Core–Shell Structured Fe–N–C Catalysts with Enriched Iron Sites in Surface Layers for Proton-Exchange Membrane Fuel Cells

In Situ Templated Synthesis of Sponge-like Zn/Sb Dual-Atom Catalysts for Efficient Oxygen Reduction in Zn-Air Batteries

Developing efficient electrocatalysts that can improve the oxygen reduction reaction (ORR) activity and optimize mass transfer efficiency is crucial for advancing rechargeable Zn-air batteries (ZABs). Herein, we report an in situ template strategy utilizing in situ formed Zn nanoclusters to construct a sponge-like framework with atomically dispersed dual-atom Zn/Sb sites (Zn/Sb-NC-g). The sponge-like structure with well-defined mesopores (2-5 nm) enhances both the mass transport of oxygen intermediates and the exposure of Zn/Sb-Nx active sites, thereby optimizing ORR kinetics. Systematic X-ray absorption spectroscopy (XAS) and X-ray photoelectron spectroscopy (XPS) analyses confirm the atomic-level dispersion of Zn/Sb atoms and their electronic interactions, which promote intrinsic ORR activity. The Zn/Sb-NC-g catalyst demonstrates superior ORR activity (with a half-wave potential reaching 0.905 V versus reversible hydrogen electrode), accelerated ORR kinetics, and excellent mass-transport property, which is significantly superior to its microporous and Zn single-atom counterparts. When assembled into ZABs, the catalyst delivers remarkable peak power densities up to 209 and 426 mW cm-2 in aqueous and flexible batteries, respectively, with favorable cycling stability for over 1000 h at 10 mA cm-2. Such a synthetic strategy for constructing sponge-like porous structure with dual-atom Zn/Sb sites offers an effective approach to develop highly efficient electrocatalysts for Zn-air batteries.

Understanding the Mechanism of Fe-N-C Catalyst Oxygen Reduction Reaction Performance Enhancement: The Impact of Iron Valence State and Nitrogen Content

Optimizing non-noble catalysts for the oxygen reduction reaction (ORR) is crucial for advancing energy storage and conversion technologies. This study investigates the influence of iron valence states and nitrogen precursor contents on the physicochemical properties and electrochemical performance of lignin-based Fe-N-C catalysts. Catalysts are synthesized using different valence iron sources and varying pyrrole contents. The results reveal that iron(II) doping increases microporosity and specific surface area, while iron(III) doping enhances mesoporous and iron contents of the carbon materials. XPS and Raman spectroscopy confirm the successful incorporation of Fe-Nx active sites in the as-prepared LFeIIIPx catalysts. Electrochemical tests demonstrate that LFeIIIP10 exhibits the highest ORR activity, surpassing commercial Pt/C in half-wave potential (E1/2) and limiting current density (JL). The direct formate fuel cell (DFFC) with an LFeIIIP10 air cathode achieves a maximum power density of 24.7 mW cm-2, 32% higher than that with a Pt/C cathode. This study highlights the critical role of tailoring iron valence states and nitrogen levels to develop high ORR performance, cost-effective Fe-N-C catalysts, providing valuable insights for the future design of non-noble metal catalysts in energy applications.

High-performance rechargeable zinc-air batteries enabled by cobalt iron anchored on nitrogen-doped carbon matrix as bifunctional electrocatalyst

Developing efficient bifunctional oxygen reduction reaction (ORR)/oxygen evolution reaction (OER) electrocatalysts is potential ways for achieving high rechargeable zinc-air (Zn-air) battery performance. Herein, we report an iron (II) acetate-assisted strategy to synthesize Co3Fe7-NC-OAc catalyst with cobalt iron (Co3Fe7) alloy anchored on nitrogen-doped carbon (NC) matrix, which can serve as efficient ORR/OER bifunctional electrocatalysts for rechargeable Zn-air batteries. Apart from alloying with Co to form ORR/OER active Co3Fe7 nanoparticles, the incorporation of iron (II) acetate has expanded the pore size inside the Co3Fe7-NC-OAc catalyst to serve as gas transfer channels, and has induced synergetic electronic coupling between Co3Fe7 nanoparticles and NC matrix for boosting catalytic activity. Therefore, Co3Fe7-NC-OAc exhibits favorable ORR activity with a most positive half-wave potential of 0.90 V vs. RHE, fast ORR kinetics with a highest kinetic current density of 57.4 mA cm-2 at 0.85 V vs. RHE, and fast O2 diffusion and transport that enables smaller mass transport overpotential at high current density up to 800 mA cm-2. Additionally, Co3Fe7-NC-OAc can catalyze OER with low overpotential of 310 mV at 10 mA cm-2. When employed as air electrode for Zn-air batteries, Co3Fe7-NC-OAc achieve high peak power densities of 193 mW cm-2 and 587 mW cm-2 in liquid and solid-state Zn-air batteries. The liquid battery also exhibits high specific capacity and remarkable cycling performance. This work opens up a new opportunity for developing highly efficient bifunctional electrocatalysts for Zn-air battery applications.

