The challenge of achieving a high density of Fe-based active sites in a highly graphitic carbon matrix

Abstract

As one of the most promising platinum group metal-free (PGM-free) catalysts for oxygen reduction reaction (ORR), Fe-N-C catalysts with a high density of FeNx moieties integrated in a highly graphitic carbon matrix with a proper porous structure have attracted extensive attention to combine the high activity, high stability and high accessibility of active sites. Herein, we investigated a ZnCl2/NaCl eutectic salts-assisted ionothermal carbonization method (ICM) to synthesize Fe-N-C catalysts with tailored porous structure, high specific surface area and a high degree of graphitization. However, it was found to be challenging to anchor a high density of FeNx sites onto highly graphitized carbon. Iron precursors with preexisting Fe-N coordination were required to form FeNx sites in the nitrogen-doped carbon with a high degree of graphitization, while individual Fe and N precursors led to a Fe-N-C catalyst with poor-ORR activity. This provides valuable insights into the synthesis-structure relationship. Moreover, the FeNx moieties were identified as the major active sites in acidic conditions, while both FeNx sites and Fe2O3 were found to be active in alkaline medium.