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DOE OSTI2019

Understanding Structure–Property Relationships of MoO 3 -Promoted Rh Catalysts for Syngas Conversion to Alcohols

Rh-based catalysts have shown promise for the direct conversion of syngas to higher oxygenates. Although improvements in higher oxygenate yield have been achieved by combining Rh with metal oxide promoters, details of the structure of the promoted catalyst and the role of the promoter in enhancing catalytic performance are not well understood. In this work, we show that MoO 3 -promoted Rh nanoparticles form a novel catalyst structure in which Mo substitutes into the Rh surface, leading to both a 66-fold increase in turnover frequency and an enhancement in oxygenate yield. By applying a combination of atomically controlled synthesis, in situ characterization, and theoretical calculations, we gain an understanding of the promoter-Rh interactions that govern catalytic performance for MoO 3 -promoted Rh. We use atomic layer deposition to modify Rh nanoparticles with monolayer-precise amounts of MoO 3 , with a high degree of control over the structure of the catalyst. Through in situ X-ray absorption spectroscopy, we find that the atomic structure of the catalytic surface under reaction conditions consists of Mo–OH species substituted into the surface of the Rh nanoparticles. Furthermore, using density functional theory calculations, we identify two roles of MoO 3 : first, the presence of Mo–OH in the catalyst surface enhances CO dissociation and also stabilizes a methanol synthesis pathway not present in the unpromoted catalyst; and second, hydrogen spillover from Mo–OH sites to adsorbed species on the Rh surface enhances hydrogenation rates of reaction intermediates.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Control of Molecular Bonding Strength on Metal Catalysts with Organic Monolayers for CO 2 Reduction

The development of separate levers for controlling the bonding strength of different reactive species on catalyst surfaces is challenging but essential for the design of highly active and selective catalysts. For example, during CO 2 reduction, production of CO often requires balancing a trade-off between the adsorption strength of the reactant and product states: weak binding of CO is desirable from a selectivity perspective, but weak binding of CO 2 leads to low activity. Here in this paper, we demonstrate a new method of controlling both CO 2 adsorption and CO desorption over supported metal catalysts by employing a single self-assembly step where organic monolayer films were deposited on the catalyst support. Binding of phosphonic acid monolayers on supported Pt and Pd catalysts weakened CO binding via a through-support effect. The weakened CO adsorption was generally accompanied by decreased adsorption and reactivity of CO 2 . However, by the incorporation of basic amine functions at controlled positions in the modifying film, strong CO 2 adsorption and hydrogenation reactivity could be restored. Thus, both through-surface and through-space interactions could be manipulated by design of the organic modifiers. After surface modification, the catalysts exhibited significantly improved selectivity (up to ~99% at conversions near 50%) and activity toward CO production. Moreover, the rate of deactivation was notably reduced due to prevention of CO poisoning.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Predicting Thermal Excursions During in situ Oxidative Regeneration of Packed Bed Catalytic Fast Pyrolysis Catalyst

Ex situ catalytic fast pyrolysis (CFP) uses a secondary reactor to upgrade biomass pyrolysis vapors to stabilized CFP oils with reduced oxygen content. In one configuration, the secondary reactor is operated as a packed-bed swing reactor system which allows coke-deactivated beds to be decarbonized in situ while other beds remain online for vapor upgrading. In situ decarbonization must be done carefully to avoid irreversible deactivation and/or physical degradation of catalyst pellets. Given that packed bed reactors are well known to have poor heat transfer characteristics, this is a critical issue impacting scaleability and commercial viability of the technology. To predict thermal excursions during regeneration, finite element computational models have been built to assist in scaling up oxidative decarbonization of a Pt/TiO2 CFP catalyst (0.5 mm spheres) from a bench scale packed bed with 100 g of catalyst to a pilot scale packed bed with 2 kg of catalyst and internal cooling tubes. Based on transient measurements of outlet temperature and effluent CO2 concentration, and using an assumed coke profile and activation energy, this paper demonstrates that specific combinations of effective thermal conductivity and wall heat transfer coefficient can fit bench scale oxidative regeneration data equally well. For the upscaled 2 kg bed, four bench-scale “best fit” parameter pairs give different predictions for location and magnitude of thermal excursions, with the maximum computed bed temperature gradients ranging from 30 °C cm-1 to as high as 3000 °C cm-1. The larger the fraction of heat removal by conduction through the cooling tubes, the greater the differences between the parameter pairs. The modelling results presented in this paper cast doubt on the industrial viability of the proposed combination of catalyst, bed and regeneration process, and point to the need for alternate reactor designs. However, there is considerable uncertainly in some of the key model parameters. The reliability of model predictions can be increased by adding more temperature measurements at key bed locations, testing additional variations in process conditions, performing careful bed dissections to determine the true coke profile, and perhaps most importantly, directly measuring the effective thermal conductivity of the catalyst pellets.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Tungsten single-atom catalysts for the efficient conversion of isobutene into highly branched liquid hydrocarbons

