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DOE OSTI2021

Engineering block co-polymer anion exchange membrane domains for highly efficient electrode-decoupled redox flow batteries

We report, anion exchange membranes (AEMs) with high permselectivity, chemical stability and mechanical robustness are a key enabling technology for a variety of electrochemical energy conversion and storage systems such as fuel cells, redox flow batteries and water electrolyzers. Herein we examine well understood chemically stable triblock co-polymer AEMs derived by the chloromethylation (CM-) and subsequent trimethylamine (TMA) functionalization of polystyrene-block-poly(ethylene-ran-butylene)-block-polystyrene (SEBS) block co-polymers. We show using small angle X-ray scattering (SAXS) that the introduction of a hydrophobic reinforcement matrix disrupts phase segregation and decreases ionic domain sizes in these AEM separators. The reinforcement matrix simultaneously causes the ultimate tensile strength (UTS) of the reinforced separator to increase by almost 600% compared to the unreinforced form, while maintaining comparable elasticity (ca. 500% elongation at break). Such reinforced r-SEBS30-TMA separators enable electrode-decoupled redox flow batteries (ED-RFBs) with significantly improved lifetimes by decreasing per cycle capacity fade from 0.5% to <0.05%. This 10× improvement in operando permselectivity opens the door to ED-RFBs employing inexpensive elemental actives achieving decades-long usable lifespans.

25 ENERGY STORAGE↗

DOE OSTI2021

Resolving ECRH deposition broadening due to edge turbulence in DIII-D

Microwave heat pulse propagation experiments have demonstrated a correlation between millimeter-scale turbulence and deposition profile broadening of electron cyclotron (EC) waves on the DIII-D tokamak. In a set of discharges in DIII-D, a variation in edge density fluctuations on the mm-scale is associated with 40%–150% broader deposition profiles, expressed in terms of normalized minor radius, as compared with equilibrium ray tracing. The 1D power profile is determined from transport analysis of the electron temperature response to EC power modulation using perturbative analysis with a square wave power modulation at 20–70 Hz, producing a series of Fourier harmonics that are fit collectively to resolve transport. Fitting an integrated heat flux expressed in the Fourier basis of the modulation to diffusive, convective, and coupled transport terms in a linear model can resolve the broadened EC deposition width from the power perturbation to resolve a broadening in each case. The best fit degree of beam broadening observed scales approximately linearly with the Doppler backscattering measured fluctuation level in the steep gradient region. Quantifying the effect of edge fluctuation broadening on EC current drive power needs of future devices will require 3D full-wave codes that can be validated on the current generation of machines. These DIII-D experiments provide a quantitative measure of fluctuation effects and a dataset to benchmark full-wave simulations that can model and eventually predict nonlinear effects neglected by 1D equilibrium beam and ray tracing.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

Lower-hybrid drift waves and their interaction with plasmas in a 3D symmetric reconnection simulation with zero guide field

We investigate lower-hybrid drift waves (LHDW) in symmetric magnetic reconnection with zero guide field using three-dimensional particle-in-cell simulations. The long-wavelength mode with kρiρe∼1 develops in the bifurcated electron current layer around the X-line within the width of the electron meandering motion from the mid-plane, where ρi(e) is the ion (electron) gyroradius. The short-wavelength mode with kρe∼1 develops in the separatrix region downstream of the electron outflow jet, producing electron vortices in the background flow frame. Electrons follow the E × B drift with corrections from the diamagnetic drift and are heated inside the vortices with diverging electric fields. In the vortices, ions have comparable E × B and inertia drifts, which together mostly cancel the diamagnetic drift. Toward the center of diverging field vortices, ions are decelerated, leading to a decrease in the perpendicular temperature, while the loss of low-energy ions results in an increase in the parallel temperature. Parallel electric fields exist as a combination of the LHDW wave field projected to the magnetic field direction and the penetration of whistler waves that are mainly outside of the LHDW layer. The magnetic flux tube is twisted in the vortices. The twist may potentially lead to slippage reconnection, as indicated by the non-uniform parallel potential variation across field lines, while the periodic variations of the twisting directions are a limiting factor.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2022

Particle-in-cell modeling of plasma jet merging in the large-Hall-parameter regime

