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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 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Safety Review of the Hydrogen Components of a Reference Design of the Wind-H2-Green Steel/Ammonia Project

The Department of Energy Hydrogen Fuel Cell Technology Office and Wind Energy Technologies Office's Wind-H2-Green Steel/Ammonia project is an initiative to demonstrate the feasibility and efficacy of GW-scale integrated energy systems. The team designed reference facilities that utilize wind- and solar-produced hydrogen for industrial steel and ammonia production. This novel concept warranted review of safety codes and standards as they apply to the designs and the identification of codes and standards gaps. This report reviews hydrogen production and storage codes and standards using reference design specifications from a Minnesota steel plant. Requirements, recommendations, and exclusions for the system were identified. Observed gaps included non-specific salt cavern storage requirements, electrolyzer capacity beyond regulated ranges, and lack of requirements for iron reduction via hydrogen. This report will aide future project design efforts and may provide a basis for safety reviews in new designs for industrial facilities with hydrogen production integration.

08 HYDROGEN↗
DOE OSTI2020

Hydrogen Energy: Production and Utilization for a Green Economy [Slides]

The scope of the presentation includes: 1. Introduce high-level aspects of hydrogen fuel systems; and, 2. Showcase research addressing relevant challenges: Proton exchange membrane fuel cells (PEMFCs) (Subzero temperature applications and AFM characterization of catalyst layers); and, Non-precious-metal hydrogen evolution catalysts).

08 HYDROGEN↗
DOE OSTI2024

Gold Nanoparticle Mesoporous Carbon Composite as Catalyst for Hydrogen Evolution Reaction

Increased environmental pollution and the shortage of the current fossil fuel energy supply has increased the demand for eco-friendly energy sources. Hydrogen energy has become a potential solution due to its availability and green combustion byproduct. Hydrogen feedstock materials like sodium borohydride (NaBH 4 ) are promising sources of hydrogen; however, the rate at which the hydrogen is released during its reaction with water is slow and requires a stable catalyst. In this study, gold nanoparticles were deposited onto mesoporous carbon to form a nano-composite catalyst (AuNP-MCM), which was then characterized via transmission electron microscopy (TEM), powder X-ray diffraction (P-XRD), and scanning electron microscopy/energy dispersive X-ray spectroscopy (SEM/EDS). The composite’s catalytic ability in a hydrogen evolution reaction was tested under varying conditions, including NaBH 4 concentration, pH, and temperature, and it showed an activation of energy of 30.0 kJ mol -1 . It was determined that the optimal reaction conditions include high NaBH 4 concentrations, lower pH, and higher temperatures. This catalyst, with its stability and competitively low activation energy, makes it a promising material for hydrogen generation.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Guiding Sustainable Hydrogen Integration: A Capacity Building Approach

The Hydrogen Considerations Tree is designed to empower institutions to explore and consider the costs, benefits, and tradeoffs of hydrogen and its derivatives (e.g. e-fuels and green ammonia) and inform hydrogen strategy, policy and investment decisions within unique contexts around the world. Key topics are organized into a "Considerations Tree," enabling stakeholders to explore technical, regulatory, economic, environmental, social, and other analysis questions systematically and holistically.

HYDROGEN↗
DOE OSTI2025

In-Situ Atomic-Scale Revelation of Amorphous Metallic Iron Formation during Hydrogen-Driven Reduction of Iron Oxides

The transition to hydrogen as a green reductant in metal production is critical for decarbonizing the metallurgical industry, yet atomic-scale mechanisms governing reduction pathways and phase evolution remain unresolved. Using in-situ environmental transmission electron microscopy, we identify a hidden pathway that reveals dynamic formation of amorphous metallic iron (Fe) during the hydrogen-driven reduction of ferrous oxides of Fe 3 O 4 and FeO. Real-time imaging uncovers three coexisting transformation routes: (i) Fe 3 O 4 → FeO, (ii) Fe 3 O 4 → amorphous Fe, and (iii) FeO → amorphous Fe. The resulting amorphous Fe exhibits fluid-like mobility, enabling its rapid aggregation and crystallization into core-shell nanostructures, with a crystalline core enveloped by an amorphous shell. Complementary ab initio molecular dynamics simulations trace the amorphous Fe formation to interfacial strain at the metal/oxide interfaces, where large lattice mismatches destabilize the metal lattice during initial metallization. This interplay between thermodynamics and kinetics governs phase evolution: thermodynamics favors a self-limiting amorphous Fe overlayer, while rapid oxide reduction kinetics drives amorphous overgrowth. Our findings demonstrate that amorphous intermediates bypass rate-limiting crystalline steps, providing mechanistic insights to optimize H 2 -based processes for sustainable steelmaking. In conclusion, these insights bridge the gap between macroscopic process engineering and atomic-scale dynamics, with broader implications for catalysis and nanostructured material synthesis, where oxide reduction pathways critically shape functional phases and microstructures.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Green Methanol via an Integrated Direct Air Capture, CO 2 Electrolyzer, and Hydrogenation Reactor