The catalytic transformation of isobutene into branched liquid hydrocarbons is crucial for the production of reformulated gasoline and fuel additives. Conventional supported catalysts often lack high activity and selectivity toward the desired highly branched dimers and trimers in isobutene oligomerization. Here, by developing a tungsten single-atom catalyst (W SAC ) atomically dispersed on a silica-doped alumina (SDA) support, we report that the W SAC /SDA catalyst enables efficient and selective conversion of isobutene into highly branched C 8 and C 12 liquid olefins while suppressing the formation of heavier hydrocarbons. The atomically dispersed W 1 –O 3 moieties incorporated within the SDA support were synthesized via a high-temperature pyrolysis of a templating zinc metal–organic framework (Zn-MOF) under argon, followed by annealing in static air. The W SAC /SDA catalysts with 1.6–3.7 wt% W loading exhibited single-atom dispersion (∼0.2 nm) and outstanding performance, achieving up to 60% and 95% selectivity to branched C8 olefins at 150 °C and 250 °C, respectively, under ambient pressure. With the demonstrated high activity, selectivity, and stability, the W SAC /SDA catalyst system presents a promising platform for next-generation heterogeneous catalysts for the efficient and selective upgrading of isobutene into high-performance fuel additives.

Branched Olefins↗

DOE OSTI2015

Bi-Sn alloy catalyst for simultaneous morphology and doping control of silicon nanowires in radial junction solar cells

Low-melting point metals such as bismuth (Bi) and tin (Sn) are ideal choices for mediating a low temperature growth of silicon nanowires (SiNWs) for radial junction thin film solar cells. The incorporation of Bi catalyst atoms leads to sufficient n-type doping in the SiNWs core that exempts the use of hazardous dopant gases, while an easy morphology control with pure Bi catalyst has never been demonstrated so far. We here propose a Bi-Sn alloy catalyst strategy to achieve both a beneficial catalyst-doping and an ideal SiNW morphology control. In addition to a potential of further growth temperature reduction, we show that the alloy catalyst can remain quite stable during a vapor-liquid-solid growth, while providing still sufficient n-type catalyst-doping to the SiNWs. Radial junction solar cells constructed over the alloy-catalyzed SiNWs have demonstrated a strongly enhanced photocurrent generation, thanks to optimized nanowire morphology, and largely improved performance compared to the reference samples based on the pure Bi or Sn-catalyzed SiNWs.

14 SOLAR ENERGY↗

DOE OSTI2022

Scalable synthesis of supported catalysts using fluidized bed atomic layer deposition

Overcoating layers deposited on the surface of heterogeneous catalysts using atomic layer deposition (ALD) have been shown to increase catalyst activity, lifetime, and selectivity. In this study, we performed Al 2 O 3 ALD and Pd ALD in a commercial fluidized bed reactor on high surface area mesoporous powder supports to create overcoated catalysts with high precursor utilization. We investigated the reaction mechanism for both Al 2 O 3 ALD and Pd ALD using in situ mass spectrometry and developed a mathematical model to understand the precursor saturation behaviors. We characterized the catalyst samples using a variety of techniques to measure the surface area, porosity, composition, and surface chemistry of the overcoated catalysts. Finally, we used propane dehydrogenation as a probe reaction to evaluate the performance of the catalysts prepared by fluidized bed ALD.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Engineered Catalyst Support with Improved Durability at Higher Weight Percentage of Platinum

