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DOE OSTI2026

Through‐Plane Conductive Hydrophobic Electrodes for CO 2 Electrolysis to Ethylene

Copper catalyst gas diffusion electrodes (GDEs) have demonstrated unique electrochemical selectivity converting CO 2 to C 2 -hydrocarbons such as ethylene and ethanol but have been challenged by their hydrophobic chemical stability and internal electrical resistance leading to low energy efficiency. Carbon-supported GDEs have low electrical resistance but lack sufficient stability at industrially relevant current densities. While polymer-supported GDEs have improved hydrophobicity, they also display high in-plane electrical resistance, particularly at industrial scales. Here, in this work, we demonstrate a composite gas diffusion layer that combines hydrophobic porous polymers with an electrically conductive backbone addressing these core gas diffusion electrode (GDE) scaling challenges. We investigate the material properties of standalone porous perfluoropolyether (PFPE) polymers, including porosity and surface morphology, under varying processing conditions and then incorporate these polymers into a porous copper foam. This composite enhances the mechanical rigidity necessary for cell assembly and provides a through-plane electrical conduction path to reduce electrical resistive losses. This enhanced PFPE composite GDE displays efficient CO 2 reduction, achieving 15% ethylene energy efficiency at 100 cm 2 . These findings contribute to the development of advanced catalyst materials and electrode architectures and promote scalable strategies for electrochemical conversion of CO 2 into high-value carbon products.

Chemistry↗

DOE OSTI2024

Tuning Strong Metal–Support Interactions via Synergistic Alloying

The encapsulation phenomenon associated with strong metal-support interaction (SMSI) has been largely restricted to catalyst systems consisting of group VIII metals with high surface energy and reducible transition metal oxide supports with low surface energy. Here, we demonstrate an encapsulation phenomenon that, while sharing morphological similarities with conventional SMSI, follows a distinctive pathway. This is shown by the encapsulation of CuAu nanoparticles (NPs) supported on highly ordered pyrolytic graphite (HOPG). Through dynamic monitoring of Cu, Au, and Cu 50 Au 50 NPs in an oxidizing atmosphere using ambient-pressure X-ray photoelectron spectroscopy, we show that this spontaneous encapsulation is achieved through the synergistic effect of the alloying elements. Specifically, the surface segregation of Cu promotes dissociative O 2 adsorption, leading to the formation of atomic O species, while the subsurface enrichment of Au hinders O incorporation into the bulk of CuAu NPs. Consequently, O spillover onto the graphite support occurs, resulting in the oxidation of the HOPG surface into graphitic oxide species. The higher affinity of the graphitic oxide species toward the Cu-segregated surface prompts their migration from the HOPG support to encapsulate the CuAu NPs. Finally, these results transcend the conventional SMSI and bear practical implications for the design and development of heterogeneous catalysts, particularly in carbon-supported alloy systems.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Thermodynamic Trends for Reduction of CO by Molecular Complexes

Selective reduction of CO 2 into fuels and chemical feedstocks is highly desirable to reduce our dependence on fossil fuels. Most molecular catalysts afford 2e – reduction products, such as CO or HCO 2 – , as opposed to more reduced products. Here we present an analysis of the thermodynamic limitations for reduction of the CO ligand in the form of a series of isostructural group 6 carbonyl complexes, Cp*M(CO) 3 (P(OMe) 3 ) + (M = Cr, Mo, and W). Additionally, the free energy for stepwise transfer of a hydride (H – ) and a proton (H + ) to the CO ligand, resulting in a hydroxycarbene (CHOH) complex, was measured by equilibration with H – /H + donors and acceptors with known hydricity or acidity. Together, these two reaction steps are equivalent to a net addition of H 2 across the CO ligand. A large and unfavorable free energy for H 2 addition (Δ G ° H2 ) was measured for all three complexes and decreases in the order Cr > Mo > W. The trend for these complexes is opposite to the trend previously reported for group 7 carbonyl complexes, for which Δ G ° H2 decreases moving up the group, Re > Mn. Computational analysis indicates the trends can be described in terms of electrostatic effects, where a low Δ G ° H2 is obtained in complexes that balance the atomic charges of the M–C≡O fragment of the complex. These findings can be used to design metal carbonyl complexes with a more energetically accessible H 2 addition, which will facilitate the development of molecular catalysts for reduction of CO.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Investigation of Ammonia Carrier Materials for Next Generation Ammonia Dosing System - CRADA 334 (Abstract)

