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DOE OSTI2025

Microwave-assisted pyrolysis of liquid hydrocarbons using iron-based alumina catalysts obtained by solution combustion synthesis: The effect of synthesis parameters

The microwave-absorbing and catalytic properties of iron-based alumina (FeAl x O y ) materials have enabled their use as catalysts for the microwave-assisted generation of hydrogen and carbon via pyrolysis of hydrocarbons. Solution combustion synthesis (SCS) is a promising method to fabricate these materials, but the pyrolysis performance still needs to be improved. The present work investigated how altering the SCS parameters affects the pyrolysis of diesel fuel, gasoline, and crude oil. Two fuels (citric acid and glycine), four Fe:Al molar ratios, and two heating modes (hotplate and furnace) were tested. Fe/γ-Al 2 O 3 and Fe/β-SiC catalysts were prepared via incipient wetness impregnation for comparison. Among the three fossil fuels tested, diesel fuel yielded the highest amounts of H 2 and least amounts of CO x . The choice of fuel for the SCS process and the Fe/Al ratio strongly affected pyrolysis performance as they influence properties important for both catalysis and microwave absorption. The use of glycine resulted in catalysts that exhibited high H 2 yield and low CO 2 generation, which is explained by the revealed structural differences. The increase in the Fe:Al molar ratio accelerated microwave heating by adding more magnetic loss but also increased the amount of CO x . When the optimal SCS parameters were used, FeAl x O y catalysts outperformed Fe/γ-Al 2 O 3 and Fe/β-SiC. The high H 2 generation efficiency of the SCS catalysts is explained by their enhanced microwave-absorption properties. Scanning electron microscopy and energy dispersive X-ray spectroscopy revealed the formation of large-diameter CNTs via the tip-growth mechanism. The regeneration of SCS catalysts was demonstrated via the Boudouard reaction.

Carbon nanotubes↗

DOE OSTI2024

Effect of Support on Iron-Based Catalyst Toward CO2-Free H2 Production From Methane Pyrolysis

The global demand for low-emission hydrogen production is increasing rapidly due to the potential for hydrogen to substitute conventional fossil fuels in energy-related applications. Among practical technologies such as steam reforming of methane (SMR), water electrolysis, and methane pyrolysis, methane pyrolysis has the most potential to produce economical- and near-zero-emission hydrogen. The reaction during methane pyrolysis produces a solid carbon by-product that can be monetized to offset production costs. However, this route is not without research challenges, and the selective formation of high-value carbon remains a critical issue. Supported nickel, iron, and cobalt, have been widely investigated for methane pyrolysis. Although iron-based catalysts are less active than Ni, iron catalysts offer less resistance to coke formation, are inexpensive, and have a longer lifetime. One area not sufficiently explored is the effect of support materials other than Al2O3 for the iron-based catalysts. Therefore, we investigated a detailed variation of support materials to study their influence on the catalytic performance. Moreover, this study offers a fair and direct comparison among all catalytic materials which were synthesized and studied under identical conditions. This direct comparison of the obtained results is important because results reported in different publications are often not comparable due to very different reaction conditions.

Gull, Nathan↗

NASA NTRS1978

Concentration-response data on toxicity of pyrolysis gases from some natural and synthetic polymers

Concentration-response data are presented on the toxic effects of the pyrolysis gases from some natural and synthetic polymers, using the toxicity screening test method developed at the University of San Francisco. The pyrolysis gases from wool, red oak, Douglas fir, polycaprolactam, polyether sulfone, polyaryl sulfone, and polyphenylene sulfide appeared to exhibit the concentration-response relationships commonly encountered in toxicology. Carbon monoxide seemed to be an important toxicant in the pyrolysis gases from red oak, Douglas fir, and polycaprolactam, but did not appear to have been the principal toxicant in the pyrolysis gases from polyether sulfone and polyphenylene sulfide.

Hilado, C. J.↗

NASA NTRS1978

Effect of pyrolysis temperature on toxicity of gases from a polyethylene polymer

A polyethylene polymer was evaluated for time of toxic effect to occur as the result of exposure to gases generated by pyrolysis at various temperatures, using the toxicity screening test method developed at the University of San Francisco. Times to various animal responses decreased with increasing pyrolysis temperature over the range from 400 C to 800 C. Responses at a pyrolysis temperature of 350 C were more rapid than would be expected from the other data, and may indicate the predominance of different pyrolysis reactions in this particular temperature region.

