Developing highly efficient catalysts for the oxygen reduction reaction (ORR) is key to the fabrication of commercially viable fuel cell devices and metal–air batteries for future energy applications. Herein, we review the most recent advances in the development of Pt-based and Pt-free materials in the field of fuel cell ORR catalysis. This review covers catalyst material selection, design, synthesis, and characterization, as well as the theoretical understanding of the catalysis process and mechanisms. The integration of these catalysts into fuel cell operations and the resulting performance/durability are also discussed. Finally, we provide insights into the remaining challenges and directions for future perspectives and research.

Recent advancements in Pt and Pt-free catalysts for oxygen reduction reaction

With the development of renewable energy and electrified transportation, electrochemical energy storage will be more important in the future than it has ever been in the past. Although lithium-ion batteries (LIBs) are traditionally considered to be the most likeliest candidate thanks to their relatively long cycle life and high energy efficiency, their limited energy density as well as cost are still causing a bottleneck for their long-term application. Alternatively, metal–air batteries have been proposed as a very promising large-scale electricity storage technology with the replacement of the intercalation reaction mechanism by the catalytic redox reaction of a light weight metal–oxygen couple. Generally, based on the electrolyte, these metal–air batteries can be divided into aqueous and nonaqueous systems, corresponding to two typical batteries of Zn–air and Li–air, respectively. The prominent feature of both batteries are their extremely high theoretical energy density, especially for nonaqueous Li–air batteries, which far exceeds the best that can be achieved with LIBs. In this review, we focus on the major obstacle of sluggish kinetics of the cathode in both batteries, and summarize the fundamentals and recent advances related to the oxygen catalyst materials. According to the electrolyte, the aqueous and nonaqueous electrocatalytic mechanisms of the oxygen reduction and evolution reactions are discussed. Subsequently, seven groups of oxygen catalysts, which have played catalytic roles in both systems, are selectively reviewed, including transition metal oxides (single-metal oxides and mixed-metal oxides), functional carbon materials (nanostructured carbons and doped carbons), metal oxide–nanocarbon hybrid materials, metal–nitrogen complexes (non-pyrolyzed and pyrolyzed), transition metal nitrides, conductive polymers, and precious metals (alloys). Nonaqueous systems have the advantages of energy density and rechargeability over aqueous systems and have gradually become the research focus of metal–air batteries. However, there are considerable challenges beyond catalysts from aqueous to nonaqueous electrolytes, which are also discussed in this review. Finally, several future research directions are proposed based on the results achieved in this field, with emphasis on nonaqueous Li–air batteries.

Oxygen electrocatalysts in metal–air batteries: from aqueous to nonaqueous electrolytes

Despite intense research in past decades, the lack of high-performance catalysts for fuel cell reactions remains a challenge in realizing fuel cell technologies for transportation applications. Here we report a facile strategy for synthesizing hierarchical platinum-cobalt nanowires with high-index, platinum-rich facets and ordered intermetallic structure. These structural features enable unprecedented performance for the oxygen reduction and alcohol oxidation reactions. The specific/mass activities of the platinum-cobalt nanowires for oxygen reduction reaction are 39.6/33.7 times higher than commercial Pt/C catalyst, respectively. Density functional theory simulations reveal that the active threefold hollow sites on the platinum-rich high-index facets provide an additional factor in enhancing oxygen reduction reaction activities. The nanowires are stable in the electrochemical conditions and also thermally stable. This work may represent a key step towards scalable production of high-performance platinum-based nanowires for applications in catalysis and energy conversion.

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Surface engineering of hierarchical platinum-cobalt nanowires for efficient electrocatalysis

Abstract Electrochemical surface oxidation of carbon black Vulcan XC-72 and multiwalled carbon nanotube (MWNT) has been compared following potentiostatic treatments up to 168 h under condition simulating PEMFC cathode environment (60 °C, N2 purged 0.5 M H2SO4, and a constant potential of 0.9 V). The subsequent electrochemical characterization at different treatment time intervals suggests that MWNT is electrochemically more stable than Vulcan XC-72 with less surface oxide formation and 30% lower corrosion current under the investigated condition. As a result of high corrosion resistance, MWNT shows lower loss of Pt surface area and oxygen reduction reaction activity when used as fuel cell catalyst support.

http://ma.ecsdl.org/content/MA2005-02/33/1168.full.pdf

Durability Investigation of Carbon Nanotube as Catalyst Support for Proton Exchange Membrane Fuel Cell Electrode

Three-dimensional (3D) Pt-based alloy nanostructures composed of one-dimensional (1D) nanowires/nanorods have recently attracted significant interest as electrocatalysts. In this work, we report an effective solvothermal method for the direct preparation of 3D Pt-Co nanowire assemblies (NWAs) with tunable composition. The composition- and structure-dependent electrocatalytic performance is thoroughly investigated. Because of the bimetallic synergetic effect and unique structural advantage, the as-prepared 3D Pt3Co NWA outperforms commercial Pt/carbon and Pt black catalysts and even 3D Pt NWA. The electrochemical results demonstrate that the 3D Pt3Co NWA is indeed a promising electrocatalyst with enhanced catalytic activity and improved durability for practical electrocatalytic applications.

One‐Pot Synthesis of Pt–Co Alloy Nanowire Assemblies with Tunable Composition and Enhanced Electrocatalytic Properties

In it for the long haul: Clusters of Pt nanowires (3D Pt nanoassemblies, Pt NA) serve as an electrocatalyst for low-temperature fuel cells. These Pt nanoassemblies exhibit remarkably high stability following thousands of voltage cycles and good catalytic activity, when compared with a commercial Pt catalyst and 20 % wt Pt catalyst supported on carbon black (20 % Pt/CB).

Wan Theng Ng

Papers

Self‐Supported Interconnected Pt Nanoassemblies as Highly Stable Electrocatalysts for Low‐Temperature Fuel Cells

Self-Supported Interconnected Pt Nanoassemblies as Highly Stable Electrocatalysts for Low-Temperatur