Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “electrolyzer”

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 397 records · Page 22
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

A Tandem Electrolysis Process for Multi-Carbon Chemical Production from Carbon Dioxide (Final Technical Report)

a two-step CO 2 electroreduction process for selective production of acetate and ethylene was successfully developed at the kW-scale. The CO 2 and CO electrolyzers were first investigated individually on the Watt-scale to achieve high current densities and more durable operation by using a reinforced GDL. High CO 2 conversion was obtained in the first CO 2 electrolyzer to produce a CO-dominant gas stream with minimal CO 2 , and highly pure acetate stream was produced in the second CO electrolyzer by using NiFe anode, which promoted alcohol oxidation to carboxylates. The two-step process operated stably for 200 h with acetate and ethylene as the major C 2+ products. Degradation mechanism study revealed that the flooding and the salt formation in the GDL is likely the biggest contributor to the performance degradation for both CO 2 and CO electrolyzers. A 1,000 cm 2 CO electrolyzer stack was then designed, fabricated, and operated up to a total current of 300 A along with a 500 cm 2 CO 2 electrolyzer stack which was operated up to a total current of 100 A. The CO electrolyzer stack demonstrated good stability at 300 A for at least 125 h at a carbon selectivity >96%. The impact of CO 2 , O 2 , N 2 , SO x , and NO x gas impurities on the CO electrolyzer stack was studied and a relatively high resistance to these contaminants was demonstrated. Electroreduction of CO 2 into acetic acid was also demonstrated to be environmentally favorable when compared to the traditional production of acetic acid when powered by renewable electricity. Additionally, electricity cost was identified as the primary source of cost sensitivity indicating substantial economic improvements could be achieved by continuing to drive down the cost of renewable electricity. Overall, the presented approach demonstrates the feasibility of the two-step electrochemical CO 2 reduction process for the effective production of C 2+ products at the kW-scale which should inspire future scaling efforts accelerating commercialization.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

System and process for the production of renewable fuels and chemicals

A renewable fuel production system includes a carbon dioxide capture unit for extracting carbon dioxide from atmospheric air, a carbon dioxide electrolyzer for converting carbon dioxide to carbon monoxide, a water electrolyzer for converting water to hydrogen, a synfuels generator for converting carbon monoxide produced by the carbon dioxide electrolyzer and hydrogen produced by the water electrolyzer to a fuel. The fuel produced can be synthetic gasoline and/or synthetic diesel. A renewable fuel production process includes the steps of extracting carbon dioxide from atmospheric air via a carbon dioxide capture unit, converting carbon dioxide to carbon monoxide via a carbon dioxide electrolyzer, converting water to hydrogen via a water electrolyzer, and converting carbon monoxide produced via the carbon dioxide electrolyzer and H.sub.2 produced via the water electrolyzer to a fuel. The system is also capable of simultaneously or alternatively producing a separate industrial chemical.

Masel, Richard I.↗
DOE OSTI2026

Water-Fed, Photovoltaic-Driven Anion-Exchange Membrane Water Electrolysis for Solar Hydrogen Production

Direct coupled photovoltaic (PV)-electrolysis is a promising approach for low-cost hydrogen production, avoiding the need for separate electricity generation. Without solar concentration, the operating current densities of a PV-electrolyzer are small, and low capital costs are needed to reach hydrogen production cost targets (<$2/kg). Anion-exchange membrane (AEM) electrolyzers could be well-suited for this application due to their ability to use platinum group metal (PGM)-free catalysts and operate without supporting electrolytes, but a water-fed PV-AEM system has not yet been demonstrated. In this work, the performance of two AEM electrolyzer designs under pure-water, low-temperature, and diurnal-cycling conditions was evaluated. A simple PV-electrolyzer system design with direct electric coupling to a commercial 84 cm2 Si mini module and passive heating and water flow to the electrolyzer was used for on-sun testing in October 2025. The best-performing PV-AEM system achieved an average solar-to-hydrogen (STH) efficiency of 6.6% and a production rate of 15 mg/kWh/m2 of solar irradiance over 11 days. Minimal electrolyzer corrosion was observed, with no loss in efficiency over the diurnal cycles. While highlighting areas for improved electrolyzer and system design, this work is a proof of concept for distributed hydrogen production using inexpensive and abundant materials.

