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Featuring work from the group of Professor Jun Chen As featured in:
at Key Laboratory of Advanced Energy Materials
Chemistry (Ministry of Education), Chemistry College,
Nankai University, Tianjin, China.
Metal–air batteries: from oxygen reduction electrochemistry
to cathode catalysts

Metal–air batteries represent one class of promising power sources


for applications. The most prominent feature of a metal–air battery
is the combination of a metal anode with high energy density
(from the earth) and an air electrode with open structure to draw
cathode active materials (i.e., oxygen) from air. Four groups of
catalysts for the cathode oxygen reduction/evolution, the design See Cheng and Chen
Chem. Soc. Rev., 2012, 41, 2172.
& optimization of air-electrode structure, and the challenges and
perspectives of research directions are selectively surveyed.

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Cite this: Chem. Soc. Rev., 2012, 41, 2172–2192

www.rsc.org/csr CRITICAL REVIEW


Metal–air batteries: from oxygen reduction electrochemistry to
cathode catalysts
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Fangyi Cheng and Jun Chen*


Received 27th August 2011
DOI: 10.1039/c1cs15228a

Because of the remarkably high theoretical energy output, metal–air batteries represent one class
of promising power sources for applications in next-generation electronics, electrified
transportation and energy storage of smart grids. The most prominent feature of a metal–air
battery is the combination of a metal anode with high energy density and an air electrode with
open structure to draw cathode active materials (i.e., oxygen) from air. In this critical review, we
present the fundamentals and recent advances related to the fields of metal–air batteries, with a
focus on the electrochemistry and materials chemistry of air electrodes. The battery
electrochemistry and catalytic mechanism of oxygen reduction reactions are discussed on the basis
of aqueous and organic electrolytes. Four groups of extensively studied catalysts for the cathode
oxygen reduction/evolution are selectively surveyed from materials chemistry to electrode properties
and battery application: Pt and Pt-based alloys (e.g., PtAu nanoparticles), carbonaceous materials
(e.g., graphene nanosheets), transition-metal oxides (e.g., Mn-based spinels and perovskites), and
inorganic–organic composites (e.g., metal macrocycle derivatives). The design and optimization of
air-electrode structure are also outlined. Furthermore, remarks on the challenges and perspectives of
research directions are proposed for further development of metal–air batteries (219 references).

1. Introduction the worldwide consciousness of the low-carbon economy and


sustainable concept greatly promote the progress of chemical
Modern society depends on the widespread use of reliable devices power sources such as batteries and fuel cells.1 Current prevailing
for electrochemical energy storage and conversion. Nowadays,
battery chemistries, rechargeable Li batteries in particular,
have gained commercial success in powering portable consumer
Key Laboratory of Advanced Energy Materials Chemistry (Ministry devices.2 However, they are still insufficient to keep pace with the
of Education), Chemistry College, Nankai University, Tianjin,
300071, People’s Republic of China. E-mail: chenabc@nankai.edu.cn; rapid development of electronics implementing 3-Generation
Fax: +86-22-23506808; Tel: +86-22-23506808 (3G) or 4G multimedia and communication technologies.

Fangyi Cheng received his Jun Chen is a Cheung Kong


BSc degree in Chemistry in Scholar Professor at Nankai
2003 and a PhD (with Prof. University. He is the director
Jun Chen) in Materials of the Key Laboratory of
Physics and Chemistry in Advanced Energy Materials
2009. At present, Dr Cheng Chemistry (Ministry of
is a lecturer at Nankai Uni- Education). He obtained his
versity. Since 2003, he has BSc and MSc degrees from
mainly studied the preparation Nankai University in 1989
of Mn-based oxides with and 1992, respectively, and
controllable structures and their his PhD from Wollongong
applications as battery materials University (Australia) in
or electrocatalysts. His current 1999. He held the NEDO
research interest is focused on fellowship at National Insti-
Fangyi Cheng functional materials for efficient Jun Chen tute of AIST Kansai Center
energy storage and conversion. (Japan) from 1999 to 2002.
His research expertise is nanomaterials for energy storage &
conversion with batteries, fuel cells, and solar cells.

2172 Chem. Soc. Rev., 2012, 41, 2172–2192 This journal is c The Royal Society of Chemistry 2012
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In addition, the emerging applications of batteries in electrified would sustain the production of 1 billion 10 kW h zinc–air
transportation (such as plug-in hybrid electric vehicles and batteries to power all worldwide vehicles.14 In addition, the
electric vehicles) and energy storage (for integrating renewable anode design and the cathode catalyst in metal–air batteries are
energy in the so-called smart/intelligent grids) demand high less demanding as compared to fuel cells. Therefore, metal–air
energy density, low cost, increased safety, and environmental chemistries hold promise for large-scale development and appli-
compatibility.3,4 Thus, an innovation in battery science and cations and have attracted increasing research interest because
technology is required to build better power sources for our of their prominent advantages.15
modern lifestyle needs.5 One of the main fields being explored for Of different types of metal–air chemistries, the primary
the possible breakthrough refers to metal–air batteries. Zn–air cell has been commercialized as a hearing-aid battery;
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Metal–air batteries generate electricity through a redox Al–air and Mg–air cells have also found military applications
reaction between metal and oxygen in air. They are featured (e.g., underwater propulsion) and are under development as
with open cell structure, which admits the supply of the cathode saline systems.6 Although not fully electrically rechargeable at
active material—oxygen—continuously and almost infinitely present, Zn–air, Al–air and Mg–air batteries may be recharged
from an external source (air). This feature makes them akin mechanically by quickly and simply replacing the discharged
to a fuel cell, with the ‘‘fuel’’ being a metal. Compared with anode and spent electrolyte slurry with fresh metal electrode
other ubiquitous batteries such as the primary Zn–MnO2 and electrolyte, making them ‘‘refuellable’’. In addition, the
(Zn–Mn) and the rechargeable lead–acid, nickel–metal hydride spent electrolyte slurry containing metal oxides and oxide
(Ni–MH) and lithium-ion batteries,6 the metal–air family has hydroxides can be recycled and regenerated to the metallic form
notably higher theoretical energy density (Fig. 1). Such high using electrolysis or even solar thermal decomposition.14,16,17
energy content is due to the fact that the cathode oxygen is not Accordingly, these batteries can be indirectly rechargeable.
stored in the cell and meanwhile the anode metal possesses a Electrically rechargeable metal–air batteries currently remain
high ratio of valence electrons to atomic nuclei.7 Especially, the at research and development level.9,15,18 Particularly, in 1996
Li–air system releases an extremely high theoretical specific Abraham and Jiang first reported a successful rechargeable
energy of nearly 11 700 W h kg 1, which is close to the value for Li–O2 battery fabricated with a Li metal anode, a carbon
one of the most energy-dense liquids—gasoline.8,9 composite cathode, and a Li+ conductive organic polymer
In terms of theoretical gravimetric energy density, metal–air electrolyte membrane.8 Later, Read investigated the effect of
batteries and fuel cells are possible contenders that could bring electrolyte and air cathode formulation on the battery perfor-
electric propulsion on par with the current gasoline-engine mance of an aprotic Li–O2 cell.19 In 2006, Bruce and co-workers
system. Fuel cells are viewed as a future solution to energy demonstrated sustainable cycling of a Li–O2 battery for tens of
issues due to advantages of environmental friendliness, high cycles.20 Recently, new research interest in Li–air batteries has
energy conversion efficiency, rapid start-up and shut-down, grown rapidly, aiming at taking the advantage of such a
etc. However, fuel cell technologies are currently confronted fascinating system to substitute rechargeable Li–ion batteries
with formidable challenges ranging from difficult hydrogen that are based on Li-intercalation electrodes.5,9,15,21
production/storage/transportation to complicated cell design, Like other battery technologies, metal–air batteries also
low stability of the electrodes, and high cost of the materials.10–13 suffer from a series of scientific and technological problems.
In comparison, light elements such as Zn, Al and Mg are well The main issues include low utilization efficiency of the anode
known for their high abundance (e.g., Al is the most abundant and sluggish kinetics of the cathode, resulting in limited
metal in the earth’s crust), low cost and environmental compat- practical energy density. For the anode, severe passivation
ibility. It is estimated that 21 months of global zinc production and corrosion of anode exist in electrolytes. The accumulation
of metal oxides, hydroxides or other species on the anode
surface retards further electrolyte access and thus prevents
discharging the remaining active material. The self-discharge
and corrosion of the metal anode degrades the coulombic
efficiency of the anode and shortens the battery shelf life. An
efficient strategy to address the deterioration issue is operating
the metal–air cells with reserve structure, in which one of the
key components of the cell is separated from a remainder until
activation.6 For the cathode (i.e., air electrode), the major
obstacles are the intrinsic slow reactions, high overpotentials,
and poor reversibility of oxygen chemistry.22 Reactions at the
cathode may involve complex processes and the underlying
mechanism remains elusive in many cases. Not surprisingly,
the air electrode is by far the dominating factor affecting the
performance of state-of-the-art metal–air batteries. While
using oxygen from surrounding air is generally considered as
Fig. 1 Comparison of the gravimetric energy density of some the most intriguing aspect, the air electrode, unfortunately
representative types of primary/rechargeable batteries, metal–air batteries, appears to be the most complicated, expensive and sometimes
H2–air fuel cell and gasoline. The theoretical values are calculated on the bulky component of a metal–air battery. As a result, if
basis of thermodynamics of active materials. metal–air batteries are to realize their full potential, the most

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important tasks should include first elucidating the basic oxygen


chemistry and then exploiting highly efficient air electrodes for
accelerating the electrochemical oxygen reduction reaction
(ORR) and/or oxygen evolution reaction (OER). In this context,
much effort has been dedicated to the investigation of the
cathode reaction mechanism, the development of efficient bifunc-
tional catalytic materials for ORR/OER, and the rationalization
of electrode structures for facilitating mass/charge transport and
interface interaction.9,15,23–32
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In this article, we intend to review the fundamentals and the


most recent and significant scientific progresses made in the
fields relevant to metal–air batteries, with emphasis placed on
air electrodes. The brief introduction of the operation principles,
the illustration of cathode electrochemical reactions, the survey
of intensively investigated catalyst materials, and the discussion
of the design and optimization of cathode structure will be
sequentially presented in the following sections, while the final
conclusion remarks on future challenges and perspectives. The
aim is to provide a better understanding of the promising
metal–air battery technologies.

