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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 433 records · Page 24
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Energy Systems Integration Facility (ESIF): World-Class Systems Integration Capabilities and Research

The Energy Systems Integration Facility (ESIF), located at the National Renewable Energy Laboratory (NREL) South Table Mountain campus, is a world-renowned user facility for research and development of modern, advanced, and clean energy technologies. ESIF is distinguished by its continuously evolving, highly integrated systems that span throughout the building, connecting research capabilities across multiple laboratories and test areas. The primary ESIF research systems include: [1] data, cyber, and control networks, [2] research electrical distribution buses (REDB), [3] thermal integration infrastructure, and [4] hydrogen systems. The data, cyber, and control networks provide monitoring, control, communication, automation, visualization, and time series data storage and tagging capabilities for research projects and ESIF systems, including facility safety functions. The REDB system consists of four dedicated AC and DC electrical power networks that can connect devices located across the facility through versatile, automatic circuit configuration to support complex power electronics experiments up to the megawatt-scale. The thermal integration infrastructure consists of three temperature-conditioned water loops that provide heating and cooling interfaces and capabilities for thermal energy research. The hydrogen systems provide megawatt-scale hydrogen production, drying, compression, high-pressure storage, and delivery to laboratory end uses, including hydrogen fuel cell vehicle fueling. The ESIF research systems interconnect and extend throughout the various lab areas of the facility to create elaborate networks composed of diverse technologies for cutting-edge research. The ESIF capabilities are operated and stewarded by the ESIF Research Operations group, who also actively upgrade and advance the systems to ensure they remain ahead of anticipated research - enabling the success of many pioneering energy integration projects. The poster, created by members of the ESIF Research Operations team, highlights and summarizes the four core integrated systems at ESIF. The poster was first presented at the internal NREL Energize Forum on May 13th, 2024, and received the "Best Poster" award.

capabilities↗
DOE OSTI2025

A comprehensive review of diffuse reflectance infrared Fourier transform spectroscopy (DRIFTS) techniques in protonic ceramic cells (PCCs): Current status and future perspective

Protonic ceramic cells (PCCs) have emerged as a promising technology for power generation, energy storage, and value-added chemical synthesis, offering benefits such as fuel flexibility, low emissions, and efficient operation at intermediate temperatures (300–600 ​°C). Recently, significant breakthroughs in materials and manufacturing methods have markedly enhanced the performance of PCCs. However, establishing a fundamental understanding of their electrocatalytic reactions has gained less attention. As a fast and cost-effective method for physicochemical fingerprinting, diffuse reflectance infrared Fourier transform spectroscopy (DRIFTS) has proven to be a surface-sensitive analytical tool for structural and functional studies. This review critically examines the most up-to-date applications of DRIFTS for characterizing key components of PCCs, including oxygen electrodes, protonic electrolytes, and hydrogen electrodes for different applications, with a focus on revealing hydration properties and catalytic reactions, and guiding rational material design. The challenges for advancing DRIFTS, including quantitative capabilities and operando applications for PCC investigations, are highlighted and strategies to tackle these challenges are discussed. Ultimately, this review underscores the critical role of DRIFTS in accelerating the development of high-performance and durable PCCs for next-generation energy solutions, offering methodologies and insights broadly applicable to a wide range of electrochemical energy conversion and storage technologies.

Diffuse Reflectance Infrared Fourier Transform Spe↗
DOE OSTI2021

Compact ammonia reforming at low temperature using catalytic membrane reactors

Ammonia is a leading carrier for the storage and transport of renewable hydrogen, but its deployment requires scalable technologies for efficient decomposition and purification. In this work, we report on the efficient delivery of high purity hydrogen from ammonia decomposition using a catalytic membrane reactor (CMR). Improvements to the electroless plating process reduced the Pd membrane thickness by >35%, resulting in commensurate increases in hydrogen permeance without sacrificing selectivity. To increase throughput a commercial Ru/Al 2 O 3 catalyst was added to the lumen, and the CMR could process ammonia flowrates 10–50 times higher than an equivalent packed bed reactor while maintaining the same level of conversion. It is shown that the earth-abundant zeolite clinoptilolite could reduce ammonia impurities in the permeated H 2 to the levels required by PEM fuel cells (<25 ppb). Performance increased significantly across a >500-h durability test due to improvements in membrane permeability. Finally, the results show that CMRs are a viable technology for distributed production of hydrogen from ammonia.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Poly(diallylmethylammonium) proton conducting membranes with high ionic conductivity at intermediate temperatures