08 HYDROGEN↗
NASA NTRSDate not supplied

Technology Assessment for Producing Propellant From Lunar Water

Introduction: The presence of water ice in permanently shadowed regions (PSRs) on the lunar surface may enable a sustained human presence on the Moon with minimal need for consumables. One of the most valuable uses of lunar water is to produce rocket propellant. A sustained human presence on the Moon will re-quire frequent launches from the lunar surface, and each launch will require tons of propellant. However, many other volatiles are likely to be present in the areas where lunar water is stable1. Producing propellant from lunar water in-situ will require the separation and purification of water before it can be electrolyzed into oxygen and hydrogen gas. The Resource Exploration and Science of OUR Cosmic Environment (RESOURCE) project, funded by the Solar System Exploration Research Virtual Institute (SSERVI) program, includes a task to demonstrate the end-to-end process of water extraction, capture, purification and electrolysis to produce pure/dry oxygen gas sourced from an icy regolith mixture. Water Purification: The requirements for water purity are driven by the type of water electrolyzer used. For example, the water electrolyzer currently used on the International Space Station is based on proton ex-change membrane (PEM) technology. PEM-based electrolyzers require water to be ultrapure and deionized (>10 MegaOhm-cm) so that electrical conductivity is limited to the membranes themselves, where electrical current is used to convert H2O into H2 and O2.. A practical first step toward purifying water that is sourced from a lunar PSR is to use freeze distillation to separate water from other volatiles2. A sub-micronic filter can also be used to ensure that a minimal amount of dust is present in any lunar water that is captured. The combination of freeze distillation and sub-micronic filtration will result in relatively pure water but would require a deionization step if being fed into a PEM electrolyzer. Water Electrolysis: An alternative to PEM electrolysis is to use a Solid Oxide Electrolyzer (SOE). This technology operates at a much higher operating temperature (~800oC) and has a limited pressure range but does not require water to be ultrapure and deionized. Another advantage of SOE technology is that it produces pure dry oxygen gas without the need of an additional drying step. PEM electrolyzers produce humid oxygen gas and the humidity must be removed prior to liquefaction. Assessment: In order to compare PEM and SOE technologies side-by-side, they must be compared at a system level that includes water purification and gas drying steps. Engineers at the Johnson Space Center up-dated and utilized a detailed In-Situ Resource Utilization (ISRU) system model to compare and select the best option for the RESOURCE project which will conclude with a laboratory demonstration of the process of producing pure/dry oxygen from an icy regolith mixture in 2025.

A.J. Paz↗
NASA NTRSDate not supplied

Technology Assessment for Producing Propellant From Lunar Water

Introduction: The presence of water ice in permanently shadowed regions (PSRs) on the lunar surface may enable a sustained human presence on the Moon with minimal need for consumables. One of the most valuable uses of lunar water is to produce rocket propellant. A sustained human presence on the Moon will re-quire frequent launches from the lunar surface, and each launch will require tons of propellant. However, many other volatiles are likely to be present in the areas where lunar water is stable1. Producing propellant from lunar water in-situ will require the separation and purification of water before it can be electrolyzed into oxygen and hydrogen gas. The Resource Exploration and Science of OUR Cosmic Environment (RESOURCE) project, funded by the Solar System Exploration Research Virtual Institute (SSERVI) program, includes a task to demonstrate the end-to-end process of water extraction, capture, purification and electrolysis to produce pure/dry oxygen gas sourced from an icy regolith mixture. Water Purification: The requirements for water purity are driven by the type of water electrolyzer used. For example, the water electrolyzer currently used on the International Space Station is based on proton ex-change membrane (PEM) technology. PEM-based electrolyzers require water to be ultrapure and deionized (>10 MegaOhm-cm) so that electrical conductivity is limited to the membranes themselves, where electrical current is used to convert H2O into H2 and O2.. A practical first step toward purifying water that is sourced from a lunar PSR is to use freeze distillation to separate water from other volatiles2. A sub-micronic filter can also be used to ensure that a minimal amount of dust is present in any lunar water that is captured. The combination of freeze distillation and sub-micronic filtration will result in relatively pure water but would require a deionization step if being fed into a PEM electrolyzer. Water Electrolysis: An alternative to PEM electrolysis is to use a Solid Oxide Electrolyzer (SOE). This technology operates at a much higher operating temperature (~800oC) and has a limited pressure range but does not require water to be ultrapure and deionized. Another advantage of SOE technology is that it produces pure dry oxygen gas without the need of an additional drying step. PEM electrolyzers produce humid oxygen gas and the humidity must be removed prior to liquefaction. Assessment: In order to compare PEM and SOE technologies side-by-side, they must be compared at a system level that includes water purification and gas drying steps. Engineers at the Johnson Space Center up-dated and utilized a detailed In-Situ Resource Utilization (ISRU) system model to compare and select the best option for the RESOURCE project which will conclude with a laboratory demonstration of the process of producing pure/dry oxygen from an icy regolith mixture in 2025.

