Toward pH Independent Oxygen Reduction Reaction by Polydopamine Derived 3D Interconnected, Iron Carbide Embedded Graphitic Carbon

Recent advancements on the development of nonprecious electrocatalysts with iron (Fe) incorporated active centers have generated confidence on realizing cost-effective proton exchange membrane fuel cells (PEMFCs). However, most of these catalysts that emerged as a substitution for the platinum supported on carbon (Pt/C) catalysts in oxygen reduction reaction (ORR) are active under basic conditions, and their feasibility in PEMFCs remains as a challenge. In this scenario, this work reports the synthesis of a Pt-free oxygen reduction electrocatalyst prepared by the annealing of polydopamine grown melamine foam. The prepared catalyst has a three-dimensional (3D) interconnected bilayer network structure possessing the carbon nitride backbone wrapped by graphitic carbon layer bearing iron carbides and nitrides as the active centers (3D-FePDC). Interestingly, the 3D-FePDC catalyst displayed an ORR activity both under acidic and basic conditions. Whereas the ORR performance of 3D-FePDC closely matches that of the commercial Pt/C in the basic medium, it displays only a low overpotential value of 60 mV under acidic conditions compared to its Pt counterpart. The kinetics of ORR on 3D-FePDC is found to be similar to the four-electron (4e) reduction pathway displayed by Pt/C. Testing of a PEMFC in a single cell mode by using 3D-FePDC as the cathode catalyst and Nafion membrane delivered a maximum power density of 278 mW cm–2, which is a promising value expected from a system based on the nonprecious metal cathode. Ultimately, as a cost-effective catalyst that can effectively perform irrespective of the pH conditions, 3D-FePDC offers significant prospects in the areas like fuel cells and metal–air batteries which work in acidic and/or basic conditions.