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Abbreviation (ISO4): Prog Chem      Editor in chief: Jincai ZHAO

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Review

Degradation Mechanisms and Durability Improvement Strategies of Fe-N-C Catalysts for Oxygen Reduction Reaction

  • Longhao Li 2 ,
  • Wei Zhou , 2, * ,
  • Liang Xie 2 ,
  • Chaowei Yang 2 ,
  • Xiaoxiao Meng , 1, 2, * ,
  • Jihui Gao 2
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  • 1 State Key Laboratory of Urban Water Resource and Environment, Harbin Institute of Technology, Harbin 150090, China
  • 2 School of Energy Science and Engineering, Harbin Institute of Technology, Harbin 150001, China
* e-mail: (Wei Zhou);
(Xiaoxiao Meng)

Received date: 2023-07-26

  Revised date: 2023-09-29

  Online published: 2024-02-26

Supported by

Open Project of State Key Laboratory of Urban Water Resource and Environment, Harbin Institute of Technology(HC202331)

Abstract

Among the many non-precious metal catalysts that have been reported so far, M-N-C catalysts based on transition metal-nitrogen-carbon structure are considered as the most promising candidates to replace Pt-based catalysts for oxygen reduction reaction. Compared with other M-N-C catalysts, Fe-N-C catalysts exhibit the highest ORR activity in acidic environments due to the suitable adsorption energy of oxygen-containing intermediates and thermodynamically favorable 4e pathway. However, the practical application of this catalyst is still limited by the challenge of insufficient stability under the high voltage and strong acidic conditions of PEMFC. Thus, the preparation of stable and efficient Fe-N-C catalysts still faces many challenges. In this review, we systematically summarize the common synthesis methods of Fe-N-C catalysts, including spatial confinement method and template-assisted strategy, outline the half-cell and single-cell test methods used to evaluate the catalyst stability, and analyze the reasons for the discrepancies between the two test results. In order to design highly stable catalysts, a clear knowledge and understanding of the degradation mechanism is required, so we describe four possible degradation mechanisms for Fe-N-C catalysts: demetallization, carbon oxidation, protonation, and microporous water flooding, subsequently we propose some specific strategies to enhance the stability of Fe-N-C catalysts. Finally, the future development direction of Fe-N-C catalysts is discussed in this review. It is hoped that the comprehensive and in-depth study of Fe-N-C catalysts will guide the design and development of highly stable Fe-N-C catalysts for the application of PEMFC.

Contents

1 Introduction

2 Synthesis methods of Fe-N-C catalysts

2.1 Spatial confinement method

2.2 The template method

2.3 Other methods

3 Stability test protocols for Fe-N-C catalysts

3.1 Half-cell test

3.2 Single-cell test

3.3 Analysis of the variability of the results of the two test protocols

4 Degradation mechanisms of Fe-N-C catalysts

4.1 Demetalation

4.2 Carbon crossion

4.3 Protonation

4.4 Water flooding in microporous

5 Durability improvement strategies of Fe-N-C catalysts

5.1 Stable carbon matrix

5.2 Stable active sites

5.3 Avoiding fenton reaction

6 Conclusion and outlook

Cite this article

Longhao Li , Wei Zhou , Liang Xie , Chaowei Yang , Xiaoxiao Meng , Jihui Gao . Degradation Mechanisms and Durability Improvement Strategies of Fe-N-C Catalysts for Oxygen Reduction Reaction[J]. Progress in Chemistry, 2024 , 36(3) : 376 -392 . DOI: 10.7536/PC230725

1 Introduction

Energy shortage and environmental pollution have become important issues related to the sustainable development of human society. Under the goal of "double carbon" strategy, the development of renewable energy and clean energy has become the research focus of energy and related fields. Proton exchange membrane fuel cell (PEMFC) is considered to be the most promising next-generation electrochemical energy conversion device because of its zero emission, wide range of applications, and high energy density[1][2][3][4]. The oxygen reduction reaction (ORR), which occurs at the cathode, has an extremely slow kinetic characteristic [5,6] compared to the hydrogen oxidation reaction (HOR) at the anode. Therefore, efficient electrocatalysts are needed to reduce the large overpotential and speed up the reaction. In the oxygen reduction reaction, the O2 molecule is reduced to H2O2 via a two-electron pathway or to H2O via a four-electron pathway[7][8]. Pt-based catalysts are ideal catalysts for the ORR process due to their good catalytic performance. However, there are still many obstacles to the commercial application of Pt-based catalysts in fuel cells due to their high cost (40% of the total cost of fuel cell stacks), scarce resources, and the poor tolerance of Pt to methanol, carbon monoxide (CO), and chlorides[9][10]. Therefore, it is of great significance to develop non-noble metal catalysts with low cost, high activity and durability.
Through the unremitting efforts of researchers in the field, many non-noble metal catalysts have been widely reported, such as molecular catalysts, transition metal-nitrogen-carbon catalysts (M-N-C, M = Fe, Co, Mn), metal nitrides/oxides/sulfides and so on[11~13][14][15,16][17][18~20]. Among these catalysts, the M-N-C catalyst is considered to be the most promising candidate to replace the Pt-based catalyst. Compared with other M-N-C catalysts, Fe-N-C catalysts exhibit the highest ORR activity in acidic environment due to the suitable adsorption energy of oxygen-containing intermediates and the thermodynamically favorable 4 e pathway. However, under the high voltage and strong acidic conditions of PEMFC, the stability of the catalyst is still far from that of the commercial Pt/C catalyst, which is far from the set cycle life index of 8000 H[21]. It can be seen that the preparation of stable and efficient Fe-N-C catalysts still faces many challenges.
After more than ten years of development, the activity of Fe-N-C catalyst has approached or even exceeded that of Pt/C catalyst, but its stability still hinders the process of commercial application. In order to improve the stability of Fe-N-C catalyst in practical application scenarios, it is necessary to accurately analyze its deactivation mechanism and propose possible life extension strategies. In this paper, the synthesis methods and laboratory test standards of Fe-N-C catalysts are reviewed, four possible deactivation mechanisms are described, and the strategies to inhibit deactivation are proposed from three aspects: the construction of stable carbon supports, active sites and the avoidance of Fenton reaction.

2 Synthesis of Fe-N-C catalyst

The research on transition metal-nitrogen-carbon catalysts can be traced back to 1964, when Jasinski first discovered that cobalt phthalocyanine (CoPc) had electrochemical reduction properties for oxygen[22]. More and more transition metal macrocyclic compounds have been used in the preparation of ORR catalysts after confirming that these macrocyclic compounds all have MN4structure. With the development of research, it has been found that instead of using macrocyclic compounds with MN4structure, it is more convenient to prepare highly active M-N-C catalysts by one-pot pyrolysis method in which small molecular transition metal salts, nitrogen-containing compounds (or nitrogen-containing atmosphere) and carbon supports are heat-treated together. The PEMFC test results under H2-O2 conditions show that the current density of the catalyst at 0. 8 V reaches the 99 A·cm-3, which is close to the target of 130 A·cm-3 to be achieved before 2010[23]. However, the one-pot pyrolysis method has some defects: the experimental conditions are complex, it is not easy to form a universal synthesis process, and due to the uncertainty of the pyrolysis process, it is difficult to ensure that the metal loading and atomic dispersion of the catalyst are the same for each synthesis. In order to further optimize the catalyst design and achieve commercial application, attention has been gradually turned to the single-atom Fe-N-C catalyst with 100% atom utilization.
With the continuous reduction of spatial scale, the performance of catalysts will change qualitatively, which means that single-atom catalysts have some special properties compared with nanoparticles and clusters. Due to the high surface free energy of single-atom catalysts, they are prone to migration and agglomeration during calcination. In recent years, researchers have developed many efficient and versatile synthesis methods. Host-guest chemical strategy is one of the most widely used synthetic methods. In this paper, two common synthetic methods based on host-guest chemical strategy are listed: (1) space restriction method[24]; (2) Template method.