ISRU↗
DOE OSTI2026

Project Development of an Electrochemical Denitration and Caustic Generation System for HLW Pretreatment at Hanford - 26350

An engineering-scale electrochemical processing skid is proposed to perform the denitration of Hanford tank waste, which would help to mitigate a key process concern with the direct feed processing of the Hanford Tank Waste Treatment and Immobilization Plant (WTP). The reduction of nitrates and organic compounds in the waste feed will directly reduce hazardous NOx and ammonia gases generated during the vitrification process, which in turn will aid in addressing potential regulatory and safety challenges associated with processing large volumes of tank waste. This paper highlights the past legacy work, project layout, accomplishments from Phase 1 and research and development envisioned for Phase 2. An innovative electrochemical denitration and caustic generation (EDCGe) process was demonstrated for the pretreatment of tank waste at the Savannah River Site (SRS) in the early 2000s. The denitration electrolyzer, off-gas abatement system, and caustic generator electrolyzer are being developed with the intent that the denitration electrolyzer will convert nitrate and nitrite anions to nitrogen gas while also yielding other gaseous byproducts, which may include N2O, NH3, VOCs, and H2. The gaseous byproducts will be managed via a tandem off-gas catalyst-bed treatment system. The caustic generation electrolyzer will recycle NaOH from the feed to produce a clean caustic stream for use within the batching tanks at Hanford, aiding in the preparation of waste for WTP. The reduction in hazardous emissions and improved waste treatment processes provides a robust solution for nuclear waste management, contributing to environmental safety and regulatory compliance. The EDCGe technology is being adapted, modified, and updated for the preparation of the Direct Feed-High Level Waste (DF-HLW) flowsheet at Hanford. Phase 1 demonstrated a bench-scale proof-of-concept for reactions involving the denitration electrolyzer and gas phase abatement of ammonia. The electrochemical technology is drawing on the scientific outcomes that were reported in the legacy work. The results from Phase 1 demonstrated the viability of the EDCGe system in reducing the nitrogen species of simple non-radioactive waste simulants. Commercially available alloys used as electrode materials and membranes are being studied for the denitration and caustic generation electrolyzers. The continuation of this project holds promise for broader applications, such as energy-efficient ammonia production, and contributes significant advancements in nuclear waste management. Additional material discovery has been investigated into ceramic Na super ion conductive (NaSICON) materials and off-gas abatement catalyst discovery. NaSICON is of interest for selective transport of Na within the electrolyzers to make a clean caustic stream. Future integration and optimization efforts, informed by Phase 1 results and ongoing research, will continue to drive advancements in nuclear waste management technology. The technology developed for the EDCGe treatment of tank waste will also have broader potential to inform other fields, such as energy-efficient ammonia production, as well as ammonia abatement catalysis through the lessons learned in electrochemical nitrate reduction. The applications and benefits of this research extend beyond Hanford and the Savannah River Site, supported by a collaborative team of scientists and engineers from national labs, academia, and industry, ensuring a comprehensive approach to solving complex waste treatment challenges. The team is leveraging advanced electrochemical technologies, machine learning, novel catalysts tailored for gaseous nitrogen species, and cutting-edge reactor systems to enhance the process efficiency and effectiveness of the denitration process.