The merging process of magnetized plasma jets with parameters relevant to the plasma-jet-driven magneto-inertial fusion (PJMIF) design and the plasma liner experiment (PLX) is modeled by fully kinetic particle-in-cell (PIC) simulations in one and two spatial dimensions. Here, the modified two-stream instability is identified to be the main mechanism responsible for stopping the plasma jets and preventing species interpenetration. The electron and ion Hall parameters of the merged plasma are greater than unity, and the plasma β is close to unity, which is the desired characteristic of planned experiments at PLX. Our 2D PIC simulations validate the results of the radiation magneto-hydrodynamics code FLASH, which will be the primary tool for modeling various stages of future PJMIF experiments.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

Roadmap on energy harvesting materials

Ambient energy harvesting has great potential to contribute to sustainable development and address growing environmental challenges. Converting waste energy from energy-intensive processes and systems (e.g. combustion engines and furnaces) is crucial to reducing their environmental impact and achieving net-zero emissions. Compact energy harvesters will also be key to powering the exponentially growing smart devices ecosystem that is part of the Internet of Things, thus enabling futuristic applications that can improve our quality of life (e.g. smart homes, smart cities, smart manufacturing, and smart healthcare). To achieve these goals, innovative materials are needed to efficiently convert ambient energy into electricity through various physical mechanisms, such as the photovoltaic effect, thermoelectricity, piezoelectricity, triboelectricity, and radiofrequency wireless power transfer. By bringing together the perspectives of experts in various types of energy harvesting materials, this Roadmap provides extensive insights into recent advances and present challenges in the field. Additionally, the Roadmap analyses the key performance metrics of these technologies in relation to their ultimate energy conversion limits. Building on these insights, the Roadmap outlines promising directions for future research to fully harness the potential of energy harvesting materials for green energy anytime, anywhere.

14 SOLAR ENERGY↗

DOE OSTI2023

Structural Characteristics and Phase Evolution of Calcium-Reduced (Sm,Zr)(Fe,Co,Ti) 12 Particles

Magnetic materials are essential for applications in electronics, energy conversion and many other industrial and technological sectors. Among the permanent magnets, rare-earth magnets exhibit the strongest properties and dominate the market shares in related applications. However, due to the increasing cost and unstable supply, the research on reducing the rare-earth elements in magnets attracts significant increasing interest. Rare-earth-lean samarium transition metal (TM) compounds (SmTM 12 or 1:12 for short) have made breakthroughs in 2020 and the (Sm,Zr)(Fe,Co,Ti) 12 monocrystalline particles synthesized by a Ca reduction of elemental oxides at high temperature demonstrated an order of magnitude improvement in coercivity at room temperature. In this study, we made structural analysis of (Sm,Zr)(Fe,Co,Ti) 12 particles to elucidate the impact of synthesis conditions, microstructure and phase transformation on the evolution of magnetic properties.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Reevaluation of XPS Pt 4f peak fitting: Ti 3s plasmon peak interference and Pt metallic peak asymmetry in Pt@TiO2 system

The structural, electronic, and electrochemical properties of noble metals supported on transition metal oxides, such as Pt nanoparticles (NPs) supported on TiO2 (Pt@TiO2), have been extensively studied for their relevance to energy technologies, including photocatalysis, electrocatalysis, and electrochemical energy conversion. As the need to lower the amount of Pt and other noble metals used in energy conversion systems becomes urgent, it is essential to accurately quantify the loading of these metals and electronic density redistribution between them and their supports. X-ray photoelectron spectroscopy (XPS) is widely used for the identification and quantification of chemical species. In particular, fitting of the Pt 4f spectra for Pt@TiO2 is frequently performed to determine the chemical environment and oxidation state of Pt, which strongly affect the physical behavior and catalytic performance of this system. Here, we show that neglecting contributions due to the Pt surroundings and the asymmetry of the Pt metal peak in the line shape fitting can lead to severe mischaracterization of the oxidation state of Pt. We quantify the effects of background contributions that stem from the TiO2 support and discuss how factoring in the strong asymmetry of Pt 4f doublets, which stems from the shake-up type processes, affects the interpretation of Pt 4f XPS line shape.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Numerical and Experimental Study of an Aircraft Igniter Plasma Jet Discharge