2. Electrochemical cathode reactions


The metal–air battery is composed of a metal anode, an air-
electrode and a separator soaked in metal-ion conducting Fig. 2 Schematic representation of the structure and operation principle
electrolyte, as schematically shown in Fig. 2. In a basic of a metal–air battery and the liquid-gas-solid (catalyst) interface in the
chemistry, the metal anode is oxidized and releases electrons air electrode.
to the external circuit when the cell is discharged. At the same
time, oxygen diffuses into the cathode, accepts the electrons the anode reactions and overall reactions of different metal–air
from the anode and is reduced to oxygen-containing species. systems with alkaline aqueous electrolytes. It should be noted
The dissociated metal ions and oxygen-reduced species migrate that the actual cell potentials are generally much lower than
across the electrolyte and combine to form metal oxides. When the given theoretical values due to overpotentials derived from
the cell is charged (for rechargeable metal–air batteries), the both anode and cathode polarization.
process is reversed, with metal plating at the anode and oxygen The ORR in alkaline environments at ambient temperature
evolving at the cathode. Because the solubility of oxygen is is more favourable than in acidic environments because of
generally low in liquid electrolyte and a catalyst is required to better kinetics and lower overpotentials.22 The exchange current
facilitate its reduction, the cathode electrochemical reactions density is higher by approximately an order of magnitude,
mainly take place at the liquid–gas–solid interface (i.e., the rendering feasible the use of non-noble metal electrocatalysts.
so-called three-phase zone) in the air electrode. Consequently, Additionally, based on the Nernst equation, the electrode
oxygen transportation properties of the electrolyte play potential will nominally shift by 0.83 V ( 59 mV multiplied
important roles in determining the battery performance.26,27 by 14) if the pH value of electrolyte changes from 0 to 14. This
Furthermore, it should be noted that the involved electro- negative potential shift affects the electric field at electrode–
chemical reactions and the overall product may differ from electrolyte interface, resulting in significant weakening of binding
each other among various types of metal–air batteries, depending strengths for adsorbates, especially for charged species.30
on the specific metal, the electrolyte and the catalytic materials
adopted.24,25 In this section, the basic electrochemical cathode Table 1 Electrochemical reactions and the theoretical standard
potential of selected metal–air batteries with aqueous alkaline
reactions of metal–air batteries are discussed separately on the electrolytes
basis of aqueous and organic electrolytes.
Metal air cells Anode (a) and overall (o) reactions E0/Va
2.1 Aqueous electrolyte configuration
Zn–air (a) Zn + 2OH - ZnO + H2O + 2e 1.25
Metals such as Li, Mg, Al and Zn can react violently to (o) 2Zn + O2 - 2ZnO 1.65
Mg–air (a) 2Mg + 4OH - 2Mg(OH)2 + 4e 2.69
generate hydrogen in acidic media with a great deal of released
(o) 2Mg + O2 + 2H2O - 2Mg(OH)2 3.09
heat. The resulting severe anode corrosion and complicated Al–air (a) Al + 3OH - Al(OH)3 + 3e 2.31
thermal management make the acidic electrolyte inappropriate (o) 4Al + 3O2 + 6H2O - Al(OH)3 2.71
for practical application. In addition, there are few electro- Li–air (a) Li + OH - LiOH + e 2.95
(o) 4Li + O2 + 2H2O - 4LiOH 3.35
catalytic materials that are stable under the strongly acidic
circumstances and the aggressive oxidizing environments at
a
The standard potentials (E0) are given by assuming a potential of
0.40 V for the cathode reaction. All potentials are reported vs. the
oxygen cathode. Thus, alkaline solutions are commonly used
standard hydrogen electrode (SHE).
for aqueous electrolyte-based metal–air batteries. Table 1 lists

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Accordingly, adsorption of spectator ions in alkaline media


should be decreased to a great extent, giving rise to more facile
electrocatalytic processes than that in acidic media.28 A notable
disadvantage of using alkaline electrolytes includes carbonate
precipitation due to the reaction between carbon dioxide and
hydroxide (CO2 + 2OH - CO32 + H2O), similar to that in
the case of alkaline fuel cells.31 The poor solubility of carbonates
in alkaline media may cause clogging of electrode pores and
thereby blocking of electrolyte channels. To circumvent this
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drawback of CO2 sensitivity, it is helpful to feed purified air or


employ a selective membrane that is permeable to O2. Moreover,
the use of a circulating electrolyte is beneficial as the saturation
of carbonate is attained much more slowly than that in immo-
bilized electrolyte.
The cathode oxygen reduction is a series of complex electro-
chemical reactions, which are proposed to involve multistep
electron-transfer processes and complicated oxygen-containing
species such as O, OH, O2 and HO2 .28,29,31,32 In alkaline
electrolytes, the related cathode reactions can be briefly given as:
O2 + 2H2O + 4e - 4OH (E0 = 0.40 V) (1) Fig. 3 (a) Different configurations of O2 adsorption on catalyst
surfaces: on top end-on, bridge end-on, bridge side-on one site,
O2 + H2O + 2e - HO2 + OH 0
(E = 0.07 V) (2)
and bridge side-on two sites, from left to right. Simplified electro-
HO2 + H2O + 2e - 3OH (E0 = 0.87 V) (3) chemical catalysis process of the ORR on metal surfaces in the case of
(b) end-on O2 adsorption, and (c) bidentate O2 adsorption, corres-
2HO2 - 2OH + O2 (4) ponding to the 2e reduction (with generated peroxide species) and the
direct 4e reduction, respectively. (d) One of the proposed catalytic
As has been well documented, oxygen reduction may proceed ORR pathways at a metal oxide/alkaline electrolyte interface.
via a four-electron (4e) pathway or a two-electron (2e) pathway
on surfaces of metals.28,29,31,32 The ORR pathways and mechan- Both the above mentioned 4e and 2e reaction schemes may
isms may vary with the catalytic materials applied. Even for the occur concomitantly and compete with each other. Recent
same catalyst, the ORR behaves as a structure-sensitive reaction. experimental study and mathematical modelling have shown
Different configurations of oxygen adsorption exist on active that dual-path ORR mechanisms comprising both direct 4e
sites of catalyst (Fig. 3a), depending on the crystallographic and series 2  2e pathways exist on carbon-supported Pt
structure (surface geometry) and the binding energy. The O2 nanoparticles.35 In high potential intervals, the direct path is
adsorption configurations and the O2-surface interactions affect dominating, while at low potential the reduction switches to
the ORR pathways.29,33 For the end-on manner, only one O the peroxide-mediated path. In addition, transport effects such
atom is coordinated perpendicularly to the surface and one as desorption and re-adsorption of intermediates play an
electron transfer is favored, contributing mainly to the 2e path- important role in the kinetics and pathway-selectivity of the
way (Fig. 3b and eqn (2)) with peroxide generation. In contrast, ORR.36 Non-covalent interactions between hydrated alkali-
the parallel coordination with two O atoms adsorbed on the metal cations and adsorbed species on active sites also exert
surface favors O2 dissociation and more likely leads to the direct significant effect on the ORR characteristics.37 The real
4e ORR pathway (Fig. 3c and eqn (1)) without peroxide surface reactions may be masked due to limitation of analysis
formation. The 2e oxygen reduction may be followed by either techniques, and hence there are possibly more underlying
another further 2e reduction of peroxide (eqn (3)) or a chemical pathways. Furthermore, if the serial reduction or chemical
disproportionation of peroxide (eqn (4)). This process can be decomposition of intermediate species proceeds extremely
described as a serial 2  2e pathway. quickly, the generated peroxide would be simultaneously
In the case of metal oxides, the surface charge distribution is reduced to hydroxide and thus the overall process could be
different from that of a metal. The surface cations of stoichio- also viewed as an apparent 4e reduction reaction. For example,
metric oxides are not fully coordinated with oxygen. Anion previous studies have shown that manganese oxides are highly
coordination is completed by the oxygen of H2O in aqueous catalytically active toward the peroxide decomposition and/or
solution. Reduction of a surface cation is charge-compensated reduction, and results in a detected ORR with apparent quasi-4e
by protonation of a surface oxygen ligand. Accordingly, a transfer.38–42 Therefore, the determination of an explicit ORR
four-step catalytic mechanism has been proposed for the ORR mechanism may be a challenging task in many cases.
pathway on the surfaces of transition-metal oxides (Fig. 3d).31 The direct 4e oxygen reduction is desirable due to its high
This proposal includes steps of surface hydroxide displace- energy efficiency, while the 2e pathway is unfavorable since the
ment, surface peroxide formation, surface oxide formation, produced peroxide species are corrosive and can cause pre-
and surface hydroxide regeneration. The competition between mature degradation of the electrochemical cell.22,31 It is now
the O22 /OH displacement and OH regeneration is found to generally recognized that the 4e reduction predominates on
be rate-limiting for the ORR kinetics in alkaline electrolyte.34 noble metals whereas the 2e reduction primarily participates

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on carbonaceous materials.24,43 For transition-metal oxides According to electrochemical analysis, Laoire et al.
and metal macrocycles, various ORR pathways exist, relying proposed the following scheme for the possible cathode
on the specific crystal structure, molecular composition, or reactions.50,51
experimental parameters.43,44 The electrochemical character-
O2 + Li+ + e - LiO2 (7)
istics of different catalytic materials will be discussed in detail
in section 3. 2LiO2 - Li2O2 + O2 (8)
2.2 Organic electrolyte configuration LiO2 + Li+ + e - Li2O2 (9)
The aqueous electrolyte configuration is featured with prominent +
+ 2e - 2Li2O
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Li2O2 + 2Li (10)