Rodene, Dylan [Savannah River National Laboratory ↗
DOE OSTI2026

Comparing Tandem Cell Designs for Electrochemical CO 2 Reduction to Ethylene

Electrochemical carbon dioxide reduction (CO 2 R) is a promising approach for the decentralized production of fuels such as ethylene (C 2 H 4 ). However, the use of Cu, the most efficient metal CO 2 R catalyst for the generation of C 2 H 4 known to date, generally yields a product stream with poor selectivity. In an effort to increase selectivity, the reaction from CO 2 to C 2 H 4 can be broken down into two steps using tandem CO 2 R electrolyzers: formation of CO from CO 2 and subsequent reduction of CO to C 2 H 4 . Here, in this study, we present two novel tandem electrolyzer architectures that closely integrate two cathodes, one for CO generation and one for conversion to C 2 H 4 , while still enabling independent electrical control of the cathodic surfaces. Cathode segmentation in each of these designs also permits the controlled sequencing of mass flow of chemical intermediates in the order of Au to Cu cathode catalysts, in contrast to earlier work relying on uncontrolled, passive diffusion to facilitate the flow of chemical intermediates between catalysts. When comparing the performance of the newly developed electrolyzer cell designs with a dual electrolyzer system, we found that the dual electrolyzer system yields the highest C 2 H 4 faradaic efficiencies (FEs) of 31% and C 2 H 4 concentrations (∼8 mol %). However, a single Cu-containing electrolyzer outperformed all three tandem systems in terms of C 2 H 4 FE (34%). Our findings, enabled by independent control of the two tandem cathode surfaces, indicate that tandem CO 2 R systems need to be evaluated carefully by testing them at various relevant current densities.

C2H4↗
DOE OSTI2026

Public Reference Data for Megawatt-Scale Hydrogen Electrolysis - NLR Historical Solar PV

The U.S. Department of Energy and National Laboratory of the Rockies (NLR) demonstrate hydrogen electrolysis from variable sources, hydrogen compression and storage, and hydrogen fuel cell power production using megawatt-scale equipment at NLR’s Flatirons Campus as part of the Advanced Research on Integrated Energy Systems (ARIES) research platform. This dataset represents part of that effort and is intended for academic, national laboratory, industrial, and other stakeholders to plan, design, and validate models of megawatt-scale hydrogen technologies and diverse energy infrastructure nationwide. These data provide a baseline for how existing hydrogen electrolysis technologies perform when coupled with various energy technologies. Future datasets will demonstrate how existing hydrogen fuel cell technologies can provide controllable, dispatchable, and variable power output for artificial intelligence data centers and other variable loads. This dataset entry describes the behavior of a 1.25-MW proton exchange membrane MC250 electrolyzer system, manufactured by Nel Hydrogen , [1] when fed historical data generated by the 430-kW, fixed-axis solar photovoltaic (PV) array located at NLR’s Flatirons Campus. (While the electrolyzer balance of plant supports up to 2.5 MW of electrolysis, NLR only has a single 1.25-MW electrolysis stack.) Solar PV power output data for the 2020 calendar year were categorized on a daily basis by total energy generation and standard deviation. Each day was then ranked by these metrics, and the 25th, 50th, and 100th percentiles were selected. The 75th percentile day did not exhibit sufficient variability to make for a valuable experiment. A similar process was used for the related historical wind dataset . [2] The historical days in 2020 that represented these percentiles are Dec. 19, March 29, and May 4, respectively. The entire solar day’s power profile was then fed through the MC250 electrolyzer. Due to its length, the 100th percentile day experiment was split into two parts, and the final 3 hours of the solar day were not captured. These final 3 hours contained no spikes or dips of interest and simply represented a slow decay of input solar power. Also, a single timestamp (13:13:47 on Jan. 14, 2026) was lost in the hydrogen system supervisory control and data acquisition. Finally, during the 25th percentile experiment (solar day Dec. 19, 2020) data recording was lost from 11:00:13 to 11:14:45. The roughly 15 minutes of the solar profile were rerun at the end of the experiment and spliced into this time slot during post-processing. The electrolysis system controls hydrogen production by varying direct current applied to the stack, from a maximum of 3,000 A to a minimum safe operation of 300 A, or 10%. Because the current–voltage characteristic changes as the stack ages and efficiency degrades, the actual minimum safe operating power changes over time. The historical solar profiles were translated from power (kilowatts) to current (amperes) using a curve fit with calibration data and sent to the electrolyzer power supply at 1-Hz frequency. For more details on the statistical analysis process, see the slide deck “Public Reference Data for Megawatt-Scale Hydrogen Electrolysis: NLR Historical Solar PV Analysis and Profile Generation” accessible with this data entry. These datasets report relevant hydrogen balance-of-plant and system data, all captured at 1 Hz, including hydrogen mass production measured with an Emerson Coriolis flow meter. Each .zip file represents a single solar PV electrolysis experiment and is formatted as: {technology}_{percentile}_{scaling factor} For instance, “solarPV-430kW_25_2x.zip” reports the experiment using the 25th percentile solar data from the historical 2020 solar PV dataset, scaled to 200%. Scaling factors were applied to the generated solar PV power output files to more closely match the 1.25-MW capacity of the electrolyzer. Each .zip folder contains the following files: A .csv file containing raw data. An .xlsx file explaining all the fields in the raw data. A .png plot showing the time series of hydrogen production, electrolysis power consumption, and solar power input. A PDF file detailing the historical solar data statistical analysis used to generate the solar profile. An experiment labeled “characterization_200.zip” demonstrates the MC250 electrolyzer steady-state response with 30-minute load steps for a total duration of 5 hours. Finally, a .csv file is provided with all experiments combined into one dataset labeled "combined_solarPV_experiments.csv". [1] nelhydrogen.com/product/mc-series-electrolyser . [2] data.nlr.gov/submissions/316 .

