorption process of ORR intermediates, and hence it is imperative for the axial oxygen ligand to bind neither too strongly nor too weakly to the Zr atom. The coordination engineering strategy can successfully enhance the ORR activity, shifting the ORR overpotential from 0.75 V and 0.92 V to 0.33 V and 0.32 V. This study provides new insights into the origin of ORR activity by connecting the novel geometric descriptor to the electronic structure and finally it is connected to the ORR activity.

Review on the Degradation Mechanisms of Metal-N-C Catalysts for the Oxygen Reduction Reaction in Acid Electrolyte: Current Understanding and Mitigation Approaches

One bottleneck hampering the widespread use of fuel cell vehicles, in particular of proton exchange membrane fuel cells (PEMFCs), is the high cost of the cathode where the oxygen reduction reaction (ORR) occurs, due to the current need of precious metals to catalyze this reaction. Electrochemists tackle this issue in the short/medium term by developing catalysts with improved utilization or efficiency of platinum, and in the longer term, by developing catalysts based on Earth-abundant elements. Considerable progress has been achieved in the initial performance of Metal-nitrogen-carbon (Metal-N-C) catalysts for the ORR, especially with Fe-N-C materials. However, until now, this high performance cannot be maintained for a sufficiently long time in an operating PEMFC. The identification and mitigation of the degradation mechanisms of Metal-N-C electrocatalysts in the acidic environment of PEMFCs has therefore become an important research topic. Here, we review recent advances in the understanding of the degradation mechanisms of Metal-N-C electrocatalysts, including the recently identified importance of combined oxygen and electrochemical potential. Results obtained in a liquid electrolyte and a PEMFC device are discussed, as well as insights gained from in situ and operando techniques. We also review the mitigation approaches that the scientific community has hitherto investigated to overcome the durability issues of Metal-N-C electrocatalysts.

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 Catalytic Active Sites for Durable Proton Exchange Membrane Fuel Cell: Catalytic Degradation and Poisoning Perspectives

Recent progress in synthetic strategies, analysis techniques, and computational modeling assist researchers to develop more active catalysts including metallic clusters to single-atom active sites (SACs). Metal coordinated N-doped carbons (M-N-C) are the most auspicious, with a large number of atomic sites, markedly performing for a series of electrochemical reactions. This perspective sums up the latest innovative and computational comprehension, while giving credit to earlier/pioneering work in carbonaceous assembly materials towards robust electrocatalytic activity for proton exchange membrane fuel cells via inclusive performance assessment of the oxygen reduction reaction (ORR). M-N_x -C_y are exclusively defined active sites for ORR, so there is a unique possibility to intellectually design the relatively new catalysts with much improved activity, selectivity, and durability. Moreover, some SACs structures provide better performance in fuel cells testing with long-term durability. The efforts to understand the connection in SACs based M-N_x -C_y moieties and how these relate to catalytic ORR performance are also conveyed. Owing to comprehensive practical application in the field, this study has covered very encouraging aspects to the current durability status of M-N-C based catalysts for fuel cells followed by degradation mechanisms such as macro-, microdegradation, catalytic poisoning, and future challenges.

Recent Advances in ZIF-Derived Atomic Metal-N-C Electrocatalysts for Oxygen Reduction Reaction: Synthetic Strategies, Active Centers, and Stabilities

Exploring highly active, stable electrocatalysts with earth-abundant metal centers for the oxygen reduction reaction (ORR) is essential for sustainable energy conversion. Due to the high cost and scarcity of platinum, it is a general trend to develop metal-N-C (M-N-C) electrocatalysts, especially those prepared from the zeolite imidazolate framework (ZIF) to replace/minimize usage of noble metals in ORR electrocatalysis for their amazingly high catalytic efficiency, great stability, and readily-tuned electronic structure. In this review, the most pivotal advances in mechanisms leading to declined catalytic performance, synthetic strategies, and design principles in engineering ZIF-derived M-N-C for efficient ORR catalysis, are presented. Notably, this review focuses on how to improve intrinsic ORR activity, such as M-N_x -C_y coordination structures, doping metal-free heteroatoms in M-N-C, dual/multi-metal sites, hydrogen passivation, and edge-hosted M-N_x . Meanwhile, how to increase active sites density, including formation of M-N complex, spatial confinement effects, and porous structure design, are discussed. Thereafter, challenges and future perspectives of M-N-C are also proposed. The authors believe this instructive review will provide experimental and theoretical guidance for designing future, highly active ORR electrocatalysts, and facilitate their applications in diverse ORR-related energy technologies.

