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All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Direct Air Capture Using Trapped Small Amines in Hierarchical Nanoporous Capsules on Porous Electrospun Fibers (Final Technical Report)

This report summarizes the carbon capture research and development conducted by The State University of New York at Buffalo (UB) and GTI Energy (GTI) for award “DE-FE0031969: Direct Air Capture Using Trapped Small Amines in Hierarchical Nanoporous Capsules on Porous Electrospun Fibers” sponsored by the U.S. Department of Energy (DOE). The objective of this project is to develop an innovative sorbent structure of trapped small amines in HNC embedded in PEF for DAC. This involves tailoring both sorbent and PEF materials to achieve a compact system for DAC with high capacity for CO 2 at concentrations typically available in air and at near ambient conditions. An innovative sorbent structure of trapped small amines in hierarchical nanoporous capsules (HNC) embedded in porous electrospun fibers (PEF) was developed for direct air capture (DAC). This involves tailoring both sorbent and PEF materials to achieve a compact system for DAC with high capacity for CO 2 at concentrations typically available in air and at near ambient conditions. An interfacial polymerization process was developed, which utilized loaded amines inside mesoporous silica and trimesoyl chloride (TMC) dissolved in organic solvents as the precursors, to generate a polyamide (PA) coating layer on mesoporous silica and thus trap amines. Reaction conditions, including TMC concentration, organic solvents, reaction time, etc., for interfacial polymerization were optimized to effectively trap loaded amines, and cyclic heating-cooling operation was conducted to evaluate the coating quality. Larger pore volume mesoporous silica was also synthesized to increase amine loading and thus increase CO 2 capacity. The optimized sorbent material exhibited CO 2 capacity as high as 4.88 mmol/g under humid DAC conditions and negligible loss (<1%) during 10 cyclic heating-cooling operations. The optimized PA-coated sorbent also showed fast adsorption and desorption kinetics, with <20% t1/2 increase compared to uncoated sorbent. PEF fabrication conditions, including organic solvents for dissolving core and shell polymers, voltage, distance from the nozzle to the collection panel, etc. were adjusted to better incorporate HNC. After incorporating the optimized sorbent material into PEF, the structured sorbent had a CO 2 capacity of approximately 4.0 mmol/g under humid DAC conditions, with capacity loss of 0.17% per cycle and t1/2 increase less than 10%. A techno-economic analysis (TEA) for the process design for a DAC system based on our developed sorbent structure of trapped small amines in HNC embedded in PEF was conducted. The process design included process description and major equipment sizing and energy and mass balances in addition to scale-up research results and estimated capture cost. Aspen Adsorption Simulator was used to fit the experimentally measured breakthrough curves and extract equilibrium and kinetic data of the optimized sorbent. Our results indicated that for a DAC plant with CO 2 productivity of 3,000 tonne/year, the levelized cost of CO 2 capture was $\$$612/tonne, with the largest contribution of 44.33% from the fixed operation cost. Increasing CO 2 productivity, while maintaining similar fixed operation cost, is expected to significantly reduce the CO 2 capture cost. A sensitivity study was also conducted to understand the influence of total plant cost, sorbent cost, CO 2 concentration in the feed, sorbent mat lifetime, sorbent regeneration electricity, and adsorption blower pressure drop on the levelized cost of CO 2 capture, revealing a capture cost range of $\$$520-870/tonne.

36 MATERIALS SCIENCE↗
NASA NTRS2001

Characterization of a Laminate Flat Plate Diffusion Flame in Microgravity using PIV, Visible and CH Emissions