2.1 Space limited method

Zeolitic imidazolate frameworks (ZIFs), as a subclass of MOFs composed of transition metal cations and 2-methylimidazole, have atomically dispersed metal sites and are well suited as precursors for the preparation of M-N-C catalysts[25~29]. In 2022, Sun et al. Synthesized Hemin @ ZIF-8 precursor by using Hemin molecules containing carboxyl and Fe as iron source, mixing with Zn(NO3)2·6H2O and then mixing with methanol solution containing 2-methylimidazole, and successfully prepared an oxygen-containing Fe-N-C catalyst after pyrolysis at 900 ° C in N2 atmosphere (Figure 1A)[30]. This catalyst exhibits a Tafel slope (74 mV·dec-1) in acidic solution comparable to the commercial Pt/C catalyst (76 mV·dec-1) and reaches power densities of 0.88 W·cm-2 and 1.24 W·cm-2 in proton exchange membrane fuel cells and anion exchange membrane fuel cells, respectively. In Fe-N-C catalysts, besides the FeN4 sites with good 4 e selectivity, some non-metallic N-C sites show high 2 e selectivity, which has a negative impact on the overall stability of the catalyst. The key to improve the stability of Fe-N-C catalyst is to select the appropriate preparation method to transform and eliminate these active sites for side reactions. Xia et al. Synthesized Fe @ ZIF-8 precursor with similar materials and steps using Fe(NO33·9H2O as iron source, and obtained five kinds of Fe-N-C catalysts (FeNC-900, FeNC-1000, FeNC-1100, Fe NC-1200, Fe NC-1300) by pyrolysis at high temperature (900 ~ 1300 ℃), which had not been paid attention to before. After 30 H of constant voltage (0.5 V) test, the current density of the membrane electrode loaded with FeNC-900 decreased by 83.5%, while the current density of the membrane electrode loaded with[31]; After 50 H, the current density of the membrane electrode loaded with FeNC-1300 decreased by only 7.9%. It is found that the improvement of stability is due to the removal of non-coordination sites of nitrogen atoms with low activity, which are prone to produce harmful H2O2 by-products, at high temperature, and the transformation of the less stable D1 site (FeN4C12) into the more stable D2 structural site (FeN4C10)( in this temperature range[31]. Transition metal oxides may be a better choice for precursors than traditional transition metal salts. Liu et al. Pyrolyzed the prepared Fe2O3@ZIF-8 precursor at 800 ° C under Ar atmosphere using Fe2O3 as the iron source, and due to the coordination of Fe ions gradually released from Fe2O3 during pyrolysis with N ligands, this catalyst has a higher density and more dispersed active sites than the Fe-N-C catalyst prepared by direct pyrolysis of Fe @ ZIF-8[32]. When mixed with NH4Cl and then heat treated at 1100 ° C in Ar atmosphere, the NH4Cl decomposed into NH3 and HCl, which was used to form a large number of micropores and defects on the carbon basal plane, and in the following chemical vapor deposition treatment, a thin carbon layer doped with nitrogen was covered on the carbon basal plane to repair the defects. After the above treatment, a part of the pyrrole nitrogen coordinated with the central atom Fe was converted into pyridine nitrogen with better stability, thus improving the overall stability of the catalyst. The results show that in the fuel cell durability test, the voltage at a current density of 0.8 A·cm-2 only decreased by 30 mV after 30 000 voltage cycles (0.6 – 1.0 V), reaching the target of a decrease of less than or equal to 30 mV before 2025, and the cell performance of this catalyst at the end of the durability test is comparable to that of commercial Pt/C[33].
图1 Fe-N-C催化剂的合成方法:(a)一步热解法合成O-FeN4C-O示意图[30];(b)提高热解Fe-N-C催化剂的ORR稳定性的高温下微观结构演变示意图[31];(c)在不同的温度和气氛下通过三步热解法合成多孔FeN4-O-NCR催化剂示意图[34];(d)以一维Fe2O3为模板合成多孔碳纳米棒Fe/N-CNR催化剂示意图[39];(e)合成Fe-N-C/N-OMC催化剂的示意图[40]

Fig. 1 Synthesis methods of Fe-N-C catalysts(a)Schematic diagram of synthesis process of O-FeN4C-O[30]. Copyright 2022 Elsevier Inc.(b)Schematic illustration of microstructure evolution at high temperatures for improving ORR stability of pyrolyzed Fe-N-C catalysts[31]. Copyright 2022 Wiley-VCH.(c)Synthesis of porous FeN4-O-NCR catalysts by three-step pyrolysis under different temperatures and atmospheres[34]. Copyright 2022 Wiley-VCH Gmbh.(d)Synthesis of porous carbon nanorod Fe/N-CNR catalysts using one-dimensional Fe2O3 as a template[39]. Copyright 2020 Elsevier B.V.(e)Schematic illustration for the synthesis of Fe-N-C/N-OMC catalyst[40]. Copyright 2020 Wiley-VCH Gmbh.

In the preparation of catalysts, increasing the pyrolysis temperature can improve the stability of the carbon skeleton, thereby improving the stability of the catalyst, but the control space of a single pyrolysis is relatively limited. Through multiple pyrolysis, not only the stability of the carbon support can be further improved, but also the addition sequence of metal salts and precursors can be flexibly adjusted, and the pore structure of the carbon support can be adjusted by post-treatment, which is a new design direction for Fe-N-C catalysts with high stability. Peng et al. Reported a porous FeN4-O-NCR electrocatalyst loaded with catalytically accessible FeN4-O sites on N-doped carbon nanorods[34]. During the synthesis process, the carbon nanorods formed by the first pyrolysis inherited the high aspect ratio of the MOF-74-Rod precursor, but all the sizes were significantly reduced; During the second pyrolysis, KOH and NH3 are added, O element and N element are successfully introduced, and a porous structure is formed; Subsequently, Fe-Phen was added and combined with microwave-assisted pyrolysis to synthesize the axially coordinated O FeN4-O-NC catalyst (Fig. 1C), and the half-wave voltage only decreased by 5 mV after 5000 voltage cycles (0.6 ~ 1.0 V) under alkaline conditions. Liu et al. Synthesized a Fe-N-C catalyst with a multi-dimensional concave structure by using a carboxylate molecular tailoring method. This molecular tailoring strategy endows the Fe @ MNC-OAc catalyst with dense accessible active sites, multi-dimensional mass transfer paths, and a hierarchical porous structure[35]. Firstly, 2-methylimidazole and Zn(NO32·6H2O were mixed with methanol solution, and then Fe salt and NaOAc were added to obtain the precursor Fe @ ZIF8-OAc, which was heated from room temperature to 900 ℃ at a heating rate of 5 ℃/min and kept for 3 H. After the sample was cooled to room temperature, the unstable Fe element was washed away with 0.5 mol/L H2SO4, and the temperature was raised to 700 ℃ again to repair the carbon skeleton. After 5000 voltage cycles (0.6 – 1.0 V) under acidic conditions, the half-wave voltage decreased by only 5 mV. As a bottom-up synthesis method, the steric confinement method can anchor single atoms by using pre-constructed confined space such as nanocages/pores/defects. The advantage of this method is that it can stabilize the isolated metal atoms on the support, further inhibit the migration and aggregation of metal atoms, and produce high-density isolated metal sites[36]. However, the randomness of one-step pyrolysis makes it difficult to ensure the uniformity of active sites, which reduces the atom utilization of the catalyst[37]. Moreover, the improvement of the stability of the carbon skeleton by one-step pyrolysis is relatively limited, and multiple pyrolysis combined with pickling can ensure a higher atom utilization rate while improving the stability.

