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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Low temperature upcycling of polyethylene to gasoline range chemicals: Hydrogen transfer and heat compensation to endothermic pyrolysis reaction over zeolites

Selective production of gasoline ranged chemicals were of great interest in the field of plastic upcycling. Here this work reports exothermic hydrogen transfer reaction which was observed when HY zeolite was adopted to catalytic pyrolyze the polyethylene to gasoline ranged chemicals, while it was not observed when H-ZSM5 was used as catalyst. Both zeolite catalysts could significantly bring down the reaction temperature from 500 to 300–350 °C. TG-FITR analysis revealed that products obtained with HY zeolites were dominated with saturated hydrocarbons as compared to H-ZSM5 where the combination of alkanes, alkenes, and aromatics was obtained. In addition to the formation of saturated compounds, the TG-DSC analysis confirmed that, over the HY zeolites, the endothermic hydrogen transfer reaction of olefins occurred along with the pyrolysis of LDPE visibly when the zeolite ratio in the zeolite/polyethylene mixture exceeded 50% by mass. The TG results also indicated that the polyethylene undergone nearly 100% converted with very few residues. Further product analysis from batch pyrolysis by GC-MS confirmed that gasoline ranged iso-alkanes were produced over HY zeolite. This study highlighted that coupling exothermic hydrogen transfer reactions with endothermic pyrolysis could be an energy-efficient way of producing gasoline ranged chemicals. Chemical upcycling of plastics is tunable by using different zeolite combinations for the formation of desired products.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

The effect of ferrous sulfate pretreatment on the optimal temperature for production of sugars during autothermal pyrolysis

Fast pyrolysis is a promising technology for producing cellulosic sugars from lignocellulosic biomass. Success in this endeavor requires measures that prevent naturally occurring alkali and alkaline earth metals (AAEM) from breaking pyranose and furanose rings in lignocellulosic biomass. This is especially critical for high ash feedstocks like corn stover and other kinds of herbaceous biomass. Pretreating corn stover with ferrous sulfate converts AAEM into thermally stable salts, which passivates the catalytic activity of these metals and dramatically improves sugar yields. AAEM passivation in combination with autothermal (partial oxidative) operation improves the prospects for intensifying the production of sugars via fast pyrolysis. We hypothesized that pretreated biomass pyrolyzed in the presence of oxygen can substantially influence the temperature dependence of pyrolysis kinetics. Here, we found that autothermal (air-blown) pyrolysis of ferrous sulfate pretreated corn stover achieved maximum sugar yield of 15.6 wt% (biomass basis) at 450 °C, whereas the maximum phenolic oil yield of 9.2 wt% (biomass basis) was reached at 500 °C. Considering these tradeoffs in yields of these highly desirable pyrolysis products, the ideal operating temperature is between 450 and 500 °C. These results suggest that two-stage pyrolysis might allow maximum recovery of both sugars and phenolic oil.

09 BIOMASS FUELS↗
NASA NTRS2023

Coupled Fluid Dynamics and Material Response Simulations for Nitrogen High Enthalpy Flows

The study focuses on the interaction of nitrogen flows with thermal protection systems during atmospheric re-entry for NASA flight missions. The Ares multiphysics coupling tool is employed to investigate the coupling between the fluid (US3D) and material response (Icarus) solvers using various modeling approaches. These approaches include the equilibrium thin-film coefficients approach, a weakly coupled approach with temperature coupling, and an approach considering the full chemical composition of the surface and the transfer of pyrolysis gases. The objective is to understand and accurately represent the mechanisms of nitrogen interaction with the surface, such as nitridation and catalytic recombination. The study aims to assess the accuracy of the different approaches by comparing them to experimental results obtained from NASA arc-jet facilities. By addressing these challenges and improving the understanding of nitrogen-surface interactions, it is expected to enhance the design and performance analysis of thermal protection systems for future missions.

