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DOE OSTI2021

Benefits of Fast Battery Formation in a Model System

Lithium-ion battery formation affects battery cost, energy density, and lifetime. An improved understanding of the first cycle of solid-electrolyte interphase (SEI) growth on carbonaceous negative electrodes could aid in the design of optimized formation protocols. In this work, we systematically study SEI growth during the formation of carbon black negative electrodes in a standard carbonate electrolyte. We show that the initial ethylene carbonate (EC) reduction reaction occurs at ~0.5-1.2 V during the first lithiation, except under fast lithiation rates (≥10C). The products of this EC reduction reaction do not passivate the electrode; only the SEI formed at lower potentials affects the second-cycle Coulombic efficiency. Thus, cycling quickly through the voltage regime of this reaction can decrease both formation time and first-cycle capacity loss, without an increase in subsequent-cycle capacity loss. We also show that the capacity consumed by this reaction is minimized at low temperatures and low salt concentrations. Finally, we discuss the mechanism behind our experimental results. This work reveals the fundamental processes underlying initial SEI growth on carbonaceous negative electrodes and provides insights for both optimizing the battery formation process and enabling novel electrolytes.

25 ENERGY STORAGE↗

NASA NTRS1975

Research and development of an electrochemical biocide reactor

An alternate disinfecting process to chemical agents, heat, or radiation in an aqueous media has been studied. The process is called an electrochemical biocide and employs cyclic, low-level voltages at chemically inert electrodes to pass alternating current through water and, in the process, to destroy microorganisms. The paper describes experimental hardware, methodology, and results with a tracer microorganism (Escherichia coli). The results presented show the effects on microorganism kill of operating parameters, including current density (15 to 55 mA/sq cm (14 to 51 ASF)), waveform of applied electrical signal (square, triangular, sine), frequency of applied electrical signal (0.5 to 1.5 Hz), process water flow rate (100 to 600 cc/min (1.6 to 9.5 gph)), and reactor resident time (0 to 4 min). Comparisons are made between the disinfecting property of the electrochemical biocide and chlorine, bromine, and iodine.

See, G. G.↗

DOE OSTI2022

Progress and Prospects of Inorganic Solid-State Electrolyte-Based All-Solid-State Pouch Cells

Here, all-solid-state batteries have piqued global research interest because of their unprecedented safety and high energy density. Significant advances have been made in achieving high room-temperature ionic conductivity and good air stability of solid-state electrolytes (SSEs), mitigating the challenges at the electrode–electrolyte interface, and developing feasible manufacturing processes. Along with the advances in fundamental study, all-solid-state pouch cells using inorganic SSEs have been widely demonstrated, revealing their immense potential for industrialization. This review provides an overview of inorganic all-solid-state pouch cells, focusing on ultrathin SSE membranes, sheet-type thick solid-state electrodes, and bipolar stacking. Moreover, several critical parameters directly influencing the energy density of all-solid-state Li-ion and lithium–sulfur pouch cells are outlined. Finally, perspectives on all-solid-state pouch cells are provided and specific metrics to meet certain energy density targets are specified. This review looks to facilitate the development of inorganic all-solid-state pouch cells with high energy density and excellent safety.

25 ENERGY STORAGE↗

NASA NTRS2024

System Modeling of a Lunar Molten Regolith Electrolysis Plant

In-Situ Resource Utilization (ISRU) is the process of extracting local resources to produce commodities for propulsion, life support systems, and off-planet construction rather than transporting consumables from Earth. Molten Regolith Electrolysis (MRE) is a novel ISRU method of extracting oxygen gas and metal alloy from lunar regolith. The MRE process involves placing lunar regolith between two electrodes, through which current is passed, to melt the regolith and reduce the metal oxide constituents by direct electrolysis (e.g. FeO, SiO 2 , MgO, Al 2 O 3 ) into oxygen gas and metal alloys. The oxygen is liquefied and used as propellant for landers, while the metals (e.g. Ferro-alloys) are further processed and used in structural building materials and parts manufacturing. A system model was developed that accounted for the major processes of an MRE plant (from excavation of raw materials to storage of products) to assess the feasibility of a lunar MRE plant. The S ystem Engineering and Integration ( S E&I) I SRU M odeling and A nalysis (SIMA) team utilized its previously documented system sizing model, the Mission Analysis and Integration Tool (MAIT) as framework of the system model. MAIT uses MATLAB/Simulink to integrate subsystem models into a complete system model of the MRE plant. Total mass, volume, and power requirements were computed for numerous iterations of a MRE plant.