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.

One-Step Preparation of Fe/N/C Single-Atom Catalysts Containing Fe-N4 Sites from an Iron Complex Precursor with 5,6,7,8-Tetraphenyl-1,12-Diazatriphenylene Ligands

Fe/N/C single-atom catalysts containing Fe-N_x sites prepared by pyrolysis are promising cathode materials for fuel cells and metal-air batteries due to their high oxygen reduction reaction (ORR) activities. We have developed iron complexes containing N2- or N3-chelating coordination structures with preorganized aromatic rings in a 1,12-diazatriphenylene framework tethering bromo substituents as precursors to precisely construct Fe-N₄ sites in an Fe/N/C catalyst. One-step pyrolysis of the iron complex with carbon black forms atomically dispersed Fe-N₄ sites without iron aggregates. X-ray absorption spectroscopy (XAS) and electrochemical measurements revealed that the iron complex with N3-coordination is more effectively converted to Fe-N₄ sites catalyzing ORR with a TOF value of 0.21 e site^-1  s^-1 at 0.8 V vs. RHE. This indicates that the formation of Fe-N₄ sites is controlled by precise tuning of the chemical structure of the iron complex precursor.

High Durability of a 14-Membered Hexaaza Macrocyclic Fe Complex for an Acidic Oxygen Reduction Reaction Revealed by In Situ XAS Analysis

Nonplatinum metal (NPM) catalysts for the oxygen reduction reaction (ORR) in proton exchange membrane fuel cells (PEMFCs) have been developed; however, NPM catalysts still need to be improved in terms of both their catalytic activity and durability. To overcome these problems, an Fe active site contained within a more compact ligand than conventional, porphyrinic, 16-membered ring ligands, or more specifically, a hexaaza macrocyclic ligand with a 14-membered ring (14MR), was developed. In this study, the durability of the Fe-14MR complex was compared to that of Fe phthalocyanine (FePc), which has a 16-membered ring ligand, using in situ X-ray absorption spectroscopy; demetalation of the Fe complexes was directly observed during electrochemical experiments performed under acidic ORR conditions. It was found that Fe-14MR is significantly more resistant to demetalation than FePc during the ORR.

Improving the Stability of Non-Noble-Metal M-N-C Catalysts for Proton-Exchange-Membrane Fuel Cells through M-N Bond Length and Coordination Regulation

An effective and universal strategy is developed to enhance the stability of the non-noble-metal M-N_x /C catalyst in proton exchange membrane fuel cells (PEMFCs) by improving the bonding strength between metal ions and chelating polymers, i.e., poly(acrylic acid) (PAA) homopolymer and poly(acrylic acid-maleic acid) (P(AA-MA)) copolymer with different AA/MA ratios. Mössbauer spectroscopy and X-ray absorption spectroscopy (XAS) reveal that the optimal P(AA-MA)-Fe-N catalyst with a higher Fe³⁺ -polymer binding constant possesses longer FeN bonds and exclusive Fe-N₄ /C moiety compared to PAA-Fe-N, which consists of ≈15% low-coordinated Fe-N₂ /N₃ structures. The optimized P(AA-MA)-Fe-N catalyst exhibits outstanding ORR activity and stability in both half-cell and PEMFC cathodes, with the retention rate of current density approaching 100% for the first 37 h at 0.55 V in an H₂ -air fuel cell. Density functional theory (DFT) calculations suggest that the Fe-N₄ /C site could optimize the difference between the adsorption energy of the Fe atoms on the support (E_ad ) and the bulk cohesive energy (E_coh ) relative to Fe-N₂ /N₃ moieties, thereby strongly stabilizing Fe centers against demetalation.

