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Chemical Engineering Journal 395 (2020) 125158

Contents lists available at ScienceDirect

Chemical Engineering Journal


journal homepage: www.elsevier.com/locate/cej

FeCo nanoparticles wrapped in N-doped carbon derived from Prussian blue T


analogue and dicyandiamide as efficient oxygen reduction electrocatalysts
for Al-air batteries
Linfang Cuia,b, Mingxing Chena,b, Ge Huoa,b, Xian-Zhu Fua, , Jing-Li Luoa,c,
⁎ ⁎

a
College of Materials Science and Engineering, Shenzhen University, 1066 Xueyuan Ave, Nanshan District, Shenzhen 518055, China
b
Key Laboratory of Optoelectronic Devices and Systems of Ministry of Education and Guangdong Province, College of Optoelectronic Engineering, Shenzhen University,
Shenzhen 518060, China
c
Department of Chemical and Materials Engineering, University of Alberta, Edmonton, Alberta T6G 1H9, Canada

HIGHLIGHTS GRAPHICAL ABSTRACT

• N-doped graphitic carbon embedded


with FeCo nanoparticles has been
FeCo nanoparticles wrapped in N-doped carbon is developed as efficient oxygen reduction electrocatalysts for
Al-air batteries
prepared.
• The PD-800 is an efficient ORR cata-
lyst and comparable with Pt/C.
• Al-air battery for PD-800 surpasses
that of Pt/C catalyst.

ARTICLE INFO ABSTRACT

Keywords: Developing highly active and durable electrocatalysts with low-cost for the oxygen reduction reaction (ORR) is of
FeCo alloy paramount importance for promoting economical and high-performance Al-air batteries. Herein, nitrogen-doped
N-doped carbon carbon decorated with FeCo nanoparticles catalysts is prepared by a low-cost and facile approach employed Prussian
Oxygen reduction reaction blue analogue and dicyandiamide as precursors. The obtained catalyst exhibits remarkable ORR activity with an
Al-air battery
onset potential (0.981 V vs. RHE) and a high half-wave potential (0.848 V vs. RHE), as well as superior stability in
alkaline conditions. The outstanding electrocatalytic performance of electrocatalysts might be resulted from the
hierarchical porous structure and synergetic effect between FeCo alloy and N-doped graphitic carbon species. As a
demonstration, the optimized catalysts are employed as the cathode catalysts in a Al-air battery, which shows re-
markable discharge performance with higher open-circuit voltage of 1.67 V and large power density of
98.62 mW cm−2 which exceeding commercial Pt/C electrocatalysts (1.65 V, 90.81 mW cm−2), and exceptional cycle
stability of 40 h (4 cycles). This work will provide a chance to explore scalable advanced catalysts in Al-air battery.


Corresponding authors at: College of Materials Science and Engineering, Shenzhen University, 1066 Xueyuan Ave, Nanshan District, Shenzhen 518055, China
(J.L. Luo).
E-mail addresses: xz.fu@szu.edu.cn (X.-Z. Fu), luoj@ualberta.ca (J.-L. Luo).

https://doi.org/10.1016/j.cej.2020.125158
Received 11 February 2020; Received in revised form 1 April 2020; Accepted 18 April 2020
Available online 23 April 2020
1385-8947/ © 2020 Elsevier B.V. All rights reserved.
L. Cui, et al. Chemical Engineering Journal 395 (2020) 125158