This project pioneered a groundbreaking reactor design to produce green methanol by harnessing the electrochemical CO 2 reduction reaction (eCO 2 RR), a cornerstone of power-to-fuels technology. The effort integrated three innovative technologies to achieve carbon-neutral methanol production at a target cost of under $\$$800/ton: 1. Direct Air Capture (DAC): Using a cutting-edge sorbent material developed at Holocene, scalable models were developed to integrate captured atmospheric CO₂ into the reactor system. 2. Intermediate-Temperature CO 2 Electrolyzer: Developed by the University of Tennessee (UTK), this electrolyzer utilizes a cost-effective, proton-conducting solid acid electrolyte (CsH 2 PO 4 , CDP) and a mixed-metal oxide cathode. It achieves high faradaic efficiencies (>98%) by effectively suppressing hydrogen evolution at high current densities, converting CO 2 to CO with remarkable selectivity. 3. Catalysis and Reactor Engineering: Oak Ridge National Laboratory (ORNL) contributed world-class expertise in heterogeneous catalysis and reactor design. Their advanced ASPEN modeling drove systems integration and supported techno-economic and life cycle analyses. This effort was further bolstered by partnerships with industry leaders Air Company and Plug Power, who provided critical guidance on scaling, systems engineering, and the integration of water electrolyzers into large-scale operations. During Phase 1, the team focused on modeling and validating a lab-scale reactor demonstrating the feasibility of the integrated approach. Key accomplishments include a 52% increase in current density at 0.8 V while maintaining >98% CO faradaic efficiency, successful 10× scale-up of the electrolyzer with performance within 5% of coin-cell results, best-in-class durability (168-hour test at 0.6 V with 0.14 mA/cm 2 -h degradation), validated TEA confirming the $\$$800/ton methanol target, and completed preliminary LCA showing potential for net-negative GHG emissions under renewable energy scenarios.

10 SYNTHETIC FUELS↗
DOE OSTI2025

Anion-Exchange-Membrane Electrolysis with Alkali-Free Water Feed

Hydrogen is a green and sustainable energy vector that can facilitate the large-scale integration of intermittent renewable energy, renewable fuels for heavy transport, and deep decarbonization of hard-to-abate industries. Anion-exchange-membrane water electrolyzers (AEM-WEs) have several achieved or expected competitive advantages over other electrolysis technologies, including the use of precious metal-free electrocatalysts at both electrodes, fluorine-free hydrocarbon-based ionomeric membranes and bipolar plates based on inexpensive materials. Contrasting the analogous proton-exchange-membrane system (PEM-WE), where pure water is circulated (no support electrolyte), the current generation of AEM-WEs necessitates the circulation of a dilute aqueous alkaline electrolyte for reaching high energy efficiency and durability. For several reasons, including but not limited to lower cost of balance-of-plant, lower operating cost and improved device's lifetime, achieving high cell efficiency and performance using an alkali-free water feed is highly desirable. In this review, we develop and build a foundational understanding of AEM-WEs operating with pure water, as well as discuss the effects of operating with natural water feeds like seawater. After a discussion of the possible advantages of pure-water-fed AEM-WEs, we cover the thermodynamic and kinetic processes involved in AEM-WE, followed by a detailed review of materials and components and their integration in the device. We highlight the influence of electrolyte composition and alkali/electrolyte-free feed on the membrane-electrode assembly, ionomers, electrocatalysts, porous transport layer, bipolar plates and operating configuration. We provide evidence for how the pure water feed engenders several issues related to the degradation of device components and propose mitigation strategies.

Electrodes↗
DOE OSTI2025

Migratory Strategy is a Key Factor Driving Interactions at Wind Energy Facilities in At-Risk North American Bats

Animal migration remains poorly understood for many organisms, impeding understanding of movement dynamics and limiting conservation actions. We develop a framework that scales from movements of individuals to the dynamics of continental migration using data synthesis of endogenous markers, which we apply to three North American bat species with unexplained high rates of fatalities at wind energy facilities. The two species experiencing the highest fatality rates exhibit a "pell-mell" migration strategy in which individuals move from summer habitats in multiple directions, both to higher and lower latitudes, during autumn. We link movements to higher latitudes to encounters with wind energy facilities and report that the timing of pell-mell migration strongly overlaps with that of fatalities at the continental level. These findings support the hypothesis that migration distance and strategy are drivers of increased interactions with wind energy facilities, highlighting the significance of understanding migratory strategy to achieve conservation goals.