Motivated by fire safety concerns and the advent of long-term micro-gravity facilities, a cooperative program has been developed to study the mechanisms and material properties that control flow assisted (co-current) flame spread. This program has used as a common fire scenario a reacting steady-state boundary layer. Preliminary studies explored the aerodynamics of a reacting boundary layer by simulating a condensed fuel by means of a gas burner. Stability curves for ethane air flames were obtained and different burning regimes were identified. An important feature of this study was the independent identification of the different mechanisms leading to the instability of the flow. It was observed that fuel injection velocity and thermal expansion independently contributed to the separation of the flow at the leading edge of the burner. The occurrence of separation resulted in complex three-dimensional flow patterns that have a dominant effect on critical fire safety parameters such as the stand-off distance and flame length. This work was extended to a solid fuel (PMMA) leading to a Sounding Rocket experiment (Mini-Texus-6). The solid phase showed similar flow patterns, mostly present at low flow velocities (<100 mm/s) but the results clearly demonstrated that the thermal balance at the pyrolyzing fuel surface is the dominant mechanism that controls both stand-off distance and flame length. This thermal balance could be described in a global manner by means of a total mass transfer or "B" number. This "B" number incorporates surface re-radiation, radiative feedback and in-depth heat conduction as first prescribed by Emmons. The mass transfer number becomes the single parameter that determines the evolution of these fire safety variables (flame length, stand-off distance) and therefore can be used as a ranking criterion to assess the flammability of materials. The particular configuration is representative of the NASA upward flame spread test (Test 1) therefore this approach can be used in the interpretation of the results obtained from this test. Nevertheless, complete validation of this approach has not been fully achieved due, mainly because all the measurements necessary to compare with the theoretical predictions have not been obtained. Following these studies two different directions have been taken. The first attempts to elucidate the details of the gas phase combustion reaction and the associated flow field by means of quantitative and qualitative measurements. The second approach, a more practical one, is to apply this methodology to the assessment of material flammability. The former is currently being conducted with a gas burner because it allows for easier control and longer experimentation time. The results obtained so far will be presented in more detail. The latter is a new program therefore only a brief summary of the objectives will be presented.

Joulain, P.↗
NASA NTRS1994

Theoretical, observational, and isotopic estimates of the lifetime of the solar nebula

There are a variety of isotopic data for meteorites which suggest that the protostellar nebula existed and was involved in making planetary materials for some 10(exp 7) yr or more. Many cosmochemists, however, advocate alternative interpretations of such data in order to comply with a perceived constraint, from theoretical considerations, that the nebula existed only for a much shorter time, usually stated as less than or = 10(exp 6) yr. In this paper, we review evidence relevant to solar nebula duration which is available through three different disciplines: theoretical modelling of star formation, isotopic data from meteorites, and astronomical observations of T Tauri stars. Theoretical models based on observations of present star-forming regions indicate that stars like the Sun form by dynamical gravitational collapse of dense cores of cold molecular clouds in the interstellar medium. The collapse to a star and disk occurs rapidly on a time scale of the order 10(exp 5) yr. Disks evolve by dissipating energy while redistributing angular momentum, but it is difficult to predict the rate of evolution, particularly for low mass (compared to the star) disks which nonetheless still contain enough material to account for the observed planetary system. There is no compelling evidence, from available theories of disk structure and evolution, that the solar nebula must have evolved rapidly and could not have persisted for more than 1 Ma. In considering chronologically relevant isotopic data for meteorites, we focus on three methodologies: absolute ages by U-Pb/Pb-Pb, and relative ages by short-lived radionuclides (especially Al-26) and by evolution of Sr-87/Sr-86. Two kinds of meteoritic materials-refractory inclusions such as CAIs and differentiated meteorites (eucrites and angrites) - appear to have experience potentially dateable nebular events. In both case, the most straightforward interpretations of the available data indicate nebular events spanning several Ma. We also consider alternative interpretations, particularly the hypothesis of radically heterogeneous distribution of Al-26, which would avoid these chronological interpretations. The principal impetus for such alternative interpretations seems to be precisely the obviation of the chronological interpretation (i.e., the presumption rather than the inference of a short (less than or = Ma) lifetime of the nebula). Astronomical observations of T Tauri stars indicate that the presence of dusty disks is a common if not universal feature, that the disks are massive enough to accomodate a planetary system such as ours, and that at least some persist for 10(exp 7) yr or more. The results are consistent with the time scales inferred from the meteorite isotopic data. They cannot be considered conclusive with regard to solar nebula time scales, however,in part because it is difficult to relate disk observations to processes that affect meteorites, and in part because the ages assigned for these stars could be wrong by a factor of several in either direction. We conclude that the balance of available evidence favors the view that the nebula existed and was active for at least several Ma. However, because the evidence is not definitive, it is important that the issue be perceived to be an open question, whose answer should be sought rather than presumed.

Podosek, Frank A.↗
NASA NTRS2019

Subsurface Cl-bearing salts as potential contributors to recurring slope lineae (RSL) on Mars