Proton Exchange Membrane (PEM) fuel cells are a suitable electrochemical power source for heavy duty vehicle (HDV) applications due to their high efficiency and durability. The cathode of the fuel cell uses a higher geometric loading of platinum (∼0.2 to 0.4 mg Pt /cm 2 ) for the electrocatalysis of the kinetically sluggish Oxygen Reduction Reaction (ORR) which requires higher weight percent loading of the metal (∼50%) on the carbon support to decrease the catalyst layer thickness and hence, the reactant transport losses. The conventionally used supports for platinum catalyst, such as the KetjenBlack TM type high surface area carbon (HSC) features limited mesopore area for the dispersion of Pt nanoparticles leading to increased aggregation and poor durability. Here, we show a new class of carbon materials known as the Engineered Catalyst Support (ECS) developed by Pajarito Powder with higher mesopore fraction for the dispersion of higher weight percentage of Pt nanoparticles. ECS materials can disperse up to 50% Pt by weight of the catalyst thereby enabling lower catalyst layer thickness with higher performance retained after durability test. A comprehensive set of physico-chemical and electrochemical studies in membrane electrode assembly (MEA) are reported to understand the performance and durability of Pt/ECS catalysts.

08 HYDROGEN↗

DOE OSTI2017

Non-PGM cell catalysts

A unique approach has been developed to probe the non-PGM catalyst active site for the Oxygen Reduction Reaction (ORR) for PEMFCs. Iron based functionalities have been engineered into a variety of catalysts to evaluate their impact on activity for the ORR. A series of high surface area catalysts were synthesized and the impact of the chemical structure on the electrochemical and electrocatalytic properties was investigated. Elemental and surface analyses of the prepared catalysts reveal the incorporation of iron in a targeted and controlled manner. A high surface area framework catalyst was prepared that shows exceptional activity, comparable to state-of-the-art materials. The results of this research project provided critical seed data for the newly awarded ElectroCat project, which focuses on rationally designed framework catalysts for the oxygen reduction reaction.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Highly-Accessible Catalysts for Durable High-Power Performance (Final Technical Report)

Reduction of costly Pt usage in proton exchange membrane fuel cell (PEMFC) electrodes is one of the major challenges towards development and commercialization of fuel cell electric vehicles (FCEV). However, reducing the Pt loading results in increasing local mass transport fluxes, and eventual performance loss, especially at high power. In this project, a team of 4 universities, 2 companies, and a national lab came together to develop fuel cell catalysts and electrodes with high performance and durability. The were several key concepts addressed in this project. The first concept is to develop a carbon support that possess internal porosity which are believed to enhance kinetic activity of the catalysts, and yet the pore morphology allows for good reactant transport. The second concept is to improve the Pt-electrolyte interface in hope to reduce the local transport resistance. This was done by using new ionomers and ionic liquids. The last concept involves improving the catalyst stability by introducing Pt alloy catalyst with ordered intermetallic phase. The collaborative platform provided by DOE funding enabled development of a highly active and durable catalyst with performance that exceeds previous catalysts and meets the DOE targets for light duty vehicle application.

08 HYDROGEN↗

DOE OSTI2021

Durable Mn-Based PGM-Free Catalysts for Polymer Electrolyte Membrane Fuel Cells

This proposed project aims to develop and evaluate novel manganese based, nitrogen-derived, PGM-free electrocatalysts (denoted as Mn-N-C) to fully address the membrane electrolyte assemblies (MEA)’s ionomer degradation issue resulting from iron. Four thrusts will be pursed in this proposed project. First, advanced first-principles computation methods will be employed to accelerate the rational catalyst design and synthesis. Second, an effective hydro-gel method will be used to maximize atomic Mn active sites embedded in carbon matrix. Next, state-of-the art methods in fuel cell companies will be used to fabricate MEAs containing the Mn-N-C catalysts. Finally, industry standards will be rigorously followed to evaluate fuel cell performance and durability of the Mn-N-C catalysts. With successful completion of the project, it is expected that the following outcomes will be achieved. (1) A set of MEAs containing the Mn-N-C catalysts and with active area large than 50 cm 2 for independent testing, (2) testing results demonstrating that the MEAs of Mn-N-C catalysts have mass activity of 0.044 A/cm 2 at 0.9 VIR-free and H 2 /air performance of 0.50 V at 1.0 A/cm 2 ; (3) fundamental understanding of the composition-structure-property relation of the PGM-free Mn- N-C catalysts, and (4) computational data, measurement data, and publications deposited into the database of ElectroCat Consortium.