Copper cluster regulated by N, B atoms for enhanced CO2 electroreduction to formate

Electrochemical CO2 conversion into formate by intermittent renewable electricity, presents a captivating prospect for both the storage of renewable electrical energy and the utilization of emitted CO2. Typically, Cu-based catalysts in CO2 reduction reactions favor the production of CO and other by-products. However, we have shifted this selectivity by incorporating B, N co-doped carbon (BNC) in the fabrication of Cu clusters. These Cu clusters are regulated with B, N atoms in a porous carbon matrix (Cu/BN-C), and Zn2+ ions were added to achieve Cu clusters with the diameter size of ∼1.0 nm. The obtained Cu/BN-C possesses a significantly improved catalytic performance in CO2 reduction to formate with a Faradaic efficiency (FE) of up to 70 % and partial current density (jformate) surpassing 20.8 mA cm-2 at -1.0 V vs RHE. The high FE and jformate are maintained over a 12-hour. The overall catalytic performance of Cu/BN-C outperforms those of the other investigated catalysts. Based on the density functional theory (DFT) calculation, the exceptional catalytic behavior is attributed to the synergistic effect between Cu clusters and N, B atoms by modulating the electronic structure and enhancing the charge transfer properties, which promoted a preferential adsorption of HCOO* over COOH*, favoring formate formation.

Concurrently Boosting Activity and Stability of Oxygen Reduction Reaction Catalysts via Judiciously Crafting Fe-Mn Dual Atoms for Fuel Cells

The ability to unlock the interplay between the activity and stability of oxygen reduction reaction (ORR) represents an important endeavor toward creating robust ORR catalysts for efficient fuel cells. Herein, we report an effective strategy to concurrent enhance the activity and stability of ORR catalysts via constructing atomically dispersed Fe-Mn dual-metal sites on N-doped carbon (denoted (FeMn-DA)-N-C) for both anion-exchange membrane fuel cells (AEMFC) and proton exchange membrane fuel cells (PEMFC). The (FeMn-DA)-N-C catalysts possess ample dual-metal atoms consisting of adjacent Fe-N4 and Mn-N4 sites on the carbon surface, yielded via a facile doping-adsorption-pyrolysis route. The introduction of Mn carries several advantageous attributes: increasing the number of active sites, effectively anchoring Fe due to effective electron transfer to Mn (revealed by X-ray absorption spectroscopy and density-functional theory (DFT), thus preventing the aggregation of Fe), and effectively circumventing the occurrence of Fenton reaction, thus reducing the consumption of Fe. The (FeMn-DA)-N-C catalysts showcase half-wave potentials of 0.92 and 0.82 V in 0.1 M KOH and 0.1 M HClO4, respectively, as well as outstanding stability. As manifested by DFT calculations, the introduction of Mn affects the electronic structure of Fe, down-shifts the d-band Fe active center, accelerates the desorption of OH groups, and creates higher limiting potentials. The AEMFC and PEMFC with (FeMn-DA)-N-C as the cathode catalyst display high power densities of 1060 and 746 mW cm-2, respectively, underscoring their promising potential for practical applications. Our study highlights the robustness of designing Fe-containing dual-atom ORR catalysts to promote both activity and stability for energy conversion and storage materials and devices.

