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

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At least 379 records · Page 21
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Robust highly durable solid oxide fuel cell cathodes – Improved materials compatibility & self-regulating surface chemistry

Solid oxide fuel cells (SOFCs) are electrochemical conversion devices that directly transform hydrogen or hydrocarbon fuels to electricity, with energy efficiencies as high as 90%, coupled with reduced emissions. Several factors, however, remain to be addressed when considering scale-up of SOFC technology, including the need to overcome decreased performance due to sluggish rates of the oxygen reduction reaction (ORR) at the cathode under reduced temperatures and susceptibility to degradation in performance from surface poisoning e.g. from chromia, while limiting the use of critical raw materials (lanthanides and transition metals) present in high performing mixed ionic electronic conducting electrodes like (La,Sr)CoO 3 (LSC). In this project we explored the key descriptors for determining ORR activity in SOFC electrodes and tried to recover performance degradation by applying them to SOFC electrodes. In order to do this, we first selected a model mixed ionic electronic conducting (MIEC) oxide, Pr-doped CeO 2 (Pr 0.1 Ce 0.9 O 2-δ , PCO), which is a chemically stable fluorite and free of inherent poison sources (e.g. Sr segregation in LSC) that potentially react with external impurities such as Cr-species vaporized from the interconnect. The three approaches originally planned in this project are as follows: 1) evaluation of scavenger exsolution characteristics, 2) study of scavengers gettering efficacy following Cr and Si poisoning and 3) integration of new compositions into porous electrodes. Among them, exceptional progress has been made in 2) and 3), especially understanding the role of surface infiltrants in impacting electrode performance and degradation of PCO materials. We found that the Smith acidity scale for binary oxides serves as a powerful descriptor for tuning and predicting the oxygen exchange kinetics on MIEC PCO surfaces. As a result, with infiltration with binary oxides, ranging from strongly basic (Li 2 O) to strongly acidic (SiO 2 ) onto the surface of porous PCO, it was possible to systematically vary the chemical surface exchange coefficient (k chem ) by 6 orders of magnitude! L i2 O increased k chem by nearly 1,000 times over that of pristine PCO, while SiO 2 decreased k chem by nearly the same factor. Strikingly, although the pre-exponential of k chem scales linearly with the acidity of the infiltrated binary oxide, there is nearly no change in the activation energy. With this insight, we attributed the origin of these dramatic changes in k chem values to the systematic increase and decrease in the surface electron density induced by infiltrated binary oxides. More interestingly, although both Cr 2 O 3 and SiO 2 were determined to be acidic by Smith, suggesting that this feature could likely be the primary reason that these compounds serve to poison the ORR on SOFC cathodes, the effect of poisoning could be subsequently tuned by adding multiple infiltrants and controlling their relative surface acidities. We also systematically examined the effect of serial infiltration of basic and acidic oxides. It turned out that serial infiltration of Li not only recovers approximately 20-fold degraded k chem of PCO by acidic Cr 2 O 3 but its k chem is enhanced even beyond that of the non-infiltrated PCO by more than three orders of magnitude. This was further verified with a screen-printing PCO symmetric cell in terms of the electrode performance (area-specific resistance, ASR) related to approach 3). These observations point to acidity as a key descriptor not only in tuning and predicting the ORR activity of SOFC cathodes that largely determines the overall performance of SOFC, but in mitigating and reactivating poisoned electrode performance. This work provides novel guidelines for making the electrode performance much more active and robust in SOFCs, which can further be applied to all applications requiring oxygen exchange reaction, such as electrolyzers, permeation membranes and gas sensors.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2023

Scalable and Cost-Effective Roll-To-Roll Additive Manufacturing of Highly Durable and Thermal Insulating Silica-Carbon Aerogel (Final Report)

