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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 397 records · Page 22
All sourcesNASA NTRSDOE OSTI
NASA NTRS2015

Experimentally Determined Heat Transfer Coefficients for Spacesuit Liquid Cooled Garments

A Human-In-The-Loop (HITL) Portable Life Support System 2.0 (PLSS 2.0) test has been conducted at NASA Johnson Space Center in the PLSS Development Laboratory from October 27, 2014 to December 19, 2014. These closed-loop tests of the PLSS 2.0 system integrated with human subjects in the Mark III Suit at 3.7 psi to 4.3 psi above ambient pressure performing treadmill exercise at various metabolic rates from standing rest to 3000 BTU/hr (880 W). The bulk of the PLSS 2.0 was at ambient pressure but effluent water vapor from the Spacesuit Water Membrane Evaporator (SWME) and the Auxiliary Membrane Evaporator (Mini-ME), and effluent carbon dioxide from the Rapid Cycle Amine (RCA) were ported to vacuum to test performance of these components in flight-like conditions. One of the objectives of this test was to determine the heat transfer coefficient (UA) of the Liquid Cooling Garment (LCG). The UA, an important factor for modeling the heat rejection of an LCG, was determined in a variety of conditions by varying inlet water temperature, flowrate, and metabolic rate. Three LCG configurations were tested: the Extravehicular Mobility Unit (EMU) LCG, the Oceaneering Space Systems (OSS) LCG, and the OSS auxiliary LCG. Other factors influencing accurate UA determination, such as overall heat balance, LCG fit, and the skin temperature measurement, will also be discussed.

Bue, Grant↗
NASA NTRS2015

Experimentally Determined Overall Heat Transfer Coefficients for Spacesuit Liquid Cooled Garments

A Human-In-The-Loop (HITL) Portable Life Support System 2.0 (PLSS 2.0) test has been conducted at NASA Johnson Space Center in the PLSS Development Laboratory from October 27, 2014 to December 19, 2014. These closed-loop tests of the PLSS 2.0 system integrated with human subjects in the Mark III Suit at 3.7 psi to 4.3 psi above ambient pressure performing treadmill exercise at various metabolic rates from standing rest to 3000 BTU/hr (880 W). The bulk of the PLSS 2.0 was at ambient pressure but effluent water vapor from the Spacesuit Water Membrane Evaporator (SWME) and the Auxiliary Membrane Evaporator (Mini-ME), and effluent carbon dioxide from the Rapid Cycle Amine (RCA) were ported to vacuum to test performance of these components in flight-like conditions. One of the objectives of this test was to determine the overall heat transfer coefficient (UA) of the Liquid Cooling Garment (LCG). The UA, an important factor for modeling the heat rejection of an LCG, was determined in a variety of conditions by varying inlet water temperature, flow rate, and metabolic rate. Three LCG configurations were tested: the Extravehicular Mobility Unit (EMU) LCG, the Oceaneering Space Systems (OSS) LCG, and the OSS auxiliary LCG. Other factors influencing accurate UA determination, such as overall heat balance, LCG fit, and the skin temperature measurement, will also be discussed.

Bue, Grant↗
NASA NTRS2017

Evolving Maturation of the Series-Bosch System

Human exploration missions to Mars and other destinations beyond low Earth orbit require highly robust, reliable, and maintainable life support systems that maximize recycling of water and oxygen. In order to meet this requirement, NASA has continued the development of a Series-Bosch System, a two stage reactor process that reduces carbon dioxide (CO2) with hydrogen (H2) to produce water and solid carbon. Theoretically, the Bosch process can recover 100% of the oxygen (O2) from CO2 in the form of water, making it an attractive option for long duration missions. The Series Bosch system includes a reverse water gas shift (RWGS) reactor, a carbon formation reactor (CFR), an H2 extraction membrane, and a CO2 extraction membrane. In 2016, the results of integrated testing of the Series Bosch system showed great promise and resulted in design modifications to the CFR to further improve performance. This year, integrated testing was conducted with the modified reactor to evaluate its performance and compare it with the performance of the previous configuration. Additionally, a CFR with the capability to load new catalyst and remove spent catalyst in-situ was built. Flow demonstrations were performed to evaluate both the catalyst loading and removal process and the hardware performance. The results of the integrated testing with the modified CFR as well as the flow demonstrations are discussed in this paper.

