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DOE OSTI2026

Decoupling plasma, catalyst, and gaseous mechanisms for non-oxidative methane conversion

Direct non-oxidative methane (CH 4 ) conversion to value-added hydrogen (H 2 ) and C 2 products remains hindered by fundamental catalytic scaling constraints and rapid surface deactivation at elevated temperatures. Plasma-enabled catalysis offers a promising route to overcome the thermodynamic and kinetic barriers of direct non-oxidative methane upgrading at mild conditions, yet control over C–C product selectivity and catalyst stability remains elusive. Here, we establish a unified mechanistic framework including Langmuir–Hinshelwood (L–H) and Langmuir–Rideal (L–R) mechanisms that disentangles the roles of plasma excitation (including vibrationally activated species and radicals), surface temperature (T sur ), and catalyst binding energy in steering CH 4 conversion to H 2 and C 2 hydrocarbons. Through a combination of density functional theory (DFT) informed microkinetic modeling, in situ and ex situ surface characterization, and product quantification under dielectric barrier discharge conditions, we show that vibrationally excited CH 4 lowers activation barriers selectively for dissociative chemisorption, enabling surface activation across a wide range of transition metal catalysts at low thermal energy input. We find that once CH 4 is dissociatively chemisorbed, the branching between C 2 H 2 , C 2 H 4 , and C 2 H 6 is governed by surface properties (carbon binding energy, T sur , etc), regardless of plasma excitation. The DFT informed microkinetic model decouples the effects of molecular activation from surface properties and indentifies operating windows that maximize target yields while suppressing carbon accumulation and subsequent catalytic inactivation. Experiments on polycrystalline Cu/Al 2 O 3 , Ni/Al 2 O 3 , and Pt/Al 2 O 3 validate these predictions, revealing catalyst-dependent branching toward ethane or ethylene and distinct deactivation profiles. We unify these trends into a generalized three-dimensional plasma-thermal-catalytic design space, from which reduced descriptors such as T vib /T sur in the limit of vibrationally excited L–H pathways emerge as predictive metrics. These results enable rational tuning of methane conversion pathways and unlock selective C 2 formation using earth-abundant metals under mild plasma conditions.

catalyst inactivation↗

DOE OSTI2024

Co-synthesis of Hydrogen and High-Value Carbon Products from Methane Pyrolysis

The ARPA-E Methane Pyrolysis Project successfully developed a scalable technology for hydrogen production with low-CO x emission through methane pyrolysis, co-producing high-value carbon nanotubes (CNTs). The project focused on optimizing reactor design, enhancing catalyst performance, and assessing techno-economic feasibility to create a commercially viable and environmentally sustainable process. The fluidized bed reactor achieved over 90% methane (CH 4 ) conversion by using a 5% CO 2 co-feed, which stabilizes carbon yields and minimizes catalyst deactivation. This setup allowed for continuous operation across ten cycles, each consisting of a 14-minute pyrolysis phase followed by a 10-minute dislodging phase to remove a fraction of the accumulated carbon, resulting in stable performance and high-quality CNT production. In parallel, monolith reactors coated with Fe demonstrated a sustained methane conversion of 73% while producing CNTs with high crystallinity. Although promising for continuous operation, monolith reactors face challenges in coating durability and scalability, highlighting areas for further optimization in commercial applications. Catalyst formulation played a key role in enhancing process efficiency. The core catalyst used was 5%Fe/Al 2 O 3 (wt%), optimized through wet impregnation, which improved CNT morphology, yielding longer and more uniform CNTs. The catalyst's performance was further enhanced by adding promoters: 2.5 wt% Ni increased methane conversion close to the thermodynamic limit, while 2.5 wt% Mn improved CNT alignment and crystallinity, and 1.5 wt% NaCl boosted CNT morphology but slightly lowered methane conversion. These adjustments allowed the reactor to maintain high methane conversion while producing high-quality CNTs, enabling stable performance over multiple cycles. To address carbon buildup and ensure uninterrupted operation, a pneumatic conveying tube was implemented for effective carbon dislodging in the fluidized bed configuration. CO 2 and H 2 O co-feeds were also introduced to enhance carbon removal, with CO 2 boosting CNT yield by approximately 15%. This setup enabled stable reactor operation across multiple cycles, preventing clogging and minimizing catalyst wear, making the process suitable for industrial scaling. Techno-economic analysis (TEA) projected hydrogen production costs between $\$$1.00 and $\$$1.64 per kilogram, with CNT values assumed at $\$$375/ton and $\$$100/ton. The life cycle assessment showed that CO 2 emissions could be as low as 0.64 kg CO 2 e/kg H 2 at 95% methane conversion assuming an electricity input of 50 kg CO 2 e/MWh. Even at 50% methane conversion, emissions remained below 1 kg CO 2 e/kg H 2 , demonstrating the process's low-emission potential and making it a viable alternative to traditional steam methane reforming. Overall, the results from this project demonstrate the feasibility of a pyrolysis process where carbon is continuously removed from the catalyst surface and hydrogen is continuously produced until a catalyst regeneration step is required to fully clean the catalyst surface and renew catalyst performance. Major open challenges are related to avoiding the loss of catalyst material in the dislodged carbon during fluidized bed conditions, since our best result demonstrated a carbon purity of ~70 wt. % (rest being iron and alumina). A monolith reactor was used to favor dislodgement of carbon compared to fluidized bed conditions but our results do not demonstrate an advantage of the monolith configuration. Catalyst performance was similar to fluidized bed conditions with slower deactivation rates overall, but we could not observe carbon dislodging in any of the tens of experiments that were run at Stanford. Our results show that the most relevant areas of improvement are related to the fundamental understanding of the iron-carbon interface for dislodging, and the development of catalyst that can produce CNTs via a base-growth mechanism such that catalyst is not lost in the dislodgement steps. The final report documents all findings and methodologies in detail, providing a valuable resource for the scientific community. By building on these results, researchers can further advance methane pyrolysis technology, moving toward a more sustainable, scalable pathway for hydrogen production. This work lays the foundation for future research and commercial efforts to reduce emissions in hydrogen production while generating valuable carbon products.

