Heteroatom‑Coordinated Fe–N4 Catalysts for Enhanced Oxygen Reduction in Alkaline Seawater Zinc‑Air Batteries

Published in Chemistry and Materials

Heteroatom‑Coordinated Fe–N4 Catalysts for Enhanced Oxygen Reduction in Alkaline Seawater Zinc‑Air Batteries
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Heteroatom-Coordinated Fe–N4 Catalysts for Enhanced Oxygen Reduction in Alkaline Seawater Zinc-Air Batteries - Nano-Micro Letters

Seawater zinc-air batteries are promising energy storage devices due to their high energy density and utilization of seawater electrolytes. However, their efficiency is hindered by the sluggish oxygen reduction reaction (ORR) and chloride-induced degradation over conventional catalysts. In this study, we proposed a universal synthetic strategy to construct heteroatom axially coordinated Fe–N4 single-atom seawater catalyst materials (Cl–Fe–N4 and S–Fe–N4). X-ray absorption spectroscopy confirmed their five-coordinated square pyramidal structure. Systematic evaluation of catalytic activities revealed that compared with S–Fe–N4, Cl–Fe–N4 exhibits smaller electrochemical active surface area and specific surface area, yet demonstrates higher limiting current density (5.8 mA cm−2). The assembled zinc-air batteries using Cl–Fe–N4 showed superior power density (187.7 mW cm−2 at 245.1 mA cm−2), indicating that Cl axial coordination more effectively enhances the intrinsic ORR activity. Moreover, Cl–Fe–N4 demonstrates stronger Cl− poisoning resistance in seawater environments. Chronoamperometry tests and zinc-air battery cycling performance evaluations confirmed its enhanced stability. Density functional theory calculations revealed that the introduction of heteroatoms in the axial direction regulates the electron center of Fe single atom, leading to more active reaction intermediates and increased electron density of Fe single sites, thereby enhancing the reduction in adsorbed intermediates and hence the overall ORR catalytic activity.

As maritime electrification and blue-energy harvesting accelerate, conventional Pt/C cathodes collapse in natural seawater because chloride ions poison active sites and shift the oxygen-reduction pathway from the desired 4 e- route to the parasitic 2 e- peroxide route. Now, researchers from Central South University and Xi’an Jiaotong-Liverpool University, led by Professor Jun Wu and Professor Danlei Li, have unveiled a universal oxidative-polymerization route that axially clamps Fe–N4 single-atom sites with heteroatoms (Cl or S) to create square-pyramidal “Cl–Fe–N4” catalysts that repel Cl- while doubling reaction kinetics. The work is published in Nano-Micro Letters.

Why Heteroatom Axial Coordination Matters
Chloride Shield: Axial Cl pulls electron density toward itself, generating a negatively charged Fe center that electro-statically rejects Cl⁻ adsorption, keeping 96.7 % current retention after 12 h in pH-13 synthetic seawater.
 Intrinsic Boost: The Cl–Fe bond shortens the Fe–N bond length to 1.91 Å, down-shifts the d-band center to –2.94 eV and lowers the *OH-to-H2O rate-limiting step from 0.86 eV to 0.63 eV, delivering a record 5.8 mA cm-2 limiting current density that outperforms 40 wt % Pt/C (3.0 mA cm-2).
Seawater Compatibility: The five-coordinated geometry maintains a strict 4 e- pathway (n = 4.02) even in 0.5 M KCl, whereas undoped Fe–N4 collapses to 2.24.

Innovative Design and Features
One-Pot Synthesis: 1,5-diaminonaphthalene oxidative polymerization at 80 °C followed by 950 °C Ar pyrolysis and acid leaching yields 708 m2 g-1 microporous carbon with atomically dispersed Fe and 4.73 % N content.
Spectroscopic Proof: HAADF-STEM, XANES and EXAFS confirm the absence of Fe clusters; only a single Fe–Cl shell at 2.17 Å is detected, matching square-pyramidal Cl–Fe–N4.
Device Validation: When coated on nickel-foam air-cathodes (1 mg cm-2), the Cl–Fe–N4 seawater zinc-air battery delivers 187.7 mW cm-2 peak power at 245.1 mA cm-2 and sustains 200 h of deep discharge–charge cycles at 10 mA cm-2 with only 7 mV half-wave-potential decay.

Applications and Future Outlook
Maritime Power Packs: Coupled with printable Zn anodes, the catalyst enables pouch cells that operate directly in ocean water, promising buoy-based sensors and unmanned underwater vehicles.
Off-Grid Desalination: High current density at low overpotential allows SZAB-driven membrane pumps that consume 30 % less energy than conventional reverse-osmosis systems.
Scalable Manufacturing: The precursor ink is water/ethanol-based and the maximum processing temperature is <1000 °C, making roll-to-roll production compatible with existing carbon-fiber lines.
Next-Gen Tuning: The team is exploring F and Br axial ligands and dual-metal (Fe/Co) centers to further widen the operating salinity window to 10 wt % NaCl.

This comprehensive study provides a materials-by-design playbook for turning the most abundant anion in the ocean—chloride—from a poison into a performance descriptor, paving the way for truly seawater-robust energy storage and conversion devices.

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Batteries
Physical Sciences > Materials Science > Materials for Energy and Catalysis > Batteries
Electrochemistry
Physical Sciences > Chemistry > Physical Chemistry > Electrochemistry
Electrocatalysis
Physical Sciences > Materials Science > Materials for Energy and Catalysis > Electrocatalysis
Nanoscale Design, Synthesis and Processing
Physical Sciences > Materials Science > Nanotechnology > Nanoscale Design, Synthesis and Processing
  • Nano-Micro Letters Nano-Micro Letters

    Nano-Micro Letters is a peer-reviewed, international, interdisciplinary and open-access journal that focus on science, experiments, engineering, technologies and applications of nano- or microscale structure and system in physics, chemistry, biology, material science, and pharmacy.