Synthesis and Active Site Identification of Fe−N−C Single-Atom Catalysts for the Oxygen Reduction Reaction

FeN3S1─OH Single-Atom Sites Anchored on Hollow Porous Carbon for Highly Efficient pH-Universal Oxygen Reduction Reaction

Regulating the asymmetric active center of a single-atom catalyst to optimize the binding energy is critical but challenging to improve the overall efficiency of the electrocatalysts. Herein, an effective strategy is developed by introducing an axial hydroxyl (OH) group to the Fe─N4 center, simultaneously assisting with the further construction of asymmetric configurations by replacing one N atom with one S atom, forming FeN3S1─OH configuration. This novel structure can optimize the electronic structure and d-band center shift to reduce the reaction energy barrier, thereby promoting oxygen reduction reaction (ORR) and oxygen evolution reaction (OER) catalytic activities. The optimal catalyst, FeSA-S/N-C (FeN3S1─OH anchored on hollow porous carbon) displays remarkable ORR performance with a half-wave potential of 0.92, 0.78, and 0.64 V versus RHE in 0.1 m KOH, 0.5 m H2SO4, and 0.1 m PBS, respectively. The rechargeable liquid Zn-air batteries (LZABs) equipped with FeSA-S/N-C display a higher power density of 128.35 mW cm-2, long-term operational stability of over 500 h, and outstanding reversibility. More importantly, the corresponding flexible solid-state ZABs (FSZABs@FeSA-S/N-C) display negligible voltage changes at different bending angles during the charging and discharging processes. This work provides a new perspective for the design and optimization of asymmetric configuration for single-atom catalysts applied to the area of energy conversion and storage.

Elucidating the impact of oxygen functional groups on the catalytic activity of M-N4-C catalysts for the oxygen reduction reaction: a density functional theory and machine learning approach

Efforts to enhance the efficiency of electrocatalysts for the oxygen reduction reaction (ORR) in energy conversion and storage devices present formidable challenges. In this endeavor, M-N4-C single-atom catalysts (MN4) have emerged as promising candidates due to their precise atomic structure and adaptable electronic properties. However, MN4 catalysts inherently introduce oxygen functional groups (OGs), intricately influencing the catalytic process and complicating the identification of active sites. This study employs advanced density functional theory (DFT) calculations to investigate the profound influence of OGs on ORR catalysis within MN4 catalysts (referred to as OGs@MN4, where M represents Fe or Co). We established the following activity order for the 2eORR: for OGs@CoN4: OH@CoN4 > CoN4 > CHO@CoN4 > C-O-C@CoN4 > COC@CoN4 > COOH@CoN4 > CO@CoN4; for OGs@FeN4: COC@FeN4 > CO@FeN4 > OH@FeN4 > FeN4 > COOH@FeN4 > CHO@FeN4 > C-O-C@FeN4. Multiple oxygen combinations were constructed and found to be the true origin of MN4 activity (for instance, the overpotential of 2OH@CoN4 as low as 0.07 V). Furthermore, we explored the performance of the OGs@MN4 system through charge and d-band center analysis, revealing the limitations of previous electron-withdrawing/donating strategies. Machine learning analysis, including GBR, GPR, and LINER models, effectively guides the prediction of catalyst performance (with an R2 value of 0.93 for predicting ΔG*OOH_vac in the GBR model). The Eg descriptor was identified as the primary factor characterizing ΔG*OOH_vac (accounting for 62.8%; OGs@CoN4: R2 = 0.9077, OGs@FeN4: R2 = 0.7781). This study unveils the significant impact of OGs on MN4 catalysts and pioneers design and synthesis criteria rooted in Eg. These innovative findings provide valuable insights into understanding the origins of catalytic activity and guiding the design of carbon-based single-atom catalysts, appealing to a broad audience interested in energy conversion technologies and materials science.