08 HYDROGEN↗

DOE OSTI2026

AOI 5 Improved Efficiency of Medium- and Heavy-Duty Natural Gas and Propane (LPG) Engines

Spark-ignited heavy-duty (HD) natural gas engines typically experience efficiency losses at part-load operation due to throttling requirements needed to maintain stoichiometric combustion. A substantial portion of medium- and heavy-duty engine operation occurs in this low-load region, resulting in increased brake-specific carbon dioxide emissions and reduced overall efficiency. This project designed, developed and demonstrated cylinder deactivation (CDA) technology on an HD natural gas engine to mitigate these losses. CDA enables selective deactivation of cylinders, reducing pumping losses while maintaining required torque output and meeting vehicle noise, vibration, and harshness (NVH) targets. The project objectives were successfully achieved, demonstrating up to 12% improvement in fuel consumption over the next generation HD NG engine on key low loaded HD cycles and maintained compliance with 0.02 g/hp-hr NO x emissions with comparable or better vibrations to current product. These results confirm that CDA technology can substantially improve the fuel efficiency and environmental performance of heavy-duty natural gas engines, reinforcing their potential as a low-carbon bridge solution in the transition toward zero-emission transportation technologies.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

Effect of Mo precursors in Microwave-assisted Methane Dehydroaromatization over Mo/HZSM5 catalysts

Natural gas flaring occurs in remote shale regions due to limited pipeline takeaway capacity. The conversion of the associated natural gas into aromatics in modular microwave reactors is a viable alternative to monetize the wasted gas. Microwaves offer rapid, selective heating in compact reactor systems that can enable on-demand chemical production at the well-site. Mo-HZSM-5 catalysts are widely used for aromatic production, but the location and nature of the active sites are still under debate. This study focuses on the use of 6 different Mo precursors to elucidate insights into the Mo properties that are desirable for BTX production. The catalysts were characterized by different methods (XPS, TPR, Raman, etc) to determine differences in Mo catalytic properties that may affect performance and understand these differences through performance testing under microwave at 700C for methane dehydroaromatization. Metal precursors that enable a better distribution of Mo into the pores and over the surface lead to improved benzene yield, whereas those that limited Mo to primarily the surface suffer rapid deactivation and low benzene yields. Additionally, strong Lewis acidity that arises from the sodium containing precursor drastically shifts the product selectivity towards dehydrogenation, which produces more ethylene and carbon. This catalyst had the highest deactivation constant of all catalysts tested.

