Optimizing Fe-N-C Electrocatalysts for PEMFCs: Influence of Constituents and Pyrolysis on Properties and Performance

Proton exchange membrane fuel cells (PEMFCs) are promising alternative technologies with applications in stationary power systems, vehicles, and portable electronics due to their low temperature operation, fast start-up, and environmental advantages. However, the high cost of platinum-based catalysts, in particular for the oxygen reduction reaction (ORR) of the cathode side, prevents their widespread incorporation. Fe-N-C electrocatalysts have emerged as viable alternatives to platinum. In this study, different precursor components were investigated for the way that they affect the pyrolysis process, which is crucial for tailoring the final catalyst properties. In particular, carbon allotropes such as carbon Vulcan, Ketjenblack, and carbon nanotubes were selected for their unique structures and properties. In addition, various sources of iron (FeCl2, FeCl3, and K[Fe(SCN)4]) were evaluated. The influence of the pyrolysis atmosphere on the resulting Fe-N-C catalyst structures was also assessed. Through an integrated structure and surface chemistry analyses, as well as electrochemical tests with rotating disk electrode experiments in acidic media, the ORR performance and stability of these catalysts were defined. By examining the relationships between carbon sources and iron precursors, this research provides valuable information for the optimization of Fe-N-C catalysts in fuel cell applications.