1. Introduction nitrogen source to tune the structure and N dopant of the MOF-derived
porous carbon, a highly porous framework of N-doped graphitic carbon
Recently, Al-air batteries (AABs) have been evidenced as a pro- with FeCo nanoparticles encapsulated are synthesized by the thermal-
mising choice to meet ever-growing energy demands, due to their treatment of the mixture of DCDA and Prussian blue analog Fe3[Co
merits of higher theoretical voltage and energy density, excellent se- (CN)6]2 in Ar atmosphere. The resultant Fe3[Co(CN)6]2/DCDA com-
curity and stability in operation [1,2]. Moreover, aluminum is earth- posite derived catalysts have an unique hierarchical micro-/meso-
abundance, low costs, recyclable as well as environmental metal com- porous structures. The integration of the architecture with abundant
pared with the noble metal and its materials [3]. Nevertheless, the FeCo species and N-doped graphitic carbon active sites enables the
performance and efficiency of AABs are still hindered by the intrinsic catalyst excellent ORR activity and long-term durability in alkaline
sluggish kinetics of oxygen reduction reactions (ORR) at cathode [4]. electrolyte, and dramatically higher than most of reported MOFs de-
Thus, it is imperative to explore cost-effective ORR catalysts with en- rived catalysts. The equipped Al-air battery as the cathode catalysts
hanced activity and improved durability for boosting applications of Al- exhibits an outstanding discharge performance, even outperforming the
air batteries. As of today, the noble metal (Pt) and Pt-based materials Pt/C catalyst. This work may afford an alternative methodology for the
are still considered to be the benchmark and most efficient catalysts for rational design of highly efficient catalysts based on alloy nanoparticles
catalyzing ORR, but their exorbitant price and poor stability seriously encapsulated with carbon shell, and it is rewarding to develop these
obstruct prevailing applications [5–7]. In this regard, it is therefore catalysts for their application in metal-air batteries.
urgent to develop inexpensive and scalable ORR catalysts with high-
efficiency as an alternative for noble metal materials. 2. Experimental section
Tremendous efforts have been devoted to developing non-precious
metal catalysts including carbonaceous materials doped with heteroa- 2.1. Preparation of catalyst
toms (i.e. N, P, S, B, F) [4,8], transition metals and their derivations
(such as oxides, carbides, nitrides, sulphides and phosphides) [9,10], as All purchased chemicals were of analytical grade and used as re-
well as transition metal-N-doped carbon (M−N−C) [11–13]. There- ceived. Deionized (DI) water with a resistivity of 18.2 MΩ cm was used
into, three-dimensional (3-d) earth-abundant transition metals (i.e. Fe, for all experiments. In this work, a Prussian blue analogue (PBA) Fe3[Co
Co, Ni) have recently emerged as a new family of materials toward the (CN)6]2 was prepared by a chemical precipitation reaction between
ORR with high activity and stability, rendering the great potential for FeSO4·7H2O (Sigma–Aldrich) and K3[Co(CN)6]2 (Beijing J&K Co., Ltd.,
diverse catalytic environmental [14,15]. Especially, large numbers of China) in aqueous solution of polyvinylpyrrolidone (PVP, average MW
research groups have exploited intermetallic alloys of the transition 58000, Aladdin Co., China). The desired product was referred to as
metals, FeCo [16–19], FeNi [20], and NiCo [15,21,22] for ORR cata- FeCo-PBA. The approach for FeCo-PBA was prepared according to the
lysts, which are contributed to new integrate functionalities formed by previously reported literatures [28,29], except for some little mod-
intermetallic interactions between individual metals. However, elec- ification. In a typical procedure, 0.005 mol of K3[Co(CN)6]2 was dis-
trocatalytic ORR in basic/acidic medium toward is precluded by the solved in 40 mL DI water containing 1.5 g of PVP. Then 50 mL of
self-aggregation and poor stability. The carbon shell coating has been FeSO4·7H2O (9 mM) was added dropwise into the premixed solution
regarded as an effective way to protect alloys from aggregation and under magnetic stirring, followed by stirring for another 30 min and
degradation when alloys are subjected to ORR, because carbon coating aged at room temperature for 24 h. The precipitates were collected after
can effectively isolate alloys from the electrolyte solutions [18,19]. The several centrifuge-wash with deionized (DI) water and ethanol cycles,
carbon coating doped with nitrogen (N), and N-doped carbonaceous and finally dried in vacuum drier at 40 °C for 24 h.
materials have also been confirmed as a promising ORR catalyst. The To prepare the FeCo-PBA/dicyandiamide (DCDA) composite, the as-
insertion of N dopants into the carbonaceous materials display sig- synthesized FeCo-PBA were mixed with DCDA according to the mass
nificant improvement of catalysts’ conductivity and electronic affinity ratio of 1:10 and grinded for 20 min. Then, the homogeneous precursor
of the carbon matrix, resulting in an enhancement in electrocatalyst was placed into a crucible under the nitrogen atmosphere, and annealed
activity and producing more active sites [8,22]. Moreover, there are at a designated temperature (600, 700, 800 and 900 °C) for 2 h with a
synergetic effects between N-doped carbon materials and transition rate of 5 °C min−1. To remove the unstable and inactive species, the
metals, which can enhance ORR catalytic activity greatly by modifying obtained carbonized products were immersed in 0.5 M H2SO4 aqueous
the local electronic structure and optimizing the intermediate adsorp- solution for 24 h in room temperature. Subsequently, the products were
tion. For example, FeCo alloy nanoparticles assembled in the Nitrogen- washed with DI water until pH = 7, and then dried at 60 °C for 24 h.
doped carbon nanofibers exhibits superior bifunctional activities to- The finial products were designated as PD-T, where T refers to the
ward ORR and OER in KOH solution [23]. CoNi nanoparticles em- annealing temperature. To confirm the vital effect of DCDA, the fabri-
bedded in the N-doped carbon tubes could improve ORR and OER cation of pure FeCo-PBA (marked as PA-800) was also studied under the
performance in all the pH-dependence media [21]. However, the cur- identical conditions as PD-800.
rent non-precious metal catalysts still show undesirable intrinsic ac-
tivities, and thus lead to their activities are inferior compared with 2.2. Material characterizations
commercial Pt/C. There is still a long way to develop the non-precious
metal catalysts to be competitive in the family of ORR electrocatalysts, Wide-angle X-ray diffraction (XRD) patterns were collected using X-
because of their undesirable intrinsic activities and durability. ray diffractometer (Bruker D8 Advance) at 50 kV and 360 mA with Cu-
The well-organized metal–organic frameworks (MOFs) have been Kɑ radiation (λ = 1.54178 Å). Field-emission scanning electron mi-
regarded as an attract platform for the fabrication of porous carbon- croscope (FESEM, SU-70) and Field-emission transmission electron
based materials because of the coexistence of abundant nitrogen species microscope (FEI Tecnai G2 F20) were employed to characterize the
and various transition metals, as well as porous structure, which en- morphologies of the samples, and Raman spectrum of the samples were
dows its deprived hybrid composites with abundant of N-C or M−N−C carried out on a RENIDHAW invia instrument with a 532 nm excitation
active sites for electrocatalysis [24]. As a class of MOFs, Prussian blue laser source. X-ray photoelectron spectroscopy (XPS, ESCALAB 250XI,
analog (PBA) has recently stood out as a promising precursors for Thermo Scientific) was employed to analyze the elemental composi-
preparation of the porous carbon frameworks [25–27]. However, in- tions and chemical states of elements of sample surface, and C 1s
ferior electrical conductivity and loss of nitrogen caused by carboni- (284.8 eV) was employed as a reference to calibrate all binding energies
zation greatly restrict their electrocatalytic activity. for samples. Specific surface areas and pore size distributions of the
Herein, we adopt dicyandiamide (DCDA) as secondary carbon and catalysts were analyzed using Brunauer-Emmett-Teller (BET, 3FIex),