gas flaring reduction↗

DOE OSTI2025

Evaluating the impacts of Variable Message Signs on Airport Curbside Performance Using Microsimulation

Curbs play a vital role in facilitating vehicle access and egress for individuals at airports. Inefficiently allocating this resource hinders airport accessibility and productivity, resulting in congestion, longer travel times, and increased pollution. As airport demand fluctuates throughout the day and grows over time, airports face intensified curbside pressure. Yet, curb management research is significantly less robust at airports than in urban areas. Given the unbalanced nature of airport demand—riders tend to arrive simultaneously at specific entrances at certain hours—Variable Message Sign (VMS) arises as a cost-effective technology to divert vehicles from congested to underutilized curbs. Still, VMS implementation faces a significant challenge. Historically, airports have managed VMS heuristically and by intuition rather than an evidence-based approach. This research investigates the impacts of implementing VMS on curb performance at airports. By considering different driver compliance rates (DCR), we aim to determine when the sign should be turned on and off to diverge traffic to avoid undesired externalities while enhancing curb performance. Using a validated agent-based microsimulation model, VISSIM, we analyzed the Seattle-Tacoma (SeaTac) Airport as a case study. We modeled sixteen VMS management scenarios and a baseline where the message sign is not displayed, diverging vehicles between the departures and arrivals access levels at four different moments (early morning, morning, afternoon, and late night). We quantified the effects of VMS using seven metrics, including curb productivity index (CPI), curb accessibility (CA), queue length, queue duration, delay, vehicle counts, and emissions. The results of each scenario were compared against the baseline using absolute and relative changes and Repeated Measures ANOVA. Overall, VMS improved curb performance and traffic conditions at the airport, reducing emissions by 14.8% to 8.9%. Moreover, significant reductions in queue length (1,150 ft to 100 ft) and duration (15 to 144 minutes) were observed in the sending link under all VMS policies. However, impacts on the receiving link varied based on congestion, with significant increases in queue duration (9.8 to 24 min) when congested but no substantial changes in free flow. Notably, diverging vehicles to congested links resulted in non-significant results, and activating late and deactivating late VMS affected curb productivity (-5.8% to -61.4%), curb accessibility (-16.5% to -25.8%), cumulative counts (-33.4% to -59.4%), and vehicle delay (95.98% to 594.3%). Activating VMS before congestion begins in the sending link and deactivating before a queue forms in the receiving link yield the most significant improvements: 8.1% to 10.1% in CPI, 9.4% to9.6% in CA, -29.3% to -77.9% in total delay, -11.6% to -13.9% in total emissions, and 101% to 103% in cumulative counts. As the analysis was made with a wide range of time periods, access levels, driver compliance rates, and scenarios, we believe our findings can provide valuable insights into how airports should manage VMS. Our work introduces a novel approach to the scientific airport literature, as some of our metrics were previously unexplored. Additionally, we propose a methodology that other airports can adopt to maximize their curb performance.

Gutierrez, Jorge D.↗

DOE OSTI2024

Butene-Rich Alkene Formation from 2,3-Butanediol through Dioxolane Intermediates

The cost-effective production of sustainable aviation fuels (SAF) remains a major challenge within the energy sector. One approach to address this is the fermentation of biomass feedstocks into oxygenates followed by catalytic conversion to alkenes or other oligomerization precursors. 2,3-Butanediol (BDO) is a promising fermentation product due to its four-carbon nature, its decreased microorganism toxicity and associated higher maximum fermentation titers relative to other alcohols and oxygenates, and its capacity to be readily converted into butene isomers and longer chain alkenes. BDO conversion is currently constrained by separation challenges for BDO isolation due to its high boiling point and hydrophilicity. Here, this work expands upon previous BDO reactive separation via dioxolane formation over a solid acid catalyst by investigating the conversion of dioxolanes into alkene mixtures. Dioxolanes were formed from a range of aldehydes and subsequently converted over a Cu/ZSM-5 catalyst (448–523 K) via an ether cleavage, hydrogenation, and dehydration reaction network to form alkene-rich product mixtures (96% C 3+ alkene yield, 523 K). This selectivity is greater than that of direct BDO conversion to alkenes over an identical catalyst (89%, 523 K). C 3+ alkene selectivity is maximized between 498 and 523 K at complete dioxolane conversion without significant alkene hydrogenation to alkanes. The alkene product distributions can be tailored via both aldehyde selection during dioxolane formation and the dioxolane conversion reaction temperature. Alkene mixtures from dioxolane conversion predominantly reflect the carbon chain length and stereochemistry of BDO and the initial aldehyde at or below 498 K, yet higher reaction temperatures yield alkene mixtures of similar carbon chain distributions, regardless of initial aldehyde selection. Deactivation of the Cu/ZSM-5 catalyst is observed for multiple steps of the overall reaction network but can be minimized by facilitating the complete dioxolane-to-alkene reaction network at temperatures of at least 498 K.

