The development of catalysts free of platinum-group metals and with both a high activity and durability for the oxygen reduction reaction in proton exchange membrane fuel cells is a grand challenge. Here we report an atomically dispersed Co and N co-doped carbon (Co–N–C) catalyst with a high catalytic oxygen reduction reaction activity comparable to that of a similarly synthesized Fe–N–C catalyst but with a four-time enhanced durability. The Co–N–C catalyst achieved a current density of 0.022 A cm−2 at 0.9 ViR-free (internal resistance-compensated voltage) and peak power density of 0.64 W cm−2 in 1.0 bar H2/O2 fuel cells, higher than that of non-iron platinum-group-metal-free catalysts reported in the literature. Importantly, we identified two main degradation mechanisms for metal (M)–N–C catalysts: catalyst oxidation by radicals and active-site demetallation. The enhanced durability of Co–N–C relative to Fe–N–C is attributed to the lower activity of Co ions for Fenton reactions that produce radicals from the main oxygen reduction reaction by-product, H2O2, and the significantly enhanced resistance to demetallation of Co–N–C. Platinum-group-metal-free, non-iron catalysts are highly desirable for the oxygen reduction reaction at proton exchange membrane (PEM) fuel cell cathodes, as they avoid the detrimental Fenton reactions. Now, a cobalt and nitrogen co-doped carbon catalyst with atomically dispersed porphyrin-like CoN4C12 sites is reported with an improved activity and durability in PEM fuel cell conditions.

Performance enhancement and degradation mechanism identification of a single-atom Co–N–C catalyst for proton exchange membrane fuel cells

The past 30 years have seen progress in the development of Pt-based nanocatalysts for the oxygen reduction reaction, and some are now in production on a commercial basis and used for polymer electrolyte fuel cells (PEFCs) for automotives and other applications. Further improvements in catalytic activity are required for wider uptake of PEFCs, however. In laboratories, researchers have developed various catalysts that have much higher activities than commercial ones, and these state-of-the-art catalysts have potential to improve energy conversion efficiencies and reduce the usage of platinum in PEFCs. There are several technical issues that must be solved before they can be applied in fuel cell vehicles, which require a high power density and practical durability, as well as high efficiency. In this Review, the development history of Pt-based nanocatalysts and recent analytical studies are summarized to identify the origin of these technical issues. Promising strategies for overcoming those issues are also discussed. This Review summarizes the development history of Pt-based nanocatalysts and recent analytical studies to identify the technical issues in the automobile application, proposing promising strategies for overcoming the trade-offs among the efficiency,power density, and durability of polymer electrolyte fuel cells.

Challenges in applying highly active Pt-based nanostructured catalysts for oxygen reduction reactions to fuel cell vehicles.

Energy management of hybrid electric vehicles: A review of energy optimization of fuel cell hybrid power system based on genetic algorithm

Replacing scarce and expensive platinum (Pt) with metal–nitrogen–carbon (M–N–C) catalysts for the oxygen reduction reaction in proton exchange membrane fuel cells has largely been impeded by the low oxygen reduction reaction activity of M–N–C due to low active site density and site utilization. Herein, we overcome these limits by implementing chemical vapour deposition to synthesize Fe–N–C by flowing iron chloride vapour over a Zn–N–C substrate at 750 °C, leading to high-temperature trans-metalation of Zn–N4 sites into Fe–N4 sites. Characterization by multiple techniques shows that all Fe–N4 sites formed via this approach are gas-phase and electrochemically accessible. As a result, the Fe–N–C catalyst has an active site density of 1.92 × 1020 sites per gram with 100% site utilization. This catalyst delivers an unprecedented oxygen reduction reaction activity of 33 mA cm−2 at 0.90 V (iR-corrected; i, current; R, resistance) in a H2–O2 proton exchange membrane fuel cell at 1.0 bar and 80 °C. Replacing platinum with metal–nitrogen–carbon catalysts for the oxygen reduction reaction in proton exchange membrane fuel cells has been impeded by low activity. These limitations have now been overcome by the trans-metalation of Zn–N4 sites into Fe–N4 sites.

https://hal.archives-ouvertes.fr/hal-03024544/document

Chemical vapour deposition of Fe-N-C oxygen reduction catalysts with full utilization of dense Fe-N4 sites.

Overview of the next quarter century vision of hydrogen fuel cell electric vehicles

Direct hydrogen fuel cell electric vehicle cost analysis: System and high-volume manufacturing description, validation, and outlook

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Direct hydrogen fuel cell electric vehicle cost analysis: System and high-volume manufacturing description, validation, and outlook