Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “fuel cell technologies”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 361 records · Page 20

Uncovering fast solid-acid proton conductors based on dynamics of polyanion groups and proton bonding strength

Achieving high proton conductivity in inorganic solids is key for advancing many electrochemical technologies, including low-energy nano-electronics and energy-efficient fuel cells and electrolyzers. A quantitative understanding of the physical traits of a material that regulate proton diffusion is necessary for accelerating the discovery of fast proton conductors. In this work, we have mapped the structural, chemical and dynamic properties of solid acids to the elementary steps of the Grotthuss mechanism of proton diffusion. Our approach combines ab initio molecular dynamics simulations, analysis of phonon spectra and atomic structure calculations. We have identified the donor–hydrogen bond lengths and the acidity of polyanion groups as key descriptors of local proton transfer and the vibrational frequencies of the cation framework as the key descriptor of lattice flexibility. The latter facilitates rotations of polyanion groups and long-range proton migration in solid acid proton conductors. The calculated lattice flexibility also correlates with the experimentally reported superprotonic transition temperatures. Using these descriptors, we have screened the Materials Project database and identified potential solid acid proton conductors with monovalent, divalent and trivalent cations, including Ag + , Sr 2+ , Ba 2+ and Er 3+ cations, which go beyond the traditionally considered monovalent alkali cations (Cs + , Rb + , K + , and NH 4 + ) in solid acids.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Method—Using Microelectrodes to Explore Solid Polymer Electrolytes

Solid polymer electrolytes are an emerging technology in electrochemistry driven by their use in energy applications such as fuel cells, electrolyzers, and solid-state batteries. Compared to traditional liquid electrolytes, solid polymer electrolytes provide safer, cheaper, and potentially improved device performance. However, there is a lack of standard experimental methods for studying solid electrolytes. Microelectrodes have inherent benefits capable of filling this experimental gap due primarily to their integration into model electrochemical cells with solid electrolytes that represent complex interfaces, enabling additional insight into reaction processes. In this tutorial review, we explore the use of microelectrodes to study solid polymer electrolytes, beginning with a brief history of the field including common experimental cell designs and their benefits and drawbacks. Methods of evaluating essential kinetic and mass-transport parameters are then examined. In addition, the key studies of the past 30 years utilizing microelectrode cells and solid polymer electrolytes are summarized, with important results highlighted and compared. Finally, future studies of solid polymer electrolytes with microelectrodes and potential new avenues of research are commented on.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Techno-Economic Assessment of CHP Systems in Wastewater Treatment Plants

Wastewater treatment plant (WWTP) utilization of combined heat and power (CHP) systems allows for the efficient use of on-site biogas production, as well as increased annual savings in utility costs. In this paper, a review of biogas energy recovery options, CHP prime mover technologies, and the costs associated with biogas cleaning give a broad summary of the current state of CHP technology in WWTPs. Even though there are six different prime mover technologies, the main ones currently being implemented in WWTPs are micro turbines, fuel cells and reciprocating engines. Different prime movers offer varying efficiencies, installation costs, and biogas impurity (H2S, siloxanes, HCl) tolerances. To evaluate the long-term savings capabilities, a techno-economic assessment of a CHP installation at a case study WWTP shows the payback, annual savings, and initial costs associated with the installation of a CHP system. In this case, a study a payback of 5.7 years and a net present value of USD 709,000 can be achieved when the WWTP generates over 2,000,000 m3 of biogas per year and utilizes over 36,000 GJ of natural gas per year.

54 ENVIRONMENTAL SCIENCES↗

Assessing the National Off-Cycle Benefits of 2-Layer HVAC Technology Using Dynamometer Testing and a National Simulation Framework

Some CO2-reducing technologies have real-world benefits not captured by regulatory testing methods. This paper documents a two-layer heating, ventilation, and air-conditioning (HVAC) system that facilitates faster engine warmup through strategic increased air recirculation. The performance of this technology was assessed on a 2020 Hyundai Sonata. Empirical performance of the technology was obtained through dynamometer tests at Argonne National Laboratory. Performance of the vehicle across multiple cycles and cell ambient temperatures with the two-layer technology active and inactive indicated fuel consumption reduction in nearly all cases. A thermally sensitive powertrain model, the National Renewable Energy Laboratory's FASTSim Hot, was calibrated and validated against vehicle testing data. The developed model included the engine, cabin, and HVAC system controls. Validation of component thermal models and engine efficiency ensured accurate thermal dynamics, fuel consumption, and two-layer benefit. The real-world benefit of the two-layer technology was calculated by simulating the validated powertrain model across a representative test matrix comparing performance with and without the two-layer system. Simulation across the test matrix revealed a real-world representative benefit of 0.0835%. Analysis of test matrix results at the regional level revealed the most benefit in cold climates and rural regions. Mean results across cycle length sensitivity simulations revealed a larger real-world benefit of 0.0872%. These benefit values can be considered a more accurate assessment of real-world technology performance. Future work is planned to explore the requisite number of drive cycles to ensure the full technology benefit is captured.

