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At least 73 records · Page 4

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DOE OSTI2025

Nanoscopic Plugs Block Hydrogen Crossover in Submicron Thick Proton-Conducting SiO 2 Membranes for Water Electrolysis

Zero-gap electrolyzers based on submicron thick proton-conducting oxide membranes (POMs) represent a promising approach to increasing the efficiency of H 2 production from water electrolysis while moving away from conventional perfluorosulfonic acid (PFSA) membranes. A critical barrier to the commercialization of such electrolyzers is that the ultrathin nature of POMs, which is necessary to achieve low cell resistance, makes them more susceptible to defects that can lead to unacceptably high rates of H 2 crossover. Herein, we demonstrate an approach to mitigate this problem through selective deposition of carbon-containing silicon oxide (SiO x C y ) “nanoplugs” into the defects of submicron thick SiO 2 membranes using a facile electrochemically mediated deposition process. Selective deposition of nanoplugs within the defects was verified by multiple characterization techniques, while scanning electrochemical microscopy (SECM) was used to confirm selective plugging of H 2 -crossover hotspots associated with defects at identical locations. Thanks to the use of nanoplugs, the H 2 permeance of 250 nm thick SiO 2 membranes was reduced by 5 to 6 orders of magnitude compared to the unmodified atomic layer deposition (ALD) SiO 2 membranes while having negligible impact on the ionic resistance of the membrane. These plug-modified membranes also enabled safe and stable operation of a zero-gap full cell electrolysis cell, in contrast to cells lacking nanoplugs that produced anode effluent streams having H 2 concentrations near or exceeding the lower flammability limit (LFL) of H 2 . Furthermore, beyond water electrolysis, this defect-sealing strategy has the potential to be broadly implemented in other applications, such as fuel cells and flow batteries, offering a versatile solution to mitigate crossover-related performance losses.

ALD SiO2↗

DOE OSTI2024

Sustainable and Energy-Efficient Production of Rare-Earth Metals via Chloride-Based Molten Salt Electrolysis

Neodymium metal is a critical component of rare earth magnets, essential for electric vehicles and the green energy transition, but its production has severe environmental impacts across its mining, separation, purification, and metal electrowinning steps. Specifically, conventional neodymium electrowinning in oxyfluoride molten salts using a consumable graphite anode generates greenhouse gases, e.g., carbon dioxide and perfluorocarbon (PFC). We propose an alternative chloride-based molten salt electrolysis process utilizing a novel dimensionally stable anode (DSA). Our process lowers the specific electrical energy consumption compared to the state of the art, while producing reusable chlorine gas and eliminating direct CO 2 and PFC emissions. Chloride-based molten salt electrolysis of NdCl 3 (1.65 M) added to a LiCl–KCl eutectic (45:55 wt %), while using a RuO 2 -coated DSA enables high Coulombic efficiency (>80%), low specific energy consumption (2.3 kWh/kg-Nd), and excellent electrowon Nd product purity (>97 wt %). Life cycle analysis, excluding the common input feedstock (Nd 2 O 3 ), shows that the global warming potential for the proposed chloride-based electrolysis approach is 5 kg CO 2 equivalent, compared to 9–16 kg CO 2 equivalent for the conventional process, representing a 44–69% reduction in CO 2 emissions.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Cutting-edge methods for amplifying the oxygen evolution reaction during seawater electrolysis: a brief synopsis

Electrochemical water splitting has been considered a clean and continual way for hydrogen (H 2 ) production. Direct seawater electrolysis is a potentially attractive technology due to the ample access to seawater and scarce freshwater resources in some regions. However, the presence of impurities (e.g., Cl - , Mg 2+ ) and the resulting corrosion and side reactions, such as the chloride oxidation reaction (ClOR), makes seawater electrocatalysis more challenging than that of fresh or alkaline water due to competition with the oxygen evolution reaction (OER) at the anode. Consequently, much effort has been devoted to developing approaches to enhance OER performance and suppress the ClOR. In this minireview, we summarize three general strategies for enhancing OER activity and selectivity in seawater electrolysis based on three different concepts: (1) the sole development of robust and high-performance OER catalysts in pure seawater electrolytes, (2) the introduction of additives to seawater electrolytes (e.g., alkalis and/or salts without chloride) to enhance the potential equilibrium gap between the ClOR and OER in combination with regular highly active OER catalysts, and (3) a combination of approaches (1) and (2). Finally, the current challenges and potential opportunities for green H 2 production from seawater electrolysis are briefly presented.

