China's first development of iron-free fuel cell catalysts that are free of precious metals

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Recently, a groundbreaking study led by Dr. Deng Dehui from the State Key Laboratory of Catalysis at the Dalian Institute of Chemical Physics, along with researcher Pan Xiulian and academician Bao Xinhe, in collaboration with the Fuel Cell Research Department of the Clean Energy National Laboratory, has successfully demonstrated the first experimental replacement of noble metals in fuel cell catalysts with iron. The findings were recently published online in the prestigious journal Angewandte Chemie, marking a significant step forward in clean energy technology.

Hydrogen-based power generation is seen as a key component in the future of sustainable and advanced energy systems. Proton exchange membrane fuel cells (PEMFCs) are central to this vision, offering high efficiency and low emissions. However, their widespread use has been limited due to the heavy reliance on expensive precious metals like platinum, palladium, and rhodium as catalysts. This dependency not only increases costs but also hinders scalability. Thus, reducing or eliminating the use of these costly materials has become a major focus in fuel cell research.

In response, the research team developed an innovative approach by encapsulating iron-based nanoparticles within the hollow structure of carbon nanotubes. Using advanced tools such as the deep ultraviolet light emission electron microscope and X-ray absorption spectroscopy at the Shanghai Light Source, they were able to observe for the first time how the d-electrons of metallic iron interact with the carbon atoms in the nanotube walls. These electrons then migrate to the outer surface of the carbon tube, directly facilitating the oxygen reduction reaction—an essential process in fuel cell operation.

The combination of experimental data and theoretical modeling revealed that the carbon shell acts as a protective barrier, preventing direct contact between the reactive gases and the iron nanoparticles. This significantly reduces the risk of oxidation and poisoning by impurities in the reaction environment. As a result, the stability and performance of iron-based catalysts as cathode materials in fuel cells have been greatly improved, addressing a long-standing challenge in the field.

Industry experts are optimistic about the implications of this research. They believe it not only offers a promising alternative to traditional noble metal catalysts but also introduces new design principles for developing robust catalysts suitable for harsh operating conditions. This could pave the way for more cost-effective and sustainable fuel cell technologies in the future.

The study was supported by the National Natural Science Foundation of China and the Ministry of Science and Technology. (Trainee reporter: Qiu Rui)

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