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L. Cui, et al. Chemical Engineering Journal 395 (2020) 125158

Barrett-Joyner-Halenda (BJH) methods was used. Ahead of testing, all a typical ORR are calculated from the Koutecky-Levich equations:
catalysts were degassed in a vacuum overnight at 60 °C. Inductively 1 1 1 1 1
coupled plasma optical emission spectroscopy (ICP-OES) was con- = + = +
J Jk JL Jk B 2
1
(4)
ducted on PerkinElmer 8300.
2
- 1
B = 0.62nFC0 D03 6 (5)
2.3. Electrochemical characterizations
Here, J, Jk and JL are the measured current density, kinetic current
The electrochemical activities of all the as-synthesized catalysts density and diffusion limit current density, respectively. ω is the an-
were conducted in a conventional three-electrode system on a CHI 760E gular rate of the disc in rpm and n is the electron transfer number, F is
workstation (Shanghai Chenhua, China) at 25 ± 1 °C. Glassy carbon Faraday constant (F = 96485C mol−1). C0 and D0 are the bulk con-
(GC) electrode (5 mm diameter, area of 0.196 cm2), Pt foil (2 × 2 cm2 centration (1.2 × 10−6 mol cm−3) and diffusion coefficient
square) and Ag/AgCl-3.5 M electrode were employed as the working (1.9 × 10−5 cm2 s−1) of O2 in 0.1 M KOH solution, υ is the kinetic
electrode, counter electrode, and reference electrode, respectively. viscosity (υ = 0.01 cm2 s−1). It’s noted that the coefficient 0.2 is
Ahead of using, GC electrode was polished with 0.3 μm and 0.05 μm adopted when the rotation speed is presented in rpm.
alumina slurry in turn, and then was rinsed with DI water and dried at To further understand of the ORR catalyzed by the as-synthesized
room temperature. The catalyst ink was prepared in the following: 4 mg samples, the overall number of transfer electrons (n) and the yield of
of the catalyst was dispersed in 1 mL solution of 2:1 v/v ethanol/ H2O2 in ORR process can be evaluated on the base of rotating ring-disc
deionized water mixed solvent with 20 μL of 5 wt% Nafion (Sigma- electrode (RRDE) using the following formulas:
Aldrich), and subsequently ultrasonicated for 30 min to form a homo- IR
geneous suspension. Then, 20 μL of suspension was carefully dropped H2 O2 (%) = 200 ×
N

onto the GC rotating disc electrode (RDE) to yield a loading of ID + IR


N (6)
~0.4 mg cm−2. For comparison, 20 wt% Pt/C (Alfa Aesar) ink was ID
formed like other catalyst inks with a similar procedure, and the N= 4 ×
ID + IR /N (7)
loading was 0.1 mg cm−2 for Pt/C. Prior to the ORR measurements, the
electrolyte was purged with N2/O2 for approximately 30 min. The in which IR and ID represent the ring current and the Faradaic current
cyclic voltammetry (CV) curves were tested in N2/O2-saturated 0.1 M densities at the disc, N is the current collecting efficiency of the Pt ring
KOH with a scan rate of 10 mV s−1. LSV tests were measured using the and determined to be 0.37.
RDE in O2-saturated 0.1 M KOH solution at a sweep rate of 10 mV s−1
with different electrode rotation rates from 100 to 2025 rpm, and the 2.4. Al-air battery evaluation
potential range from 0.2 to −0.8 V (vs. Ag/AgCl). Long-time and me-
thanol crossover measurements were conducted in O2-saturated solu- To explore the potential of the as-synthesized materials in metal-air
tion under a rotating speed of 1600 rpm. For the anti-methanol tests, battery applications, Al-air batteries were performed in a configuration
the current was recorded when 3.0 M methanol was added into the of homemade electrochemical cell, where Al foil was employed as
electrolyte at 400 s. All measurements initially versus Ag/AgCl and anode and 4.0 M KOH as electrolyte. As for the cathode, which con-
were normalized to reversible hydrogen electrode (RHE) according to taining of a conductive current collector(Nickel foams), a gas diffusion
the following formula: layer (Teflon-coated carbon fiber paper, catalyst loading 1.0 mg cm−2)
and a catalyst layer (as-synthesized catalyst, PVDF and carbon black
ERHE = E(Ag/AgCl) + 0.197 + 0.059 × pH (1)
with a mass ratio of 3:4:7). Subsequently, the homogeneous electro-
For the ORR, electrochemical impedance spectroscopy (EIS) was catalyst slurry is uniformly loaded on a Ni foam with an area of
tested in O2-saturated 0.1 M KOH electrolyte at an amplitude of 10 mV 1 × 1 cm2. Prior to electrochemical testing, the above components are
with varying frequency from 0.01 Hz to 1000 kHz. The Tafel curves pressed under 2 MPa pressure for 1 min, and then, drying it at 60 °C for
were obtained by fitting the LSV linear portions of the polarization plots 12 h to remove the solvent. All Al-air batteries test is conducted on a
according to the equation: CHI 760E electrochemical workstation at room temperature. The spe-
cific capacity can be calculated using the following equation:
= a+ blog |j| (2)
Specific capacity = It/ m
where a and b are constant and depend on specific catalysts and con-
ditions, and j is the current density. where I is the discharging current (A), t is the discharging time (s) and
The kinetic current density (Jk), known as mass-transport correction Δm is the weight loss of the anode (g).
for different rotating disk electrodes, is determined based on the fol-
lowing formula [30,31]: 3. Results and discussion
J*JL
Jk = 3.1. Catalyst preparation and characterization
JL J (3)