Hilado, C. J.↗

NASA NTRS1986

Shock-tube pyrolysis of chlorinated hydrocarbons - Formation of soot

Soot formation in pyrolysis of chlorinated methanes, their mixtures with methane, and chlorinated ethylenes were studied behind reflected shock waves by monitoring the attenuation of an He-Ne laser beam. An additional single-pulse shock-tube study was conducted for the pyrolysis of methane, methyl chloride, and dichloromethane. The experiments were performed at temperatures 1300-3000 K, pressures of 0.4-3.6 bar, and total carbon atom concentrations of 1-5 x 10 to the 17th atoms cu cm. The amounts of soot produced in the pyrolysis of chlorinated hydrocarbons are larger than that of their nonchlorinated counterparts. The sooting behavior and product distribution can be generally explained in terms of chlorine-catalyzed chemical reaction mechanisms. The pathway to soot from chlorinated methanes and ethylenes with high H:Cl ratio proceeds via the formation of C2H, C2H2, and C2H3 species. For chlorinated hydrocarbons with low H:Cl ratio, the formation of C2 and its contribution to soot formation at high temperatures becomes significant. There is evidence for the importance of CHCl radical and its reactions in the pyrolysis of dichloromethane.

Frenklach, M.↗

NASA NTRS1995

Confined-Pyrolysis as an Experimental Method for Hydrothermal Organic Synthesis

A closed pyrolysis system has been developed as a tool for studying the reactions of organic compounds under extreme hydrothermal conditions. Small high pressure stainless steel vessels in which the ratio of sediment or sample to water has been adjusted to eliminate the headspace at peak experimental conditions confines the organic components to the bulk solid matrix and eliminates the partitioning of the organic compounds away from the inorganic components during the experiment. Confined pyrolysis experiments were performed to simulate thermally driven catagenetic changes in sedimentary organic matter using a solids to water ratio of 3.4 to 1. The extent of alteration was measured by monitoring the steroid and triterpenoid biomarkers and polycyclic aromatic hydrocarbon distributions. These pyrolysis experiments duplicated the hydrothermal transformations observed in nature. Molecular probe experiments using alkadienes, alkenes and alkanes in H2O and D2O elucidated the isomerization and hydrogenation reactions of aliphatic and the competing oxidative reactions occurring under hydrothermal conditions. This confined pyrolysis technique is being applied to test experiments on organic synthesis of relevance to chemical evolution for the origin of life.

Leif, Roald N.↗

NASA NTRS1999

Methane Pyrolysis and Disposing Off Resulting Carbon

Sabatier/Electrolysis (S/E) is a leading process for producing methane and oxygen for application to Mars ISPP. One significant problem with this process is that it produces an excess of methane for combustion with the amount of oxygen that is produced. Therefore, one must discard roughly half of the methane to obtain the proper stoichiometric methane/oxygen mixture for ascent from Mars. This is wasteful of hydrogen, which must be brought from Earth and is difficult to transport to Mars and store on Mars. To reduced the problem of transporting hydrogen to Mars, the S/E process can be augmented by another process which reduces overall hydrogen requirement. Three conceptual approaches for doing this are (1) recover hydrogen from the excess methane produced by the S/E process, (2) convert the methane to a higher hydrocarbon or other organic with a lower H/C ratio than methane, and (3) use a separate process (such as zirconia or reverse water gas shift reaction) to produce additional oxygen, thus utilizing all the methane produced by the Sabatier process. We report our results here on recovering hydrogen from the excess methane using pyrolysis of methane. Pyrolysis has the advantage that it produces almost pure hydrogen, and any unreacted methane can pass through the S/E process reactor. It has the disadvantage that disposing of the carbon produced by pyrolysis presents difficulties. Hydrogen may be obtained from methane by pyrolysis in the temperature range 10000-12000C. The main reaction products are hydrogen and carbon, though very small amounts of higher hydrocarbons, including aromatic hydrocarbons are formed. The conversion efficiency is about 95% at 12000C. One needs to distinguish between thermodynamic equilibrium conversion and conversion limited by kinetics in a finite reactor.