Effect of Pyrolysis Conditions on the Performance of Co–Doped MOF–Derived Carbon Catalysts for Oxygen Reduction Reaction

MOF–derived porous carbon is a type of promising catalyst to replace expensive Pt–based catalysts for oxygen reduction reaction (ORR). The catalytic activity for ORR depends closely on pyrolysis conditions. In this work, a Co–doped ZIF–8 material was chosen as a research object. The effect of pyrolysis conditions (temperature, heating rate, two–step heating) on the ORR performance of ZIF–derived carbon catalysts was systematically studied. The Co–ZIF–8 catalyst carbonized at 900 °C exhibits better ORR catalytic activity than that carbonized at 800 °C and 1000 °C. Moreover, a low heating rate can enhance catalytic activity. Two–step pyrolysis is proven to be an effective way to improve the performance of catalysts. Reducing the heating rate in the low–temperature stage is more beneficial to the ORR performance, compared to the heating rate in the high–temperature stage. The results show that the Co–ZIF–8 catalyst exhibits the best performance when the precursor was heated to 350 °C at 2 °C/min, and then heated to 900 °C at 5 °C/min. The optimum Co–ZIF–8 catalyst shows a half–wave potential of 0.82 V and a current density of 5.2 mA·cm−2 in 0.1 M KOH solution. It also exhibits high content of defects and good graphitization. TEM mapping shows that Co and N atoms are highly dispersed in the polyhedral carbon skeleton. However, two–step pyrolysis has no significant effect on the stability of the catalyst.

PANI/TiO2 nanocomposite-based chemiresistive gas sensor for the detection of E. Coli bacteria

In the modern pace of the world, food safety is a major concern. In this work, a simple chemiresistive type gas sensor was fabricated to detect Escherichia Coli (E. coli) bacteria. Polyaniline (PANI) films were deposited on the indium tin oxide substrate by an electrochemical deposition method. TiO2 nanoparticles were synthesised by facile hydrothermal method. PANI films were modified using hydrothermally prepared TiO2 nanoparticles by a spin coating method. X-ray diffraction (XRD), field emission scanning electron microscope (FESEM), Fourier transform infrared (FTIR) and ultraviolet-visible spectrophotometer techniques were used to characterise the PANI/TiO2 nanocomposites. The peaks obtained in the XRD pattern confirmed the anatase phase of TiO2 nanoparticles. FESEM analysis showed the nanofibrous structure of the nanocomposite. The FTIR characteristic peaks confirmed the formation of the nanocomposite. The electrical resistance of the sensors was evaluated as a function of the bacterial concentration. The PT2 (TiO2 coated 5 times on PANI) in comparison with PT1 (TiO2 coated 3 times on PANI) exhibited good sensitivity to the gas molecules at room temperature. The p-n junction at PANI/TiO2 interface improved the physical adsorption of gas molecules. Since no specific antibodies or receptors are used, the sensor has the potential for adaptation to real-life applications. Thus low cost, real-time, portable, reusable and sensitive bacteria sensors were fabricated and tested.

ZIF67@MFC-Derived Co/N-C@CNFs Interconnected Frameworks with Graphitic Carbon-Encapsulated Co Nanoparticles as Highly Stable and Efficient Electrocatalysts for Oxygen Reduction Reactions