The spark discharge of an aircraft plasma jet igniter is studied using high-fidelity numerical simulations and X-ray radiography measurements. The target problem here features the thermal expansion of hot gas introduced by the electric spark within a confined igniter cavity, which eventually evolves into a pulsed jet of a high-temperature kernel. A comprehensive set of models adapted from existing strategies for internal combustion engine spark plug discharge is extended to the target problem, including the modeling of energy deposition, plasma reactions, thermodynamic properties, and heat losses. A series of validation and parameter studies are performed and presented. The kernel size is found to be sensitive to heat losses arising from radiation and hot gas remained within the discharge cavity, rather than heat conduction to the wall in the discharge cavity. Depending on the enforced shape of the post-breakdown electric arc, the spark kernel can be off-centered, tilted, and considerably asymmetric. These features have been previously not considered when studying such igniter configurations and may have a first-order impact on the ignition process. Provided a proper setup of the heat loss models and electric arc shape, the numerical results are quantitatively comparable to the experimental results in terms of the kernel size, shape, and velocity throughout different stages after the spark discharge.

Tang, Yihao↗

DOE OSTI2022

Structural, Optical and Mechanical Properties of Nanocrystalline Molybdenum Thin Films Deposited under Variable Substrate Temperature

Molybdenum (Mo), which is one among the refractory metals, is a promising material with a wide variety of technological applications in microelectronics, optoelectronics, and energy conversion and storage. However, understanding the structure–property correlation and optimization at the nanoscale dimension is quite important to meet the requirements of the emerging nanoelectronics and nanophotonics. In this context, we focused our efforts to derive a comprehensive understanding of the nanoscale structure, phase, and electronic properties of nanocrystalline Mo films with variable microstructure and grain size. Molybdenum films were deposited under varying temperature (25–500 °C), which resulted in Mo films with variable grain size of 9–22 nm. The grazing incidence X-ray diffraction analyses indicate the (110) preferred growth behavior the Mo films, though there is a marked decrease in hardness and elastic modulus values. In particular, there is a sizable difference in maximum and minimum elastic modulus values; the elastic modulus decreased from ~460 to 260–280 GPa with increasing substrate temperature from 25–500 °C. The plasticity index and wear resistance index values show a dramatic change with substrate temperature and grain size. Additionally, the optical properties of the nanocrystalline Mo films evaluated by spectroscopic ellipsometry indicate a marked dependence on the growth temperature and grain size. This dependence on grain size variation was particularly notable for the refractive index where Mo films with lower grain size fell in a range between ~2.75–3.75 across the measured wavelength as opposed to the range of 1.5–2.5 for samples deposited at temperatures of 400–500 °C, where the grain size is relatively higher. The conductive atomic force microscopy (AFM) studies indicate a direct correlation with grain size variation and grain versus grain boundary conduction; the trend noted was improved electrical conductivity of the Mo films in correlation with increasing grain size. The combined ellipsometry and conductive AFM studies allowed us to optimize the structure–property correlation in nanocrystalline Mo films for application in electronics and optoelectronics.

36 MATERIALS SCIENCE↗

DOE OSTI2022

1.2.4.404 - Data-Driven Approach for Hydropower Plant Controller Prototyping Using Remote Hardware in the Loop (DR-HIL)

Real-time prototyping of hydropower plant controls is important for reducing the cost and the risk of field deployment. This project will 1) collect design and operational data from actual hydro plants and 2) use a physics-informed machine learning approach for real-time emulation of hydropower plants, including hydro turbine and hydrodynamics. The data-driven models will be interfaced with digital real-time simulation at NREL’s Flatirons campus for hardware-in-the-loop (HIL) testing of the governor hardware device or controller-HIL (CHIL). The proposed approach will also establish the connectivity based remote CHIL testing capability using real-time data streams from an actual hydro plant. This integrated hydro-plant emulation with CHIL will be used to prototype hydro-governor controls and eventually provide an opportunity to test hydropower integrated with various technologies (e.g. conventional and renewable generation, energy conversion, etc.) as HIL.

controls prototyping↗

DOE OSTI2022

Techno-Economic Analysis

This National Energy Technology Laboratory presentation was given at the Carbon Conversion Procurement Grant Program Regional Workshops. The workshops are organized collaboratively by the DOE Office of Fossil Energy and Carbon Management and the United States Energy Association. There are a series of four workshops scheduled: 1) August 30, 2022 in Knoxville, TN (University of Tennessee) 2) September 13, 2022 in Emeryville, CA (Lawrence Berkeley National Laboratory 3) September 27, 2022 in New York, NY (Orrick, Herrington, & Sutcliffe LLP) 4) October 18, 2022 in Minneapolis, MN (TBD) The intent of the workshop is to provide potential applicants with background on the Procurement Grants program and the types of information requested. The specific purpose of this presentation is to give a high-level overview of techno-economic analysis to an audience that has little to no experience conducting them. The intent is to help the audience understand why techno-economic analysis is requested in the application process and to educate on its utility.

