Highly dispersed carbon-encapsulated FeS/Fe3C nanoparticles distributed in Fe-N-C for enhanced oxygen electrocatalysis and Zn-air batteries

Transition metal single-atom catalysts (SACs) have been widely used in oxygen reduction reactions (ORR) and oxygen evolution reaction (OER) due to its greatest atomic utilization and low costs, which catalytic performance can be further enhanced by electron distribution adjustment. Herein, we synthesized a carbon-encapsulated FeS/Fe3C nanoparticles doped carbon-based Fe single atom catalyst from fluid catalytic cracking (FCC) slurry though a one-pot pyrolysis. The synergistic effect between FeS/Fe3C nanoparticles and Fe single atom structure (FeNx) promotes the ORR/OER processes, which may due to the reduction of the adsorption free energy of intermediates. Meanwhile, the polyaromatic hydrocarbon in FCC slurry enhances the graphitization of catalyst to facilitate charge transfer in electrocatalysis process, and the carbon-encapsulated nanoparticles sites possess higher stability and dispersion. As a result, the optimized catalyst (FeS/Fe3C@Fe-N-C) presents a high nanoparticles dispersion and graphitization level, which has a higher ORR catalytic ability (E1/2 = 0.91 V vs RHE) compared with commercial Pt/C (20 wt%, E1/2 = 0.879 V vs RHE) and a similar OER catalytic ability (E10 = 0.1.506 V vs RHE) compared with RuO2 (E10 = 1.518 V vs RHE). A liquid Zn-air battery assembled with FeS/Fe3C@Fe-N-C show a peak power density of 113 mW cm−2 and an open potential of 1.432 V. This work sheds light on a new method to design transition metal active sites carbon based single-atom catalyst for enhanced ORR and OER processes.