We report laboratory experimental results that support a brine-related hypothesis for the recurring slope lineae (RSL) on Mars in which the subsurface Cl-salts, i.e., hydrous chlorides and oxychlorine salts (HyCOS) are the potential source materials. Our experiments revealed that within the observed RSL temperature window TRSL (250–300 K), the deliquescence of HyCOS could occur in relative humidity ranges (RH≥22%–46%) much lower than those for hydrous (Mg, Fe)-sulfates (RH≥75%–96%). In addition, we demonstrated that the RH values kept by common HyCOS and hydrous sulfates in enclosures have a general trend as RH(sulfates) > RH(perchlorates) > RH(chlorides) (with same type of cation) in wide T range. It means that the required RH range for a Cl-bearing salt to deliquescence can be satisfied by a co-existing salt of different type, e.g., in the subsurface layers of mixed salts on Mars. Furthermore, we found a strong temperature dependence of the deliquescence rates for all tested HyCOS, e.g., a duration of 1–5 sols for all HyCOS at the high end (300 K) of TRSL, and of 20–70 sols for all tested HyCOS (except NaClO4·H2O) at the low end (250 K) of TRSL, which is consistent with the observed seasonal behavior of RSL on Mars. From a mass-balance point of view, the currently observed evidences on Mars do not support a fully-brine-wetted track model, thus we suggest a brine-triggered granular-flow model for the most RSL. Considering the recurrence of RSL in consecutive martian years, our experimental results support the rehydration of remnant HyCOS layers during a martian cold season through H2O vapor-to-salt direct interaction. We found that the evidences of HyCOS rehydration under Mars relevant P-T-RH conditions are detectable in a few minutes by in situ Raman spectroscopy. This rehydration would facilitate the recharge of H2O back into subsurface HyCOS, which could serve as the source material to trigger RSL in a subsequent warm season. The major limiting factor for this rehydration is the H2O supply, i.e., the H2O vapor density carried by current Mars atmospheric circulation and the diffusion rate of H2O vapor into the salt-rich subsurface in a cold season. In a worst-case scenario, these H2O supplies can support a maximum increase of hydration degrees of two for totally dehydrated HyCOS, whereas the full rehydration of subsurface HyCOS layers can be easily reached during a>30° obliquity period that has H2O vapor density 10× to 20× times the value of current obliquity. Overall, our results imply the existence of a large amount of Cl-bearing salts in the subsurface at RSL sites.

Alian Wang↗
NASA NTRS1994

Theoretical, observational, and isotopic estimates of the lifetime of the solar nebula

There are a variety of isotopic data for meteorites which suggest that the protostellar nebula existed and was involved in making planetary materials for some 10(exp 7) yr or more. Many cosmochemists, however, advocate alternative interpretations of such data in order to comply with a perceived constraint, from theoretical considerations, that the nebula existed only for a much shorter time, usually stated as less than or equal to 10(exp 6) yr. In this paper, we review evidence relevant to solar nebula duration which is available through three different disciplines: theoretical modeling of star formation, isotopic data from meteorites, and astronomical observations of T Tauri stars. Theoretical models based on observations of present star-forming regions indicate that stars like the Sun form by dynamical gravitational collapse of dense cores of cold molcular clouds in the interstellar clouds in the interstellar medium. The collapse to a star and disk occurs rapidly, on a time scale of the order 10(exp 5) yr. Disks evolve by dissipating energy while redistributing angular momentum, but it is difficult to predict the rate of evolution, particularly for low mass (compared to the star) disks which nonetheless still contain enough material to account for the observed planetary system. There is no compelling evidence, from available theories of disk structure and evolution, that the solar nebula must have evolved rapidly and could not have persisted for more than 1 Ma. In considering chronoloically relevant isotopic data for meteorites, we focus on three methodologies: absolute ages by U-Pb/Pb-Pb, and relative ages by short-lived radionuclides (especially Al-26) and by evolution of Sr-87/Sr-86. Two kinds of meteoritic materials-refractory inclusions such as CAIs and differential meteorites (eucrites and augrites) -- appear to have experienced potentially dateable nebular events. In both cases, the most straightforward interpretations of the available data indicate nebular events spanning several Ma. We also consider alternative interpretations, particularly the hypothesis of radically heterogeneous distribution of Al-26, which would avoid these chronological interpretations. The principal impetus for such alternative interpretations seems to be precisely the obviation of the chronological interpretation (i.e., the presumption rather than the inference of a short (less than or equal to 1 Ma) lifetime of the nebula). Astronomical observations of T Tauri stars indicate that the presence of dusty disks is a common if not universal feature, that the disks are massive enough to accomodate a planetary system such as ours, and that at least some persist for 110(exp 7) yr or more. The results are consistent with the time scales inferred from the meteoritic isotopic data. They cannot be considered conclusive with regard to solar nebula time scales, however, in part because it is difficult to relate disk observations to processes that affect meteorites, and in part because the ages assigned for these stars could be wrong by a factor of several in either direction. We conclude that the balance of available evidence favors the view that the nebula existed and was active for at least several Ma. However, because the evidence is not definitive, it is important that the issue be perceived to be an open question, whose answer should be sought rather than presumed.