Eggshell-Like Carbon Microspheres with Curvature Scheme: Distorted Energy Band and Atomic Charge Waves-Driven High Performance for Zinc-Air Battery

A metal-free nanocarbon with an eggshell structure is synthesized from chitosan (CS) and natural spherical graphite (NSG) as a cathode electrocatalyst for clean zinc-air batteries and fuel cells. It is developed using CS-derived carbons as an eggshell, covering NSG cores. The synthesis involves the in situ growth of CS on NSG, followed by ammonia-assisted pyrolysis for carbonization. The resulting catalyst displays a curved structure and completely coated NSG, showing superior oxygen reduction reaction (ORR) performance. In 1 M NaOH, the ORR half-wave potential reached 0.93 V, surpassing the commercial Pt/C catalyst by 50 mV. Furthermore, a zinc-air battery featuring the catalyst achieves a peak power density of 167 mW cm-2 with excellent stability, outperforming the Pt/C. The improved performance of the eggshell carbons can be attributed to the distorted energy band of the active sites in the form of N-C moieties. More importantly, the curved thin eggshells induce built-in electric fields that can promote electron redistribution to generate atomic charge waves around the N-C moieties on the carbon shells. As a result, the high positively charged and stable C+ sites adjacent to N atoms optimize the adsorption strength of oxygen molecules, thereby facilitating performance.

PGM-free single atom catalysts for the oxygen reduction reaction in proton exchange membrane fuel cells

The progress of proton exchange membrane fuel cells (PEMFCs) in the clean energy sector is notable for its efficiency and eco-friendliness, although challenges remain in terms of durability, cost and power density. The oxygen reduction reaction (ORR) is a key sluggish process and although current platinum-based catalysts are effective, their high cost and instability is a significant barrier. Single-atom catalysts (SACs) offer an economically viable alternative with comparable catalytic activity for ORR. The primary concern regarding SACs is their operational stability under PEMFCs conditions. In this article, we review current strategies for increasing the catalytic activity of SACs, including increasing active site density, optimizing metal center coordination through heteroatom doping, and engineering porous substrates. To enhance durability, we discuss methods to stabilize metal centers, mitigate the effects of the Fenton reaction, and improve graphitization of the carbon matrix. Future research should apply computational chemistry to predict catalyst properties, develop in situ characterization for real-time active site analysis, explore novel catalysts without the use of platinum-based catalysts to reduce dependence on rare and noble metal, and investigate the long-term stability of catalyst under operating conditions. The aim is to engineer SACs that meet and surpass the performance benchmarks of PEMFCs, contributing to a sustainable energy future.

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.

Strontium doped Fe-based porous carbon for highly efficient electrocatalytic ORR and MOR reactions

The catalytic activity improvement of Fe-based active sites derived from metal organic frameworks toward oxygen reduction reaction (ORR) and methanol oxidation reaction (MOR) remains a major challenge. In this study, the growth of strontium decorated 2-methylimidazole zinc salt (Sr/ZIF-8) is prepared as a carrier to vapor deposited iron formation Sr doped Fe-based nitrogen-doped carbon framework (named as Sr/FeNC). After high-temperature pyrolysis and vapor deposition, strontium carbonate nanocrystals are evenly dispersed on the shrunk dodecahedron carbon frame and multitudinous Fe-based active catalytic sites are embedded in carbon skeleton. The optimal Sr/FeNC-2 catalyst demonstrates the outstanding ORR performance in terms of a half-wave potential of 0.851 V and an onset potential of 0.90 V, while Sr/FeNC-2 exhibits a high current density of 18.2 mA cm-2 and a lower Tafel slope of 21 mV dec-1 in MOR. The exceptional catalytic activity could be ascribed to the synergistic coupling effect of strontium compounds with Fe-based catalytic sites (Fe-Nx, Fe, and iron oxide). In particular, the formation of SrCO3 affects the bonding configuration of the iron species sites, leading to an optimization of the electronic structure within the multihole carbon matrix. The synthetic approach presents a prospective strategy for future endeavors in developing innovative and advanced bifunctional catalysts for ORR and MOR.

Single atom iron implanted polydopamine-modified hollow leaf-like N-doped carbon catalyst for improving oxygen reduction reaction and zinc-air batteries

