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Significant progress was made toward the development of a commercially marketable hydrogen nickel oxide battery. The costs projected for this battery are remarkably low when one considers where the learning curve is for commercialization of this system. Further developmental efforts on this project are warranted as the H2/NiO battery is already cost competitive with other battery systems.
The iron and steel industry is an important manufacturing sector and one of the largest energy consumers in the United States and globally. Hydrogen direct reduction of iron ore (H2DRI) is considered a promising process that could enhance domestic steel production. This process requires hydrogen inlet temperatures up to 950 degrees C to drive the endothermic reduction of the iron ore pellets. In this work we investigate the technoeconomic performance of an H2DRI plant using electric thermal energy storage (ETES) technologies for the hydrogen heating, compared to conventional natural gas fired heaters, hydrogen fired heaters, and electric hydrogen heaters. A technoeconomic analysis framework for the plant is developed and used in multiple case studies, covering different hydrogen prices, grid electricity profiles, and financing scenarios. The levelized cost of steel production is found out to be in the range of $775-950/mt, which is mostly inside the benchmarked steel price of $941/mt. ETES-based hydrogen heating is found to be in par with conventional natural gas fired heaters, and cheaper than hydrogen fired heaters and electric hydrogen heaters. The major cost drivers are the iron ore and hydrogen feedstock, followed by the hydrogen compression and heating capital. Several insights and suggested future directions are identified.
Iron and steel production are responsible for 90 million MtCO2 per year in the United States. Hydrogen direct reduction of iron (H2DRI) is a promising pathway for a more sustainable iron production than commercially deployed technologies which rely on natural gas. The H2DRI process requires hydrogen at a temperature of up to 950 degrees C fed into a reduction furnace to produce pellets or briquettes that are used in the downstream iron and steelmaking process. In this work, we propose to use an electrical thermal energy storage (ETES) system, that can use renewable electricity to store high-temperature heat and dispatch it upon demand. Such a system can buffer the H2DRI plant from the variability of electricity prices by charging during curtailment and running the plant from storage during times of peak electricity price. We have developed heat transfer models for two different ETES systems that can be used to heat up hydrogen to the required temperatures: a particle-based ETES and a firebrick ETES. These models are used to evaluate the performance of such a system and support the sizing and preliminary cost estimation. The preliminary results using both models show that designing ETES systems for an industrial-scale H2DRI furnace is feasible. The firebrick ETES system has limited operational duration, which might limit the price buffering effect unless significantly oversized. The particle ETES system heat exchanger has industry-feasible dimensions, but its storage capacity would be decided upon the number of particle storage silos.
Stereocontrol is of critical importance in organic synthesis. In this study, we demonstrate how heterogeneous electrochemical hydrogenation enables diastereocontrol simply by tuning electrochemical hydrogenation mechanisms without altering the adsorption conformation of a reactant on the electrode. We use 4-hydroxy-1-tetralone (4-OH-tetralone) as a model reactant, where diastereomers can be produced during the hydrogenation of the carbonyl group. In traditional thermocatalytic hydrogenation, H 2 first dissociates on the catalyst surface to form surface-adsorbed hydrogen (H*), and therefore, H* is always added to the organic reactant from the catalyst side via hydrogen atom transfer (HAT). Thus, in order to flip the diastereoselectivity, the adsorbed reactant itself must be physically flipped. In contrast, electrochemical hydrogenation can occur either via HAT, where H is added from the electrode surface, or via proton-coupled electron transfer (PCET), where H is added from the solution side of the adsorbed reactant. Thus, without changing the adsorption conformation of the reactant, opposite diastereomers can be obtained by switching the hydrogenation mechanism (HAT vs PCET). In this work, using a combination of experimental and computational studies, we demonstrate two examples of flipping diastereoselectivity by different electrochemical hydrogenation mechanisms. In the first case, we achieve opposite diastereoselectivities using metals that adopt different hydrogenation mechanisms (HAT vs PCET). In the second case, we flip the diastereoselectivity by varying the applied potential, which switches one hydrogenation mechanism to the other on the same metal electrode. In each case, our results offer an atomic-level understanding of the preferred hydrogenation mechanism that enables the corresponding diastereoselectivity.
