Novel carbon-supported Fe-N electrocatalysts synthesized through heat treatment of iron tripyridyl triazine complexes for the PEM fuel cell oxygen reduction reaction

2,4,6-Tris(2-pyridyl)-1,3,5-triazine (TPTZ) was used as a ligand to prepare iron-TPTZ (Fe-TPTZ) complexes for the development of a new oxygen reduction reaction (ORR) catalyst. The prepared Fe-TPTZ complexes were then heat-treated at temperatures ranging from 400 °C to 1100 °C to obtain carbon-supported Fe-N catalysts (Fe-N/C). These catalysts were characterized in terms of catalyst composition, structure, and morphology by several instrumental methods such as energy dispersive X-ray, X-ray diffraction, transmission electron microscopy, and X-ray photoelectron spectroscopy. With respect to the ORR activity, the Fe-N/C catalysts were also evaluated by cyclic voltammetry, as well as rotating disk and ring-disk electrodes. The results showed that among the heat-treated catalysts, that obtained at a heat-treatment temperature of 800 °C is the most active ORR catalyst. The overall electron transfer number for the catalyzed ORR was determined to be between 3.5 and 3.8, with 10-30% H₂O₂ production. The ORR catalytic activity of this catalyst was also tested in a hydrogen-air proton exchange membrane (PEM) fuel cell. At a cell voltage of 0.30 V, this fuel cell can give a current density of 0.23 A cm⁻² with a maximum MEA power density of 0.070 W cm⁻² indicating that this catalyst has potential to be used as a non-noble catalyst in PEM fuel cells.     

Fe loading of a carbon-supported Fe–N electrocatalyst and its effect on the oxygen reduction reaction

Carbon-supported non-noble metal catalysts with Fe as the metal and tripyridyl triazine (TPTZ) as the ligand (Fe-TPTZ/C) were synthesized using a simple chemical method. How the Fe loading in this Fe-TPTZ/C catalyst affected the ORR activity was investigated using several Fe loadings: 0.2, 0.4, 0.7, 2.7, 4.7, 5.8 and 7.8 wt%. The as-prepared catalysts were then heat-treated at 800 °C in an N₂ environment to obtain catalysts of Fe–N/C. Energy dispersive X-ray spectroscopy (EDX) was used to identify the Fe–N/C catalysts. These Fe–N/C catalysts showed significant ORR activity improvement over the as-prepared Fe-TPTZ/C catalysts. The kinetics of the ORR catalyzed by the catalysts with different Fe loadings was studied using the rotating disk electrode technique. It was observed that a 4.7 wt% Fe loading yielded the best catalytic ORR activity. Regarding the overall ORR electron transfer number, it was found that as the catalyst's Fe loading increased, the overall ORR electron transfer number changed from 2.9 to 3.9, suggesting that increasing the Fe loading could alter the ORR mechanism from a 2-electron to a 4-electron transfer dominated process. The Tafel method was also used to obtain one important kinetic parameter: the exchange current density. A fuel cell was assembled using a membrane electrode assembly with 4.7 wt% Fe loaded Fe–N/C as the cathode catalyst, and the cell was tested for both performance and durability, yielding a 1000-h lifetime.     

The effect of boron doping into Co-C-N and Fe-C-N electrocatalysts on the oxygen reduction reaction

Co-C-N and Fe-C-N thin film catalysts have been modified by controlled doping with boron. Corresponding novel thin film catalysts Co-C-N-B and Fe-C-N-B were synthesized by combinatorial magnetron sputter deposition in an Ar/N₂ gas mixture followed by subsequent heat-treatment between 700 and 1000 °C in an argon atmosphere. The nitrogen content of the as-prepared thin film catalysts could be increased by the addition of boron. Furthermore, the amount of remaining nitrogen in heat-treated catalyst samples was significantly higher in case of boron containing samples. The thin film catalysts were characterized by means of X-ray diffraction (XRD) analysis, electron microprobe and electrochemical measurements. For electrochemical studies the activity as oxygen reduction reaction (ORR) catalyst was investigated using the rotating ring-disk electrode (RRDE) technique in 0.1 M HClO₄ solution at room temperature. The catalytic activity was found to decrease with the boron content in the thin film catalysts even though the N-content increased.     

