Fe‐N‐C Oxygen Reduction Fuel Cell Catalyst Derived from Carbendazim: Synthesis,Structure, and Reactivity

New non‐PGM catalysts from the family of Fe‐N‐C pyrolyzed materials are reported. They are synthesized using a templating silica powder with iron nitrate and carbendazim (CBDZ) precursors (sacrificial support method). The synthesis involves high temperature pyrolysis, followed by etching of the sacrificial support (silica) and obtaining a “self‐supported” open frame morphology catalyst. Both the temperature of heat treatment and Fe to CBDZ ratio play a crucial role in the final catalytic activity in oxygen reduction reaction (ORR). Prepared materials have extremely high durability in RDE tests, ending up with more than 94% of initial activity (by E_1/2 value) after 10 000 cycles in an oxygen atmosphere, which is the result we report for the first time. Evaluation of these new M‐N‐C catalysts in a single membrane electrode assembly (MEA) has shown an exceptionally high open circuit voltage (OCV) of 1 V and the world's second best performance with no IR correction. MEA tests have shown high current density of 700 mA cm^‐2 at 0.6 V and 120 mA cm^‐2 at 0.8 V. In‐depth structure‐to‐property correlation presents an evidence that Fe‐N_x centers are the active sites playing a key role in oxygen reduction reaction.     

Biaxial Strains Mediated Oxygen Reduction Electrocatalysis on Fenton Reaction Resistant L10‐PtZn Fuel Cell Cathode

PtM alloy catalysts (e.g., PtFe, PtCo), especially in an intermetallic L1₀ structure, have attracted considerable interest due to their respectable activity and stability for the oxygen reduction reaction (ORR) in proton exchange membrane fuel cells (PEMFCs). However, metal‐catalyzed formation of ·OH from H₂O₂ (i.e., Fenton reaction) by Fe‐ or Co‐containing catalysts causes severe degradation of PEM/catalyst layers, hindering the prospects of commercial applications. Zinc is known as an antioxidant in Fenton reaction, but is rarely alloyed with Pt owing to its relatively negative redox potential. Here, sub‐4 nm intermetallic L1₀‐PtZn nanoparticles (NPs) are synthesized as high‐performance PEMFC cathode catalysts. In PEMFC tests, the L1₀‐PtZn cathode achieves outstanding activity (0.52 A mg_Pt^?1 at 0.9 V_iR‐free, and peak power density of 2.00 W cm^?2) and stability (only 16.6% loss in mass activity after 30 000 voltage cycles), exceeding the U.S. DOE 2020 targets and most of the reported ORR catalysts. Density function theory calculations reveal that biaxial strains developed upon the disorder‐order (A1? L1₀) transition of PtZn NPs would modulate the surface Pt? Pt distances and optimize Pt? O binding for ORR activity enhancement, while the increased vacancy formation energy of Zn atoms in an ordered structure accounts for the improved stability.     

Facile Metal Coordination of Active Site Imprinted Nitrogen Doped Carbons for the Conservative Preparation of Non‐Noble Metal Oxygen Reduction Electrocatalysts

Iron‐ or cobalt‐coordinated heteroatom doped carbons are promising alternatives for Pt‐based cathode catalysts in polymer‐electrolyte fuel cells. Currently, these catalysts are obtained at high temperatures. The reaction conditions complicate the selective and concentrated formation of metal–nitrogen active sites. Herein a mild procedure is introduced, which is conservative toward the carbon support and leads to active‐site formation at low temperatures in a wet‐chemical metal‐coordination step. Active‐site imprinted nitrogen doped carbons are synthesized via ionothermal carbonization employing Lewis‐acidic Mg²⁺ salt. The obtained carbons with large tubular porosity and imprinted N₄ sites lead to very active catalysts with a half‐wave potential (E_1/2) of up to 0.76 V versus RHE in acidic electrolyte after coordination with iron. The catalyst shows 4e^? selectivity and exceptional stability with a half‐wave potential shift of only 5 mV after 1000 cycles. The X‐ray absorption fine structure as well as the X‐ray absorption near edge structure profiles of the most active catalyst closely match that of iron(II)phthalocyanine, proving the formation of active and stable FeN₄ sites at 80 °C. Metal‐coordination with other transition metals reveals that Zn–N_x sites are inactive, while cobalt gives rise to a strong performance increase even at very low concentrations.     