High temperature proton exchange membrane fuel cells are being lately investigated because of their high energy efficiency, their superior heat/water management, CO tolerance, and electrode reaction kinetics. To further advance this technology, the polymer membrane portfolio and performance should be improved for intermediate or high temperature operation (>100 °C). In this work we present new poly(diallylmethylammonium) proton conducting membranes with high ionic conductivity at 120 °C. First, new protic ionic liquids, hereafter called DAMAH + X - , were synthesized leading to diallylmethylammonium monomers with different counter-anions. By radical cyclopolymerization through thermal and photoinitiation mechanisms, self-standing protic polymeric membranes of poly(diallylmethylammonium X - ) were obtained. Membranes showed good thermal stability (>250 °C) and mechanical properties without the need of additives such as (protic) ionic liquids, solvents or inorganic charges. Great attention was paid to understand the effect of the different counter-anions on the membrane properties. As a general trend, fluorinated anions coming from strong acids confer high ionic conductivity and allow to reduce the hygroscopic properties on the protic polymeric membranes. Proton structural and dynamical stability at different temperatures and humidification conditions were investigated by Neutron Scattering (QENS and NR). The optimized poly(diallylmethylammonium X - ) shows similar ionic conductivity values than Nafion 212 under varying relative humidity conditions at 80 °C. Furthermore, it shows a high ionic conductivity value of 1.9 × 10 -3 Scm -1 at 120 °C under dry conditions.

08 HYDROGEN↗
DOE OSTI2024

Simulation-Based Assessment of Energy Consumption of Alternative Powertrains in Agricultural Tractors

The objectives of this research were to develop simulation models for agricultural tractors with different powertrain technologies and evaluate the energy consumption in typical agricultural operations. Simulation models were developed for conventional, parallel hybrid electric, series hybrid electric, fuel cell hybrid, and battery electric powertrains. Autonomie vehicle simulation software (version 2022) was used for the simulations and the tractor models were simulated in two tilling cycles and in a road transport cycle with a trailer. The alternative powertrains were configured to have at least the same tractive performance as the conventional, diesel engine-powered tractor model. The simulation results showed that the potential of the parallel and series hybrid powertrains to improve energy efficiency depends heavily on the tractor size and the operating cycle conditions. The fuel cell hybrid and battery electric powertrains have a higher potential to reduce energy consumption and emissions but still have inherent technical challenges for practical operation. The battery-powered electric tractor would require improvements in the storage energy density to have a comparable operational performance in comparison to other powertrains. The fuel cell hybrid tractor already provided an adequate operating performance but the availability of hydrogen and refueling infrastructure could be challenging to resolve in the farming context.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

The importance of cycle-by-cycle data in performing rapid battery technology development and validation

Lithium-ion battery (LiB) technology is playing a crucial role in transforming the predominantly fossil fuel-based transportation and stationary storage sectors to achieve a low-carbon economy. Rapid innovation in the LiB materials to electrode to cell design is happening to satisfy the performance, life, and safety metrics required by those myriads of applications. Lately, advanced analytics, such as machine-learning or artificial intelligence (ML/AI) techniques, are being used more frequently to aid in expedited LiB technology development, performance validation, and life prediction. The success of these techniques often relies on a large volume of well-defined and high-quality battery test data. On the other hand, most battery developers and research and development (R&D) communities are still following a classical approach to develop batteries, which is running calendar- and/or cycle-aging tests, performing reference performance tests (RPTs), and conducting post-mortem analyses periodically without paying attention to the wealth of data often not collected during the calendar or cycle life aging tests. This sparse data collection approach is time- and resource-intensive, requiring data capture and evaluation of months to years of RPT data to diagnose accurate battery state of performance, health, and safety. Even so, the underlying aging modes and mechanisms can be missed. If collected properly, battery test data during cycling or calendaring can be efficiently combined with ML/AI techniques to create powerful tools in the rapid diagnosis of battery state of performance, health, and safety along with insights into underlying aging modes and mechanisms. In this report, we discuss the importance of effective cycle-by-cycle (CBC) data collection with example case studies. Within a reasonable timeframe, RPT data are often inadequate in capturing many of the crucial battery aging dynamics, which often predominantly show up in CBC test data. Finally, we also show examples of ML/AI techniques that use CBC data in rapid diagnosis and projection of LiB state of health (SOH) to motivate the scientific community in collecting and using CBC data to facilitate expeditious technology development and validation.