Stanley, Christine↗
NASA NTRS2017

Evolving Maturation of the Series-Bosch System

Human exploration missions to Mars and other destinations beyond low Earth orbit require highly robust, reliable, and maintainable life support systems that maximize recycling of water and oxygen. In order to meet this requirement, NASA has continued the development of a Series-Bosch System, a two stage reactor process that reduces carbon dioxide (CO2) with hydrogen (H2) to produce water and solid carbon. Theoretically, the Bosch process can recover 100% of the oxygen (O2) from CO2 in the form of water, making it an attractive option for long duration missions. The Series Bosch system includes a reverse water gas shift (RWGS) reactor, a carbon formation reactor (CFR), an H2 extraction membrane, and a CO2 extraction membrane. In 2016, the results of integrated testing of the Series Bosch system showed great promise and resulted in design modifications to the CFR to further improve performance. This year, integrated testing was conducted with the modified reactor to evaluate its performance and compare it with the performance of the previous configuration. Additionally, a CFR with the capability to load new catalyst and remove spent catalyst in-situ was built. Flow demonstrations were performed to evaluate both the catalyst loading and removal process and the hardware performance. The results of the integrated testing with the modified CFR as well as the flow demonstrations are discussed in this paper.

Abney, Morgan B.↗
DOE OSTI2021

Scalable Polymeric Few-Nanometer Organosilica Membranes with Hydrothermal Stability for Selective Hydrogen Separation

Nanoporous silica membranes exhibit excellent H 2 /CO 2 separation properties for sustainable H 2 production and CO 2 capture but are prepared via complicated thermal processes above 400 °C, which prevent their scalable production at a low cost. Here, we demonstrate the rapid fabrication (within 2 min) of ultrathin silica-like membranes (~3 nm) via an oxygen plasma treatment of polydimethylsiloxane-based thin-film composite membranes at 20 °C. The resulting organosilica membranes unexpectedly exhibit H2 permeance of 280-930 GPU (1 GPU = 3.347 x 10 -10 mol m -2 s -1 Pa -1 ) and H2/CO2 selectivity of 93-32 at 200 °C, far surpassing state-of-the-art membranes and Robeson’s upper bound for H 2 /CO 2 separation. When challenged with a 3 d simulated syngas test containing water vapor at 200 °C and a 340 d stability test, the membrane shows durable separation performance and excellent hydrothermal stability. The robust H 2 /CO 2 separation properties coupled with excellent scalability demonstrate the great potential of these organosilica membranes for economic H 2 production with minimal carbon emissions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Proton selective membranes based on two dimensional materials

Proton conductive membrane includes a proton selective layer of 80-100% carbon with sp2 hybridization having a thickness of 0.3-100 nm, with 0-20% of hydrogen, oxygen, nitrogen and sp3 carbon; wherein the sp2 carbon is in a form of graphene-like material; the proton selective layer having a plurality of pores formed by any of 7, 8, 9 or 10 sp2 carbon cycles or a combination thereof, with the pores having an effective diameter of up to 0.6 nm; an ionomeric polymer layer on the proton selective layer. Total thickness of the proton conductive membrane is less than 50 microns. The ionomeric polymer is PFSA (perfluorinated sulfonic acid), PVP (polyvinylpyrrolidone) or PVA (poly vinyl alcohol) with iodide or bromide counterion dissolved inside. The graphene-like material is CVD graphene or reduced graphene oxide (rGO). A D to G Raman band ratio of the membrane is more than 0.1.