The research objective of this project is to demonstrate low cost silica aerogel insulation materials with high R-value and low installed price of R7.5/inch, and $0.94/ft2-inch, respectively, which can meet the cost and performance targets of the Department of Energy’s 2030 Building Technology Office Emerging Technologies program. The main tasks of this project include the following three topics: a) Low-cost silica gel precursor: Repeat silica sol gel chemical approach which is reproducible and scalable. Also explore suitability of water-glass on silica aerogel system to further control cost efficiency. In addition, our aim is to synthesize hollow silica using low-cost precursors. Sodium silicate (water glass) was chosen as our silica source because of its availability and low price compared to the other precursors; b) In situ ambient pressure-drying (APD) and surface modification: confirm and improve silica aerogel under cost-effective continuous ambient pressure-drying and investigate silica aerogel performance under time and temperature dependence; c) Roll-to-Roll (R2R) manufacturing with the targeted structure, thermal and mechanical characteristics: evaluate 3D printing with silica aerogel precursor to modify aerogel formation.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Development of organic-inorganic hybrid selective layers via vapor phase infiltration to enhance the durability of perovskite solar cells

Despite the rapid increase in power conversion efficiency (PCE) of perovskite solar cells (PSCs) over the last decade, stability remains a major roadblock to commercialization. This work proposes the use of vapor phase infiltration (VPI) as a tool to create hybrid organic-inorganic layers that improve the stability of organic charge transport layers, such as hole-selective spiro-OMeTAD in these PSC and other organic electronic devices. Using X-ray photoelectron spectroscopy (XPS), ultraviolet photoelectron spectroscopy (UPS), and grazing incident wide-angle X-ray scattering (GIWAXS), we identify that infiltration of TiO X via VPI hinders the crystallization of the spiro-OMeTAD layer by likely preventing the π- π stacking of the molecules. Infiltrated PSCs retained around 80% of their original efficiency after an operando stability test of 60 h at 75 °C, double the efficiency retained by devices without infiltration. This work provides a blueprint for using VPI to stabilize organic charge transport layers via prevention of π- π stacking that leads to deleterious crystallization that shortens device lifetimes.

14 SOLAR ENERGY↗
DOE OSTI2022

Durable, High-Performance Unitized Reversible Fuel Cells Based on Proton Conductors

The main objective of this project was to develop robust, highly efficient, and economically viable H + -conducting membrane-based, unitized reversible fuel cell (H-URFC) technology for large-scale co-located energy storage and power generation. Another objective of this project is to gain a profound understanding of the degradation mechanisms of key stack materials and interfaces using various in situ, ex situ, and operando measurements guided by theoretical analysis. Nanostructured components will be integrated into cell design and the interfaces between electrodes and electrolyte will be modified with active bi-functional catalysts and protective coatings in order to achieve >70% roundtrip efficiency at 1 A/cm2 in both the fuel cell and the electrolysis modes. The end goal of the project is to advance the technology to the point that a university-industry collaboration can be established to scale up the technology for early adoption, and eventually enabling a pathway to large-scale energy storage that utilizes chemical storage and conversion for electrical grid balancing.

08 HYDROGEN↗
DOE OSTI2022

Active and Durable PGM-free Cathodic Electrocatalysts for Fuel Cell Application

Platinum Group Metal-free (PGM-free) Oxygen Reduction Reaction (ORR) electrocatalysts possess high intrinsic activity measured by a Rotating Disk Electrode (RDE) method. However, under fuel cell operating conditions, PGM-free ORR electrocatalysts have underperformed compared to platinum catalysts. PGM-free ORR electrocatalyst’s fuel cell performance can be improved by designing and optimizing the cathodic catalyst layer (CL) and Membrane Electrode Assembly (MEA) construction such that: 1) it efficiently provides oxygen access to ORR active sites (through catalyst morphology control); 2) it removes water from the CL (by tuning the hydrophobicity of the PGM-free catalysts and the catalyst layer structure); and 3) it increases proton conductivity (by homogeneous mixing of catalysts and ionomer). Studying the CL is complex due to the absence of well-established protocols of MEA activation, especially compared to platinum-containing catalysts. PGM-free fuel cell testing protocols would need to optimize potentiostatic vs galvanostatic measurements, scan rates, parameters of Electrochemical Impedance Spectroscopy (EIS) and Beginning of Experiment (BOE) criteria. To make the PGM-free catalyst’s fuel cell performance comparable to platinum, the synergistic effort of materials design, fine tuning of the catalyst layer and comprehensive electrochemical analysis is required.