The role of nitrogen sources and hydrogen adsorption on the dynamic stability of Fe-N-C catalysts in oxygen reduction reaction

Fe-N-C catalysts are promising alternatives to Pt-based electrocatalysts for the oxygen reduction reaction (ORR) in various electrochemical applications. However, their practical implementation is impeded by their instability during prolonged operation. Various degradation mechanisms have been proposed, yet the real origin of the intrinsic instability of Fe-N-C structures under ORR operations is still disputed. Herein, we observed a new type of protonation mechanism based on advanced first-principles simulations and experimental characterizations. The results revealed strong evidence of pyrrolic-N protonation in pyrrolic-type FeN4, which plays a vital role for the low kinetic barrier of Fe leaching. Conversely, the pyridinic-type FeN4 prefers protonation at the Fe site, contributing to the higher barrier of Fe leaching and relatively higher stability. The facile pyrrolic-N protonation is verified by various spectroscopy characterizations in the Nafion-treated FePc molecule. Crucially, the presence of oxygen-containing intermediates at the Fe site can further work synergistically with N protonation to promote conversion of iron atoms (Fe-N4) into ferric oxide under working potentials, and the more positive the electrode potential, the lower the kinetic barrier of Fe leaching. These findings serve as a foundation for future research endeavors on the stability issues of Fe-N-C catalysts and advancing their application in sustainable energy conversion technologies.

3D Hollow Hierarchical Porous Carbon with Fe-N4 -OH Single-Atom Sites for High-Performance Zn-Air Batteries

The development of innovative and efficient Fe-N-C catalysts is crucial for the widespread application of zinc-air batteries (ZABs), where the inherent oxygen reduction reaction (ORR) activity of Fe single-atom sites needs to be optimized to meet the practical application. Herein, a three-dimensional (3D) hollow hierarchical porous electrocatalyst (ZIF8@FePMPDA-920) rich in asymmetric Fe-N4 -OH moieties as the single atomic sites is reported. The Fe center is in a penta-coordinated geometry with four N atoms and one O atom to form Fe-N4 -OH configuration. Compared to conventional Fe-N4 configuration, this unique structure can weaken the adsorption of intermediates by reducing the electron density of the Fe center for oxygen binding, which decreases the energy barrier of the rate-determining steps (RDS) to accelerate the ORR and oxygen evolution reaction (OER) processes for ZABs. The rechargeable liquid ZABs (LZABs) equipped with ZIF8@FePMPDA-920 display a high power density of 123.11 mW cm-2 and a long cycle life (300 h). The relevant flexible all-solid-state ZABs (FASSZABs) also display outstanding foldability and cyclical stability. This work provides a new perspective for the structural design of single-atom catalysts in the energy conversion and storage areas.

Highly active, ultra-low loading single-atom iron catalysts for catalytic transfer hydrogenation

Highly effective and selective noble metal-free catalysts attract significant attention. Here, a single-atom iron catalyst is fabricated by saturated adsorption of trace iron onto zeolitic imidazolate framework-8 (ZIF-8) followed by pyrolysis. Its performance toward catalytic transfer hydrogenation of furfural is comparable to state-of-the-art catalysts and up to four orders higher than other Fe catalysts. Isotopic labeling experiments demonstrate an intermolecular hydride transfer mechanism. First principles simulations, spectroscopic calculations and experiments, and kinetic correlations reveal that the synthesis creates pyrrolic Fe(II)-plN3 as the active center whose flexibility manifested by being pulled out of the plane, enabled by defects, is crucial for collocating the reagents and allowing the chemistry to proceed. The catalyst catalyzes chemoselectively several substrates and possesses a unique trait whereby the chemistry is hindered for more acidic substrates than the hydrogen donors. This work paves the way toward noble-metal free single-atom catalysts for important chemical reactions.