Ablation↗
DOE OSTI2022

Effects of Surface Hydrophobicity on Catalytic Transfer Hydrogenation of Styrene with Formic Acid in a Biphasic Mixture

Transfer hydrogenation (TH) of unsaturated hydrocarbons with formic acid (FA) is an attractive processing pathway for the reduction of lignocellulosic pyrolysis oils. The low solubility of hydrophobic bio-oil species in water and FA in oil necessitates the use of a biphasic system as the reaction environment. Here, we report the effects of Pd/silica catalyst surface wettability on the TH reaction rate. Modification of the surface with short chain (C1–C4) alkyl silanes resulted in an increase in the reaction rate as compared to the unmodified catalyst. In contrast, modification of the surface with sulfonate (hydrophilic) and C18 alkyl silanes (hydrophobic) resulted in a decrease in the reaction rate as compared to the unmodified catalyst. Here, the results are discussed in terms of the catalyst interfacial activity and relative affinity of the reagents to the Pd active sites. An observed change in the apparent reaction order in styrene for a hydrophilic catalyst suggests that changing catalyst surface wettability from hydrophilic to hydrophobic resulted in a switch from a transport-limited to a kinetic-limited reaction regime.

09 BIOMASS FUELS↗
DOE OSTI2023

Treasuring trash: Pt/SrTiO 3 catalysts process plastic waste into high-value materials

Single-use plastics are ubiquitous throughout modern society because they have properties that make them desirable in a wide variety of applications, including low cost of production, high thermal and chemical stability, and tunable mechanical properties. Several of the recycling methods currently used to process single-use plastic waste, such as mechanical recycling and pyrolysis, do not selectively process plastic materials into uniform products, as would be advantageous for repurposing these materials in pursuit of a circular economy. Catalytic hydrogenolysis, whereby C–C bonds in polymers are broken over a supported catalyst in the presence of H 2 , is a promising approach to converting plastics into value-added products that can be sold commercially without further purification. Here, in this account, we present some recent advances in polyolefin hydrogenolysis, with a focus on Pt nanoparticles on SrTiO 3 nanocuboid supports (Pt/STO). Current developments in this field, general challenges, and future directions are discussed.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Comparative Techno-economic Analysis and Life Cycle Assessment of Producing High-Value Chemicals and Fuels from Waste Plastic via Conventional Pyrolysis and Thermal Oxo-degradation

The rapid rise in global plastic production in recent decades has resulted in the massive generation of plastic waste. Over 75% of the plastic waste generated in the United States was sent to landfills, with a meager 8.7% recycled. Plastics are valuable feedstocks for platform chemicals and fuels. Chemical upcycling of waste high-density polyethylene (HDPE) is gaining more attention as a potentially feasible and environmentally friendly plastic waste management technology. Conventional pyrolysis (CPY) and thermal oxo-degradation (TOD) are two chemical upcycling technologies actively researched for decomposing waste HDPE into valuable chemicals and fuels. However, there are few studies on the techno-economic analysis (TEA) and life cycle assessment (LCA) of these technologies for converting waste HDPE to valuable products. This study conducts a comparative TEA and LCA study of the thermochemical decomposition of waste HDPE to produce gaseous (ethylene and propylene) and liquid (naphtha, diesel, and wax) products by CPY and TOD. The study elucidates and compares the impact of hydrocracking longer chain hydrocarbons to produce more valuable products on the TEA and LCA. The TEA showed that the fixed capital investment could range from $\$32.5$ million for TOD without hydrocracking to $\$244$ million for CPY with hydrocracking scenarios. Annual revenues range from $\$28.1$ million to $\$71.5$ million in favor of scenarios with hydrocracking. However, the net present value ranges from $\$1.4$ million to $\$265.8$ million in favor of scenarios without hydrocracking. Sensitivity analysis showed that fixed capital cost, facility capacity, and product prices have the biggest impact on the process economics of the facilities, while utilities and waste transportation to refineries have the biggest impact on environmental impacts. Here, the LCA showed that primary products from scenarios without hydrocracking can be more environmentally friendly than virgin products from petroleum processes. However, TOD and CPY with hydrocracking primary products have more emissions than those of virgin products.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1985

Fuel-rich catalytic combustion: A soot-free technique for in situ hydrogen-like enrichment

An experimental program on the catalytic oxidation of iso-octane demonstrated the feasibility of the two-stage combustion system for reducing particulate emissions. With a fuel-rich (phi = 4.8 to 7.8) catalytic combustion preburner as the first stage the combustion process was soot free at reactor outlet temperatures of 1200 K or less. Although soot was not measured directly, its absence was indicated. Reaction products collected at two positions downstream of the catalyst bed were analyzed on a gas chromatograph. Comparison of these products indicated that pyrolysis of the larger molecules continued along the drift tube and that benzene formation was a gas-phase reaction. The effective hydrogen-carbon ratio calculated from the reaction products increased by 20 to 68 percent over the range of equivalence ratios tested. The catalytic partial oxidation process also yielded a large number of smaller-containing molecules. The fraction of fuel carbon in compounds having two or fewer carbon atoms ranged from 30 percent at 1100 K to 80 percent at 1200 K.