In-Situ Resource Utilization↗

DOE OSTI2022

Surface restructuring of a perovskite-type air electrode for reversible protonic ceramic electrochemical cells

Reversible protonic ceramic electrochemical cells (R-PCECs) are ideally suited for efficient energy storage and conversion; however, one of the limiting factors to high performance is the poor stability and insufficient electrocatalytic activity for oxygen reduction and evolution of the air electrode exposed to the high concentration of steam. Here we report our findings in enhancing the electrochemical activity and durability of a perovskite-type air electrode, Ba 0.9 Co 0.7 Fe 0.2 Nb 0.1 O 3-δ (BCFN), via a water-promoted surface restructuring process. Under properly-controlled operating conditions, the BCFN electrode is naturally restructured to an Nb-rich BCFN electrode covered with Nb-deficient BCFN nanoparticles. When used as the air electrode for a fuel-electrode-supported R-PCEC, good performances are demonstrated at 650 °C, achieving a peak power density of 1.70 W cm –2 in the fuel cell mode and a current density of 2.8 A cm –2 at 1.3 V in the electrolysis mode while maintaining reasonable Faradaic efficiencies and promising durability.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2021

On the crystallography and reversibility of lithium electrodeposits at ultrahigh capacity

Abstract Lithium metal is a promising anode for energy-dense batteries but is hindered by poor reversibility caused by continuous chemical and electrochemical degradation. Here we find that by increasing the Li plating capacity to high values ( e.g ., 10–50 mAh cm −2 ), Li deposits undergo a morphological transition to produce dense structures, composed of large grains with dominantly (110) Li crystallographic facets. The resultant Li metal electrodes manifest fast kinetics for lithium stripping/plating processes with higher exchange current density, but simultaneously exhibit elevated electrochemical stability towards the electrolyte. Detailed analysis of these findings reveal that parasitic electrochemical reactions are the major reason for poor Li reversibility, and that the degradation rate from parasitic electroreduction of electrolyte components is about an order of magnitude faster than from chemical reactions. The high-capacity Li electrodes provide a straightforward strategy for interrogating the solid electrolyte interphase (SEI) on Li —with unprecedented, high signal to noise. We find that an inorganic rich SEI is formed and is primarily concentrated around the edges of lithium particles. Our findings provide straightforward, but powerful approaches for enhancing the reversibility of Li and for fundamental studies of the interphases formed in liquid and solid-state electrolytes using readily accessible analytical tools.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2026

Zero Resistance Ammetry (ZRA) Measurements of Sediment Electrochemical Gradients, Old Woman Creek, Ohio, USA, June–November 2022

This dataset contains raw and processed zero resistance ammetry (ZRA) measurements collected from wetland sediments at Old Woman Creek, a freshwater estuary on Lake Erie, Ohio, USA, between June and November 2022. Measurements were obtained using a vertically deployed electrode array positioned at multiple depths within the sediment profile to capture electrochemical gradients associated with microbial activity and sediment geochemistry. The raw dataset consists of parsed instrument log files containing timestamps, electrode pair identifiers, and measured electrical potential (mV). The processed dataset includes standardized and quality-controlled values with instrument saturation limits removed and timestamps converted to ISO 8601 format. Electrode line identifiers were mapped to physical depths, enabling interpretation of depth-resolved electrochemical gradients. Instrument saturation values (−2048, −2047, 2047, and 2048 mV) were identified as measurement limits and excluded from quantitative analyses. All data parsing, processing, and quality control steps are documented in an accompanying R Markdown script, ensuring full reproducibility from raw instrument logs to final datasets.

