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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 595 records · Page 33
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Manufacturing Cost Analysis for PEM Electrolyzers and Perspectives for Future Cost Reduction

Electrolyzer capital costs strongly influence the total levelized cost of hydrogen production and have implications for hydrogen deployment. Current electrolyzer costs are high, and large cost reductions may be needed to achieve competitive hydrogen costs and targets. Understanding pathways for cost reduction via R&D and deployment is a critical research area for informed energy planning and enabling hydrogen use. This work presents bottom-up cost estimates of polymer electrolyte membrane (PEM) electrolyzer systems tied to design specifications and discusses perspectives for cost reduction opportunities based on ongoing research. We use a detailed manufacturing and process model for a 1 MW PEM electrolyzer stack and balance of plant (BOP) for rigorous cost estimation. This allows for robust estimates of component and manufacturing costs and examination of key cost contributors. Stack costs are dominated by material costs such as iridium and platinum catalysts, especially at high manufacturing rates; power electronics and hydrogen purification equipment are the largest contributors to BOP cost. At higher manufacturing rates, better equipment utilization could reduce stack costs significantly, and we estimate that experience and bulk purchasing will allow for cost reductions to some BOP components. Still, many well-established BOP technologies and stack material costs are less likely to see significant cost reductions at high manufacturing rates. As such, manufacturing scale is limited in how much it can reduce electrolyzer costs, and additional advances for cost reduction may be needed to achieve cost targets. It will likely take many combined strategies to achieve significant cost reductions for electrolyzers and enable low-cost hydrogen production. We can use our manufacturing cost model to quantify potential cost reductions from the considerations described above and demonstrate pathways to lower cost electrolyzers. This allows for better understanding of cost reduction strategies and enables more informed research, development, and deployment for electrolyzers.

cost↗
DOE OSTI2022

Selective hydrodeoxygenation of 5-hydroxymethylfurfural (HMF) to 2,5-dimethylfuran (DMF) over carbon supported copper catalysts using isopropyl alcohol as a hydrogen donor

Selective hydrodeoxygenation (HDO) of 5-hydroxymethylfurfural to 2,5-dimethylfuran is of great importance. Here, we reveal a simple pathway for green and efficient HDO using readily available copper with in-situ hydrogen generation. A highly dispersed Cu/PBSAC catalyst consisting of small metallic Cu 0 nanoparticles carries out isopropyl alcohol (IPA) dehydrogenation and subsequent HDO of HMF. Density functional theory calculations reveal that the dehydrogenation of IPA is more favorable on Cu(211) with a lower energy barrier of ~0.6 eV. This facet exists in a higher ratio on nanosized catalysts. Batch reactions using Cu/PBSAC at 190 °C exhibited 91.9% HMF conversion and 71.7% DMF selectivity in 6 hr, and > 96% DMF yield in 10 hr. The mechanical strength of the carbon support is ideal for continuous processing for increased productivity; we demonstrate a > 90% DMF yield at 1/WHSV of 2.4 hr. The process demonstrated here can be integrated with upstream HMF separation utilizing carbon adsorbents.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Mechanism of Chlorine-Mediated Electrochemical Ethylene Oxidation in Saline Water

Chlorine as a redox mediator allows for the selective oxidation of ethylene to 2-chloroethanol, which converts to ethylene oxide in alkaline aqueous electrolyte. This strategy utilizes abundant saline water as an electrolyte and source of oxygen atoms for functionalization. We present a mechanistic study of ethylene oxidation in saline water using cobalt oxide nanoparticle catalysts. Electrochemical kinetic analysis and in situ X-ray absorption spectroscopy suggest that the resting state of the catalyst and the rate-determining step differ for the chlorine evolution reaction in the presence and absence of ethylene. In 0.6 M NaCl pH 8 electrolyte, which resembles seawater, the average current density was ~60 mA/cm 2 with a Faradaic efficiency of ~41% toward ethylene functionalization. The use of synthetic and natural seawater achieved Faradaic efficiencies above 70%, while the partial current toward the product remained invariant. Further conversion of the initial product 2-chloroethanol into ethylene glycol was also demonstrated. Here, we present a broader vision of harnessing saline water in electrochemical functionalization of organic molecules and coproduction of hydrogen.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Manipulating the Second Coordination Shell of Single-Atom Fe for Enhanced Fenton Reaction