Brabbs, T. A.↗
DOE OSTI2025

Enhancing HT-WGS catalyst performance with stable monovalent copper species via electron supply from defect-induced MgO

Magnesium oxide (MgO) exhibits excellent synergy with cerium oxide (CeO2), serving as either textural or electronic promoters during catalytic reactions. However, achieving well-dispersed CeO2-MgO is technically challenging because they are known not to form solid solutions, and the crystal growth of CeO2 suppresses the structure formation of MgO, leading to MgO being in an inhomogeneous amorphous state within CeO2-MgO. For this reason, most of research groups have been struggling with synthesizing well-dispersed CeO2-MgO. This leads them to focusing on the interaction between the active metal and cerium, overlooking the true role of magnesium. In this study, we successfully synthesized well-dispersed CeO2-MgO via a spray pyrolysis-assisted evaporation-induced self-assembly method, followed by the impregnation of Cu. The location and dispersion of Cu nanoparticles were highly dependent on the MgO distribution. Additionally, we revealed that this significantly influenced the catalytic activity and stability towards the HTS reaction and furthermore supplies electrons to monovalent Cu species, helping maintain the stable electron structure and oxidation state of Cu species considered as active sites. These findings suggest that optimizing the MgO distribution in CeO2-MgO is a promising strategy for developing efficient catalysts for the HTS reaction, emphasizing the role of MgO in designing high-performance catalysts.

Kim, Min-Jae↗
DOE OSTI2024

Synergistic Ru Co atomic pair with enhanced activity toward levulinic acid hydrogenation

Development of efficient metal-based catalysts is of great importance for levulinic acid (LA) hydrogenation to γ-valerolactone (GVL). The widely employed Ru-based catalysts are advantageous for H 2 dissociation, however, the steric hindrance for large Ru particles hampers their coordination to C=O moiety in LA, and thereby decreasing the activity. Herein, we report a Ru 1 Co 1 -N-C double single-atom catalyst (DSAC) with synergistic Ru and Co atomic pairs for LA hydrogenation into GVL. The Ru and Co doped zeolitic imidazole frameworks (RuCo-doped ZIF-8) precursor was rationally designed ((Ru+Co)/(Zn+Ru+Co) = 2 at.%), where the Zn node spatially isolates Ru and Co species, expanding the adjacent Ru-Co distance and facilitating the formation of the Ru-Co atomic pair upon pyrolysis, with each atom coordinated with three nitrogen atoms (N 3 -Ru 1 Co 1 -N 3 ). The Ru 1 Co 1 -N-C catalyst exhibits outstanding catalytic activity, with a turnover frequency (TOF) of 1980 h –1 , surpassing previously reported Ru-based catalysts. Experimental investigation and density functional theory (DFT) calculations reveal that the electron-rich Ru induced by less electronegative Co facilitates H 2 dissociation, while atomic Ru in dual-atomic pairs promotes C=O activation, Ru and Co atomic pairs synergistically enhancing LA conversion to GVL. In conclusion, this research will shed light on the precise control of active sites at atomic scale, and also provides a new concept for designing high-performance Ru-based catalysts towards LA hydrogenation to GVL.

Double single-atom catalysts↗
DOE OSTI2022

Programmable heating and quenching for efficient thermochemical synthesis

Conventional thermochemical syntheses by continuous heating under near-equilibrium conditions face critical challenges in improving the synthesis rate, selectivity, catalyst stability and energy efficiency, owing to the lack of temporal control over the reaction temperature and time, and thus the reaction pathways. As an alternative, we present a non-equilibrium, continuous synthesis technique that uses pulsed heating and quenching (for example, 0.02 s on, 1.08 s off) using a programmable electric current to rapidly switch the reaction between high (for example, up to 2,400 K) and low temperatures. The rapid quenching ensures high selectivity and good catalyst stability, as well as lowers the average temperature to reduce the energy cost. Using CH4 pyrolysis as a model reaction, our programmable heating and quenching technique leads to high selectivity to value-added C2 products (>75% versus <35% by the conventional non-catalytic method and versus <60% by most conventional methods using optimized catalysts). Our technique can be extended to a range of thermochemical reactions, such as NH 3 synthesis, for which we achieve a stable and high synthesis rate of about 6,000 μmol g Fe –1 h –1 at ambient pressure for >100 h using a non-optimized catalyst. Furthermore, this study establishes a new model towards highly efficient non-equilibrium thermochemical synthesis.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1990