Cobalt based non-precious electrocatalysts for oxygen reduction reaction in proton exchange membrane fuel cells

Cobalt based non-precious metal catalysts were synthesized using chelation of cobalt (II) by imidazole followed by heat-treatment process and investigated as a promising alternative of platinum (Pt)-based electrocatalysts in proton exchange membrane fuel cells (PEMFCs). Transmission electron microscopy (TEM), X-ray diffraction (XRD) and X-ray photoelectron spectroscopy (XPS) measurements were used to characterize the synthesized CoN_x/C catalysts. The activities of the catalysts towards oxygen reduction reaction (ORR) were investigated by electrochemical measurements and single cell tests, respectively. Optimization of the heat-treatment temperature was also explored. The results indicate that the as-prepared catalyst presents a promising electrochemical activity for the ORR with an approximate four-electron process. The maximum power density obtained in a H₂/O₂ PEMFC is as high as 200 mW cm⁻² with CoN_x/C loading of 2.0 mg cm⁻².     

Effect of Co on oxygen reduction reaction catalyzed by Pt catalyst, and its implications for fuel cell contamination

The oxygen reduction reaction (ORR) catalyzed by Pt was studied in the presence of Co²⁺ using cyclic voltammetry (CV), rotating disk electrode (RDE), and rotating ring-disk electrode (RRDE) techniques in an effort to understand fuel cell cathode contamination caused by Co²⁺. Findings indicated that Co²⁺ could weakly adsorb on the Pt surface, resulting in a slight change in ORR exchange current densities. However, this weak adsorption had no significant effect on the nature of the ORR rate determining steps. The results from both RDE and RRDE indicated that the overall electron transfer number of the ORR in the presence of Co²⁺ was reduced, with ∼9% more H₂O₂ being produced. We speculate that the weakly adsorbed Co²⁺ on Pt could react with the H₂O₂ intermediate and form a Co²⁺-H₂O₂ intermediate, inhibiting the further reduction of H₂O₂ and thus resulting in more H₂O₂ production. The fuel cell performance drop observed in the presence of Co²⁺ could be attributed to the reduction in overall electron transfer number and the increase in H₂O₂ production. Higher production could intensify the attack by H₂O₂ and its radicals on membrane electrode assembly components, including the ionomer, carbon support, Pt particles, and membrane, leading to fuel cell degradation.     

Oxygen reduction reaction (ORR) catalyzed by carbon-supported cobalt polypyrrole (Co-PPy/C) electrocatalysts

This paper reports the experimental characterization of carbon-supported cobalt polypyrrole (Co-PPy/C) catalysts synthesized using a chemical method of polymerization synthesis. Both unpyrolyzed and pyrolyzed catalysts were characterized using electrochemical techniques such as cyclic voltammetry (CV), rotating disk electrode (RDE), as well as rotating ring disk electrode (RRDE) to quantitatively obtain the oxygen reduction reaction (ORR) kinetic constants and the reaction mechanisms. The pyrolyzed catalyst showed significantly improved ORR activity as well as different ORR mechanisms, suggesting that heat-treatment is a necessary step for catalyst activity improvement. To understand the heat-treatment effect, X-ray photoelectron spectroscopy (XPS) was used to detect surface structure changes. The XPS results showed that after the sample was heat-treated, new nitrogen peaks corresponding to pyrrolic (or pyridone) and graphitic (quaternary) type nitrogens could be observed. Both of these species may be assigned to sites catalytically active towards the ORR, resulting in activity enhancement as well as a mechanism change from a two-electron dominant to a four-electron dominant reduction process, when compared to that of the unpyrolyzed catalyst.     

