Fe-N-C Oxygen Reduction Catalysts Via Chemical Vapor Deposition in Fluidized Bed Reactor

Abstract

Metal nitrogen carbon catalysts (MNC) are an attractive substitute for platinum-based catalysts in the oxygen reduction reaction (ORR) in PEM fuel cells. However, state-of-the-art MNC catalysts still suffer from low activity and instability. Li et al. [1] demonstrated the use of zinc imidazolate frameworks (ZIF-8) in chemical vapor deposition (CVD) to form active sites without unwanted particle formation or additional treatment steps. In this method, gaseous iron chloride exchanges the zinc in the precatalyst to form active sites.In this work, we introduce a vertical fluidized bed reactor (FBR) for high-scale synthesis of FeNC via CVD, allowing for uniform dispersion of the precatalyst and better zinc-iron exchange. Furthermore, we investigated the influence of differently sized ZIF-8 on the CVD and the formation of the FeNC catalyst.The final catalysts were characterized for their electrochemical activity in a rotating ring disc setup, their site density via CO-chemisorption, and their respective turnover frequency. The physicochemical characterization includes the analysis of surface area and pore structure via nitrogen physisorption, SEM, and TEM, as well as surface structure and compositional analysis via elemental analysis, ICP-OES, and XPS.The exchange of Zn was in the range of 90%, resulting in an iron content of 3.8 wt% with only the formation of desired Fe-Nx active sites. STEM-EDX imaging shows an even distribution of iron and nitrogen in the catalyst, with mean particle sizes of 110 nm. In rotating disc electrode experiments with 0.5 M sulfuric acid, mass activities of 0.23 A/g at 0.9 V vs RHE were achieved.Commercially nano-scaled ZIF-8 with mean particle sizes of 500 nm, synthesized particles with mean sizes of 110 nm were tested, compared to the commercial ZIF-8 Basolite Z1200 with mean particle sizes of 4.9 µm. We could show improved activity in RRDE of the nano-scaled ZIF-8 materials compared to the macro-scaled Basolite.Applying this highly scalable synthesis method for MNC catalysts could be a viable way to achieve high-performance catalysts for ORR.[1] Li Jiao, Jingkun Li, Lynne Larochelle Richard, Qiang Sun, Thomas Stracensky, et al.. Chemical vapour deposition of Fe–N–C oxygen reduction catalysts with full utilization of dense Fe–N4 sites. Nature Materials, 2021, 20, pp.1385-1391.