Nitrogen-doped graphite encapsulated Fe/Fe3C nanoparticles and carbon black for enhanced performance towards oxygen reduction

Non-noble metal (NNM) catalysts have recently attracted intensive interest for their high catalytic performance towards oxygen reduction reaction (ORR) at low cost. Herein, a novel NNM catalyst was synthesized by the simple pyrolysis of carbon black, urea and a Fe-containing precursor, which exhibits excellent ORR catalytic activity, superior durability and methanol tolerance versus the Pt/C catalyst in both alkaline and acidic solutions. Scanning electron microscopy (SEM), transmission electron microscopy (TEM) and X-ray diffraction (XRD) characterizations demonstrate that the product is a nitrogen-doped hybrid of graphite encapsulated Fe/Fe3C nanoparticles and carbon black. X-ray photoelectron spectrum (XPS) and electrochemical analyses indicate that the catalytic performance and chemical stability correlate closely with a nitrogen-rich layer on the Fe/Fe3C nanoparticle after pyrolysis with presence of urea, leading to the same four-electron pathway towards ORR as the Pt/C catalyst. The hybrid is prospective to be an efficient ORR electrocatalyst for direct methanol fuel cells with high catalytic performance at low cost.