virtues of low cost, wide availability and high ionic conduc-
tivity. However, for electrochemical processes occurring in This mechanism states a first one-electron reduction of oxygen
aqueous media, the working potential window is limited to superoxide followed by a further reduction of superoxide to
to the potential range within which H2O is stable against peroxide via another one-electron reaction. Interestingly, the
evolution of hydrogen or oxygen. Consequently, although reduction mechanism is strongly influenced by the solvent and
metal–air batteries such as the Al and Mg-based cells have the supporting electrolyte. In solutions containing large
high theoretical voltages (Table 1) of approaching or exceed- cations, the cathode reaction proceeds through a one-electron
ing 3 V, the practical voltages are far below such values when reversible process with the O2/O2 redox couple, whereas in
aqueous electrolytes are applied. Particularly, the reaction the Li+-containing electrolyte, the oxygen reduction reactions
between lithium and water is dangerous, making metallic are irreversible or quasi-reversible processes, to form different
lithium unsafe to operate directly at an aqueous environment. products including O2 , O22 and O2 .51 The cation effect on
As a result, the aqueous Li-system requires a specially mechanism and product can be interpreted using Pearson’s
designed water-stable layer or membrane (e.g., film composed hard–soft acid–base theory coupled with the different relative
of solid-state Li+ conducting glass-ceramic materials) to stabilities of the Li+–(solvent)n complexes. Lithium ion, super-
protect the Li anode.26,45–49 Even so, there has been little oxide and peroxide behave as a hard Lewis acid, a moderately
evidence that the electrochemical cathode and anode reactions soft base and a strong Lewis base, respectively. The formation
are reversible within an aqueous system. Instead, successful of Li+–(solvent)n complexes would lower the acidity of Li+, in
demonstration of electrically rechargeable metal–air batteries rough proportion to the donor number of the solvent. Solvents
is on the basis of organic electrolytes. Herein, the aprotic with high donor number provide increased stability of the
configuration is discussed, with focus laid on the recharge- Li+(solvent)n–O2 and thus result in reversible O2/O2 . In
able Li–air system since it has triggered intensive current solvents with low donor number, O2 quickly decomposes to
interest. O22 or may be fully electrochemically reduced to O2 .
The profile of a non-aqueous Li–air battery is similar to a Using density functional theory (DFT), Hummelshøj et al.
conventional lithium battery using electrolyte of lithium salt described an alternative cathode reaction mechanism involving
dissolved in aprotic solvents. The most notable difference lies the following two steps:52
in the cathode. For a classic Li battery, the cathode is a lithium
Li+ + e + O2 + * - LiO2* (11)
intercalation-material undergoing cathode reactions of Li+
uptake/removal. The cathode active material of a Li–air Li+ + e + LiO2* - Li2O2 (12)
battery is O2, which is not stored in the cathode but is drawn
from outside the cell. The cathode reactions of an aprotic where * denotes a surface site on Li2O2 where the growth
Li–air cell differ from the Li-intercalation process. The possible takes place. Given this mechanism, the free energy diagram of
net reactions of a Li–air battery are envisioned as follows, with surface-bound species and intermediates estimated from DFT
four or two electrons transferred per molecular O2.8,9,15,19,20,26 qualitatively explains the large asymmetry observed experi-
mentally between the discharge and the charge overpotentials
4Li + O2 - 2Li2O (E0 = 2.91 V vs. Li+/Li) (5) (see for example, in Fig. 6). The DFT calculation also indicates
that during charge, the formation of Li vacancies is thermo-
2Li + O2 - Li2O2 (E0 = 2.96 or 3.10 V vs. Li+/Li) (6)
dynamically favoured and the vacancies are mobile from
The reported standard cell potential of eqn (6) is not uniform, surface to bulk, which will pin the Fermi level at the top of
which may be derived from different Gibbs free energies. the antibonding peroxide p*(2px) and p*(2py) levels in the
Because of the close E0 values of the above two reactions, Li2O2 valance band.52,53 Thus, the existence of neutral Li
either lithium oxide or lithium peroxide is highly thermo- vacancies in the Li2O2 surface is essential to generate electrical
dynamically feasible to be the discharge product. Despite the conductivity for the operation of a Li–air battery since Li2O2
apparent simplicity of eqn (5) and (6), the detailed mechanism is an insulator. Questions remain how the initial nucleation
of the cathode reaction is far from having been definitively of Li2O2 proceeds at the cathode and whether the surface
and quantitatively clarified. Like the oxygen reduction in conductivity can maintain fast electrochemical growth of
aqueous media, the cathode reaction in aprotic electrolytes is Li2O2 on Li2O2 deposits.
a complex process involving stepwise reactions and several Experimental evidences such as ex situ Raman spectra and
oxygen-containing species. Different mechanisms have been powder X-ray diffraction (XRD) data have demonstrated that
suggested to interpret the cathode reactions of the aprotic Li2O2 predominates the discharge product of the cathode of an
Li–air cells. aprotic Li–air cell.8,20 Recently, in situ spectroscopic studies

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have further proved that LiO2 is an intermediate on O2 reduced in the presence of catalysts, which can accelerate para-
reduction in non-aqueous solvent.54 In situ surface enhanced sitic reactions. Recognition of electrolyte decomposition there-
Raman spectroscopy (SERS) and in situ differential electro- by implies that compatible electrolytes need to be developed for
chemical mass spectroscopy (DEMS) provide direct evidence Li–air batteries with sustainable cycling performance. In this
that oxygen is first reduced to intermediate superoxide, which regard, alternative electrolytes such as boron esters, ethers,
then disproportionates to peroxide (see eqn (7) and (8)). How- ionic liquids and solid-state electrolytes (e.g., Li+-conducting
ever, on reverse charging the cathode, Li2O2 decomposes polymer or ceramic) may have some advantages and deserve
directly in a one-step reaction to evolve O2, without a LiO2 further research.60–64
intermediate pathway.54 Although being presented as the inter- Compared with the above mentioned catalyst-indispensable
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mediates, the superoxide species are highly oxidizing and cathode reactions in aqueous electrolytes, oxygen reduction
reactive and can induce several additional side reactions.55,56 can possibly proceed without catalysts in nonaqueous electro-
Nonaqueous electrolytes used up to date for Li-based lytes containing Li+. In addition, the cathode reactions in an
battery chemistries include alkyl carbonates (e.g., ethylene aprotic Li–air battery generate intermediates and products
carbonate, propylene carbonate, dimethyl carbonate or their (either Li2O2 or carbonate species) that are drastically less
combination), ethers (e.g., dioxolane, tetrahydrofuran), and dissolvable in the organic electrolyte. The accumulation of
esters (butyrolactone), which have high oxidation stability insoluble solids may clog the pores of the air electrode, block
and solvate lithium salts such as LiPF6, LiN(SO2CF3)2 and the catalyst surface, and electrically passivate the battery.
LiSO3CF3.57 In the widely employed aprotic organic carbonate- The charge transfer and mass transport at the interface of
based electrolytes, the discharge products of the air electrode the cathode are hence limiting factors that affect battery
contain a series of carbonate species but with almost no Li2O2, performance.24 Thus, the specific capacity of a Li–air battery
as a result of electrolyte decomposition.58 Very recently, correlates intimately with the character of the cathode. As
detailed investigations of the Li–O2 battery with carbonate elec- carbonaceous materials often serve and dominate inside the air
trolyte have shown that discharging the cathode forms electrode, the specific capacity is generally reported relative to
C3H6(OCO2Li)2, Li2CO3, HCO2Li, CH3CO2Li, CO2 and H2O the weight of carbon.
(Fig. 4), which have been specifically identified by the combi- Apart from the mechanisms outlined above, the nature of
nation of XRD, SERS, DEMS, NMR and FTIR analyzing catalyst surface may also exert a great effect on the cathode
techniques.59 On recharging, oxidation of these carbonate reaction pathways. By comparing the voltammetry and intrinsic
species occurs with evolution of H2O and CO2. The charge/ ORR activity for well defined surfaces of glass carbon as well as
discharge pathway in the absence of reversible Li2O2 formation polycrystalline Au and Pt electrodes in aprotic organic electro-
is inconsistent with most of previously proposed mechanisms lytes, Lu et al. have shown that the reduction mechanism and the
but on the other hand, could explain the discharge/charge discharge product likely depend on the catalysts.65 The proposed
voltage gap and the gradual capacity fade widely observed in first ORR step is the formation of superoxide radicals, which are
Li–O2 cells. The formation of carbonate species may consume weakly adsorbed species and might be solvated by cations or
electrolyte and accumulate in the air electrode, thus degrading solvents to diffuse into the bulk of electrolyte. The superoxide
the electrode performance and causing poor rechargeability of radicals then react with Li+ to form surface-adsorbed LiO2,
the batteries. The stability of the electrolyte could be further which undergo alternative subsequent pathways. For catalysts

Fig. 4 Proposed reaction scheme of the formation of discharge products in a Li–O2 battery with alkyl carbonate electrolytes. The discharged
compounds include Li propyl dicarbonate, Li formate, Li acetate, Li2CO3, CO2 and H2O, as marked in red. Reprinted with permission from
ref. 59. Copyright 2011, American Chemical Society.

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with relatively weak oxygen chemisorptions (e.g., carbon), LiO2 fractional amount is supporting Pt monolayers on suitable
can be reduced to Li2O2. For catalysts forming a strong bond metal substrates with specific surfaces, which facilitates kinetics
with O2 (e.g., Pt), LiO2 is probably reduced with preferential of O–O bond breaking and hydrogenation of reactive inter-
formation of Li2O. The catalyst-dependent ORR activity66–68 mediates and results in activity surpassing pure Pt.75 Besides,
and pathway indicate that mechanistic study on electrode with the most viable strategy to simultaneously enhance perfor-
composite catalytic materials (e.g., including components of mance and lower cost is alloying Pt with other appropriate
carbon and metals or metal oxides) may be not straightforward noble metals or early transition metals that are less expensive.
and the catalyst screening should be performed with more Recently, substantial progress has been made in fundamental
caution. understanding the electrocatalytic properties of Pt-based alloys
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In view of the inconsistency among various proposed (or intermetallic compounds).76–82 Study on the Pt3Ni(111)
mechanisms,8,20,50–54,58,59,65 explicit unraveling the cathode surface has indicated an unusual electronic structure (the
reactions of metal–air batteries is far from a settled issue d-band centre position) and highly structured compositional
to date. Despite the complexity of cathode reductions, estab- oscillation in the near surface region, where the outermost and
lishing the detailed pathway and the correlation between third layers are Pt-rich and the second layer is Ni-rich.76 As the
the mechanism/activity and the catalyst is a key first step weak interaction between the Pt surface atoms and nonreactive
to understand the origin of the charge and the discharge oxygenated species increases the active sites for O2 adsorption,
behaviours of metal–air batteries and, is also important and the Pt3Ni(111) surface is 10-fold more active than the Pt(111)
sometimes prerequisite to guide the development of highly surface for the ORR. Electrocatalytic trends in the ORR has
active air electrodes. been established in terms of a relationship between the surface
composition, specific activity and the electronic structure of
3. Catalytic materials for air electrodes Pt3M (M = Fe, Co, Ni, Ti, V) surfaces.77 The relationship shows
volcano-type behaviour, where a balance between adsorption
As the cathode reaction of a metal–air battery is generally a energies of reactive intermediates and surface coverage by
catalytic electrochemical process, the electrocatalyst in the air spectator species governs the maximum catalytic activity.
electrode plays a vital role in determining the electrode Computational and experimental results have further indi-
performance. ORR catalysts have been the subject of extensive cated the volcano relationship for a series of different catalysts
studies for many years in fuel cells technologies, which involve with Pt overlayers (Fig. 5a).78 The oxygen adsorption energy is
invariably cathode oxygen reduction. The cathode catalyst to thus a good descriptor for the ORR activity. A surface that
a large extent determines the energy conversion efficiency and binds oxygen 0–0.4 eV more weakly than Pt(111) should
is responsible for the high cost of a fuel cell.10–13,31 In exhibit an activity higher than Pt, with the optimum value at
principle, most of the catalytic materials applicable to fuel roughly 0.2 eV. The oxygen adsorption energy on the skins in
cells could also serve in metal–air batteries and so could be turn correlates with the heat of formation of the bulk alloy
the strategies and techniques to enhance the cathode efficiency. (DEalloy, defined as the difference between the total energy of
A variety of materials have been employed as the cathode the alloy and the constituents in metallic form), for a range of
catalysts, ranging from noble metals and metal alloys to Pt and Pd alloys (Fig. 5b). Based on these findings, Pt3Sc
carbons, transition-metal oxides/chalcogenides and metal and Pt3Y binary alloys stand out as the most stable. Notably,
macrocyclic compounds. Review on the cathode electrocatalysts Pt3Y exhibits significant activity improvement over Pt, with
can be found in different literatures.22,28,29,31,32,43,44,69,70 In this a B60 mV positive shift of half-wave potential and a factor
section, only selected catalytic materials and examples are of 6–10 higher kinetic current density in the range of
presented, focusing on the most recently reported progress and 0.9–0.87 V.78 Recent experimental investigation has confirmed
those of direct relevance to metal–air batteries. the superb stability and activity of Pt–Y alloy.81 The kinetic
current density of Pt–Y electrode depends on the alloy com-
3.1 Noble metals and alloys
position, showing a volcano curve trend with the maximum at
Noble metals such as the Pt-group metals, in particular Pt Pt70Y30. The ORR stability is associated with the number
itself, have been intensively studied as ORR catalysts for many of d-band vacancies of Pt, which correlates with the degree of
decades and continue to spur ongoing interest, because of their alloying and the lattice stain.81 In regard to the screening of
known high stability and superior electrocatalytic activity. Pt-based alloy catalysts, the surface stability at high electro-
As a result of the relevant well-established knowledge, Pt is chemical potentials is demonstrated to be a sensitive measure
often chosen as a benchmark material in current studies of according to a recent theoretical study on a group of Pt2M
alternative catalysts. Platinum nanoparticles well dispersed on skin alloys.82 Maintaining a zero O coverage is required to
high-surface-area support (e.g., carbon) are the state-of-the- attain high stability as the dissolution of surface atoms in
art ORR electrocatalysts. However, the scarcity and cost of Pt alloys is significantly facilitated with increasing O coverage.
make it necessity to further increase the catalytic activity and Furthermore, the surface corrosion energy and the free energy
stability yet reduce the noble metal loading of Pt-based barrier to OOH dissociation are identified as quantitative
catalysts. Along this line, tuning the size and morphology of descriptors for tuning catalyst composition. Accordingly,
Pt-based nanostructures to achieve small/dispersive size, high Pt2Mo achieves considerable stability and activity because of
surface areas and desired highly active facets has proven as low overall kinetic barrier for the ORR.82
efficient route to improve the ORR properties on a mass In addition to the influence of composition, the structure
basis.71–74 An interesting method to decrease Pt loading to a of Pt-alloys also exerts a prominent effect on the catalytic