Sharma, P. K.↗

NASA NTRS2007

Pyrolysis process for producing fuel gas

Solid waste resource recovery in space is effected by pyrolysis processing, to produce light gases as the main products (CH.sub.4, H.sub.2, CO.sub.2, CO, H.sub.2O, NH.sub.3) and a reactive carbon-rich char as the main byproduct. Significant amounts of liquid products are formed under less severe pyrolysis conditions, and are cracked almost completely to gases as the temperature is raised. A primary pyrolysis model for the composite mixture is based on an existing model for whole biomass materials, and an artificial neural network models the changes in gas composition with the severity of pyrolysis conditions.

Serio, Michael A.↗

NASA NTRS2007

Pyrolysis processing for solid waste resource recovery

Serio, Michael A.↗

NASA NTRS2011

Effects of Non-Equilibrium Chemistry and Darcy-Forchheimer Flow of Pyrolysis Gas for a Charring Ablator

The Fully Implicit Ablation and Thermal Response code, FIAT, simulates pyrolysis and ablation of thermal protection materials and systems. The governing equations, which include energy conservation, a three-component decomposition model, and a surface energy balance, are solved with a moving grid. This work describes new modeling capabilities that are added to a special version of FIAT. These capabilities include a time-dependent pyrolysis gas flow momentum equation with Darcy-Forchheimer terms and pyrolysis gas species conservation equations with finite-rate homogeneous chemical reactions. The total energy conservation equation is also enhanced for consistency with these new additions. Parametric studies are performed using this enhanced version of FIAT. Two groups of analyses of Phenolic Impregnated Carbon Ablator (PICA) are presented. In the first group, an Orion flight environment for a proposed Lunar-return trajectory is considered. In the second group, various test conditions for arcjet models are examined. The central focus of these parametric studies is to understand the effect of pyrolysis gas momentum transfer on PICA material in-depth thermal responses with finite-rate, equilibrium, or frozen homogeneous gas chemistry. Results are presented, discussed, and compared with those predicted by the baseline PICA/FIAT ablation and thermal response model developed by the Orion Thermal Protection System Advanced Development Project.

Ablation↗

NASA NTRS2017

Analysis of Mixed Aryl/Alkyl Esters by Pyrolysis Gas Chromatography-Mass Spectrometry in the Presence of Perchlorate

Mars is an important target for Astrobiology. A key goal of the MSL mission was to determine whether Mars was habitable in the past, a que-tion that has now been definitely determined to be yes. Another key goal for Mars exploration is to understand the origin and distribution of organic material on Mars; this question is being addressed by the SAM instrument on MSL, and will also be informed by two upcoming Mars exploration missions, ExoMars and Mars 2020. These latter two missions have instrumentation capable of detecting and characterize organic molecules. Over the next decade, these missions will analyze organics in surface, near-surface and sub-surface samples. Each mission has the capability to analyze organics by different methods (pyrolysis gas chromatography-mass spectrometry [py-GC-MS]; laser desorption and thermal volatilization GC-MS; and Raman spectroscopy). Plausibly extraterrestrial organics were recently discovered by the Mars Science Laboratory (MSL), providing an important first step towards understanding the organic inventory on Mars [1]. The compounds detected were chlorobenzenes and chloroalkanes, but it was argued that chlorination of these compounds occurred during pyrolysis of samples containing unchlorinated organics in the presence of perchlorate. A recent report analyzed a suite of aromatic (benzene, toluene, benzoic acid, phthalic acid, and mellitic acid) and aliphatic (acetic acid, propane, propanol, and hexane) by pyrolysis under SAM-like conditions in the presence of perchlorate to attempt to constrain possible precursor molecules for the organic molecules detected on Mars. For aromatic compounds, the aromatic acids all readily produced SAM-relevant chlorobenzes, whereas benzene and toluene did not. This observation suggests that the chlorobenzene detected on Mars could have derived from compounds like mellitic acid, consistent with the previous hypothesis by Benner et al. [3]. Among the aliphatic molecules, it was shown that pyrolysis of alkanes and alcohols in the presence of perchlorates produced polychlorine containing chloro-alkanes similar to what was observed on Mars. Surpris-ingly, however, similar treatment of acetic acid pro-duced chloroketones, instead, and no chloroalkanes were reported. This suggests that the chloroalkanes detected in the Sheepbed mudstone were not derived from aliphatic carboxylic acids, but instead were from more reduced alcohols or even alkanes, or perhaps were degradation products of more complicated organic material. Because organics analyses on mars will rely heavily on py-GC-MS of perchlorate-containing samples over the next decade, it is important to understand the fate of organic molecules of biotic and abiotic origin under such conditions. In this work we begin a series of experiments to improve our understanding of products generated during py-GC-MS of increasingly complex organic molecules (esters, amides, peptides, nucleic acids, fatty acids) in the presence of perchlorate.

