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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 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Theoretical modeling of a bottom-raised oscillating surge wave energy converter structural loadings and power performances

Here, this study presents theoretical formulations to evaluate the fundamental parameters and performance characteristics of a bottom-raised oscillating surge wave energy converter (OSWEC) device. Employing a flat plate assumption and potential flow formulation in elliptical coordinates, closed-form equations for the added mass, radiation damping, and excitation forces/torques in the relevant pitch-pitch and surge-pitch directions of motion are developed and used to calculate the system's response amplitude operator and the forces and moments acting on the foundation. The model is benchmarked against numerical simulations using WAMIT and WEC-Sim, showcasing excellent agreement. The sensitivity of plate thickness on the analytical hydrodynamic solutions is investigated over several thickness-to-width ratios ranging from 1:80 to 1:10. The results show that as the thickness of the benchmark OSWEC increases, the deviation of the analytical hydrodynamic coefficients from the numerical solutions grows from 3% to 25%. Differences in the excitation forces and torques, however, are contained within 12%. While the flat plate assumption is a limitation of the proposed analytical model, the error is within a reasonable margin for use in the design space exploration phase before a higher-fidelity (and thus more computationally expensive) model is employed. A parametric study demonstrates the ability of the analytical model to quickly sweep over a domain of OSWEC dimensions, illustrating the analytical model's utility in the early phases of design.

13 HYDRO ENERGY↗
DOE OSTI2025

Enabling fast-charging of lithium-ion batteries through printed electrodes

It has been well recognized that introducing secondary porous networks (SPNs) into the electrodes can effectively improve the electrochemical performance of lithium-ion batteries (LIBs), especially under fast-charging operations. However, the process complexity and high cost limit the commercial success of advanced electrodes with SPNs. To address this issue, we developed a facile screen-printing process to produce structured graphite electrodes with SPNs. The experimental results demonstrated that, by tuning the diameter and center-to-center (C2C) distance of emulsion dots on the stencil screen, the pore diameters and C2C pore distances of SPNs in screenprinted electrodes can be precisely controlled in the range of 100 mu m to 1 mm and 100 mu m to 3 mm respectively. In addition, the SPNs with hexagonal and square-shape pore alignments have also been imprinted onto the electrode coatings through adjusting the patterns of screen stencils. Used as anodes, the printed graphite electrodes demonstrated significantly reduced overpotential and voltage fluctuation under fast-charging operations from 2C to 6C. Coupled with LiNi 0.6 Mn 0.2 Co 0.2 O 2 (NMC622) cathodes, the full cells with printed graphite anodes exhibited an unprecedently stable performance with almost no capacity decay up to 170 cycles when charged to 80 % SOC at 2C. Observations from electron microscopy showed plated lithium undetectable at the surface of printed graphite electrodes after numerous cycles. The electrochemical analysis on the voltage evolution during the cell rest period indicated the significantly delayed onset of lithium plating in the presence of printed graphite electrodes. In conclusion, all these results suggest that the significantly improved cell performance is associated with the shortened Li-ion diffusion distance, reduced polarization and suppressed Li plating in the printed electrodes with patterned SPNs.

25 ENERGY STORAGE↗
DOE OSTI2024

Microjet printing of metal salt or oxide targets for nuclear reaction studies on radionuclides

Radioactive targets for direct measurements of neutron-induced reactions are required to improve evaluated cross-section data and, ultimately, the fidelity of neutron reaction network simulations. Electrodeposition and molecular plating are the current state-of-the-art radioactive target production techniques, but not all metals can be electrodeposited or molecular plated with high yields. Alternative techniques can be expensive or may produce targets that are unsatisfactory in terms of thickness, yield, or purity. Microjet printing is a new, rather inexpensive technique that utilizes equipment with a small footprint and has the potential to produce thin, highly radioactive targets with good uniformity and minimal impurities from the target fabrication process. This study involved optimizing the process of producing microjet printed targets to allow for the fabrication of a stable vanadium(V) oxide (V 2 O 5 ) target that was compared with an analogous electrodeposition V 2 O 5 target manufactured via the application of a vanadium chemical conversion coating on aluminum (Al) foil. Finally, the results from these studies suggest microjet printing could be used to produce relatively uniform target layers with adequate film thicknesses (< 15 μm). V 2 O 5 microjet printed targets, when compared with chemical conversion coating V 2 O 5 targets, appeared to be qualitatively less uniform and quantitatively larger in thickness (11.7(27) μm vs. 5.3(18) μm). However, the conversion coating target contained more impurities and the Al backing had a higher background contribution to measurements of neutron-induced reactions as opposed to targets produced via microjet printing. Overall, the results from this study suggest microjet printing has the capability to be an excellent alternative target production technique to the electrodeposition and molecular plating methods.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2025