Sequential Synthesis and Active‐Site Coordination Principle of Precious Metal Single‐Atom Catalysts for Oxygen Reduction Reaction and PEM Fuel Cells

Carbon‐supported precious metal single‐atom catalysts (PM SACs) have shown promising application in proton exchange membrane fuel cells (PEMFCs). However, the coordination principle of the active site, consisting of one PM atom and several coordinating anions, is still unclear for PM SACs. Here, a sequential coordination method is developed to dope a large amount of PM atoms (Ir, Rh, Pt and Pd) into a zeolite imidazolate framework (ZIF), which are further pyrolyzed into nitrogen‐coordinated PM SACs. The PM loadings are as high as 1.2–4.5 wt%, achieving the highest PM loadings in ZIF‐derived SACs to date. In the acidic half‐cell, Ir₁‐N/C and Rh₁‐N/C exhibit much higher oxygen reduction reaction (ORR) activities than nanoparticle catalysts Ir/C and Rh/C. In the contrast, the activities of Pd₁‐N/C and Pt₁‐N/C are considerably lower than Pd/C and Pt/C. Density function theory (DFT) calculations reveal that the ORR activity of PM SAC depends on the match between the OH* adsorption on PM and the electronegativity of coordinating anions, and the stronger OH* adsorption is, the higher electronegativity is needed for the coordinating anions. PEMFC tests confirm the active‐site coordination principle and show the extremely high atomic efficiency of Ir₁‐N/C. The revealed principle provides guidance for designing future PM SACs for PEMFCs.     

Post Iron Decoration of Mesoporous Nitrogen‐Doped Carbon Spheres for Efficient Electrochemical Oxygen Reduction

Iron–nitrogen–carbon (Fe–N–C) catalysts are considered as the most promising nonprecious metal catalysts for oxygen reduction reactions (ORRs). Their synthesis generally involves complex pyrolysis reactions at high temperature, making it difficult to optimize their composition, pore structure, and active sites. This study reports a simple synthesis strategy by reacting preformed nitrogen‐doped carbon scaffolds with iron pentacarbonyl, a liquid precursor that can effectively form active sites with the nitrogen sites, enabling more effective control of the catalyst. The resultant catalyst possesses a well‐defined mesoporous structure, a high surface area, and optimized active sites. The catalysts exhibit high ORR activity comparable to that of Pt/C catalyst (40% Pt loading) in alkaline media, with excellent stability and methanol tolerance. The synthetic strategy can be extended to synthesize other metal–N–C catalysts.     

Atomic Fe‐Doped MOF‐Derived Carbon Polyhedrons with High Active‐Center Density and Ultra‐High Performance toward PEM Fuel Cells

A metalorganic gaseous doping approach for constructing nitrogen‐doped carbon polyhedron catalysts embedded with single Fe atoms is reported. The resulting catalysts are characterized using scanning transmission electron microscopy, X‐ray photoelectron spectroscopy, and X‐ray absorption spectroscopy; for the optimal sample, calculated densities of Fe–N_x sites and active N sites reach 1.75812 × 10¹³ and 1.93693 × 10¹⁴ sites cm^‐2, respectively. Its oxygen reduction reaction half‐wave potential (0.864 V) is 50 mV higher than that of 20 wt% Pt/C catalyst in an alkaline medium and comparable to the latter (0.78 V vs 0.84 V) in an acidic medium, along with outstanding durability. More importantly, when used as a hydrogen–oxygen polymer electrolyte membrane fuel cell (PEMFC) cathode catalyst with a catalyst loading as low as 1 mg cm^‐2 (compared with a conventional loading of 4 mg cm^‐2), it exhibits a current density of 1100 mA cm^‐2 at 0.6 V and 637 mA cm^‐2 at 0.7 V, with a power density of 775 mW cm^‐2, or 0.775 kW g^–1 of catalyst. In a hydrogen–air PEMFC, current density reaches 650 mA cm^‐2 at 0.6 V and 350 mA cm^‐2 at 0.7 V, and the maximum power density is 463 mW cm^‐2, which makes it a promising candidate for cathode catalyst toward high‐performance PEMFCs.     

A New Approach to Fuel Cell Electrodes: Lanthanum Aluminate Yielding Fine Pt Nanoparticle Exsolution for Oxygen Reduction Reaction

Designing an electrocatalyst with low Pt content is an immediate need for essential reactions in low temperature fuel cell systems. In the present work, La_0.9925Ba_0.0075Al_0.995Pt_0.005O₃ is aimed at using with low (only 0.5%) Pt doping as an electrocatalyst for oxygen reduction reaction (ORR). The low doping level renders exsolution of 1–2 nm nanoparticles with uniform dispersion upon reduction in H₂/N₂ at low temperatures. Pt exsolved perovskite oxides deliver significantly enhanced catalytic activity for ORR and improved stability in alkaline media. This study demonstrates that LaAlO₃ with low noble metal content holds immense potential as an electrocatalyst in real fuel cell systems.     