08 HYDROGEN↗
DOE OSTI2019

Modeling Electrolysis-based H2 Production for Grid Service Assessment

Hydrogen is a promising clean and renewable source of energy. Its high energy density offers a unique and effective means to store energy. The integration of hydrogen production devices with the power grid could lead to a cleaner and more reliable grid operation at reasonable costs. In this work, the capability of Proton Exchange Membrane (PEM) electrolyzers to perform grid services is assessed using a battery equivalent model approach. The Battery Equivalent Model (BEM) has been developed to represent the physics and operation of a fleet of PEM electrolyzers. The BEM model has been designed to be modular and readily incorporated into grid planning studies. This application of PEM electrolyzers can be integrated with other power generation and consumption devices, aggregating capabilities of each device to enhance the ability of the integrated system to provide grid services and improves grid stability. The developed model is evaluated using ancillary support services including peak management, frequency regulation, voltage regulation, artificial inertia, spinning reserve, and wholesale market price response using a representative price and power system profiles. The BEM model has also been evaluated to provide frequency regulation service that conforms to the IEEE 1547-2018 standard. Metrics such as energy efficiency, charging efficiency, hydrogen production rate, and service efficacy have been incorporated into the model to quantify the performance of the fleet while responding to grid services. Results show the electrolyzer fleet's effectiveness in quickly adjusting its real power consumption based on grid service requests. The energy efficiency of the fleet is maintained relatively high – in the range of 78% and 90% during the service operation. These results demonstrate the ability of PEM electrolyzers to effectively provide fast dispatch capability through storing off-peak hour energy while regulating power consumption during peak hours. The BEM model can assist in quantifying the stability and variability impacts from integration of PEM electrolyzers with intermittent renewable resources in grid integration studies.

08 HYDROGEN↗
DOE OSTI2023

Decarbonization of the Electric Power Sector and Implications for Low-Cost Hydrogen Production from Water Electrolysis

Increasing development of wind and solar generation in the power sector can create economic opportunities for the deployment of water electrolyzers that produce hydrogen. Temporal variation in the marginal cost of energy in future decarbonized grids can make it favorable for electrolyzers to dispatchably ramp hydrogen production up and down in response to low- and high-cost times. Using this strategy, low-cost hydrogen production is enabled by electrolyzers that are low-capital cost and tolerant to frequent on/off cycling. Ramping down hydrogen production to a designated turndown ratio can avoid performance degradation caused by on/off cycling by not shutting the electrolyzer completely off. This comes with a slight cost penalty which can be minimized if the turndown ratio is low (i.e., the system ramps down hydrogen production to close to zero). These results suggest that electrolyzers integrated into future power systems are likely to benefit from the ability to ramp operation up and down quickly and operate in a standby mode. This analysis forms a basis for comparative tradeoffs between electrolyzer capital cost, operating strategy, and system durability and demonstrates the importance of considering all three factors in technoeconomic analysis.