Podosek, Frank A.↗
NASA NTRS2000

Convective Melting of Particles in Flow Under Microgravity Conditions

Study of melting of dispersed or packed solid particles in a fluid under gravity and microgravity conditions provides benchmark information for many engineering applications such as material processing, environmental assessment and protection and space fire protection. During such processes, packed or dispersed solid particles are interacting with fluid flow at above-melting temperatures. By unmasking the buoyancy effects in coupled flow, phase change and heat transport phenomena, a better understanding of melting rate in non-thermal equilibrium, convective conditions can be studied. A series of flight experiments were conducted onboard the NASA KC-135 Microgravity Research Airplane. The Particle Melting in Plow (PMF) module was designed to allow flow through the initially packed ice particles at controlled temperature and velocity. To achieve this, a close-loop flow system was designed. Video images were taken to record the visualization of the melting process, from which a time variation of packed particle thickness distribution at different times can be obtained by the image analysis method. The fluid temperature distribution within the melting zone is measured by thermocouples. An infrared camera was mounted from the top of the test section to record the ice-water thermal images at a given location. The results from thermal images yield local temperature variation between melting solid and liquid and local Stephan number. Typical results for a number of cases are presented. The mathematical model, describing mass, energy, and momentum balance equations for the liquid and solid phases, is presented. It is found that melting rate is influenced mainly by the ratio of Reynolds number (based on the initial particle diameter) to the Froud number, and Stephan number. At the absence of gravity, Froud number approaches zero, Reynolds number and Stephan number become dominant factors governing the melting rate. The numerically determined results are compared with the experimental ones. It is found that the discrepancy between the predicted and measured melting rate is largely due to the inaccuracy in the constitutive equations for effective thermal physical properties, such as effective thermal conductivity and diffusivity, and transport properties, such as particle interaction coefficient, and local heat transfer coefficient of particles.

Stewart, C.↗
DOE OSTI2022

A pilot-process for calcium hydroxide production from iron slag by low-temperature precipitation

The production of Ca(OH) 2 via thermal decomposition of limestone is an energy intensive process resulting in significant CO 2 emissions. However, if produced in a manner that obviates the need for the thermal decomposition of limestone, Ca(OH) 2 could be a “CO 2 -negative” material. Herein, we design and demonstrate the operation of a continuous, low-temperature (< 100 °C), aqueous-phase pilot-process to produce Ca(OH) 2 using calcium extracted from alkaline industrial wastes. The three-step process encompasses unit operations including: (i) calcium leaching from basic oxygen furnace BOF slag, (ii) leachate concentration by reverse osmosis (RO), and (iii) Ca(OH) 2 precipitation by temperature swing. Here this process presents several advantages compared to the traditional route. First, it advances the recycling of waste from the steel industry. Second, it operates significantly below the temperature used in conventional lime production (900 °C) as it bypasses limestone calcination, responsible for ~65% of the CO 2 emissions from the current process. Thus, the new process has a lower CO 2 footprint and enables the use of industrial waste heat. The mass and energy balances were quantified to reveal that increasing the calcium concentration of the feed solution and the precipitation temperature, decrease the energy demands of the RO step, thereby reducing the process’s overall CO 2 footprint. The pilot system operated continuously and achieved a production rate of nearly 1 kg per day of Ca(OH) 2 with a purity greater than 95 wt%. The average particle size of the precipitates depended on the residence time in the precipitation reactor, demonstrating an ability to produce size-controlled particulates. Importantly, the process achieved full water recirculation/reutilization level indicative of a low-consumable water demand. The outcomes offer new insights and understanding relevant to developing and upscaling low-CO 2 processes for cement, lime, and portlandite.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS2017

Supportability Challenges, Metrics, and Key Decisions for Future Human Spaceflight

Future crewed missions beyond Low Earth Orbit (LEO) represent a logistical challenge that is unprecedented in human space flight. Astronauts will travel farther and stay in space for longer than any previous mission, far from timely abort or resupply from Earth. Under these conditions, supportability { defined as the set of system characteristics that influence the logistics and support required to enable safe and effective operations of systems { will be a much more significant driver of space system lifecycle properties than it has been in the past. This paper presents an overview of supportability for future human space flight. The particular challenges of future missions are discussed, with the differences between past, present, and future missions highlighted. The relationship between supportability metrics and mission cost, performance, schedule, and risk is also discussed. A set of pro- posed strategies for managing supportability is presented (including reliability growth, uncertainty reduction, level of repair, commonality, redundancy, In-Space Manufacturing (ISM) (including the use of material recycling and In-Situ Resource Utilization (ISRU) for spares and maintenance items), reduced complexity, and spares inventory decisions such as the use of predeployed or cached spares - along with a discussion of the potential impacts of each of those strategies. References are provided to various sources that describe these supportability metrics and strategies, as well as associated modeling and optimization techniques, in greater detail. Overall, supportability is an emergent system characteristic and a holistic challenge for future system development. System designers and mission planners must carefully consider and balance the supportability metrics and decisions described in this paper in order to enable safe and effective beyond-LEO human space flight.