2-layer↗

Achieving American Leadership in the Hydrogen Supply Chain Factsheet

Hydrogen has been identified as a key energy option to enable full decarbonization of the energy system. A secure, resilient supply chain will be critical to achieving emissions reductions and capturing the economic opportunity inherent in the energy sector transition. Electrolyzers and fuel cells are two critical components of the hydrogen supply chain that today are largely nascent industries with limited data on supply chain needs and constraints. This fact sheet summarizes findings from an accompanying report that is one in a series of deep dive assessments of the energy industrial base called for in Executive Order 14017 on America’s supply chains. The report identifies key considerations for the development of water electrolyzer and fuel cell supply chains and materials, focusing on polymer electrolyte and solid oxide technologies, to meet future demand for hydrogen produced by electrolysis and achieve U.S. decarbonization goals.

Source record↗

Building a Prospective LCA Framework to Analyze Emerging Technologies in a Dynamic System Context

NREL's Lifecycle Analysis Integration into Opensource Numerical models (LiAISON) framework computes temporally explicit life cycle impacts and resource uses for specific technologies (foreground) in a dynamic system context (background). LiAISON computes results for a series of environmental mid-points enabling an analysis of prospective tradeoffs of emerging technologies toward 2100. This prospective feature is of critical importance when analyzing present-day emerging technologies whose large-scale impacts during deployment phases will occur in different, future system contexts. LiAISON systematically accounts for dynamic system changes by applying an integrated background of the future energy-economy-land-climate system, generated by exogenous integrated assessment models (IAMs). Using IAM scenarios, LiAISON generates a time-series of life cycle inventory (LCI) databases, which are then used to calculate the impacts per functional unit per time step. This expands current practice of using static, future system assumptions, e.g., a specific grid-mix each year. Further, IAM scenarios are provided in a standardized format of shared-socioeconomic pathways (SSP) and representative concentration pathways (RCP) combinations. These are coherent, regularly, published, and peer-reviewed scenario combinations that establish a reproducible and standardized societal and climate mitigation futures context. They are comparable across IAMs and expand the system boundary of the traditional LCA by including dimensions such as societal and behavioral changes. We apply the framework to assess two emerging Power-to-Hydrogen processes, high temperature electrolysis using solid oxide fuel cell (HT-SOE) and polymer electrolyte membrane electrolysis (PEME). We compare the technologies to a baseline Hydrogen production process via steam methane reforming. Despite the decarbonized electricity systems' beneficial effects on the PtH2 processes' carbon intensities, we find environmental tradeoffs, which require technology improvements via learning-by-doing to be alleviated. Future work via ongoing collaborations will focus on linking the framework to other energy-economy-land-climate models and open-source life cycle inventory databases.

ENERGY PLANNING, POLICY, AND ECONOMY↗

Conductivity and Transference Number Determination Protocols for Solid Oxide Cell Materials

To standardize materials and component characterization for next generation hydrogen production and energy generation solid oxide cell (SOC) technologies, test protocols are being established to facilitate comparison across the numerous laboratories and research institutions where SOC development for application in solid oxide fuel cells (SOFCs) and solid oxide electrolyzes cells (SOEC) is conducted. This paper proposes guiding protocols for fundamental electrical properties characterization of SOC materials, including temperature- and oxygen partial pressure (pO 2 )-dependent conductivity measurements, and use of the electromotive force for determining the transference numbers, or contributions of each charge carrier (i.e., ions and electrons), to the total conductivity. The protocol for Archimedes density measurements is also provided as an integral technique to both of these methods.