Lean-burn gasoline and diesel engines can offer substantially higher fuel efficiency, good driving performance, and reduced carbon dioxide emission compared to stoichiometric gasoline engines. Various catalyst technologies have been developed to remove the pollutants from these engines. For example, a three-way catalyst (TWC) is used to remove hydrocarbons (HC), carbon monoxide (CO), and nitrogen oxides (NOx) from gasoline engines during the stoichiometric conditions. During the lean-burn conditions, a TWC or a diesel oxidation catalyst (DOC) is used to control HC and CO emissions. NOx is removed by either lean NOx trap catalyst (LNT) that can store NOx under lean conditions and reduce NOx under rich conditions, or selective catalytic reduction catalyst (SCR) that can selectively remove NOx with a reducing agent. Among the NOx reduction catalyst technologies, SCR offers a number of advantages, including excellent NOx reduction efficiency over a wide range of temperatures and overall lower system cost. In fact, the SCR technology using ammonia (NH3) as reductant has been proven effective and used commercially for the removal of NOx emissions from stationary sources since the 1970s. Currently, SCR is being used to meet the NOx emission standards for diesel engines in Europe and North America, and also being considered for meeting the future NOx emission standards for lean-burn gasoline engines. Because of the challenges associated with storage, handling and transportation of ammonia on a vehicle, aqueous urea solution (e.g., Diesel Exhaust Fluid, AdBlue) has been developed as ammonia storage compound for mobile applications. When the aqueous urea solution is sprayed into exhaust gas stream, urea is decomposed to release ammonia, which then reduces NOx over the downstream SCR catalyst. Although aqueous urea solution technology has enabled automakers and engine manufacturers to meet the current NOx emission standards, this process of releasing ammonia requires a hot exhaust gas and sufficient mixing, creating challenges for low temperature NOx emission control and aftertreatment system packaging. For these reasons, alternative technologies have been developed as ammonia sources (e.g., solid urea, ammonium carbamate, metal ammine chloride) during the past few years. These technologies promise more convenient handling and distribution of ammonia sources, and help maximize the low-temperature performance of SCR catalysts and reduce the overall system volume and weight. However, none of these alternative technologies can be successfully implemented without the industry consensus. Therefore, the USCAR SCR work group, which is comprised of representatives from GM, Ford, and Chrysler, has decided to investigate the potential alternative ammonia carriers, define common standard vehicle interfaces, and address personal and environmental safety concerns with part suppliers and chemical companies. Under this CRADA Project, USCAR and Battelle will investigate alternative ammonia carrier materials that are currently under development. Based on the data and information derived under the CRADA project, the USCAR SCR work group plans to build the consensus and make recommendations for the industry.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Investigation of Ammonia Carrier Materials for Next Generation Ammonia Dosing System - CRADA 334 (Abstract)

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2019

Synthesis and Characterization of Acridinium Dyes for Photoredox Catalysis

Photoredox catalysis is a rapidly evolving platform for synthetic methods development. The prominent use of acridinium salts as a sustainable option for photoredox catalysts has driven the development of more robust and synthetically useful versions based on this scaffold. However, more complicated syntheses, increased cost, and limited commercial availability have hindered the adoption of these catalysts by the greater synthetic community. By utilizing the direct conversion of a xanthylium salt into the corresponding acridinium as the key transformation, we present an efficient and scalable preparation of the most synthetically useful acridinium reported to date. This divergent strategy also enabled the preparation of a suite of novel acridinium dyes, allowing for a systematic investigation of substitution effects on their photophysical properties.

