Acid-free pyrolytic synthesis of M-N-C catalyst

A catalyst made by a method comprising:

• a) forming a first reaction mixture that includes a metal source, a nitrogen source, and at least one silica template, the at least one silica template including silica particles;
• b) mechanochemically mixing a combination of the first reaction mixture and a fluorinated polymer to form a first pre-pyrolysis powder;
• c) performing a first pyrolysis of the first pre-pyrolysis powder to form a first pyrolyzed composition, the first pyrolysis being performed at a first temperature greater than about 800° C. and under an inert atmosphere such that at least a portion of silica particles is removed and mesostructured carbon is formed;
• d) mechanochemically mixing the first pyrolyzed composition to form a second pre-pyrolysis powder;
• and
• e) performing a second pyrolysis of the second pre-pyrolysis powder to form a final catalyst powder, the second pyrolysis being performed under a reductive atmosphere at a second temperature that is greater than about 800° C.

An electrochemical cell comprising:

• an electrolyte;
• a catalytically active electrode having an active material disposed on a current collector, the active material including a catalyst made by:
• a) forming a first reaction mixture that includes a metal source, a nitrogen source, and at least one silica template, the at least one silica template including silica particles;
• b) mechanochemically mixing a combination of the first reaction mixture and a fluorinated polymer to form a first pre-pyrolysis powder;
• c) performing a first pyrolysis of the first pre-pyrolysis powder to form a first pyrolyzed composition, the first pyrolysis being performed at a first temperature greater than about 800° C. and under an inert atmosphere such that at least a portion of silica particles is removed and mesostructured carbon is formed;
• d) mechanochemically mixing the first pyrolyzed composition to form a second pre-pyrolysis powder;
• and
• e) performing a second pyrolysis of the second pre-pyrolysis powder to form a final catalyst powder, the second pyrolysis being performed under a reductive atmosphere at a second temperature that is greater than about 800° C.;
• a counter electrode, wherein the catalytically active electrode and the counter electrode are immersed in the electrolyte;
• and
• a voltage source that biases the catalytically active electrode relative to the counter electrode.

A method for making a nitrogen-doped porous carbon comprising:

• a) forming a first reaction mixture that includes a nitrogen and carbon source, a silica source, and a fluorinated polymer;
• b) mechanochemically mixing the first reaction mixture to form a first pre-pyrolysis powder;
• c) performing a first pyrolysis of the first pre-pyrolysis powder to form a first pyrolyzed composition, the first pyrolysis being performed at a first temperature greater than about 800° C. and under an inert atmosphere such that at least a portion of silica particles is removed and mesostructured carbon is formed;
• and
• d) performing a second pyrolysis of the first pyrolyzed composition, to form a nitrogen-doped porous carbon, the second pyrolysis being performed under a reductive atmosphere at a second temperature that is greater than about 800° C.