08 HYDROGEN↗
DOE OSTI2023

The Durability of Piston Seals in Hydraulic Power Take-off Systems in Wave Energy Converters

Hydraulic cylinder seals are a critical component of hydraulic power take-off (PTO) systems in wave energy converters (WECs). Primary hydraulic piston seal wear is a major concern for the longevity of hydraulic PTOs, especially in the context of the effort and expense associated with seal replacement. Piston seals, made from polymeric elastomers, are used to contain and isolate high pressure fluids within PTO systems. A specific challenge for WEC designers is knowing, with confidence, the relative expected lifetimes of commercially available seals and seal materials for the unique long travel and continuous use case of WEC hydraulic systems. This information is critical to accurately determine operating expense (OPEX) and levelized cost of electricity (LCOE). If failures of seals occur earlier than their designed lifetime, the estimated operations, and maintenance (O&M) and LCOE costs may double based on estimation. Unfortunately, information from seal manufacturers on longevity in these applications is not generally available and quantitative performance comparison between different manufacturers is not available, creating significant uncertainty on use of hydraulic PTO system in wave power generation. In this project, PNNL, with advice from different WEC device and seal manufacturers, has created a framework to address the industry need for available, dependable and comparative data for seals and seals materials for WEC hydraulic applications including piston seals, glide rings, and shaft seals. Commonly used and candidate seal materials were identified and available information on the materials such as mechanical and fatigue performance, chemical (fluid) compatibility, and cost has been compiled. Hardware and strategy for bench scale measurement of key materials and seal performance and pathway for publicly available library of hydraulic seal materials, properties, suppliers, and options have also been identified for future implementation. The results of this project were presented at WPTO Seedling Symposium 2023 and OCEANS 2023. The results of the literature review including identified polymer seals and ideal operating conditions were summaried and compiled to a database WEC-SealsDB hosted locally at PNNL.

16 TIDAL AND WAVE POWER↗
DOE OSTI2024

Inexpensive and durable aerogel-based VIP cores

The goal of this project was development of low-cost aerogels to be used as cores of Vacuum Insulated Panels (VIP). The specific aims were: 1. Aerogels to be based on phenolic chemistry to minimize flammability. 2. Aerogels to be in monolithic form and to have mechanical properties sufficient to allow their use as cores of VIPs without collapsing after evacuation. 3. Aerogels to have a cost per kg lower than the cost of fumed silica, one of the most common VIP cores. The achievements are: 1. Phenolic aerogels have been fabricated in monolithic form with thermal conductivity of 0.023 W/m·K, density ~ 0.25 g/cm 3 and a modulus of compression > 10 MPa. The aerogels can withstand the stresses of VIP evacuation without any appreciable deformation. 2. Drying of aerogels was carried in the initial stages of the project via sublimation of frozen solvents, following the procedure described in M. F. Bertino and T. Selden, “Fabrication of Aerogels and Aerogel Composites by Ambient Pressure Sublimation of Frozen Solvents”, PCT/US20/39485. Monoliths as large as 30 x 30 x 2 cm can be fabricated with the proprietary ambient fabrication technique which are free of cracks and warping. 3. Cost analysis was carried out and refined multiple times, cost drivers were identified, and the fabrication procedure was streamlined. Our cost model yields an aerogel cost of $\$$5.78/kg, which compares well with the price of fumed silica ($\$$6.2/kg FOB New York as of March 2023). 4. The monoliths can be cut into custom shapes and used as VIP cores. Cores fabricated with our technique have a thermal conductivity λ = 0.011 W/m·K at a pressure >10 mbar. 5. A variant of the technology yielded fireproof materials, described in M. F. Bertino, T. Moon, G. Waller, J. Ko and D. Clifford, “Fireproof thermal insulation”, Provisional Patent Application 63/415,386. 6. A spin-off company was created (ThermaGel Innovations, Inc.) which licensed technologies developed under this award. PI Bertino is a board member of the newco which is now raising capital to build a pilot plant.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Durable Low-Cost Pressure Vessels for Bulk Hydrogen Storage