Development of nonprecious metal catalysts for oxygen reduction reaction (ORR) to reduce or eliminate Pt-based electrocatalysts is of great importance for fuel cells. Herein, Co/N-codoped carbon with carbon nanofiber (CNF) interconnected three-dimensional (3D) frameworks and graphitic carbon-encapsulated Co nanoparticles were designed and successfully prepared via the in situ growth of zeolitic imidazolate framework-67 (ZIF67) with biomass nano-microfibrillar cellulose (MFC) and then pyrolysis. The catalyst (Co/N-C@CNFs) exhibited outstanding long-term catalytic durability with 92.7% current retention after 70 000 s, which was much higher than that of commercial Pt/C in alkaline media. The support and connection of CNFs to Co/N-C frameworks and the protection of Co nanoparticles by graphite layers contribute to their impressive long-term catalytic stability. Meanwhile, Co/C-N@CNFs displayed excellent ORR catalytic performance (E₀ = 0.952 V vs RHE, E_1/2 = 0.852 V vs RHE, and n: 4.2) in alkaline media. This strategy provides new insights into developing advanced nonprecious metal carbon-based catalysts for ORR.

Bimetallic carbon nanotube encapsulated Fe-Ni catalysts from fast pyrolysis of waste plastics and their oxygen reduction properties

Carbon-based bimetallic electrocatalysts were obtained by catalytic pyrolysis of waste plastics with Fe-Ni-based catalysts and were used as efficient oxygen reduction reaction (ORR) catalysts in this study. The prepared iron-nickel alloy nanoparticles encapsulated in oxidized carbon nanotubes (FeNi-OCNTs) are solid products with a unique structure. Moreover, the chemical composition and structural features of FeNi-OCNTs were determined. The iron-nickel alloy nanoparticles were wrapped in carbon layers, and the carbon nanotubes had an outer diameter of 20-50 nm and micron-scale lengths. FeNi-OCNT with a Fe/Ni ratio of 1:2 (FeNi-OCNT12) exhibited remarkable electrochemical performance as an ORR catalyst with a positive onset potential of 1.01 V (vs. RHE) and a half-wave potential of 0.87 V (vs. RHE), which were comparable to those of a commercial 20% Pt/C catalyst. Furthermore, FeNi-OCNT12 exhibited promising long-term stability and higher tolerance to methanol than the commercial 20% Pt/C catalyst in an alkaline medium. These properties were attributable to the protective OCNT coating of the iron-nickel alloy nanoparticles.

Atomically dispersed metal–nitrogen–carbon catalysts for fuel cells: advances in catalyst design, electrode performance, and durability improvement

The review provides a comprehensive understanding of the atomically dispersed metal–nitrogen–carbon cathode catalysts for proton-exchange membrane fuel cell applications.

Hierarchically Porous Co-N-C Cathode Catalyst Layers for Anion Exchange Membrane Fuel Cells

As a new class of metal-nitrogen-carbon (M-N-C) material with 3 D microstructure, zeolitic imidazolate frameworks (ZIFs) are used to synthesize highly active electrocatalysts for the oxygen reduction reaction, as substitutes for commercial Pt/C in anion exchange membrane fuel cells. However, to form an effective catalyst layer (CL), the relationship between the microstructure of the ZIF-derived catalyst and the fuel cell performance must be investigated. In this work, a hierarchically porous CL based on the carbon black (CB)-controlled synthesis of a Co-based ZIF (denoted as ZIF-CB-700) is constructed to optimize the triple-phase boundary (TPB) and mass transfer. The power density at 40 °C of ZIF-CB-700 (95.4 mW cm^-2 ) as cathode catalyst is about 4 times higher than that of the catalyst synthesized in the absence of CB and is comparable to that of the commercial 60 % Pt/C catalyst (112.0 mW cm^-2 ). Both online and offline measurements suggest that the morphology and microstructure of the CL is crucial to form an active TPB region, dominating the fuel cell performance rather than only the high catalyst activity.

