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.

While platinum has hitherto been the element of choice for catalysing oxygen electroreduction in acidic polymer fuel cells, tremendous progress has been reported for pyrolysed Fe-N-C materials. However, the structure of their active sites has remained elusive, delaying further advance. Here, we synthesized Fe-N-C materials quasi-free of crystallographic iron structures after argon or ammonia pyrolysis. These materials exhibit nearly identical Mössbauer spectra and identical X-ray absorption near-edge spectroscopy (XANES) spectra, revealing the same Fe-centred moieties. However, the much higher activity and basicity of NH3-pyrolysed Fe-N-C materials demonstrates that the turnover frequency of Fe-centred moieties depends on the physico-chemical properties of the support. Following a thorough XANES analysis, the detailed structures of two FeN4 porphyrinic architectures with different O2 adsorption modes were then identified. These porphyrinic moieties are not easily integrated in graphene sheets, in contrast with Fe-centred moieties assumed hitherto for pyrolysed Fe-N-C materials. These new insights open the path to bottom-up synthesis approaches and studies on site-support interactions.

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.

Fe-based catalytic sites for the reduction of oxygen in acidic medium have been identified by 57Fe Mössbauer spectroscopy of Fe/N/C catalysts containing 0.03 to 1.55 wt% Fe, which were prepared by impregnation of iron acetate on carbon black followed by heat-treatment in NH3 at 950°C. Four different Fe-species were detected at all iron concentrations: three doublets assigned to molecular FeN4-like sites with their ferrous ion in low (D1), medium (D2) or high spin state (D3), and two other doublets assigned to a single Fe-species (D4 and D5) consisting of surface oxidized nitride nanoparticles (FexN, with x≤2.1). A fifth Fe-species appears only in those catalysts with Fe-contents ≥ 0.27 wt%. It is characterized by a very broad singlet, which has been assigned to incomplete FeN4-like sites that quickly dissolve in contact with an acid. Among the five Fe-species identified in these catalysts, only D1 and D3 display catalytic activity for the oxygen reduction reaction (ORR) in the acid medium, with D3 featuring a composite structure with a protonated neighbour basic nitrogen and being by far the most active species, with an estimated turn over frequency for the ORR of 11.4 e− site−1 s−1 at 0.8V vs RHE. Moreover, all D1 sites and between 1/2 to 2/3 of the D3 sites are acid-resistant. A scheme for the mechanism of site formation upon heat-treatment is also proposed. This identification of the ORR-active sites in these catalysts is of crucial importance to design strategies to improve the catalytic activity and stability of these materials.

Nine non-noble-metal catalysts (NNMCs) from five different laboratories were investigated for the catalysis of O(2) electroreduction in an acidic medium. The catalyst precursors were synthesized by wet impregnation, planetary ball milling, a foaming-agent technique, or a templating method. All catalyst precursors were subjected to one or more heat treatments at 700-1050 degrees C in an inert or reactive atmosphere. These catalysts underwent an identical set of electrochemical characterizations, including rotating-disk-electrode and polymer-electrolyte membrane fuel cell (PEMFC) tests and voltammetry under N(2). Ex situ characterization was comprised of X-ray photoelectron spectroscopy, neutron activation analysis, scanning electron microscopy, and N(2) adsorption and its analysis with an advanced model for carbonaceous powders. In PEMFC, several NNMCs display mass activities of 10-20 A g(-1) at 0.8 V versus a reversible hydrogen electrode, and one shows 80 A g(-1). The latter value corresponds to a volumetric activity of 19 A cm(-3) under reference conditions and represents one-seventh of the target defined by the U.S. Department of Energy for 2010 (130 A cm(-3)). The activity of all NNMCs is mainly governed by the microporous surface area, and active sites seem to be hosted in pore sizes of 5-15 A. The nitrogen and metal (iron or cobalt) seem to be present in sufficient amounts in the NNMCs and do not limit activity. The paper discusses probable directions for synthesizing more active NNMCs. This could be achieved through multiple pyrolysis steps, ball-milling steps, and control of the powder morphology by the addition of foaming agents and/or sulfur.

The development of efficient non-platinum group metal (non-PGM) catalysts for oxygen reduction reaction (ORR) is of paramount importance for clean and sustainable energy storage and conversion devices. The major bottleneck in developing Fe-N-C materials as the leading non-PGM catalysts lies in the poor understanding of the nature of active sites and reaction mechanisms. Herein, we report a scalable metal organic framework-derived Fe-N-C catalyst with high ORR activity demonstrated in practical H 2 /air fuel cells, and an unprecedented turnover frequency (TOF) in acid in rotating disk electrode. By characterizing the catalyst under both ex situ and operando conditions using combined microscopic and spectroscopic techniques, we show that the structures of active sites under ex situ and working conditions are drastically different. Resultantly, the active site proposed here, a non-planar ferrous Fe-N 4 moiety embedded in distorted carbon matrix characterized by a high Fe 2+/3+ redox potential, is in contrast with those proposed hitherto derived from ex situ characterizations. This site reversibly switches to an in-plane ferric Fe-N 4 moiety poisoned by oxygen adsorbates during the redox transition, with the population of active sites controlled by the Fe 2+/3+ redox potential. The unprecedented TOF of the active site is correlated to its near-optimal Fe 2+/3+ redox potential, and essentially originated from its favorable biomimetic dynamic nature that balances the site-blocking effect and O 2 dissociation. The porous and disordered carbon matrix of the catalyst plays pivotal roles for its measured high ORR activity by hosting high population of reactant-accessible active sites. 50In situ characterizations reveal that the biomimetic dynamic nature of the Fe-N-C active site with a near-optimal Fe 2+/3+ redox potential formed upon pyrolysis accounts for its high ORR activity by balancing the site-blocking effect and O 2 dissociation.

Nitrogen-doped carbon materials featuring atomically dispersed metal cations (M−N−C) are an emerging family of materials with potential applications for electrocatalysis. The electrocatalytic activity of M−N−C materials toward four-electron oxygen reduction reaction (ORR) to H 2 O is a mainstream line of research for replacing platinumgroup-metal-based catalysts at the cathode of fuel cells. However, fundamental and practical aspects of their electrocatalytic activity toward two-electron ORR to H 2 O 2 , a future green "dream" process for chemical industry, remain poorly understood. Here we combined computational and experimental efforts to uncover the trends in electrochemical H 2 O 2 production over a series of M−N−C materials (M = Mn, Fe, Co, Ni, and Cu) exclusively comprising atomically dispersed M−N x sites from molecular first-principles to bench-scale electrolyzers operating at industrial current density. We investigated the effect of the nature of a 3d metal within a series of M−N−C catalysts on the electrocatalytic activity/selectivity for ORR (H 2 O 2 and H 2 O products) and H 2 O 2 reduction reaction (H 2 O 2 RR). Co−N−C catalyst was uncovered with outstanding H 2 O 2 productivity considering its high ORR activity, highest H 2 O 2 selectivity, and lowest H 2 O 2 RR activity. The activity−selectivity trend over M−N−C materials was further analyzed by density functional theory, providing molecular-scale understandings of experimental volcano trends for four-and two-electron ORR. The predicted binding energy of HO* intermediate over Co−N−C catalyst is located near the top of the volcano accounting for favorable two-electron ORR. The industrial H 2 O 2 productivity over Co−N−C catalyst was demonstrated in a microflow cell, exhibiting an unprecedented production rate of more than 4 mol peroxide g catalyst −1 h −1 at a current density of 50 mA cm −2 .