Smirnov, Sergei↗
DOE OSTI2023

Method of manufacturing proton selective membranes based on two dimensional materials

Proton conductive membrane includes a proton selective layer of 80-100% carbon with sp2 hybridization having a thickness of 0.3-100 nm, with 0-20% of hydrogen, oxygen, nitrogen and sp3 carbon; wherein the sp2 carbon is in a form of graphene-like material; the proton selective layer having a plurality of pores formed by any of 7, 8, 9 or 10 sp2 carbon cycles or a combination thereof, with the pores having an effective diameter of up to 0.6 nm; an ionomeric polymer layer on the proton selective layer. Total thickness of the proton conductive membrane is less than 50 microns. The ionomeric polymer is PFSA (perfluorinated sulfonic acid), PVP (polyvinylpyrrolidone) or PVA (poly vinyl alcohol) with iodide or bromide counterion dissolved inside. The graphene-like material is CVD graphene or reduced graphene oxide (rGO). A D to G Raman band ratio of the membrane is more than 0.1.

Smirnov, Sergei↗
DOE OSTI2021

Cascade CO 2 electroreduction enables efficient carbonate-free production of ethylene

CO 2 electroreduction provides a route to convert waste emissions into chemicals such as ethylene (C 2 H 4 ). However, the direct transformation of CO 2 -to-C 2 H 4 suffers from CO 2 loss to carbonate, consuming up to 72% of energy input. A cascade approach—coupling a solid-oxide CO 2 -to-CO electrochemical cell (SOEC) with a CO-to-C 2 H 4 membrane electrode assembly (MEA)—would eliminate CO 2 loss to carbonate. However, this approach requires a CO-to-C 2 H 4 MEA with energy efficiency well beyond demonstrations to date. Focusing on the MEA, in this study we find that an N-tolyl substituted tetrahydro-bipyridine film improves the stabilization of key reaction intermediates, while an SSC ionomer enhances CO transport to the Cu surface, enabling a C 2 H 4 faradaic efficiency of 65% at 150 mA cm –2 for 110 h. Demonstrating a cascade SOEC-MEA approach, we achieve CO 2 -to-C 2 H 4 with a ~48% reduction in energy intensity compared with the direct route. We further reduce the energy intensity by coupling CO electroreduction (CORR) with glucose electrooxidation.

10 SYNTHETIC FUELS↗
NASA NTRS1993

Performance of high-recovery recycling reverse osmosis with wash water

Inclusion of a recycling loop for partially-desalted water from second-stage reverse-osmosis permeate has been shown useful for achieving high-recovery at moderate applied pressures. This approach has now been applied to simulated wash waters, to obtain data on retention by the membranes of solutes in a mixture comparable to anticipated spacecraft hygiene wastewaters, and to generate an estimate of the maximum concentration that can be expected without causing membrane fouling. A first experiment set provides selectivity information from a single membrane and an Igepon detergent, as a function of final concentration. A reject concentration of 3.1% Total Organic Carbon has been reached, at a pressure of 1.4 Mega Pascals, without membrane fouling. Further experiments have generated selectivity values for the recycle configuration from two washwater simulations, as a function of applied pump pressure. Reverse osmosis removal has also been tested for washwater containing detergent formulated for plant growth compatibility (containing nitrogen, phosphorous and potassium functional groups.)

Herrmann, Cal C.↗
DOE OSTI2022

A Process with Decoupled Absorber Kinetics and Solvent Regeneration through Membrane Dewatering and In-Column Heat Transfer (Final Report)