Oxygen reduction reaction on carbon-supported CoSe2 nanoparticles in an acidic medium

We investigated the effect of CoSe₂/C nanoparticle loading rate on oxygen reduction reaction (ORR) activity and H₂O₂ production using the rotating disk electrode and the rotating ring-disk electrode techniques. We prepared carbon-supported CoSe₂ nanoparticles with different nominal loading rates and evaluated these samples by means of powder X-ray diffraction. All the catalysts had an OCP value of 0.81 V vs. RHE. H₂O₂ production during the ORR process decreased with an increase in catalytic layer thickness. This decrease was related to the CoSe₂ loading on the disk electrode. H₂O₂ production also decreased with increasing catalytic site density, a phenomenon related to the CoSe₂ loading rate on the carbon substrate. The cathodic current density significantly increased with increasing catalytic layer thickness, but decreased with increasing catalytic site density. In the case of 20 wt% CoSe₂/C nanoparticles at 22 μg cm⁻², we determined that the transfer process involves about 3.5 electrons.     

Effect of synthetic reducing agents on morphology and ORR activity of carbon-supported nano-Pd–Co alloy electrocatalysts

Three different reducing agents, ethylene glycol (EG), formaldehyde (HCHO), and sodium borohydrate (NaBH₄), were used in the synthesis of carbon-supported Pd–Co catalysts (Pd–Co/C–EG, Pd–Co/C–HCHO, and Pd–Co/C–NaBH₄, respectively). The differences among these three catalysts in morphology and electrocatalytic activity for oxygen reduction reaction (ORR) were observed and characterized using X-ray diffraction, energy dispersive X-ray analysis, transmission electron microscope, Fourier transform infrared spectra, surface cyclic voltametry, and rotating disk electrode technique. It was observed that by using a mild reducing agent such as EG, well-controlled and homogenous nucleation and growth could be achieved during the catalyst synthesis. With respect to the morphology and ORR activity of synthesized catalysts, the order of preferred reducing agents was found to be EG > NaBH₄ > HCHO. In order to improve activity and stability, the catalysts were heat-treated at temperatures ranging from 300 °C to 700 °C. It was found that for all three Pd–Co/C catalysts, a temperature of 300 °C gave the best catalyst morphology and ORR activity. The investigation in ORR kinetics catalyzed by these three catalysts revealed that all three could catalyze a four-electron reduction of oxygen to produce water. The average Tafel slope of the catalyzed ORR was found to be 70 mV/dec, suggesting that the determining step in the mechanism is a one-electron transfer process. In an effort to validate the theoretical explanation, the ORR activity as a function of particle size, Pd lattice constant, and Pd–Pd bond distance of the three Pd–Co/C catalysts was also investigated. In addition, in the case of EG as reducing agent the impregnation–reduction method employed in this work was simplified, because the need for a stabilizing agent usage was removed and water was used as the solvent.     

SECM imaging of electrocatalytic activity for oxygen reduction reaction on thin film materials

The oxygen reduction reaction (ORR) on sputtered Pt thin films in acidic solution was successfully studied by scanning electrochemical microscopy (SECM) in a modified tip generation-substrate collection (TG-SC) mode. SECM images of ORR activity in different sample areas were obtained and it is shown that this TG-SC SECM technique can be used to screen electrocatalytic activity of continuous thin film samples efficiently and quickly for the ORR in an acidic medium. It is observed that this technique is not very sensitive to the tip-substrate separation within a certain range. The SECM images obtained are strongly dependent on the substrate potential. The advantages of this technique for studying ORR electrocatalysts are discussed.     