Hackett, Gregory↗

DOE OSTI2024

Photocatalytic water splitting for large-scale solar-to-chemical energy conversion and storage

Sunlight-driven water splitting allows renewable hydrogen to be produced from abundant and environmentally benign water. Large-scale societal implementation of this green fuel production technology within energy generation systems is essential for the establishment of sustainable future societies. Among various technologies, photocatalytic water splitting using particulate semiconductors has attracted increasing attention as a method to produce large amounts of green fuels at low cost. The key to making this technology practical is the development of photocatalysts capable of splitting water with high solar-to-fuel energy conversion efficiency. Furthermore, advances that enable the deployment of water-splitting photocatalysts over large areas are necessary, as is the ability to recover hydrogen safely and efficiently from the produced oxyhydrogen gas. This lead article describes the key discoveries and recent research trends in photosynthesis using particulate semiconductors and photocatalyst sheets for overall water splitting, via one-step excitation and two-step excitation (Z-scheme reactions), as well as for direct conversion of carbon dioxide into renewable fuels using water as an electron donor. We describe the latest advances in solar water-splitting and carbon dioxide reduction systems and pathways to improve their future performance, together with challenges and solutions in their practical application and scalability, including the fixation of particulate photocatalysts, hydrogen recovery, safety design of reactor systems, and approaches to separately generate hydrogen and oxygen from water.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2025

Overcoming the conversion reaction limitation at three-phase interfaces using mixed conductors towards energy-dense solid-state Li–S batteries

Lithium–sulfur (Li–S) all-solid-state batteries (ASSBs) hold great promise for next-generation safe, durable and energy-dense battery technology. However, solid-state sulfur conversion reactions are kinetically sluggish and primarily constrained to the restricted three-phase boundary area of sulfur, carbon and solid electrolytes, making it challenging to achieve high sulfur utilization. Here, in this study, we develop and implement mixed ionic–electronic conductors (MIECs) in sulfur cathodes to replace conventional solid electrolytes and invoke conversion reactions at sulfur–MIEC interfaces in addition to traditional three-phase boundaries. Microscopic and tomographic analyses reveal the emergence of mixed-conducting domains embedded in sulfur at sulfur–MIEC boundaries, helping promote the thorough conversion of active sulfur into Li 2 S. Consequently, substantially improved active sulfur ratios (up to 87.3%) and conversion degrees (>94%) are achieved in Li–S ASSBs with high discharge capacity (>1,450 mAh g –1 ) and long cycle life (>1,000 cycles). The strategy is also applied to enhance the active material utilization of other conversion cathodes.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Supply Chain Sustainability Analysis of Renewable Hydrocarbon Fuels via Indirect Liquefaction, Hydrothermal Liquefaction, Combined Algal Processing, and Biochemical Conversion: Update of the 2021 State-of-Technology Cases

The Department of Energy’s (DOE) Bioenergy Technologies Office (BETO) aims to develop and deploy technologies to transform renewable biomass resources into commercially viable, high-performance biofuels, bioproducts, and biopower through public and private partnerships. BETO and its national laboratory teams conduct in-depth techno-economic assessments (TEA) of biomass feedstock supply and logistics and conversion technologies to produce biofuels. There are two general types of TEAs: A design case outlines a target case (future projection) for a particular biofuel pathway. It informs R&D priorities by identifying areas in need of improvement, tracks sustainability impact of R&D, and provides goals and benchmarks against which technology progress is assessed. A state of technology (SOT) analysis assesses progress within and across relevant technology areas based on actual results at current experimental scales relative to technical targets and cost goals from design cases, and includes technical, economic, and environmental criteria as available.