Interaction of Planar Brushes with End-Functionalized Carboxylic or Amine Groups: Water Structure, Hydrogen Bonds, and Electrostatic Correlations

In this work we present a detailed analysis of two parallel plates grafted with polyethylene glycol (PEG) terminated with carboxylic or amine groups, and discuss the cases of opposite and same charge in the presence of electrolytes. We analyze the screening of charged groups by electrolytes, the role of hydrogen bonds in enhancing attraction or repulsion, hydration forces, competitive binding with counterions, and the hydrogen bond network, crucial to stabilizing the system. Our simulations reveal that, for large plate separation, the system is well described as a “Stern layer”, characterized by strong counterion binding and a subsequent weak diffuse layer. For short plate separation, the system is characterized by strong correlations among end groups and counterions. We also discuss the relevance of charged carboxylic/amine groups in different problems with a particular emphasis on nanoparticle assembly.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Toward Lithium Recovery Using Modular (and Membraneless) Phase Separation and Extraction (MPSE) Technology with Ionic Liquid (IL) Solvents: Effect of Coatings

In this work, a single-channel slope-plate Modular and Membrane-less Phase Separation and Extraction (MPSE) device was fabricated using 3D printing. The slope-plate was designed with an insertable glass slide to enable surface modification with coatings. Self-assembled monolayers (SAMs) and perfluoropolyether (Zdol) coatings were applied to tailor surface wettability and enhance phase separation. Using a model biphasic system of water and hexadecane, both coatings significantly improved the separation efficiency compared to the uncoated device by promoting selective wetting. Building on these results, lithium extraction from a simulated saline solution was investigated using 1-ethyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide ([EMIM][NTf₂]) as the ionic liquid (IL) extractant. The IL effectively extracted Li⁺ from the aqueous phase in bulk extraction, demonstrating its potential for lithium recovery. However, the low interfacial tension between the IL and aqueous phases posed challenges for phase separation. The application of SAM and Zdol coatings effectively mitigated this issue. Overall, integrating tailored surface chemistry with the slope-plate MPSE design shows great promise as an efficient and scalable platform for studying liquid–liquid separation and optimizing ionic liquid–based extraction processes for lithium recovery from saline sources.

3D printing↗
DOE OSTI2024

Hydride-Based Interlayer for Solid-State Anode-Free Battery

Solid-state batteries (SSBs) are considered a promising approach to realizing an anode-free concept with high energy densities. However, the initial Coulombic efficiency (ICE) has remained insufficient for anode-free batteries using sulfide-based solid electrolytes (SEs). Herein, we incorporated a hydride-based interlayer, 3LiBH 4 -LiI (LBHI), between a typical sulfide SE, Li 6 PS 5 Cl, and the Cu current collector. Further, by investigating the Li plating and stripping behaviors and the (electro)chemical stability between SEs and plated Li, we demonstrated that LBHI can effectively improve interfacial stability, leading to an ICE exceeding 94% in anode-free half cells. This interlayer also improves Coulombic efficiencies and specific capacities in anode-free full cells. Furthermore, the utilization of LBHI enables one to study Li plating behaviors without interference from interfacial (electro)chemical instabilities. The analysis of stack pressure evolution during electrochemical cycling reveals that soft shorting in SSBs arises from both dendrite formation and deformation, offering insights into further optimizing solid-state anode-free batteries.