EARTH SCIENCE > AGRICULTURE > SOILS > ELECTRICAL C↗

NASA NTRS1980

A study on the electrolysis of sulfur dioxide and water for the sulfur cycle hydrogen production process

Experimental electrolysis cells using various platinum catalyzed carbon electrodes were tested. When operated at 200 mA/sq cm current density using 50 w/o acid at 50 C and 1 atm, a reference cell required 1.22 volts and degraded rapidly. After several improvements were incorporated into electrodes and the test cell configuration, a later cell required only 0.77 volts under identical operating conditions. At a lower current density, 100 mA/sq cm, the cell required only 0.63 volts. Kinetic studies on metal electrodes, measurements of temperature effects on electrode kinetics, investigations of electrocatalytic activities of metal electrodes over a wide range of acid concentrations, cyclic voltametric studies and evaluation of alternate catalysts were also conducted. From diffusivity experiments, a cation exchange membrane material, P-4010, exhibited an excellent diffusion coefficient, more than two orders of magnitude lower than that of rubber. Ionic resistivity measurements of eight materials showed that microporous rubber had the lowest resistivity.

Source record↗

DOE OSTI2022

A resonant electro-physical transmutation method for water purification

We present an electro-transmutation (ET) method of water purification using the Quantum Kinetic Fusor™. Electrolysis experiments were performed with residential well water and seawater coupled with two different electrode materials—stainless steel and aluminum—to test the effectiveness of ET in removing contaminants and altering the physiochemistry (e.g., pH, alkalinity) and isotopic composition of water. ET effectively removed contaminants at power inputs as low 0.142 mA cm –2 , i.e., 1.9–4.2 watts, which is substantially lower than other electrochemical techniques. The ET process also reduces, and in some cases eliminates, electrode surface area degradation. This outcome is outside the field of traditional Faraday electrolysis, further distinguishing the ET process as potentially more cost-effective than other water purification methods. Importantly, the experiments reveal ET is an exceptionally low input energy generator. This finding is based on the presence of exotic x-rays (Bremsstrahlung) emissions during operation (1–20 KeV).

42 ENGINEERING↗

DOE OSTI2024

Methods of fabricating porous ceramic electrodes for solid state battery applications

Compositions and methods for the fabrication of electrode and porous lithium-garnet electrolyte scaffolds for use in solid state batteries and other devices are provided. The methods produce porous structures using phase inversion or high shear compaction processes to fabricate a solid-state battery electrode material from LLZO electrolytes. Engineered electrode structures with a porous scaffold of solid electrolyte material provide lower interfacial resistances and a mechanical support for a thin solid electrode layer improving performance.

Tucker, Michael↗

DOE OSTI2023

Proton-Conducting Solid Oxide Electrolysis Cells for Large-scale Hydrogen Production at Intermediate Temperatures

Proton-conducting electrolyte based SOECs offer potential for operation at low to intermediate temperatures. Although yttrium-doped barium zirconate (BZY) and ceria-doped barium zirconate (BCY) have conductivity of 0.01 and 0.017 S.cm -1 respectively at 650C in comparison to the conductivity of 0.015 S.cm -1 for 8-YSZ at 850°C, there remains technology gaps and research needs related to understanding of chemical and structural stability in oxidizing and/or reducing atmospheres at intermediate temperatures, material processing and densification techniques, high polarization losses, and electrode poisoning due to intrinsic and extrinsic gas phase contaminants. Synthesis methods have produced proton-conducting materials and cells that met degradation rate targets, showcasing stable hydrogen production. Improved performance was evident in the HSOEC cell, achieving higher hydrogen production at a lower operating temperature compared to standard cells. Collaborations with multiple research facilities ensured scaling up of synthesis processes and milestone achievements for large-scale manufacturing. Assessment of contaminants revealed their adverse effects on electrode performance and structural stability. Contaminants like Cr and Si compounds, in high humidity, degraded electrodes by forming stable silicate and chromates, inhibiting active surface reactions. Getter materials showed promise in capturing contaminants, suggesting potential for mitigation.

08 HYDROGEN↗

NASA NTRS2003

Flight Weight Design Nickel-Hydrogen Cells Using Lightweight Nickel Fiber Electrodes

The goal of this program is to develop a lightweight nickel electrode for advanced aerospace nickel-hydrogen cells and batteries with improved specific energy and specific volume. The lightweight nickel electrode will improve the specific energy of a nickel-hydrogen cell by >50%. These near-term advanced batteries will reduce power system mass and volume, while decreasing the cost, thus increasing mission capabilities and enabling small spacecraft missions. This development also offers a cost savings over the traditional sinter development methods for fabrication. The technology has been transferred to Eagle-Picher, a major aerospace battery manufacturer, who has scaled up the process developed at NASA GRC and fabricated electrodes for incorporation into flight-weight nickel-hydrogen cells.