2.2 Template method

The obtained carbon skeleton is filled with disordered micropores during pyrolysis at high temperature, and the embedding of a large number of monatomic active sites in the disordered micropores usually leads to the aggregation of iron species and the generation of metal nanoparticles due to steric hindrance and mass transfer resistance, which has a non-negligible effect on the catalytic performance. The template-assisted strategy can be used to adjust the morphological and structural properties of the catalyst during pyrolysis or etching, and then synthesize Fe-N-C electrocatalysts with high iron loading and fully exposed active sites, which is of great significance to further improve the ORR activity.
The template method promotes the formation of ordered porous structures by introducing a template agent that can be removed during the synthesis process. The control of pore structure will directly affect the mass transfer problem of the catalyst and the formation of three-phase interface, and then control the stability. Niu et al. Formed FeO (OH) nanoparticles on polymer substrates by hydrothermal treatment of FeCl3 and 2-fluoroaniline, and the template FeO (OH) was decomposed into Fe3+ and gaseous water when pyrolyzed at 800 ° C[38]. After the above reaction process, highly ordered mesopores were successfully left on the carbon support, and the active site density of the catalyst was improved. Cyclic voltammetry results showed that the synthesized catalyst exhibited a higher peak current density (1.51 mA·cm-2) than that of the Pt/C catalyst (1.20 mA·cm-2), and the current density retention rate was 93. 3% after continuous operation in 0. 7 V potassium hydroxide solution for 10 000 s, which was much higher than that of the Pt/C catalyst (50. 4%).
When the template method is used to synthesize the catalyst, the microscopic morphology and size of the catalyst are determined by the template. Gong et al. Successfully prepared atomically Fe and N co-doped hierarchical porous carbon nanorods (Fe/N-CNR) catalyst by in situ polymerization[39]. In this method, the 1D Fe2O3 obtained by high temperature oxidation of Fe-MIL-88 B was used as a template to induce the polymerization of 1D rod-like structures. Moreover, the residual Fe2O3 after polymerization is beneficial to maintaining the original high porosity of the material and promoting the formation of highly active atomic-scale Fe-N4 sites during carbonization (Fig. 1D). The final Fe/N-CNR catalyst showed excellent ORR activity and stability, and the half-wave voltage decreased by 12. 5 mV after 5000 voltage cycles (0. 6 ~ 1.0 V) under alkaline conditions. In addition to this self-sacrificial template, SiO2 has also become a widely used template because it can restrict the free migration of iron. Han et al. Impregnated an ordered mesoporous SiO2 template with a pore size of 8.4 nm with a methanol solution containing Fe (II) -Phen complex and 2-methylimidazole, and pyrolyzed the resulting sample under Ar atmosphere to convert the precursor into a nitrogen-doped ordered mesoporous carbon framework[40]. A three-dimensional N-doped ordered mesoporous carbon supported Fe atom catalyst (Fe-N-C/NOMC) was prepared by heat treatment of the residue under Ar atmosphere after removing the SiO2 template with HF, as shown in Figure 1E. The catalyst exhibits a half-wave voltage of 0.92 V under alkaline conditions, which is better than that of Pt/C catalyst. After 5000 voltage cycles (0.6 ~ 1.0 V), the half-wave voltage drops by only 5 mV, demonstrating excellent stability. In the synthesis process, the acid washing step can remove unstable metal particles and oxides, reduce the pollution to the electrolyte, and improve the stability of the catalyst. At present, the use of multiple pyrolysis is still less, but from the results of some literatures, multiple pyrolysis can improve the atomic dispersion, thereby improving the stability, and can also improve the activity[34,35,39]. In addition, the addition of Fe species after pyrolysis to form the precursor is also a way to improve the stability. Table 1 summarizes the Fe-N-C catalysts with better stability in the field in recent years[30~32,35,41~49]. The template method is also a bottom-up synthesis method, which can not only effectively restrict and stabilize the single metal sites, but also significantly change the pore structure, such as specific surface area and pore volume, during pyrolysis[50]. The template used in the synthesis of nanomaterials can be divided into soft template and hard template, and the template used in the synthesis of Fe-N-C catalyst is mostly hard template.Compared with the soft template, it has the advantages of high stability and good confinement, and can strictly control the size and morphology of the catalyst, but the disadvantage is that the structure is relatively single, and the morphology of the nanomaterials prepared by the hard template is less[51].
表1 近年代表性Fe-N-C催化剂半电池和全电池测试性能

Table 1 Summary of representative Fe-N-C catalysts half-cell and full-cell performance in recent years

Catalysts Half-cell test Performance Single-cell test Performance
FeNC-1200[31] 10 000 square cycles between 0.6 and
1.0 V/RHE in O2-saturated 0.1 M HClO4
E1/2 8 mV constant voltage of 0.5 V under H2-O2 condition for 30 h current density loss 20%
Fe-AC-CVD[32] 10 000 square cycles between 0.6 and
1.0 V/RHE in O2-saturated 0.5 M H2SO4
E1/2 17 mV 30,000 square cycles between 0.6 and OCV in H2-Air PEMFC current density loss 13%
O-FeN4-O[30] 10 000 square cycles between 0.6 and
1.0 V/RHE in O2-saturated 0.5 M H2SO4
E1/2 10 mV constant current density of 0.5 A·cm-2 under H2-O2 condition for 50 h potential loss 33%
Fe-N-C/Pd[41] 30 000 square cycles between 0.6 and
1.0 V/RHE in O2-saturated 0.1 M HClO4
E1/2 13.5 mV - -
ZIF-NC-0.5Fe-700[42] 30 000 square cycles between 0.6 and
1.0 V/RHE in O2-saturated 0.5 M H2SO4
E1/2 31 mV - -
Fe-N-C/F[43] - - constant voltage of 0.6 V under H2-O2 condition for 100 h current density loss 3%
Fe/PI-1000-III-NH3[44] - - constant current of 30mA under H2-O2 condition for 1000 h potential loss 15%
PANI-FeCo-C[45] - - constant voltage of 0.4 V under H2-O2 condition for 700 h current density loss 3%
Fe-ZIF/CNT/1[46] 1 000 square cycles between 0.9 and
1.4 V/RHE in N2-saturated 0.1 M HClO4
E1/2 42 mV constant voltage of 0.4 V under H2-O2 condition for 30 h current density loss 34%
Fe/N,S-HC[47] 1 000 square cycles between 0.6 and
1.0 V/RHE in N2-saturated 0.1 M KOH
E1/2 7 mV - -
Fe@MNC-OAc[35] 10 000 square cycles between 0.6 and
1.0 V/RHE in O2-saturated 0.1 M HClO4
E1/2 9 mV - -
FeSA/FeAC-2DNPC[48] 10 000 square cycles between 0.6 and
1.0 V/RHE in O2-saturated 0.5 M H2SO4
E1/2 15 mV constant voltage of 0.5 V under H2-Air condition for 30 h slight decrease in current density for the first 32 hours, then stabilized
P(AA-MA)(5-1)-Fe-N[49] 5 000 square cycles between 0.6 and
1.0 V/RHE in O2-saturated 0.5 M H2SO4
E1/2 5 mV constant voltage of 0.55 V under H2-O2 condition for 30 h virtually no loss of current density during the initial 37 hours

2.3 Other methods

In addition to the host-guest chemical strategy, other synthesis methods are also widely used, such as co-precipitation, chemical vapor deposition, ball milling and so on[52][53][54]. Generally speaking, the single-atom Fe-N-C catalysts prepared by multiple pyrolysis and wet chemical methods have better stability. However, it should be noted that the stability of the catalyst is also related to the operating conditions and environment in practical applications, so it needs to be verified in specific application scenarios.