Axial optimization of biomimetic nanoenzyme catalysts applied to oxygen reduction reactions

Inspired by the bio-oxygen oxidation/reduction processes of hemoglobin, iron-based transition metal-like enzyme catalysts have been explored as oxygen reduction reaction (ORR) electrocatalysts. We synthesized a chlorine-coordinated monatomic iron material (FeN₄Cl-SAzyme) via a high temperature pyrolysis method as a catalyst for the ORR. The half-wave potential (E_1/2) was 0.885 V, which exceeded those of Pt/C and the other FeN₄X-SAzyme (X = F, Br, I) catalysts. Furthermore, through density functional theory (DFT) calculations, we systematically explored the better performance reason of FeN₄Cl-SAzyme. This work offers a promising approach toward high-performance single atom electrocatalysts.

N-Doped Carbon as a Promoted Substrate for Ir Nanoclusters toward Hydrogen Oxidation in Alkaline Electrolytes

Development of effective electrocatalysts toward hydrogen oxidation with a low content of noble metals has attracted the attention of the catalytic community. In this work, a novel catalyst composed of nitrogen-doped carbon acting as the substrate and Ir nanoclusters as active species was prepared, which was then employed as an effective catalyst for the hydrogen oxidation reaction (HOR) in an alkaline electrolyte. In 0.1 M KOH, the optimized catalyst provides an exchange current density of 0.144 mA cm_Ir^-2 for HOR that outperforms the catalytic activity of the commercial Pt/C catalyst with a Pt content of 20 wt %. The substrate induces highly active Ir sites that markedly boosted the electrocatalytic activity for HOR. The nitrogen-doped carbon substrate increases the stability of Ir nanoclusters and decreases the absorption energy of hydrogen on Ir sites; at the same time, the higher electrostatic potential around the adsorbed hydrogen on Ir/N-doped carbon also enables them to be easily attracted by OH^- species, both of which enhanced the catalytic activity. The excellent catalytic activity and the understanding shown here will give some hints for the development of HOR catalysts used in alkaline electrolytes.

Design of Novel Transition-Metal-Doped C6N2 with High-Efficiency Polysulfide Anchoring and Catalytic Performances toward Application in Lithium-Sulfur Batteries

Lithium-sulfur (Li-S) batteries are highly expected because of their high theoretical specific capacity and energy density. However, its application still faces challenges, including the shuttle effect affecting the sulfur reduction reaction, the high decomposition energy barrier of Li₂S during charging, the volume change of sulfur, and the poor conductivity during charging and discharging. Here, combined with density functional theory and particle swarm optimization algorithm for the nitrogen carbide monolayer structural search (C_mN_8-m, m = 1-8), the surprising discovery is that a single metal-atom-doped C₆N₂ monolayer could effectively accelerate the conversion of lithium polysulfide and anchor lithium polysulfide during discharging and decrease the decomposition energy barrier of Li₂S during charging. This "anchoring and catalyzing" mechanism effectively reduces the shuttle effect and greatly improves the reaction kinetics. Among a series of metal atoms, Cr is the best doping element, and it exhibits suitable adsorption energy for polysulfides and the lowest decomposition energy barrier for Li₂S. This work opens up a new way for the development of transition-metal-doped carbon-nitrogen materials with an excellent catalytic activity for lithium polysulfide as cathode materials for Li-S batteries.

Iron atom-cluster interactions increase activity and improve durability in Fe-N-C fuel cells

Simultaneously increasing the activity and stability of the single-atom active sites of M–N–C catalysts is critical but remains a great challenge. Here, we report an Fe–N–C catalyst with nitrogen-coordinated iron clusters and closely surrounding Fe–N₄ active sites for oxygen reduction reaction in acidic fuel cells. A strong electronic interaction is built between iron clusters and satellite Fe–N₄ due to unblocked electron transfer pathways and very short interacting distances. The iron clusters optimize the adsorption strength of oxygen reduction intermediates on Fe–N₄ and also shorten the bond amplitude of Fe–N₄ with incoherent vibrations. As a result, both the activity and stability of Fe–N₄ sites are increased by about 60% in terms of turnover frequency and demetalation resistance. This work shows the great potential of strong electronic interactions between multiphase metal species for improvements of single-atom catalysts.