This report summarizes the work conducted on project DE-FE0031604 where University of Kentucky Center for Applied Energy (UK CAER) has validated its intensified CO 2 capture process through substantial enhancements to the kinetics of the absorption process and energy reductions by absorber temperature profile modification, dewatering and heat integration technologies for achieving significant capital and operating cost reductions. To address DOE’s objective of improving post-combustion CO 2 capture technology and reducing associated cost, UK CAER employed an intensified process which combined three key aspects targeted at overcoming inherent limitations or barriers in the conventional CO 2 capture and desorption process. The process designed to be independent of the type of solvent used, included (1) the use of 3-D printed two-channel structured packing material to control the temperature profile and increase the CO 2 absorption rate in the absorber, (2) a zeolite membrane dewatering unit for dewatering of the carbon-rich solvent to decouple solvent concentration needs for CO 2 absorption and desorption, and (3) a rich-split feed with two-phase flow heat transfer prior to the stripper that provided a secondary point of vapor generation to provide energy savings in steam extraction and solvent regeneration. The project was executed over two budget periods. This involved testing of individual process components which included the advanced heat transfer packing and the dewatering membrane on UK CAER’s 30 liter per minute (L/min) CO 2 (3” Column) capture bench unit with simulated flue gas in the first budget period. Subsequent scaled-up testing of these components together with the split-feed configuration were also tested in UK CAER’s 0.1 MWth CO 2 capture unit with coal-derived flue gas in the second-budget period. Long term studies were done during this period to assess process and solvent performance over extended duration. Project partners Lawrence Livermore National Laboratory (LLNL) and Media & Process Technology (MPT) led the development efforts for the advanced packing material and dewatering membrane respectively. Data from the long term testing was used as input for an environmental, health and safety (EH&S) assessment for the process and scaled technology performed by ALL4 LLC. Trimeric Corporation also completed a techno-economic analysis (TEA) for the UK CAER technology which was compared to the DOE reference Case B12B. Tests on the 3” column capture unit showed that the advanced heat transfer packing could be used to lower the bulge temperature in the absorber, and this was also proven in the scaled testing in the 0.1 MWth CO 2 capture unit. The bulge temperature could be lowered by >10 °C, changing the temperature profile in the absorber, and showed potential to enhance absorption with the ability to tailor the profile to provide conditions suitable for a solvent’s properties and kinetics. Conditions for short term evaluation of a 19” zeolite dewatering membrane on the 3” column capture unit yielded desirable fluxes and sustained rejection rates of >80%. However, for the scaled testing of six membrane modules consisting of 21 parts of 31-inch-long membrane tubes in each bundle (surface area 0.3 m 2 ), over a more extended duration, similar rejection rates could not be achieved. With the split-feed of the rich stream to the stripper, improved heat recovery minimized waste heat exiting the top of the stripper. The stripper exhaust temperatures could be reduced by >10 °C; reducing the amount of water vaporization contributed to lowering the regeneration energy by ~ 15%. The energy benefit could be sustained from the long term monitoring of the solvent performance. The solvent properties were not significantly impacted over the long-term operations. The benefits of the UK CAER process demonstrated experimentally were mostly validated from the TEA comparing a commercial scale application of the technology to DOE reference Case B12B. The cost of CO 2 capture for the UK CAER technology was estimated to be ~$34.97/tonne of CO 2 captured; a reduction of 23% compared to Case B12B. The increase in cost of electricity was also shown to be 16% lower than that of Case B12B. The total parasitic demand was also shown to be 11% lower. The key drivers for the benefits are a result of the process intensification approaches employed in the UK CAER technology for enhanced solvent performance, effective heat recovery and improved energy performance. The EH&S assessment did not find any major environmental concerns or barriers to the full scale implementation of the technology.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

Demo-scale testing of a hybrid membrane-sorbent system for post-combustion CO2 capture

TDA Research is developing a novel hybrid membrane-sorbent system for the post-combustion capture of carbon dioxide (CO 2 ) from supercritical pulverized coal (PC) power generation facilities or large point industrial emitters. Here, the novel design incorporates a 1st-stage continuous membrane separator developed by Membrane Technology and Research, Inc. (MTR) with a dual-bed radial-flow sorbent contactor (designed and developed at TDA). Testing of a pilot unit at 1 MWe scale has been conducted at the site for emerging technologies at the Technology Centre Mongstad (TCM) in Mongstad, Norway using residue fluid catalytic cracker (RFCC) flue gas from Equinor’s Mongstad refinery.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2024