08 HYDROGEN↗

DOE OSTI2023

Data Projection of the High Temperature Electrolysis System in the Dynamic Energy Transport and Integration Laboratory using Dynamic System Scaling

For nuclear power to be flexible in a functioning Integrated Energy System (IES), excess produced heat must be stored or utilized during times of low power demand to ensure a load factor of 1 while load balancing. The Dynamic Energy Transport and Integration Laboratory (DETAIL) is one facility that is under development to emulate IES conditions on the engineering-scale, planned to conduct virtual real time operations with industry-scale facilities, and is currently testing thermal storage and high temperature electrolysis. As part of the study to develop a method to preprocess input signals or postprocess output signals between systems of different scales via Dynamical System Scaling (DSS), the current research is one of the continued efforts branching from the data projection activity conducted for the Thermal Energy Distribution System and currently engages the High Temperature Electrolysis (HTE) System in DETAIL. The HTE SOEC electrical, fluid, and thermal dynamics Figure of Merits (FOM) were identified, governing equations and closure relations were successfully scaled, and relations between FOM scaling ratios were determined. Setting the scaling objectives to reform existing data to project a data set that doubly accelerated the electrolysis process while preserving the produced amount of hydrogen was generated for the full transient. The calculated boundary conditions were inlet temperature, stack current, and inlet steam mass flow rate at 1470 K, 121.1 A, and 1.886 g/s, respectively. The research outcomes demonstrated an output signal postprocessing case accelerating the hydrogen production without changing geometry, number of cells, and partial pressures.

08 HYDROGEN↗

NASA NTRSDate not supplied

Feasibility Testing of Silver Electrolysis for Disinfection of Spacecraft Potable Water Systems

Anodic dissolution of silver electrodes, or “silver electrolysis,” is being investigated as a means of introducing biocidal silver into potable water on exploration spacecraft. A proof-of-concept prototype of a silver electrolysis reactor was developed, and feasibility was demonstrated for imparting a target silver concentration into a spacecraft water system. Prototype testing showed that the primary initial concerns related to the technology - inefficiencies of electrolysis in low conductivity water, the potential formation of resistive oxides on the electrode surfaces, and the potential for release of electrolytically-generated silver particles to the effluent water - were not problematic over the duration of the feasibility testing. The testing also demonstrated advantages of the technology, including the ability to consistently deliver silver at targeted concentrations and the ability to directly correlate the silver concentration to measurements of water conductivity. On the other hand, the reliability of the system has not yet been demonstrated. During prototype testing, intermittent periods of poor reactor performance manifested as a decrease in voltage accompanied by a decrease in silver output. It was determined that the cause of this behavior was silver-based deposits on inter-electrode wetted surfaces forming a conductive “bridge” between electrodes. Ongoing testing and refinement of the prototype reactor design seek to elucidate the root cause the bridging phenomenon and identify associated mitigation strategies. Once resolved, long-term performance testing is planned as part of continued development of the electrolytic silver dosing system.

Silver↗

DOE OSTI2023

Carbon Corrosion in CO2 Electrolysis Systems

Driven by concerns over climate change, interest in CO2 conversion technologies has dramatically increased in recent years. By viewing CO2 as a readily available feedstock, many pathways for the production of carbon-neutral fuels and chemicals become available. In converting CO2, low carbon emitting energy sources must be used to ensure a low carbon footprint of the fuel and chemical products. The low-temperature electrochemical conversion of CO2 is a promising technology and allows for direct integration with renewable electricity sources. The development of low-temperature CO2 electrolysis technologies is informed by both PEM fuel cells and water electrolyzers, both of which are at a higher stage of development. However, CO2 electrolysis operates at a much higher cell voltage (-3V) than other low-temperature electrochemical processes, which can have implications for materials compatibility in the electrolyzer device. Carbon corrosion is of particular concern for the anode of CO2 electrolyzers, as a large driving force for corrosion exists due to the high required cell potentials. In this presentation, recent observations will be shared on carbon corrosion of the anode gas diffusion electrode (GDE) in low-temperature alkaline exchange membrane CO2 electrolysis. Results from ex-situ tests designed to isolate the carbon corrosion process for anode GDEs will be shared. These results will provide guidance on materials selection for CO2 utilization MEAs, which need to have a lifetime of several years to ensure industrial viability.