3 Stability test standard of Fe-N-C catalyst

3.1 Half-cell test

For the convenience of operation, the potential cycle in solution is usually carried out under acidic or alkaline conditions, which is called half-cell test, which can reflect the activity and stability of the catalyst under fuel cell operating conditions to a certain extent. Researchers usually select a triangular wave or square wave voltage cycle in the range of 0.6 ~ 1.0 V as the Accelerated Stress Test (AST), and compare the linear sweep voltammetric curve at the initial time with that at the end state to evaluate the deactivation of the catalyst. In addition to this, constant voltage/constant current tests are also frequently used to evaluate the stability of fuel cell catalysts. For non-precious metal catalysts, although many researchers have proved the good stability of the catalyst by the experimental results of Rotating Disk Electrode (RDE) test in liquid environment, this practice is not appropriate in some cases. Zhao et al. Synthesized the FeIM-ZIF-8 catalyst by pyrolysis of ZIF-8, and when the RDE test was conducted in 0.1 M HClO4, the activity did not decrease significantly no matter 10 500 voltage cycles under Ar atmosphere (Fig. 2a) or 2000 voltage cycles under O2 atmosphere (Fig. 2b)[55]. However, subsequent fuel cell tests came to the opposite conclusion, with the activity decaying rapidly from the initial moment, and only 25% of the initial current density remained after the reaction lasted for 100 H (Fig. 2C). Similarly, this phenomenon still exists for noble metal catalysts (fig. 3)[56]. This shows that in order to accurately evaluate the stability of PEMFC cathode non-precious metal catalyst, the stability test of single cell should be carried out, which can better reflect the real situation.
图2 在RRDE和MEA稳定性测试中测量的FeIM/ZIF-8的ORR极化曲线:RRDE测试条件包括在(a)0.1 M Ar饱和的HClO4或(b) 0.1 M O2饱和的HClO4中以50 mV·s-1的速度从0.0到1.1V循环多次,然后在O2饱和的HClO4中以10 mV·s-1的扫描速率测量极化曲线; (c)在H2-Air中进行100 h稳定性测试,测量以FeIM/ZIF-8为阴极催化剂的单体电池(Nafion 117膜)在0.5 V时的电流密度[55]

Fig. 2 ORR polarization curves of FeIM/ZIF-8 measured during RRDE and MEA stability test: RRDE test conditions include cycling from 0.0 to 1.1 V at 50 mV·s-1 in(a)0.1 M Ar-purged HClO4 or(b)0.1 M O2-purged HClO4 at 25 ℃ for multiple cycles, followed by polarization curve measurement in O2-purged HClO4 at the scan rate of 10 mV·s-1.(c) 100-hour stability test by measuring the current density at 0.5 V of a single cell with FeIM/ZIF-8 as the cathode catalyst(Nafion 117 membrane)operated with H2-air[55]. Copyright 2012 The Royal Society of Chemistry.

图3 目前较出色的Pt催化剂在RDE和MEA测试中性能对比[56]

Fig. 3 Performance of state-of-the-art Pt catalysts evaluated in RDE and MEA[56].Copyright 2021 Springer Nature Limited.

3.2 Single cell test

The single cell test means that the catalyst slurry is coated on the proton exchange Membrane to form a Membrane Electrode Assembly (MEA), which is loaded into the fuel cell test system for stability test. According to the fuel cell test protocol, there are currently four main test standards for precious metal catalysts and membrane electrodes for fuel cells[55].
(1) Catalyst stability: The surface of the catalyst was oxidized and reduced by continuous scanning of triangular wave potential (0.6 ~ 1.0 V) to accelerate its attenuation. The triangular wave potential range used is close to the voltage variation range of a real vehicle fuel cell, and at the same time, the decay of the catalyst itself is accelerated to the greatest extent on the premise of minimizing the influence of carrier corrosion. This standard is only applicable to the evaluation of platinum-based carbon-supported catalysts. (2) Carbon support stability: The electrochemical oxidation of the carbon support is accelerated by rapid triangular wave potential cycling (1.0 ~ 1.5 V), while the degradation of the catalyst is minimized. The used potential range is close to the start/stop state of the real vehicle fuel cell system. (3) Chemical stability of MEA: It accelerates the generation of free radicals by maintaining the open circuit potential, resulting in the attenuation of membranes and other MEA components. (4) Mechanical stability of MEA: Cyclic regulation of humidity can cause swelling and contraction of the membrane, thereby accelerating the breakage (cracks and holes) of the membrane. In 2022, Los Alamos National Laboratory (LANL) released a "tailor-made" test standard for non-precious metal catalysts, which is different from platinum-based catalysts mainly in the upper limit of cycling voltage and the change of cathode gas from N2 to O2[57]. This is due to the fact that the potential cycling of single-atom M-N-C catalysts in an inert gas atmosphere tends to result in a relatively small performance loss, masking the actual durability of this type of ORR catalyst. When this type of catalyst is subjected to potential cycling in the presence of O2, which is closer to the actual PEMFC operating conditions, more significant performance degradation occurs[58].
The traditional way to test the durability of non-precious metal catalysts electrochemically is to accelerate the stress test and apply a constant voltage or current for a certain period of time, generally until 80% of the performance is lost. This method only superficially indicates the rate of catalyst degradation, but does not provide any information about the cause and mechanism of catalyst degradation. Electrochemical impedance spectroscopy (EIS) can be used to analyze the interfacial charge transfer and reactant diffusion impedance of ORR reaction, which provides a new idea for decoupling the deactivation mechanism of Fe-N-C catalyst. Liu et al. Used the relaxation time distribution technique (DRT) to analyze the EIS results under fuel cell operating conditions for 60 hours, so that the changes of O2 molecular diffusion, O2 molecular adsorption-desorption and charge transfer at the electrode interface, and proton conduction resistance with time corresponding to low, medium, and high frequencies, respectively, could be determined[59][59]. This advanced electrochemical characterization technique provides a new perspective to resolve the rapid deactivation of Fe-N-C catalysts in fuel cells.

3.3 Analysis of the difference between the two test results

Due to the different experimental devices and test environments of RDE and MEA, many catalysts with good performance in solution conditions have a "cliff-like" performance decline after being loaded into MEA. The main reasons can be attributed to the following two points: (1) oxygen solubility difference; (2) Difference of catalyst dosage.
In the RDE test, in order to control the mass transfer rate of the reactant and the effective diffusion layer thickness, a certain rotating speed is applied to the electrode, but the current density obtained in the experiment is often small due to the low solubility of the O2. In the MEA test, in order to achieve the power density required by PEMFC, the device needs to provide a large current, which can not be reflected by the data obtained by RDE. Mason et al. Constructed microporous nanocrystalline silicalite-1-NCs with hydrophobic inner surface and hydrophilic outer surface, which greatly improved the dissolution of O2 in the electrolyte and increased the ORR current density in RDE by 3.8 ~ 3.9 times[60]; Considering the low intrinsic activity of non-noble metal catalyst, a large loading is needed to achieve the activity matching with Pt catalyst in the MEA test, and a thick catalyst layer will increase the mass transfer resistance of reactants, which is not conducive to the diffusion of O2 and the timely discharge of H2O. In addition, many active sites buried in the catalyst layer have no chance to contact with the reactants, resulting in low catalyst utilization and accessibility, which does not exist for the rotating disk electrode with a thin catalyst layer.
In addition to the above two main reasons, the unique high working temperature (60 ~ 120 ℃) of MEA and the damage of reactive oxygen species (ROS) induced by H2O2 to the membrane electrode will also widen the gap between the two test results. Therefore, in order to correctly evaluate the performance of non-precious metal catalysts in practical application scenarios, it is necessary to optimize the design of catalysts and build a reasonable and efficient MEA.

4 Deactivation mechanism of Fe-N-C catalyst

The M-N-C catalyst composed of transition metal, nitrogen and carbon exhibits significantly improved catalytic activity; However, the stability (operation under constant conditions) and durability (operation under dynamic conditions) of this class of PGM-free catalysts are still not satisfactory for practical applications. Therefore, more and more studies have focused on exploring and alleviating the degradation pathway of PGM-free catalysts. The M-N-C catalyst in PEMFC usually loses its activity rapidly in the initial stage (< 20 H), and then slowly reduces its performance in the following stage, which is divided into two stages: fast deactivation and slow deactivation. The fast deactivation in the first stage is the main reason for the activity decay. With the development of research, the main deactivation mechanisms can be attributed to the following four points: (1) demetallization; (2) carbon oxidation; (3) protonation; (4) Micropore flooding.