25 ENERGY STORAGE↗
DOE OSTI2024

Design and Validation of a High-Throughput Reductive Catalytic Fractionation Method

Reductive catalytic fractionation (RCF) is a promising method to extract and depolymerize lignin from biomass, and bench-scale studies have enabled considerable progress in the past decade. RCF experiments are typically conducted in pressurized batch reactors with volumes ranging between 50 and 1000 mL, limiting the throughput of these experiments to one to six reactions per day for an individual researcher. Here, we report a high-throughput RCF (HTP-RCF) method in which batch RCF reactions are conducted in 1 mL wells machined directly into Hastelloy reactor plates. The plate reactors can seal high pressures produced by organic solvents by vertically stacking multiple reactor plates, leading to a compact and modular system capable of performing 240 reactions per experiment. Using this setup, we screened solvent mixtures and catalyst loadings for hydrogen-free RCF using 50 mg poplar and 0.5 mL reaction solvent. The system of 1:1 isopropanol/methanol showed optimal monomer yields and selectivity to 4-propyl substituted monomers, and validation reactions using 75 mL batch reactors produced identical monomer yields. To accommodate the low material loadings, we then developed a workup procedure for parallel filtration, washing, and drying of samples and a 1H nuclear magnetic resonance spectroscopy method to measure the RCF oil yield without performing liquid-liquid extraction. As a demonstration of this experimental pipeline, 50 unique switchgrass samples were screened in RCF reactions in the HTP-RCF system, revealing a wide range of monomer yields (21-36%), S/G ratios (0.41-0.93), and oil yields (40-75%). These results were successfully validated by repeating RCF reactions in 75 mL batch reactors for a subset of samples. We anticipate that this approach can be used to rapidly screen substrates, catalysts, and reaction conditions in high-pressure batch reactions with higher throughput than standard batch reactors.

BIOMASS FUELS,INORGANIC, ORGANIC, PHYSICAL, AND AN↗
DOE OSTI2024

High-throughput single-cell transcriptomics of bacteria using combinatorial barcoding

Microbial split-pool ligation transcriptomics (microSPLiT) is a high-throughput single-cell RNA sequencing method for bacteria. With four combinatorial barcoding rounds, microSPLiT can profile transcriptional states in hundreds of thousands of Gram-negative and Gram-positive bacteria in a single experiment without specialized equipment. As bacterial samples are fixed and permeabilized before barcoding, they can be collected and stored ahead of time. During the first barcoding round, the fixed and permeabilized bacteria are distributed into a 96-well plate, where their transcripts are reverse transcribed into cDNA and labeled with the first well-specific barcode inside the cells. The cells are mixed and redistributed two more times into new 96-well plates, where the second and third barcodes are appended to the cDNA via in-cell ligation reactions. Finally, the cells are mixed and divided into aliquot sub-libraries, which can be stored until future use or prepared for sequencing with the addition of a fourth barcode. It takes 4 days to generate sequencing-ready libraries, including 1 day for collection and overnight fixation of samples. Here, the standard plate setup enables single-cell transcriptional profiling of up to 1 million bacterial cells and up to 96 samples in a single barcoding experiment, with the possibility of expansion by adding barcoding rounds. The protocol requires experience in basic molecular biology techniques, handling of bacterial samples and preparation of DNA libraries for next-generation sequencing. It can be performed by experienced undergraduate or graduate students. Data analysis requires access to computing resources, familiarity with Unix command line and basic experience with Python or R.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2024

Operando investigations of the solid electrolyte interphase in the lithium mediated nitrogen reduction reaction

The lithium-mediated nitrogen reduction reaction (Li-NRR) represents a promising approach for electrochemical nitrogen activation, in which the solid electrolyte interphase (SEI) layer formed on the electrochemically plated lithium plays a key role. Herein, we used time-resolved, operando, grazing incidence wide-angle X-ray scattering (GI WAXS) to identify SEI species and reaction intermediates in the Li-NRR, comparing LiBF 4 and LiClO 4 as electrolyte salts. In this study, we demonstrated how the SEI composition influences the Li-NRR performance by regulating proton transport to the plated Li. When LiBF 4 is used as the electrolyte salt, the formation of LiF and lithium ethoxide (LiEtO) is observed. Reaction intermediates such as LiH and LiN x H y species were found and provide insight into reaction pathways towards undesired and desired products, respectively. Observed restructuring of the Cu (111) single crystal substrate also indicates interaction with plated Li that could possibly influence the Li-NRR performance. Together, these experiments give molecular insight into how to design Li-NRR systems and their SEI layers for optimal performance.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

First principles density functional theory study of tritium species adsorption on Ni(111) surface and diffusion in nickel-sublayer for tritium storage