08 HYDROGEN↗

DOE OSTI2026

Understanding_the_deactivation_mechanisms_of_ethanol_conversion_over_Cu-Y_Beta_catalyst

Direct conversion of bioethanol to C₃⁺olefins is a promising pathway for sustainable aviation fuel (SAF) production, but catalyst deactivation limits long-term operation. The stability and deactivation mechanisms of multifunctional Cu–Y/Beta zeolite catalysts were investigated for ethanol-to-olefins conversion over 300 h time-on-stream in the presence of H2. Catalytic testing reveals progressive losses in ethanol conversion and C₃⁺ olefin selectivity accompanied by increased acetaldehyde formation. The catalyst testing studies correlate with a suite of characterizations of fresh, spent, and regenerated catalysts to identify the deactivation factors. The loss of Y Lewis acid sites is the primary deactivation element. Reversible acid site deactivation is caused by coke deposition, which blocks Y-derived Lewis acid sites responsible for aldol condensation, MPV reduction, and alcohol dehydration. Minor irreversible deactivation is observed and possibly results from hydrothermal dehydroxylation of Y–silanol interactions, resulting in permanent loss of Lewis acidity without zeolite framework degradation or Y aggregation. Cu sites undergo limited agglomeration into small nanoparticles but contribute insignificantly to catalyst deactivation, under the investigated time frame. Oxidative regeneration removes coke and redistributes Cu sites, leading to full recovery of the initial catalytic performance though the Y Lewis acid sites are unable to fully recover. These findings establish Lewis acid site degradation as the primary deactivation mechanism impacting long-term catalyst stability

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Fe-Exchanged Small-Pore Zeolites as Ammonia Selective Catalytic Reduction (NH 3 -SCR) Catalysts

Cu-exchanged small-pore zeolites have been extensively studied in the past decade as state-of-the-art selective catalytic reduction (SCR) catalysts for diesel engine exhaust NOx abatement for the transportation industry. During this time, Fe-exchanged small-pore zeolites, e.g., Fe/SSZ-13, Fe/SAPO-34, Fe/SSZ-39 and high-silica Fe/LTA, have also been investigated but much less extensively. In comparison to their Cu-exchanged counterparts, such Fe/zeolite catalysts display inferior low-temperature activities, but improved stability and high-temperature SCR selectivities. Such characteristics entitle these catalysts to be considered as key components of highly efficient emission control systems to improve the overall catalyst performance. In this short review, recent studies on Fe-exchanged small-pore zeolite SCR catalysts are summarized, including (1) the synthesis of small-pore Fe/zeolites; (2) nature of the SCR active Fe species in these catalysts as determined by experimental and theoretical approaches, including Fe species transformation during hydrothermal aging; (3) SCR reactions and structure-function correlations; and (4) a few aspects on industrial applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2016

Fischer-Tropsch Cobalt Catalyst Activation and Handling Through Wax Enclosure Methods

Fischer-Tropsch (F-T) synthesis is considered a gas to liquid process which converts syn-gas, a gaseous mixture of hydrogen and carbon monoxide, into liquids of various hydrocarbon chain length and product distributions. Cobalt based catalysts are used in F-T synthesis and are the focus of this paper. One key concern with handling cobalt based catalysts is that the active form of catalyst is in a reduced state, metallic cobalt, which oxidizes readily in air. In laboratory experiments, the precursor cobalt oxide catalyst is activated in a fixed bed at 350 C then transferred into a continuous stirred tank reactor (CSTR) with inert gas. NASA has developed a process which involves the enclosure of active cobalt catalyst in a wax mold to prevent oxidation during storage and handling. This improved method allows for precise catalyst loading and delivery into a CSTR. Preliminary results indicate similar activity levels in the F-T reaction in comparison to the direct injection method. The work in this paper was supported by the NASA Fundamental Aeronautics Subsonics Fixed Wing Project.