Metal-nitrogen-carbon (MNC) catalysts, especially FeNC catalysts, are considered promising candidates to replace Pt-based catalysts, but FeNC catalysts still present certain challenges in controlled-synthesis and energy device applications. In this paper, through the modification strategy of poly-dopamine (PDA) to maintain 2D leaf morphology to obtain more active sites and further adjust the N content, N-doped porous carbon monatomic iron catalyst (Fe_SA/NPCs) with rich-nitrogen content was prepared. XPS analysis showed that compared with C-ZIF-Fe, the contents of graphite nitrogen and pyridine nitrogen increased in Fe_SA/NPCs. The hollow structure with defects and Fe-N₄ configuration of Fe single atom show more active sites for the catalyst, and positively promote the diffusion of reactants, oxygen exchange and electron transport, thus changing the reaction kinetics and promoting the improvement of ORR activity. Fe_SA/NPCs electrocatalyst exhibits good half-wave potential and onset potential at low loading (E_1/2 = 0.93 V, E_onset = 1.0 V). In addition, the methanol tolerance, stability and Tafel slope are better than those of commercial Pt/C. Excitingly, the zinc-air cell with Fe_SA/NPCs as cathode material achieves a power density of 223 mW cm^-2 and exhibits a long-term stability higher than 200 h. This work shows that nitrogen-doped porous carbon materials as well as iron monoatoms play important roles in improving electrocatalytic performance.

Atomic Fe/Zn anchored N, S co-doped nano-porous carbon for boosting oxygen reduction reaction

Dual-single-atom catalysts are well-known due to their excellent catalytic performance of oxygen reduction reaction (ORR) and the tunable coordination environment of the active sites. However, it is still challengable to finely modulate the electronic states of the metal atoms and facilely fabricate a catalyst with dual-single atoms homogeneously dispersed on conductive skeletons with good mass transport. Herein, atomic FeN_x/ZnN_x sites anchored N, S co-doped nano-porous carbon plates/nanotubes material (Fe_0.10ZnNSC) is rationally prepared via a facile room-temperature reaction and high-temperature pyrolysis. The as-prepared Fe_0.10ZnNSC catalyst exhibits a positive onset potential of 0.956 V, an impressive half-wave potential of 0.875 V, excellent long-term durability, and a high methanol resistance, outperforming the benchmark Pt/C. The outstanding ORR performance of Fe_0.10ZnNSC is due to its unique nanoarchitecture: a large specific surface area (1092.8 cm² g^-1) and well-developed nanopore structure ensure the high accessibility of active sites; the high conductivity of the carbon matrix guarantees a strong ability to transport electrons to the active sites; and the optimized electronic states of FeN_x and ZnN_x sites possess good oxygen intermediate adsorption/desorption capacity. This strategy can be extended to design and fabricate other non-precious dual-single-atom ORR catalysts.

High-performance atomic Co/N co-doped porous carbon catalysts derived from Co-doped metal-organic frameworks for oxygen reduction

Improving the activity and durability of carbon-based catalysts is a key challenge for their application in fuel cells. Herein, we report a highly active and durable Co/N co-doped carbon (CoNC) catalyst prepared via pyrolysis of Co-doped zeolitic-imidazolate framework-8 (ZIF-8), which was synthesized by controlling the feeding sequence to enable Co to replace Zn in the metal-organic framework (MOF). The catalyst exhibited excellent oxygen reduction reaction (ORR) performance, while the half-wave potential decreased by only 8 mV after 5,000 accelerated stress test (AST) cycles in an acidic solution. Furthermore, the catalyst exhibited satisfactory cathodic catalytic performance when utilized in a hydrogen/oxygen single proton exchange membrane (PEM) fuel cell and a Zn-air battery, yielding maximum power densities of 530 and 164 mW cm^-2, respectively. X-ray absorption spectroscopy (XAS) and high-angle annular dark field-scanning transmission electron microscopy (HAAD-STEM) analyses revealed that Co was present in the catalyst as single atoms coordinated with N to form Co-N moieties, which results in the high catalytic performance. These results show that the reported catalyst is a promising material for inclusion into future fuel cell designs.

Dual Metal Site Fe Single Atom Catalyst with Improved Stability in Acidic Conditions

Dual atom catalysts (DACs) not only retain uniform active sites and high atomic utilization efficiency as the single atom catalysts, but the two adjacent metal sites also cooperate and play a synergistic role to achieve additional benefits. However, the relationships connecting their dual-site synergistic effects on catalytic performance are not well rationalized due to limited pairs available from experiments. Herein, Fe/M dual sites supported by nitrogen doped carbon (Fe/M-N-C whereby M from 3 d–5 d electron containing transition metals) have been screened as an oxygen reduction reaction (ORR) catalyst. The results show that the absorption strength of ORR intermediates on four nitrogen coordinated metals is weaker than the three coordinated metals, which promotes favourable ORR activities. As a result, we recommended FeIr, FeRh, FeRu and FeOs as promising ORR catalysts. Ab initio molecular dynamic (AIMD) simulations suggest Fe/M-N-C (M = Ir, Rh, Ru and Os) catalysts with encouraging structural stability at room temperature. Furthermore, it is found that the nitrogen atoms in-between metals are vulnerable sites for proton attacking, yet the protonation process demands high energy, even under O2 atmosphere, which underlines good tolerance under acidic conditions. This work provides a broad understanding of Fe based catalyst and a new direction for catalytic design.