It is challenging to break the activity–stability trade-off in Fe–N–C fuel cell catalysts. Here, the authors show that interactions between iron atoms and clusters accelerate reaction kinetics and suppress demetalation to improve fuel cell stability.

New insights into the key bifunctional role of sulfur in Fe-N-C single-atom catalysts for ORR/OER

Sulfur-doping of non-noble metal Fe-N-C single-atom catalysts (SACs) shows a key bifunctional role in promoting ORR and OER activity. The controversial claims about the enhanced ORR activity and the ambiguity of the OER activity brought about by S-doping demand in-depth investigation. Here, systematic theoretical investigation was carried out. Unlike previously believed, coordinative S-doping gives rise to a precisely regulated OOH* stabilization effect, which is revealed to be the origin of the bifunctional ORR/OER activity. The fine regulation is reflected in two aspects: (1) Compared with other intermediates, the regulation of OOH* adsorption is more obvious. (2) More sulfur-doping leads to excessive strong or weak stabilization, which is not conducive to ORR/OER. The single S doping elevates the charge density and opens the metallic spin channels of Fe-N₃|S, moves the d-band center towards the Fermi level, all contributing to moderate OOH* stabilization. It is hoped that these results will promote the development of heteroatom-doped bifunctional SACs.

Metal-Organic Frameworks Derived Electrocatalysts for Oxygen and Carbon Dioxide Reduction Reaction

The increasing demands of energy and environmental concerns have motivated researchers to cultivate renewable energy resources for replacing conventional fossil fuels. The modern energy conversion and storage devices required high efficient and stable electrocatalysts to fulfil the market demands. In previous years, we are witness for considerable developments of scientific attention in Metal-organic Frameworks (MOFs) and their derived nanomaterials in electrocatalysis. In current review article, we have discussed the progress of optimistic strategies and approaches for the manufacturing of MOF-derived functional materials and their presentation as electrocatalysts for significant energy related reactions. MOFs functioning as a self-sacrificing template bid different benefits for the preparation of metal nanostructures, metal oxides and carbon-abundant materials promoting through the porous structure, organic functionalities, abundance of metal sites and large surface area. Thorough study for the recent advancement in the MOF-derived materials, metal-coordinated N-doped carbons with single-atom active sites are emerging candidates for future commercial applications. However, there are some tasks that should be addressed, to attain improved, appreciative and controlled structural parameters for catalytic and chemical behavior.

Enhancing ORR Activity of Fullerene-Derived Carbons by Implanting Fe in Assembled Diamine-C60 Spheres

Fullerene-derived carbons have been demonstrated as effective electrode materials for electrocatalytic reactions. The rational arrangement of heteroatoms in the carbon structure is essential to yield high catalytic activity. Herein, assembled...

Active site engineering of single-atom carbonaceous electrocatalysts for the oxygen reduction reaction

The electrocatalytic oxygen reduction reaction (ORR) is the vital process at the cathode of next-generation electrochemical storage and conversion technologies, such as metal-air batteries and fuel cells. Single-metal-atom and nitrogen co-doped carbonaceous electrocatalysts (M-N-C) have emerged as attractive alternatives to noble-metal platinum for catalyzing the kinetically sluggish ORR due to their high electrical conductivity, large surface area, and structural tunability at the atomic level, however, their application is limited by the low intrinsic activity of the metal-nitrogen coordination sites (M-N x ) and inferior site density. In this Perspective, we summarize the recent progress and milestones relating to the active site engineering of single atom carbonous electrocatalysts for enhancing the ORR activity. Particular emphasis is placed on the emerging strategies for regulating the electronic structure of the single metal site and populating the site density. In addition, challenges and perspectives are provided regarding the future development of single atom carbonous electrocatalysts for the ORR and their utilization in practical use.