2,3-butanediol↗

DOE OSTI2024

Identifying Controlling Variables for Mercury Vapors in Alpha-4 at Y-12: Two Year Data Collection Update

Multiple sensor packages were deployed at Alpha-4 by SRNL, in collaboration with United Cleanup Oak Ridge LLC (UCOR), to monitor mercury vapor concentrations and meteorological parameters. These sensors collected data, inside and outside of the legacy-use facility, for approximately two years. Though data gaps still exist, particularly in colder months, several controlling variables were identified that govern mercury vapor concentrations within Alpha-4. Temperature, barometric pressure gradients, humidity, and wind speed have been identified as controlling variables. A strong positive correlation was seen between mercury vapor concentrations and temperature which generally followed diurnal fluctuations. Temperatures below approximately 10 degrees Celsius did not show any spikes above the PEL, indicating more work can be performed at any time during the winter months – more data should be collected to confirm consistency in this finding. Additionally, spikes in mercury vapor concentrations above that of the permissible exposure limit (PEL; 100 µg/m 3 ) occurred primarily in late afternoon or evening/overnight hours (between 3 PM and 6 AM), which suggests D&D operations might be best scheduled during morning or daytime hours prior to the late afternoon. However, a limited number of spikes did occur outside of the identified window, although this may be attributed to disturbances in air flow and mercury vapor release from work activities performed inside of the Alpha-4 building. The analysis conducted allows for a strong predictive capability for estimating mercury vapor concentrations based upon accurate meteorological parameters. Still, additional data collection, particularly in the winter months, could help to strengthen the predictive power and validate the identified data trends. Further, increased temporal resolution could also help to better characterize the incipient stages of the increases and decreases in the mercury vapor concentration. Continued monitoring support by SRNL at Y-12 is underway at Alpha-4 to further close remaining data gaps and support deactivation and decommissioning work. Within a collaborative effort with UCOR, the SRNL team is collecting mercury vapor data to study the efficacy of a novel mercury suppressant, FerroBlack® which was recently deployed at Alpha-4. In addition, modifications to the current monitoring setup to increase measurement resolution is also being investigated.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Steam‐Assisted Selective CO 2 Hydrogenation to Ethanol over Ru−In Catalysts

Abstract Multicomponent catalysts can be designed to synergistically combine reaction intermediates at interfacial active sites, but restructuring makes systematic control and understanding of such dynamics challenging. We here unveil how reducibility and mobility of indium oxide species in Ru‐based catalysts crucially control the direct, selective conversion of CO 2 to ethanol. When uncontrolled, reduced indium oxide species occupy the Ru surface, leading to deactivation. With the addition of steam as a mild oxidant and using porous polymer layers to control In mobility, Ru−In 2 O 3 interface sites are stabilized, and ethanol can be produced with superior overall selectivity (70 %, rest CO). Our work highlights how engineering of bifunctional active ensembles enables cooperativity and synergy at tailored interfaces, which unlocks unprecedented performance in heterogeneous catalysts.