Comparative life cycle analysis on ethylene production from electrocatalytic reduction of carbon dioxide

Ethylene is one of the largest greenhouse gas emitters and the most diversly used commodity chemicals globally. Electrocatalytic reduction of CO 2 to ethylene received great attention from the research society to decarbonize the ethylene production. Here, in this study, a life-cycle analysis is conducted using the Greenhouse Gases, Regulated Emissions, and Energy use in Technologies (GREET) model on the three electrocatalytic CO 2 -reduction pathways (or “e-ethylene” pathways): i) cascade conversion via carbon monoxide intermediate; ii) single-step conversion in membrane electrode assembly (MEA); and iii) single-step conversion in alkaline flow cell. The results showed that the electricity consumption is the lowest for the cascade pathway (164 MJ/kg), thus resulting in the lowest cradle-to-gate carbon intensity [18 kgCO 2 e/kg with United States (US) average grid)] among the three pathways followed by the single-step MEA (32 kgCO 2 e/kg) and then by the single-step alkaline (56 kgCO 2 e/kg). However, all three e-ethylene pathways were significantly more carbon-intensive than their fossil-based counterpart (1.1 kgCO 2 e/kg) due to their excessive energy consumption with the current state of technology. With renewable electricity, all three pathways yielded negative carbon intensity: from -3.1 kgCO 2 e/kg to -1.6 kgCO 2 e/kg depending on the source of CO 2 . The threshold carbon intensity of electricity (TCIE), defined as the upper bound of the carbon intensity of electricity to achieve lower carbon intensity for e-ethylene compared to fossil-based ethylene, is calculated for both current and future state of e-ethylene technologies. The cascade pathway had the highest TCIE out of the three e-ethylene pathways for both current (92 gCO 2 e/kWh) and future (124 gCO 2 e/kWh) state of technologies. However, the carbon intensity of average US grid (i.e., 467 and 303 gCO 2 e/kWh for current and future projections) were higher than the TCIEs of the corresponding timeline. Thus, reducing electricity requirement for e-ethylene pathways and bringing low-carbon generation mix in the United States (US) grid faster than the current projection are both essential to decarbonize ethylene and its downstream chemicals/polymers.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
NASA NTRS1992

Catalysts for ultrahigh current density oxygen cathodes for space fuel cell applications

The objective was to identify promising electrocatalyst/support systems for oxygen cathodes capable of operating at ultrahigh current densities in alkaline fuel cells. Such cells will require operation at relatively high temperatures and O2 pressures. A number of materials were prepared, including Pb-Ru and Pb-Ir pyrochlores, RuO2 and Pt-doped RuO2, lithiated NiO and La-Ni perovskites. Several of these materials were prepared using techniques that had not been previously used to prepare them. Particularly interesting was the use of the alkaline solution technique to prepare Pt-doped and Pb-Ru pyrochlores in high area form. Also interesting was the use of the fusion (melt) method for preparing the Pb-Ru pyrochlore. Several of the materials were also deposited with platinum. Well-crystallized Pb2Ru2O(7-y) was used to fabricate very high performance O2 cathodes with good stability in room temperature KOH. This material was also found to be stable over a useful potential range at approx. 140 C in concentrated KOH. For some of the samples, fabrication of the gas-fed electrodes could not be fully optimized during this project period. Future work may be directed at this problem. Pyrochlores that were not well-crystallized were found to be unstable in alkaline solution. Very good O2 reduction performance and stability were observed with Pb2RuO(7-y) in a carbon-based gas-fed electrode with an anion-conducting membrane placed on the electrolyte side of the electrode. The performance came within a factor of about two of that observed without carbon. High area platinum and gold supported on several conductive metal oxide supports were examined. Only small improvements in O2 reduction performance at room temperature were observed for Pb2Ru2O(7-y) as a support because of the high intrinsic activity of the pyrochlore. In contrast, a large improvement was observed for Li-doped NiO as a support for Pt. Very poor performance was observed for Au deposited on Li-NiO at approx. 150 C. Nearly reversible behavior was observed for the O2/OH(-) couple for Li-doped NiO at approx. 200 C. The temperature dependence for the O2 reduction was examined.