Fe–Nx/C electrocatalysts synthesized by pyrolysis of Fe(II)–2,3,5,6-tetra(2-pyridyl)pyrazine complex for PEM fuel cell oxygen reduction reaction

2,3,5,6-Tetra(2-pyridyl)pyrazine (TPPZ) was employed as a ligand to prepare an iron(II) complex (Fe–TPPZ) that served as a precursor to synthesize carbon-supported catalysts (Fe–N_x/C) through heat-treatment at 600, 700, 800 and 900 °C under N₂ atmosphere. Both the structure and composition of the synthesized Fe–N_x/C were analyzed by X-ray diffraction and energy-dispersive X-ray microanalysis, respectively. The rotating disk and ring-disk electrode measurements showed that these catalysts have strong ORR activity with an overall 4-electron transfer process through a (2 + 2)-electron transfer mechanism, which was assigned to the catalytic function of the Fe–N_x center. A study on the heat-treatment temperature on the ORR activity showed that 800 °C is the optimal temperature for the synthesized catalysts. Furthermore, the effect of both catalyst and Nafion^® ionomer loadings in the catalyst layer on the corresponding ORR activity was also investigated. The kinetic parameters such as the chemical reaction rate between O₂ and Fe–N_x/C (adduct formation reaction), the rate constant for the rate-determining step (RDS), and the electron numbers in the ORR, were obtained. The methanol tolerance of the catalyst was also tested. To validate the ORR activity, a membrane electrode assembly in which the cathode catalyst layer contained Fe–N_x/C was constructed and tested in a real fuel cell. The results obtained are encouraging when compared with similar non-noble catalysts.     

Investigation into the activity of heteropolyacids towards the oxygen reduction reaction on PEMFC cathodes

A total of 18 heteropolyacids (HPAs) were investigated to determine their activity as non-Pt oxygen reduction reaction (ORR) catalysts in polymer electrolyte membrane fuel cell cathodes (PEMFCs). Polarization curves, cyclic voltammetry and impedance spectroscopy determined that, of the HPAs tested, only molybdenum based HPAs are active for the ORR and that vanadium substitutions improved the activity. The reduction potentials of the HPAs in the fuel cell environment were determined by cyclic voltammetry. This showed that no activity is seen above 0.55 V, as the catalysts must first be reduced in situ by 4e⁻ before the HPA can reduce oxygen. The potential at which the HPA can be reduced has been determined to be the limiting factor when using these catalysts for ORR in PEMFCs. Power densities of 67 mW/cm² at 0.2 V were obtained using H₅PMo₁₀V₂O₄₀. Molybdenum based HPAs were covalently bonded to the carbon achieving mass loadings 3× that obtained through adsorption. Using this approach catalyst, performance was improved to 86 mW/cm² at 0.2 V. The increased loadings did not significantly increase the potentials at which the HPA becomes active for the ORR. We were able to show that MEA degradation, as measured by F⁻ emission rates, using these catalysts are reduced during accelerated testing protocols.     

Additive treatment effect of TiO2 as supports for Pt-based electrocatalysts on oxygen reduction reaction activity

In this study, we investigated the additive treatment effect of TiO₂ as alternative support materials to common carbon black for Pt-based electrocatalysts on electrocatalytic activity for oxygen reduction reaction (ORR). The shape of TiO₂ was varied by hydrothermal treatment with various additives, such as urea, thiourea, and hydrofluoric acid. From the results of transmission electron microscopy (TEM) images and ultraviolet-visible spectroscopy (UV-vis) spectra, it was identified that the morphology of hydrofluoric acid (HF)-treated TiO₂ was changed into a round shape having lower aspect ratio than other samples, and its band gap was decreased. Notably, the electronic state of HF-treated TiO₂ support was changed into highly reduced (electron rich) state which led to the increase of ORR activity, compared to other samples treated with different additives or before treatment. The electrocatalytic characteristics changes after treatment with various additives were investigated by using X-ray diffraction (XRD), X-ray photoemission spectroscopy (XPS), cyclic voltammograms (CV), and rotating disk electrode (RDE) techniques.     