Zhou, Chengshuang↗

DOE OSTI2024

Steam-Assisted Selective CO 2 Hydrogenation to Ethanol over Ru–In Catalysts

Multicomponent catalysts can be designed to synergistically combine reaction intermediates at interfacial active sites, but restructuring makes systematic control and understanding of such dynamics challenging. In this work, we unveil how reducibility and mobility of indium oxide species in Ru-based catalysts crucially control the direct, selective conversion of CO 2 to ethanol. When uncontrolled, reduced indium oxide species occupy the Ru surface, leading to deactivation. With the addition of steam as a mild oxidant and using porous polymer layers to control In mobility, Ru–In 2 O 3 interface sites are stabilized, and ethanol can be produced with superior overall selectivity (70 %, rest CO). Our work highlights how engineering of bifunctional active ensembles enables cooperativity and synergy at tailored interfaces, which unlocks unprecedented performance in heterogeneous catalysts.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

A Stable Site‐Isolated Mono(phosphine)‐Rhodium Catalyst on a Metal‐Organic Layer for Highly Efficient Hydrogenation Reactions

Abstract Phosphine‐ligated transition metal complexes play a pivotal role in modern catalysis, but our understanding of the impact of ligand counts on the catalysis performance of the metal center is limited. Here we report the synthesis of a low‐coordinate mono(phosphine)‐Rh catalyst on a metal‐organic layer (MOL), P‐MOL • Rh, and its applications in the hydrogenation of mono‐, di‐, and tri‐substituted alkenes as well as aryl nitriles with turnover numbers (TONs) of up to 390000. Mechanistic investigations and density functional theory calculations revealed the lowering of reaction energy barriers by the low steric hindrance of site‐isolated mono(phosphine)‐Rh sites on the MOL to provide superior catalytic activity over homogeneous Rh catalysts. The MOL also prevents catalyst deactivation to enable recycle and reuse of P‐MOL • Rh in catalytic hydrogenation reactions.

Chemistry↗

DOE OSTI2024

Fuel‐Driven π‐Conjugated Superstructures to Form Transient Conductive Hydrogels

Despite advances in creating dissipative materials with transient properties, such as hydrogels and active droplets, their application remains confined to temporal changes in structural properties. Developing out-of-equilibrium materials whose electronic functions are parameterized by a chemical reaction cycle is challenging. Yet, this class of materials is required to construct biomimetic materials. In contrast to traditional chemical reaction cycles that exploit molecularly dissolved building blocks at thermodynamic equilibrium, we show that fiber structures derived from reactive naphthalene diimide (NDI) building blocks can be used as resting states to form far-from-equilibrium conductive hydrogels after the addition of chemical fuels. Upon fueling the NDI-derived fibers, a dual-component activation and deactivation pathway is deduced by kinetic analysis and is absent when using a molecularly dissolved resting state. Investigating the solid-state morphologies of the structures formed throughout the fuel-driven reaction cycle using cryo-EM reveals that the resting thermodynamic fibers evolve to transient thicker fibrils and layered superstructures. We show that the transient redox-active hydrogels exhibit a nearly threefold increase in electrical conductivity upon fuel consumption before reverting to their original value over hours. In conclusion, these far-from-equilibrium materials are potential candidates in applications such as programmable biorobotics and chemical computing.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Self‐Stabilized Heterometallic Pair Sites for Selective Ethanol Dehydrogenation on Pt–Cr–Ag Alloy Catalysts

Self‐stabilized, heterometallic pair‐sites can enable fine‐tuning of catalytic functionality while also mitigating dynamic structural changes that degrade catalytic performance. This study demonstrates the development and characterization of trimetallic Pt x Cr x Ag 1‐2x ( x ≤ 0.1) alloys with active Pt–Cr pair‐ensembles for non‐oxidative ethanol dehydrogenation, leveraging predictions that favorable bonding stabilizes Pt–Cr pairs diluted in Ag. Operando X‐ray absorption spectroscopy confirms the preferential formation and stability of Pt–Cr pairings dispersed throughout the Ag matrix, and ambient‐pressure X‐ray photoelectron spectroscopy shows that Pt–Cr sites have significant activity for ethanol dehydrogenation, while suppressing reaction processes that deactivate binary Pt–Ag and Cr–Ag alloys. This work demonstrates that stabilizing heterometallic pair sites within trimetallic alloys provides a new avenue for designing catalysts with discrete active sites that are durable and highly selective.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Impact of Iron Species Dispersion on Fe/ZSM–5 Catalyst Performance for Methane Dehydroaromatization (MDA)