Single-Atom (Iron-Based) Catalysts: Synthesis and Applications

Supported single-metal atom catalysts (SACs) are constituted of isolated active metal centers, which are heterogenized on inert supports such as graphene, porous carbon, and metal oxides. Their thermal stability, electronic properties, and catalytic activities can be controlled via interactions between the single-metal atom center and neighboring heteroatoms such as nitrogen, oxygen, and sulfur. Due to the atomic dispersion of the active catalytic centers, the amount of metal required for catalysis can be decreased, thus offering new possibilities to control the selectivity of a given transformation as well as to improve catalyst turnover frequencies and turnover numbers. This review aims to comprehensively summarize the synthesis of Fe-SACs with a focus on anchoring single atoms (SA) on carbon/graphene supports. The characterization of these advanced materials using various spectroscopic techniques and their applications in diverse research areas are described. When applicable, mechanistic investigations conducted to understand the specific behavior of Fe-SACs-based catalysts are highlighted, including the use of theoretical models.

Resolving the Dilemma of Fe-N-C Catalysts by the Selective Synthesis of Tetrapyrrolic Active Sites via an Imprinting Strategy

Combining the abundance and inexpensiveness of their constituent elements with their atomic dispersion, atomically dispersed Fe-N-C catalysts represent the most promising alternative to precious-metal-based materials in proton exchange membrane (PEM) fuel cells. Due to the high temperatures involved in their synthesis and the sensitivity of Fe ions toward carbothermal reduction, current synthetic methods are intrinsically limited in type and amount of the desired, catalytically active Fe-N₄ sites, and high active site densities have been out of reach (dilemma of Fe-N-C catalysts). We herein identify a paradigm change in the synthesis of Fe-N-C catalysts arising from the developments of other M-N-C single-atom catalysts. Supported by DFT calculations we propose fundamental principles for the synthesis of M-N-C materials. We further exploit the proposed principles in a novel synthetic strategy to surpass the dilemma of Fe-N-C catalysts. The selective formation of tetrapyrrolic Zn-N₄ sites in a tailor-made Zn-N-C material is utilized as an active-site imprint for the preparation of a corresponding Fe-N-C catalyst. By successive low- and high-temperature ion exchange reactions, we obtain a phase-pure Fe-N-C catalyst, with a high loading of atomically dispersed Fe (>3 wt %). Moreover, the catalyst is entirely composed of tetrapyrrolic Fe-N₄ sites. The density of tetrapyrrolic Fe-N₄ sites is more than six times as high as for previously reported tetrapyrrolic single-site Fe-N-C fuel cell catalysts.

Degradation and regeneration of Fe-N x active sites for the oxygen reduction reaction: the role of surface oxidation, Fe demetallation and local carbon microporosity

The severe degradation of Fe-N-C electrocatalysts during a long-term oxygen reduction reaction (ORR) has become a major obstacle for application in proton-exchange membrane fuel cells. Understanding the degradation mechanism and regeneration of aged Fe-N-C catalysts would be of particular interest for extending their service life. Herein, we show that the by-product hydrogen peroxide during the ORR not only results in the oxidation of the carbon surface but also causes the demetallation of Fe active sites. Quantitative analysis reveals that the Fe demetallation constitutes the main reason for catalyst degradation, while previously reported carbon surface oxidation plays a minor role. We further reveal that post thermal annealing of the aged catalysts can transform the oxygen functional groups on the carbon surface into micropores. These newly formed micropores not only help to increase the active-site density but also the intrinsic ORR activity of the neighbouring Fe-N₄ sites, both contributing to complete activity recovery of aged Fe-N-C catalysts.

