In recent years, non-Pt-based ORR catalysts have been developing rapidly and have achieved performance comparable to or even surpassing Pt precious metal catalysts in specific reactions, offering new possibilities for Pt-based catalyst replacement and showing great promise for application. This paper reviews the recent research progress of non-Pt-based fuel cell ORR catalysts. The latest research progress of non-Pt-based ORR SACs (including single metal active site ORR SACs, multi-metal active site ORR SACs, and non-Pt-based noble metal catalyst ORR SACs), non-metallic ORR catalysts, alloy-based ORR catalysts, high-entropy alloy ORR catalysts, and other non-Pt-based fuel cell ORR catalysts are presented in detail. This paper discusses in detail the synthesis methods, characterization means, optimization of performance, and application prospects of these non-Pt-based ORR catalysts. In addition, this review details the excellent performance of these catalysts in terms of compositional and structural controllability, electrical conductivity, and chemical stability, as well as their ability to exhibit ORR activity comparable to that of commercial Pt/C catalysts. This field is full of opportunities and challenges. In summary, non-Pt-based fuel cells show great potential in ORR. With the continuous improvement of preparation and characterization technologies, catalysts have broad application and market prospects. In addition, the development trend of non-precious metal fuel cell catalysts is reviewed.

The development of efficient and low-cost non-metallic catalysts is of great significance for the oxygen reduction reaction (ORR) in fuel cells. Heteroatom-doped carbon-based catalysts are one of the popular candidates, although their preparation method is still under exploration. In this work, single (CS)-, double (NCS)-, and triple (NBCS)-heteroatom-doped carbon-based catalysts were successfully prepared by a “cook-off” process. The morphology, elemental composition, and bonding structure of the catalysts were investigated by SEM, TEM, Raman spectra, BET, and XPS. ORR catalytic performance measurements suggested an activity trend of CS < NCS < NBCS, and NBCS demonstrated better methanol resistance and slightly higher stability than the commercial Pt/C catalyst, as evaluated with both rotating disk electrode (RDE) and rotating ring-disk electrode (RRDE) systems. The mechanism for the promoted performance was also proposed based on the conductivity of the catalysts. In this paper, the heteroatoms N, B, and S were co-doped into activated carbon using a simple, fast, and efficient preparation method with high electrical conductivity and also increased active sites, showing high electrocatalytic activity and good stability. This work provides a new approach to preparing highly active non-Pt catalysts for oxygen reduction reactions.