Methane dehydroaromatization (MDA) is one of the most promising technologies for directly transforming methane into aromatics. Unlike the extensively investigated Mo/ZSM-5 catalysts, the structure and, consequently, the catalytic activity of Fe/ZSM-5 are markedly influenced by the method of preparation, as shown here. In this study, we prepared 2 % and 4 % Fe/ZSM-5 catalysts via wet impregnation (WI) and incipient wetness impregnation (IWI). Characterizations (XRD, STEM, UV-Vis, NH 3 -TPD and H 2 -TPR) reveal that 2 %Fe-WI mainly possesses isolated or low-polymerized Fe species within zeolite channels, leading to a rapid activation and a higher benzene yield due to the faster reduction to iron suboxides under MDA conditions. In contrast, 2 %Fe-IWI contains bulk iron oxide aggregates, resulting in a slower activation as these aggregates transform into iron carbide through successive reduction and carbonization. Here, a deactivation kinetic study applied to the 2 % catalysts further demonstrates the quantitative relation between Fe site isolation and catalytic activity. Although both 4 % catalysts inevitably form sizable iron oxide clusters and particles due to the high Fe/Al ratio, similar trends are noted, with the WI catalysts exhibiting a shorter induction/activation period and a higher yield of benzene, paralleling observations made with 2 % catalysts.

03 NATURAL GAS↗

DOE OSTI2025

Active and Stable PtPd Diesel Oxidation Catalysts under Industry‐Defined Test Protocols

Nanoparticle-supported Pt and Pd catalysts are employed industrially to convert CO and hydrocarbon residue from incomplete diesel fuel combustion into more environmentally-benign products. However, these catalysts deactivate over time due to sintering, especially for Pt nanoparticles which readily generate volatile species under high operating temperatures. Here, we turned the detrimental vapor-mediated sintering of Pt into an advantage by using a physical mixture of Pt and Pd catalysts prepared using a raspberry-colloid-templating (RCT) method. The RCT method produced Pt/Al 2 O 3 and Pd/Al 2 O 3 catalysts with partially embedded NPs to inhibit surface-mediated sintering pathways. As validated using an industry-defined emission control test protocol, aging a physical mixture of Pt/Al 2 O 3 and Pd/Al 2 O 3 at high temperature produced an alloyed PtPd/Al 2 O 3 catalyst that outperformed the fresh catalyst mixture and both individual catalysts for hydrocarbon conversion, while exhibiting high catalytic stability and resistance to sintering and to SO 2 poisoning. X-ray photoelectron spectroscopy revealed that in the aged catalyst mixture, half of the Pd content existed in the more active metallic state, compared to the less active oxide forms in the fresh mixture and both individual catalysts, explaining the unusual activity enhancement. Our results represent a practical approach to producing active and stable PtPd/Al 2 O 3 diesel oxidation catalysts for emission control applications.

Lim, Kang Rui Garrick [Harvard University, Cambrid↗

DOE OSTI2026

Simultaneous Determination of Halogens and Metals in Waste Plastic Pyrolysis Oil by Inductively Coupled Plasma Mass Spectrometry

A major barrier to integrating pyrolysis-derived oil into conventional refinery technology is the presence of impurities, particularly halogens and metals, that can deactivate catalysts. This study presents a novel, cost-effective approach for the simultaneous analysis of a subset of halogens, metals, nonmetals, and metalloids in complex, industrially relevant distilled pyrolysis oil samples, this was previously achievable only through multiple techniques. Excellent results were obtained using a widely accessible inductively coupled plasma mass spectrometry (ICP-MS) method with helium gas mode and standard laboratory consumables, enabling high-throughput analysis and efficient evaluation of adsorbent performance. Sample preparation is straightforward, requiring only dilution in a compatible matrix, and provides accurate and precise quantification, with 75%–137% spike recovery for Be, Ti, V, Cr, Fe, Ni, Co, Cu, As, Se, Mo, Cd, Sb, Tl, and Pb, and 62%–65% spike recovery for Cl and 109%–133% spike recovery for Br. Additionally, an enhanced version of the method using ICP-MS/MS and hydrogen gas is described, which has higher accuracy with 69%–112% spike recovery for Be, B, Ti, V, Fe, Co, Ni, Cu, As, Se, Mo, Cd, Sb, Tl, and Pb, with 85%–102% spike recovery for Cl and 63%–93% spike recovery for Br. Helium mode detection limits for industrially relevant elements (V, Fe, Ni, Cu, As, and Pb) are less than 1.7 µg/kg, and less than 0.2 mg/kg for Br and Cl. Furthermore, this methodology facilitates rapid systematic evaluation of adsorption capacities of materials under time-on-stream conditions and supports robust comparisons across diverse operating environments.