25 ENERGY STORAGE↗

Cradle-to-Grave Lifecycle Analysis of U.S. Light-Duty Vehicle-Fuel Pathways: A Greenhouse Gas Emissions and Economic Assessment of Current (2020) and Future (2030-2035) Technologies

This study provides a comprehensive life cycle analysis (LCA), or cradle-to-grave (C2G) analysis, of the cost and greenhouse gas (GHG) emissions of a variety of vehicle-fuel pathways, the levelized cost of driving (LCD) and cost of avoided GHG emissions. The C2G analysis assesses light duty midsize sedans and small sport utility vehicles (SUVs) across a variety of vehicle-fuel technology pathways, including conventional internal combustion engine vehicles (ICEVs), flexible hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), battery electric vehicles (BEVs) with varying vehicle ranges, and fuel cell electric vehicles (FCEVs). In evaluating the vehicle-fuel combinations, this study considers both low-volume and high-volume “CURRENT TECHNOLOGY” cases (nominally 2020) and a high-volume “FUTURE TECHNOLOGY” lower-carbon case (nominally 2030–2035).

33 ADVANCED PROPULSION SYSTEMS↗

Detailed Simulation Datasets Quantifying U.S. DOE VTO/HFTO R&D Benefits Across Light- to Heavy-Duty Vehicles

For more than 20 years, Argonne National Laboratory’s Vehicle & Mobility Systems Department has assessed how R&D investments by the U.S. Department of Energy’s Transportation Technologies Office and Alternative Fuels and Feedstocks Office affect vehicle energy use and cost. The analyses are performed using Autonomie, Argonne’s full-vehicle simulation tool for energy consumption, performance, and cost. The study covers five time frames ranging from present day through 2050, with more than 30 vehicle classes and applications (10 light duty and >20 medium and heavy duty), as well as six powertrain configurations (conventional, start-stop, hybrid electric vehicle, plug-in hybrid electric vehicle, battery-electric vehicle, and fuel cell electric vehicle) and five fuels (gasoline, diesel, natural gas, hydrogen, and electricity). Low and high technology uncertainty scenarios have been considered to capture a realistic range of outcomes. The resulting datasets include the assumptions used (i.e., efficiency, $/kWh), vehicle-level data (power, energy, weight, and cost), and outputs such as energy consumption, manufacturer’s suggested retail price, and total cost of ownership. These data are critical to stakeholders working in transportation, technology assessment, and long-term R&D planning.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Reliability and Durability Testing of Glass Ceramic Seals for Praxair’s Oxygen Transport Membranes

Praxair has been developing Oxygen Transport Membrane (OTM) systems for the efficient conversion of natural gas to syngas which can subsequently be used in chemical synthesis, generation of industrial gases (H2, CO) or synthesis of liquid fuels. One of the technical barriers for commercialization of this technology is the reliability of key components of OTM systems – Seals and Membranes. Praxair has been testing these components at the process conditions expected for commercial systems. However, long-term durability data is currently limited and is not sufficiently available to make well informed predictions of OTM reliability which represents one of the major risks that could prevent the technology from being fully commercialized. Pacific Northwest National Laboratory (PNNL) has been developing high temperature seals and ceramic membranes for applications similar to OTM systems such as Solid Oxide Fuel Cells. The goal of the cooperative development between Praxair and PNNL is to generate long-term data such that there is sufficient confidence in the OTM seal and membrane reliability predictions to enable the process technology to be fully commercialized.

03 NATURAL GAS↗

Composition, Activity, and Stability of IrO x Oxygen Evolution Reaction Electrocatalysts

The oxygen evolution reaction (OER) is integral to several electrochemical energy conversion and storage technologies, including carbon dioxide reduction to value added fuels, nitrogen reduction to ammonia, reversible fuel cells, rechargeable metal−air batteries, and water electrolysis to produce hydrogen. Iridium oxide (IrO x ) is widely recognized as the benchmark OER catalyst for acidic environments. Despite widespread use of IrO x catalysts, most notably in proton-exchange membrane water electrolyzers (PEMWEs), a comprehensive understanding of the physicochemical properties of commercial catalysts and the impact of these properties on both the activity and stability of these catalysts is lacking. Here, we study commercial IrO x catalysts with different physicochemical properties, three nominally considered amorphous and three rutile, to elucidate how structural and compositional variations affect OER activity and stability. Utilizing standardized aqueous electrochemical protocols, time-resolved dissolution quantification using inductively-coupled plasma mass spectrometry, and physicochemical characterization, including multiple synchrotron X-ray techniques, we systematically correlate catalyst properties with OER performance and degradation behavior aided by principal component analysis (PCA). Our results demonstrate the general trend of amorphous IrO x having higher intrinsic activity but limited stability and crystalline rutile IrO 2 having lower activity but enhanced stability against dissolution. The trends within the amorphous and rutile catalyst groups correlate with inherent material properties, including phase composition and structure, crystallinity, particle size, surface area, and surface structure/chemistry. Notably, we identify a rutile catalyst with the largest crystallite/ domain sizes, moderate surface area, a small fraction of hydrous phase, and a favorable pore structure (trimodal distributions of pore sizes ranging from 2−5 nm) that exhibits the best balance between activity and stability among the six catalysts studied here. These findings illustrate a fundamental structure-governed trade-off between activity and stability and highlight the critical role of surface chemistry modification and structure engineering in IrO x catalyst optimization.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Engineering block co-polymer anion exchange membrane domains for highly efficient electrode-decoupled redox flow batteries