Britton, Doris L.↗

DOE OSTI2024

Forming more and sharper sensing protrusions on graphene-based electrodes through annealing

A better understanding of the microstructure, physicochemical properties, and sensing behavior of an electrode is critical in developing quick, high sensitivity, and robust electrochemical sensors. Here, in this study, a single electrode was fabricated with self-prepared graphene ink through a drop-cast process followed with a subsequent annealing treatment. The graphene ink-based electrodes were characterized through AFM, contact angle, FTIR, impedance spectra, Raman, and SEM to understand annealing treatment effects. The dynamic response of the electrode to humidity, and vapors of ethanol, propanol, or acetone was measured using a four-point probe station in a closed chamber. The annealing treatment increased the conductivity of the electrode and improved its sensing performance by forming more and sharper protrusions on the electrode surface. These unique surface protrusions suggest that the annealed graphene ink-based electrodes hold great potential in developing high-performance electrochemical sensors.

42 ENGINEERING↗

NASA NTRS1979

Ion confinement and transport in a toroidal plasma with externally imposed radial electric fields

Strong electric fields were imposed along the minor radius of the toroidal plasma by biasing it with electrodes maintained at kilovolt potentials. Coherent, low-frequency disturbances characteristic of various magnetohydrodynamic instabilities were absent in the high-density, well-confined regime. High, direct-current radial electric fields with magnitudes up to 135 volts per centimeter penetrated inward to at least one-half the plasma radius. When the electric field pointed radially toward, the ion transport was inward against a strong local density gradient; and the plasma density and confinement time were significantly enhanced. The radial transport along the electric field appeared to be consistent with fluctuation-induced transport. With negative electrode polarity the particle confinement was consistent with a balance of two processes: a radial infusion of ions, in those sectors of the plasma not containing electrodes, that resulted from the radially inward fields; and ion losses to the electrodes, each of the which acted as a sink and drew ions out of the plasma. A simple model of particle confinement was proposed in which the particle confinement time is proportional to the plasma volume. The scaling predicted by this model was consistent with experimental measurements.

Roth, J. R.↗

NASA NTRS2005

Modifications of Fabrication of Vibratory Microgyroscopes

A micromachining process for the fabrication of vibratory microgyroscopes from silicon wafers, and aspects of the microgyroscope design that are inextricably linked with the fabrication process, have been modified in an effort to increase production yields from perspectives of both quantity and quality. Prior to the modifications, the effective production yield of working microgyroscopes was limited to one or less per wafer. The modifications are part of a continuing effort to improve the design and increase production yields to more than 30 working microgyroscopes per wafer. A discussion of pertinent aspects of the unmodified design and the unmodified fabrication process is prerequisite to a meaningful description of the modifications. The design of the microgyroscope package was not conducive to high yield and rapid testing of many microgyroscopes. One of the major impediments to high yield and testing was found to lie in vibration- isolation beams around the four edges of each microgyroscope, which beams were found to be unnecessary for achieving high resonance quality factors (Q values) characterizing the vibrations of petallike cantilevers. The fabrication process included an 8- m-deep plasma etch. The purpose of the etch was to create 8- m vertical gaps, below which were to be placed large gold evaporated electrodes and sensing pads to drive and sense resonant vibrations of the "petals." The process also included a step in which bridges between dies were cut to separate the dies. The etched areas must be kept clean and smooth (free of debris and spikes), because any object close to 8 m high in those areas would stop the vibrations. However, it was found that after the etch, there remained some spikes with heights that were, variously, almost as high or as high as the etch depth. It also was found that the cutting of bridges created silicon debris, some of which lodged in the 8- m gaps and some of which landed on top of the petals. The masses added to the petals by the debris altered resonance frequencies and/or Q values to unacceptable degrees. Hence, the spikes and the debris have been conjectured to cause most of the observed malfunctions of newly fabricated microgyroscopes. Another pertinent aspect of the unmodified design and process was the fabrication of electrodes and the 8- m capacitance gap on a 500- m-thick wafer, and the fabrication of a 3-mm-thick baseplate from another wafer. It was necessary to bond these wafers to each other in an assembly step that was later found to be superfluous in that it could be eliminated by a suitable modification of the design.