Burton, A. S.↗

DOE OSTI2025

Impact of low-chemical storage pretreatment of loblolly pine bark on biochar from microwave pyrolysis

Forest product residues such as bark represent a low-cost, abundant feedstock for bioenergy, but their high ash and alkali and alkaline earth metal (AAEM) content limit thermochemical conversion efficiency. This study evaluates the use of low-severity chemical pretreatments during anaerobic storage to improve the performance of microwave pyrolysis for loblolly pine bark. Bark was treated with dilute sulfuric acid (0.1% and 1%, w/w) or sodium hydroxide (4%, w/w) and incubated anaerobically for one or two weeks to simulate in-pile biorefinery storage. The most effective treatment—1% H2SO4 for two weeks—reduced AAEM content by 35.7% and increased bio-oil yield by 11% compared to untreated controls, while also reducing pyrolysis gas production. In contrast, alkali treatment did not reduce AAEM levels and led to decreased bio-oil yields with increased gas formation. Although biochar yields were relatively stable across treatments, their physicochemical characteristics varied significantly. Acid-treated bark yielded biochars with higher carbon content, lower O/C and H/C ratios, greater surface area, and enhanced heating values. These improvements suggest that chemical pretreatment during storage can tailor biochar quality for specific end uses. Biochars produced under optimized conditions exhibited properties suitable for soil amendment, carbon sequestration, and solid fuel applications. This integrated approach—combining storage, mild chemical conditioning, and microwave pyrolysis—provides a viable pathway to enhance the value and sustainability of bark-derived bioenergy products.

09 - BIOMASS FUELS↗

DOE OSTI2026

Life cycle analysis of hydrogen production via methane pyrolysis using plasma arc

Steam methane reforming of natural gas is the primary method of producing hydrogen in the United States, accounting for 95% of all hydrogen produced there. Methane pyrolysis, an alternative production pathway that decomposes natural gas into solid carbon and hydrogen, both eliminates CO 2 emissions associated with methane reforming and allows for additional income from carbon black. A life-cycle inventory of this process has been developed using ASPEN Plus to model the methane pyrolysis (plasma arc) process. From well to gate, hydrogen production via methane pyrolysis produces 2.78 kg CO 2 e/kg H 2 of greenhouse gas emissions using mass allocation of emissions between hydrogen and carbon black coproducts. The well-to-gate emissions are mainly driven by electricity consumption (∼38 kW h/kg H 2 ), which accounts for 81% of the emissions; if renewable electricity is used, well-to-gate emissions can be reduced to −0.448 kg CO 2 e/kg H 2 .

08 HYDROGEN↗

DOE OSTI2024

Demystifying In Situ Pyrolysis Chemistry for High-Performance Polyanionic Cathodes in Sodium-Ion Batteries

In this article, the carbon coating strategy has emerged as an indispensable approach to improve the conductivity of polyanionic cathodes. However, owing to the complex reaction process between precursors of carbon and cathode, establishing a unified screening principle for carbonaceous precursors remains a technical challenge. Herein, we reveal that carbonaceous precursor pyrolysis chemistry undeniably influences the formation process and performance of Na 3 V 2 (PO 4 ) 3 (NVP) cathodes from in situ insights. By investigating three types of carbonaceous precursors, it is found that O/H-containing functional groups can provide more bonding sites for cathode precursors and generate a reducing atmosphere by pyrolysis, which is beneficial to the formation of polyanionic materials and a uniform carbon coating layer. Conversely, excessive pyrolysis of functional groups leads to a significant amount of gas, which is detrimental to the compactness of the carbon layer. Furthermore, the substantial presence of residual heteroatoms diminishes graphitization. In this case, it is demonstrated that carbon dots (CDs) precursors with suitable functional groups can comprehensively enhance the Na+ migration rate, reversibility, and interface stability of the cathode material. As a result, the NVP/CDs cathode displays outstanding capacity retention, maintaining 92% after 10,000 cycles at a high rate of 50 C. Altogether, these findings provide a valuable benchmark for carbon source selection for polyanionic cathodes.