Long-duration energy storage (LDES) in the form of gaseous hydrogen is vital for fossil fuel power plants to reduce frequent shutdowns and rapid start-ups. It's also crucial in renewable energy power plants for grid stabilization. WireTough Cylinders (WTC) has developed a Type II-S pressure vessel that uses steel liners that are hoop-wrapped with multiple layers of high-strength, cost-effective, and readily available steel wires. This design enables the vessel to withstand significantly higher pressures. It addresses hydrogen embrittlement issues and cyclic loading from repeated pressurization and depressurization during service. The WireTough design is cost-efficient, robust, and fatigue-resistant (with a 30-year design life) and is ASME certified for ground storage of hydrogen at a maximum operating pressure (MOP) of 350 bar and a design pressure of 500 bar. The cylinder has a 645 mm outside diameter and a water capacity of 1,715 liters, capable of storing 40.7 KG of hydrogen at MOP. Two prototypes were successfully produced to showcase the manufacturing technologies, with one being certified under ASME Section VIII Division 3 rules. Preliminary design work for a similar Type II-S vessel with a 500 bar MOP was also completed. The 350 bar and 500 bar Type II-S vessels were shown respectively to be 47.5% to 60% more cost-effective and 55% and 62.5% lighter based on per KG of hydrogen stored, when compared with their Type 1 counterparts.

08 HYDROGEN↗
DOE OSTI2024

A Multifunctional Isostructural Bilayer Oxygen Evolution Electrode for Durable Intermediate-Temperature Electrochemical Water Splitting

The overarching goal of the proposed research is to address SOEC’s degradation problem by advancing a new isostructural highly electrocatalytically active bilayer oxygen evolution reaction (OER) electrode, consisting of a LSCF (La 1-x Sr x Co 1-y Fe y O 3-δ ) core and a SCT (SrCo 0.9 Ta 0.1 O 3-δ ) shell, to achieve high and sustainable rate of oxygen evolution matching operating current densities without encountering delamination. To realize this goal, the project has adopted a combined experimental and theoretical approach to conduct research in the following six areas closely associated with SOPO tasks: 1) Development of electrocatalytically active bilayer oxygen electrodes (SOPO task-1) 2) Development of new symmetric three electrode cell (STEC) methodology to extract electrokinetic data of oxygen electrodes (SOPO task-2) 3) Quantification of electrokinetics of bilayer oxygen electrodes and correlation with degradation and delamination (SOPO task-2) 4) Performances of bilayer oxygen electrodes under fuel cells and electrolyzers modes (SOPO task-3) 5) Microscale modeling of oxygen electrode/electrolyte interface in solid oxide electrolysis cells (SOPO task-4) 6) Prediction of crack growth rate at oxygen electrode/electrolyte interface in solid oxide electrolysis cells (SOPO task-4)

08 HYDROGEN↗
DOE OSTI2024

Spectral and Temperature-Dependent Optical Metrology: Towards More Robust, Effective and Durable Materials for Concentrated Solar Power

The primary objective of this project is to develop reliable and standardized spectroscopic measurement techniques to determine radiative properties, specifically the emittance and reflectance, of materials relevant for the next generation (Gen3) concentrated solar power (CSP) technologies. Experimental measurements will span near- and mid-infrared wavelengths (1–20 µm) with emphasis on quantifying the influences of: (1) operating temperatures of 25–1000 °C, (2) thermal cycling, and (3) environmental exposure of materials during operation (vacuum/air). A secondary goal is to develop open-access and digitized databases to host and share experimental data, together with standardized measurement protocols and operating procedures to determine optical properties of materials. This project will also include reasonable emphasis on developing predictive modeling tools to augment experimental data to extract more fundamental and material-specific radiative properties.

14 SOLAR ENERGY↗
DOE OSTI2023

Intermediate Temperature Proton‐Conducting Solid Oxide Electrolysis Cells with Improved Performance and Durability

