Ultrasonic spray pyrolysis (USP) was used to synthesize a high-surface-area CoTMPP/C catalyst for oxygen reduction reaction (ORR). SEM micrographs showed that the USP-derived CoTMPP/C consists of spherical, porous and uniform particles with a diameter of 2-5 mu m, which is superior to that with a random morphology and large particle sizes (up to 100 mu m) synthesized by the conventional heat-treatment method. BET results revealed that the USP-derived catalyst had a higher specific surface area (834 m(2) g(-1)) than the conventional one. Cyclic voltammetric, rotating ring-disk electrode (RRDE) and H-2-air PEM fuel cell testing were employed to evaluate the USP-derived CoTMPP/C. The kinetic current density of the USP-derived catalyst at 0.7 V versus NHE was two times higher than that of the conventional catalyst. Compared to Pt/C catalyst, the USP-derived CoTMPP/C catalyst showed a strong methanol tolerance and a higher ORR activity in the presence of methanol. In a H-2-air PEM fuel cell with USP-derived CoTMPP/C as the cathode catalyst, the cell performance was much higher than that with conventional heat-treated CoTMMP/C as the catalyst. (c) 2007 Elsevier Ltd. All rights reserved.