capital cost↗
DOE OSTI2021

Bipolar Membranes for Ion Management in (Photo)Electrochemical Energy Conversion

Conspectus (Photo)electrochemical energy conversion is important in the development of a carbon-neutral energy economy because it can provide a pathway for mitigating the intermittency of renewable energy sources such as wind and solar. In order to operate efficiently, these technologies, which include photoelectrochemical cells, water and CO 2 electrolyzers, fuel cells, and redox flow batteries, require fast charge transfer kinetics at the electrode/electrolyte interface as well as robust ion management in the electrolyte. In conventional electrolyzers and fuel cells, the electrolyte is strongly acidic or basic and ionic current is carried by H + or OH – ions. In contrast, photoelectrodes and electrocatalysts for water splitting are often studied in buffered solutions. The question of ion balance in these systems led us to analyze the polarization losses due to ion concentration gradients in cells that employed various buffer–membrane combinations. Continuously driving the buffer ions across an ionomer membrane not only lowers the buffer capacity of an aqueous electrolyte but also introduces pH gradients that result in significant energy losses. To address the problem, we and other groups have studied the use of reverse-biased bipolar membranes (BPMs) in (photo)electrolytic cells. BPMs consist of an anion exchange layer (AEL) laminated with a cation exchange layer (CEL) and are usually equipped with a catalytic layer in between to accelerate the water dissociation reaction. At the AEL/CEL interface, water dissociates into protons and hydroxide ions, which replenish those consumed at the cathode and anode. Compared to conventional water electrolyzers with proton/anion exchange membranes (PEM/AEM), BPM electrolyzers provide the unique advantage of continuously operating the cathode and anode under different pH conditions, which is desirable when the two electrode reactions have different pH requirements. BPMs also enable the use of buffered electrolytes at pH values that are optimized for electrode stability and product selectivity in applications such as CO 2 electrolysis. Product crossover losses and CO 2 pumping can be dramatically reduced in BPM-based CO 2 electrolyzers, relative to conventional alkaline membranes, by electrostatic repulsion (of anionic products) and electroosmotic drag (for neutral products). BPM-based gas fed CO 2 electrolyzers can achieve high current density, but they suffer from low Faradaic efficiency (FE) due to the acidic local environment of the CEL. This problem can be mitigated by adding an aqueous buffering layer or by creating a weak acid cation exchange film on the CEL face of the membrane. The use of BPMs in fuel cells and redox flow batteries offers some interesting advantages. Configurations with both reverse and forward bias have been studied, but forward bias has been favored due to material compatibility, reaction kinetics, and thermodynamic considerations. The net reaction at the AEL/CEL interface is the acid–base neutralization reaction, which has a high inherent reaction rate constant, but in the BPM is limited to a nanometric space-charge layer and requires efficient catalysis to achieve high current density. Understanding the mechanism of the acid–base neutralization and the opposite process, the water dissociation reaction, will be essential for improving the performance of forward-biased BPMs. In conclusion, this Account reviews our current understanding of the working mechanisms of BPMs and discusses how we can use them to effectively manage ions for various (photo)electrochemical applications.

Yan, Zhifei↗
DOE OSTI2015

Design Insights for Tuning the Electrocatalytic Activity of Perovskite Oxides for the Oxygen Evolution Reaction