Tryk, Donald A.↗
NASA NTRSDate not supplied

CO2-Based Manufacturing System for Recombinant Protein Production

Space biomanufacturing is a potential In Situ Resource Utilization (ISRU) strategy to provide critical consumables and products while minimizing the launched mass for long-duration, deep space missions. On Earth, the primary biological conversion of CO 2 to biomass is through photosynthesis, and sugars from photosynthetic organisms are used as feedstocks for microbial biomanufacturing. The efficiency of non-biological reduction of CO 2 to organic molecules, such as acetate or ethanol, has greatly increased in recent years. We are designing a biomanufacturing system to rely on electrochemical CO 2 conversion products for carbon substrates to support microbial growth and production of recombinant proteins. The preliminary design includes a gas-permeable membrane bioreactor with dry salts that are rehydrated and mixed with the carbon source to support growth of bacteria or yeast. The system architecture has a partially automated bioprocessing system to concentrate biomass and purify recombinant protein. This system is designed to operate semi-autonomously with minimal crew intervention. The specific use-case scenario is to produce a thermal stable carbonic anhydrase to increase the efficiency of a proposed liquid amine CO 2 removal subsystem of an environmental control and life-support system (ECLSS) on Mars.

Biomanufacturing↗
NASA NTRSDate not supplied

Development of a Space Compatible Biomanufacturing System

Space biomanufacturing is a potential In Situ Resource Utilization (ISRU) strategy to provide critical consumables and products while minimizing the launched mass for long-duration, deep space missions. On Earth, the primary biological conversion of CO 2 to biomass is through photosynthesis, and sugars from photosynthetic organisms are used as feedstocks for microbial biomanufacturing. The efficiency of non-biological reduction of CO 2 to organic molecules, such as acetate or ethanol, has greatly increased in recent years. We are designing a biomanufacturing system to rely on electrochemical CO 2 conversion products for carbon substrates to support microbial growth and production of recombinant proteins. The preliminary design includes a gas-permeable membrane bioreactor with dry salts that are rehydrated and mixed with the carbon source to support growth of bacteria or yeast. The system architecture has a partially automated bioprocessing system to concentrate biomass and purify recombinant protein. This system is designed to operate semi-autonomously with minimal crew intervention. The specific use-case scenario is to produce a thermal stable carbonic anhydrase to increase the efficiency of a proposed liquid amine CO 2 removal subsystem of an environmental control and life-support system (ECLSS) on Mars.

Recombinant↗
DOE OSTI2022

Anion-exchange membranes with internal microchannels for water control in CO 2 electrolysis

Electrochemical reduction of carbon dioxide (CO 2 R) poses substantial promise to convert abundant feedstocks (water and CO 2 ) to value-added chemicals and fuels using solely renewable energy. However, recent membrane-electrode assembly (MEA) devices that have been demonstrated to achieve high rates of CO 2 R are limited by water management within the cell, due to both consumption of water by the CO 2 R reaction and electro-osmotic fluxes that transport water from the cathode to the anode. Additionally, crossover of potassium (K + ) ions poses concern at high current densities where saturation and precipitation of the salt ions can degrade cell performance. Herein, a device architecture incorporating an anion-exchange membrane (AEM) with internal water channels to mitigate MEA dehydration is proposed and demonstrated. A macroscale, two-dimensional continuum model is used to assess water fluxes and local water content within the modified MEA, as well as to determine the optimal channel geometry and composition. The modified AEMs are then fabricated and tested experimentally, demonstrating that the internal channels can both reduce K + cation crossover as well as improve AEM conductivity and therefore overall cell performance. This work demonstrates the promise of these materials, and operando water-management strategies in general, in handling some of the major hurdles in the development of MEA devices for CO 2 R.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Methods for carbon dioxide hydrogenation