2178 Chem. Soc. Rev., 2012, 41, 2172–2192 This journal is c The Royal Society of Chemistry 2012
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to Fe loss in aggressive electrolytes. In this respect, we note that


modifying Pt nanoparticles with Au clusters can greatly stabilize
the Pt-based ORR electrocatalysts by raising the Pt oxidation
potential.83
In depth understanding of the effect of composition, struc-
ture, size and shape on the ORR catalytic characteristics of
Pt-based alloys will doubtlessly enlighten our efforts in exploiting,
designing and fabricating more efficient yet economic catalysts.
Concerning the practical application of noble metal-based cata-
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lysts in metal–air batteries, their repeated or recyclable use should


be imperative. One can easily conceive that rechargeable metal–
air batteries, owing to the materials-saving character, seem to be
suitable to accept the noble metal catalysts. However, satisfactory
rechargeability of metal–air cells remains a formidable challenge
requiring rechargeable air electrodes. The cathode oxygen reac-
tions are generally irreversible with slow kinetics, as discussed in
section 2. To realize the cycling of an air electrode, we need to find
a catalyst capable of accelerating the ORR upon discharging and
mediating the OER on charging. Fortunately, noble metals can
serve as electrocatalysts for both the ORR and the OER.22
Furthermore, gaining a synergistic effect is possible by combing
one metal that is highly active for the ORR and another metal
that is highly active for the OER to form a bifunctional catalyst.
Indeed, recent application of PtAu nanoparticles in Li–O2 cells
has showed much promise.84 As shown in Fig. 6, PtAu/C delivers
discharge voltages comparable to that of Au/C and charge
voltage comparable to that of Pt/C. Surface Au and Pt atoms
contribute to the ORR and OER kinetics, respectively. Conse-
quently, the overall voltage gap between discharge and charge is
significantly reduced in PtAu, conferring a round-trip efficiency
Fig. 5 Pt-alloys for electrocatalysis of the oxygen reduction reaction (defined as the ratio of discharge to charge voltages) of about
(ORR): (a) Volcano plots of the oxygen reduction kinetic current 77% for the as-assembled Li–O2 cell. Whether this bifunctional
density (jk) as a function of the calculated oxygen adsorption energy catalyst can lead to better cycling performance, however, still
(DEo); (b) computational results showing the relationship between
remains to be seen.
the oxygen binding energy on Pt/Pd skin surfaces and alloying energy.
Cheaper precious metals such as palladium and silver and
Data are shown relative to Pt while circles and squares in (b) represent
50 and 25% of the alloying element in the second layer. Reprinted their alloys have also been the subject of many investigations
with permission from ref. 78. Copyright 2009, Macmillan Publishers because of their modest activity and relatively higher
Limited. abundance.85–97 In particular, Ag exhibits reasonably activity
and stability with the price only about 1% that of Pt, rendering
activity and durability. For example, dealloyed Pt–Cu core– it as an attractive ORR catalyst.28 Compared to Pt, Ag is relatively
shell structure shows exceptionally high catalytic reactivity for less stable and less electrocatalytically active in acidic media.
the ORR.79 Strains are found to form in Pt-enriched shell,
which are supported on a Cu core with a smaller lattice para-
meter. The compressive strain in the shell tunes the electronic
band structure of Pt and weakens the chemisorption of reactive
intermediates, resulting in increased reactivity. Moreover, recent
investigation on FePt nanoparticles has revealed the structure-
dependent catalytic stability by comparing the performance
between face centered cubic (fcc) and face centered tetragonal
(fct) structures.80 In the chemically disordered fcc structure, Fe
and Pt atoms are positioned randomly in the fcc lattice, while in
the chemically ordered fct structure, Fe and Pt atoms are
intermetallically stacked. The fct-FePt exhibits better catalytic
activity and durability towards the ORR, due to the well ordered
Fig. 6 Li–O2 battery operated with different catalyst: (a) initial
intermetallic structure, which preserves compositional and struc- galvanostatic discharge/charge profiles of Au/C, Pt/C and PtAu/C at
tural stability and offers catalytically active facets with Pt lying 100 mA g 1carbon; (b) discharge/charge curves at different current
on the top and Fe locating in the underlayer.80 The FePt densities. The horizontal dashed line marks the nominal equilibrium
nanoparticles, however, still suffer from problems of particle potential of O2/Li2O2. Reprinted with permission from ref. 84.
aggregation and activity decay during prolonged operation due Copyright 2010, American Chemical Society.

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The electrocatalytic ORR on Ag(111) single crystal surface walls is more conductive and oxidant resistant and facilitates
shows pH-dependent behaviour.87 The ORR in 0.1 M HClO4 mass transport.104 Furthermore, functionalization of the
occurs as a 2e, a mixed 2e and 4e, and a 4e reduction process carbon support such as by surface modification or doping,
sequentially from low to high overpotentials. Additionally, the exerts a prominent effect on enhancing the durability of ORR
onset potential is shifted negatively to B0.4 mV in acidic catalysts. Heteroatom (such as S, P and N) doped carbons
environment. In contrast, in 0.1 M KOH the ORR proceeds have been extensively investigated.105,106 In particular, nitrogen
through almost entirely a 4e pathway in the whole potential has proven to be a very efficient functional component or
range.87 Carbon-supported Ag nanoparticles (Ag/C) also dopant to mitigate activity degradation.107–111 Nitrogen can
promote a 4e ORR pathway over a wide potential range in be incorporated into the graphitic network in the graphitic,
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0.1 M NaOH solution.94 Furthermore, recent studies have pyridinic and pyrrolic form.109 Doping of nitrogen increases the
shown that porous Ag membranes provide electrocatalytic degree of defectiveness and edge plane sites in graphitic carbon
function (with high exchange current density), mechanical materials. The type and content of the nitrogen functional
support and a means of current collection in alkaline group affects the following aspects of the catalyst system: the
cathodes.93,95 Thus, silver-based catalysts are more adaptive size and dispersion of the supported metal particles, support/
to be used in alkaline electrolytes and are promising cathode catalyst chemical bonding, and the electronic structure of
materials with good balance between cost and performance. supported catalyst nanoparticles.108,109 These are influential
factors in the catalytic activity and durability toward the
3.2 Carbonaceous materials
ORR. Taking into consideration the effect of both carbon
The exclusive use of platinum is not feasible for the future forms and nitrogen doping, highly stable and active ORR
widespread deployment of electrochemical devices based on catalysts have been obtained by loading Pt nanoparticles on
oxygen electrodes.98,99 Development of well-performing noble nitrogen-doped ordered mesoporous carbons.111 Carbons can
metal-free cathode catalysts is the ultimate solution to the be also modified with other materials to improve electrode
obstacle of Pt cost and scarcity.43,44,69,70,98,99 One of the performance. For example, carbon nanotubes combined with
most inexpensive alternatives is carbonaceous materials, which tungsten carbide can be used as highly efficient hybrid supports
have attracted extensive attention either as catalyst supports for Pt electrocatalysts that impart a more positive onset
or as metal-free catalysts in electrocatalytic chemistry of potential and increased current density.112 In addition, carbon
oxygen.100–138 Carbons generally provide notable merits black shows a two-fold increase of corrosion resistance through
including low cost, wide availability, wettability, large surface surface modification of tungsten carbide nanoparticles.113
areas, high electrical conductivity and good stability under While carbon black materials (e.g., Vulcan XC-72) have
harsh environments.101 The most developed cathode catalysts been the most conventional catalyst support in literatures,
are usually supported on finely divided carbon with nanoscale increasing interest has been emphasized on carbon materials
particle size and good dispersion. with novel texture and morphologies, especially porous carbons
Carbon materials exist in a variety of forms with different and nanostructured carbons.101,114,115 Carbon nanostructures
electronic, optical, spectroscopic and electrochemical properties.102 can serve not only as catalyst supports but also as catalytically
Carbon atoms can be sp3 hybridised or sp2 hybridised and active components themselves because of different electro-
arranged in a diamond or graphite structure. The completely chemical properties from that of traditional bulk carbon forms.
sp3 hybridised carbon with tetrahedral bonding is featured The peculiar carbon nanostructures include one-dimensional
with hardness and low electrical conductivity and thus is (1D) nanotubes and nanofibers, 2D graphite and graphene
uninteresting as an electrode material without intentional intro- nanosheets, and nanoporous architectures. Carbon nanotubes
duction of functional dopants. The sp2 hybridised carbon are an efficient substrate for dispersing a catalyst component
materials have abundant allotropes including different poly- (especially Pt nanoparticles) due to facile electronic conductivity
morphisms of graphites (e.g., glass carbon, carbon fibers, highly and structural integrity and open structure that facilitates
oriented pyrolytic and natural crystalline graphite, etc.), diffusion of reactants, products and intermediates in and out
fullerene, graphene, carbon nanotubes, and so on. The graphitic of the catalytic layer.116–119 Carbon nanotube-based hybrid
materials are suited to electrode applications because of favour- materials generally show remarkably enhanced electrocatalytic
able electrical conducting properties.102 performance due to synergistic effects.120,121 Nitrogen-doped
It is worth noting that the electrochemical performance carbon nanotubes can act as noble-metal free catalysts.122,123
of graphitic electrodes varies with the interior structure, Carbon nanofibers are also potential oxygen electrode
morphology, and surface effects such as termination and materials.124 Graphene and functionalized graphene materials
surface modification. Electrode kinetics may differ signifi- have recently attracted increasing interest as metal-free electro-
cantly between the basal plane (parallel to the graphite layer) catalysts for oxygen reduction.125,126 These abundant carbon
and edge plane (perpendicular to the graphite layer) within a nanostructures and their doping or surface modification with
graphitic structure. A graphitic structure with a large number functionalities may enable researchers to well tailor the catalytic
of edge-plane sites (e.g., edge-plane pyrolytic graphite and properties.
multiwalled carbon nanotubes) exhibits higher activity toward As one of the typical examples illustrating the viable appli-
the ORR.103 In addition, the pore size, wall thickness and cation of carbon nanostructures, vertically aligned nitrogen-
wall crystallinity of carbon materials affect their catalytic doped carbon nanotubes (VA-NCNTs) can act as a metal-free
performance. As substrate to support metal nanoparticles, electrode to catalyze the 4e ORR in alkaline electrolyte.127 The
mesoporous carbon with large pore size and thicker crystalline VA-NCNTs even outperform their Pt/C counterparts in ORR