25 ENERGY STORAGE↗
DOE OSTI2021

Microfluidic Liquid-Liquid Extraction Chip with Integrated Raman Sensors (Phase I and Phase II Final Report)

As demand for electricity continues to increase worldwide, the world’s nuclear power generating capacity will continue to grow. Nuclear power is the most environmentally benign way of producing electricity on a large scale. The long-term successful use of nuclear power, however, is critically dependent upon adequate and safe processing and disposal of spent nuclear fuels. A very important feature of nuclear energy is that spent fuels can be reprocessed to recover fissile and fertile materials that can then be used as fresh fuel for nuclear power plants. The DOE-NE Fuel Cycle Research and Development (FCR&D) is currently developing nuclear material reprocessing technologies. In a typical nuclear fuel reprocessing system, centrifugal contactors are used as liquid-liquid extraction devices where two immiscible liquids are mixed at high speeds using a rotor, which creates a fine dispersion of droplets of organic phase in an aqueous phase that contains the analyte. Understanding the extraction efficiency at these contactors through modeling and simulation is important in the development of reprocessing technologies and the optimization of current technologies such as the PUREX process. The outcome of this program will be a liquid-liquid microfluidic flow cell chip with embedded spectroscopic sensors for the analysis of extracted analytes. This device will be useful in the optimization of new fuel reprocessing schemes as well as existing reprocessing processes by providing a microfluidic modeling platform to optimize extraction parameters. The Phase I and Phase II work developed a microfluidic chip design that allows integration of Raman and absorption fiber optic probes and successfully demonstrated the feasibility of using Raman and absorption probes to detect key analytes that partition into the aqueous and organic phases.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

FCET Solid Oxide Fuel Cell Testing and Development: CRADA 526 [Abstract only]

The purpose of the proposed project is for PNNL to test the performance of prototype solid oxide fuel cells (SOFCs) created by FCET. Such testing will provide FCET with independent performance data that can be communicated to potential clients and/or investors. Additionally, PNNL will collaborate with FCET on design changes to improve fuel cell performance. Intellectual property developed in this way will benefit FCET with improved products to market, and PNNL through royalty revenue. The key technology held by FCET is a process to deposit extremely thin layers of oxide materials, from 10-50 nm in thickness. The range of possible materials that can be deposited with their method is broad, but this project will focus on the yttria-stabilized zirconia (YSZ) electrolytes for SOFCs. Thin, gas tight YSZ membranes have been a long-sought target in SOFC research. The thinner the YSZ, the lower the cell resistance, and the higher performance of the cell (or the lower the operating temperature). 10-50 nm would be a major step change in YSZ thickness from the state of the art. PNNL can team with FCET on future R&D projects and push this technology forward to improve energy efficiency and reduce carbon emissions.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2023

The Qualification of Sealability and Creep Relaxation of Additively Manufactured Zytel Gaskets for PEM Fuel Cells

