Combining the abundance
and inexpensiveness of their constituent
elements with their atomic dispersion, atomically dispersed Fe–N–C
catalysts represent the most promising alternative to precious-metal-based
materials in proton exchange membrane (PEM) fuel cells. Due to the
high temperatures involved in their synthesis and the sensitivity
of Fe ions toward carbothermal reduction, current synthetic methods
are intrinsically limited in type and amount of the desired, catalytically
active Fe–N4 sites, and high active site densities
have been out of reach (dilemma of Fe–N–C catalysts).
We herein identify a paradigm change in the synthesis of Fe–N–C
catalysts arising from the developments of other M–N–C
single-atom catalysts. Supported by DFT calculations we propose fundamental
principles for the synthesis of M–N–C materials. We
further exploit the proposed principles in a novel synthetic strategy
to surpass the dilemma of Fe–N–C catalysts. The selective
formation of tetrapyrrolic Zn–N4 sites in a tailor-made
Zn–N–C material is utilized as an active-site imprint
for the preparation of a corresponding Fe–N–C catalyst.
By successive low- and high-temperature ion exchange reactions, we
obtain a phase-pure Fe–N–C catalyst, with a high loading
of atomically dispersed Fe (>3 wt %). Moreover, the catalyst is
entirely
composed of tetrapyrrolic Fe–N4 sites. The density
of tetrapyrrolic Fe–N4 sites is more than six times
as high as for previously reported tetrapyrrolic single-site Fe–N–C
fuel cell catalysts.