BIOMASS FUELS↗

DOE OSTI2025

Durable, Ultra-Thin Diaphragms for Liquid Alkaline Water Electrolysis

W. L. Gore & Associates assembled a world class team (De Nora Tech, LLC; New York University; and thyssenkrupp nucera) to develop durable, ultra-low resistance diaphragms that dramatically improve system efficiency, dynamic response, and operational flexibility. To enable the use of ultra-thin diaphragms, an optimized electrode package was chosen as part of an electrode down select study. Ultra-thin diaphragms based on microporous polymer scaffolds imbibed with zirconia nanoparticles were developed and tested. Performance and durability on par with incumbent materials was demonstrated. A transparent electrolyzer to directly observe in-situ diaphragm-bubble interactions was designed and built, and simultaneous optical and electrochemical performance tests were performed. A Pressurized Alkaline Water Electrolysis (PAWE) single cell test station was designed to support advanced R&D in high-pressure electrolysis, particularly for evaluating novel electrode and separator configurations under elevated temperature and pressure operating conditions. Due to early project termination, the original scope could not be fully achieved.

08 HYDROGEN↗

DOE OSTI2026

Impact of anion-exchange membrane degradation on long-term CO 2 electrolysis to ethylene

Electrochemical CO 2 reduction (eCO2R) to ethylene offers a unique opportunity to diversify domestic supply chains for chemical manufacturing. Large-scale deployment of eCO2R to ethylene reactors is currently limited by low energy efficiencies and poor durability. Herein, we demonstrate >100 h of continuous electrolysis at an industrially relevant current density of 200 mA cm −2 in a 25 cm 2 geometric area zero-gap reactor with a full-cell voltage <3.1 V and ethylene Faradaic efficiency >30%. Incorporating expanded polytetrafluoroethylene (PTFE)-supported electrodes into zero-gap reactors allows for durable electrode catalysts that are resistant to flooding, and this enables wider ranges of operating parameters not typically accessible in CO 2 electrolysis. Finally, we identify membrane degradation, evidenced by a loss of membrane ion-exchange capacity, as the leading cause of performance loss over 144 h of electrolysis.

Energy - Conversion↗

DOE OSTI2025

A life cycle assessment of e-hydrogen production using proton-exchange membrane water electrolysis coupled with desalination in Saudi Arabia

Hydrogen, considered a crucial element in the transition towards a sustainable energy future, offers the potential to mitigate greenhouse gas (GHG) emissions and reduce reliance on fossil fuels. Here, this study explores the viability of hydrogen production using proton exchange membrane water electrolysis (PEMWE) as a key driver of decarbonization within the Vision 2030 framework in the Kingdom of Saudi Arabia. A first-of-a-kind life cycle assessment (LCA) of electrolytic hydrogen (e-hydrogen) production using PEMWE in the Kingdom is performed. As the hydrogen will be produced in a freshwater scarce region, the inclusion of water desalination processes adds an important dimension to the assessment, reflecting the local context and resource availability. Two main renewable energy scenarios are assessed: solar energy through photovoltaics (PV) and wind energy through onshore turbines. The global warming potential (GWP) results indicate a GHG emissions reduction of up to 95 % compared to the state-of-the-art steam methane reforming process if the electrolysis process is powered exclusively by renewable electricity. The scenarios powered by solar and wind energy result in 3.66 and 0.76 kg CO 2 eq/kg H 2 , respectively. The metal depletion is assessed to consider the requirement of rare materials, with a 7.19 × 10 −2 kg Cu eq/kg H 2 for the solar scenario and 2.82 × 10 −2 kg Cu eq/kg H 2 for the wind scenario. A contribution analysis reveals that the majority of emissions in both scenarios originate from the electricity used for electrolysis, with the electrolyser itself contributing minimally. The absolute impact of the water desalination process is the same in both scenarios; however, it appears more prominent in the wind-powered case due to the significantly lower overall emissions in that scenario. The findings underscore the importance of renewable energy integration and process optimization in minimizing environmental impacts and advancing the sustainability of e-hydrogen production.

08 HYDROGEN↗

DOE OSTI2022

Self-adhesive ionomers for durable low-temperature anion exchange membrane electrolysis

Low-temperature water electrolysis using an anion conductive polymer electrolyte has several potential advantages over other technologies, however, the fabrication of durable alkaline electrodes remains a challenge. Detachment of catalysts results in the loss of electrochemical surface area. Simple mixtures of ionomer and catalyst can suffer from poor catalyst adhesion because only physical adhesion is used to bind the components together. A family of chemically bonded, self-adherent, hydroxide conducting ionomers were synthesized and tested under alkaline electrolysis conditions with nickel ferrite anode electrocatalysts and platinum-nickel cathode catalyst. The ionomers are based on hydroxide conducting poly(norbornene) polymers used as the solid polymer electrolyte in alkaline fuel cells and electrolyzers. The synthesized terpolymer ionomers have been functionalized to provide pendant sites for covalent chemical bonding of bis(phenyl)-A-diglycidyl ether to the ionomer, catalyst, and porous transport layer. The electrodes show excellent adhesion between the catalyst particles, porous transport layer and ionomer, as determined by adhesion measurements and electrolysis performance. As a result, the AEM electrolyzer had stable voltage performance under high current density (1 A/ cm 2 at 1.83 V (67% voltage efficiency)) for extended time periods (>600 h) without degradation.