The purpose of this thesis is to study the feasibility of low-cost additive manufacturing of gaskets for proton exchange membrane fuel cells exposed to extreme temperature conditions ranging from -55°C to 100°C. With the growing popularity and decreasing costs of additive manufacturing technologies, specifically Material Extrusion (ME), research is being conducted to determine the feasibility of ME components. Thermally cycled PEMFCs may exhibit accelerated gasket deterioration, therefore, the mechanical stability of material extruded gaskets following a harsh thermal cycle must be assessed. The feasibility of the material extruded gaskets will be proven by manufacturing optimization and mechanical testing. The target material for this study is Zytel by DuPont Chemical. The mechanical stability will be assessed via sealability and creep relaxation testing according to ASTM F37B and ASTM F38B respectively. Because the capabilities to conduct sealability testing at temperature were not available, each specimen was thermally soaked and allowed to return to room temperature prior to testing. As a result of sealability experiments, the 100°C-soaked specimens resulted in lower leak rates with a higher precision when compared to specimens soaked at -55°C and 22°C at across all compressive loads. It was observed from results from creep relaxation testing that there is thermal contraction and expansion occurring at 55°C and 100°C respectively, which can be observed by the resultant graphs. The recoverability of thermally cycled specimens are better than those that just experienced a high temperature hold. After the seven-day thermal cycle, the samples stabilized and maintained their structure.

Lazarin, Robert↗
DOE OSTI2023

Acoustic Monitoring of Pyroprocessing Equipment

This paper provides an introduction to using acoustic monitoring to advance detection techniques for pyroprocessing in support of nuclear safeguards and non-proliferation. The usage of free air acoustic monitoring has been previously demonstrated at Idaho National Laboratory (INL) facilities such as the Advanced Test Reactor and the National Security Test Range. However, the proposed work revolves around a new deployment environment, the Fuel Conditioning Facility, that brings forward several questions regarding the performance of the technology in non-free air media. The confinement of the pyroprocessing equipment to a heavily shielded hot cell, the atmosphere of the hot cell containing argon gas, and the radiation dose inside the hot cell are all new environments for acoustic monitoring. To our knowledge, acoustic measurements have not been completed in such an environment before. This offers a new opportunity to study not only the acoustic signatures of the equipment inside of the hot cell, but also the propagation of the signals through the hot cell and at distances away from their origination. The objective of this paper is to explain the planned instruments to monitor the Fuel Conditioning Facility in order to evaluate acoustic signals emitted from equipment during various stages of operation. Identifying these signals can potentially enable the identification of specific pieces of equipment used in pyroprocessing and produce information of their operational status. If successful, this type of monitoring could offer a new method to aid in safeguards and proliferation detection of pyroprocessing activities.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2023

Operational and scaling-up barriers of SOEC and mitigation strategies to boost H 2 production- a comprehensive review

Solid oxide electrolysis cells (SOECs) proffer a flexible and environmentally friendly solution to reduce CO 2 emissions and/or produce H 2 fuel for various applications. Here, the integration of this technology with renewable energy systems makes them even more promising in realizing a near-perpetual green energy infrastructure in the near future. SOEC technology has achieved stupendous improvement in recent years, and some of the limiting factors to the commercialization of this technology have been explored. It is, therefore, necessary to have a succinct outlook of the different factors that contribute to the recent developments in SOEC technology. The current work presents a comprehensive review of the state-of-the-art SOEC component materials and their degradation mechanisms, SOEC modeling essentials and efficiencies, and the scalability of SOECs. Although SOEC is considered a highly promising technology and sufficient multifaceted research has been done, yet not been widely commercialized. Despite the improvement to mitigate degradation of the SOEC materials, a large share of the degradation concerns sprang from charge transfer reaction at the triple-phase boundaries of the H 2 -electrode. Part of which can be improved by microkinetic modeling of these materials supported by their characterization to give insight into their development. Some other directions for the future in advancing this technology toward the commercialization stage are thoroughly addressed.

08 HYDROGEN↗
DOE OSTI2025

Redesigning protonic ceramic electrochemical cells to lower the operating temperature

Protonic ceramic electrochemical cells (PCECs) can operate at intermediate temperatures (450° to 600°C) for power generation and hydrogen production. However, the operating temperature is still too high to revolutionize ceramic electrochemical cell technology. Lowering the operating temperature to <450°C will enable a wider material choice and reduce system costs. We present approaches to redesigning PCECs via readily fabricated single-grain–thick, chemically homogeneous, and robust electrolytes and a nano-micro positive electrode. At 450°C, the PCECs achieve a peak power density of 1.6 watt per square centimeter on H 2 fuel, 0.5 watt per square centimeter on NH 3 fuel, and 0.3 watt per square centimeter on CH 4 fuel in fuel cell mode. In steam electrolysis mode, a current density of >0.6 ampere per square centimeter with a Faradaic efficiency of >90% is achievable at 1.4 volt and 400°C. In addition, exceptional durability (>2000 hours) has been demonstrated, with a degradation rate of <0.01 millivolt per 100 hours in fuel cell mode at 400°C.

