Efficient iron-cobalt oxide bifunctional electrode catalysts in rechargeable high current density zinc-air batteries

Iron-cobalt (FeCo) oxides dispersed on reduced graphene oxide (rGO) were synthesized from nitrate precursors at loading levels from 10 wt% to 60 wt%. These catalysts were tested in lab-scale zinc-air batteries (ZABs) at a high current density of 100 mA cm^-2 of the cathode area for the first time, cycling between 60 min of discharging and 60 min of charging. The optimum loading level for the best ZAB cycling performance was found to be 40 wt%, at which CoFe₂O₄ and CoO nanocrystals were detected. A discharge capacity of at least 90% was maintained for about 60 cycles with FeCo 40 wt%, demonstrating superior stability over amorphous FeCo oxides with FeCo 10 wt% despite similar performance at electrochemical tests. At a high current density of 100 mA cm^-2, OER catalytic activity was found to be the limiting factor in ZAB's cyclability. The discrepancies between the ORR/OER catalytic activities by electrochemical and battery cycling test results highlight the role and importance of rGO in improving electrical conductivity and activation of metal oxide electrocatalysts under high current density conditions. The difference of battery cycling test results from traditional electrochemical test results suggests that electrochemical tests conducted at low current densities may be inadequate in predicting practical battery cycling performance.