08 HYDROGEN↗

DOE OSTI2023

Exploiting electricity market dynamics using flexible electrolysis units for retrofitting methanol synthesis

Here we investigate the economic viability of integrating flexible electrolysis units to produce hydrogen in methanol synthesis processes. Specifically, we investigate whether this approach can help reduce methanol production costs by strategically exploiting dynamics of electricity markets. Our study integrates high-fidelity process simulations, optimization tools, and microkinetic modeling (informed by density functional theory) to conduct detailed techno-economic analyses and to compare performance against traditional processes that use hydrogen produced via steam-methane reforming (SMR). We also use this approach to estimate the levelized cost of hydrogen (LCOH) as a function of time-varying electricity prices (from day-ahead and real-time prices) and of key techno-economic parameters. Our results show that the proposed electrification framework is cost-competitive under certain electricity market conditions. Specifically, we find that, when the electrolysis system is operated in flexible mode (and can respond to dynamics of electricity markets), the associated electricity cost nearly collapses to zero. Conversely, when the unit is not flexible (and cannot respond to markets), the electricity cost comprises 60% of the total cost. Our results also reveal that the LCOH of the flexible electrolysis system participating in real-time electricity markets is 31% lower than the LCOH obtained from SMR. Overall, this indicates that exploiting the dynamics of electricity markets can make hydrogen production cost-competitive and this can lead to viable alternatives to electrify methanol production and other hydrogen-based processes.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2026

Low-voltage syngas synthesis via BPM electrolysis of CO 2 capture and aldehyde solution

A bipolar membrane electrolyzer coupling bicarbonate electrolysis with formaldehyde oxidation directly produces syngas (H 2 : CO = 1) at 1.7 V and 200 mA cm −2 with 200% combined Faradaic efficiency. We demonstrate an electrochemical syngas production platform that couples bicarbonate electrolysis with formaldehyde oxidation in a bipolar membrane electrode assembly. This strategy doubles syngas (CO + H 2 ) throughput compared to conventional CO 2 electrolysis by generating CO at the cathode and H 2 at the anode. The system achieves a full-cell voltage of 1.7 V while operating at an industrially relevant current density of 200 mA cm −2 . The system maintained a combined Faradaic efficiency of 200% over 8 hours. The process produces syngas with a 1 : 1 H 2 : CO ratio, aligning with downstream requirements for Fischer–Tropsch synthesis. We further investigated how Cu anode active sites and electrolyte composition affect formaldehyde oxidation activity. Our integrated electrolytic system reduces levelized energy by 45–61% relative to conventional electrochemical syngas production platforms.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Correlation Between Microscopic Current Fluctuations Observed at Ultra-Microelectrodes and Macroscopic Bulk Electrolysis Performance in Redox-Active Microemulsions

Microemulsions (μEs) have been proposed as redox flow battery (RFB) electrolytes that maximize ionic conductivity and charge capacity by synergizing two immiscible phases. However, charge transfer during electrolysis in μEs is poorly understood. Here, we show that ultramicroelectrode electrolysis of ferrocene-loaded μEs –20%, 60%, and 90% water - reveals stochastic current fluctuations. These are differentiated in the scanning electrochemical microscopy (SECM) geometry, where power spectral density analysis showed distinct changes in the frequency contributions. SECM in the substrate generation-tip collection mode showed that fluctuations arise under mass-transfer control. Significant differences in the diffusion coefficient of ferrocene species were deducted from SECM approach curves, suggesting phase transfer behavior. Using bulk electrolysis, we calculated the charge accessibility and cycling behavior in the μEs. A decrease in the stochastic behavior of the μEs seems to correlate to a higher accessibility and cycling performance, with the 90% water μE displaying the best reversibility and the 60% the lowest. Altogether, these results suggest that Marangoni-type convection driven by concentration gradients and/or μE restructuring during charge transfer play a role in the electrochemical performance of μEs. This presents opportunities for screening and diagnosing the performance of these emerging RFB electrolytes.