Science & Technology - Other Topics↗
DOE OSTI2025

Tailoring the structural durability and proton conductivity of electrolytes for highly fuel-flexible and reversible ceramic cells

A durable and high ionic conducting electrolyte is critical for achieving fuel-flexible and reversible protonic ceramic cells (PCCs) at reduced temperatures since the developed electrolyte materials are vulnerable to steam, CO 2 , or coking deterioration. Here, we report a fast-conducting electrolyte material BaZr 0.06 Ce 0.7 Y 0.06 Yb 0.06 Hf 0.06 Gd 0.06 O 3−δ (BZCYYbHG), demonstrating excellent durability against CO 2 and H 2 O under the realistic electrolysis operations, and a high conductivity of 0.017 S cm −1 at 550 °C for lowering the PCC operating temperature. Further, density functional theory calculations indicate that the higher configurational entropy of mixing at the B-site cations slightly reduces the hydrogen adsorption energy, suggesting a higher incorporation rate of protons or hydrogen atoms into the electrolyte bulk. Ultimately, single cells with the BZCYYbHG electrolyte deliver peak power densities of 1.39, 1.12, and 0.7 W cm −2 in H 2 , NH 3 , and wet CH 4 at 550 °C with promising durability. In addition, the PCCs achieve a current density of −1.61 A cm −2 at 1.3 V and 550 °C with a high faradaic efficiency of 91.3% at −0.5 A cm −2 , enabling stable operations in steam electrolysis mode under humid air (30% H 2 O), wet air containing CO 2 (up to 10%), and reversible cycling.

25 ENERGY STORAGE↗
DOE OSTI2021

Baseplate Temperature–Dependent Vertical Composition Gradient in Pseudo–Bilayer Films for Printing Non–Fullerene Organic Solar Cells

Numerous previous reports on the sequential deposition (SD) technique have demonstrated that this approach can achieve a p–i–n active layer architecture with an ideal vertical composition gradient, which is one of the critical factors that can influence the physical processes that determine the photovoltaic performance of organic solar cells. Herein, a commonly used photovoltaic system comprised of PM6 as a donor and Y6 as an acceptor is investigated with respect to sequential blade–processing deposition to comprehensively explore the morphology characteristics as a function of baseplate temperature. A systematic study of the temperature–dependent blend morphology elucidates the SD–processed configuration merits and device physics behind temperature–controlled degree of vertical composition gradient, and constructs the temperature–microstructure–property relationship for the corresponding photovoltaic parameters. The result shows, as the temperature increases, the morphology of the active layer has undergone a distinct evolution from the pseudo–bulk heterojunction to a pseudo–planar heterojunction and then to a pseudo–planar bilayer, leading to a non–monotonic correlation between baseplate temperature and device performance. Further, this investigation not only reveals the importance of precisely controlling baseplate temperature for gaining vertical morphology control, but also provides a path toward rational optimization of device performance in the lab–to–fab transition.

14 SOLAR ENERGY↗
DOE OSTI2022

Reversible Solid Oxide Fuel Cell Systems for Energy Storage and Hydrogen Production

FuelCell Energy (FCE) studied the performance, design, and economics of a reversible solid-oxide fuel cell/electrolyzer integrated with a natural gas-based electricity generation plant and used as an energy storage system. Increased market penetration of renewable energy is challenging for operators of fossilbased plants which are not suited for quick turndown and ramp-up. Process simulations studies show that with utilization of waste heat from the power plant, a high roundtrip efficiency (RTE) around 70% is possible, providing excellent market potential for this energy storage technology, potentially providing improved economics and lifetime for such power plant. The market potential and economics as a function of production volume are analyzed in detail. FCE is continuing the development and commercialization of its solid oxide technology.

08 HYDROGEN↗