The nickel-plated zircaloy-4 is used as a tritium ( 3 H) getter in the tritium-producing burnable absorber rods (TPBARs) to capture 3 H produced in the 6 Li-riched annular γ-LiAlO 2 pellet under neutron irradiation. The experimental data and our previous theoretical results showed that the 3 H species produced from the γ-LiAlO 2 pellet were mainly 3 H 2 and 3 H 2 O. These 3 H species diffuse from the surface of the LiAlO 2 pellet across vacuum to the nickel-plated zircaloy-4 getter and then further diffuse into the getter to chemically form metal hydrides. While a number of studies show that oxygen binds strongly as compared to 3 H on the nickel (Ni) layer, the detailed mechanism of 3 H species absorption and diffusion across the Ni plate and Ni/Zr interface are still unclear. By employing density functional theory calculations, here we explored the 3 H 2 and 3 H 2 O species adsorption and dissociation on the Ni(111) surface and diffusion into the Ni sublayer. Our results indicated that the 3 H 2 and 3 H 2 O dissociate on the Ni(111) surface. The NiO x and Ni(O 3 H) x could be formed in the Ni layer due to the higher oxygen (O) diffusion energy barrier and formation of Ni vacancy defects. The oxygen was found to be retained in the Ni layer from diffusing across the Ni–Zr interface. This was revealed by comparing the diffusion barriers for 3 H with O. 3 H was found to have nearly three times smaller diffusion barrier than for O, making 3 H comparatively easier to diffuse through the Ni layer. In conclusion, the obtained results provide guidelines for experimental measurements on 3 H retention behavior in TPBARs and may open further avenues to explore the impurity effects on 3 H diffusion and storage at the Ni/zircaloy interfaces.

Tafen, De Nyago [National Energy Technology Lab. (↗
DOE OSTI2025

Multifrequency eddy-current detection of fast transient thermal signatures for in situ monitoring applications

Eddy-current (EC) nondestructive evaluation has a long history of use in a variety of ex situ defect monitoring applications because of its exquisite sensitivity to local material variations. Due to the relationship between a material's conductivity and its temperature, EC methods have also been used to investigate quasistatic, long-range temperature variations in casting applications. However, these techniques remain underutilized for the measurement of rapidly varying, spatially nonuniform temperature distributions. In this work, we construct a model system capable of generating repeatable temperature transients in steel plates and measure real-time eddy-current signals with millisecond time resolution and spatial resolution of the order of 1 mm. Using a combination of Multiphysics simulations, fast thermal imaging, and time-resolved holographic interferometry, we tease apart contributions to the eddy-current signals arising from temperature variations and transient plate deformation. Finally, we perform a systematic study in which we vary the plate thickness and the eddy-current excitation frequency to demonstrate that eddy-current techniques can provide information about a three-dimensional, time-varying, subsurface thermal distribution, which is inaccessible to the traditional thermal imaging techniques.

Rosenberg, Ethan R. [Lawrence Livermore National L↗
DOE OSTI2026

Calculating the space-charge-limited current density for nonplanar geometries by simulating the charge-free electric field

Calculating the space-charge-limited-current density (SCLCD) for a complicated diode geometry often requires computationally expensive particle-in-cell (PIC) codes. Here, this paper addresses this issue by using the charge-free electric field $E_0$ calculated using COMSOL Multiphysics to determine local and global SCLCD. The SCLCD obtained by using the surface average of $|E_0|^2$ on the cathode recovers theoretical results for one-dimensional (1D) planar, cylindrical, and tip-to-tip geometries in appropriate limits. We next compared tip-to-tip calculations with the SCLCD obtained using the PIC code Empire. The SCLCD calculated using COMSOL agreed well with Empire for flatter 1D tip-to-tip geometries and diverged with increasing sharpness. Physically, Empire predicts lower SCLCD than COMSOL because the electrons spread due to concentrated space-charge at the tip, whereas theory assumes that the electrons follow the charge-free electric field lines. We further assess the behavior of the SCLCD for tips protruding from the centers of flat, circular plates of various areas. Larger plate areas with constant tip size recover the 1D planar SCLCD globally and 1D tip-to-tip SCLCD locally, while reducing the difference between Empire and COMSOL calculations since larger plates capture more of the emitted electrons, reducing SCLCD suppression due to beam spreading. These results show that charge-free electric field simulations can be used to determine the SCLCD without needing to simulate particle dynamics in PIC.