While current methods use oxidizable metals as electron donors to effectively reduce Fe 3+ , they suffer from the irreversible oxidation of these metals, ultimately compromising the catalyst’s longevity. To address this challenge, we engineered the second coordination shell of a single-atom Fe center by doping boron (B) onto a graphene-based support (Fe 1 /B-graphene) and utilized H 2 O 2 as the electron source for efficient Fe 2+ regeneration. Experimental results, supported by theoretical calculations, revealed that the Fe–O–B motif functions like a micro galvanic cell, with intermediary O atoms facilitating electron transfer between electrodes. Specifically, electrons consumed during H 2 O 2 activation at Fe 1 sites (positive electrode) are replenished by electrons extracted from H 2 O 2 at B atoms (negative electrode), where the activation energy for H 2 O 2 oxidation is significantly lower than that at Fe 1 sites. This study offers inspirational insights into the design of Fenton catalysts through precise regulation of the second coordination shell, demonstrating the potential of tailoring the outer coordination environment of single-atom catalysts to enhance catalytic performance across various reactions.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Gold‐Catalyzed C−H Functionalization Polycondensation for the Synthesis of Aromatic Polymers

Abstract Homogeneous gold (Au) complexes have demonstrated tremendous utility in modern organic chemistry; however, their application for the synthesis of polymers remains rare. Herein, we demonstrate the first catalytic application of Au complexes toward the polycondensation of alkyne‐containing comonomers and heteroarene nucleophiles. Polymerization occurs through successive intermolecular hydroarylation reactions to produce high molecular weight aromatic copolymers with 1,1‐disubstituted alkene backbone linkages. Clear correlations between the rate and degree of polymerization (DP) were established based on catalyst structure and counterion pairing, thus enabling polymerization reactions that proceeded with remarkable efficiency, high reactivity, and exceptional DPs. The reactivity is broad in scope, enabling the copolymerization of highly functionalized aromatic and aliphatic monomers. These results highlight the untapped utility of Au catalysis in providing access to new macromolecular constructs.

King, Eric R.↗
DOE OSTI2024

Catalysis Center for Energy Innovation

CCEI was founded in 2009 as a transformative catalysis center for energy innovation that combines fundamental science with technology transfer to address one of today’s most challenging problems: transforming lignocellulosic biomass into renewable transportation fuels and chemicals. Center members made significant progress toward solving this grand challenge by creating new heterogeneous catalysts and developing processes involving their use.

09 BIOMASS FUELS↗
DOE OSTI2024

Numerical Simulation of Biogenic Fluid Catalytic Cracking (BFCC) Regenerators at Different Scales with MFIX-Exa

Catalytic Fast Pyrolysis (CFP) is a process that converts biomass into liquid intermediates suitable for transportation fuels by rapidly heating it in the presence of a catalyst, aiming to produce stable oils with reduced oxygen content. During CFP, the catalyst can become deactivated by the accumulation of coke, a carbon-rich deposit formed from the decomposition of biomass components. Unlike in petroleum refining, regenerating coked catalysts from biomass pyrolysis requires specific approaches due to the different chemical nature of the coke formed. An experimental technique, Temperature Programmed Oxidation (TPO), was used to study the de-coking process by gradually increasing temperature while monitoring the production of CO and CO2, which provides data for kinetic modeling. Utilizing data from TPO experiments, coke combustion kinetic model was developed to describe the rate of coke removal at different temperatures, allowing for simulation of regeneration processes. Then kinetic model is integrated into MFIX-Exa for the simulation of Biogenic Fluid Catalytic Cracker (BFCC) regenerator at different scales, enabling analysis of catalyst flow, temperature distribution, and regeneration efficiency under various operating conditions.

biogenic fluid catalytic cracking↗
DOE OSTI2020

Electrochemical Oxidation of Organic Molecules at Lower Overpotential: Accessing Broader Functional Group Compatibility with Electron-Proton Transfer Mediators