A method of carbon dioxide hydrogenation comprises introducing gaseous water to a positive electrode of an electrolysis cell comprising the positive electrode, a negative electrode, and a proton-conducting membrane between the positive electrode and the negative electrode. The proton-conducting membrane comprises an electrolyte material having an ionic conductivity greater than or equal to about 10-2 S/cm at one or more temperatures within a range of from about 150° C. to about 650° C. Carbon dioxide is introduced to the negative electrode of the electrolysis cell. A potential difference is applied between the positive electrode and the negative electrode of the electrolysis cell to generate hydrogen ions from the gaseous water that diffuses through the proton-conducting membrane and hydrogenates the carbon dioxide at the negative electrode. A carbon dioxide hydrogenation system is also described.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

A Novel Hollow Fiber Membrane Reactor for High Purity H 2 Generation from Thermal Catalytic NH 3 Decomposition (Final Report)

Ammonia (NH 3 ), as a promising carbon neutral liquid fuel (CNLF) and an effective H 2 source, can be synthesized from air and water (N 2 extracted from air and H 2 from water) using renewable energy sources. To produce H 2 as an intermediate, it is essential to develop effective and economic NH 3 decomposition technologies. We have been developing an innovative hollow fiber membrane reactor for high purity H 2 generation from thermal catalytic NH 3 decomposition. The objective of the proposed research is to fabricate a compact and robust prototype with high energy efficiency (>80%) to deliver high purity (>99%) H2 at high rate per volume (>0.15 g H 2 /h/cm 3 ) from NH3 decomposition at low temperature (<450 °C) and high conversion (>99%). Our overall technical approach is to effectively combine an active catalyst for NH 3 decomposition with a selective H 2 membrane separation process in a novel, compact modular system to generate high purity H 2 and simultaneously achieve high NH 3 conversion and optimize the entire system energy efficiency. This novel integrated membrane reactor design, together with low-cost, highly active Ru-based catalyst, makes it most appropriate for the project objective. The proposed applied research and development work, therefore, represents an innovative and transformational solution to H 2 generation from thermal catalytic NH 3 decomposition. During the course of our research we i) synthesized and characterized ruthenium(Ru)-based catalysts, evaluated their catalytic performance for NH 3 decomposition and optimized the catalyst composition and performance based on machine learning, ii) prepared SAPO-34, MFI membranes on α-alumina hollow fibers and measured their performance for H 2 /N 2 , H 2 /N 2 /NH 3 separation and evaluated carbon molecular sieve (CMS) and Pd/Ag membranes for H 2 /N 2 , H 2 /N 2 /NH 3 separation at different conditions, iii) designed and evaluated several types of membrane reactors for H 2 production from NH 3 decomposition, and iv) evaluated the H 2 delivery cost base on catalysts development, membrane development and membrane reactor. For 3,1,12 RuYK catalyst, H 2 productivity of 6.35 mmol/min/gcat with NH 3 conversion of 95~98% was achieved at 5 bar and 400 °C; for SAPO-34 membrane, the best membrane showed H 2 permeance of 7.56×10 -7 mol/(m 2 ∙s∙Pa) and H 2 /N 2 selectivity of 23.1 at 20 °C; For CMS and Pd/Ag membranes, both showed superior stability for 71%H 2 /24%N 2 /5%NH 3 mixture separation at 450 °C and 7 bar for over 120 h; for the membrane reactor, high H 2 purity of >99.99% with NH 3 conversion of >99.4% were achieved in Pd/Ag membrane reactor at 450 °C, and the NH 3 concentration was always below 10 ppb in H 2 product. The H 2 generation rate was calculated to be as high as 0.47 g/h/cm 3 and the energy efficiency was calculated to be 88%. The membrane reactor showed superior stability for over 370 h and high H 2 purity, H 2 production rate and NH 3 conversion. Based on calculation, the H 2 delivery cost can be as low as $3.66/kg.

08 HYDROGEN↗