where J is the experimentally measured current density, and JL is the The synthetic strategy of FeCo alloy nanoparticles encapsulated in
obtained diffusion limited current density. N-doped graphitic carbon is described in the experimental section and
The electron transfer number (n) and kinetic current density (Jk) for schematically illustrated in Fig. 1. First, uniform Fe/Co-PBA nanocubes

Fig. 1. Schematic illustration of the preparation


of the PD-T catalyst.

3
L. Cui, et al. Chemical Engineering Journal 395 (2020) 125158

were synthesized as precursor through coprecipitation method in the


solution of PVP. Then, the desired PD-T was obtained by pyrolyzing the
mixture of solid Fe/Co-PBA nanocubes with DCDA at elevated tem-
perature under Ar atmosphere. DCDA is usually added as a precursor
for pyrolysis, and it can serve as the in situ template to produce the
layered graphitic nitride, which can regarded as a sacrificial template
for producing graphite materials [32].
As depicted in Fig. 2a and b, Fe/Co-PBA shows cubic morphology
and uniform size, its size is ca. 600–900 nm, and its pattern was con-
firmed by XRD result in Fig. 2c. After the carbonization treatment of the
mixture of the Fe/Co-PBA and DCDA at desired temperature, the
morphology and their network structure are preserved, along with a
slight size shrinkage (Fig. 2d and e), and the EDS mappings confirm that
C, Co, N, Fe, S are uniformly dispersed in the whole carbon matrix for
PD-800 (Fig. S1). There are no obvious differences in morphology and
size among these samples with different carbonation temperature
treatments in the hybrid (Fig. S2 and Fig. S3). Similar XRD patterns
(Figs. 2f and S4) of these PD-T and PA-800 samples are observed with
three main peaks centered at 44.9°, 65.3° and 82.6° for (1 1 0), (2 0 0)
and (2 1 1) planes, which correspond to the FeCo alloy (JCPDS No. 49-
1567), respectively. A distinct peak at approximately 26° for (0 0 2)
plane belonging to the graphitic carbon is detected in all samples,
confirming that the highly graphitized carbon is obtained in the cata- Fig. 3. (a) TEM and (b) HRTEM images of PD-800 (inset in (b) SAED pattern of
lysts. Also, Fe3C (assigned by &) is observed in PD-800 and PD-900, PD-800). (c) N2 adsorption–desorption isotherm and (d) pore size distribution
indicating that Fe3C alloy is formed in the hybrid catalysts. The ratio of curve of PD-800.
FeCo and Fe3C is 9.75 measured by the ICP-OES technique. The ex-
cellent ORR activity thus might be ascribed to the active sites for FeCo carbon shell. These results indicate the formation of FeCo nanoparticles
nanoparticles, N-doped graphitic carbon and Fe3C [23,33]. within the N-doped carbon layer and confirmed by the above-discussed
The microstructure of PD-800 catalyst is further observed by TEM XRD patterns (Fig. S5a and b). In addition, the FeCo nanoparticles size
and HRTEM. The black portion shown in TEM image is assignable to the for PD-900 (~25 nm) is larger than PD-800, and then the decreased
alloy particles wrapped by several graphitic carbon layers with a electrocatalytic activity for the PD-900. The select area electron dif-
0.34 nm lattice fringe (Fig. 3a). {Ma, 2019 #217}{Ma, 2019 #217} fraction (SAED) pattern (inset in Fig. 3a) reveals that the crystalline
Based on the analysis of HRTEM (Fig. 3b), the size of the FeCo alloy nature of the as-prepared PD-800. In order to analyze the specific sur-
nanoparticles are approximately 20 nm. Furthermore, FeCo alloy na- face area and porous structure, N2 adsorption/desorption measure-
noparticles with the lattice spacing of 0.202 nm, corresponding to the ments are carried out on the catalysts (Figs. 3c and S5c), which displays
(1 1 0) lattice fringe, which clearly demonstrates that the PD-800 a type-IV isotherm with a distinct hysteresis loop at a higher pressure
composite is constructed by FeCo alloy nanoparticles encapsulated by range from 0.4 to 1.0, representing the coexistence of micropores and
N-doped graphitic carbon shell (inset in Fig. 3b). In comparison, the PD- mesopores, which will provide more reactive active sites and hence
900 also resulted in similar FeCo alloy nanoparticles embedded by

Fig. 2. SEM images of (a, b) FeCo-PBA. (c) XRD patterns of the as-prepared Fe3[Co(CN)6]2. SEM images of (d, e) PD-800. (f) XRD patterns of PD-T samples.