Progress in the Development of Fe-Based PGM-Free Electrocatalysts for the Oxygen Reduction Reaction

Development of alternative energy sources is crucial to tackle challenges encountered by the growing global energy demand. Hydrogen fuel, a promising way to store energy produced from renewable power sources, can be converted into electrical energy at high efficiency via direct electrochemical conversion in fuel cells, releasing water as the sole byproduct. One important drawback to current fuel-cell technology is the high content of platinum-group-metal (PGM) electrocatalysts required to perform the sluggish oxygen reduction reaction (ORR). Addressing this challenge, remarkable progress has been made in the development of low-cost PGM-free electrocatalysts synthesized from inexpensive, earth-abundant, and easily sourced materials such as iron, nitrogen, and carbon (Fe-N-C). PGM-free Fe-N-C electrocatalysts now exhibit ORR activities approaching that of PGM electrocatalysts but at a fraction of the cost, promising to significantly reduce overall fuel-cell technology costs. Herein, recent developments in PGM-free electrocatalysis, demonstrating increased fuel-cell performance, as well as efforts aimed at understanding the key limiting factor, i.e., the nature of the PGM-free active site, are summarized. Further improvements will be accomplished through the controlled and/or rationally designed synthesis of materials with higher active-site densities, while at the same time establishing methods to mitigate catalyst degradation.

PGM-Free Cathode Catalysts for PEM Fuel Cells: A Mini-Review on Stability Challenges

In recent years, significant progress has been achieved in the development of platinum group metal-free (PGM-free) oxygen reduction reaction (ORR) catalysts for proton exchange membrane (PEM) fuel cells. At the same time the limited durability of these catalysts remains a great challenge that needs to be addressed. This mini-review summarizes the recent progress in understanding the main causes of instability of PGM-free ORR catalysts in acidic environments, focusing on transition metal/nitrogen codoped systems (M-N-C catalysts, M: Fe, Co, Mn), particularly MN_x moiety active sites. Of several possible degradation mechanisms, demetalation and carbon oxidation are found to be the most likely reasons for M-N-C catalysts/cathodes degradation.

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.

Enhancement of Fe-N-C carbon catalyst activity for the oxygen reduction reaction: effective increment of active sites by a short and repeated heating process

Controlling the formation of Fe-N-C catalytic sites is crucial to activate the oxygen reduction reaction (ORR) for realization of non-precious electrocatalysts in proton exchange membrane fuel cells (PEMFCs). We present a quantitative study on the effect of a newly obtained thermal history on the formation of Fe-N-C catalytic sites. A short and repeated heating process is employed as the new thermal history, where short heating (1 min) followed by quenching is applied to a sample with arbitrary repetition. Through electrochemical quantitative analysis, it is found that the new process effectively increases the Fe-N-C mass-based site density (MSD) to almost twice that achieved using a conventional continuous heating process, while the turn-over frequency (TOF) is independent of the process. Elemental analysis shows that the new process effectively suppresses the thermal desorption of Fe and N atoms during the initial formation stage and consequently contributes to an increase in the Fe-N-C site density. The resultant catalytic activity (gravimetric kinetic current density (0.8 V vs. RHE)) is 1.8 times higher than that achieved with the continuous heating process. The results indicate that fine control of the thermal history can effectively increase the catalytic activity and provide guidelines for further activation of non-precious ORR electrocatalysts for PEMFCs.

Critical advancements in achieving high power and stable nonprecious metal catalyst-based MEAs for real-world proton exchange membrane fuel cell applications

Despite great progress in the development of nonprecious metal catalysts (NPMCs) over the past several decades, the performance and stability of these promising catalysts have not yet achieved commercial readiness for proton exchange membrane fuel cells (PEMFCs). Through rational design of the cathode catalyst layer (CCL), we demonstrate the highest reported performance for an NPMC-based membrane electrode assembly (MEA), achieving a peak power of 570 mW/cm² under air. This record performance is achieved using a precommercial catalyst for which nearly all pores are <3 nm in diameter, challenging previous beliefs regarding the need for larger catalyst pores to achieve high current densities. This advance is achieved at industrially relevant scales (50 cm² MEA) using a precommercial NPMC. In situ electrochemical analysis of the CCLs is also used to help gain insight into the degradation mechanism observed during galvanostatic testing. Overall, the performance of this NPMC-based MEA has achieved commercial readiness and will be introduced into an NPMC-based product for portable power applications.

