Developing a high-performance ORR (oxygen reduction reaction) catalyst at low cost has been a challenge for the commercialization of high-energy density and low production cost aluminium-air batteries. Herein, we report a catalyst, prepared by pyrolyzing the shell waste of peanut or pistachio, followed by concurrent nitrogen-doping and FeCo alloy nanoparticle loading. Large surface area (1246.4 m ² g ^-1 ) of pistachio shell-derived carbon can be obtained by combining physical and chemical treatments of the biomass. Such a large surface area carbon eases nitrogen doping and provides more nucleation sites for FeCo alloy growth, furnishing the resultant catalyst (FeCo/N-C-Pistachio) with higher content of N, Fe, and Co with a larger electrochemically active surface area as compared to its peanut shell counterpart (FeCo/N-C-Peanut). The FeCo/N-C-Pistachio displays a promising onset potential of 0.93 V vs. RHE and a high saturating current density of 4.49 mA cm ^-2 , suggesting its high ORR activity. An aluminium-air battery, with FeCo/N-C-Pistachio catalyst on the cathode and coupled with a commercial aluminium 1100 anode, delivers a power density of 99.7 mW cm ^-2 and a stable discharge voltage at 1.37 V over 5 h of operation. This high-performance, low-cost, and environmentally sustainable electrocatalyst shows potential for large-scale adoption of aluminium-air batteries.

Despite its commercial success as a primary battery, Zn-air battery is struggling to sustain a reasonable cycling performance mainly because of the lack of robust bifunctional electrocatalysts which smoothen the oxygen reduction reaction (ORR) and oxygen evolution reaction (OER) taking place on its air-cathode. Composites of carbon/manganese oxide have emerged as a potential solution with high catalytic performance; however, the use of non-renewable carbon sources with tedious and non-scalable synthetic methods notably compromised the merit of being low cost. In this work, high quantity of carbon is produced from renewable source of readily available table sugar by a facile room temperature dehydration process, on which manganese oxide nanorods are grown to yield an electrocatalyst of MnO_x@AC-S with high oxygen bifunctional catalytic activities. A Zn-air battery with the MnO_x@AC-S composite catalyst in its air-cathode delivers a peak power density of 116 mW cm⁻² and relatively stable cycling performance over 215 discharge and charge cycles. With decent performance and high synthetic yield achieved for the MnO_x@AC-S catalyst form a renewable source, this research sheds light on the advancement of low-cost yet efficient electrocatalyst for the industrialization of rechargeable Zn-air battery.