Metal-Nitrogen-Carbon Catalysts of Specifically Coordinated Configurations toward Typical Electrochemical Redox Reactions

Metal-nitrogen-carbon (M-N-C) material with specifically coordinated configurations is a promising alternative to costly Pt-based catalysts. In the past few years, great progress is made in the studies of M-N-C materials, including the structure modulation and local coordination environment identification via advanced synthetic strategies and characterization techniques, which boost the electrocatalytic performances and deepen the understanding of the underlying fundamentals. In this review, the most recent advances of M-N-C catalysts with specifically coordinated configurations of M-N_x (x = 1-6) are summarized as comprehensively as possible, with an emphasis on the synthetic strategy, characterization techniques, and applications in typical electrocatalytic reactions of the oxygen reduction reaction, oxygen evolution reaction, hydrogen evolution reaction, CO₂ reduction reaction, etc., along with mechanistic exploration by experiments and theoretical calculations. Furthermore, the challenges and potential perspectives for the future development of M-N-C catalysts are discussed.

Highly porous Fe/N/C catalyst for oxygen reduction: the importance of pores

Fe/N/C full of ultrafine Fe-based species and pores is synthesized by pyrolyzing a g-C₃N₄-coordinated Fe matrix embedded in carbon for oxygen reduction. Enhanced oxygen reduction activity is observed on Fe/N/C with higher pore volume and the Fe/N/C catalyst with the largest pore volume shows the highest half-wave potential of 0.890 V.

ZIF-8 derived Fe‒N coordination moieties anchored carbon nanocubes for efficient peroxymonosulfate activation via non-radical pathways: Role of FeNx sites

Developing high-efficient hybrids carbon catalysts for PMS-based advanced oxidation process (AOPs) are crucial in the field of environmental remediation. In this work, novel carbon nanocubes (xFe‒N‒C) with three-dimensional porous structure and abundant well-dispersed FeN_x sites were obtained via a skillful cage-encapsulated-precursor pyrolysis strategy. The as-synthesized xFe‒N‒C exhibited superb activity for phenol degradation by activating peroxymonosulfate (PMS). Besides, the catalytic system not only possessed good recycling performance, wide pH adaptation and relatively low activation energy, but also had high resistance to environmental interference. Singlet oxygen (¹O₂) dominated non-radical process was responsible for phenol degradation rather than traditional radical pathways. Impressively, the doping level of Fe could regulate FeN_x contents in catalysts, and the catalytic activity of xFe‒N‒C was greatly enhanced with increasing FeN_x contents. Based on density functional theory calculations (DFT), the introduction of FeN_x sites regulated the electronic structure of catalysts. Such electron-deficient Fe center acted as electron acceptor to receive electrons transmitted by the adsorbed PMS, thus generating highly reactive ¹O₂ for rapid phenol oxidation. This work provides a new insight into the innovation in transition metal-nitrogen hybrid carbon catalysts and highlights the pivotal roles of FeN_x sites in ¹O₂ generation during PMS activation process.

In Situ/Operando Electrocatalyst Characterization by X-ray Absorption Spectroscopy

During the last decades, X-ray absorption spectroscopy (XAS) has become an indispensable method for probing the structure and composition of heterogeneous catalysts, revealing the nature of the active sites and establishing links between structural motifs in a catalyst, local electronic structure, and catalytic properties. Here we discuss the fundamental principles of the XAS method and describe the progress in the instrumentation and data analysis approaches undertaken for deciphering X-ray absorption near edge structure (XANES) and extended X-ray absorption fine structure (EXAFS) spectra. Recent usages of XAS in the field of heterogeneous catalysis, with emphasis on examples concerning electrocatalysis, will be presented. The latter is a rapidly developing field with immense industrial applications but also unique challenges in terms of the experimental characterization restrictions and advanced modeling approaches required. This review will highlight the new insight that can be gained with XAS on complex real-world electrocatalysts including their working mechanisms and the dynamic processes taking place in the course of a chemical reaction. More specifically, we will discuss applications of in situ and operando XAS to probe the catalyst's interactions with the environment (support, electrolyte, ligands, adsorbates, reaction products, and intermediates) and its structural, chemical, and electronic transformations as it adapts to the reaction conditions.