Fuel-rich catalytic combustion: A fuel processor for high-speed propulsion

Fuel-rich catalytic combustion of Jet-A fuel was studied over the equivalence ratio range 4.7 to 7.8, which yielded combustion temperatures of 1250 to 1060 K. The process was soot-free and the gaseous products were similar to those obtained in the iso-octane study. A carbon atom balance across the catalyst bed calculated for the gaseous products accounted for about 70 to 90 percent of the fuel carbon; the balance was condensed as a liquid in the cold trap. It was shown that 52 to 77 percent of the fuel carbon was C1, C2, and C3 molecules. The viability of using fuel-rich catalytic combustion as a technique for preheating a practical fuel to very high temperatures was demonstrated. Preliminary results from the scaled up version of the catalytic combustor produced a high-temperature fuel containing large amounts of hydrogen and carbon monoxide. The balance of the fuel was completely vaporized and in various stages of pyrolysis and oxidation. Visual observations indicate that there was no soot present.

Brabbs, Theodore A.↗
NASA NTRS1990

Fuel-rich catalytic combustion - A fuel processor for high-speed propulsion

Fuel-rich catalytic combustion of Jet-A fuel was studied over the equivalence ratio range 4.7 to 7.8, which yielded combustion temperatures of 1250 to 1060 K. The process was soot-free and the gaseous products were similar to those obtained in the iso-octane study. A carbon atom balance across the catalyst bed calculated for the gaseous products accounted for about 70 to 90 percent of the fuel carbon; the balance was condensed as a liquid in the cold trap. It was shown that 52 to 77 percent of the fuel carbon was C1, C2, and C3 molecules. The viability of using fuel-rich catalytic combustion as a technique for preheating a practical fuel to very high temperatuers was demonstrated. Preliminary results from the scaled up version of the catalytic combustor produced a high-temperature fuel containing large amounts of hydrogen and carbon monoxide. The balance of the fuel was completely vaporized and in various stages of pyrolysis and oxidation. Visual observations indicate that there was no soot present.

Brabbs, Theodore A.↗
NASA NTRS1989

Non-noble electrocatalysts for alkaline fuel cells

The doping of solid phase precursors followed by pyrolysis or the copyrolysis of gas phase precursors has allowed us to produce catalysts with good activity toward oxygen reduction. Efforts are currently underway to better understand the reasons for the catalytic activity of the bulk doped catalysts with a view toward further improving their activity.

Sarangapani, S.↗
DOE OSTI2022

Valorizing the carbon byproduct of methane pyrolysis in batteries

While low-cost natural gas remains abundant, the energy content of this fuel can be utilized without greenhouse gas emissions through the production of molecular hydrogen and solid carbon via methane pyrolysis. In the absence of a carbon tax, methane pyrolysis is not economically competitive with current hydrogen production methods unless the carbon byproducts can be valorized. In this work, we assess the viability of the carbon byproduct produced from methane pyrolysis in molten salts as high-value-added anode or conductive additive for secondary Li-ion and Na-ion batteries. Raman characterization and electrochemical differential capacity analysis demonstrate that the use of molten salt mixtures with catalytically-active FeCl 3 - or MnCl 2 result in more graphitic carbon co-products. These graphitic carbons exhibit the best electrochemical performance (up to 272 mAh/g of reversible capacity) when used as Li-ion anodes. For all carbon samples studied here, disordered carbon domains and retained salt species trapped and/or intercalated into the carbon structure were identified by X-ray photoelectron and multinuclear solid-state nuclear magnetic resonance spectroscopy. The latter lead to reduced electrochemical activity and reversibility, and poorer rate performance compared to commercial carbon anodes. The electronic conductivity of the pyrolyzed carbons is found to be highly dependent on their purity, with the purest carbon exhibiting an electronic conductivity nearly on par with that of commercial carbon additives. These findings suggest that more effective removal of the salt catalyst could enable applications of these carbons in secondary batteries, providing a financial incentive for the large-scale implementation of methane pyrolysis for “low-carbon” hydrogen production.