Chemistry↗

DOE OSTI2021

Single-atom catalysts with anionic metal centers: promising electrocatalysts for the oxygen reduction reaction and beyond

Ongoing efforts to develop single-atom catalysts (SACs) for the oxygen reduction reaction (ORR) typically focus on SACs with cationic metal centers, while SACs with anionic metal centers (anionic SACs) have been generally neglected. However, anionic SACs may offer excellent active sites for ORR, since anionic metal centers could facilitate the activation of O2 by back donating electrons to the antibonding orbitals of O2. In this work, we propose a simple guideline for designing anionic SACs: the metal centers should have larger electronegativity than the surrounding atoms in the substrate on which the metal atoms are supported. By means of density functional theory (DFT) simulations, we identified 13 anionic metal centers (Co, Ni, Cu, Ru, Rh, Pd, Ag, Re, Os, Ir, Pt, Au, and Hg) dispersed on pristine or defective antimonene substrates as new anionic SACs, among which anionic Au and Co metal centers exhibit limiting potentials comparable to, or even better than, conventional Pt-based catalysts towards ORR. We also found that anionic Os and Re metal centers on the defective antimonene can electrochemically catalyze the nitrogen reduction reaction (NRR) with a limiting potential close to that of stepped Ru(0001). Overall, our work shows promise towards the rational design of anionic SACs and their utility for applications as electrocatalysts for ORR and other important electrochemical reactions.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Atomically synergistic Zn-Cr catalyst for iso-stoichiometric co-conversion of ethane and CO2 to ethylene and CO

Abstract Developing atomically synergistic bifunctional catalysts relies on the creation of colocalized active atoms to facilitate distinct elementary steps in catalytic cycles. Herein, we show that the atomically-synergistic binuclear-site catalyst (ABC) consisting of $${{{{{\rm{Zn}}}}}}^{\delta+}$$ Zn δ + -O-Cr 6+ on zeolite SSZ-13 displays unique catalytic properties for iso-stoichiometric co-conversion of ethane and CO 2 . Ethylene selectivity and utilization of converted CO 2 can reach 100 % and 99.0% under 500 °C at ethane conversion of 9.6%, respectively. In-situ/ex-situ spectroscopic studies and DFT calculations reveal atomic synergies between acidic Zn and redox Cr sites. $${{{{{\rm{Zn}}}}}}^{\delta+}$$ Zn δ + ( $$0 \, < \, \delta \, < \, 2$$ 0 < δ < 2 ) sites facilitate β-C-H bond cleavage in ethane and the formation of Zn-H δ - hydride, thereby the enhanced basicity promotes CO 2 adsorption/activation and prevents ethane C-C bond scission. The redox Cr site accelerates CO 2 dissociation by replenishing lattice oxygen and facilitates H 2 O formation/desorption. This study presents the advantages of the ABC concept, paving the way for the rational design of novel advanced catalysts.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Synergistic effect of polyaniline on stabilizing Pt nanoparticles in PEMFCs†

The stability of Pt nanoparticles on a carbon support is crucial for the lifespan of polymer electrolyte membrane fuel cells as well as other electrocatalysis systems such as electrolyzers. Here we took the approach of utilizing the covalently grafted polyaniline on carbon to stabilize Pt nanoparticles by simultaneously alleviating the particle migration and mitigating the Ostwald ripening, which are two major mechanisms for loss of the catalyst stability. A comprehensive investigation of the stability and performance of Pt catalyst nanoparticles on these supports reveals that the polyaniline can shift the Pt L edge binding energy and the Pt 4f peak energy, leading to the increased redox potential of the Pt nanoparticles and making them more resistant to oxidation. Interestingly, the highest polyaniline density (50 wt%) does not show the best catalyst stability, rather, the second (33 wt%) demonstrates the best catalyst stability among these catalysts. Combining the XPS, XAS and fuel cell stability studies, we concluded that the locations of the Pt nanoparticles over the polyaniline layer on the carbon surface depend on the surface density of the polyaniline over the carbon surface. The Pt nanoparticles in the 50 wt% polyaniline catalyst are wrapped by the polyaniline polymer but do not sit directly on the carbon surface, while Pt nanoparticles in the 33 wt% polyaniline catalyst sit on the carbon surface and are densely surrounded by the polyaniline polymer. The results show that the mass activity loss is 12.5% while the ECSA (electrochemically active surface area) loss is 37.1% after 30k cycles of accelerating stress test for the 33 wt% polyaniline catalyst, far exceeding the DOE 2020 target for MEA (i.e., mass activity loss < 50%, and ECSA loss < 40%). Overall, the polyaniline has a synergistic effect on mitigating the surface migration and slowing down the Ostwald ripening to stabilize the Pt nanoparticles in fuel cells. The novel strategy to stabilize Pt nanoparticles using polyaniline opens a new pathway in the development of highly stable catalysts: relying on the functionalization group on the carbon support, instead of just focusing on the catalyst itself.