Fischer-Tropsch↗

DOE OSTI2019

Evaluating Cu/BEA Catalyst Performance with Techno-Economic Analysis to Develop a Market-Responsive Biorefinery Concept Around the Conversion of Methanol to High-Octane Hydrocarbons

A recent advancement in the conversion of methanol to hydrocarbon fuels is the development of a Cu-modified beta zeolite catalyst (Cu/BEA) that exhibits a higher productivity and yield than the parent H-form BEA catalyst in the production of branched C4-C8 hydrocarbons. This Cu/BEA catalyst enables process improvements in the High-Octane Gasoline (HOG) pathway, which operates under lower severity conditions than traditional methanol-to-fuels processes, offering a lower coke formation rate, higher selectivity to C5+gasoline-range hydrocarbons, and subsequently, improved process economics based on a recent process model and techno-economic analysis (TEA). Here, a market-responsive biorefinery concept around methanol and the HOG pathway is presented, where the major C4 products, isobutane and isobutene, serve as versatile intermediates that can either be recycled to increase the yield of the HOG product or directed to jet-fuel range hydrocarbons. Based on simulated recycle experiments with 13C-labeled isobutane, the Cu/BEA catalyst achieved increased yield to the HOG products during DME homologation by activating the co-fed isobutane and incorporating it into the chain growth pathway, as evidenced by the presence of isotopically-labeled 13C in C5+ products. Olefin coupling of an isobutene-rich mixture was also investigated, and the fuel properties of the resulting synthetic kerosene product were within the specifications for a typical jet-fuel. These experimental results were incorporated into an updated Aspen-based process model and TEA to quantify their impact on a market-responsive biorefinery concept. The improvements offered by C4 recycling with the Cu/BEA catalyst result in a decrease in the methanol-to-fuel synthesis cost from 101 cents per gallon of gasoline equivalent (GGE) with the baseline BEA catalyst to 72 cents/GGE, due in part to a significantly increased HOG yield from 40 to 55 GGE/dry-ton biomass. Expanding the process model to direct C4 products to a jet-range hydrocarbon product demonstrated a yield of 42 GGE/dry-ton HOG with 12 GGE/dry-ton distillate, resulting in a minor increase in the fuel synthesis cost to 77 cents/GGE versus the HOG-only case. With continued development, these advancements in fuel yield and reductions in cost position a market-responsive biorefinery around the HOG pathway to be competitive against mature fuel-synthesis technologies from a variety of carbon sources through methanol.

09 BIOMASS FUELS↗

DOE OSTI2023

Improving Durability of Fuel Cells with Platinum-rich Alloy Cathode Catalysts

Pt 3 Co-alloy based nanoparticle catalysts are very active for oxygen reduction reaction (ORR) thereby enabling high performance of proton exchange membrane fuel cells (PEMFC) for automotive propulsion. However, these catalyst materials degrade due to a combination of electrochemical surface area (ECSA) loss and dissolution of cobalt-alloying element from the nanoparticles. Dissolution of cobalt has a two-fold impact on the durability of fuel cells—i) a loss in the low-current density kinetic region due to a decrease in specific activity and ii) a loss in the high-current density transport region due to Co 2+ contamination of the ionomer phase. Cobalt dissolution-contamination needs to be mitigated as it limits fuel cell performance and lifetime for heavy-duty automotive applications. In this article, we study the use of PtCo-alloy catalysts with Pt-rich compositions using catalyst-specific accelerated stress test measurement in membrane electrode assemblies to decrease the amount of dissolved Co and mitigate its subsequent contamination effects. We demonstrate Pt 5 Co and Pt 7 Co compositions to enable significant improvements in durability (∼50 mV and ∼100 mV with respect to Pt 3 Co after 30,000 voltage cycles) with a minor but acceptable compromise in the initial specific activity of the catalyst.

