Boosting Oxygen Reduction Reaction with Fe-Based Single-Atom Catalysts: The Role of Cluster Interactions
Authors: Dessalle Anthony , Quílez-Bermejo Javier , Xu Feina , Fierro Vanessa , Celzard Alain 
Published: February 2024

Fuel cells (FCs) have emerged as a promising alternative for efficient electricity production in the future [1]. However, their widespread commercialization is hindered by their prohibitive cost due to the large amount of platinum used in these electrochemical systems [2]. Platinum is used to accelerate the unfavorable kinetics of the cathodic oxygen reduction reaction (ORR) [3]. To achieve large-scale and cost-effective development of FCs, it is essential to find high-performance platinum-free catalysts. Two solutions are mainly reported in the literature: the development of non-precious metal-based carbon catalysts and metal-free carbon catalysts. However, the work reported on these two types of carbon catalysts is sometimes contradictory regarding the actual nature of the active sites and the mechanisms of reduction of oxygen molecules on the catalyst [4].
Pyrolyzed metal-nitrogen-carbon (M-N-C) catalysts for the ORR, especially single-atom catalysts (SACs), have been widely studied because they exhibit excellent electrocatalytic performance, thanks to the high content of metal atoms anchored on a carbon support [5]. Recent research has indicated that the combination of single-atom active sites with metal nanoclusters can further improve the catalytic activity, but the underlying mechanism remains unclear [6]. Therefore, it is necessary to develop model catalysts based on both single-atoms and nanoclusters to better understand their catalytic activity.
In this work, we prepared nitrogen-doped and iron-doped carbon catalysts (called Fe-NC below) with precise control of the type of iron in the material. First, the functionalization of an activated carbon was performed by carbonizing it under air in the presence of urea. Then, the sample was placed in an autoclave for hydrothermal treatment in the presence of FeCl3.6H2O to allow the incorporation of iron, and thermal post-treatment was applied to synthesize model catalysts (Fig. 1a). The precursor ratio and final pyrolysis temperature were adjusted and optimized to produce either iron-based single atoms (SA) (here referred to as FeSA-NC) or atomic clusters (AC) associated with single atoms (here referred to as FeSA+AC-NC). The results show that the iron-based catalysts exhibit outstanding catalytic activity (Fig. 1b) and durability (Fig. 1c) in alkaline medium for the ORR, even better than commercial Pt (20 wt.%)/C in the case of FeSA+AC-NC. The analysis provided insight into the development of highly efficient multifunctional electrocatalysts, where the presence of iron nanoclusters was found to be a crucial determinant of the catalytic activity for the ORR.
[1] M.K. Debe, Electrocatalyst approaches and challenges for automotive fuel cells, Nature. 486 (2012) 43–51. https://doi.org/10.1038/nature11115.
[2] C. Sealy, The problem with platinum, Mater. Today. 11 (2008) 65–68. https://doi.org/10.1016/S1369-7021(08)70254-2.
[3] M. Borghei, J. Lehtonen, L. Liu, O.J. Rojas, Advanced Biomass-Derived Electrocatalysts for the Oxygen Reduction Reaction, Adv. Mater. 30 (2018) 1703691. https://doi.org/10.1002/adma.201703691.
[4] A. Dessalle, J. Quílez-Bermejo, V. Fierro, F. Xu, A. Celzard, Recent progress in the development of efficient biomass-based ORR electrocatalysts, Carbon. 203 (2023) 237–260. https://doi.org/10.1016/j.carbon.2022.11.073.
[5] K. Liu, J. Fu, Y. Lin, T. Luo, G. Ni, H. Li, et al., Insights into the activity of single-atom Fe-N-C catalysts for oxygen reduction reaction, Nat. Commun. 13 (2022) 2075. https://doi.org/10.1038/s41467-022-29797-1.
[6] X. Wan, Q. Liu, J. Liu, S. Liu, X. Liu, L. Zheng, et al., Iron atom–cluster interactions increase activity and improve durability in Fe–N–C fuel cells, Nat. Commun. 13 (2022) 2963. https://doi.org/10.1038/s41467-022-30702-z.

Figure 1