08 HYDROGEN↗
DOE OSTI2023

Facile and Scalable Synthesis of Metal- and Nitrogen-Doped Carbon Nanotubes for Efficient Electrochemical CO 2 Reduction

Metal- and nitrogen-doped carbon (M–N–C) is a promising material to catalyze electrochemical CO 2 reduction reaction (CO 2 RR). However, most M–N–C catalysts in the literature require complicated synthesis procedures and produce small quantities per batch, limiting the commercialization potential. In this work, we developed a simple and scalable synthesis method to convert metal-impurity-containing commercial carbon nanotubes (CNTs) and nitrogen-containing organic precursors into M–N–C via one-step moderate-temperature (650 °C) pyrolysis without any other treatment nor the need to add metal precursors. Batches of catalysts in varied mass up to 10 g (150 mL in volume) per batch were synthesized, and repeatable catalytic performances were demonstrated. To the best of our knowledge, the 10 g batch is one of the largest batches of CO2RR catalysts synthesized in the literature while requiring minimal synthesis steps. The catalyst possessed single-atomic iron–nitrogen (Fe–N) sites, enabling a high performance of >95% CO product selectivity at a high current density of 400 mA/cm 2 and high stability for 45 h at 100 mA/cm 2 in a flow cell testing. The catalyst outperformed a benchmark noble-metal nanoparticle catalyst and achieved longer stability than many other reported M–N–C catalysts in the literature. The scalable and cost-effective synthesis developed in this work paves a pathway toward practical CO 2 RR applications. The direct utilization of metal impurities from raw CNTs for efficient catalyst synthesis with minimal treatment is a green and sustainable engineering approach.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS2013

Trash-to-Gas: Converting Space Trash into Useful Products

NASA's Logistical Reduction and Repurposing (LRR) project is a collaborative effort in which NASA is determined to reduce total logistical mass through reduction, reuse and recycling of various wastes and components of long duration space missions and habitats. LRR is focusing on four distinct advanced areas of study: Advanced Clothing System, Logistics-to-Living, Heat Melt Compactor and Trash to Supply Gas (TtSG). The objective of TtSG is to develop technologies that convert material waste, human waste and food waste into high-value products. High-value products include life support oxygen and water, rocket fuels, raw material production feedstocks, and other energy sources. There are multiple pathways for converting waste to products involving single or multi-step processes. This paper discusses thermal oxidation methods of converting waste to methane. Different wastes, including food, food packaging, Maximum Absorbent Garments (MAGs), human waste simulants, and cotton washcloths have been evaluated in a thermal degradation reactor under conditions promoting pyrolysis, gasification or incineration. The goal was to evaluate the degradation processes at varying temperatures and ramp cycles and to maximize production of desirable products and minimize high molecular weight hydrocarbon (tar) production. Catalytic cracking was also evaluated to minimize tar production. The quantities of CO2, CO, CH4, and H2O were measured under the different thermal degradation conditions. The conversion efficiencies of these products were used to determine the best methods for producing desired products.

Caraccio, Anne J.↗
NASA NTRS2013

Trash to Gas: Converting Space Trash into Useful Products

NASA's Logistical Reduction and Repurposing (LRR) project is a collaborative effort in which NASA is determined to reduce total logistical mass through reduction, reuse and recycling of various wastes and components of long duration space missions and habitats. LRR is focusing on four distinct advanced areas of study: Advanced Clothing System, Logistics-to-Living, Heat Melt Compactor and Trash to Supply Gas (TtSG). The objective of TtSG is to develop technologies that convert material waste, human waste and food waste into high-value products. High-value products include life support oxygen and water, rocket fuels, raw material production feedstocks, and other energy sources. There are multiple pathways for converting waste to products involving single or multi-step processes. This paper discusses thermal oxidation methods of converting waste to methane. Different wastes, including food, food packaging, Maximum Absorbent Garments (MAGs), human waste simulants, and cotton washcloths have been evaluated in a thermal degradation reactor under conditions promoting pyrolysis, gasification or incineration. The goal was to evaluate the degradation processes at varying temperatures and ramp cycles and to maximize production of desirable products and minimize high molecular weight hydrocarbon (tar) production. Catalytic cracking was also evaluated to minimize tar production. The quantities of C02, CO, CH4, and H20 were measured under the different thermal degradation conditions. The conversion efficiencies of these products were used to determine the best methods for producing desired products.

Trash-to-Gas↗