Nano-structured non-platinum catalysts for automotive fuel cell application

A highly active and durable non-platinum group metal (non-PGM) electrocatalyst was synthesized at high temperature from a catalyst precursor involving a ferrous iron salt and a nitrogen-containing charge-transfer salt as a precursor to form a nano-structured catalyst with performance level that makes it suitable for automotive applications. Such precursors have not been previously investigated for non-PGM catalysts. The synthesized material belongs to the class of metal-nitrogen–carbon catalysts and possesses an open-frame structure controlled by the silica-templating synthesis method. Thorough characterization using X-ray photoelectron, Mössbauer and in situ X-ray absorption spectroscopies demonstrates the successful formation of FeNxCy moieties that are active towards the oxygen reduction reaction. We report high kinetic current densities and high power performance in both rotating disk electrode and membrane electrode assembly studies. This Fe–N–C catalyst, jointly investigated by academic and industry partners, has shown high durability under different protocols, including that defined by the US Department of Energy Durability Working Group and Nissan׳s load cycling protocol. In summary, the present Fe–N–C catalyst is highly active and durable, making it a viable alternative to Pt-based electrocatalysts for automobile fuel cell applications. [Display omitted] •Highly active and durable non-PGM ORR catalyst.•Validation of activity and durability by Nissan Technical Center North America.•Insights into ORR mechanism on non-PGM Fe–N–C catalyst.•Hypothesis of active sites for non-PGM Fe–N–C catalyst.