Owens, Andrew C.↗
NASA NTRS1991

Areas of Seal R/D at GE

About four years ago, work was completed on a 36 inch diameter gas to gas carbon ring seal used to buffer low pressure turbine air at the rim of the forward outer flowpath on the GE36 unducted fan (UDF) engine. At about the same time, we were developing a long life counter-rotating intershaft air-oil seal of approximately 7.6 inch diameter for operation at 800 fps, 800 F, and 50 psid. Although we were successful in meeting most program goals with a split ring seal of the axial bushing type, the seal with the greatest payoff in life and air leakage rates, bearing many features in common with the GE36 seal, could not be successfully tested because of the structural weakness of the primary seal ring carbon material. This was a split ring seal using a hybrid combination of orifice compensated hydrostatic and shrouded hydrodynamic gas bearings. We are presently working to develop this design in conjunction with high strength materials being developed by Pure Carbon Co. In the area of engine secondary gas flow path-sealing for performance improvement, we are currently working with carbon and all metal face seals. A 15 inch diameter all metal 'aspirating' face seal, using self-acting hydrostatic bearings, was successfully tested to 700 fps, 100 psid, and 1000 F, demonstrating long life at flow reduction of 86 percent compared to a 'best' labyrinth. This seal will be developed through 1400 F, 900 fps, and 350 psid. The seal 'aspirates' closed at about idle speed pressure during engine start and reopens at engine shutdown. A hydraulic thrust balance seal, currently using orifice compensated hydrostatics, is under development. Other aspects of these projects are briefly covered.

Pope, A. Nelson↗
DOE OSTI2026

Interfacial Inversion of Stealth Surfactants

Amphiphilic macromolecular surfactants segregate to liquid–liquid interfaces, thereby reducing the interfacial tension and free energy. Here, we investigated “stealth surfactants” in the form of core–shell bottlebrush polymers comprised of pH-responsive diblock copolymer side chains forming a hydrophilic core and a hydrophobic shell, enabling solubility in oil. At liquid–liquid interfaces, these polymers undergo a structural “inversion”, with hydrophilic blocks segregating into the aqueous phase and hydrophobic blocks residing in the oil phase. The reconfiguration kinetics and surfactant properties are influenced by multiple factors, including the molecular weights of the backbone and side chain components, the hydrophilic-to-hydrophobic balance of the side chains, and the pH of the aqueous phase. An observed nonmonotonic dependence of interfacial tension with time is attributed to a progressive structural inversion, where the projected area of the macromolecule onto the interface decreases. To validate this inversion hypothesis, interfacial properties were characterized by sum-frequency generation vibrational spectroscopy, which revealed configurational changes of the core–shell bottlebrush polymers at the fluid interface and revealed a pH-dependent interfacial coverage. Coarse-grained molecular dynamics simulations supported these experimental findings, showing that the pH-responsive core and hydrophobic shell assume a time-averaged configuration with orientations parallel and perpendicular to the plane of the interface, respectively. These findings open routes to design multistimuli-responsive polymeric surfactants and compatibilizers, expanding their potential applications in advanced interfacial systems.

Stealth surfactants↗
DOE OSTI2025

Toucan: A performance portable, scalable implementation of the DECA algorithm

In the field of additive manufacturing (AM), cellular automata (CA) is extensively used to simulate microstructural evolution during solidification. However, while traditional CA approaches are relatively fast, they still require a substantial number of time steps, are limited to moderate volumes, and are relatively difficult to improve through parallelism due to the highly localized nature of the solidification front. Here, to address these issues of time to solution and load balancing, we introduce Toucan, a parallel, performance-portable, and scalable code written in C++ with the Kokkos library that leverages the discrete event inspired cellular automata (DECA) algorithm to perform parallel-in-time (PinT) grain growth simulations. Toucan effectively mitigates load balancing issues by distributing the computational workload more evenly across processors, enhancing scalability and efficiency. We conduct both strong and weak scaling studies on up to 64 GPUs on the Frontier supercomputer, demonstrating that Toucan significantly outperforms the current state-of-the-art, time-stepped CA code, ExaCA, on both single and multi-GPU simulations. Even in AM-specific weak scaling scenarios, Toucan maintains near-ideal scaling, in contrast to the linear increase observed with ExaCA due to the moving laser raster pattern. This study highlights Toucan’s potential to transform microstructural simulations in AM by radically improving both efficiency and scalability over existing methods.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Particle scale impacts on deconstruction energy of pine residues