Magnetic nanoplatelets hold significant potential for various technical applications due to their ability to switch between a fully magnetized state with high magnetization and a vortex‐like configuration that eliminates stray fields in the absence of an external field. This study presents the synthesis of uniform CoNi nanoplatelets through the topotactic reduction of metal hydroxides using hydrogen plasma. The reduction process is analyzed via magnetometry, leveraging the transition from paramagnetic hydroxide to ferromagnetic metal. Lorentz transmission electron microscopy and scanning transmission X‐ray microscopy confirm the presence of magnetic vortex‐like structures in isolated Co 0.85 Ni 0.15 nanoplatelets at ambient temperature. Additionally, micromagnetic simulations are conducted to further explore the magnetic properties of the nanoplatelets, revealing the formation of magnetic vortex remanent states at diameters between 200 nm and 1 μm and a thickness of around 12 nm. Notably, structural defects and thickness variations do not directly destabilize the magnetic vortex configurations.
This project, funded by the U.S. Department of Energy (DOE) – Office of Fossil Energy under Award Number DE-FE0032177, aimed to assess the feasibility of an integrated Laser-Induced Breakdown Spectroscopy (LIBS) system with advanced machine learning (ML) models for real-time characterization and potential control of hydrogen gasifiers running on waste materials as feedstocks. This was a multidisciplinary effort that encompassed the acquisition and standardized analysis of individual and blended feedstocks—comprising biomass, coal waste, and plastic waste, followed by the development of a dynamic LIBS bench system for material sample analysis and development of predictive ML models. Comprehensive laboratory testing enabled the creation of a robust elemental dataset that served as the foundation for ML model training. Techniques such as Random Forest, Gradient Boosting, Support Vector Regression, and Neural Networks were employed to predict key feedstock properties, including higher heating value (HHV), moisture content, thermal conductivity, and ash composition with high accuracy. The results were validated against experimental data and demonstrated strong potential for real-time application in gasifier control systems. The project concluded with a study on the integration of the LIBS+ML approach for gasifier control and a techno-economic analysis of the implementation of the approach into hydrogen (H 2 ) gasification systems. Dissemination of results was carried out at a DOE meeting. This work establishes a scalable framework for automated, in-line feedstock quality assessment, offering significant implications for process optimization and emissions reduction in hydrogen production.
The Department of Energy Hydrogen Fuel Cell Technology Office and Wind Energy Technologies Office's Wind-H2-Green Steel/Ammonia project is an initiative to demonstrate the feasibility and efficacy of GW-scale integrated energy systems. The team designed reference facilities that utilize wind- and solar-produced hydrogen for industrial steel and ammonia production. This novel concept warranted review of safety codes and standards as they apply to the designs and the identification of codes and standards gaps. This report reviews hydrogen production and storage codes and standards using reference design specifications from a Minnesota steel plant. Requirements, recommendations, and exclusions for the system were identified. Observed gaps included non-specific salt cavern storage requirements, electrolyzer capacity beyond regulated ranges, and lack of requirements for iron reduction via hydrogen. This report will aide future project design efforts and may provide a basis for safety reviews in new designs for industrial facilities with hydrogen production integration.
