Fe-N doped carbon materials from oily sludge as electrocatalysts for alkaline oxygen reduction reaction

Abstract

Alkaline oxygen reduction reaction (ORR) presents an important role for energy conversion technologies and requires the development of an efficient electrocatalyst. Pt-based catalysts provide suitable activity; however, Pt production accessibility and high costs create hurdles to their commercial implementation. Fe coordinated within N-doped carbon materials (Fe–N–C) are a promising alternative due to their high ORR catalytic activity, although the currently commercially available Fe–N–C materials rely on harsh synthetic protocols which can lead to increased environmental impacts. In this work we target this issue by taking advantage of an oily sludge waste currently generated in refineries to synthesize Fe–N–C materials, thus, avoiding the environmental impact caused by the management of this waste. The solid particles within oily sludge, which present a high concentration of C and Fe, were combined by different nitrogen sources and pyrolyzed at high temperatures. The prepared materials present a hierarchical pore structure with surface areas up to 547 m2 g−1. X-ray photoelectron spectroscopy analysis found that the impregnation of N using phenanthroline promotes the formation of pyridinic-N structures, which enhances the ORR performance compared to melamine doping. Additional doping of Fe with phenanthroline results in an ORR mass activity of 1.23 ± 0.04 A gFeNC at 0.9 VRHE, iR-free in a rotating disc electrode (0.1 M KOH). This catalyst also shows a lower relative loss in activity at 0.9 VRHE after 8000 cycles in O2-saturated conditions compared to a commercial FeNC catalyst, PMF D14401, (−63.5 vs −69 %, respectively), demonstrating promise as a cheap and simple route to Fe–N–C catalysts for alkaline ORR.