Li, Chenzhao↗

DOE OSTI2018

Lithium Electrochemical Tuning for Electrocatalysis

Abstract Electrocatalysis is of great importance to a variety of energy conversion processes, where developing highly efficient catalysts is critical. While common strategies involve screening a wide range of materials with new chemical compositions or structures, a different approach to continuously, controllably, and effectively tune the electronic properties of existing catalytic materials for optimized activities has been demonstrated recently. Inspired by studies in lithium‐ion batteries, systematical lithium electrochemical tuning (LiET) methods such as Li intercalation, extraction, cycling, and strain engineering, are employed to effectively tune the electronic structures of different existing catalysts and thus improve their catalytic activities dramatically. Herein, the advantages of the LiET method in electrocatalysis are introduced, and then some recent representative examples in improving the performances of important electrochemical reactions are reviewed briefly. Lastly, a few promising directions on extending the applications of the LiET method in electrocatalysis are proposed.

Lu, Zhiyi↗

DOE OSTI2024

Probing Basal and Prismatic Planes of Graphitic Materials for Metal Single Atom and Subnanometer Cluster Stabilization

Abstract Supported metal single atom catalysis is a dynamic research area in catalysis science combining the advantages of homogeneous and heterogeneous catalysis. Understanding the interactions between metal single atoms and the support constitutes a challenge facing the development of such catalysts, since these interactions are essential in optimizing the catalytic performance. For conventional carbon supports, two types of surfaces can contribute to single atom stabilization: the basal planes and the prismatic surface; both of which can be decorated by defects and surface oxygen groups. To date, most studies on carbon‐supported single atom catalysts focused on nitrogen‐doped carbons, which, unlike classic carbon materials, have a fairly well‐defined chemical environment. Herein we report the synthesis, characterization and modeling of rhodium single atom catalysts supported on carbon materials presenting distinct concentrations of surface oxygen groups and basal/prismatic surface area. The influence of these parameters on the speciation of the Rh species, their coordination and ultimately on their catalytic performance in hydrogenation and hydroformylation reactions is analyzed. The results obtained show that catalysis itself is an interesting tool for the fine characterization of these materials, for which the detection of small quantities of metal clusters remains a challenge, even when combining several cutting‐edge analytical methods.

Vidal, Mathieu↗

DOE OSTI2020

Nanoarray-Based Monolithic Adsorbers for SO 2 Removal

Nanoarray-based monolithic catalysts have been developed for various applications, including CO oxidation, hydrocarbon combustion, lean NO x trapping, and low-pressure CO 2 hydrogenation. In this work, SO 2 adsorption properties have been explored and evaluated on the cordierite honeycomb monoliths grown with zinc oxide nanoarray (ZnO), zinc oxide nanoarray washcoated by BaCO 3 nanoparticles (ZnO/BaCO 3 ), and manganese oxide nanowire array with cryptomelane structure (MnO x ) at a temperature range from 50 to 425 °C. All samples show temperature-dependent SO 2 adsorption behaviors. The adsorption results reveal the performance order: MnO x > ZnO/BaCO 3 > ZnO, with ~ 90% SO 2 adsorbed in MnO x at 425 °C. Washcoated BaCO 3 contributes to the improvement of SO 2 adsorption in ZnO nanoarray, and the best performance displayed in MnO x may be attributed to their high specific surface area. After regeneration, nanoarrays all exhibit good thermal stability during test-regeneration cycles. No additional phase is formed in regenerated ZnO nanoarrays (ZnO-R), while BaCO 3 is converted to BaSO 4 in the regenerated ZnO/BaCO 3 nanoarrays (ZnO/BaCO 3 -R), and the sulfur species (possibly MnSO 4 ) and Mn 2 O 3 are found in regenerated MnO x nanoarrays (MnO x -R). It is noted that a small amount of sulfur species (possibly MnSO 4 ) may promote the SO 2 adsorption of MnO x -R at a lower temperature, while the formed Mn 2 O 3 contributes to the deactivation of MnO x -R.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Layer structured bifunctional monolith catalysts for energy-efficient conversion of CO 2 to dimethyl ether