08 HYDROGEN↗
DOE OSTI2020

A Beehive Inspired Hydrogen Photocatalytic Device Integrating a Carbo–Benzene Triptych Material for Efficient Solar Photo–Reduction of Seawater

The dream to produce green, clean and sustainable hydrogen from earth-abundant and free resources such as seawater and sunlight is highly motivating because of the interest for desirable economical and societal applications in energy. However, it remains challenging to develop an efficient and unassisted photocatalytic device to split seawater molecules with just sunlight without any external bias. For the first time, a such novel hierarchical material has been developed, based on thin film technology that integrates TiO 2 semiconductor layers, embedded gold nanoparticles and a photosensitive carbo-benzene layer. The design of the triptych device placing the photocatalyst in be-to-be increases the photoactive surface area by a factor 2. Its stability (>120 successive hours of hydrogen production and >5 days in a day/night representative alternation) and efficiency (STH 0.06%) are measured in NaCl-salted water. Here, the chloride ions act as hole scavengers and induce an increase of pH increasing in turn the sun-driven hydrogen production rate.

42 ENGINEERING↗
DOE OSTI2023

Synthesis of Platinum Nanoparticles Supported on Fused Nanosized Carbon Spheres Derived from Sustainable Source for Application in a Hydrogen Generation Reaction

The dwindling supply of fossil fuels has prompted the search for an alternative energy source that could effectively replace them. Potential renewable energy sources such as solar, wind, tidal, and geothermal are all promising but each has its own drawbacks. Hydrogen gas on the other hand can be combusted to produce energy with only water as a byproduct and can be steadily generated via the aqueous media hydrolysis reaction of Sodium Borohydride (NaBH 4 ). This study successfully synthesized fused carbon spheres derived from sugar and decorated them with platinum nanoparticles to form a novel composite material (PtFCS) for catalyzing this reaction. The platinum nanoparticles were produced by reducing chloroplatinic acid in a solution with sodium borohydride and using sodium citrate as a capping agent for the nanoparticles. Transmission electron microscopy (TEM), Energy-dispersive X-ray spectroscopy (EDS), Fourier-transform infrared spectroscopy (FTIR), and X-ray diffraction (XRD) were used to characterize and determine the size and shape of the Pt nanoparticles (PtNPs) and fused carbon spheres. TEM was able to determine the average size of the fused carbon spheres to be 200 nm and the average size for the PtNPs to be 2–3 nm. The PtFCS composite was tested for its ability to catalyze the hydrolysis of NaBH 4 under various reaction conditions including various solution pH, various temperatures, and various dosages of sodium borohydride. The catalyst was found to perform the best under acidic solution conditions (pH 6), producing hydrogen at a rate of 0.0438 mL/mg cat ·min. The catalyst was determined to have an activation energy of 53.0 kJ/mol and could be used multiple times in succession with no loss in the volume of hydrogen produced. This sugar-derived composite catalyst shows promise and could be implemented as a sustainable catalyst for the generation of hydrogen fuel.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Experimental determination of hydrogen isotopic equilibrium in the system H 2 O (l) -H 2(g) from 3 to 90 °C

Molecular hydrogen (H 2 ) is found in a variety of settings on and in the Earth from low-temperature sediments to hydrothermal vents, and is actively being considered as an energy resource for the transition to a green energy future. The hydrogen isotopic composition of H 2 , given as D/H ratios or δD, varies in nature by hundreds of per mil from ∼−800 ‰ in hydrothermal and sedimentary systems to ∼+450 ‰ in the stratosphere. This range reflects a variety of processes, including kinetic isotope effects associated with formation and destruction and equilibration with water, the latter proceeding at fast (order year) timescales at low temperatures (<100 °C). At isotopic equilibrium, the D/H fractionation factor between liquid water and hydrogen ( D α H2O(l)-H2(g) ) is a function of temperature and can thus be used as a geothermometer for H 2 formation or re-equilibration temperatures. Multiple studies have produced theoretical calculations for hydrogen isotopic equilibrium between H 2 and water vapor. However, only three published experimental calibrations used in geochemistry exist for the H 2 O-H 2 system: two between 51 and 742 °C for H 2 O (g) -H 2(g) (Suess, 1949, Cerrai et al., 1954), and one in the H 2 O (l) -H 2(g) system for temperatures <100 °C (Rolston et al., 1976). Despite these calibrations existing, there is uncertainty on their accuracy at low temperatures (<100 °C; e.g., Horibe and Craig, 1995).