2180 Chem. Soc. Rev., 2012, 41, 2172–2192 This journal is c The Royal Society of Chemistry 2012
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activity and durability. Such superb performance and the additive in the air electrode of aqueous Zn–air, Mg–air, and
unexpected 4e pathway are believed to arise from the incor- Al–air batteries.6 In Li–air cells that are relatively less dependent
poration of electron-accepting nitrogen atoms in the conjugated on catalyst, active carbons in the cathode is capable to sustain
nanotube carbon plane, which impart a high positive charge considerable cell performance.8 Recent examples have demon-
density on adjacent carbon atoms, favouring parallel diatomic strated that carbon nanostructures such as carbon nanofibers
adsorption.127 Improved electrocatalytic activity could be and graphene nanosheets (GNSs) can be used as the cathode
achieved after heat treatment of the nitrogen-doped carbon for Li–O2 batteries with both nonaqueous electrolyte and
nanotubes.128 Moreover, nitrogen-doped porous carbons and aqueous–organic hybrid electrolyte.124,135–137 Carbon nanofibers
graphenes have also exhibited remarkable ORR activity and grown on a porous alumina substrate can be used as binder-
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durability comparable to or better than the commercial free electrodes that provide gravimetric energies of about
Pt/C catalysts.129–132 For instance, 1D nitrogen-doped carbon 2500 W h kgelectrode 1 at power of about 100 W kg 1.124 In
nanocapsules, which are synthesized from a single-component the nonaqueous Li–O2 cell, GNSs (Fig. 8a) result in high
precursor template route, outperform the benchmark Pt/C discharge capacity exceeding 8000 mA h g 1 (Fig. 8c).135 For
catalyst in electrocatalytic activities in alkaline electrolytes (as the hybrid-electrolyte cell, heat-treated GNSs give rise to
shown in Fig. 7).132 The prominent catalytic performances excellent cyclability of up to 50 charge–discharge cycles.136
suggest that carbonaceous materials with nitrogen doping are The performance of GNSs is significantly better than the
promising metal-free ORR electrocatalysts. comparative BP-2000 and Vulcan XC-72 carbons. The superi-
However, it should be noted that the nature of the active ority of GNSs derives from the large surface areas, high
sites and the ORR mechanism in the intensively investigated electronic conductivity, and the unique structure that provides
nitrogen-containing carbon materials have not been clearly 3D diffusion channels and numerous active sites/defects at the
elucidated.133 The generally accepted opinion is that the doped edges (as shown in Fig. 8b). Interestingly, pencil-trace (multi-
nitrogen atoms play a crucial role in the ORR. The exposure layered graphene nanosheets) on the surface of a ceramic Li–ion
of edge planes and the creation of impurity band/surface states conducting film can serve as a novel catalytic electrode for
near the Fermi level are also viewed as causes behind the rechargeable Li–air batteries.137 Furthermore, comparing dis-
catalytic activity.134 Functional groups on carbon surfaces are charge characteristics of Li–air cells with different carbon
suggested to modify the electronic band structure and thus cathodes has revealed that the mesopore volume of carbon
tune the ORR properties.134 Recent DFT calculations imply materials has a large contribution to the capacity.138 Therefore,
that the edge structure of carbon is involved in ORR activity the employment of carbon nanostructures with optimized
by lowering the oxygen adsorption barrier and electron transfer
barrier, and meanwhile, the type of doped-N determines the
ORR pathway selectivity.126 Computational study, together
with more direct experimental techniques, will provide much
insight in understanding the carbon-based catalysts.
Application of carbon materials is ubiquitous in air electrodes
for practical metal–air batteries. While carbon itself is catalyti-
cally active toward the ORR (mainly through a 2e pathway), it
serves mainly as a catalyst support and electrical conducting

Fig. 7 Nitrogen-doped carbon nanocapsules (NCNC) as non-noble Fig. 8 Application of carbonaceous materials in Li–O2 batteries:
electrocatalysts for the ORR in alkaline media: (a) schematic presen- TEM image of the graphene nanosheets electrode (a) before and
tation of their fabrication, (b) SEM and (c) TEM images of the (b) after discharge (the square marks thicker product deposit, indicating
capsules, and (d) linear sweep voltammograms of the NCNC (the high activity at the edges); (c) Discharge/charge profiles of Li–O2 batteries
subscript denotes the synthesized temperature) and the benchmark with different carbon cathodes at a current density of 75 mA g 1.
Pt/C (E-TEK). Reproduced with permission from ref. 132. Copyright Reproduced with permission from ref. 135. Copyright 2011 Royal
2011, Royal Society of Chemistry. Society of Chemistry.

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morphologies and textures may offer great opportunity to attain


high-performance metal–air batteries.
3.3 Transition-metal oxides
Transition-metal oxides and in some cases transition-metal
chalcogenides, carbides, nitrides, oxynitrides and carbo-
nitrides represent another family of cathode electrocatalysts
as an alternative to traditional noble metals.99 Their prominent
advantages generally include high abundance, low cost, and
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environmental friendliness. Although some of them lack suffi-


cient stability in acidic media, generally they are reasonably
stable in alkaline electrolytes, making these compounds
applicable to electrochemical catalysis. For example, titanium
oxides are demonstrated to be good functionalized cocatalytic
supports for both non-precious metals and noble metals.139–141
Nanostructured titanium oxide supports can modify the
surface electronic structure of Pt and provide high structural
and chemical stability due to strong metal/support inter- Fig. 9 Presentations of the structures of some binary and ternary
action.141 Titanium nitrides can be used as efficient cathode manganese oxides. c- and t-AMn2O4 denote cubic and tetragonal
electrocatalysts.142 Transition-metal carbides, especially in nano- Mn-based spinels, respectively, with the A-site cations being tetra-
size, can also act as promising supports to promote the activity gonally coordinated with oxygen. BMnO3 represents the Mn-based
and stability of Pt or Pd-based ORR electrocatalysts.143,144 perovskite with the B-site ions being marked in green. Metal cations in
A, B and Mn sites can be substituted by other metal ions.
Early transition metals of group VII and VIII elements
(e.g., Mn, Fe, Co and Ni) possess multiple valences, resulting
in a variety of oxides and chalcogenides/carbides. For example, through the first proton insertion process to form MnOOH,
manganese may exist in different valence states of Mn(II), the second O2 adsorption onto two neighboring MnOOH
Mn(III) and Mn(IV), corresponding to abundant and ubiqui- surface sties (via the bridge adsorption-manner), the third
tous manganese oxides ranging from MnO, Mn3O4 to Mn2O3 rate-determining electron-transfer step involving electro-
and MnO2.145 The combination of two or three transition splitting of the adsorbed O2 species to Oads, and the final
metals with oxygen will lead to a series of ternary or quaternary electrochemical reduction of Oads to OH .40 In this scenario,
composite metal oxides. Even for manganese oxides with the the Mn(III)/Mn(IV) redox couple acts as the oxygen acceptor/
same nominal elemental composition and valence, they are donor mediator and assists the electron transfer. The series
possibly featured with different crystallographic structures pathway undergoes a first 2e reduction process to intermediate
(Fig. 9). The variable valences and abundant structures of HO2 and the sequent disproportionation of HO2 .149 The
transition-metal oxides give rise to rich redox electrochemistry major difference between the two reaction schemes can be
and materials chemistry, providing a vast opportunity for the attributed to the manner of oxygen adsorption on active
search and development of valuable noble metal-free catalysts. surface sites (Fig. 3a). The end-on O2 adsorption does not
Important progress in transition-metal chalcogenides (especially favour the breaking of O–O bonds and hence tends to yield
the Chevrel-phase compounds and cobalt sulfides/selenides) HO2 rather than OH . More study is thus required to clarify
can be found in the review presented by Alonso-Vante and the oxygen adsorption behaviours on the surface of manganese
co-workers and the references cited therein.44 We focus herein oxides. Regardless of this uncertainty, the redox reaction between
on metal oxides (especially Mn-based oxides), which have Mn species with different valence synergistically contributes to
been extensively studied as electrocatalysts for air electrodes. mediate the reduction process in both pathways. The involve-
Manganese oxides are of special interest in oxygen electro- ment of Mn(IV)/Mn(III) in the ORR electrocatalysis has been
chemistry. One possible reason of the motivation is that confirmed by in situ X-ray absorption near edge structure
Mn–Ca–O complex cluster is the catalytic active centre of (XANES) study.38
oxygen evolution in photosystem II in nature.146–148 However, In addition to the ORR mechanism, promoting the develop-
the complex redox chemistry and different crystallographic ment of highly active manganese oxide catalysts necessitates a
structures of manganese oxides make it rather difficult to systematic study on the influential physical and chemical
explicitly understand the oxygen reduction and evolution parameters. It has been demonstrated that factors exerting
mechanisms and to clarify the materials properties that govern an important effect on the catalytic performance may include
the catalytic activity. composition, structure, phases, valence, morphology, size,
Electrochemically active manganese oxides such as Mn5O8, surface area, electrical conductivity, etc.38–42 The influence of
Mn3O4, Mn2O3, MnO2 and MnOOH all exhibit catalytic composition on the properties has been scarcely investigated.
activities towards the ORR in alkaline media.38–43,149,150 The One trend is that the ORR catalytic activity correlates with
catalytic ORR mechanism, however, is still in debate. Both a the Mn valence,149 but a clear relationship remains to be
direct 4e pathway and series 2  2e pathway have been established. However, it is obvious that the crystallographic
suggested to interpret the observed apparent overall 4e ORR structures and morphologies greatly affect the performance of
process. For MnO2, the direct 4e oxygen reduction proceeds manganese oxides.42 For MnO2-based catalysts, the activity