4.1 Demetallization

For Fe-N-C catalysts, the active center is usually a Metal-nitrogen-carbon (M-N-C) structure formed by iron (Fe), nitrogen (N) and carbon (C) atoms, in which Fe atoms play a key role in catalysis. However, due to the agglomeration effect during pyrolysis, there are inevitably nano-oxide or carbide particles formed by the polymerization of metal atoms in the synthesized catalysts. In acidic environment, these iron-containing species will dissolve, which will affect the activity and stability of the catalyst.
In 2015, Choi et al. Used scanning flow cell (SFC) coupled with inductively coupled plasma mass spectrometry (ICP-MS) to detect the amount of Fe dissolved from Fe-N-C catalyst in real time during the voltage change process, and the results showed that when the voltage decreased to 0.77 V, the dissolved Fe species began to be detected in the solution (Figure 4A), but the ORR activity did not decrease at this time, which was due to the fact that the detected Fe2+ originated from Fe nanoparticles with poor catalytic activity[61].
图4 (a)计时电流法实验中SFC/ICP-MS记录的铁的溶解情况,实验温度和步长分别为20 ℃和0.1 V[61]; 在0.1M HClO4中进行5000次电压循环(1.2~1.5V)前(b)后(c)拍摄的单个Fe-N-C颗粒暗场IL-STEM显微照片[61];(d)描述Fe-N-C催化剂失活机制相互耦合循环的示意图,包括脱金属、Fenton反应和碳氧化[67];(e)电化学探针法检测工况条件下催化层H2O2浓度的示意图[64]

Fig. 4 Deactivation mechanism of Fe-N-C catalysts:(a)Online SFC/ICP-MS results. The Fe dissolution was recorded at 20 ℃ during a stepwise chronoamperometry experiment with a 0.1 V step size[61]; Morphology change of a single Fe-N-C particle. Dark-field IL-STEM micrographs b)before and c) after 5000 cycles performed between 1.2 and 1.5 V at 50 ℃ in a 0.1 M HClO4 electrolyte[61]. Copyright 2015 WILEY-VCH Verlag GmbH & Co.KGaA, Weinheim.(d) Schematic illustration describing autocatalytic degradation cycle comprising demetalation, Fenton(-like) reaction, and carbon oxidation[67]. Copyright 2021 Elsevier Inc.(e)Schematic of the electrochemical probe method to in-operando monitor the H2O2 concentration in the fuel cell catalyst layer[64]. Copyright 2022 Elsevier B.V.

Although the metal center atom in the Fe-N-C structure is more resistant to dissolution, the generated active oxygen species such as · OH will cause strong oxidative corrosion to the carbon support and proton exchange membrane due to the Fenton reaction between Fe2+ and H2O2 generated in the 2e process, which will greatly shorten the catalyst life and irreversibly reduce the cell performance. In addition, some studies have shown that there is H2O2 one-electron reduction of (H2O2electrochemical reduction) in the ORR process in acidic system, and the rate of hydroxyl radical formation is significantly higher than that of Fenton (-like) reaction[62]. Wan et al. Deeply explored the deactivation mechanism of molecular catalyst FePc with similar FeN4structure to Fe-N-C catalyst, and formed a good linear relationship between the · OH content determined by coumarin as a fluorescent probe and the degree of kinetic current decay before and after the stability test.Similar X-ray photoelectron spectroscopy (XPS) and surface-enhanced Raman spectroscopy (SERS) signals were observed for the · OH-treated FePc catalyst and the control experiment after ORR reaction, which means that · OH is the main reason for the deactivation of the molecular catalyst FePc[63]. In subsequent experiments, they extended the deactivation mechanism to the Fe-N-C catalyst synthesized by pyrolysis.
In 2022, Qiu et al. Used the in-situ electrochemical probe method to detect the H2O2 concentration of the cathode catalyst layer of PEMFC in real time, thus revealing its dynamic variation (Figure 4E)[64]. It is found that the local H2O2 concentration in the cathode catalyst layer can reach up to 17 mmol/L under PEMFC operation, which further reveals the causes of deactivation of non-precious metal catalysts and provides a direction for the life extension strategy of catalysts. To improve the solubility resistance of the FeN4 site, strengthening the bond energy of the Fe — N bond is the most direct and effective strategy. Gao et al. Constructed Fe-N-C catalyst loaded with Metallic particles[65]. The linear relationships of Fe dissolved amount, oxidation state, and Fe-N bond energy were established by in situ ICP-MS, X-ray absorption spectroscopy (XAS), and DFT calculations. Therefore, a universal mechanism for metal particles to inhibit the dissolution of Fe monoatomic sites is proposed: as electron donors, metal particles increase the electron density of FeN4 sites and reduce the oxidation state of Fe, which strengthens the bond energy of Fe — N bond and inhibits the dissolution of iron. The experimental results and theoretical calculation show that Pt particles can suppress the demetallization effect to the greatest extent compared with other metal elements. In fact, in this kind of composite catalyst, the Fe-N-C structure can also be used as a support to regulate the electronic structure of Pt particles/clusters and weaken the *O adsorption strength on Pt particles/clusters, thus inhibiting the formation of Pt oxides and reducing the dissolution rate of Pt in acidic and alkaline electrolytes[66]. To sum up, this particle-assisted single-atom strategy can improve the solubility resistance of metal particles and Fe single-atom sites at the same time by using the interaction between the two, thus promoting the overall stability of the catalyst.

4.2 Carbon oxidation corrosion

Carbon oxidation corrosion is another main reason for the deactivation of non-precious metal catalysts. Unlike precious metal catalysts (such as Pt, Pd), the carbon skeleton in M-N-C catalysts not only acts as a catalyst support to support active sites, but also participates in coordination bonding, and its oxidation and corrosion will directly affect the activity of the catalyst. Therefore, it is particularly important to study the mechanism of carbon oxidation corrosion in non-precious metal catalysts.
Generally, carbon oxidation corrosion is divided into electrochemical oxidation and chemical oxidation. Electrochemical oxidation generally occurs under extreme operating conditions of the PEMFC, such as start-stop, rapid load change, and gas transport channel blockage by impurities. The hydrogen supply at the anode side is insufficient to meet the electron demand of the fuel cell system. At this time, the fuel cell will obtain additional electrons through abnormal reactions, such as OER/COR. At high voltage (> 0.9 V), the electrochemical oxidation of carbon will become very severe. According to Choi et al., when the voltage reaches 0.9 V and 1.2 V, carbon is gradually oxidized to CO2 and CO[61]. In addition, after 5000 times of stability tests at 1.2 ~ 1.5 V, the two-dimensional images of carbon materials show 5% ~ 15% area reduction (Fig. 4 B, C), which means that different degrees of pore collapse and shedding have occurred.
Chemical oxidation means that during the oxygen reduction reaction, the active sites on the surface of the catalyst may be attacked by reactive oxygen species (such as · OH, HO2·)), which react with the carbon support, and the resulting chemical oxidation leads to the formation of surface oxygen-containing groups, such as hydroxyl and epoxy groups, which reduce the conversion frequency (TOF) of FeN4 sites by weakening the binding with O2. Unlike electrochemical corrosion, chemical corrosion is independent of temperature and potential. In 2020, Kumar et al. Designed three different voltage cycling intervals (0.3 ~ 0.7 V, 0.5 ~ 0.9 V, 0.6 ~ 1.0 V) at 80 ℃ for LSV test, and there was no significant difference in ORR activity[58]. It is worth noting that the corrosion of carbon materials can also lead to the shedding of metal atoms in the Fe-N-C structure, which accelerates the demetallization process. It can be seen that there is a coupling relationship between demetallization and carbon corrosion, and the bridge of this synergistic effect is the attack of reactive oxygen species (Figure 4D)[67].
Carbon oxidation corrosion not only directly leads to the decrease of catalyst activity, but also may lead to the change of catalyst morphology, the increase of hydrophilicity and the decrease of surface area, which indirectly accelerates the deactivation of catalyst. Therefore, slowing down carbon corrosion is one of the important ways to improve the long-term stability of Fe-N-C catalyst.

