Iron-based catalysts for the oxygen-reduction reaction in polymer electrolyte membrane fuel cells have been poorly competitive with platinum catalysts, in part because they have a comparatively low number of active sites per unit volume. We produced microporous carbon-supported iron-based catalysts with active sites believed to contain iron cations coordinated by pyridinic nitrogen functionalities in the interstices of graphitic sheets within the micropores. We found that the greatest increase in site density was obtained when a mixture of carbon support, phenanthroline, and ferrous acetate was ball-milled and then pyrolyzed twice, first in argon, then in ammonia. The current density of a cathode made with the best iron-based electrocatalyst reported here can equal that of a platinum-based cathode with a loading of 0.4 milligram of platinum per square centimeter at a cell voltage of >/=0.9 volt.

H(2)-air polymer-electrolyte-membrane fuel cells are electrochemical power generators with potential vehicle propulsion applications. To help reduce their cost and encourage widespread use, research has focused on replacing the expensive Pt-based electrocatalysts in polymer-electrolyte-membrane fuel cells with a lower-cost alternative. Fe-based cathode catalysts are promising contenders, but their power density has been low compared with Pt-based cathodes, largely due to poor mass-transport properties. Here we report an iron-acetate/phenanthroline/zeolitic-imidazolate-framework-derived electrocatalyst with increased volumetric activity and enhanced mass-transport properties. The zeolitic-imidazolate-framework serves as a microporous host for phenanthroline and ferrous acetate to form a catalyst precursor that is subsequently heat treated. A cathode made with the best electrocatalyst from this work, tested in H(2)-O(2,) has a power density of 0.75 W cm(-2) at 0.6 V, a meaningful voltage for polymer-electrolyte-membrane fuel cells operation, comparable with that of a commercial Pt-based cathode tested under identical conditions.

Hydrogen produced from water and renewable energy could fuel a large fleet of proton-exchange-fuel-cell vehicles in the future. However, the dependence on expensive Pt-based electrocatalysts in such fuel cells remains a major obstacle for a widespread deployment of this technology. One solution to overcome this predicament is to reduce the Pt content by a factor of ten by replacing the Pt-based catalysts with non-precious metal catalysts at the oxygen-reducing cathode. Fe-and Co-based electrocatalysts for this reaction have been studied for over 50 years, but they were insufficiently active for the high efficiency and power density needed for transportation fuel cells. Recently, several breakthroughs occurred that have increased the activity and durability of non-precious metal catalysts (NPMCs), which can now be regarded as potential competitors to Pt-based catalysts. This review focuses on the new synthesis methods that have led to these breakthroughs. A modeling analysis is also conducted to analyze the improvements required from NPMC-based cathodes to match the performance of Pt-based cathodes, even at high current density. While no further breakthrough in volume-specific activity of NPMCs is required, incremental improvements of the volume-specific activity and effective protonic conductivity within the fuel-cell cathode are necessary. Regarding durability, NPMCs with the best combination of durability and activity result in ca. 3 times lower fuel cell performance than the most active NPMCs at 0.80 V. Thus, major tasks will be to combine durability with higher activity, and also improve durability at cell voltages greater than 0.60 V.

The high cost of proton-exchange-membrane fuel cells would be considerably reduced if platinumbased catalysts were replaced by iron-based substitutes, which have recently demonstrated comparable activity for oxygen reduction, but whose cause of activity decay in acidic medium has been elusive. Here, we reveal that the activity of Fe/N/C-catalysts prepared through a pyrolysis in NH3 is mostly imparted by acid-resistant FeN4-sites whose turnover frequency for the O2 reduction can be regulated by fine chemical changes of the catalyst surface. We show that surface N-groups protonate at pH 1 and subsequently bind anions. This results in decreased activity for the O2 reduction. The anions can be removed chemically or thermally, which restores the activity of acid-resistant FeN4-sites. These results are interpreted as an increased turnover frequency of FeN4-sites when specific surface N-groups protonate. These unprecedented findings provide new perspective for stabilizing the most active Fe/N/C-catalysts known to date.

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