Rechargeable metal-air batteries and water electrolyzers based on aqueous alkaline electrolytes hold the potential to be sustainable solutions to address the challenge of storing large amounts of electrical energy generated from solar and wind resources. For these batteries and electrolyzers to be economically viable, it is essential to have efficient, durable, and inexpensive electrocatalysts for the oxygen evolution reaction. In this article, we describe new insights for predicting and tuning the activity of inexpensive transition metal oxides for designing efficient and inexpensive electrocatalysts. We have focused on understanding the factors determining the electrocatalytic activity for oxygen evolution in a strong alkaline medium. To this end, we have conducted a systematic investigation of nanophase calcium-doped lanthanum cobalt manganese oxide, an example of a mixed metal oxide that can be tuned for its electrocatalytic activity by varying the transition metal composition. Using X-ray absorption spectroscopy (XANES), X-ray photoelectron spectroscopy (XPS), electrochemical polarization experiments, and analysis of mechanisms, we have identified the key determinants of electrocatalytic activity. We have found that the Tafel slopes are determined by the oxidation states and the bond energy of the surface intermediates of Mn-OH and Co-OH bonds while the catalytic activity increased with the average d-electron occupancy of the sigma* orbital of the M-OH bond. We anticipate that such understanding will be very useful in predicting the behavior of other transition metal oxide catalysts.

ORR↗
DOE OSTI2025

Achieving the hydrogen shot: Interrogating ionomer interfaces

The aim of this study is to enable the hydrogen economy and decarbonize various sectors in our environment that requires less expensive and more durable water electrolyzers, which can meet the Hydrogen-Shot target. The key is to improve the ionomer interfaces in low-temperature water electrolyzers as rapidly as possible, but to do so, it requires a systematic and holistic campaign combining both experiments and theory. In this perspective, we discuss the issues of electrolyzers and needs for translational science. We then present the approach that the Energy EarthShot Research Center: Center for Ionomer-based Water Electrolysis is taking in hopes of inspiring the community with this approach that can be leveraged to multiple problems and technologies.Graphical abstractHighlightsOne way to achieve the Hydrogen-Shot goal of low-cost, clean hydrogen, is advancing research and development on the interfaces of water electrolyzers for both performance and lifetime. The Center for Ionomer-based Water Electrolysis is exploring new techniques and strategies to not only interrogate interfacial phenomena in water electrolyzers to increase efficiency and durability, but also a new paradigm related to synergistic, cojoined experimental and theoretical research.DiscussionCatalyst\ionomer interfaces are complex and not fully understood, but through investigating different interfaces and utilizing digital and physical twins, we can elucidate key mechanisms and understanding.Understanding the dynamic double layer in electrochemical systems that use solid electrolytes is crucial to identifying and mitigating the controlling phenomena to enable increased performance and durability at the technology level.Studying the time and length scales of interfacial changes can be a powerful tool to understand reaction mechanisms and changes in the electrolyzer performance and durability.

Fornaciari, Julie C↗
DOE OSTI2021

CO 2 and Renewable Electricity into Chemicals: Formic Acid Production from Coal Flue Gas

Formic acid (FA) is an industrial chemical. It is used as a preservative for silage, as a digestive aid for animals, as a fluid for fracking, as a pharmaceutical intermediate and in leather tanning. The global formic acid market is valued at 777.4 million USD in 2020 and is expected to reach 851.8 million USD by the end of 2026. A new major formic acid application is the use of formic acid as a key feedstock for the bioprocessing industry. It has the potential to grow tremendously if we can lower the cost of formic acid production compared with the current fossil-fuel one. Recently, Dioxide Materials has developed a technology that can directly convert CO 2 to pure formic acid with a three-compartment CO 2 electrolyzer. However, the electrolyzer performance needs further improvement for the technology to be commercially viable. The major objective of this project is to develop the electrolyzer technology to enable formic acid as a feedstock for the bioprocessing industry to be economically manufactured from flue gas from a coal fired pilot plant. In particular, the project is to understand how to run the electrolyzer for the conversion of CO 2 into formic acid using flue gas from a coal fired power plant as a source of CO 2 . The work will include characterizing how the performance of the electrolyzer changes with low CO 2 concentration and impurities, developing new cell designs that can still operate with feedstocks with low CO 2 concentrations, testing simulated flue gas in the electrolyzer system and developing filters to remove any impurities that arise.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Integrating Solar Energy, Desalination, and Electrolysis