4.3 Protonation

Liu et al. First attributed the loss of PEMFC activity under acidic conditions to the protonation of pyridine nitrogen. The lone electron pair on pyridine nitrogen may combine with the proton in the acidic medium of PEMFC, resulting in the inactivation of pyridine nitrogen in ORR, because the loss of lone electron pair will weaken the adsorption of oxygen molecules[68]. Herranz et al. Proposed another protonation mechanism, that is, the surface basic N group is protonated and then combined with the anion by electrostatic interaction, which can be restored by removing the anion adsorbed on the basic nitrogen group in an acidic environment by heating or chemical methods[69]. According to the quantitative calculation study, the bare Fe-N4 site is difficult to demetalate due to the stable Fe — N bond. When two *OH are bound to the metal center on the same side, the Fe center will form an unstable *Fe(OH)2 intermediate and interact with the protonated N, which will further lead to demetalation and reduced catalytic activity[70]. It is still controversial whether the mechanism of protonation is the main reason for the decrease of catalytic performance.

4.4 Micropore flooding

In PEMFC, the ORR process of the cathode catalyst layer will produce more water, and the Fe-N-C catalyst is prepared from porous materials, when the pore absorbs water through capillary force, it will lead to flooding of the catalyst pore. According to the research of Jaouen et al., the activity decline of the catalyst becomes more and more serious with the increase of the proportion of micropores, and the active sites of FeN4 are mainly distributed in the micropores, so they concluded that the flooding phenomenon of micropores is an important factor causing the deactivation of the catalyst[71]. However, because Jaouen et al. Did not establish a direct link between the degree of micropore flooding and the degree of deactivation, this inference is not rigorous. Choi et al. Conducted electrochemical performance tests under 60% and 100% relative humidity conditions respectively, and observed similar double layer capacitance changes and polarization curves, which indicated that most of the micropores in the Fe-N-C catalyst were wet in the initial stage, and micropore flooding was not the main reason for the rapid deactivation of PEMFC in the initial stage[72]. The hydrophilicity of micropores is mainly caused by — OH and — OOH adsorbed on the carbon basal plane after carbon oxidation corrosion, but because the transport of ions requires the presence of water, the proper wetting of micropores is essential for good performance, and the construction of micropore walls with too strong hydrophobicity will inhibit the occurrence of ORR process[73]. Therefore, it is very important to rationally regulate the hydrophilicity/hydrophobicity of carbon carriers.
Demetallization and protonation reflect the deactivation behavior at the atom/active site scale, while micropore flooding explains the deactivation phenomenon induced by the accessibility of the catalyst active site from a more macroscopic perspective of the mass transfer of oxygen and water molecules. On the one hand, carbon oxidation corrosion will lead to the loss of metal centers due to the defects of carbon skeleton, on the other hand, the regulation of oxygen functional groups on the hydrophilicity of the interface will also affect the transport behavior of reactant/product molecules and induce deactivation. It can be seen that due to the special structure of Fe-N-C catalyst, the oxidation/corrosion phenomenon of carbon support has a more significant effect on the stability of Fe-N-C catalyst.

5 Life extension strategy of Fe-N-C catalyst

5.1 Stabilized carbon support

5.1.1 Increasing graphitization degree

The graphitized carbon support makes the catalyst more stable because graphitization involves the rearrangement of carbon atoms, which have fewer opportunities to become non-coordinating atoms, making the reaction pathway of carbon oxidation kinetically sluggish. Miao et al. Successfully synthesized an atomically dispersed and highly graphitized single-atom catalyst SA-Fe-N by the self-locking reaction of metal ions and sodium alginate (SA), which showed excellent stability under acidic conditions (Figure 5A), and the E1/2 of the catalyst only decreased by 10 mV after 5000 potential cycles in 0.5 M H2SO4[74]. Combined with XRD and Raman spectroscopy, SA has a promoting effect on improving the graphitization degree of the support (Fig. 5B); Carbon nanotube is also an ideal support for Fe-N-C catalyst because of its good graphitization degree. Xia et al. Prepared Fe-N/CNT-2 catalyst with high loading and high graphitization degree by the post-treatment method of secondary acid washing plus annealing, which showed superior stability to the ZIF-derived Fe-ZIF series[75]. After 30 H PEMFC constant voltage (0. 4 V) stability test, the current density decreased by 44%, which was lower than that of Fe-ZIF catalyst (76%), and the advantage of increasing the voltage to 0. 7 V still existed, which indicated that the use of carbon nanotubes as carbon precursors could improve the oxidation resistance of the catalyst. However, the pursuit of a high degree of graphitization will limit the activity of the catalyst, because a high degree of graphitization will lead to a reduction in the number of voids accommodating transition metals and nitrogen atoms, reducing the density of active sites.
图5 构建稳定碳载体的策略:(a)SA-Fe-N-1.5-800的AST测试结果[74];(b)使用不同浓度的SA合成的SA-Fe-N催化剂与不含SA的Fe-N-C催化剂的拉曼光谱结果[74];(c)微孔/介孔面积与ORR质量活性关系[76];(d)六种含不同微孔率的Fe-N-C催化剂的稳定性测试结果[77]

Fig. 5 Strategies for building stable carbon substrate:(a)AST test results of SA-Fe-N-1.5-800[74];(b)Raman spectra of SA-Fe-N catalysts synthesized using different concentrations of SA versus Fe-N-C catalysts without SA[74]. Copyright 2018 WILEY-VCH Verlag GmbH & Co.KGaA, Weinheim.(c)Relationship between mesopore and micropore area and ORR mass activity[76]. Copyright 2021 Elsevier Inc.(d)Stability test results of six Fe-N-C catalysts with different micropore ratios[77]. Copyright 2016 American Chemistry Society

5.1.2 Adjust the proportion of grading holes

For Fe-N-C catalysts, the complex pore structure of carbon support largely determines the performance of the material, so exploring the role of each pore and the appropriate proportion of hierarchical pores will provide guidance for the directional synthesis of catalysts. Jauoen et al. found that the active sites were mainly distributed in the micropores, and then compared the ORR activity of catalysts with different pore distributions, and found that the ORR activity was linearly related to the proportion of micropores (5 ~ 20 20Å) in the catalyst, while the content of mesopores (20 ~ 100 100Å) was not significantly related to the ORR activity (Fig. 5C), which further confirmed the above conclusion[76]. However, with the increasing proportion of micropores, the space occupied by mesopores/macropores for transporting substances will be reduced, which will aggravate the transport resistance of reactants and products, and the stability of Fe-N-C catalysts will face challenges. Shao et al. Compared the stability of six Fe-N-C catalysts with different proportions of micropores, and all the stability tests were conducted in a H2-O2 fuel cell at a constant voltage of 0.5 V[77]. The numbers after each curve in Figure 5d represent the micropore area/total area. When the test was carried out for 100 H, the MEA performance of the catalyst loaded with 55% microporosity decreased by about 50%, while the MEA performance of the catalyst loaded with 84% microporosity decreased by about 80%. A similar conclusion was also put forward by Wan et al. When the Fe-N-C catalyst was etched by CO2(0~5%) with different concentrations, the BET specific surface area of the material increased with the increase of CO2 concentration, while the microporosity gradually decreased, and the ORR activity gradually increased[78]. This means that from the point of view of material synthesis, we should not pursue too high microporosity, but should find a suitable proportion of hierarchical pores. In order to explore the relationship between the pore size of the carbon support and the catalytic activity in more detail, Wang et al. Used organic molecules of different sizes as electrochemical probes to identify the contribution of pore sizes in different size ranges to the ORR activity, and the results showed that the micropores of 0.8 ~ 2 nm in the Fe-N-C catalyst contributed more than 70% of the activity[79]. This is due to the fact that acidic Nafion molecules are difficult to enter the micropore due to size constraints, so that the active sites in the micropore are not inactivated by acid-base neutralization[79].