A monolith supported bifunctional catalyst for the direct conversion of CO 2 to dimethyl ether was developed and evaluated. The catalyst consists of a layer structured configuration, in which a CuO/ZnO/ZrO 2 component for methanol synthesis using CO 2 as feedstock and a Ferrierite zeolite component for the subsequent dehydration reaction are washcoated onto the channel surfaces of a metallic monolith substrate as two consecutive layers. The metal substrate provides heat conduction to regulate the catalyst bed temperature. The layered configuration significantly improves the synergistic effects of the two components, resulting in a 20% increase in the productivity for dimethyl ether at 240 °C as compared with the conventional catalysts with the two components being blended in various levels of proximity. Furthermore, the layer structured design minimizes the undesirable interaction between the two components and drastically improves the on-stream durability of the catalyst. No activity decline was observed in a 146-h performance test.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2019

Modular design: Implementing proven engineering principles in biotechnology

Modular design resides at the foundation of contemporary engineering, enabling rapid, efficient, and reproducible construction and maintenance of complex systems across applications. Remarkably, modularity has recently been discovered as a governing principle in natural biological systems from genes to proteins to complex networks within a cell and organism communities. The convergent knowledge of natural and engineered modular systems provides a key to drive modern biotechnology to address emergent challenges associated with health, food, energy, and the environment. Here, we first present the theory and application of modular design in traditional engineering fields. We further discuss the significance and impact of modular architectures on systems biology and biotechnology. Next, we focus on the very recent theoretical and experimental advances in modular cell engineering that seeks to enable rapid and systematic development of microbial catalysts capable of efficiently synthesizing a large space of useful chemicals. We conclude with an outlook towards theoretical and practical opportunities for a more systematic and effective application of modular engineering in biotechnology.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2023

Electrochemical conversion of methane to ethylene, olefins, and paraffins using metal-supported solid oxide cells

Electrochemical oxidative coupling of methane (E-OCM) with Sr 2 Fe 1·5 Mo 0·5 O 6–δ (SFM) catalyst is demonstrated with metal-supported solid oxide cells (MS-SOC). SFM anode and Pr 6 O 11 cathode catalysts are loaded into a porous symmetric-architecture cell by infiltration and firing. The most effective chelating agent (citric acid/ethyl glycol) and optimal firing/reducing temperatures (850 °C/750 °C) for the SFM catalyst precursor solution are selected and confirmed by cell testing. Operating temperature, cell voltage, and oxygen concentration at the cathode greatly affect the methane conversion rate and product selectivity by controlling the oxygen ion flow. CH 4 conversion of 85.8% is obtained, with C 2 H 4 , C 2 H 6 , and H 2 concentrations of 10.5%, 12.3%, and 25.6% at 800 °C, respectively, in the product exhaust gas. Reasonable stability of the current density and methane conversion is demonstrated during 200 h operation. Furthermore, this research demonstrates technical progress in catalyst and device development for the E-OCM reaction to synthesize valuable chemicals.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2020

Oxide-catalyzed self- and cross-condensation of cycloketones. Kinetically relevant steps that determine product distribution