2182 Chem. Soc. Rev., 2012, 41, 2172–2192 This journal is c The Royal Society of Chemistry 2012
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and oxygen 2p orbitals. Applying such a principle, LaMnO3+d


and LaNiO3 exhibit intrinsic ORR activity comparable to
state-of-the-art Pt/C in alkaline media.34 Nanosized composites
of perovskite-type La1 xSrxMnO3 and carbon nanotubes also
show remarkable electrocatalytic performance.157 Furthermore,
a recent example indicates that a composite electrode con-
sisting of LaMnO3 and LaNiO3 displays excellent bifunctional
ORR/OER activity.158 As shown in Fig. 10, LaNiO3 has high
electrical conductivity and high OER activity while LaMnO3
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is highly active for the ORR; their combination offers a benefi-


cial balance between the ORR/OER electrocatalytic activity and
the stability against anodic polarization.158 The prominent bifunc-
tional electrochemical performances of perovskite composites
suggest their promising use in rechargeable metal–air batteries.
Cobalt and manganese spinels are also highly potential
candidates as electrocatalysts for bifunctional air electrodes
because of high catalytic activity and good corrosion stability
in alkaline solutions.153–155 It should be noted that the
Fig. 10 Polarization curves of different electrodes in KOH aqueous preparation method of a spinel oxide greatly influences its
electrolyte: (a) carbon-supported LaMnO3, (b) LaMnO3/LaNiO3 physiochemical properties and electrochemical charac-
(10 wt% LaMnO3), (c) LaMnO3/LaNiO3 (30 wt% LaMnO3), (d) neat teristics.154 Conventional synthesis of crystalline ternary
LaNiO3. The anodic and cathodic polarization corresponds to the spinels normally follows the ceramic route and requires a
electrocatalytic OER and ORR process, respectively. Reproduced high heating temperature. Although having a good crystal-
from ref. 158 by permission of The Electrochemical Society. linity, the resulting product often exhibits limited electro-
chemical activity due to large particle size and low surface
follows an order of a- > b- > g-MnO2, which is attributed to areas. Recently, a facile and rapid room-temperature synthetic
a combinative effect of their intrinsic tunnel size and electrical methodology has been developed for highly active spinels.156
conductivity. For MnO2 catalysts with the same phase, the The preparation is based on a reduction of amorphous MnO2
nanostructures apparently outperform the micro-sized particles precursors in aqueous solution containing divalent metal ions
due to smaller size and higher specific surface areas. Moreover, such as Co2+. With preserved morphology resembling the
the nature of preferentially exposed facets of manganese oxides parent precursor, the prepared Co–Mn–O nanocrystalline
would be another influential factor,41 which requires further spinels possess high surface areas, numerous defects and
investigation. Furthermore, combining manganese oxide with abundant vacancies, and manifest remarkably higher activity
another electrocatalytic component seems to be an efficient towards the ORR/OER as compared to their counterparts
strategy in enhancing the ORR activity. The obtained composite synthesized at high temperature (shown in Fig. 11). Interest-
catalysts such as manganese oxide nanoparticles electrodeposited ingly, the Co–Mn–O spinels show phase-dependent electro-
on platinum substrate150 and palladium nanoparticles deposited lytic characteristics, that is, the cubic phase outperforms the
on MnO2 nanorods151 are superior to both pristine noble metals tetragonal phase in catalyzing the ORR while the trend is in
and undecorated manganese oxides. reverse for the OER. Such phase-dependent character is
Like binary manganese oxides, composite manganese oxides attributed to the different oxygen binding ability on the surface
incorporating mixed-valence transition metals have also of the two phases, as evidenced from both experimental
attracted extensive interest.24,34,152–158 Extra merits of compo- and computational analysis.156 Following a similar synthetic
site oxides generally include increased structural stability and strategy, hollow ZnMn2O4 spinel nanospheres and nanocubes
the ability to combine one type of active sites favourable for have also been selectively prepared and show respectable
the ORR and the other type of sites beneficial to the OER, electrocatalytic performance.163 This demonstrated example
rendering them possible bifunctional catalysts for air electrodes proves the feasibility of rational design and controllable
that can serve in rechargeable metal–air batteries.159,160 synthesis of spinel-based bifunctional electrocatalysts for air
Composite oxides adopting the spinel or perovskite structure electrodes.
are particularly attractive. The spinel and perovskite structures The above examples indicate that manganese-based oxides,
allow partial cation substitution (see for example in Fig. 9) to especially in the composite form incorporated with another
form a large number of oxides,161,162 enabling researchers to multivalence transition-metal, should be promising alternative
tune their catalytic properties. to Pt-based catalysts in alkaline media. Not surprisingly, they
Recent study has shown that the ORR activity of perovskite have already found wide practical applications in alkaline
family correlates primarily to s*-orbital (eg) occupation and metal–air batteries (see illustrated examples in ref. 24 and
secondarily to the extent of transition metal–oxygen covalency, references cited therein). Very recently, Lee et al. have
which serve as activity descriptors.34 The design principle for reported that Mn3O4 nanoparticles anchored on ionic liquid
improving the ORR activity of perovskites is an eg-filling having modified graphene nanosheets exhibit high ORR catalytic
a value of B1 for maximum activity, which can be further activity and their use in an Zn–air battery lead to a maximum
enhanced by increasing the covalency between the metal 3d peak power density of 120 mW cm 2.164 Applications of

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structural networks, the rich defect properties and the ionic


transport mechanism of these materials, it is possible that
some of them can be adapted as catalysts in metal–air batteries
as well. Meanwhile, the design concept of cathodes for SOFCs
may be also applicable to air electrodes. Accordingly, transition-
metal oxides along this line are worthy of further studies.
3.4 Inorganic–organic composites
Tremendous effort has been directed to the development of
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inorganic–organic composite (this oversimplified term is used


here to intentionally denote the integration of inorganic metal
centre and organic matrix) materials as noble metal-free
catalysts for oxygen electrochemistry.43,98,99,171–192 This promising
family of alternative electrocatalysts include transition-metal
macrocyclic complexes, metal–polymer composites, and the rele-
Fig. 11 Cobalt–manganese spinel oxides as electrocatalysts for the
vant heat-treated derivatives.
ORR and OER. SEM images of (a) tetragonal-phase spinel nano- Transition-metal macrocycles (e.g., TMPP, PC, TPP and
structures (RT-t-spinel) and (b) cubic-phase spinel nanostructures TAA, molecular structure shown in Fig. 12a–d) have been
(RT-c-spinel) synthesized at room temperature. Voltammograms of extensively investigated from the synthesis methodology to
the (c) ORR and (d) OER recorded on different catalysts. Compar- the catalysis mechanism, as reviewed in detail in several
isons are also given to the counterpart cubic-phase (HT-c-spinel) and recent publications.43,99,133,172,173,181 The primary motivation
tetragonal-phase (HT-t-spinel) bulk spinels synthesized using high- possibly arises from the intention to mimic the photosynthesis
temperature ceramic method. Reproduced from ref. 156. Copyright process in nature that involves metalloporphyrins. Although
2011, Macmillan Publishers Limited. having undergone several decades of studies, the catalytic
nature of the metal-macrocyclic family remains elusive. It is
manganese oxides in aprotic Li–air cells can be also found in generally believed that C, N and transition-metal (Fe or Co)
different literatures.20,165–168 When used as catalysts in the are involved in the catalytically active sites, which can be
oxygen cathode, manganese oxide nanoparticles supported on simply labelled as M–Nx/C (x is normally 2 or 4) species.99,185
carbon and MnO2 nanowires mixed with carbon can deliver However, it is difficult to reach a consensus as to what plays
high capacities with capacity retention for a few charge and the predominant role. At least, the functionality of metal is
discharge cycles.166,167 Likewise, the combination of Pd and unclear and in debate.
MnO2 results in stable capacity for 20 cycles and is highly Recently, the mechanisms of the ORR on carbon-supported
effective in decreasing the charge potential to nearly its Fe-phthalocyanine (FePc/C) and Co-phthalocyanine (CoPc/C)
theoretical value and improving the energy efficiency from catalysts in alkaline media have been elucidated by combining
60 to 89%.168 It can be predicted that composite manganese electrochemical techniques and density functional theory (DFT)
oxides such as Mn-based spinels and perovskites are also computational study.178 The FePc/C catalyst exhibits a more
useful cathode catalysts in rechargeable Li–air batteries. positive onset potential and higher current density than that of
It should be noted that most of the transition-metal oxides, CoPc/C. Remarkably, the ORR proceeds via a 4e pathway on
owing to their semiconducting character, can not provide as FePc/C while it is through a 2e pathway on CoPc/C (Fig. 13a).
high a electrical conductivity as in the cases of metal and The DFT results indicate that the structure of H2O2 adsorption
carbon-based catalyts. Thus, oxide materials are generally is essentially different on the surfaces of the two catalysts
mixed mechanically with a large amount of carbon powders (Fig. 13b). During H2O2 adsorption, the breaking of the O–O
to fabricate air electrodes with low resistance. However, the bond enables the 4e ORR on FePc while the absence of O–O
addition of electrical conducting agent may not only hinder bond cleavage accounts for the 2e reduction. These investiga-
the interface contact but also lower the loading level of the tions thus imply that the metal centers exert a vital effect on
active component. An alternative strategy is using hybrid determining the activities and mechanisms of electrocatalytic
materials that firmly combine an oxide with a highly conducting ORR on metal macrocyclic compounds.
substrate such as carbon nanostructures.120,169,170 The synergistic On the other hand, since some metal-free macrocyclic
coupling of nanomaterials also enables bifunctional electro- compounds (pyridine-like, pyridone-like and graphite-like
chemical catalysis that can be hardly achieved within a single species with N/C and without metal such as nitrogen-doped
component. For example, binary Co3O4 spinel, a material with carbon materials discussed in section 3.2) are highly catalyti-
considerable OER activity but little ORR activity, when grown cally active, metals may be not a necessary part in the active
on nitrogen-doped graphene to form a hybrid nanomaterial, sites but only participate in creating the active centres consisting
exhibits high performance for both ORR and OER in alkaline of C and N. Recent study on the role of residual metal in ORR
electrolyte according to a latest report.170 in CoPc-based carbon catalysts has verified that Co hardly
Finally, it is relevant to mention here that various classes contributes to the catalytic activity.186 Even if the metal is
of oxide-ion conducting compounds (including some classic indispensable, the coordination character of transition metals
perovskite-based oxides) have been widely used in solid oxide to N and its effect on the catalytic properties have not been fully
fuel cells (SOFCs).162 If we take into consideration the flexible understood. In addition, recent study on a CuFe–N/C catalyst

