FeCo Nanoparticle-Loaded Nutshell-Derived Porous Carbon as Sustainable Catalyst in Al-Air Batteries

Developing a high-performance ORR (oxygen reduction reaction) catalyst at low cost has been a challenge for the commercialization of high-energy density and low production cost aluminium-air batteries. Herein, we report a catalyst, prepared by pyrolyzing the shell waste of peanut or pistachio, followed by concurrent nitrogen-doping and FeCo alloy nanoparticle loading. Large surface area (1246.4 m2 g-1) of pistachio shell-derived carbon can be obtained by combining physical and chemical treatments of the biomass. Such a large surface area carbon eases nitrogen doping and provides more nucleation sites for FeCo alloy growth, furnishing the resultant catalyst (FeCo/N-C-Pistachio) with higher content of N, Fe, and Co with a larger electrochemically active surface area as compared to its peanut shell counterpart (FeCo/N-C-Peanut). The FeCo/N-C-Pistachio displays a promising onset potential of 0.93 V vs. RHE and a high saturating current density of 4.49 mA cm-2, suggesting its high ORR activity. An aluminium-air battery, with FeCo/N-C-Pistachio catalyst on the cathode and coupled with a commercial aluminium 1100 anode, delivers a power density of 99.7 mW cm-2 and a stable discharge voltage at 1.37 V over 5 h of operation. This high-performance, low-cost, and environmentally sustainable electrocatalyst shows potential for large-scale adoption of aluminium-air batteries.