Pacific Northwest National Laboratory (PNNL) tested electrolyte coatings from Fuel Cell Enabling Technologies, Inc. (FCET) for use in solid oxide fuel cells (SOFCs). The key technology held by FCET is a process to deposit thin layers of oxide materials, less than 1 μm in thickness. The range of possible materials that can be deposited with their method is broad, but this project focused on the gadolinium-doped ceria (GDC) and yttria-stabilized zirconia (YSZ) electrolytes for SOFCs. Thin, gas tight electrolyte membranes have been a long-sought target in SOFC research. The thinner the electrolyte, the lower the cell resistance, and the higher performance of the cell (or the lower the operating temperature). A YSZ thickness of 1 μm would be a step change from the state-of-the-art, tape-cast electrolytes (~10 μm). An in-house prototype SOFC stack from FCET was first tested. The sealing geometry of the prototype stack was determined to be problematic, and testing shifted to button cells. Anode-supported solid oxide electrolysis cell (SOEC) button cells without an electrolyte layer were produced at PNNL and sent to FCET for coating with electrolyte. Three cells were tested with a gadolinium-doped ceria (GDC) electrolyte applied via spin coating. GDC was chosen for its conductivity at lower temperatures than YSZ. All three cells failed during initial reduction under hydrogen at 600°C. Testing then shifted to YSZ, which is the standard SOFC electrolyte. Several button cells were coated with YSZ and examined with scanning electron microscopy (SEM). A promising coating of ~1 mm thickness was observed under SEM. A similarly coated button cell was tested and failed similarly to previous tests during reduction at 600°C. The YSZ coating appeared dense and uniform in SEM analysis. The roughness of the underlying Ni/YSZ anode is on the order of 1 μm, and that may have compromised the gas-tightness of the coating. Further development is warranted to understand and refine the coating process. Thin YSZ applied via this spin-coating technique could be used as a low-cost, drop-in replacement in large-scale SOFC manufacturing processes, improving cell performance and lowering the cost per watt of SOFCs.
Hydrogen plasma is gaining significant interest as a promising pathway for direct iron ore reduction and for lowering process temperatures but the reduction mechanism remains poorly understood. In this work we analyzed the plasma and thermal reduction of thin-film hematite (Fe 2 O 3 ) at temperatures below 340 °C using X-ray diffraction and scanning electron microscopy with energy-dispersive X-ray spectroscopy. Plasma reduced the incubation period by an order of magnitude and increased the reduction rate by a factor of 2.6 compared to thermal reduction. Plasma-produced H-atoms facilitate the formation of numerous iron nucleation sites, bypassing the energetically unfavorable dissociative adsorption of H 2 on iron oxide. These iron nuclei can autocatalyze the reduction of the surrounding hematite via a hydrogen spillover mechanism. Our results demonstrate that plasma-derived H-atoms primarily impact the initial nucleation-limited stage. These new insights provide a mechanistic framework that can aid the implementation and optimization of hydrogen plasma-assisted iron oxide reduction at reduced temperatures.
The lithium-mediated nitrogen reduction reaction (Li-NRR) is currently the most promising strategy for electrochemical ammonia synthesis. In this study, we present an operando grazing incidence wide angle X-ray scattering (GI WAXS) investigation using an improved electrochemical flow cell that enables hydrogen oxidation at the anode and thereby eliminates the need of a sacrificial proton donor. The improved cell design also increases nitrogen availability and mass transport, achieving ammonia faradaic efficiencies (FEs) up to 36%. This setup allows direct analysis of reaction intermediates and the solid electrolyte interphase (SEI) using state-of-the-art diglyme-based electrolytes. We identify lithium amide (LiNH2) as the only stable, crystalline intermediate, providing direct insight into the Li-NRR mechanism. Notably, in diglyme-based electrolytes, the SEI composition differs significantly from that in tetrahydrofuran-based systems, with reduced LiF content and the formation of previously unreported crystalline diglyme–lithium salt complexes. These species likely influence ammonia selectivity and long-term stability. Our findings highlight how the electrolyte composition and cell architecture govern Li-NRR selectivity and efficiency, offering a foundation for the rational design of next-generation SEI layers and solid electrolytes to enable scalable electrochemical ammonia synthesis.