08 HYDROGEN↗

DOE OSTI2022

Integrated Solar-Driven Device with a Front Surface Semitransparent Catalysts for Unassisted CO 2 Reduction

Monolithic integrated photovoltaic-driven electrochemical (PV-EC) artificial photosynthesis is reported for unassisted CO 2 reduction. The PV-EC structures employ triple junction photoelectrodes with a front mounted semitransparent catalyst layer as a photocathode. The catalyst layer is comprised of an array of microscale triangular metallic prisms that redirect incoming light toward open areas of the photoelectrode to reduce shadow losses. Full wave electromagnetic simulations of the prism array (PA) structure guide optimization of geometries and length scales. An integrated device is constructed with Ag catalyst prisms covering 35% of the surface area. The experimental device has close to 80% of the transmittance with a catalytic surface area equivalent 144% of the glass substrate area. Experimentally this photocathode demonstrates a direct solar-to-CO conversion efficiency of 5.9% with 50 h stability. Selective electrodeposition of Cu catalysts onto the surface of the Ag triangular prisms allows CO2 conversion to higher value products enabling demonstration of a solar-to-C 2+ product efficiency of 3.1%. This design featuring structures that have a semitransparent catalyst layer on a PV-EC cell is a general solution to light loss by shadowing for front surface mounted metal catalysts, and opens a route for the development of artificial photosynthesis based on this scalable design approach.

14 SOLAR ENERGY↗

DOE OSTI2024

Regulating the Third Metal to Design and Engineer Multilayered NiFeM (M: Co, Mn, and Cu) Nanofoam Anode Catalysts for Anion-Exchange Membrane Water Electrolyzers

In this study, alkaline anion-exchange membrane water electrolyzers (AEMWEs) for green hydrogen production have received intensive attention due to their feasibility of using earth-abundant platinum group metal (PGM)-free catalysts. Herein, the third metal is incorporated into NiFe-based catalysts to regulate their electronic structures and morphologies, aiming to achieve sufficient oxygen evolution reaction (OER) activity and performance in AEMWEs. The ternary NiFeM (M: Cu, Co, or Mn) catalysts are featured with multiple layered structures and nanofoam network morphologies, consisting of highly OER-active amorphous Ni-rich oxide shells and electrically conductive metallic alloy cores. The physical and electronic perturbations to the NiFe induced by a third element lead to a fine-tuning of the redox ability of the metal sites at the reaction centers, which breaks the scaling relationship between OH* and O* intermediates at the reaction centers. Thus, the unique structural configuration and electronic regulation simultaneously benefit catalytic activity and performance improvements. These NiFeM nanofoam catalysts demonstrated promising anode performance in actual AEMWEs, comparable to the IrO 2 reference, especially at high current densities. Notably, using various electrolytes (e.g., KOH solution or pure water) for AEMWEs exhibited a different performance trend among studied NiFeM catalysts, likely due to dynamic changes of catalysts under various OER environments.

25 ENERGY STORAGE↗

DOE OSTI2017

Ni 3 FeN‐Supported Fe 3 Pt Intermetallic Nanoalloy as a High‐Performance Bifunctional Catalyst for Metal–Air Batteries

Abstract Electrocatalysts for both the oxygen reduction and evolution reactions (ORR and OER) are vital for the performances of rechargeable metal–air batteries. Herein, we report an advanced bifunctional oxygen electrocatalyst consisting of porous metallic nickel‐iron nitride (Ni 3 FeN) supporting ordered Fe 3 Pt intermetallic nanoalloy. In this hybrid catalyst, the bimetallic nitride Ni 3 FeN mainly contributes to the high activity for the OER while the ordered Fe 3 Pt nanoalloy contributes to the excellent activity for the ORR. Robust Ni 3 FeN‐supported Fe 3 Pt catalysts show superior catalytic performance to the state‐of‐the‐art ORR catalyst (Pt/C) and OER catalyst (Ir/C). The Fe 3 Pt/Ni 3 FeN bifunctional catalyst enables Zn–air batteries to achieve a long‐term cycling performance of over 480 h at 10 mA cm −2 with high efficiency. The extraordinarily high performance of the Fe 3 Pt/Ni 3 FeN bifunctional catalyst makes it a very promising air cathode in alkaline electrolyte.

Cui, Zhiming↗