The goal of this Case Study was to quantify the impacts of variable moisture and ash on hammer mill throughput and energy consumption and on generation of fines that are not able to be fed to conversion, as compared to a status quo Base Case system. Also considered was convertible carbon content (minimum carbon specification) and maximum ash content and the delivered feedstock cost impacts of not being able to feed residue not meeting both specifications to the conversion reactor. Laboratory data on the impacts of input particle size and moisture content on the exit particle size were received from FCIC Subtask 5.2 from their single particle impact population balance modeling study. Additional throughput and energy consumption data were obtained from FCIC Subtask 5.2 for the same grinder with a 6 mm screen in place. These data were utilized to develop the necessary response surface equations to perform throughput analysis using discrete event simulation. Because the ash contents in the separated fines had not been analyzed in the laboratory at the time of the model runs, we chose to assume that the ash distributed proportionally with total mass into the overs and unders in the disk screen following grinding. Key takeaways from this Case Study are that it is significantly more cost effective to hammer mill the residue prior to drying, even though the grinder throughput is lower and energy consumption is higher versus drying first before grinding. An effect of dry grinding versus high moisture grinding is the production of higher amounts of fines during dry grinding, leading to significantly more of the ground feedstock being rejected by conversion for being below a minimum particle size. With wet grinding the system is still able to produce more preprocessed feedstock meeting the minimum particle size specification even though the instantaneous throughput is lower than for the case of grinding dry feedstock. Additionally, even without the higher fines production from dry grinding, the status quo would still be more costly than wet grinding because the material is rejected after the drying energy has already been input for the dry grinding case. Finally, significant reductions in drying energy are obtained by drying after grinding, and those reductions are of far greater magnitude than the grinding energy increase.

09 BIOMASS FUELS↗
NASA NTRS1994

The growth of zeolites A, X and mordenite in space

Zeolites are a class of crystalline aluminosilicate materials that form the backbone of the chemical process industry worldwide. They are used primarily as adsorbents and catalysts and support to a significant extent the positive balance of trade realized by the chemical industry in the United States (around $19 billion in 1991). The magnitude of their efforts can be appreciated when one realizes that since their introduction as 'cracking catalysts' in the early 1960's, they have saved the equivalent of 60 percent of the total oil production from Alaska's North Slope. Thus the performance of zeolite catalysts can have a profound effect on the U.S. economy. It is estimated that a 1 percent increase in yield of the gasoline fraction per barrel of oil would represent a savings of 22 million barrels of crude oil per year, representing a reduction of $400 million in the United States' balance of payments. Thus any activity that results in improvement in zeolite catalyst performance is of significant scientific and industrial interest. In addition, due to their 'stability,' uniformity, and, within limits, their 'engineerable' structures, zeolites are being tested as potential adsorbents to purify gases and liquids at the parts-per-billion levels needed in today's electronic, biomedical, and biotechnology industries and for the environment. Other exotic applications, such as host materials for quantum-confined semiconductor atomic arrays, are also being investigated. Because of the importance of this class of material, extensive efforts have been made to characterize their structures and to understand their nucleation and growth mechanisms, so as to be able to custom-make zeolites for a desired application. To date, both the nucleation mechanics and chemistry (such as what are the 'key' nutrients) are, as yet, still unknown for many, if not all, systems. The problem is compounded because there is usually a 'gel' phase present that is assumed to control the degree of supersaturation, and this gel undergoes a continuous 'polymerization' type reaction during nucleation and growth. Generally, for structure characterization and diffusion studies, which are useful in evaluating zeolites for improving yield in petroleum refining as well as for many of the proposed new applications (e.g., catalytic membranes, molecular electronics, chemical sensors) large zeolites (greater than 100 to 1000 times normal size) with minimum lattice defects are desired. Presently, the lack of understanding of zeolite nucleation and growth precludes the custom design of zeolites for these or other uses. It was hypothesized that the microgravity levels achieved in an orbiting spacecraft could help to isolate the possible effects of natural convection (which affects defect formation) and minimize sedimentation, which occurs since zeolites are twice as dense as the solution from which they are formed. This was expected to promote larger crystals by allowing growing crystals a longer residence time in a high-concentration nutrient field. Thus it was hypothesized that the microgravity environment of Earth orbit would allow the growth of large, more defect-free zeolite crystals in high yield.