4
L. Cui, et al. Chemical Engineering Journal 395 (2020) 125158

improve the efficiency of ORR-related species [6,34].The Brunauer- X-ray photoelectron spectroscopy (XPS) is an effective method to
Emmet-Teller (BET) specific surface area and pore volume of PD-800 detect the chemical compositions and state of samples. The XPS survey
are measured to be 203.41 m2 g−1 and 0.361 cm3 g−1, which are larger spectrum of all samples directly reveals the existence of C, N, O, S, Co
than 164.46 m2 g−1and 0.136 cm3 g−1 for PD-900. A larger specific and Fe elements, indicating that N, Co and Fe heteroatoms have been
surface means a large number of active sites exposed for the catalysts, successfully doped into the carbon backbone [44]. Moreover, the cor-
resulting in an enhanced electrocatalytic performance. Moreover, a responding EDS elemental-mapping images for PD-800 further de-
detailed pore structure analysis (Figs. 3d and S5d) further reveals that monstrate the homogenous distribution of C, N, S, Co and Fe elements
the hierarchical microporous and mesoporous structure, which are re- throughout the whole carbon architecture (Fig. S1). The presence of O
sponsible for transporting O2 and electrolyte to the active sites [35]. is possibly due to the incorporation of physic-chemically absorbed
Furthermore, the mesoporous structure not only facilitates mass oxygen or the residual oxygen-group in precursor, and the induction of
transfer but also leads to the exposure of more active sites [22]. The O atoms can alter the electronic structure of carbon atoms, thus influ-
unique architecture porous characteristics endows the PD-800 hybrid encing the adsorption of O2 for ORR [41,45]. As for S element in the
with more catalytically active sites, which will facilitate the effective sample, which possibly stems from the existence of SO42− affiliated to
electron/ion transport during the electrochemical reaction. samples. During the process of carbonization, the SO42− might be re-
Raman spectroscopy is deemed as an effective method to detect the duced and thus resulted in the generation of the element S. As shown in
structure defectiveness and degree of graphitization of samples. It can Table S1, with increasing carbonization temperature from 600 to
be seen clearly that there are two distinct peaks around 1344 and 900 °C, the contents of Fe, Co, C, N, O, S and the total nitrogen content
1572 cm−1 for all the samples, corresponding to D band and G band of decrease obviously, whilst the amount of C increases. Meanwhile, it
carbon materials, respectively (Figs. 4a and S4b) [36]. The D band is should be noted that the pyridine- and pyrrolic-N are predominant for
ascribed to the graphene edges or disordered structure, and accompany the PD-T at low temperature, whereas the graphite-N is predominant at
with the defect for its activation [37]. Generally, the intensity ratio of high temperature due to its stability better than the other two N species
the D to G band (ID/IG) is used to evaluate the degree of disorder in the under higher temperature, and the results are in good accordance with
sp2 carbon materials, and a higher value indicates a higher defect de- the previous report [46]. Notably, compared with the PA-800, the
gree [38]. Additionally, some reports have revealed that defects of content of total nitrogen in PD-800 increases and reaches up to 3.23 at
carbon materials can enhance the electrocatalytic ORR activity %, suggesting that the decomposition of the FeCo-PBA/DCDA compo-
[39–41]. It can be seen from Fig. 4a that the value of ID/IG decreases site and subsequent chemical deposition can improve the content of
from 0.95 (PD-600) to 0.83 (PD-900) with the carbonization tempera- doped nitrogen, which likely result in generate amount of N-based ac-
ture, resulting in a higher degree of graphitization, which thus brings tive sites and promote the ORR of PD-800 [42]. In addition, the high-
about an enhancement for electrocatalytic activity of materials [36]. It resolution N 1s spectra of PD-800 could be divided into five peaks at
is also found that the total nitrogen content decreases from 7.75 at % 398.1 eV (pyridinic -N), 398.9 eV (M (Fe/Co)-Nx), 401.1 eV (graphitic-
(PD-600) to 1.93 at % (PD-900) with increasing pyrolysis temperature N), 399.8 eV (pyrrolic-N) and 402.8 eV (oxidized N), and their relative
(Table S1), which implies that the number of potential N-based active percentage are 14.8, 17.5, 33.3, 12.4 and 22%, respectively (Fig. 4c)
sites is diminishing [42]. In addition, the ratio of ID/IG is 0.88 for PD- [44,47]. This confirms the N dopant is successfully doped into the
800, higher than that of PA-800 (0.83) (Fig. S3b), verifying that the carbon matrix. According to the previous reports, these N types except
existence of DCDA can promote the formation of a higher amount of for the uncertain oxidized N are believed to boost the catalytic activity
defect structures carbon matrix, which is beneficial for producing towards ORR [48]. The pyridinic N, M (Fe/Co)-Nx and pyrrolic-N are
amount of active sites for electrocatalytic activity of PD-800 [41,43]. considered to facilitate the onset potential, while graphitic-N is

Fig. 4. (a) Comparative Raman spectrum of the electrocatalysts. Survey XPS spectrum of the PD-800. (b) High-resolution XPS spectra accompany with the corre-
sponding fitting plots of (c) N 1 s, d) C 1 s, (e) Fe 2p and (f) Co 2p of the PD-800.