2184 Chem. Soc. Rev., 2012, 41, 2172–2192 This journal is c The Royal Society of Chemistry 2012
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Fig. 12 Structures of some representative transition-metal macrocycles


(a–d) and proposed active sites of some transition-metal macrocycle
composite catalysts (e–g): (a) tetramethoxy tetraphenyl porphyrin
(TMPP), (b) phthalocyanine (PC), (c) tetraphenyl porphyrins (TPP), Fig. 13 Carbon-supported Fe-phthalocyanine (FePc/C) and
(d) tetraazaanulene (TAA), (e) metal-aromatic cycles attached to the Co-phthalocyanine (CoPc/C) as the ORR catalysts in alkaline
edges of graphitic sheets,177 (f) presumed catalytic moiety derived from solutions. (a) Voltammetry profiles of FePc/C, CoPc/C, and the
heat treatment of a metal-polyaniline complex in N2,179 and (g) supposed comparative Pt/C recorded on a rotating ring-disk electrode. The disk
configuration of metal-polypyrrole composite catalyst.171 M represents a and ring current densities are represented by Id and Ir, respectively.
transition-metal such as Fe, Co, Ni, Mn, etc. The inset curves display the H2O2 yields on the three catalysts.
(b) Density functional theory (DFT) calculation results showing the
has provided new insight into the functionality of bicore metals: optimized structural configurations for HOOH adsorbed on FePc
Fe(III)Nx serves as the active site for ORR and the Cu(II)/Cu(I) (left) and H2OO adsorbed on CoFc. The central yellow ball, the two
redox mediator functions as the electron shuttle.180 Further- red balls, blue balls and light white balls correspond to the Fe/Co, O,
more, for homogenous catalysts such as cobalt tetraphenyl- N, C and H atoms, respectively. Reprinted with permission from
porphyrin, multiple functional groups may participate in the ref. 178. Copyright 2009, American Chemical Society.
multi-centred catalytic process to create a concerted action.187
Anyway, the nitrogen presence appears to be an utmost require- the supporting substrate, the heat treatment condition, and
ment for attaining activity. There is also possibility that the the synthesis method.173 The metal-ion centre exerts a signifi-
catalytically active sites vary with the composition and structure cant effect on the redox and charge-transfer properties of the
of this diverse class of materials. For example, homogeneous metal macrocycles and the most active metals are Fe and Co.
oxygen reduction on metal-free porphyrin involves binding of Logically, a combination of the two would perform even
molecular oxygen to the protonated free porphyrin base.188 The better. In regard to heat treatment, the temperature, duration,
different modes of binding and activation of oxygen molecules on atmosphere, and treatment method are important parameters.
non-metal sites would permit alternative catalytic routes for There is often a trade-off between catalytic activity and stability,
metal macrocycles for heterogeneous redox processes. More and rationalizing the pyrolysis condition is an interesting
fundamental studies are clearly required to identify the nature research subject. Dahn and co-workers have investigated the
of real active sites and elucidate the catalysis mechanism. activity of sputtered M–C–N (M is transition-metal such as V,
Because of the normally insufficient long-term stability Cr, Mn, Fe, Co, and Ni) films for the ORR in acid and alkaline
of metal-macrocyclic compounds in strong acidic or alkali electrolytes.174–176 The choice of M, the N doping, and the
environments, inorganic–organic composite electrocatalysts heat-treatment temperature play important roles in the activity
are generally prepared by the pyrolysis of a variety of pre- and stability of the heat-treated MxC1 x yNy catalyst libraries.
cursors containing metal, nitrogen and carbon. Their catalytic The optimum heat-treatment temperature is in the range of
activities are found to depend on a series of parameters, such 700–900 1C. In alkaline solutions, the activities of the catalysts
as the type and content of central metal, the precursors, follow Co > Ni > Mn > V > Cr, while in acid solutions,

This journal is c The Royal Society of Chemistry 2012 Chem. Soc. Rev., 2012, 41, 2172–2192 2185
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the order is Fe > Co > Cr > Ni. The N doping increases the derived formulations (Fig. 12f) combine high ORR activity with
activity. Although Cr is less active, the CrxC1 x yNy libraries performance durability and 4e reduction selectivity.179 Polypyr-
show good passivation against corrosion.175 These results suggest role is also good precursor for pyrolyzed metal-containing
that the ORR catalytic performance could be rationalized by composite ORR catalysts.191,192 Pyrolyzed iron-polypyrrole
carefully adjusting the influential factors. mesoporous spheres with honeycomb-like structure and large
The structure of the macrocycles influences the ligand–metal volumetric surface area, which increase the active site density
interaction and the character of the pyrolyzed species, which and favour mass transport, can be used as a highly efficient
however, is not easy to be directly correlated as the pyrolysis non-noble ORR catalyst.191 As for other inorganic–organic
destroys the structure of the precursor. Since nitrogen appears composite series, improving these promising catalysts requires
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to be a necessary part in the catalytic centre, increasing further in-depth mechanistic study on the origin of the intrinsic
surface nitrogen content is of vital importance in enhancing activity and stability.
the activity. Strategies to increase nitrogen incorporation Inorganic–organic composite catalyst materials have been
include tailoring the nitrogen-containing precursors, utilizing employed in the air electrodes of laboratory metal–air batteries.
gaseous (NH3 or CH3CN) etching in the pyrolysis process, For example, carbon-supported FeCo-EDA catalysts prepared
and employing new impregnation approaches.99 With respect by pyrolysis of a mixture of iron sulfate, cobalt nitrates and
to the carbon support, the identified influential factors are ethylenediamine (EDA) show outstanding ORR activity and
disordered carbon degree/content and microporosity. According stability in alkaline electrolyte.182 Compared with the commer-
to previous insights into the catalyst design, Dodelet and cial Pt/C catalyst, the FeCo-EDA catalyst exhibits a nearly 3
co-workers reported in 2009 the best iron-based catalysts with times higher mass activity and 2.5 times better activity retention
ORR catalytic activity comparable to Pt.177 They selected highly after accelerated degradation testing. The superior performance
microporous Black Pearl 2000 as the carbon support and used is attributed to its good structural stability and morphological
planetary ball-milling to fill the support pores with pore filler preservation (shown in Fig. 14a and b), in contrast to severe
(1,10-phenanthroline) and iron precursor (ferrous acetate). The agglomeration of Pt particles. Single cell performance testing on
best-performing Fe-based catalyst with the greatest increase in the assembled aqueous Zn–air batteries demonstrates higher
active site density was obtained by pyrolyzing the mixture first polarization current density and higher peak power density
in argon and then in ammonia. The active sites were believed (Fig. 14c and d).182 These results indicate great potential of
to contain iron cations coordinated by pyridinic nitrogen func- FeCo-EDA materials as cathode catalyst for aqueous metal–air
tionalities that were anchored in the interstices of graphitic batteries. Catalytic application of metal macrocycles in non-
sheets within the micropores of the support (illustrated in aqueous Li–air cells has also been reported.183 Pyrolyzed FeCu-
Fig. 12e).177 While the initial activity of this catalyst was a phthalocyanine supported on high surface area carbon black
factor of >35 relative to previously reported Fe-based catalysts, can simultaneously accelerate the 2e oxygen reduction and
its stability should be improved to meet the requirement of catalyze the chemical disproportionation of Li2O2, resulting in
practical application.
In addition to the relatively expensive and complex macro-
cyclic compounds, heterocyclic conjugated polymers such as
polypyrrole, polyaniline and poly(3,4-ethylenedioxythio-
phene) (PEDOT) are also attractive materials in oxygen
electrocatalysis.171,179,189,190 These polymers are characterized
by low cost, high electrical conductivity, abundant function-
alities and distinct redox properties. They can be utilized as
direct electrocatalysts,189 as bridges between substrate and
catalyst to promote physical and electrical contact,190 as
matrices for incorporating metal ion to create active sites,171
and as nitrogen/carbon precursors for pyrolyzed M–Nx/C
materials.179 For example, polypyrrole is used as a matrix
for entrapping cobalt to generate Co–N active sites (Fig. 12g)
for the ORR.171 Such transition metal–polymer composite
materials prepared via a pyrolysis-free process can deliver
considerable ORR activity with respectable stability over a
long operating time. Compared to this non-pyrolyzed compo-
site, the high-temperature system synthesized using mixture of
precursors of metal and heteroatom polymer exhibits better
activity.
Polyaniline has been proven as a suitable template compounds
Fig. 14 Application of FeCo-EDA (ethylenediamine) catalyst in
for C and N due to its structural similarity to graphite. The heat Zn–air batteries: TEM images of FeCo-EDA (a) before and (b) (b)
treatment of polyaniline could not only facilitate the integration accelerated degradation test; single cell performance of (c) polarization
of N-containing active sites into the partially graphitized carbon curve and (c) power density for the Zn–air cells made with FeCo-EDA
matrix but also benefit uniform distribution and increased and Pt/C. Reprinted with permission from ref. 182. Copyright 2011,
density of N sites on the surface. Consequently, polyaniline Elsevier.

2186 Chem. Soc. Rev., 2012, 41, 2172–2192 This journal is c The Royal Society of Chemistry 2012
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decreased polarization of the cells, increased recovery rate of


open-circuit voltage, and reduced apparent activation energy for
the discharge of the cells.183 Therefore, inorganic–organic compo-
sites are highly valuable candidate cathode catalysts for practical
metal–air batteries, despite relatively fewer application to date.