Sacco, Albert, Jr.↗
DOE OSTI2023

IPL-Annealed Mixed-Cation Perovskites with Robust Coating Window toward Scalable Manufacturing of Commercial Perovskite Solar Cells

Perovskite solar cells (PSCs) are a promising alternative solar technology, but the technical challenges of (1) stability/durability, (2) efficiency at scale, and (3) manufacturability must be overcome to achieve widespread PSC commercialization. The challenge of balancing solution ink formulation and scalable manufacturing is often overlooked in the literature, where focus is on adopting inks from processes that will not scale. In this study, we apply a classical roll-to-roll manufacturing perspective, utilizing both compositional engineering and intense pulsed light (IPL) annealing, to develop a mixed-cation perovskite ink with a robust coating window that simultaneously solve issues of stability and manufacturability for PSCs. Our method resulted in blade-coated, flexible, mixed-cation PSCs on ITO-PET substrates with a champion power conversion efficiency (PCE) efficiency of 16.7% using IPL annealing of the absorber layer and, to our knowledge, is one of the fastest processing methods for the perovskite layer. This overall reduction in processing time with a stable ink represents an advance toward the scaled production of perovskite solar cells on flexible substrates.

flexible perovskite solar cells↗
DOE OSTI2026

Conductivity Spectroscopy for Investigation and Discovery of Photovoltaic Materials

Conductivity spectroscopy is an extremely powerful set of methods for probing the properties of optoelectronic materials, especially photovoltaics, where photoconductivity is one of the best spectroscopic proxies for performance. Despite this power, they are substantially less commonly used than time-resolved photoluminescence (for instance) because they tend to be more expensive to implement (THz) and/or require specialized knowledge (GHz) to construct instruments, which are not widely available. The goal of this review is to illustrate the utility of these experiments in the discovery and study of photovoltaic absorber materials and simultaneously make them more accessible to the community by providing a central tutorial resource. We provide a comprehensive review of how conductivity spectroscopy has developed over the past decade and been applied in the discovery and development of photovoltaic materials, with a primary focus on emerging solution-processable technologies. Along the way we aim to demystify conductivity spectroscopy with focused tutorial sections that explain the physical models used to fit the data and illustrate how to think about “high-frequency conductivity”.

14 SOLAR ENERGY↗
DOE OSTI2023

Development of an All-Aqueous Thermally Regenerative Redox Flow Battery to Support Fossil Fuel Assets

Low-temperature thermal energy, a largely untapped resource, holds significant promise for large-scale electrical power generation globally. Various stationary sources, including industrial entities and thermal power plants, emit considerable low-temperature heat that currently remains unutilized. This energy is often overlooked because its low temperature renders it unsuitable for efficient power generation using conventional methods. However, current research is exploring diverse technologies capable of converting low-temperature heat into grid-scale power, aiming to enhance grid efficiency, further decarbonization initiatives, and facilitate a shift toward more decentralized power systems. One such innovative technology is the thermally regenerative battery (TRB), noted for its high power and energy densities compared to similar technologies, positioning it as a potential game-changer in power generation. TRBs integrate two scalable and well-established unit operations: a redox flow battery and a distillation column. This integration suggests that once an effective TRB chemistry is established, the pathway to commercialization could be expedited. The copper-based thermally regenerative ammonia battery (Cu aq -TRAB) stands out as the first TRB that circumvents electrodeposition/dissolution reactions, stabilizing Cu(I) and Cu(II) within the electrolyte and maintaining stability of all electroactive species in an aqueous phase. This stabilization has led to improvements in coulombic efficiency, open circuit potential, and copper solubility, thereby enhancing power density, energy density, and overall energy efficiency. Preliminary tests were conducted to determine the effects of various electrolyte species on the performance metrics of the battery, both theoretically and experimentally. These tests revealed that the solubility of copper in the Cu aq -TRAB electrolyte was constrained by the Cu(I)-NH 3 complex. Adjusting the background electrolyte to 5 M NH4Br and the ligand concentration to 4 M NH 3 enabled the copper concentration to reach a maximum of 0.6 M. This modification led to an estimated theoretical maximum energy density of 9.5 Wh L -1 for the Cu aq -TRAB. Additionally, full cell testing indicated a tradeoff between peak power and energy density with varying copper and ammonia concentrations. Increasing the applied current density during discharge linearly raised the average power output, with a minimal reduction in energy density due to a balance between higher ohmic overpotential and reduced time for undesirable ammonia crossover. Furthermore, a comprehensive numerical sensitivity analysis of the complete Cu aq -TRAB system was performed. This analysis aimed to assess how the battery and the distillation column responded to changes in system input parameters, providing insights into optimal research directions for enhancing system performance. The analysis revealed that at room temperature, battery power was significantly more sensitive to ohmic losses than to mass transfer, with reaction rates having minimal impact. This trend continued even at higher temperatures. Also, the thermal energy required for ammonia separation was studied, showing that increased temperatures generally reduced energy requirements, except in low-pressure scenarios above 65 °C. An investigation into membrane performance in the Cu aq -TRAB was undertaken, given the significant impact of ammonia transport control and ohmic losses on system performance. Various membranes were evaluated to identify key performance metrics. Among the tested membranes, Selemion CMVN exhibited the highest performance, with a peak power density of 84 mW cm -2 and average values of 26 ± 6.8 mW cm -2 for power density and 2.9 Wh L -1 for energy density at an applied current density of 50 mA cm -2 . An economic assessment indicated a levelized cost of storage at $410 per MWh under optimal conditions, highlighting the commercial potential of the Cu aq -TRAB when utilizing cost-effective, readily available materials.