Wright, Jack K. [Purdue Univ., West Lafayette, IN ↗
DOE OSTI2024

Simulation of plasma and neutral transport in PISCES-RF using SOLPS-ITER

In this research, the fluid plasma transport code SOLPS-ITER is applied and validated against experimental data from the plasma interaction surface component experimental station (PISCES)-RF linear plasma device to establish a physics basis for plasma and neutral transport in its two magnetic field (B-field) geometry setups-(1)the cusp and (2) non-cusp or linear B-field. The main focus of this study is to understand (1) radial plasma transport (2) heat and particle loads on the upstream dump and downstream target plate, and (3) the physics of plasma-neutral interactions in PISCES-RF. The simulation setup adheres to typical PISCES-RF experimental conditions, with a 2D helicon power deposition profile as an input heating source. SOLPS-ITER simulations reproduce experimental conditions with the Bohm diffusion model for both B-field configurations of the PISCES-RF experiment. Major energy loss channels include neutral radiation and power deposited on the wall and dump plate, with only 1% of the input power reaching the target. The ionization front is well confined near the dump plate due to the heating and puffing regions. Additionally, SOLPS-ITER simulation results are also found to be in very good agreement with the particle-in-cell calculations using the code-PICOS++ which supports the validity of SOLPS in low collisionality regime.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Bayesian parameter estimation and evaluation of the K -ω shear stress transport model for plane impinging jets

Numerical simulations with semi-empirical turbulence models are commonly used to model impinging jets, often used for cooling solid surfaces. In this work, the constants in the k-ω shear stress transport model in ANSYS FLUENT are calibrated to experimental velocity and heat transfer data for a plane turbulent impinging air jet to determine if Kennedy-O'Hagan calibration (Kennedy and O'Hagan 2001 J. R. Stat. Soc. B 63 425–64) can improve predictions of near-surface velocities and surface Nusselt numbers for similar flows. Impinging jets have been proposed to cool the target plates of the divertor in future magnetic fusion energy reactors, where simulations are used to estimate divertor performance. The flat-plate divertor (Wang et al 2009 Fusion Sci. Technol .56 1023–7) uses a plane jet of helium issuing from a B = 0.5 mm slot to cool a surface with radius of curvature of 44 B at a distance 4 B from the slot. Predictions from the calibrated numerical model are compared with independent experimental data at different flow conditions, as well as surface temperature data for a flat plate divertor test section. The contribution of this work is evaluation of the accuracy of a calibrated turbulence model for modest extrapolations in flow geometry and flow conditions for a plane impinging jet.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Seismic imaging of the Ecuadorian forearc and arc from joint ambient noise, local, and teleseismic tomography: catching the Nazca slab in the act of flattening

SUMMARY The Ecuadorian Andes are a complex region characterized by accreted oceanic terranes driven by the ongoing subduction of the oceanic Nazca plate beneath South America. Present-day tectonics in Ecuador are linked to the downgoing plate geometry featuring the subduction of the aseismic, oceanic Carnegie Ridge, which is currently entering the trench. Using seismic tomography, we jointly invert arrival times of P and S waves from local and teleseismic earthquakes with surface wave dispersion curves to image the structure of the forearc and magmatic arc of the Ecuadorian Andes. Our data set includes > 100 000 traveltimes recorded at 294 stations across Ecuador. Our images show the basement of the central forearc is composed of accreted oceanic terranes with high elastic wave speeds. Inboard of the Carnegie Ridge, the westernmost forearc and coastal cordilleras display relatively low Vp and Vs and high Vp/Vs values, which we attribute to the increased hydration and fracturing of the overriding plate due to the subduction of the thick oceanic crust of the Carnegie Ridge. We additionally image across-arc differences in magmatic architecture. The frontal volcanic arc overlies accreted terranes and is characterized by low velocities and high Vp/Vs indicative of partial melt reservoirs which are limited to the upper crust. In contrast, the main arc displays regions of partial melt across a wider range of depths. The Subandean zone of Ecuador has two active volcanoes built on continental crust suggesting the arc is expanding eastwards. The mid to lower crust does not show indications of being modified from the magmatic process. We infer that the slab is in the process of flattening as a consequence of early-stage subduction of the buoyant Carnegie Ridge.