CONSPECTUS: Electrochemical organic oxidation reactions are highly appealing because protons are often effective terminal electron acceptors, thereby avoiding undesirable stoichiometric oxidants. These reactions are often plagued by high overpotentials, however, that greatly limit their utility. Single-electron transfer (SET) from organic molecules generates high energy radical-cations. Formation of such intermediates often requires electrode potentials far above the thermodynamic potentials of the reaction and frequently causes decomposition and/or side reactions of ancillary functional groups. In this Account, we show how electrocatalytic electron-proton transfer mediators (EPTMs) address this challenge. EPTMs bypass the formation of radical-cation intermediates by supporting mechanisms that operate at electrode potentials much lower (=1 V) than analogous direct electrolysis reactions. The stable aminoxyl radical TEMPO (2,2,6,6-tetramethylpiperidine N-oxyl) is an effective mediator for electrochemical alcohol oxidation, and we have employed such processes for applications ranging from pharmaceutical synthesis to biomass conversion. A complementary electrochemical alcohol oxidation method employs a cooperative Cu/TEMPO mediator system that operates at 0.5 V lower electrode potential than the TEMPO-only mediated process. This difference, which arises from a different catalytic mechanism, rationalizes the broad functional group tolerance of Cu/TEMPO-based aerobic alcohol oxidation catalysts. Aminoxyl mediators address long-standing challenges in the "Shono oxidation", an important method for a-C–H oxidation of tertiary amides and carbamates. Shono oxidations are initiated by a high-potential SET step that limits their utility. Aminoxyl-mediated Shono-type oxidations have been developed that operate at much lower potentials and tolerate diverse functional groups. Analogous reactivity underlies a-C–H cyanation of secondary cyclic amines, a new method that enables efficient diversification of piperidine-based pharmaceutical building blocks and preparation of non-natural amino acids. Electrochemical oxidations of benzylic C–H bonds are commonly initiated by SET to generate radical cations, but such methods are again plagued by large overpotentials. Mediated electrolysis methods that promote hydrogen-atom-transfer (HAT) from benzylic C–H bonds to Fe-oxo species and phthalimide N-oxyl (PINO) support C–H oxygenation, iodination, and oxidative-coupling reactions. A complementary method merges photochemistry with electrochemistry to achieve amidation of C(sp3)–H bonds. This unique process operates at much lower overpotentials compatible with diverse functional groups. These results have broad implications for organic electrochemistry, highlighting the importance of "overpotential" considerations and the prospects for expanding synthetic utility by using mediators to bypass high-energy outer-sphere electron-transfer mechanisms. Principles demonstrated here for oxidation are equally relevant to electrochemical reductions.

Wang, Fei↗
DOE OSTI2020

Gold–Catalyzed C–H Functionalization Polycondensation for the Synthesis of Aromatic Polymers

Homogeneous gold (Au) complexes have demonstrated tremendous utility in modern organic chemistry; however, their application for the synthesis of polymers remains rare. Herein, we demonstrate the first catalytic application of Au complexes toward the polycondensation of alkyne-containing comonomers and heteroarene nucleophiles. Polymerization occurs through successive intermolecular hydroarylation reactions to produce high molecular weight aromatic copolymers with 1,1-disubstituted alkene backbone linkages. Clear correlations between the rate and degree of polymerization (DP) were established based on catalyst structure and counterion pairing, thus enabling polymerization reactions that proceeded with remarkable efficiency, high reactivity, and exceptional DPs. The reactivity is broad in scope, enabling the copolymerization of highly functionalized aromatic and aliphatic monomers. Furthermore, these results highlight the untapped utility of Au catalysis in providing access to new macromolecular constructs.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

High‐efficiency adsorption of various heavy metals by tea residue biochar loaded with nanoscale zero‐valent iron

Abstract Nanoscale zero‐valent iron (nZVI) loaded on tea residue biochar activated with phosphoric acid composites was synthesized. This adsorbent can efficiently adsorb multiple heavy metal ions such as Pb (II), Cr (III), Cu (II), and Ni (II) simultaneously. The adsorption process was found to follow the pseudo‐second‐order kinetic model. Equilibrium adsorption capacities reached 288.18, 162.34, 242.72, and 267.22 mg·g −1 for Pb(II), Cr(III), Cu(II), and Ni(II), respectively. The common interfering ions exhibited lower influence on its adsorption capacity. The adsorption mechanism includes reduction, ion exchange, surface complexation and precipitation. Furthermore, the waste adsorbent was converted into a catalyst in situ, which could catalyze the degradation of Congo red by establishing an electron transfer pathway. This research provides a new concept for the sustainable utilization of industrial tea residues and the harmless treatment of waste nZVI composite adsorbents.