We report, anion exchange membranes (AEMs) with high permselectivity, chemical stability and mechanical robustness are a key enabling technology for a variety of electrochemical energy conversion and storage systems such as fuel cells, redox flow batteries and water electrolyzers. Herein we examine well understood chemically stable triblock co-polymer AEMs derived by the chloromethylation (CM-) and subsequent trimethylamine (TMA) functionalization of polystyrene-block-poly(ethylene-ran-butylene)-block-polystyrene (SEBS) block co-polymers. We show using small angle X-ray scattering (SAXS) that the introduction of a hydrophobic reinforcement matrix disrupts phase segregation and decreases ionic domain sizes in these AEM separators. The reinforcement matrix simultaneously causes the ultimate tensile strength (UTS) of the reinforced separator to increase by almost 600% compared to the unreinforced form, while maintaining comparable elasticity (ca. 500% elongation at break). Such reinforced r-SEBS30-TMA separators enable electrode-decoupled redox flow batteries (ED-RFBs) with significantly improved lifetimes by decreasing per cycle capacity fade from 0.5% to <0.05%. This 10× improvement in operando permselectivity opens the door to ED-RFBs employing inexpensive elemental actives achieving decades-long usable lifespans.

25 ENERGY STORAGE↗

Turbocharging bio-based manufacturing processes

This project focused on technology of cell-free systems for rapid prototyping and biodiscovery of chemicals and fuels. We were able to build out our cell-free prototyping platform from being capable of only prototyping very basic chemicals (eg. 1,4-BDO) to being able to prototype complex chemicals derived from metagenomic sources (eg. microcin J25, new molecules). The throughput for the platform also increased multi-fold, from a capability of less than 50 reactions a day to above 1,000 reactions a day, allowing us to diversity the types of chemicals we can prototype.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Decarbonizing Medium & Heavy-Duty On-Road Vehicles

We analyze the decarbonization potential of medium and heavy-duty vehicles (MHDVs) across multiple vehicle classes and market segments. We evaluate the timeframe in which zero-emission vehicles (ZEVs) could achieve cost parity with conventional diesel vehicles and the implications for energy and emissions. Our results show that ZEVs can achieve cost parity with conventional vehicles by 2035 across the majority of vehicle classes and market segments. Emissions reductions range from 27% to 77% by 2050 relative to 2019 across multiple fuel cost and technology progress sensitivities. Multiple technology pathways are viable for decarbonization, including battery-electric vehicles and hydrogen fuel cell electric vehicles. This presentation is based on previous work published by NREL: Ledna, C., Muratori, M., Yip, A., Jadun, P., and Hoehne, C. 2022. Decarbonizing Medium & Heavy-Duty On-Road Vehicles: Zero-Emission Vehicles Cost Analysis. National Renewable Energy Laboratory, https://www.nrel.gov/docs/fy22osti/82081.pdf.

ADVANCED PROPULSION SYSTEMS↗

Improved Solid-State Reaction Method for Scaled-Up Synthesis of Ceramic Proton-Conducting Electrolyte Materials

Protonic ceramic electrochemical cells (PCECs) represent promising technologies in the production of clean electricity, decarbonized hydrogen, chemicals, and fuels at intermediate temperatures. One of the challenges in commercializing PCECs is to produce the electrolyte materials on a large scale. The conventional solid-state reaction (SSR) method suffers from tedious synthesis procedures and low phase purity of the products due to the formation of unwanted secondary phases. Herein, we report an improved SSR (i-SSR) method for kilogram-scale production of high phase-purity electrolyte material BaZr 0.4 Ce 0.4 Y 0.1 Yb 0.1 O 3–δ (BZCYYb4411). In this method, the ball-milled precursor powders are pelletized prior to calcination, which effectively reduces the length of the diffusion paths between the components during perovskite phase formation. In this study, the synthesis procedure and calcination temperature are carefully optimized for efficient and repeatable production based on the powder crystallization behavior. A combined technoeconomic analysis and life cycle assessment modeling suggest that the i-SSR method could reduce the total production cost and greenhouse gas emissions by up to 19% and 39%, respectively, compared to the conventional SSR method. The high quality of the synthesized electrolyte material is corroborated by the excellent electrical conductivity and electrochemical performance of the fabricated PCEC cells.