Ultrahigh-Loaded Fe Single Atoms and Fe3C Nanoparticle Catalysts as Air Cathodes for High-Performance Zn-Air Batteries

Fe-based materials containing Fe-Nx sites have emerged as promising electrocatalysts in the oxygen reduction reaction (ORR), but they still suffer structural instability which may lead to loss of catalytic activity. Herein, a novel electrocatalyst Fe₃C-FeSA@3DCN with the coexistence of Fe₃C nanoparticles and Fe single atoms (FeSA) in a three-dimensional conductive network (3DCN) is prepared via lattice confinement and defect trapping strategies with an Fe atomic loading of as high as 4.36%. In the ORR process, the limiting current density of Fe₃C-FeSA@3DCN reaches 5.72 mA cm^-2, with an onset potential of 0.926 V and a Tafel slope of 66 mV/decade, showing better catalytic activity and stability than Pt/C catalysts. Notably, its assembled aqueous and solid-state Zn-air batteries (ZABs) achieve peak power densities of 166 and 56 mW cm^-2, respectively, with a long service life of up to 200 h at a current density of 5 mA cm^-2. In addition, the assembled ZAB can provide a constant voltage on activated carbon electrodes to perform capacitive deionization to adsorb different ions. The importance of the Fe species active sites generated by Fe₃C and FeSA in the material for ORR activity to boost the electron transfer and mass transfer is demonstrated by a simple selective poisoning experiment.

MOFs for Electrochemical Energy Conversion and Storage

Metal organic frameworks (MOFs) are a family of crystalline porous materials which attracts much attention for their possible application in energy electrochemical conversion and storage devices due to their ordered structures characterized by large surface areas and the presence in selected cases of a redox-active porous skeleton. Their synthetic versatility and relevant host-guest chemistry make them suitable platform for use in stable and flexible conductive materials. In this review we summarize the most recent results obtained in this field, by analyzing the use of MOFs in fuel and solar cells with special emphasis on PEMFCs and PSCs, their application in supercapacitors and the employment in batteries by differentiating Li-, Na- and other metal ion-batteries. Finally, an overview of the water splitting reaction MOF-catalyzed is also reported.

Hierarchically Porous Three-Dimensional (3D) Carbon Nanorod Networks with a High Content of FeNx Sites for Efficient Oxygen Reduction Reaction

Efficient, durable, and inexpensive electrocatalysts are recommendable for accelerating the kinetics of oxygen reduction reaction and achieving high performance. Herein, with predesigned hierarchically porous silica nanorods as a hard template, hierarchically macro-bimodal meso/microporous 3D carbon interwoven nanorod networks containing a high content of single-atom FeNx species (Fe/RNC) were prepared by melting of precursors and confined pyrolysis within the pores of the hard template. What distinguishes the use of silica nanorods as a hard template is that it not only provides a porous texture for confined pyrolysis of the precursors but also the interwoven texture of the nanorods gives rise to a macroporous mesh-like morphology. Benefiting from the ultrahigh iron content (5.69 wt %) of the FeNx sites, a 3D porous network configuration with high accessibility of active centers, as well as a high specific surface area of 793 m²g^-1, the as-prepared Fe/RNC exhibited superior activity and durability for ORR and zinc-air batteries. For comparison, the catalyst Fe/NC-MCM, which was prepared with a similar procedure but with unimodal mesoporous silica MCM-41 nanoparticles as the hard template, possesses a less porous structure and active accessibility and thus exhibits inferior ORR activity. This work provides an effective design/nanoengineering for electrocatalysts in ORR and zinc-air batteries and will inspire more research on accessibility of active sites in non-noble carbon-based electrocatalysts.

Engineering Co and Ru dual-metal atoms on nitrogen-doped carbon as highly efficient bifunctional oxygen electrocatalysts

Designing dual-metal atoms efficient bifunctional oxygen electrocatalyst by a one-step adsorption and a pyrolysis steps.