4. Air electrode structures


One of the key features of an efficient air electrode is the
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formation of a high-surface area boundary between the active


phases involved in the oxygen reduction: air, the electrolyte,
the catalyst and the conductor.22 In metal–air cells with
aqueous electrolytes, oxygen is reduced to OH , which is
dissolved into the electrolyte. The electrocatalytic oxygen
reaction occurs at a three-phase contact zone between air,
liquid electrolyte and solid catalyst (except to the extent that
the oxygen may dissolve in the electrolyte), as schematically Fig. 15 Illustrated interfaces of air electrodes and proposed electrode
shown in Fig. 15a. It is necessary to arrange such a three-phase structures. (a) Gas–solid–liquid three-phase interface model in
interface in the air electrode, where air can diffuse throughout aqueous electrolyte. (b) Liquid–solid two-phase interface model in
and electrolyte can be adsorbed in the catalyst surface but non-aqueous electrolyte; (a) and (b) are adapted from ref. 193 with
must not flood it to the exclusion of gas. This requires careful significant modification, copyright 2010, Elsevier. (c) Model structure
construction of the catalyst layer. The catalyst layer is made of air electrode with metal mesh/foam-supported oxygen permeable
membrane (OPM, for filtering out H2O or CO2), gas diffusion layer
hydrophilic on the electrolyte side but hydrophobic on the gas
(GDL) and catalyst layer (CL). (d) Suggested porous structure of the
side.24 Thus, the surface exposed to air is generally treated
catalyst layer with hierarchical macro-/meso-/inter-particle pores for
with a water-repellent substance (e.g., paraffin wax or Teflon) both efficient electrolyte wetting and gas transportation.
while the side facing electrolyte employs hydrophilic additives.6
The balance between hydrophobic and hydrophilic properties is area occupied by macropores and mesopores could lead to
significantly important for air electrodes used in aqueous metal– remarkable performance.195 In addition, carbons with ordered
air batteries. and interconnected mesopores can be used as an efficient
Oxygen electrochemistry in non-aqueous electrolytes differs catalyst support that provides inner pores for gas diffusion
from aqueous electrolytes. In a Li–air cell based on organic and outer surfaces for electrolyte access.200 For a Li–air cell,
electrolyte, the discharge products (Li2O2 and/or Li2O) are an interconnected dual pore system (one catalyzed and one
insoluble in the electrolyte and will precipitate on the surface non-catalyzed) with multiple time-release catalyst is proposed
of the catalyst, preventing continuous air diffusion and access. to increase materials utilization, decrease diffusion limitation,
As a result, only the oxygen dissolved in the electrolyte and supply high power for long term.197 The area-specific cell
participates in the oxygen reduction. The cathode reaction capacity can be optimized by use of carbon microstructure and
takes place at the electrolyte–catalyst two-phase interface.193 loading as well as electrode porosity/thickness and electrolyte
Based on this model, the catalyst layer should be completely amount.198
wetted with liquid electrolyte to maximize the reaction areas In practical air electrodes, the detrimental effect of carbon
for high capacity. In addition, the liquid electrolyte layer on dioxide and moisture should also be taken into consideration
the catalyst surface should remain as thin as possible to for aqueous alkaline electrolytes and non-aqueous aprotic
minimize the transport distance of the dissolved oxygen for electrolytes, respectively. The presence of CO2 will incur
fast kinetics. Meanwhile, the implementation of electrolytes neutralization of the alkaline electrolyte and precipitation of
with high oxygen solubility and fast oxygen diffusivity should carbonate that blocks the diffusion/transport channels. The
also greatly benefit the improvement of the cathode performance. inclusion of H2O will cause severe Li anode corrosion and
In this context, both electrode design and electrolyte adjustment electrolyte degradation. To address these problems, it is very
(e.g., tuning parameters such as composition, solubility, polarity, helpful to use a membrane that is O2 permeable but can block
viscosity and conductivity) are desirable direction for the develop- the incorporation of CO2 or H2O from air.201,202 The current
ment of advanced Li–air batteries.26,194 collector and electrode support are also influential factors on
In view of the above demonstrated importance of the inter- the performance. Metal mesh is usually used as the current
face, the design rationale of the cathode structure should focus collector and the substrate to support the gas diffusion layer
on increasing the interface areas and enhancing air diffusion and the catalyst layer. Metal foam is an interesting alternative
and transportation. High specific surface area of catalyst because of its highly interconnected open porous network,
support is of course a prerequisite. The pore structure also which provides electrical conductivity, mass transport path-
plays a key role in determining the charge and mass transport way and mechanical flexibility.203 Fig. 15c shows a proposed
properties of the air electrode. Both experimental results and model structure of an air electrode, which consists of an oxygen
modelling have shown the influential role of pore size and selective membrane, a gas diffusion layer, and a catalyst layer
distribution in electrode performance.195–199 For an aqueous supported on metal mesh/foam. The catalyst layer should take
Zn–air battery, the use of activated carbon with high surface advantage of macro-/mesopores and inter-particle pores for

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electrolyte wetting (but not flooding) and oxygen diffusion, as Of the four categories of catalytic materials mentioned in
schematically shown in Fig. 15d. It should be noted that this review, the Pt-based noble metal family generally
multilayer structures with different catalyst compositions may possesses virtues of both high activity and favourable stability
be beneficial to bifunctional air electrodes for rechargeable but disadvantages of cost and scarcity. Alloying with cheap
metal–air batteries.32 Furthermore, since the air electrodes transition-metals and using Pt-skin overlayered structure
function mainly as electrocatalyst, ideally they should be con- are effective routes to simultaneously lower the noble metal
structed to be as thin and light as possible in order to allow space loading and further enhance the activity.75–80 The compromise
to accommodate more anode materials in the cells. Examples of between cost and performance makes the Pt-based catalysts
thin air cathodes based on composite microstructures have more adaptive to material-saving rechargeable metal–air
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shown superior battery performance compared to conventional batteries. Carbonaceous materials, transition-metal oxides,
cathode structures.204 and composite materials derived from macrocycles or polymers
(M–N/C) are promising abundant and cheap catalysts applic-
able to air electrodes. Carbons in nanostructured form such
5. Conclusions and outlook
as graphene nanosheets and N-doped carbon nanotubes are
This review has highlighted recent progress in electrochemistry attractive due to respectable activity, high electrical conduc-
and materials chemistry of air electrodes for metal–air batteries. tivity and chemical stability.132–138 Transition-metal oxides
The electrochemical reaction pathways of oxygen reduction have such as Mn-based spinels and perovskites exhibit considerably
been discussed in both aqueous media and aprotic electrolytes. high activity and durability in alkaline electrolytes, and can
Four categories of catalytic materials ranging from traditional serve as bifunctional catalysts for both the ORR and
noble metals/alloys to alternative carbons, metal oxides, and OER.152–158 The composite M–N/C catalysts enable properties
inorganic–organic composites have been selectively surveyed as tuning through adjusting the metal centres and tailoring the
catalysts for air electrodes, with demonstration of electrocatalytic organic functionality.171–190
mechanism, influential factors to catalytic properties, and elec- Proposed future research directions in these non-precious
trode performance. Some basic design rationales of air electrode metal catalytic materials would include: (1) exploiting the effect
structure have also been presented with proposed models. To of physiochemical parameters (e.g., composition, valence state,
sum up the research advances and efforts, great potential and phase, structure, defects, morphology, size, surface area, con-
huge challenges coexist in this field. ductivity, etc.) on the intrinsic catalytic activity, (2) increasing
While the metal–air systems (particularly rechargeable the density of active sites and their utilization through inno-
Li–air cells) appear to be very promising contenders as future vative design of materials and structures, and (3) optimizing
power sources for electrified transportation and energy storage, catalyst synthesis strategies and conditions (e.g., precursor,
a series of scientific and technological issues remain to be temperature, duration, atmosphere, procedures) to achieve
settled before they can be found practical applications with better activity and stability. In addition, nanotechnologies
widespread deployment. First, many relevant fundamental may open new avenues in catalyst development; nanostructured
aspects are not fully understood. For example, it is necessary electrode materials are proven as a valuable option. Further-
to clearly unravel the elusive oxygen reaction mechanisms more, Nature could help in exploiting new electrocatalysts for
(e.g., 2e vs. 4e pathways and presence or absence of Li2O2) the ORR and OER processes. For example, some enzymes can
and nature of electrocatalyts (e.g., the real active sites), which efficiently catalyze electrochemical reactions by providing both
is prerequisite to guide the design of high-efficiency air elec- redox active sites and intramolecular/interfacial electron trans-
trodes. Good predictive power arises from in-depth insights fer pathways.208 Active sites in biological enzymes generally
into the catalytic mechanism and the correlation between have a larger flexibility of redox sites and geometry as compared
materials properties and performance. To gain such insights, to the rigid surface of inorganic solid catalysts.209 Mimicking
a combination of in situ experimental analysis,54,59 theoretical natural oxygen catalytic processes would aid in searching for
investigation,34,52,77,78,156,178 nanoscale probing,205 and atomic- better catalysts.
scale modelling206 would be valuable. Rational design of the structure also contributes signifi-
In addition to the requirement of fundamental mechanistic cantly to the performance of an air electrode. The basic
study, it is of paramount importance to develop highly effi- principle is to ensure the formation of high interfacial
cient, inexpensive, environmental benign catalytic materials contact to facilitate oxygen electrocatalysis. Manipulation the
for enhancing the kinetics of the sluggish oxygen reduction hydrophobic/hydrophilic properties, the porosity and the
reactions. Similar to the case of fuel cells,10,43,70,74,99,181 the catalyst distribution within the air electrode is required to
large polarization (overpotential) and slow kinetics at permit rapid diffusion and transport of oxygen and allow for
the cathode appear to be the major challenge that limits the efficient contact between electrolytes and catalysts. Bearing in
practical electrochemical performances. Solution to this issue mind the similarity between fuel cells and metal–air batteries,
should resort to highly active catalysts for oxygen reduction concepts/techniques of cathode design/fabrication adapted in
and/or evolution reactions. Functional materials determine the former (e.g., bipolar structure) could possibly be applied to
essentially the characteristics of any type of electrochemical the latter. Likewise, multifunctional architectures (e.g., 3D struc-
devices including batteries.207 Concerning the air electrodes, ture), which have been employed to elaborately arrange the
there are a rich variety of candidate materials for the oxygen components (electrode, current collector, separator, and electro-
electrochemistry, providing great opportunity for us to screen lyte) in lithium-ion batteries,210,211 would possibly aid in the
suitable catalysts for a specific application. design of metal–air batteries.

2188 Chem. Soc. Rev., 2012, 41, 2172–2192 This journal is c The Royal Society of Chemistry 2012
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2192 Chem. Soc. Rev., 2012, 41, 2172–2192 This journal is c The Royal Society of Chemistry 2012

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