Liu, Shuang↗
DOE OSTI2026

Intrinsically Conductive {pi}‑d Conjugated Layers with Co–N4 Active Sites for Efficient Nitrate Electrocatalysis and Zinc-Nitrate Batteries

Electrochemical synthesis of ammonia from nitrate has been extensively investigated as a potential alternative to the energy-intensive Haber-Bosch process. This approach not only operates under ambient conditions but also simultaneously removes nitrate contaminants while producing ammonia as a value-added product. However, the ongoing quest lies in designing an efficient electrocatalyst that achieves a high ammonia yield rate, high selectivity, and long-term stability. Herein, we report the outstanding performance of a Co–N4 coordinated π-d layered Co3(HITP)2 (HITP = 2,3,6,7,10,11-hexaiminotriphenylene) in nitrate electrocatalysis. The unique combination of abundant Co–N4 active sites and superior electrical conductivity enables significant electrocatalytic activity, delivering a maximum ammonia yield rate of 56.8 mg cm–2 h–1 at −0.8 V vs RHE and a Faradaic efficiency of ∼91% at −0.4 V vs RHE. Mechanistic analysis reveals that alkaline conditions accelerate water dissociation to generate adsorbed hydrogen intermediates (H*), which are utilized by Co–N4 sites to drive the stepwise hydrogenation of nitrate to ammonia while suppressing competing hydrogen evolution reaction (HER) pathways. Furthermore, integration of this catalyst into a zinc-nitrate battery resulted in a maximum power density of 5.3 mW cm–2 and an open-circuit potential of ∼1.45 V. These results highlight the potential of π-d conjugated Co–N4 materials as an efficient catalyst for both environmental remediation and energy conversion.

Namvar, shahrirar↗
DOE OSTI2022

Oxo dicopper anchored on carbon nitride for selective oxidation of methane

Abstract Selective conversion of methane (CH 4 ) into value-added chemicals represents a grand challenge for the efficient utilization of rising hydrocarbon sources. We report here dimeric copper centers supported on graphitic carbon nitride (denoted as Cu 2 @C 3 N 4 ) as advanced catalysts for CH 4 partial oxidation. The copper-dimer catalysts demonstrate high selectivity for partial oxidation of methane under both thermo- and photocatalytic reaction conditions, with hydrogen peroxide (H 2 O 2 ) and oxygen (O 2 ) being used as the oxidizer, respectively. In particular, the photocatalytic oxidation of CH 4 with O 2 achieves >10% conversion, and >98% selectivity toward methyl oxygenates and a mass-specific activity of 1399.3 mmol g Cu −1 h −1 . Mechanistic studies reveal that the high reactivity of Cu 2 @C 3 N 4 can be ascribed to symphonic mechanisms among the bridging oxygen, the two copper sites and the semiconducting C 3 N 4 substrate, which do not only facilitate the heterolytic scission of C-H bond, but also promotes H 2 O 2 and O 2 activation in thermo- and photocatalysis, respectively.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS2017

Modeling a Packed Bed Reactor Utilizing the Sabatier Process

A numerical model is being developed using Python which characterizes the conversion and temperature profiles of a packed bed reactor (PBR) that utilizes the Sabatier process; the reaction produces methane and water from carbon dioxide and hydrogen. While the specific kinetics of the Sabatier reaction on the RuAl2O3 catalyst pellets are unknown, an empirical reaction rate equation1 is used for the overall reaction. As this reaction is highly exothermic, proper thermal control is of the utmost importance to ensure maximum conversion and to avoid reactor runaway. It is therefore necessary to determine what wall temperature profile will ensure safe and efficient operation of the reactor. This wall temperature will be maintained by active thermal controls on the outer surface of the reactor. Two cylindrical PBRs are currently being tested experimentally and will be used for validation of the Python model. They are similar in design except one of them is larger and incorporates a preheat loop by feeding the reactant gas through a pipe along the center of the catalyst bed. The further complexity of adding a preheat pipe to the model to mimic the larger reactor is yet to be implemented and validated; preliminary validation is done using the smaller PBR with no reactant preheating. When mapping experimental values of the wall temperature from the smaller PBR into the Python model, a good approximation of the total conversion and temperature profile has been achieved. A separate CFD model incorporates more complex three-dimensional effects by including the solid catalyst pellets within the domain. The goal is to improve the Python model to the point where the results of other reactor geometry can be reasonably predicted relatively quickly when compared to the much more computationally expensive CFD approach. Once a reactor size is narrowed down using the Python approach, CFD will be used to generate a more thorough prediction of the reactors performance.