Technical understanding: A high-performance and stable intermediate temperature proton-conducting solid oxide electrolysis cell (PCEC) will add significantly to the hydrogen roadmap of EERE. However, the low electrocatalytic activity of the air electrode and the instability of the electrolyte are technical barriers. In this research, we utilized computational fluid dynamic modeling and materials/microstructure engineering to investigate the complex reaction chain and to improve the performance and reliability of the protonic ceramic electrochemical cells. An active and stable Pr 1.8 Ba 0.2 NiO 4+δ -BaZr 0.1 Ce 0.7 Y 0.1 Yb 0.1 O 3-δ (BZCYYb) scaffold conformal coating electrode was rationally designed where the robust Pr 1.8 Ba 0.2 NiO 4+δ functions both as a catalytic active and a protective layer. The PCECs with porosity-optimized scaffold conformal coating electrodes demonstrate 1.46 Acm -2 under 1.3 V at 600°C, which is among the highest in recent years. The final optimization by computational fluid dynamic modeling and conformal coating technique was applied to evolve the PCEC air electrode from Pr 2 NiO 4+δ to Pr 1.8 Ba 0.2 NiO 4+δ -BaZr 0.1 Ce 0.7 Y 0.1 Yb 0.1 O 3-δ scaffold conformal coating. The electrolysis current was boosted from 0.445A/cm 2 to 1.46A/cm 2 at 600°C and 1.3V. A superior low degradation rate of 1mV/kh was achieved in a 5000-hour of operation. Technical effectiveness and economic feasibility: The effectiveness of this TCO conformal coating on electrolyte backbone as air electrode has been proven by long-term demonstration. Based on the highly conductive BZCYYb electrolyte and the TCO steam electrode PNO, this project rationally took advantage of the existent materials to structure a PCEC device with high TRL and low risk. The solution infiltration method used to structure the conformal coating is a standard method used by the solid oxide cell community. Very minimal adoption is needed in the current SOC fabrication process. It is a cost-effective, scalable method for manufacturing, and brings up remarkable impact on the current technical status of PCEC. Benefit to the public: The findings in the research showed the industry that the severe challenge in PCEC can be overcome in a practical way. A various energy-hydrogen ecosystem is not beyond reach. The success of this technology provides sustainable and affordable H 2 to society. It will stimulate investment from the governmental and private sectors in response to the device manufacture and deployment, and the related infrastructure construction. It will generate high-pay domestic jobs and environmental benefits to the general public in the United States.

08 HYDROGEN↗
DOE OSTI2025

Durability and Accelerated Aging Test of the Polymeric Mirror-Film Prototype (CRADA Final Report)

The participant is developing a low-cost liquid metal coating for concentrated solar power (CSP) polymeric mirrors. Current CSP technology uses bulky and costly glass mirrors. As a lighter alternative, polymeric mirror film is cheaper than glass mirrors, yet expensive to manufacture. The participant is working to develop a room temperature liquid-metal thin-film deposition technique and CSP polymeric mirror film that will reduce expenditures by 80% and film cost by 50%.

14 SOLAR ENERGY↗
DOE OSTI2023

Carbonic Anhydrase Enhanced UV-Crosslinked PEG-DA/PEO Extruded Hydrogel Flexible Filaments and Durable Grids for CO 2 Capture

In this study, poly (ethylene glycol) diacrylate/poly (ethylene oxide) (PEG-DA/PEO) interpenetrating polymer network hydrogels (IPNH) were extruded into 1D filaments and 2D grids. The suitability of this system for enzyme immobilization and CO 2 capture application was validated. IPNH chemical composition was verified spectroscopically using FTIR. The extruded filament had an average tensile strength of 6.5 MPa and elongation at break of 80%. IPNH filament can be twisted and bent and therefore is suitable for further processing using conventional textile fabrication methods. Initial activity recovery of the entrapped carbonic anhydrase (CA) calculated from esterase activity, showed a decrease with an increase in enzyme dose, while activity retention of high enzyme dose samples was over 87% after 150 days of repeated washing and testing. IPNH 2D grids that were assembled into spiral roll structured packings exhibited increased CO 2 capture efficiency with increasing enzyme dose. Long-term CO 2 capture performance of the CA immobilized IPNH structured packing was tested in a continuous solvent recirculation experiment for 1032 h, where 52% of the initial CO 2 capture performance and 34% of the enzyme contribution were retained. These results demonstrate the feasibility of using rapid UV-crosslinking to form enzyme-immobilized hydrogels by a geometrically-controllable extrusion process that uses analogous linear polymers for both viscosity enhancement and chain entanglement purposes, and achieves high activity retention and performance stability of the immobilized CA. Potential uses for this system extend to 3D printing inks and enzyme immobilization matrices for such diverse applications as biocatalytic reactors and biosensor fabrication.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