Carbon-supported manganese oxide nanoparticles as electrocatalysts for oxygen reduction reaction (orr) in neutral solution

Manganese oxides (MnO _x ) catalysts were chemically deposited onto various high specific surface area carbons. The MnO _x /C electrocatalysts were characterised using a rotating disk electrode and found to be promising as alternative, non-platinised, catalysts for the oxygen reduction reaction (ORR) in neutral pH solution. As such they were considered suitable as cathode materials for microbial fuel cells (MFCs). Metal [Ni, Mg] ion doped MnO _x /C, exhibited greater activity towards the ORR than the un-doped MnO _x /C. Divalent metals favour oxygen bond splitting and thus orientate the ORR mechanism towards the 4-electron reduction, yielding less peroxide as an intermediate.     

Fe-based catalysts for oxygen reduction in proton exchange membrane fuel cells with cyanamide as nitrogen precursor and/or pore-filler

Fe/N/C catalysts for oxygen reduction reaction were synthesized via impregnation or ballmilling. The role of cyanamide (CM) as nitrogen precursor and/or pore-filler for a highly microporous carbon (Black Pearls 2000) was investigated. The use of CM in this work resulted in two main differences compared with phenanthroline from our previous work; (i) ballmilling the precursors did not result in improved activity of the resulting catalysts, and (ii) the activity after the first pyrolysis in argon was relatively high, but did not increase after a second pyrolysis in NH₃. These differences may be explained by TGA measurements of both pore-fillers, where complete gasification of CM is observed at temperatures above 750 °C in Ar, while pyrolysis of phenanthroline in Ar results in 20 wt% residual carbon-based material. Consequently, when using CM as pore-filler with a highly microporous carbon support, the maximum microporous surface area and nitrogen content is reached after only a single pyrolysis in Ar. The most active catalyst prepared with CM was obtained by pyrolysing in Ar at 950 °C a catalyst precursor containing 1 wt% Fe, 80 wt% CM and Black Pearls 2000. This catalyst possessed about 1/6th the catalytic activity of best reported using phenanthroline as a pore-filler. Changing the carbon support had effects on the activity and stability of the catalysts. The catalysts made with a non-porous furnace black (N330) or carbon nanotubes as a carbon support were more stable but less performing than those using carbon supports having high microporous surface area like Black Pearls 2000 or Ketjenblack. The desirable properties for a pore-filler molecule used in the synthesis of Fe/N/C-catalysts by the pore-filling method are discussed.     

EIS-assisted performance analysis of non-noble metal electrocatalyst (Fe-N/C)-based PEM fuel cells in the temperature range of 23-80 °C

A carbon-supported non-noble metal catalyst, Fe-N/C, was used as the cathode catalyst to construct membrane electrolyte assemblies (MEAs) for a proton exchange membrane (PEM) fuel cell. The performance of such a fuel cell was then tested and diagnosed using electrochemical impedance spectroscopy (EIS) in the temperature range of 23-80 °C. Based on the EIS measurements, individual resistances, such as charger transfer resistance and membrane resistance, were obtained and used to simulate polarization curves (current-voltage (I-V) curves). A close agreement between the simulated I-V curves and the measured curves demonstrates consistency between the polarization and EIS data. The temperature-dependent parameters obtained via EIS, such as apparent exchange current densities and electrolyte membrane conductivities, were also used to acquire activation energies for both the oxygen reduction reaction (ORR) catalyzed by an Fe-N/C catalyst and the proton transport process across the electrolyte membrane. In addition, the maximum power densities for such a fuel cell were also analyzed.     

Nanostructured Pt-M/C (M = Fe and Co) catalysts prepared by a microemulsion method for oxygen reduction in proton exchange membrane fuel cells

Nanostructured Pt-M/C (M = Fe and Co) catalysts have been synthesized by a microemulsion method and a high-temperature route. They have been characterized by cyclic voltammetry in 1 M H₂SO₄ and for oxygen reduction in proton exchange membrane fuel cells (PEMFC). The Pt-M alloy catalysts synthesized by the microemulsion method show higher electrochemical active surface area than those prepared by the high-temperature route, and some of them exhibit improved catalytic activity towards oxygen reduction compared to pure Pt. Among the various alloy catalysts investigated, the Pt-Co/C catalyst prepared by the microemulsion method shows the best performance with the maximum catalytic activity and minimum polarization loss. Mild heat treatment of the catalysts prepared by the microemulsion method at moderate temperatures (200 °C) in reducing atmosphere is found to improve the catalytic activity due to a cleaning of the surface and an increase in the electrochemical surface area.     

