Effect of Carbon Black, Carbon Nanotubes and Carbon Nanohorns on Electrochemical Performance of FeCoN/C Catalyst in Low Concentration Direct Ammonia Fuel Cells

Direct ammonia fuel cells (DAFCs) offer a promising pathway for carbon-free energy conversion but their practical performance is limited by sluggish cathode kinetics. In this work, non-precious FeCoN catalysts offer a cost-effective solution, yet carbon support optimization is crucial for activity and stability. FeCoN/XC-72R, FeCoN/CNT, and FeCoN/CNH cathode catalysts were synthesized by annealing at 550–750 °C. Their structure and morphology were analyzed by X-ray diffraction (XRD) and scanning electron microscopy (SEM). Electrochemical behavior was evaluated by cyclic voltammetry (CV) and electrochemical impedance spectroscopy (EIS) in alkaline medium containing KOH and NH4OH. FeCoN/XC-72R exhibited the lowest resistance of 27 Ω and superior activity. In single cell tests using a 40 wt% PtIr/C anode catalyst at 2 mg cm−2, the FeCoN/XC-72R catalyst achieved the highest power density of 71 mW/cm2 under optimized conditions of 0.1M NH4OH + 3M KOH, 100 °C, and O2 feed. Among the carbon supports, carbon black (XC-72R) proved the most effective support for FeCoN catalysts in low concentration DAFCs, outperforming carbon nanotubes (CNTs) and carbon nanohorns (CNHs). These findings highlight the importance of carbon support selection in the design of efficient cathodes for next generation low concentration direct ammonia fuel cells.