A template-free method to synthesis high density iron single atoms anchored on carbon nanotubes for high temperature polymer electrolyte membrane fuel cells

Abstract Carbon supported iron single atom catalysts (FeSA) are promising materials to replace precious and expensive Pt catalysts for oxygen reduction reaction (ORR) in high temperature polymer electrolyte membrane fuel cells (HT−PEMFCs). However, to support high density of atomic iron active sites on conductive carbon supports, such as carbon nanotubes (CNTs), relies on templates to avoid aggregation of iron atoms. Here, a simple and template-free method has been developed to prepare high density iron single atoms supported CNTs. The FeSA with an atomic Fe loading of 3.5 wt% shows an onset potential (Eon) of 0.95 V and a half-wave potential (E1/2) of 0.801 V for ORR in O2-saturated 0.1 M HClO4 solution, which is comparable to that of Pt/C (Pt loading of 25 μgPt cm−2). The high ORR performance is resulted from the high-density atomic sites and the highly conductive CNTs-graphene networks. Most importantly, the FeSA exhibits a E1/2 of 0.80 V, 27 mV more positive than that of Pt/C in 0.2 M H3PO4+0.1M HClO4 electrolyte due to its high phosphate resistance ability. The applicability of as-synthesized FeSA catalysts as precious metal group (PGM)-free cathode has been demonstrated in a HT-PEMFC, delivering a peak power density of 266 mW cm−2 and excellent stability at 240 °C using anhydrous H2 as fuel. The method provides a facile and practical route for developing highly efficient PGM-free catalysts for HT−PEMFCs.