Bae, Sam Y.↗

DOE OSTI2020

Roll-to-roll production of catalyst coated membranes for low-temperature electrolyzers

Here we demonstrate a roll-to-roll (R2R) process for direct coating of anode catalyst layers on a polymer electrolyte membrane for low-temperature water electrolysis. To develop this process, we studied catalyst ink formulation, ink-membrane interactions, and coating quality. The catalyst inks were a mixture of iridium oxide (IrO2) and Nafion in a water and alcohol dispersion medium. The type of alcohol (methanol, ethanol, propanols) and water-to-alcohol ratio were varied to determine their influence on membrane swelling, dispersion quality, and coatability. Interactions of the ink dispersion medium with the membrane were characterized using sessile-drop contact-angle measurements. These measurements show that the ratio of water to alcohol has a strong influence on how rapidly the dispersion media is absorbed by the membrane. Rheology of the catalyst inks was measured to understand the microstructure of the catalyst particles in the ink. This analysis found that 1-propanol leads to better dispersion of the IrO2 particles than ethanol. Small-scale coating samples were prepared to understand coating uniformity and formation of irregularities. Subsequently, two water/1-propanol ratios (90:10 and 75:25) were down-selected for large-scale R2R slot die coating. The R2R catalyst-coated membrane (CCM) coating process increased catalyst layer production throughput by over 500x compared to our standard lab-scale spray coating. The CCMs obtained from this process were tested as single-cell membrane electrode assemblies. They exhibited a cell voltage of 1.91 V at a current density of 2 A/cm2, which is comparable to spray-coated CCMs. In conclusion, the work presented here demonstrates a continuous, scalable manufacturing process that eliminates the need for the decal transfer step typically used in CCM production.

42 ENGINEERING↗

DOE OSTI2021

Layer-structured triple-conducting electrocatalyst for water-splitting in protonic ceramic electrolysis cells: Conductivities vs. activity

Electron, proton and oxygen-triple-conducting materials are becoming the dominant steam electrode candidate to break the rate limit on the water-splitting reaction that throttles the performance of protonic ceramic electrolysis cells (PCECs). In this study, based on Pr 2 NiO 4+δ Ruddlesden-Popper phase, we manipulate these conductivities by Pr-site Ba substitution to probe the correlation of each conductivity with the kinetics of the elementary reaction steps. It is found that the proton conductivity is vital to sustain an extended active surface area for faster adsorption of reactants and desorption of products. The effect of oxygen conductivity is surprisingly found insignificant in the water-splitting reaction. On the contrary, surface oxygen removal is discovered as the most rate-limiting process. The electronic conductivity is not a direct limiting factor. However, an electron transfer process between the current collector and the electrode junction could introduce extra resistance that is perceptible at a high operating temperature range. The best water-splitting activity is obtained on a proton conductivity/oxygen surface desorption capability well-balanced sample after Ba substitution. As a result, a water-splitting reaction resistance of 0.022 Ωcm 2 , a current density of 1.96 A/cm 2 at 700 °C is achieved on Pr 1.7 Ba 0.3 NiO 4+δ , one of the best performances for PCECs.

25 ENERGY STORAGE↗

DOE OSTI2020

High-Energy All-Solid-State Organic–Lithium Batteries Based on Ceramic Electrolytes

Recent studies have identified unique properties of organic battery electrode materials such as moderate redox potentials and mechanical softness which are uniquely beneficial for all-solid-state batteries based on ceramic electrolytes. Here, we further explore the promise of organic materials and demonstrate a sulfide electrolyte- based organic-lithium battery with a specific energy of 828 Wh kg –1 , rivaling the state-of- the-art of all-solid-state batteries. Two innovation steps are responsible for the accomplishment. First, the combination of lithium anode and the high-capacity cathode material pyrene-4,5,9,10-tetraone ensures a high theoretical specific energy. Second, the microstructure of the organic cathode is optimized with the introduction of cryomilling, a technique common to processing soft materials but not familiar to electrode fabrication. The cathode material utilization increases to 99.5% as a result, up from the 55–89% previously reported for ceramic electrolyte-based solid-state organic batteries. In conclusion, the improvement highlights the special requirements of solid-state organic electrodes for microstructural engineering while preserving the chemical integrity of components.

25 ENERGY STORAGE↗