The unique ability of palladium (Pd) to absorb hydrogen and form a bulk hydride is vital for chemical transformations that involve hydrogenation reactions. Nano-structured Pd catalysts offer a promise of tuning these reaction rates by exploiting variations of reactant binding energies depending on the surface structure and morphological constraints that result in inhomogeneous strain. However, the interplay between the nano-structure of Pd and the ability of Pd to adsorb (and absorb) hydrogen as well as other reactive species needs to be better understood for a rational understanding of competitive chemical transformations at Pd surfaces. We consider the effects of the surface corrugation, strain, and subsurface Pd hydride on the reduction of benzaldehyde to benzyl alcohol in two qualitatively different samples – Pd nanoparticles and Pd gels formed by quasi-one-dimensional chains of these nanoparticles. Our electrochemical measurements and computational modelling suggest that surface concave sites, inherent to Pd gels, facilitate hydrogen transfer to the Pd subsurface region, thus weakening benzaldehyde binding to the surface. This effect is further modulated by the strain, depending on the local coordination environment on the corrugated surface. Furthermore, these findings demonstrate how structurally complex samples in the form of gels provide degrees of freedom for controlling the behavior of metal catalysts that are not available in isolated nanoparticles, which paves the way for new approaches in the design of catalytic materials and synthesis of metal hydrides.
Here, large reductions (40 % vs. compressed gaseous hydrogen vessels and 17 % vs. vacuum insulated cryo-compressed vessels) in hydrogen storage system cost are possible by operating buses with foam-insulated cryo-compressed hydrogen (CcH 2 ) vessels. Detailed thermodynamic analysis reveals that large size and rapid H 2 consumption in buses compensate for the poor performance of foam insulation (∼100 times more conductive than vacuum multilayer insulation), resulting in compact and inexpensive H 2 storage systems with sufficient H 2 capacity for the longest routes (500 km) while maintaining previously identified advantages of CcH 2 systems: increased autonomy, rapid high density refueling, and improved safety, while simultaneously avoiding vacuum insulation stability problems resulting from composite resin outgassing.
GTI Energy, with Bloom Engineering, Argonne National Laboratory and Oak Ridge National Laboratory, are developing the FlexGen-H burner. This high-efficiency burner can achieve 45•100% CO2e emissions reduction using green hydrogen with natural gas. It offers NOx, CO emissions ?50 ppm (3% O2), 15•51% fuel savings, ?50% PM2.5 reduction with turndown of ?5:1. The technology can work with renewable liquid fuels, ethanol or methanol. The technology aims to significantly reduce emissions, enhance resiliency, improve process efficiency. The paper will discuss preliminary results of development, with planned laboratory validation including safety, CFD, burner system design and market for the technology.
Molecular catalysts allow deeper study of underlying mechanisms relative to heterogeneous systems by offering a discrete active site to monitor. Mechanistic study with knowledge of key intermediates subsequently enables the development of design principles through an understanding of how improved reactivity or selectivity can be achieved through modification of the catalyst structure. The co-catalytic inclusion of redox mediators (RM), which are small molecules that can aid in the transfer of protons and electrons, has been shown to improve product conversion and selectivity in many molecular systems, through intercepting key intermediates to direct reaction pathways. The primary focus for the majority of molecular electrocatalysts has been on optimizing design for reductive reactions, such as the hydrogen evolution reaction (HER), the oxygen reduction reaction (ORR), and the carbon dioxide reduction reaction (CO 2 RR). By comparison, there has been much less focus on key oxidative reactions by molecular species, apart from the oxygen evolution reaction (OER). The focus of this review is to highlight molecular catalyst systems optimized for the electrochemical oxidation of alcohols. The electrochemical alcohol oxidation reaction (AOR) can serve a role in synthesizing value-added chemicals and can serve as the counterpart to the CO 2 RR by releasing electricity from energy-rich molecules. State-of-the-art molecular systems for the AOR are divided between single-site catalysts and co-catalytic systems with redox mediators. The AOR is contextualized as an energy relevant reaction, an overview of the area is provided, foundational improvements in catalyst systems are highlighted, and future development principles for incorporating redox mediators are suggested.