25 ENERGY STORAGE↗

DOE OSTI2024

Influence of loblolly pine anatomical fractions and tree age on oil yield and composition during fast pyrolysis

Fast pyrolysis of woody materials is a technology pathway for producing renewable fuels and chemicals. This is a presentation of isolating needles, bark, and stemwood from a single tree as well as isolating stemwood and whole tree samples from the same species of tree with different ages and pyrolyzing each individually as well as in mixtures. This gives insight into the role of tree anatomical fractions on the resulting intermediate oil product as well as into interactions between these components. The highest carbon content oil (45.1 wt% as received) was produced from a one-to-one mixture of stemwood and needles, followed by the pure stemwood (43.4–43.8 wt% as received), while the lowest oil carbon content was from a one-to-one blend of bark and needles (26.7 wt% as received). The pyrolysis oil yield (combining oil and aqueous where separation occurred) varied from 54 wt% as received (needles) to 72.3 wt% as received (stemwood). When comparing trees of different ages, we find the change in the ratio of the anatomical fractions is a dominant factor in the product composition and yields, while the product composition and yields vary slightly with tree age when only the stemwood is pyrolyzed. Here, in this study, we present the bench-scale pyrolysis, yields, and product characterization of loblolly pine feedstocks (13- vs. 23 year-old, residues, air-classified residues, whole tree, needles, bark, and stemwood).

09 BIOMASS FUELS↗

DOE OSTI2025

Non-catalytic pyrolysis of associated gas to zero CO 2 hydrogen and high value carbon black

The overall objective of this work is to perform a pre-Front End Engineering Design (pre-FEED) study of the conversion of associated gas produced at an active oil pad of a Bakken oil field producer, to high value carbon black and hydrogen using the Microwave Plasma Pyrolysis of Associated Gas (MPP-AG) process developed by H Quest Vanguard, Inc (HQV). The University of North Dakota’s Center for Process Engineering Research (CPER) collaborated with HQV to complete a design and techno-economic analysis for the MPP-AG deployed at an active Bakken well site flaring an average of 54,000 standard cubic feet per day of AG. The proposed design consists of: • A Microwave Pyrolysis Unit (MPU) which consists of H Quest’s proprietary MPP technology • A patent-pending Gas Conditioning Unit (GCU) designed by the University of North Dakota to condition intermittent and variable flow gas prior to pyrolysis. • An auxiliary unit running on the associated gas to power the GCU and MPU in an “island mode” configuration.

03 NATURAL GAS↗

DOE OSTI2024

Nonprecious Single Atom Catalyst for Methane Pyrolysis

The development of a suitable catalytic system for methane pyrolysis reactions requires a detailed investigation of the activation energy of C-H bonds on catalysts, as well as their stability against sintering and coke formation. In this work, both single-metal Ni atoms and small clusters of Ni atoms deposited on titanium nitride (TiN) plasmonic nanoparticles were characterized for the C-H bond activation of a methane pyrolysis reaction using ab initio spin-polarized density functional theory (DFT) calculations. The present work shows the complete reaction pathway, including energy barriers for C-H bond activation and dehydrogenated fragments, during the methane pyrolysis reaction on catalytic systems. Interestingly, the C-H bond activation barriers were low for both Ni single-atom and Ni-clusters, showing the energy barriers of ~1.10 eV and ~0.88 eV, respectively. Additionally, single-atom Ni-TiN showed weaker binding to adsorbates, and a net endothermic reaction pathway indicated that the single-atom Ni-TiN was expected to resist coke formation on its surface. However, these Ni single-atom catalysts can sinter, aggregate into a small cluster, and form a coke layer from the highly exothermic reaction pathway that the cluster takes despite the facile reaction pathway.

08 HYDROGEN↗

NASA NTRS1996

A generalized Biomass Pyrolysis Model Based on Superimposed Cellulose, Hemicellulose and Lignin Kinetics

The pyrolysis of general biomass materials is modeled via a superposition of cellulose, hemicellulose an lingnin kinetics. All three of the primary biomass components are modeled with multi-step kinetics involving both competetive primary pyrolysis and secodary tar decomposition reactions. Only typical (untreated) feedstocks are considered at atmospheric pyrolysis pressures.

biomass↗