58 GEOSCIENCES↗
DOE OSTI2024

Effect of Substrate Temperature on the Electrochemical and Supercapacitance Properties of Pulsed Laser-Deposited Titanium Oxynitride Thin Films

Electrocatalytically active titanium oxynitride (TiNO) thin films were fabricated on commercially available titanium metal plates using a pulsed laser deposition method for energy storage applications. The elemental composition and nature of bonding were analyzed using X-ray photoelectron spectroscopy (XPS) to reveal the reacting species and active sites responsible for the enhanced electrochemical performance of the TiNO electrodes. Symmetric supercapacitor devices were fabricated using two TiNO working electrodes separated by an ion-transporting layer to analyze their real-time performance. The galvanostatic charge–discharge studies on the symmetric cell have indicated that TiNO films deposited on the polycrystalline titanium plates at lower temperatures are superior to TiNO films deposited at higher temperatures in terms of storage characteristics. For example, TiNO films deposited at 300 °C exhibited the highest specific capacity of 69 mF/cm 2 at 0.125 mA/cm 2 with an energy density of 7.5 Wh/cm 2 . The performance of this supercapacitor (300 °C TiNO) device is also found to be ~22% better compared to that of a 500 °C TiNO supercapacitor with a capacitance retention ability of 90% after 1000 cycles. Furthermore, the difference in the electrochemical storage and capacitance properties is attributed to the reduced leaching away of oxygen from the TiNO films by the Ti plate at lower deposition temperatures, leading to higher oxygen content in the TiNO films and, consequently, a high redox activity at the electrode/electrolyte interface.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2024

Iterative Stress Reconstruction Algorithm to Estimate Three-Dimensional Residual Stress Fields in Manufactured Components

Residual stress (RS) significantly impacts the mechanical performance of components. Measurement of RS often provides incomplete data in terms of components of stress and spatial density. Employing such fields in finite element simulations results in significant modification of the field to achieve equilibrium and compatibility among strains. To overcome this, an iterative stress reconstruction algorithm (ISRA) is developed to estimate 3D RS fields that satisfy equilibrium, are stress component-wise complete, and represent the characterized data sampled. An Al 7075-T651 plate and an additively manufactured (AM) A36 steel wall are considered for RS reconstruction using measurement data from the literature. A maximum variation of ~2.5 MPa in the Al plate, and ~10 MPa in the steel wall are observed between the reconstructed and measured stresses. Furthermore, unknown stress components emerge and reach significant magnitudes (upto ~2.3 MPa in the Al plate and ~45 MPa in the AM wall) during ISRA. Indeed, it is found that minor errors in measurement or data processing are eliminated through the physical requirements during ISRA. Employing a reconstructed RS field is hence not just more accurate given its compatibility, but it additionally corrects for minor errors in measurement. Furthermore, it is found that spatially dense measurement data result in convergence with fewer iterations. Finally, although ISRA yields a nonunique solution dependent on boundary conditions, measurement errors, fitting errors, and mesh density, it accommodates for uncertainties and inaccuracies in measurement, as opposed to failing to reach a physically realistic converged solution.

42 ENGINEERING↗
DOE OSTI2025

Choline Chloride-Based Water-in-Salt Electrolyte for Efficient Iron Electrodeposition

Electrochemical production of iron is a promising low-cost and modular approach to replace the traditional blast furnace. Aqueous electrolytes for iron electrolysis are advantageous as they can be operated at near-ambient temperatures, but they suffer from inefficiencies due to the parasitic hydrogen evolution reaction. In this work, we identify a new water-in-salt electrolyte (WiSE) based on choline chloride (ChCl) for high coulombic efficiency (>85%) iron deposition. Electrochemical analysis of the partial current densities of iron plating and hydrogen co-evolution revealed that, at optimal WiSE compositions, water reduction is kinetically suppressed resulting in an increase in the Fe plating efficiency. Decreased coordination of water and increased coordination of choline’s alcohol group with the Fe 2+ ion were observed through 1 H NMR providing evidence that water reduction is kinetically suppressed in WiSE. Additionally, Raman spectroscopy revealed that complexation effects (with Cl – ) reduce Fe 2+ diffusion coefficients and corresponding limiting currents as the ChCl concentration is increased. This results in an optimal WiSE composition (4 M ChCl + 1 M FeCl 2 ) that provides kinetic suppression of HER but also low transport resistance to Fe plating yielding 85% coulombic efficiency at high current densities.

Sinclair, Nicholas Scott [Case Western Reserve Uni↗