This study conducts a global assessment of renewable hydrogen production pathways, focusing on techno-economic performance and life cycle greenhouse gas (GHG) emissions. It evaluates standalone solar photovoltaic (PV), wind, and hybrid PV/wind systems, integrated with proton exchange membrane (PEM) electrolyzers, through multi-objective optimization and considering embodied emissions in manufacturing PV, wind and electrolyzers. Results identify optimal configurations to minimize levelized cost of hydrogen (LCOH) and carbon intensity (CI) of hydrogen, showing potential reductions of cost and CI by 2030. Standalone PV systems can achieve LCOH values smaller than 6.5 USD/kg H 2 and CI less than 2.5 kg CO 2 eq/kg H 2 in regions with high solar irradiance, such as North Africa, the Middle East and Chile. Wind systems in regions such as Middle East, North Africa, Australia and Central United States achieve LCOH below 5 USD/kg H 2 and CI under 1.5 kg CO 2 eq/kg H 2 . Hybrid systems emerge as the optimal solution for minimizing both the LCOH and CI by maximizing the use of renewable energy. Moreover, the results also indicate that, with the technological advancements, future reduction in the capital cost of renewable energy systems and the PEM electrolyzer as well as the trade of coproduct O 2 could drive the LCOH of all the RES-based hydrogen systems below 1 USD/kg H 2 and the CI below zero in different regions as Middle East, North Africa and Central United State
This article presents a Co phase segregation strategy for creating stable Co cluster catalytic sites on TiO 2 , enabling selective CO 2 hydrogenation to CO. Through oxidative calcination, pre-synthesized Co-doped brookite TiO 2 nanorods transform into a mixed TiO 2 phase, leading to the phase segregation of Co species. The resulting Co clusters, stabilized by strong Co-TiO 2 interactions during reductive CO 2 hydrogenation, effectively suppress the formation of larger nanoparticles. The undercoordinated sites of these clusters promote a high CO production rate with near-unit selectivity, contrasting with Co nanoparticles, which favor CH 4 formation under identical conditions. In-situ diffuse reflectance infrared Fourier transform spectroscopy (DRIFTS) analysis indicates that the weakened CO adsorption on Co clusters is key to their enhanced CO selectivity, highlighting this method as a promising approach for efficient CO 2 utilization.
This topical review focuses on the distinct role of carbon support coordination environment of single-atom catalysts (SACs) for electrocatalysis. The article begins with an overview of atomic coordination configurations in SACs, including a discussion of the advanced characterization techniques and simulation used for understanding the active sites. A summary of key electrocatalysis applications is then provided. These processes are oxygen reduction reaction (ORR), oxygen evolution reaction (OER), hydrogen evolution reaction (HER), nitrogen reduction reaction (NRR), and carbon dioxide reduction reaction (CO 2 RR). The review then shifts to modulation of the metal atom-carbon coordination environments, focusing on nitrogen and other non-metal coordination through modulation at the first coordination shell and modulation in the second and higher coordination shells. Representative case studies are provided, starting with the classic four-nitrogen-coordinated single metal atom (M$-$N 4 ) based SACs. Bimetallic coordination models including homo-paired and hetero-paired active sites are also discussed, being categorized as emerging approaches. The theme of the discussions is the correlation between synthesis methods for selective doping, the carbon structure–electron configuration changes associated with the doping, the analytical techniques used to ascertain these changes, and the resultant electrocatalysis performance. In conclusion, critical unanswered questions as well as promising underexplored research directions are identified.
About 1.9 gigatons of steel is produced every year, emitting 8% (3.6 gigatons) of global CO 2 in the process. More than 50% of the CO 2 emissions come from a single step of steel production, known as ironmaking. Hydrogen- based direct reduction (HyDR) of iron oxide to iron has emerged as an emission-free ironmaking alternative. However, multiple physical and chemical phenomena ranging from nanometers to meters inside HyDR reactors alter the microstructure and pore networks in iron oxide pellets, in ways that resist gaseous transport of H 2 /H 2 O, slow reaction rates, and disrupt continuous reactor operation. Using synchrotron nano X-ray computed tomography and percolation theory, we quantify the evolution of pores in iron oxide pellets and demonstrate how nanoscale pore connectivity influences micro- and macroscale flow properties such as permeability, diffusivity, and tortuosity. Our modeling framework connects disparate scales and offers opportunities to accelerate HyDR.