Metal oxides with acid-base properties can be used to catalyze aldol condensation and potentially obtain valuable chemicals from biomass-derived oxygenates. Understanding the reaction mechanisms could enable the development of effective catalysts with controllable selectivity. In this work, we investigate the reaction parameters that affect the kinetics and product distribution of self- and cross-aldol condensation of cyclopentanone (CPO) and cyclohexanone (CHO) over CeO 2 and ZrO 2 catalysts by combining detailed analysis of experiments and DFT calculations. It is well-known that either the deprotonation of an α-C–H that generates an enolate or the C–C coupling that produces the dimers can be rate-limiting step. Indeed, the detailed kinetics analysis shows that the observed data can be fitted by unimolecular or bimolecular Langmuir-Hinshelwood models. Specifically, on the ZrO 2 catalyst, the unimolecular α-C–H activation is the rate limiting step for the CPO self-condensation, while the bimolecular C–C coupling limits the CHO self-condensation. By contrast, on CeO 2 , the bimolecular C–C coupling step seems to be rate-limiting for both CPO and CHO self-condensation reactions. The adsorption parameters derived from kinetics fitting indicate that when the two reactants are co-fed, the surface is preferentially covered by CHO. So, the condensation rate of [CPO]-activated products ([CPO]CPO + [CPO]CHO) decreases in the presence of CHO, due to the competitive adsorption. However, despite a higher surface coverage, CHO is not an effective electrophile because it imposes stronger steric constraints to the formation of the C–C bond than CPO. Therefore, for a given enolate, the product distribution shows that [CPO]CPO > [CPO]CHO and, similarly [CHO]CPO > [CHO]CHO. Likewise, the yields of [CPO]- and [CHO]-activated products in mixed CPO/CHO feeds are similar because the higher surface coverage and stability of the [CHO] enolate is counterbalanced by the inhibition of C–C coupling by steric constraints when CHO is involved. In summary, the overall rank of products observed experimentally can be explained in terms of a combination of the following effects: relative surface coverage of the reactants, steric constraints for the C–C coupling, stability of the enolate, and effectiveness of the electrophile to accept an electron.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Scalable fabrication of high activity nanoporous copper powders for electrochemical CO 2 reduction via ball milling and dealloying

Electrochemical CO 2 reduction (ECR) is a promising technology to close the anthropic CO 2 circle using renewable energy to achieve carbon neutrality. Future commercialization of ECR will require the development of new catalyst synthesis routes that will allow significant upscaling of catalyst production from current research-level milligram quantities to the kilogram scale and beyond while maintaining the activity and selectivity demonstrated at the research level. Here, we report on generating and testing submicron-sized nanoporous copper (npCu) particles by using a scalable approach consisting of ball milling brittle Cu-based intermetallics followed by dealloying to add nanoporosity for high surface area. The resulting npCu particles have been tested in an industry-relevant large area (25 cm 2 ) electrolyzer platform and showed Faraday efficiencies (FE) for ethylene up to 34 % at current densities of 75–100 mA/cm 2 while keeping FE for hydrogen less than 30 %. Our results demonstrate that a combination of ball milling and dealloying is a promising approach to generate large quantities of high activity and high surface area npCu particles for ECR at an industry-relevant scale.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2023

Design and operating principles for high-performing anion exchange membrane water electrolyzers

Anion-exchange-membrane water electrolyzers (AEMWEs) provide a promising pathway to utilize low-carbon renewable electricity to produce clean hydrogen at high efficiency and purity, while maintaining low system costs compared to incumbent technologies. Though significant progress has been made in developing membranes and catalysts, AEMWEs still require better performance and durability to realize widespread deployment. Here, we overcome these challenges by decoupling anode and cathode polarization behavior via integration of a reference electrode in the membrane-electrode assembly. This measurement identified that the mass-transport losses dominate the cathode overpotential if feeding with electrolytes, while kinetic losses dominate the anode overpotential. These losses are mitigated by varying electrode properties and operating strategies, where a more hydrophobic, optimal loaded cathode, a high porosity anode, and operating with the cathode dry exhibited the best performance. These findings eventually enabled achieving a high-performing and durable complete PGM-free AEMWE operating at 1.5 Acm –2 for over 500h with negligible degradation, demonstrating significant progress for AEMWEs.

25 ENERGY STORAGE↗