Unveiling Low Temperature Assembly of Dense Fe-N4 Active Sites via Hydrogenation in Advanced Oxygen Reduction Catalysts.

The single-atom Fe-N-C is a prominent material with exceptional reactivity in areas of sustainable energy and catalysis research. It is challenging to obtain the dense Fe-N4 site without the Fe nanoparticles (NPs) sintering during the Fe-N-C synthesis via high-temperature pyrolysis. Thus, a novel approach is devised for the Fe-N-C synthesis at low temperatures. Taking FeCl2 as Fe source, a hydrogen environment can facilitate oxygen removal and dichlorination processes in the synthesis, efficiently favouring Fe-N4 site formation without Fe NPs clustering at as low as 360 °C. We shed light on the reaction mechanism about hydrogen promoting Fe-N4 formation in the synthesis. By adjusting the temperature and duration, the Fe-N4 structural evolution and site density can be precisely tuned to directly influence the catalytic behaviour of the Fe-N-C material. The FeNC-H2-360 catalyst demonstrates a remarkable Fe dispersion (8.3 wt %) and superior acid ORR activity with a half-wave potential of 0.85 V and a peak power density of 1.21 W cm-2 in fuel cell. This method also generally facilitates the synthesis of various high-performance M-N-C materials (M=Fe, Co, Mn, Ni, Zn, Ru) with elevated single-atom loadings.

A plasma-assisted approach to enhance density of accessible FeN4 sites for proton exchange membrane fuel cells.

Enhancing the density and utilization of FeN4 sites can serve as a viable approach to enhance the catalytic efficacy of iron nitrogen carbon (FeNC) catalysts for oxygen reduction reaction (ORR). Herein, we present a plasma-assisted method for enhancing the porosity of nitrogen-doped carbon. Our findings indicate that the ideal ratio of mesopore to micropore area is 0.463. This ratio not only promotes the diffusion of Fe3+ but also creates additional active sites for Fe3+ loading, leading to an increase in the number of available FeN4 sites in FeNC electrocatalysts during pyrolysis. The density (76.5 µmol g-1) and utilization (21.08 %) of d-FeNC-30 are significantly higher than those of FeNC without plasma treatment, with a 2.8-fold and 2-fold increase, respectively. Remarkably, it displays outstanding performance, evidenced by a half-wave potential of 0.835 V (vs. RHE) in a 0.1 M HClO4 solution and a power density of 0.860 W cm-2 in proton exchange membrane fuel cells (PEMFCs). The developed plasma-assisted approach for improving the site density (SD) and utilization of FeN4 provides a new perspective for high-performance ORR FeNC catalysts.