5.2 Stable active site

5.2.1 Regulatory active site architecture

To prevent the dissolution of the active center, a more stable FeN4 group needs to be constructed. According to the difference of N configuration, the N atom coordinated with Fe atom in Fe-N-C catalyst is mainly divided into pyridine N, pyrrole N and graphite N, among which the FeN4 coordinated with pyridine N has the highest stability[80]. Liu et al. Used the chemical vapor deposition (CVD) method to convert a part of pyrrole N coordinated with the central atom into pyridine N, completing the transformation from the FeN4C12(S1) site with higher activity but poorer stability to the FeN4C10(S2) with lower activity but better stability[32]. Combined with quantitative analysis, it was found that the S1 and S2 sites occupied 65% and 29% respectively before CVD treatment, and the content of the two sites became closer after CVD treatment, which changed to 53% and 42% (Figure 6a). After 30,000 voltage cycles (0.6 ~ 1.0 V), the catalyst showed a residual activity close to that of commercial Pt/C. Theoretical calculations show that the stability of the S2 site is due to the high energy barrier of the protonation step, which reduces the possibility of subsequent Fe-N bond cleavage. Due to the natural activity/stability difference between S1 and S2 sites, it is particularly important to rationally regulate the relative content of the two active sites. Fe-N-C catalysts containing only highly active S1 sites were synthesized using a H2-Ar mixed atmosphere during pyrolysis. This catalyst shows good stability, and through the analysis of the material, it is found that the improvement of stability is due to the shortening of Fe-N bond length[81]. In order to construct a more stable active center, the bond length of Fe-N chemical bond has been widely concerned. Miao et al. Synthesized a P (AA-MA) -Fe-N catalyst with a large binding constant by increasing the proportion of maleic acid and polyacrylic acid in the precursor (Fig. 6B).The results show that the optimized catalyst has a longer Fe-N bond length (Fig. 6C) and better stability than the PAA-Fe-N catalyst with a lower binding constant. In the MEA stability test under H2-Air conditions, the catalyst can achieve 100% current density retention in the first 37 H, showing a significant advantage[49].
图6 构建稳定活性位点的策略:(a)CVD处理前后Fe-N-C催化剂中D1和D2位点含量的比较[32];(b)PAA-Fe-N和P(AA-MA)-Fe-N催化剂合成示意图,分别由低结合常数的PAA-Fe和高结合常数的P(AA-MA)-Fe作为前驱体制备[49];(c)P(AA-MA)(5-1)-Fe-N、PAA-Fe-N和铁箔样品的k3加权FT-EXAFS光谱[49];(d)Co(mIm)-NC(1.0)和Fe(mIm)-NC(1.0)催化剂在MEA中以0.7 V的恒定电压持续100 h的耐久性测试结果[82];(e)原子分散的M-N-C催化剂(M=Mn、Fe、Co、Ni和Cu)的电化学合成H2O2和H2O2还原趋势[83]

Fig. 6 Strategies for constructing stable active sites:(a)Comparison of D1 and D2 sites contents in Fe-N-C catalysts before and after CVD treatment[32]. Copyright 2022 Springer Nature Limited.(b)PAA-Fe-N and P(AA-MA)-Fe-N catalysts were prepared by lower binding constant PAA-Fe and higher binding constant P(AA-MA)-Fe as precursor, respectively[49];(c)k3-weighted FT-EXAFS spectra of P(AA-MA)(5-1)-Fe-N, PAA-Fe-N, and Fe foil samples[49]. Copyright 2021 Wiley-VCH Gmbh.(d)Durability tests of the Co(mIm)-NC(1.0)and Fe(mIm)-NC(1.0)catalysts in MEA in 1 bar H2-air at a constant cell voltage of 0.7 V for 100 h[82]. Copyright 2020 Springer Nature.(e)The trends in electrochemical H2O2 production and H2O2 reduction over a series of M-N-C materials(M=Mn, Fe, Co, Ni, and Cu)exclusively comprising atomically dispersed M-Nx sites from molecular first-principles to bench-scale electrolyzers operating at industrial current density[83]. Copyright 2019 American Chemistry Society.

5.2.2 Using iron-free M-N-C catalyst

Xie et al. Successfully synthesized an atomically highly dispersed Co-N-C catalyst by immobilizing the chelating ligand CoNx component in the micropores of ZIF-8 through a wet chemical method, thereby increasing the density of individual Co-N4 sites[82]. After 100 H potentiostatic (0.7 V) MEA stability test under H2-Air conditions, the catalyst exhibited superior durability to the Fe-N-C catalyst synthesized using the same method (Fig. 6d). However, in general, the two-electron selectivity of Co-N-C is higher than the four-electron selectivity, which limits the power it can provide as a cathode catalyst for PEMFC. Sun et al. Have systematically studied the H2O2 synthesis selectivity of M-N-C materials (M = Mn, Fe, Co, Ni, and Cu), and the results show that Co has the highest two-electron oxygen reduction selectivity among many metal elements (Fig. 6e), which means that Co-N-C catalysts not only provide lower power density than Fe-N-C, but also have another defect: it will bring more threats to the reaction system caused by the strong oxidation of H2O2[83]. Li et al. Prepared a tin (Sn) nanocluster catalyst for electrochemical oxygen reduction, in which Sn nanoclusters of 1 ~ 1.5 nm were immobilized in situ in a microporous nitrogen-doped carbon polyhedron with an average pore size of 0.7 nm.The Snx in SnxNC has a strong interaction with the NC support to form Sn — N bonds, and this catalyst shows comparable performance to the state-of-the-art Pt/C catalyst and far exceeds the single-atom Sn-N-C catalyst in acidic medium[84]. There was almost no performance degradation in the 10 000 s constant voltage stability test, but they did not explore longer term stability. Although the above Co-N-C, Snx-N-C catalysts show better stability compared to Fe-N-C catalyst, the more suitable adsorption energy of Fe element with ORR intermediate makes the activity of FeN4 site difficult to be surpassed by other MN4 sites. If the bimetallic catalyst Fe-M-N-C can be formed by constructing adjacent MN4 sites on the basis of retaining the FeN4structure, the MN4 sites can be used to break the restriction of the ability of monometallic centers to regulate the adsorption energy of intermediates, and the H2O2 generated by FeN4 can be further reduced to improve the stability of the catalyst[85,86].

5.3 Avoiding Fenton reaction

5.3.1 Reduced iron/iron oxide particle content

Fe2+ is the main reactant of Fenton reaction, and the activity and solubility resistance of Fe-containing particles are weaker than that of single-atom Fe-N-C structure in acidic environment, so the catalyst with low content of synthetic particles will greatly reduce the content of Fe2+ in solution. Choi et al. Successfully synthesized three Fe-N-C catalysts with different particle contents by using the "all-solid-state mixing" method without the acid washing step. The particle content of the Fe-N-C-dry0.5 catalyst is about 0, and it can be approximately considered that all the Fe species in the catalyst come from the atomically dispersed Fe-N-C structure[87]. In this study, instead of using Fe-containing salt solution, solid precursors containing Fe, N and C were mixed by ball milling, which greatly reduced the content of nanoparticles in the material. After 20 voltage cycles, the Fe-N-C-dry0.5 catalyst was almost not dissolved, and the Fe dissolution of the other two catalysts was positively correlated with the Fe particle content in the material (Fig. 7A). After 50 H of stability test, the Fe-N-C catalysts with different particle contents showed similar performance degradation (Fig. 7B), indicating that the deactivation caused by demetallization should be attributed to the dissolution of single-atom Fe coordinated with N rather than Fe-containing particles. Based on the above reasons, appropriate methods and steps should be selected in the synthesis of Fe-N-C to reduce the content of nanoparticles in the material, on the one hand, to reduce the impact of Fenton reaction, on the other hand, to improve the utilization of Fe atoms.
图7 避免发生芬顿反应的策略:(a)20圈快速循环稳定性测试结果:铁的溶解量与催化剂中结晶铁含量之间呈现正相关[87];(b)在0.5 V下进行50 h的恒电压耐久性测试时,电流密度与时间的关系曲线[87];Pt AMS(c)和Pt = N2 = Fe ABA(d)的ORR机制示意图[88];(e)Fe,Ce-N-C的结构示意图[92];(f)在O2饱和的0.1 M HClO4中进行30 000次电压循环(0.6~1.0V)的实验结果[92];(g)经过加速耐久性测试后,是否加入自由基清除剂Ta-TiOx/KB的PEMFC的电流密度衰减情况比较[93]