36 MATERIALS SCIENCE↗

Develop a Simulation Framework for Understanding Physico-Chemical Processes and Optimization of CHZ' Plastic Thermolyze Technology (CRADA Final Report)

Thermolyzer(TM) technology is a third-generation, multi-reactor, oxygen-free, low pressure, slow pyrolysis process. It has proven to be remarkably versatile in successfully processing all types of hydrocarbon waste. These include all seven types of plastics, tires, auto shredder residue, carpet, electronic waste, and composites. Working with the IACMI, Thermolyzer(TM) technology has recovered the glass and carbon fibers from wind turbine blades for reuse into new applications. Its primary output is a synthesis gas that is rich in H 2 , CH 4 , and small amounts of C 2-4 aliphatic hydrocarbons. Other components are CO and CO 2 . Three unique features set Thermolyzer(TM) apart from other pyrolysis systems: the syngas is clean enough to run in Siemens or Solar gas turbines or IC engines without fouling, clean, salable, byproducts are produced, and CO 2 emissions are lower than natural gas power plants. Research results have been obtained from an operating 7 ton/day facility. A 44 ton/day plant has successfully operated as noted above. The process works because it makes use of the recoverable embodied energy in the feedstock. Surprisingly, a pound of some plastics has the same recoverable energy content as a pound of gasoline. Thus, it is imperative to develop a process that economically converts scrap plastics (including ocean plastics) into energy and thereby conserve the non-renewable fossil fuels for future generations. The Thermolyzer(TM) technology can also be used to create liquid fuels like gasoline and diesel from hydrocarbon wastes. Because of the high hydrogen content of the synthesis gas, hydrogen can be recovered more inexpensively than the current solar or wind energy being used to electrolyze water. That hydrogen can be used for fuel cell powered vehicles or converted into ammonia for agriculture or as a hydrogen storage medium. Extension of this technology to other wastes such as tires, auto shredder residue or wood wastes would expand the circular economy.

36 MATERIALS SCIENCE↗

Roll-to-Roll Advanced Materials Manufacturing DOE Laboratory Collaboration (FY2019 Final Report)

R2R processing is used to manufacture a wide range of products for various applications which span many industrial business sectors. The overall R2R methodology has been in use for decades and this continuous technique traditionally involves deposition of material(s) onto moving webs, carriers or other continuous belt-fed or conveyor-based processes that enable successive steps to build a final version which serves to support the deposited materials. Established methods that typify R2R include tape casting, silk-screen printing, reel-to-reel vacuum deposition/coating and R2R lithography. Products supported by R2R manufacturing include micro-electronics, electro-chromic window films, PVs, fuel cells for energy conversion, battery electrodes for energy storage, and barrier and membrane materials. Due to innovation in materials and process equipment, high-quality yet very low-cost multilayer technologies have the potential to be manufactured on a very cost-competitive basis. To move energy-related products from high-cost niche applications to the commercial sector, a means must be available to enable manufacture of these products in a cost-competitive manner that is affordable. Fortunately, products such as fuel cells, thin- and mid-film PVs, batteries, electrochromic and piezoelectric films, water separation membranes, and other energy saving technologies readily lend themselves to manufacture using R2R approaches. However, more early-stage research is needed to solve the challenge of linking the materials (particles, polymers, solvents, additives) used in ink and slurry formulations, though the ink processing, coating and drying processes, to the ultimate performance of the final R2R product, especially for a process that uses multiple layers of deposition to achieve the end product.

42 ENGINEERING↗

Hydrogen from Carbonaceous Waste Material - Hydrogen Fuel Cells Prize Phase 2 Voucher: Cooperative Research and Development (Final Report)

NLR conducted a conceptual design study for scaling up biomass conversion technology from Green Fortress Engineering (GFE). GFE has proprietary technology where cellulosic biomass is thermally converted to a tar-free syngas. A ceramic membrane separation unit (MSU) previously developed with NLR can extract high-purity hydrogen from the syngas. The energy content of the retentate stream is sufficient to power the process with a gas-powered genset. Design details including mass and energy balances, process and instrumentation diagrams (P&ID), and major equipment schedules were delivered.

08 HYDROGEN↗