Nitrogen-Coordinated Single Cobalt Atom Catalysts for Oxygen Reduction in Proton Exchange Membrane Fuel Cells

Due to the Fenton reaction, the presence of Fe and peroxide in electrodes generates free radicals causing serious degradation of the organic ionomer and the membrane. Pt-free and Fe-free cathode catalysts therefore are urgently needed for durable and inexpensive proton exchange membrane fuel cells (PEMFCs). Herein, a high-performance nitrogen-coordinated single Co atom catalyst is derived from Co-doped metal-organic frameworks (MOFs) through a one-step thermal activation. Aberration-corrected electron microscopy combined with X-ray absorption spectroscopy virtually verifies the CoN₄ coordination at an atomic level in the catalysts. Through investigating effects of Co doping contents and thermal activation temperature, an atomically Co site dispersed catalyst with optimal chemical and structural properties has achieved respectable activity and stability for the oxygen reduction reaction (ORR) in challenging acidic media (e.g., half-wave potential of 0.80 V vs reversible hydrogen electrode (RHE). The performance is comparable to Fe-based catalysts and 60 mV lower than Pt/C -60 μg Pt cm^-2 ). Fuel cell tests confirm that catalyst activity and stability can translate to high-performance cathodes in PEMFCs. The remarkably enhanced ORR performance is attributed to the presence of well-dispersed CoN₄ active sites embedded in 3D porous MOF-derived carbon particles, omitting any inactive Co aggregates.

From Chlorella to Nestlike Framework Constructed with Doped Carbon Nanotubes: A Biomass-Derived, High-Performance, Bifunctional Oxygen Reduction/Evolution Catalyst

The development of effective bifunctional catalysts for the oxygen reduction reaction (ORR) and oxygen evolution reaction (OER) is significant for energy conversion systems, such as Li-air batteries, fuel cells, and water splitting technologies. Herein, a Chlorella-derived catalyst with a nestlike framework, composed of bamboolike nanotubes that encapsulate cobalt nanoparticles, has been prepared through a facile pyrolysis process. It achieves perfect bifunctional catalysis both in ORR and OER on a single catalyst. For our optimal catalyst Co/M-Chlorella-900, its ORR half-wave potential is positively shifted by 40 mV compared to that of a commercial Pt/C catalyst, and the overpotential at 10 mA cm^-2 for the OER is 23 mV lower than that of a commercial IrO₂/C catalyst in an alkaline medium. This superior bifunctional catalytic performance is benefited from the simultaneous increase of pyridinic N sites for ORR and graphitic N sites for OER. In addition, N-doped carbon-encapsulated Co nanoparticles improve both ORR and OER performance by forming new active centers. The unique nestlike carbon nanotube framework not only afforded highly dense ORR and OER active sites but also promoted the electron and mass transfer. Our catalyst also displays notable durability during the ORR and OER, making it promising for use in ORR/OER-related energy conversion systems.

A facile synthetic strategy for iron, aniline-based non-precious metal catalysts for polymer electrolyte membrane fuel cells

The development of a low cost and highly active alternative to the commercial Pt/C catalysts used in the oxygen reduction reaction (ORR) requires a facile and environmentally-friendly synthesis process to facilitate large-scale production and provide an effective replacement. Transition metals, in conjunction with nitrogen-doped carbon, are among the most promising substitute catalysts because of their high activity, inexpensive composition, and high carbon monoxide tolerance. We prepared a polyaniline-derived Fe-N-C catalyst for oxygen reduction using a facile one-pot process with no additional reagents. This process was carried out by ultrasonicating a mixture containing an iron precursor, an aniline monomer, and carbon black. The half-wave potential of the synthesized Fe-N-C catalyst for the ORR was only 10 mV less than that of a commercial Pt/C catalyst. The optimized Fe-N-C catalyst showed outstanding performance in a practical anion exchange membrane fuel cell (AEMFC), suggesting its potential as an alternative to commercial Pt/C catalysts for the ORR.