25 ENERGY STORAGE↗

DOE OSTI2025

Methanol from Integrated Direct Air Capture and Ceramic Electrolysis (MIDACE)

The Methanol from Integrated Direct Air Capture and Ceramic Electrolysis (MIDACE) project advanced a novel system concept for integrating pressurized co-electrolysis of steam and crude carbon dioxide captured directly from ambient air using a sorbent technology. The co-electrolysis produced syngas provides feedstock for a gas-to-liquid methanol synthesis reactor. The system recovers waste heat from the reactor and electrolyzer into regenerating the direct air capture sorbent. The purpose of the project was to demonstrate critical integration elements of the design and perform a technical study illustrating how a large-scale installation could achieve the $800/ton program target for green methanol production. The concept addresses the program objective to consolidate operations by combining crude CO 2 cleanup, hydrogen production, and partial CO 2 reduction steps within a carbon tolerant high temperature electrolyzer. The design lowers costs by simplifying the methanol recovery cycle, reducing carbon losses from venting, reducing sensitivity to catalyst selectivity, and avoiding syngas compression.

10 SYNTHETIC FUELS↗

NASA NTRS1975

Solid polymer electrolyte water electrolysis system development

Solid polymer electrolyte technology used in a water electrolysis system (WES) to generate oxygen and hydrogen for manned space station applications was investigated. A four-man rated, low pressure breadboard water electrolysis system with the necessary instrumentation and controls was fabricated and tested. A six man rated, high pressure, high temperature, advanced preprototype WES was developed. This configuration included the design and development of an advanced water electrolysis module, capable of operation at 400 psig and 200 F, and a dynamic phase separator/pump in place of a passive phase separator design. Evaluation of this system demonstrated the goal of safe, unattended automated operation at high pressure and high temperature with an accumulated gas generation time of over 1000 hours.

Source record↗

NASA NTRS1979

Carbon dioxide electrolysis using a ceramic electrolyte

This paper discusses the results of an experimental study of the electrical aspects of carbon dioxide electrolysis using a ceramic electrolyte. The electrolyte compositions used in this study are 8% Y2O3 stabilized ZrO2, 7.5% CaO stabilized ZrO2, and 5% Y2O3 stabilized ThO2. Results indicate that the 8% Y2O3 stabilized ZrO2 is the best material to use for electrolysis, in terms of current as a function of voltage and temperature, and in terms of efficiency of oxide ion flow through it. The poorest results were obtained with the 5% Y2O3 stabilized ThO2 composition. An electrolysis system which might be employed to reclaim oxygen and carbon from effluents of space manufacturing, assuming that an industry would have to electrolyze 258,000 tonnes of CO2 per year, is predicted to require a total cell area of 110,000 sq m of 1 mm thickness and electrical capacity of 441 MW.

Erstfeld, T. E.↗

NASA NTRS1981

Endurance test and evaluation of alkaline water electrolysis cells

Utilization in the development of multi-kW low orbit power systems is discussed. The following technological developments of alkaline water electrolysis cells for space power application were demonstrated: (1) four 92.9 cm2 single water electrolysis cells, two using LST's advanced anodes and two using LST's super anodes; (2) four single cell endurance test stands for life testing of alkaline water electrolyte cells; (3) the solid performance of the advanced electrode and 355 K; (4) the breakthrough performance of the super electrode; (5) the four single cells for over 5,000 hours each significant cell deterioration or cell failure. It is concluded that the static feed water electrolysis concept is reliable and due to the inherent simplicity of the passive water feed mechanism coupled with the use of alkaline electrolyte has greater potential for regenerative fuel cell system applications than alternative electrolyzers. A rise in cell voltage occur after 2,000-3,000 hours which was attributed to deflection of the polysulfone end plates due to creepage of the thermoplastic. More end plate support was added, and the performance of the cells was restored to the initial performance level.

Burke, K. A.↗

NASA NTRS1981

Development status of a preprototype water electrolysis subsystem

A preprototype water electrolysis subsystem was designed and fabricated for NASA's advanced regenerative life support program. A solid polymer is used for the cell electrolyte. The electrolysis module has 12 cells that can generate 5.5 kg/day of oxygen for the metabolic requirements of three crewmembers, for cabin leakage, and for the oxygen and hydrogen required for carbon dioxide collection and reduction processes. The subsystem can be operated at a pressure between 276 and 2760 kN/sq m and in a continuous constant-current, cyclic, or standby mode. A microprocessor is used to aid in operating the subsystem. Sensors and controls provide fault detection and automatic shutdown. The results of development, demonstration, and parametric testing are presented. Modifications to enhance operation in an integrated and manned test are described. Prospective improvements for the electrolysis subsystem are discussed.

Martin, R. B.↗