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L. Cui, et al. Chemical Engineering Journal 395 (2020) 125158

allegedly responsible for the limiting current density by promoting 3.2. ORR catalytic performance
adsorption of oxygen atoms [44,49,50]. Furthermore, the pyridinic-N
and graphitic-N are considered to facilitate O2 adsorption and sub- To assess the ORR activities of the as-prepared catalysts, cyclic
sequent dissociation to form intermediates (such as O* and OH*) in the voltammetry (CV) measurements is first measured using rotating disk
ORR process [51]. The high-resolution of C 1s XPS spectra (Fig. 4d) is electrode (RDE) under Ar- and O2-saturated 0.1 M KOH aqueous solu-
observed peaks at 284.5, 286.3, 288.1 and 291.7 eV, which are iden- tion at a scan rate of 10 mV s−1. All potentials are provided versus RHE.
tified for CeC, C]N, C]O and Π-Π* bonds in PD-800, confirming that As illustrated in (Fig. S7), in the case of the Ar-saturated electrolyte, all
N has been incorporated into the carbon matrix [17,38,52]. Ad- the CV curves display a similar feature without any obvious redox peak.
ditionally, the C]O bond indicates that substantial oxygen-containing In sharp contrast, a significant oxygen reduction peak is clearly ob-
groups have been successfully decorated on the surface of carbon ske- served at 0.7–0.8 V in the O2-saturated electrolyte, indicating an
leton, which can generate defects in the carbon matrix. The surface oxygen reduction activity for all the samples [59]. Among all the as-
defects on PD-800, regarded as anchoring sites for capturing oxygen prepared samples, PD-800 shows the most positive reduction peak,
and facilitate the electrocatalytic activity of the material, in agreement which predicts its best ORR activity. To further confirm the electro-
well with Raman result [17]. In order to further confirm the chemical chemical activity towards ORR, the liner sweep voltammetry (LSV) of
interaction between nitrogen and metal, the high-resolution of XPS the as-synthesized catalysts (Fig. 5a) are examined at the rotating rate
spectrum Fe 2p of and Co 2p are also studied. For the Fe 2p spectra of 1600 rpm with a sweep rate of 5 mV s−1, the performance of PD-800
(Fig. 4e), the product has six peaks at different binding energy of 707.5, is better than its counterparts. Especially, the PD-800 has an onset
711.3, 714.9, 720.4, 725.5 and 730.3 eV. The fitting peaks at 711.3 and potential of 0.981 V, which is more positive than other comparative
725.5 eV are corresponded to Fe2+ 2p3/2 and Fe2+ 2p1/2, while the catalysts and only 40 mV more negative than that of the commercial Pt/
peaks at 714.9 and 730.3 eV are assigned to Fe3+ 2p3/2 and Fe3+ 2p1/2, C (1.02 V), evidencing a higher catalytic activity of PD-800. In addition,
respectively [4,53]. The deconvolution also displays Fe with zero-va- the half-wave potential (E1/2) of PD-800 (0.848 V) is comparable with
lence state (707.5 and 720.4 eV), which are ascribed to metallic iron in that of Pt/C (E1/2 = 0.860 V). By contrast, the PA-800 displays the
FeCo alloy [54]. Moreover, the peak at 713.4 eV in the Fe 2p spectra lowest activity with a half-wave potential of 0.796 V, which may be due
provides evidence of Fe-N interactions [55]. On the other hand, the to the low content of N caused by the absence of DCDA. Taking the
peaks centered at 781.6 and 796.4 eV are, respectively, ascribed to Fe onset and half-wave potentials into consideration, although the PD-800
2p3/2 and Fe 2p1/2 [56]. From Fig. 4f, the two peaks at 780.6 and is inferior to Pt/C, it is comparable with or outperform many transition
795.7 eV correspond to Co 2p3/2 and Co 2p1/2, respectively [57]. The metal-based catalysts in alkaline media, and the detailed information is
satellite peak (785.2 eV) are also founded in the fitting plot, confirming listed in Table S2. These results exhibit an excellent ORR catalytic ac-
that the existence of Co-Nx/C species [36,58]. The Co-Nx groups in tivity of PD-800, which can be attributed to the comprehensive effects
carbon materials are regarded as the active sites, which can boost the from the following aspects. (1) Moderate graphitic degree of carbon
O2 dissociation and desorb H2O during electrochemical processes. No- framework and N dopant improve the electrical conductivity, accel-
tably, the existence of metallic Fe (0) and Co (0) elements further erating electron transport during the reaction of ORR for PD-800. The
confirms the formation of FeCo nanoparticles, which is well coincident better conductivity has been expounded by electrochemical impedance
with the XRD results. The above discussions further indicate the for- spectra (EIS) (Fig. S8) in the ORR region at 0.8 V, the charge-transfer
mation of nitrogen-doped carbon decorated with FeCo nanoparticles. resistance of PD-800 is lower in comparison with other counterparts.

Fig. 5. (a) LSV curves of the synthesized catalysts in O2-saturated 0.1 M KOH solution with electrode rotating rate of 1600 rpm, and (b) the corresponding Tafel
slopes. (c) Comparative the corresponding half-wave potential (E1/2) and kinetic current density at 0.8 V (Jk@0.8 V) for the samples. (d) The disk current densities
(bottom) and ring densities (top) of different catalysts in O2-saturated 0.1 M KOH recorded on the RRDE. (e) Current-time (i–t) chronoamperometric response for PD-
800 and Pt/C by adding of 3 M methanol after 400 s. (f) ORR chronoamperometric response of PD-800 and Pt/C in O2-saturated 0.1 M KOH with a constant potential
0.7 V (versus RHE) at 1600 rpm.

