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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
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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).
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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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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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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
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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
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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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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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This journal is c The Royal Society of Chemistry 2012 Chem. Soc. Rev., 2012, 41, 2172–2192 2187
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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
Published on 17 January 2012. Downloaded by Northeastern University on 21/05/2013 03:34:00.
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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