09 BIOMASS FUELS↗

DOE OSTI2022

Supply Chain Sustainability Analysis of Renewable Hydrocarbon Fuels via Indirect Liquefaction, Hydrothermal Liquefaction, Combined Algal Processing, and Biochemical Conversion: Update of the 2021 State-of-Technology Cases

09 BIOMASS FUELS↗

DOE OSTI2024

Ink Casting and 3D‐Extrusion Printing of Yb 14 MnSb 11 for High‐Temperature Thermoelectric Material

Abstract Complex shapes are created from Yb 14 MnSb 11 , a high‐temperature thermoelectric Zintl phase, via a two‐step process: i) layer‐by‐layer 3D‐extrusion of ink containing partially‐reacted powders which are ball‐milled from a blend of Yb, MnSb, and Sb powders; ii) heat treatment to synthesize the ternary compound Yb 14 MnSb 11 and densify the extruded powders. A high phase purity for Yb 14 MnSb 11 (83–94%) is achieved in both cast and 3D‐extruded ink specimens via a solid‐state reaction between Yb, MnSb, and Yb 4 Sb 3 during reactive sintering. Pressure‐free sintering at temperatures of 1200–1400 °C densifies the powders to 82% relative density but can also induce the decomposition of the Yb 14 MnSb 11 phase due to Yb sublimation. A process window with optimized sintering temperature and time is identified, achieving both low porosity and high phase purity and reaching a maximum zT = 0.61 at 1000 °C, about half of the maximum zT value for bulk Yb 14 MnSb 11 made via conventional processes (pressure sintering of precursor powders). The present approach – direct ink writing of ball‐milled powders, combined with reactive sintering – is a scalable and affordable method to fabricate thermoelectric legs with intricate 3D shapes, for enhanced performances in high‐temperature thermoelectric applications.

Chen, Ming [Department of Materials Science &amp, ↗

DOE OSTI2020

Understanding of A-site deficiency in layered perovskites: promotion of dual reaction kinetics for water oxidation and oxygen reduction in protonic ceramic electrochemical cells

Protonic ceramic electrochemical cells (PCECs) are promising solid-state energy conversion devices which enable the conversion of energy between electricity and hydrogen at intermediate temperatures. Rapid conversion between chemical and electrical energy via PCEC technology will assist in overcoming grand challenges in energy storage. To achieve highly efficient reversible operation between hydrogen production and electricity generation, boosting water-oxidation and oxygen reduction activities of the oxygen electrode while maintaining the durable operation is one of the early-stage technical opportunities. In this study, an A-site deficient layered perovskite (PrBa 0.8 Ca 0.2 ) 0.95 Co 2 O 6–δ has been developed as an oxygen electrode for a PCEC which presents superior electrochemical performances. The electrolysis current density reached as high as –0.72 A cm –2 at 1.3 V, and a peak power density of 0.540 W cm –2 was obtained at 600 °C in electrolysis and fuel cell mode, respectively. The PCEC with the new electrode shows good durability under practical operating conditions for 160 hours in both operating modes with no observable degradation. Here, the reversibility between the electrolysis and fuel cell mode is also successfully demonstrated.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2022

Platinum Group Metal Catalysts: Supply Chain Deep Dive Assessment

The report “America’s Strategy to Secure the Supply Chain for a Robust Clean Energy Transition” lays out the challenges and opportunities faced by the United States in the energy supply chain as well as the federal government plans to address these challenges and opportunities. It is accompanied by several issue-specific deep dive assessments, including this one, in response to Executive Order 14017 “America’s Supply Chains,” which directs the Secretary of Energy to submit a report on supply chains for the energy sector industrial base. The Executive Order is helping the federal government to build more secure and diverse U.S. supply chains, including energy supply chains. This report focuses on the supply chain for catalysts, specifically platinum group metal (PGM) catalysts, used for decarbonizing energy technologies. Catalysts are substances that increase the rate, conversion, and selectivity of chemical reactions and are used in a variety of applications such as chemical manufacturing, petroleum refining, and catalytic converters. Catalysts containing PGMs (“PGM catalysts”) are particularly useful in widespread industrial applications, including the production of high-volume chemicals such as ammonia, acetic acid, nitric acid, and the refining of crude oil into petroleum products. The PGM metals possess extraordinary properties such as being active oxidation and hydrogenation catalysts; excellent electrical conductors and electrodes; and outstanding adsorbers of oxygen and hydrogen. Within the energy industrial base, PGM catalysts improve the energy and materials efficiency of petroleum refining and chemical industry processes and reduce energy consumption in manufacturing. In addition to their use in catalytic converters, PGM catalysts are important to maximizing the efficiency of emerging decarbonization technologies, specifically in proton exchange membrane (PEM) electrolyzers for green hydrogen production from water and PEM fuel cells for transportation and stationary energy storage. Green hydrogen is expected to play a significant role in decarbonization scenarios.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