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(2) The multiphase active sites for PD-800 enables it to be employed as approach to the theoretical value (n of 4) of Pt/C and higher than that
an ORR electrocatalyst, such as FeCo nanoparticles, the metal-N inter- of PA-800, validating a quasi-four-electron transfer process for PD-800.
face coupling center, and abundant N dopant into the carbon matrix, Strikingly, the resulting PD-800 possesses a little lower Tafel slope of
leading to a synergistic effect for an improved ORR performance. In 95 mV dec−1 than Pt/C (104 mV dec−1), evidencing a fast kinetic re-
addition, the existence of Fe and Co metallic species in catalysts can lated to the ORR process (Fig. 5b). Furthermore, the kinetic current
significantly enhance the electrical conductivity and then improve density (Jk) results reveal that PD-800 (92.43 mA cm−2) is larger than
charge transfer during the ORR process. (3) The abundant defects in that of PA-800 (4.46 mA cm−2), and even far outperforms Pt/C
PD-800 can significantly enhance the ORR performance. A numerous of (9.71 mA cm−2), indicating a faster reaction kinetics and effective
studies have demonstrated that the defects of catalysts can greatly pervasion of reactants for PD-800 catalysts (Fig. 5c).
change the electronic structure and chemical characteristics of material, To further explore the ORR mechanism, we adopt rotating ring-risk
resulting in new physical–chemical properties or strong synergy effects electrode (RRDE) to calculate n and the percentage of H2O2 in the O2-
produced. In this work, N-dopants throughout the entire carbon fra- saturated electrode, and it is considered as the most effective, correct
mework has been evidenced, which can improve the defective degree of and convenient method. As depicted in Fig. 5d, it is obviously shown
PD-800. (4) The unique hierarchically porous structure enables plen- that the ring current density for PD-800 is far below PA-800, which
tiful active sites provided by numerous N-doped graphitic carbon and further reveals that the introduction of DCDA to PBA is helpful to im-
FeCo nanoparticles accessible to the diffusion of O2 and electrolyte prove the ORR catalytic performance. Moreover, the n for PD-800 is
during the reaction. These combined factors together contributed above 3.90 in the scanning potential range of 0.178–1.07 V, which is
greatly to the enhanced ORR activity for PD-800 over the comparative well coincident with RDE results, further indicating a 4e− electro-
catalysts. chemistry reaction process. Simultaneously, the amount of H2O2 for PD-
To achieve a better understanding of the reaction mechanism, the 800 in alkaline environments is lower than 10%, while PA-800 exhibits
LSV and corresponding Koutecky-Levich (K-L) curves are collected at the lowest n (1.61–3.78 from 0.178 to1.07 V) and the highest H2O2
various rotating speeds from 100 to 2025 rpm in 0.1 M KOH. For all the yields (36.8–73%), indicating that the PD-800 can provide a high ORR
samples, their LSV curves present that the limiting current density are selectivity and efficient 4-electron pathway (Fig. S11).
enhanced gradually with increasing rotation rates (Fig. S9). This Apart from the ORR catalytic activity, the durability and methanol
characteristic validated that the process of ORR is kinetically con- tolerance of the catalysts are also two vital parameters to determine an
trolled, which is caused by shortening O2 diffusion distance at higher electrocatalyst performance in a practical application [59]. Herein, the
rotation speeds [44,60]. Moreover, the corresponding K-L plot for PD- current versus time (i-t) chonoamperometry measurements are carried
800 exhibits the parallel fitting correlation (Fig. S10), which implies a out to study the stability of PD-800 and Pt/C toward ORR at a constant
first-order reaction kinetics with respect to the dissolved oxygen in voltage of 0.7 V (versus RHE). In order to evaluate the fuel crossover
electrolyte and similar electron transfer number (n) for each oxygen effect of PD-800, chronoamperometric responses for catalyzing ORR are
molecule in ORR [61,62]. The n is a vital index to evaluate the ORR tested (Fig. 5e). Once 1 M methanol (CH3OH) is added into the 0.1 M
activity of catalyst, the value for PD-800 is calculated to ~4 within the KOH electrolyte at 400 s, the current of PD-800 displays a slight change
potential range from 0.3 to 0.7 V according to K-L equation, which is while Pt/C drops sharply owing to the reaction of methanol poisoning,

Fig. 6. Electrochemical performance of the Al-


air battery with different catalysts as the
cathode in 4 M KOH. (a) Schematic illustration
of the Al-air battery. (b) Open circuit plots. (c)
Al-air batteries discharging polarization
curves and corresponding power density plots
with PD-800, PA-800 and Pt/C as the cathode
catalysts. (d) Specific capacities of the Al-air
batteries using PD-800, PA-800 and Pt/C as
cathodes at the current density of
50 mA cm−2.

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L. Cui, et al. Chemical Engineering Journal 395 (2020) 125158

Fig. 7. (a) Galvanostatic discharge plots (30 min for every discharge plateau) at different current densities. (b) The variation in the long-time discharge curves of the
battery with PD-800 as the air electrode with four times replenishing the Al anode and electrolyte.