Lazarcik, James [University of Wisconsin-Madison, ↗

DOE OSTI2025

CO2-Utilization Facilitated by Solid Reaction Mediums—A Review

Abstract This short review examines solid reaction mediums—specifically oxygen, CO 2 , and carbon carriers—within the framework of Chemical Looping (CL) to illuminate various CO 2 utilization pathways. The thermodynamic consideration for carrier selection is first discussed. This is followed by a summary of the key carrier types investigated to date, with an emphasis on elucidating the roles of compositional, structural, and surface properties of the various carriers toward their reactive performances. Besides assessing the performances of various oxygen carriers, their long-term performance, potential deactivation mechanism in the presence of CO 2, and strategies for their reactivation are also discussed in the context of chemical looping dry reforming of methane (CLDRM). While relatively underexplored, the current status of development, advantages, and potential limitations of CO 2 carriers in sorbent looping dry reforming of methane (SLDRM) and carbon carriers in chemical looping methane cracking (CLMC) are also reviewed and discussed. Emerging topics such as combined carriers are also covered along with a perspective for future research directions. Overall, this review aims to offer insights into the sustainable use of CO 2 through chemical looping, emphasizing the potential of solid reaction mediums across different carriers and the challenges associated with these solid reaction mediums.

Iftikhar, Sherafghan↗

DOE OSTI2024

The stability of single-atom catalysts in thermocatalysis

Abstract Single-atom catalysts (SACs) featuring 100% atom utilization and uniform isolated active sites have been receiving sustainable attention over the last decade, as they offer exceptional performance in various catalytic applications. The motivation behind studying SACs is to develop highly active, selective, and stable catalysts for industrial applications with desirable economic and ecological benefits. Despite their promising potential, SACs face challenges related to stability, which need to be addressed for practical implementation. In this mini-review we discuss the existing stability issues of SACs, and summarize the deactivation mechanism and behaviors, protective strategies, and regeneration methods of SACs. We highlighted the challenges and prospects of future SACs study, aiming to pave the way for their widespread application in industrial processes.

Chae, Sudong↗

DOE OSTI2025

Stepwise impregnation of bimetallic catalysts for carbon nanotube synthesis

Supported bimetallic catalysts are widely used for carbon nanotube (CNT) synthesis, yet the effects of impregnation procedure remain underexplored. Here, we investigated how the sequence of metal impregnation affects CNT synthesis. We prepared cobalt-molybdenum (Co-Mo) bimetallic catalysts on alumina supports via co- and stepwise impregnation, then compared their CNT synthesis performance under identical conditions. Stepwise-impregnated catalysts exhibited higher carbon yields than those prepared by co-impregnation. Notably, impregnating Mo after Co achieved the highest yield despite the lowest BET surface area. Synchrotron X-ray diffraction and visible/UV-Raman spectroscopy revealed that only this catalyst contained Al 2 (MoO 4 ) 3 with a MoO 4 structure. X-ray photoelectron spectroscopy clarified the surface chemistry: the catalyst with the highest CNT productivity exposed Mo entirely as Mo 6+ in Al 2 (MoO 4 ) 3 and CoMoO 4 , whereas the others contained both Mo 4+ and Mo 6+ . The MoO x species like Al 2 (MoO 4 ) 3 is known to suppress Co sintering during CNT synthesis, delaying catalyst deactivation and enhancing the carbon yield. Moreover, an inverse relationship was observed between carbon yield and the CoMoO 4 content. This is attributed to the consumption of catalytically active Co during CoMoO 4 formation, which reduces active sites for CNT growth. ICP-OES further confirmed higher Co and Mo loadings for stepwise catalysts, contributing to superior catalyst performance. The extent of CoMoO 4 formation strongly depended on the metal introduction sequence. In conclusion, this trend is illustrated by considering the relationship between the point of zero charge of support and the pH of the metal precursor solutions.

36 MATERIALS SCIENCE↗