Solar electricity enables the advancement and deployment of technologies that are strongly influenced by clean energy availability and cost. The economics of both desalination and hydrogen production from water electrolysis are dominated by the cost of energy, and the availability of inexpensive solar energy creates markets and offers incentives to the desalination and electrolyzer industries. In this report the production of high-purity water and hydrogen from seawater is focused on. Current electrolyzers require deionized water so they need to be coupled with desalination units. It is shown that such coupling is cost effective in hydrogen generation, and it also offers benefits to thermal desalination, which can utilize waste heat from electrolysis. Furthermore, such coupling can be optimized when electrolyzers operate at high current density, using low-cost solar and/or wind electricity, as such operation increases both hydrogen production and heat generation. Results of technoeconomic modeling of polymer electrolyte membrane electrolyzers define thresholds of electricity pricing, current density, and operating temperature that make clean electrolytic hydrogen cost competitive with hydrogen from steam methane reforming (SMR). By using 2020 hourly electricity pricing in California and Texas, it is estimated that hydrogen can be produced from seawater in coupled desalination-electrolyzer systems at prices near $2 kg -1 H 2 , reaching cost parity with hydrogen produced from SMR.

14 SOLAR ENERGY↗
DOE OSTI2025

Grid-responsive hydrogen production: Capital utilization and current density vs. efficiency in variable electricity markets

To achieve low-cost hydrogen production from water electrolyzers, grid tied electrolysis may need to operate dynamically to minimize the cost of supplying energy to the electrolyzer stack and produce hydrogen during low-cost hours and turn off/down during high-cost hours. Operating systems in this way can decrease capital utilization (capacity factor) and electricity costs. This strategy would shift the dominant cost drivers away from electricity (and thus efficiency) to the capital costs of the system, due to the underutilized capital when operating at low-capacity factors. Increasing the operational current density of the system could, in effect, reduce the capital cost of the system while producing hydrogen at a lower efficiency on a per unit energy basis. In the variable electricity cost profiles analyzed in this paper, increasing the current density for liquid alkaline from 0.5 A/cm2 to 1.5 Ac/m2 and proton exchange membrane electrolyzers from 2 A/cm2 to 4 A/cm2 resulted in substantial reductions in the levelized cost of hydrogen. Additionally, as capacity factors and electricity costs decrease, the optimal operating current density of the electrolyzer systems analyzed increases. These findings suggest R&D efforts should focus on increasing the operational current densities, reducing the turn down ratios, and understanding the durability implications of those strategies on low-temperature liquid alkaline and proton exchange membrane electrolyzers.

08 HYDROGEN↗
DOE OSTI2023

Modeling Wind-Hydrogen System and Analyzing Curtailment

Low-cost green hydrogen can be achieved by integrating utility-scale wind farms to an electrolyzer. The power produced by a wind farm depends on spatial and temporal changes in the wind, and this variability can affect the electrolyzer's performance. This study examines the trade-offs between two electrolyzer configurations: a large centralized electrolyzer connected to the wind farm versus several smaller distributed electrolyzers connected directly to each wind turbine. The results show that a centralized configuration generates more hydrogen because turbines that are waked and produce less power are compensated but other un-waked turbines.

electrolyzer↗
DOE OSTI2023

Advanced electrode manufacturing to enable low cost PEM electrolysis

A critical challenge for the implementation of proton exchange membrane (PEM)-based water electrolyzers for the H2@Scale vision is the capital cost, which is largely driven by related factors of overdesign and highly manual legacy manufacturing methods. Typical electrolyzer cells have an order of magnitude higher membrane thickness and catalyst loading vs. fuel cells, in part because the manufacturing methods being used are not capable of producing uniform and reliable electrodes on thin membranes with low loading. Advanced electrode manufacturing is therefore the key enabler to reduce the cost of the electrolyzer stack, particularly roll-to-roll (R2R) manufacturing of catalyst coated layers (CCLs) and catalyst coated membranes (CCMs). The electrolyzer manufacturing process still relies on traditional sheet-to-sheet (S2S) processes, which requires intensive labor to make parts to meet the specification requirements. This project leverages fuel cell expertise (GM) with Proton’s knowledge of electrolyzer components to develop the electrocatalyst ink formulations and coating processes using slot die (ORNL) and gravure (NREL) coatings, with proof of concept at the pilot-scale (Kodak).

08 HYDROGEN↗