Fig. 7 Strategies to avoid Fenton reaction:(a)Positive correlation between the cumulative amounts of Fe dissolved during the 20 fast cycles and the total content of crystalline Fe structures in the catalysts[87];(b)Current density versus time during the durability test for 50 h at 0.5 V[87]. Copyright 2016 American Chemistry Society. Schematic of the ORR mechanism for Pt AMS(c)and Pt = N2 = Fe ABA(d)[88]. Copyright 2022 Springer Nature.(e)The optimized structure of Fe,Ce-N-C[92];(f)accelerated degradation test(ADT)by cycling the potential(0.6~1.0 V)in O2-saturated 0.1 M HClO4 for 30 000 cycles to study the stability of the best-performing Fe,Ce-N-C[92]. Copyright 2023 Elsevier Inc.(g) Current density decay comparison for cells with and without Ta-TiOx/KB after the ADT[92]. Copyright 2022 Springer Nature Limited.

5.3.2 Improved 4E selectivity

With the development of single-atom catalyst (SAC), diatomic catalyst (DAC), as a new type of atom-dispersed catalyst, has been widely concerned by researchers in the fields of materials, energy, chemistry and so on. For the oxygen reduction catalyst, the diatomic active sites will be beneficial to change the adsorption mode of reactants and reaction intermediates, thereby improving the selectivity of 4E and inhibiting the Fenton reaction. Zhou et al. Designed a diatomic catalyst Pt=N2=Fe, and the results of in situ XAFS spectra showed that the oxygenated intermediate could adsorb on the Pt=N2=Fe sites with appropriate spacing, forming a Pt-O-O-Fe two-site adsorption mode[88]. This adsorption mode can provide a strong traction force for the cleavage of the O — O bond. In situ SR-FTIR revealed that the Pt=N2=Fe catalyst generated the *O-O* intermediate during the catalytic oxygen reduction reaction and promoted its direct cleavage. This effectively avoids the terminal adsorption mode in which the *OOH intermediate on the traditional monoatomic site is difficult to further cleave, and the ORR process of the monoatomic Pt site and the diatomic Pt=N2=Fe site is shown in Figure 7C. Based on the idea of assembly-pyrolysis, Zhang et al. Successfully prepared Fe-Cu diatomic catalyst by assembling macrocyclic complex molecules containing diatomic sites through porous materials, thus retaining the diatomic site structure during pyrolysis[89]. The half-wave potential of the catalyst decreased by only 5 mV after long-term ORR stability test in acidic electrolyte, which is much higher than the durability of other Fe-containing diatomic or homonuclear diatomic catalysts. The RDE experimental results show that the Fe-Cu diatomic catalyst has a H2O2 selectivity below 1%, which means that the Fenton reaction is greatly inhibited. In addition to using diatomic active sites to change the adsorption mode of O species, controlling the spin state of metal sites on a single-atom basis can also optimize the adsorption and desorption of reaction intermediates. Wei et al. Introduced Pd clusters on the catalyst surface to synthesize Fe-N-C/Pdnc catalyst with low noble metal loading, and the strong electronic interaction between Pdnc and Fe single atom triggered the transition of Fe site from low spin (LS) to medium spin (MS)[41]. Combined with the theoretical calculation, the results show that the mid-spin Fe (Ⅱ) is beneficial to the side-on adsorption mode of O2 and improves the selectivity of 4E ORR.

5.3.3 Free radical scavenger

Among the ROS produced by Fenton reaction, hydroxyl radical (· OH) is the most harmful to carbon support and polymer membrane. The introduction of a suitable free radical scavenger can well inhibit its destruction of the active site. For example, the CeO2 can consume the H2O2 generated in the cathode through the reaction, and the reaction mechanism is as follows[90].
O2 + 2H+ + 2e-=H2O2
2CeO2 + 2H+ + 2e- = Ce2O3 + H2O
Ce2O3 + H2O2 = 2CeO2 + H2O
In 2020, Shao designed a dual-active site ORR catalyst containing Fe-N-C&CeO2, which combines the catalytic effect of Fe-N4 with the protective effect of CeO2, and has good stability on the basis of high activity[91]. However, with the dissolution of CeO2, Ce ions will cause the loss of permeability of the membrane electrode, and there is a natural size difference between CeO2 nanoparticles and FeN4 sites, which makes it difficult for ROS generated in the micropores to be captured by CeO2 immediately. It has been found that the monoatomic Ce-N-C active site can also assume the role of a radical scavenger. In 2023, Chu et al. First synthesized bimetallic single-atom catalyst Fe, Ce-N-C, in which both Fe and Ce elements exist in the form of single-atom M-N4 (Fig. 7e)[92]. After in-depth analysis of the catalytic mechanism, the active sites of Ce-N4 catalyze the chemical decomposition of H2O2 and then promote the elimination of ROS, which leads to the simultaneous improvement of activity and durability. The E1/2 decreased by only 22 mV after 30,000 voltage cycles in acidic system, showing excellent stability (Figure 7 f). Ta-TiOx, as another good free radical scavenger, has also been widely concerned. In 2022, Xie et al. Synthesized well-dispersed Ta-TiOx nanoparticles on carbon supports, and used the elimination effect of Ta-TiOx on · OH and HO2· and the chemical decomposition effect on H2O2 to protect carbon supports and active centers[93]. After the accelerated durability test, the current density of MEA with radical scavenger decreased by only 3% at 0.9 V, while the current density of MEA without scavenger decreased by 33% under the same conditions (Figure 7 G). However, because the loading of M-N-C catalyst is usually large, the challenge of catalyst layer thickness will be more severe after the addition of radical scavenger.

6 Conclusion and prospect

As the most promising catalyst for the next generation of fuel cells, Fe-N-C catalyst still has much room for improvement in stability. According to the life extension strategies mentioned in this paper, it is the most direct and effective way to prevent or eliminate ROS such as H2O2/·OH.However, the difficulty lies in how to improve the 4E selectivity by optimizing the electronic structure of the active site and the adjacent carbon atoms, and how to close the space distance between the radical scavenger and the active site, so as to remove the ROS generated in the reaction process in situ. In addition, even the most exquisite active sites need the formation of three-phase interface to play a role, so it is very important to reasonably control the pore structure of carbon support and the thickness of catalyst layer. In addition to the above methods to improve catalyst durability, further in situ or condition characterization analysis is needed to clarify the deactivation mechanism of the catalyst. To sum up, efforts should be made in the following directions:
(1) Rational design of catalyst. Demetallization and carbon oxidation corrosion, as the two main causes of deactivation of Fe-N-C catalysts, are usually coupled. However, ROS is aggressive to both active sites and carbon carriers, so when designing catalysts, it is necessary to consider how to optimize the active sites to prevent or remove ROS, and how to construct carbon carriers with stable structure and proper pore distribution, so as to achieve both antioxidant and mass transfer efficiency.
(2) Process optimization of MEA. Due to the lower intrinsic activity of Fe-N-C compared with Pt/C, the thickness of the cathode catalyst layer in PEMFC is often greater than that of the anode side, and optimizing the water and gas management will improve the utilization of the catalyst and reduce the harm of flooding.
(3) More advanced in-situ and working condition characterization methods. Considering that the deactivation mechanism of Fe-N-C catalyst has not been explored clearly in the field at present, especially the principle of ROS-induced deactivation has not been clarified. Therefore, it is necessary to develop more advanced in-situ and working condition characterization methods to identify the intermediates in the reaction process and observe the possible reconstruction of the catalyst in real time, so as to form a deeper understanding of the deactivation mechanism of Fe-N-C catalyst.
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