Elaborate construction of honeycomb-like porous carbon with embedment of N-doped carbon nanotubes as efficient electrocatalyst for zinc-air battery

Devising the synthesis strategy and uncovering the evolution mechanism of carbon-based materials are critical to the development of efficient oxygen reduction reaction (ORR) electrocatalysts for renewable energy storage systems. This study reports a hierarchical ORR electrocatalyst, Co@N-CNTs/3DHC, which features ultrafine cobalt nanoparticles embedded in nitrogen-doped carbon nanotubes (Co@N-CNTs) and Co@N-CNTs firmly anchored in the nano-chambers of a three-dimensional honeycomb-like porous carbon (3DHC). The synthesis strategy of Co@N-CNTs/3DHC involves the initial construction of a precursor, followed by controllable pyrolysis step. Based on detailed analysis of both evolved gases and carbonized products of precursors, the evolution mechanism of Co@N-CNTs/3DHC is specifically proposed. Prompted by the electron reconfiguration, extensive reaction interface and fast mass-transfer pathway, the as-synthesized hierarchical Co@N-CNTs/3DHC displays superior ORR activity in alkaline media (0.88 V of half-wave potential) compared to commercial Pt/C. Impressively, zinc-air battery equipped with Co@N-CNTs/3DHC cathode presents outstanding discharge voltage and exceptional stability. This work highlights a unique perspective on the synthesis strategy and growth mechanism of Co@N-CNTs@3DHC toward creation of hierarchical 3D carbon-based composite for advanced electrochemical energy devices.