Reactor↗
DOE OSTI2020

2D Single-Atom Catalyst with Optimized Iron Sites Produced by Thermal Melting of Metal–Organic Frameworks for Oxygen Reduction Reaction

Zeolitic-imidazolate-frameworks-8 (ZIF-8) derivatives have recently been demonstrated as one of the most ideal precursors to prepare single-atom metal catalysts for oxygen reduction reaction (ORR). However, abundant single-atom metal sites are buried in the derived carbon nanoparticles, rendering them useless for ORR. In this work, a novel ZIF-8 "thermal melting" strategy is proposed to prepare a high specific surface area of Fe-N-doped graphene nanosheets (Fe-N/GNs) with single-atom Fe-sites on the surface which are accessible to electrolytes, optimizing their utilization and improving ORR activity. As a result, the Fe-N/GNs material exhibits excellent ORR activity with half-wave potentials of 0.903 V in alkaline media and 0.837 V in acidic media, which are comparable to commercial Pt/C catalysts.

2D↗
DOE OSTI2025

3D printing of architected sulfur cathodes with dual-site atomic catalysts for accelerated polysulfide kinetics and Li-ion transport in high areal-loading lithium–sulfur batteries

The practical deployment of lithium–sulfur batteries (LSBs) is hindered by fundamental limitations in conventional slurry-cast cathodes, including poor sulfur utilization, sluggish ion transport, and low areal capacity, particularly in thick electrodes required for high energy density. To address these challenges, we present direct ink writing (DIW) as an additive manufacturing strategy to fabricate advanced current-collector-free, 3D-printed sulfur cathodes (3DP S@CoNi-DSACs/NC) with hierarchically porous architectures that enhance lithium-ion diffusion, promote electrolyte penetration, and reduce interfacial resistance. The synergistic effects of Co/Ni dual-atom sites accelerate redox kinetics and mitigate polysulfide shuttling. As a result, the optimized 3DP cathode with a sulfur loading of 5.4 mg cm −2 demonstrated excellent rate capability, delivering a high reversible capacity of 1041.4 mAh g −1 at 1C with 85.5% capacity retention after 1000 cycles, significantly outperforming its cast counterpart. Remarkably, even at a higher sulfur loading of 8.1 mg cm −2 , the 3DP cathode maintains outstanding performance, achieving a discharge capacity of 1538.4 mAh g −1 and an areal capacity of 12.5 mAh cm −2 at 0.1C. This study not only demonstrates the functional integration of catalytically active materials into 3D printable sulfur cathode architectures but also offers a scalable and transformative platform for building high-performance LSBs beyond conventional electrode manufacturing methods.

3D electrode↗
DOE OSTI2022

Demonstration of 10+ hour energy storage with Φ1" laboratory size solid oxide iron–air batteries

Long duration electricity storage (LDES) with 10+ hour cycle duration is an economically competitive strategy to accelerate the penetration of renewable energy into the utility market. Unfortunately, none of the available energy storage technologies can meet the LDES requirements in terms of duration and cost. The newly emerged solid-oxide iron–air batteries (SOIABs) with energy-dense solid iron as an energy storage material have inherent advantages for LDES applications. Herein, we report for the first time the LDES capability of SOIABs even at a laboratory scale. We show that SOIABs with an Ir-catalyzed Fe-bed can achieve excellent energy density (625 W h kg –1 ), long cycle duration (12.5 h) and high round-trip efficiency (~90%) under LDES-related working conditions. Finally, given the excellent low-rate performance and the use of earth-abundant, low-cost Fe as an energy storage material, we conclude that the SOIAB is a well-suited battery technology for LDES applications.

25 ENERGY STORAGE↗
DOE OSTI2021

Dynamic structure of active sites in ceria-supported Pt catalysts for the water gas shift reaction

Oxide-supported noble metal catalysts have been extensively studied for decades for the water gas shift (WGS) reaction, a catalytic transformation central to a host of large volume processes that variously utilize or produce hydrogen. There remains considerable uncertainty as to how the specific features of the active metal-support interfacial bonding—perhaps most importantly the temporal dynamic changes occurring therein—serve to enable high activity and selectivity. Here we report the dynamic characteristics of a Pt/CeO 2 system at the atomic level for the WGS reaction and specifically reveal the synergistic effects of metal-support bonding at the perimeter region. We find that the perimeter Pt 0 -O vacancy -Ce 3+ sites are formed in the active structure, transformed at working temperatures and their appearance regulates the adsorbate behaviors. We find that the dynamic nature of this site is a key mechanistic step for the WGS reaction.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