Improved ORR activity of non-noble metal electrocatalysts by increasing ligand and metal ratio in synthetic complex precursors

In an effort to improve oxygen reduction reaction (ORR) activity by increasing the catalytic active site density in carbon-supported non-noble metal catalysts, several nitrogen-containing catalysts were synthesized through a heat treatment process at 900 °C using precursor complexes of Fe(II) and tripyridyl triazine (TPTZ). Fe to TPTZ mole ratios of 1:2, 1:3, 1:4, 1:5, 1:6, and 1:7 were used to prepare the precursor complexes. X-ray diffraction and surface electrochemical techniques were used to characterize these catalysts (Fe–N_x/C), and revealed that when the amount of TPTZ in the precursor complex was increased, the decomposition of Fe–N_x sites, which are considered active sites for the ORR, was effectively reduced, resulting in higher Fe–N_x site density and thus improving the catalysts’ ORR activity. This beneficial effect was validated through rotating disk electrode tests and analysis of the ORR kinetics catalyzed by these catalysts. The obtained results showed that as the Fe to TPTZ mole ratio in the precursor complex was decreased, the catalytic ORR activity of Fe–N_x/C increased monotonically in the mole ratio range of 1:2–1:6. Therefore, increasing the amount of ligand in the precursor metal complex was demonstrated to be an effective way to reduce the decomposition of ORR active site density and thereby enhance the ORR activity of non-noble metal catalysts.     

The effect of heat treatment on nanoparticle size and ORR activity for carbon-supported Pd-Co alloy electrocatalysts

Carbon-supported Pd-Co alloy electrocatalysts were synthesized and characterized for the purpose of the fuel cell cathode oxygen reduction reaction (ORR). An impregnation method was employed for the synthesis, in which sodium borohydride was used as a reducing agent. The synthesized catalysts were characterized in terms of structural morphology and catalytic activity by XRD, XPS and electrochemical measurements. Surface cyclic voltammetry was used to confirm the formation of the Pd-Co alloy. In order to improve activity and stability, the catalysts were heat-treated in the temperature range of 300 °C to 700 °C. The optimal heat-treatment temperature was found to be 300 °C, where the average particle size of 8.9 nm, and the highest ORR catalytic activity, were obtained. The catalyzed ORR kinetics were also studied using the rotating disk electrode (RDE) method. The kinetic parameters were then obtained. Electrocatalytic ORR activity was also examined in an acidic solution containing methanol. The results showed that the synthesized Pd-Co/C catalyst has methanol tolerant capabilities.     

Durability of carbon-supported manganese oxide nanoparticles for the oxygen reduction reaction (ORR) in alkaline medium

MnO_x/C-based electrocatalysts, prepared by the chemical deposition of manganese oxide nanoparticles on carbon, were tested towards the Oxygen Reduction Reaction (ORR) in their as-synthesized state and after ageing, either in ambient air for a year (mild ageing) or in an O₂-saturated molar KOH solution at 80 °C for three weeks (premature ageing). For each electrocatalyst, the morphology and composition were characterised using TEM, XRD and chemical analysis. ORR kinetic parameters were evaluated using the Rotating Disk Electrode (RDE) and Rotating Ring Disk Electrode (RRDE) setups. Whilst the oxygen reduction activity of the electrocatalysts barely changes after mild ageing, it decreases after premature ageing following dramatic modifications to both the chemical and crystalline structures of the carbon-supported MnO_x nanoparticles. The peroxide yield also sharply increases after premature ageing. Doping MnO_x/C with nickel or magnesium divalent cations is beneficial since it improves both the catalytic activity and selectivity towards the 4-electron ORR pathway, even after ageing.