25 ENERGY STORAGE↗
DOE OSTI2024

Nano-enhanced solid-state hydrogen storage: Balancing discovery and pragmatism for future energy solutions

Nanomaterials have revolutionized the battery industry by enhancing energy storage capacities and charging speeds, and their application in hydrogen (H 2 ) storage likewise holds strong potential, though with distinct challenges and mechanisms. H 2 is a crucial future zero-carbon energy vector given its high gravimetric energy density, which far exceeds that of liquid hydrocarbons. However, its low volumetric energy density in gaseous form currently requires storage under high pressure or at low temperature. This review critically examines the current and prospective landscapes of solid-state H 2 storage technologies, with a focus on pragmatic integration of advanced materials such as metal-organic frameworks (MOFs), magnesium-based hybrids, and novel sorbents into future energy networks. These materials, enhanced by nanotechnology, could significantly improve the efficiency and capacity of H 2 storage systems by optimizing H 2 adsorption at the nanoscale and improving the kinetics of H 2 uptake and release. We discuss various H 2 storage mechanisms—physisorption, chemisorption, and the Kubas interaction—analyzing their impact on the energy efficiency and scalability of storage solutions. The review also addresses the potential of “smart MOFs”, single-atom catalyst-doped metal hydrides, MXenes and entropy-driven alloys to enhance the performance and broaden the application range of H 2 storage systems, stressing the need for innovative materials and system integration to satisfy future energy demands. High-throughput screening, combined with machine learning algorithms, is noted as a promising approach to identify patterns and predict the behavior of novel materials under various conditions, significantly reducing the time and cost associated with experimental trials. In closing, we discuss the increasing involvement of various companies in solid-state H 2 storage, particularly in prototype vehicles, from a techno-economic perspective. In conclusion, this forward-looking perspective underscores the necessity for ongoing material innovation and system optimization to meet the stringent energy demands and ambitious sustainability targets increasingly in demand.

25 ENERGY STORAGE↗
DOE OSTI2021

Data Mining of Polymer Phase Transitions upon Temperature Changes by Small and Wide-Angle X-ray Scattering Combined with Raman Spectroscopy

The complex physical transformations of polymers upon external thermodynamic changes are related to the molecular length of the polymer and its associated multifaceted energetic balance. The understanding of subtle transitions or multistep phase transformation requires real-time phenomenological studies using a multi-technique approach that covers several length-scales and chemical states. A combination of X-ray scattering techniques with Raman spectroscopy and Differential Scanning Calorimetry was conducted to correlate the structural changes from the conformational chain to the polymer crystal and mesoscale organization. Current research applications and the experimental combination of Raman spectroscopy with simultaneous SAXS/WAXS measurements coupled to a DSC is discussed. In particular, we show that in order to obtain the maximum benefit from simultaneously obtained high-quality data sets from different techniques, one should look beyond traditional analysis techniques and instead apply multivariate analysis. Data mining strategies can be applied to develop methods to control polymer processing in an industrial context. Crystallization studies of a PVDF blend with a fluoroelastomer, known to feature complex phase transitions, were used to validate the combined approach and further analyzed by MVA.

36 MATERIALS SCIENCE↗