demonstrating that PD-800 has an excellent immunity to CH3OH in the As presented in Fig. 7a, the dynamic galvanostatic discharge per-
practical application. As illustrated in Fig. 5f, after a continuous of formance of the batteries catalyzed by PD-800 is evaluated at different
scanning 30 000 s, the PD-800 catalyst retains a superior stability with discharge current densities from 5 to 280 mA cm−2, in which the vol-
approximately 10.5% loss of its initial current density. As a contrast, the tage decreases accordingly with the continuously increase of the cur-
Pt/C fades by 11.9% under the same conditions, illustrating excellent rent. Meanwhile, for different discharge plateau, which shows ex-
stability on PD-800 compared to Pt/C. The superior stability and anti- tremely stable discharge behavior, reflecting an outstanding catalytic
methanol of PD-800 in comparison to that of the Pt/C reference enables durability. Apart from that, to investigate the variation of the voltage in
it an extremely promising material toward ORR in alkaline environ- battery for a long-term stability, the battery with PD-800 is further
ments. underwent four cycles by replenishing the Al foil and electrolyte. The
results are presented in Fig. 7b, the battery of the voltage shows only a
slight drop, further confirming that the superior catalytic stability for
3.3. Application in Al-air batteries
ORR catalyzed with PD-800 catalyst in the Al-air battery, which prob-
ably be contributed to the FeCo alloy encapsulated by the graphitic
Encouraged by the excellent ORR performance of the PD-800, which
layer embedded in the carbon matrix can effectively restrict them from
arouse us great interest to investigate its feasibility in practical ap- leaching by the alkaline media during the long-term process. The results
plicability, home-made two electrode Al-air batteries are fabricated to
further confirm that the better electrochemical properties for PD-800
assess the performance of the devices with these as-synthesized cata- catalyst will bring about an enhanced Al-air battery performance [8].
lysts as air cathodes, and paired them with Al foil as the anode in 4 M
Moreover, the exceptional PD-800-based AABs is also comparable to or
KOH, fabricated as shown in Fig. 6a. For comparison, the coupled Pt/C even better than that of reported catalysts in recently literatures (Table
is also assembled as the air cathode in the same condition. It is evident
S2), once again verifying its potential application in practical facilities.
from Fig. 6b that the PD-800-based batteries exhibit stable open circuit Therefore, the PD-800 catalyst has been proven to be a highly pro-
voltage of 1.68 V, exceed that of Pt/C (1.65 V) and PA-800 (1.44 V),
mising/competitive substitute to commercial Pt/C in the practical ap-
which disagree with the above-discussed ORR catalytic behaviors in plication of the Al-air batteries.
three-electrode configurations. The better voltage for PD-800 might be
ascribed to its hierarchical structure and large specific surface area,
which will provide channels for efficient mass-transfer and expose more 4. Conclusion
active sites (including inner sites) accessible to O2 and electrolyte
[4,63]. The discharge polarization curves in Fig. 6c further reveal the An effective approach is developed to synthesize FeCo nanoparticles
superior battery behavior based on PD-800 catalyst with N-doped encapsulated in N-doped graphitic carbon matrix as highly active ORR
carbon, which even can compete with that of Pt/C catalysts. Re- catalysts for Al-air batteries. The electrochemical test delivers out-
markably, the batteries with the PD-800 catalyst give out a maximum standing electrocatalytic activity for PD-800 hybrid catalyst toward
power density of 98.62 mW cm−2 while the batteries with commercial ORR, which is greatly enhanced comparing with that of the PA-800
Pt/C merely reach 90.81 mW cm−2, and greatly surpassing the PA-800 without adding of DCDA and competitive to Pt/C catalysts. The onset
of 27.94 mW cm−2, implying remarkable output performance of PD- potential, half-wave potential and transferred electron number of the
800.Moreover, when a primary battery setup is adopted, the specific ORR on PD-800 are 0.981 V, 0.848 V, and 4.0, respectively. The Al-air
capacity of the battery with PD-800 is estimated to be 913.41 mAh g−1 battery assembled by the PD-800 catalyst in alkaline medium even
based on the Al foil exhausted (Fig. 6d), which is better than those of surpasses the commercial Pt/C, and displays gratifying power density
Pt/C (883.53 mAh g−1) and PA-800 (793.12 mAh g−1). In addition, the and excellent long-term stability as the cathode catalysts, evidencing
inferior specific capacity for batteries with Pt/C is possibly due to the the potential for practical application. The superb catalytic activity of
change of the Pt nanoparticles and the carbon corrosion under high the PD-800 can be attributed to the integration combination of unique
potential [64]. It is worth noting that all the tested three batteries in- hierarchical porous structure, appropriate graphitization degree, FeCo
cluding the battery with the Pt/C catalyst exhibit a quite stable voltage species, active N-doped carbon, as well as the greatly enhanced electron
during the whole process of the discharge. Regardless of the above transfer between FeCo and the hybrid carbon skeleton, which are
investigations, the durability of cathode catalysts is the crucial factor to beneficial for the effective exposure of increasing active sites, as well as
determine the cycle life of the Al-air batteries, where the aluminum fast mass and charge transfer between the electrolyte and catalytic
anode and electrolyte can be replenished while the cathode catalysts active sites during the electrochemical reaction. This work will provide
must be kept unchanged. an approach to design high-performance ORR catalysts with cost

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L. Cui, et al. Chemical Engineering Journal 395 (2020) 125158

effectiveness and highly durable for the development metal-air battery. FeCo alloy nanoparticles coated by ultrathin n-doped carbon layer and en-
capsulated in carbon nanotubes as highly efficient bifunctional air electrode for
rechargeable zn-air batteries, ACS Sustainable Chem. Eng. 7 (9) (2019) 8530–8541.
Declaration of Competing Interest [20] R. Nandan, A. Gautam, K.K. Nanda, Anthocephalus cadamba shaped FeNi en-
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This work is financially supported by the National Natural Science
doped carbon nanofiber enable high performing flexible all-solid-state zinc-air
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