Current trends and perspectives on emerging Fe-derived noble-metal-free oxygen electrocatalysts

This article discusses recent progress in the development of Fe-derived noble metal-free electrocatalysts, including the strategies used for design, synthesis, and assessment of their performance in alkaline conditions.

A pyridinic Fe-N4 macrocycle models the active sites in Fe/N-doped carbon electrocatalysts

Iron- and nitrogen-doped carbon (Fe-N-C) materials are leading candidates to replace platinum catalysts for the oxygen reduction reaction (ORR) in fuel cells; however, their active site structures remain poorly understood. A leading postulate is that the iron-containing active sites exist primarily in a pyridinic Fe-N₄ ligation environment, yet, molecular model catalysts generally feature pyrrolic coordination. Herein, we report a molecular pyridinic hexaazacyclophane macrocycle, (phen₂N₂)Fe, and compare its spectroscopic, electrochemical, and catalytic properties for ORR to a typical Fe-N-C material and prototypical pyrrolic iron macrocycles. N 1s XPS and XAS signatures for (phen₂N₂)Fe are remarkably similar to those of Fe-N-C. Electrochemical studies reveal that (phen₂N₂)Fe has a relatively high Fe(III/II) potential with a correlated ORR onset potential within 150 mV of Fe-N-C. Unlike the pyrrolic macrocycles, (phen₂N₂)Fe displays excellent selectivity for four-electron ORR, comparable to Fe-N-C materials. The aggregate spectroscopic and electrochemical data demonstrate that (phen₂N₂)Fe is a more effective model of Fe-N-C active sites relative to the pyrrolic iron macrocycles, thereby establishing a new molecular platform that can aid understanding of this important class of catalytic materials.

Graphite Intercalation Compounds Derived by Green Chemistry as Oxygen Reduction Reaction Catalysts

Precious group metal (PGM) catalysts such as Pt supported on carbon supports are expensive catalysts utilized for the oxygen reduction reaction (ORR) due to their unmatched catalytic activity and durability. As an alternative, PGM-free ORR electrocatalysts that offer respectable catalytic activity are being pursued. Most of the notable PGM-free catalysts are obtained either from a bottom-up approach synthesis utilizing nitrogen-rich polymers as building blocks, or from a top down approach, where nitrogen and metal moieties are incorporated to carbonaceous matrixes. The systematic understanding of the origin of catalytic activity for either case is speculative and currently employed synthesis techniques typically generate large amounts of hazardous waste such as acids, oxidizing agents, and solvents. Herein, for the first time, we investigate the catalytic activity of graphite-based materials obtained via intercalation strategies that minimally perturb the graphitic backbone. Our outlined approaches demonstrate initial efforts to not only elucidate the role of each element but also significantly reduce the use of hazardous chemicals, which remains a pressing challenge. Graphite intercalation compounds (GIC) were obtained using fewer steps and solvent-free processes. X-ray diffraction and Raman results confirm the successful intercalation of FeCl₃ between graphite layers. Electrochemical data shows that the ORR performance of FeCl₃-intercalated GIC displays slight improvement where the onset potential reaches 0.77 V vs RHE in alkaline environments. However, expansion of the graphite and solvent-free incorporation of iron and nitrogen moieties resulted in a significant increase in ORR activity with onset potential to 0.89 V vs RHE, a maximum half-wave of 0.72 V vs RHE, and a limiting current of about 2.5 mA cm^-2. We anticipate that the use of near solvent-free processes that result in a high yield of catalysts along with the fundamental insight into the origin of electrochemical activity will tremendously impact the methodologies for developing next-generation ORR catalysts.