Oxygen Reduction Reactions on Single‐ or Few‐Atom Discrete Active Sites for Heterogeneous Catalysis

The oxygen reduction reaction (ORR) is of great importance in energy‐converting processes such as fuel cells and in metal–air batteries and is vital to facilitate the transition toward a nonfossil dependent society. The ORR has been associated with expensive noble metal catalysts that facilitate the O₂ adsorption, dissociation, and subsequent electron transfer. Single‐ or few‐atom motifs based on earth‐abundant transition metals, such as Fe, Co, and Mo, combined with nonmetallic elements, such as P, S, and N, embedded in a carbon‐based matrix represent one of the most promising alternatives. Often these are referred to as single atom catalysts; however, the coordination number of the metal atom as well as the type and nearest neighbor configuration has a strong influence on the function of the active sites, and a more adequate term to describe them is metal‐coordinated motifs. Despite intense research, their function and catalytic mechanism still puzzle researchers. They are not molecular systems with discrete energy states; neither can they fully be described by theories that are adapted for heterogeneous bulk catalysts. Here, recent results on single‐ and few‐atom electrocatalyst motifs are reviewed with an emphasis on reports discussing the function and the mechanism of the active sites.     

3D Hierarchical Core–Shell Nanostructured Arrays on Carbon Fibers as Catalysts for Direct Urea Fuel Cells

Bifunctional cobalt oxide (Co₃O₄) nanowire catalysts grown on carbon cloth (CC) fibers and their modification with nickel oxide (NiO) and manganese dioxide (MnO₂) to produce core–shell nanoarchitectures are explored as catalysts for urea oxidation reaction and oxygen reduction reaction in direct urea fuel cells (DUFC). Based on a systematic electrochemical characterization of the catalyst, the as‐developed core–shell nanoarchitectures are optimized toward DUFC performance. Under alkaline conditions with an anion exchange membrane, the DUFC with a cell configuration of Co₃O₄@NiO(1:2)/CC(a|c)Co₃O₄@MnO₂(1:2)/CC exhibits a maximum power density of 33.8 mW cm^?2 with excellent durability for 120 h without any performance loss. Furthermore, the DUFC exhibits a maximum power density of 23.2 mW cm^?2 with human urine as a fuel. These findings offer an approach to convert human waste into treasure.     

Boosting the Activity of BaCo0.4Fe0.4Zr0.1Y0.1O3−δ Perovskite for Oxygen Reduction Reactions at Low‐to‐Intermediate Temperatures through Tuning B‐Site Cation Deficiency

Doped perovskite oxides with the general formula of A_xA′_1?xB_yB′_1?yO₃ have been extensively exploited as the cathode materials of solid oxide fuel cells (SOFCs), but the performance at low‐to‐medium temperatures still needs improvement. BaCo_0.4Fe_0.4Zr_0.1Y_0.1O_3?δ (BCFZY) has been recently reported to show promising oxygen reduction reaction (ORR) activity under SOFCs' operating conditions. Here, it is reported that the activity of BCFZY can be further boosted via introducing a slight B‐site cation deficiency into the oxide lattice, and such an improvement is assigned to an increase in oxygen mobility that brings enhancement in both surface exchange and bulk diffusion kinetics. Specifically, materials with the nominal composition of Ba(Co_0.4Fe_0.4Zr_0.1Y_0.1)_0.975O_3?δ and Ba(Co_0.4Fe_0.4Zr_0.1Y_0.1)_0.95O_3?δ show significantly improved activity for ORR at reduced temperatures with the area specific resistances of 0.011 and 0.024 Ω cm² at 600 °C, as a comparison of 0.042 Ω cm² for the cation stoichiometric BCFZY. Excessive B‐site deficiencies, however, lead to the formation of impurity phases, which cause a block for charge transfer and, consequently, a reduction in electrode performance. Introducing a B‐site cation deficiency is a promising way to optimize the activity of perovskite oxides for ORR at reduced temperatures, but the degree of deficiency shall be carefully tuned.     

Exceptionally Enhanced Electrode Activity of (Pr,Ce)O2−δ‐Based Cathodes for Thin‐Film Solid Oxide Fuel Cells

It is shown that an electrochemically‐driven oxide overcoating substantially improves the performance of metal electrodes in high‐temperature electrochemical applications. As a case study, Pt thin films are overcoated with (Pr,Ce)O_2?δ (PCO) by means of a cathodic electrochemical deposition process that produces nanostructured oxide layers with a high specific surface area and uniform metal coverage and then the coated films are examined as an O₂‐electrode for thin‐film‐based solid oxide fuel cells. The combination of excellent conductivity, reactivity, and durability of PCO dramatically improves the oxygen reduction reaction rate while maintaining the nanoscale architecture of PCO layers and thus the performance of the PCO‐coated Pt thin‐film electrodes at high temperatures. As a result, with an oxide coating step lasting only 5 min, the electrode resistance is successfully reduced by more than 1000 times at 500 °C in air. These observations provide a new direction for the design of high‐performance electrodes for high‐temperature electrochemical cells.