08 HYDROGEN↗
DOE OSTI2022

A nuclear-hydrogen hybrid energy system with large-scale storage: A study in optimal dispatch and economic performance in a real-world market

Here a study in optimal dispatch and economic analysis of a novel nuclear hybrid energy system (NHES) with large-scale hydrogen storage and a novel control scheme is conducted. The control scheme makes charge and discharge decisions by using the real-time electricity price relative to the historical price distribution. The pricing data is taken from the ERCOT Houston and West load zones with different price oscillations. Six case control studies with different levels of aggressiveness were chosen for each load zone for a total of 12 case studies. It is found that in a high price volatility load zone, a more aggressive control strategy maximizes revenue, while in a less oscillatory load zone, a moderate control strategy performs better. The NHES can store energy when the price is low and sell additional electricity when the price is high, as well as participate in the ancillary services market. Due to these advantages, the NHES can generate 10–40 million USD more revenue annually than a stand-alone nuclear plant. Due to higher costs, the NHES has a higher LCOE (81.36 USD/MWh) than a stand-alone plant (68.66 USD/MWh); however, the LCOE of the NHES is still comparable to other new forms of electricity generation. It is found that both the NHES and the stand-alone plant are not economical in the existing electricity market. Due to the extra revenue generated, the hybrid system has a positive annual cashflow whereas the stand-alone plant does not. It is found that the hybrid plant needs less cost subsidy than a stand-alone plant to become economical.

08 HYDROGEN↗
DOE OSTI2021

Kinetics of furfural electrochemical hydrogenation and hydrogenolysis in acidic media on copper

Electrochemical processes can be implemented for the valorization of biomass-derived species such as furfural to generate fine chemicals and fuels. The electrochemical hydrogenation and hydrogenolysis (ECH) of furfural (FF) can produce furfuryl alcohol (FA) and 2-methylfuran (MF) as the major products over Cu catalysts in acidic conditions. The production of these species are in competition and the kinetics of these reactions should be studied so that the product distribution can be better controlled. In this work, the competing kinetics of furfural ECH to furfuryl alcohol and 2-methylfuran were studied on Cu in acidic media by using the applied cathodic potential, temperature, and initial concentration of furfural as probes. Furthermore, an increased temperature of the system was shown to promote the MF production in the range tested (15 °C and 45 °C), however the production of FA was decreased when the temperature was increased from 35 °C to 45 °C, due to significant promotion of side reactions. By varying the concentration of FF used in bulk electrolysis, we saw that the rates of reaction to FA and MF shift from positive order to zero order, suggesting a Langmuir–Hinshelwood or Eley–Rideal mechanism at –0.56 V vs. RHE and 25 °C. An analysis of the reaction mechanisms showed that a non-competitive Langmuir–Hinshelwood mechanism is likely occurring. In addition, we suggest the likely rate limiting steps based on the mechanisms are the first hydrogenation step of FF to C 4 H 3 O–CH 2 O to form FA, and the C–O cleavage of the C 4 H 3 O–CHOH intermediate to form MF.

09 BIOMASS FUELS↗
DOE OSTI2024

Chemical and electrochemical pathways to low-carbon iron and steel

Currently, the iron and steel industry is responsible for 7% of global CO 2 emissions. In this review, we summarize the operational principles of current emissions-intensive steelmaking technologies and review emerging low- and zero-carbon technologies that could substantially reduce emissions. Current technologies that are discussed include blast furnaces, electric arc furnaces, and smelting. Promising low-carbon routes include use of alternative reductants for ore processing (hydrogen direct reduction, hydrogen plasma-smelting, hydrogen smelting, and ammonia-based reduction), electrolytic iron production (with aqueous and molten oxide electrolytes) and biocarbon-based electric arc furnace operation. Advantages of each approach are presented, and remaining research hurdles are identified.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Sub-volt conversion of activated biochar and water for H 2 production near equilibrium via biochar-assisted water electrolysis

Sluggish water oxidation reactions limit water electrolysis for H 2 production, which can be alleviated by the use of carbon-based ma- terials like agricultural wastes as reducing agents. Biochar from such biomass can reduce equilibrium cell potentials at standard condi- tions from 1.23 V to 0.21 V by avoiding direct water splitting at the anode. However, some challenges hinder biochar oxidation, including poor biochar binding, electrode caking, and surface passivation. We find that enhanced C/O ratio, crystallinity, and negative zeta potential improve biochar oxidation kinetics at mod- erate temperatures. Smaller particle sizes and better mixing pre- vent electrode caking, enhancing biochar stability. Here, we report sub-volt biochar-coupled H 2 production, often referred to as a bio- char-assisted water electrolysis (BAWE), yielding 250 mA/g cat H 2 current at 100% Faradaic efficiency. Over 1 mA current was observed at a near-equilibrium cell potential of 0.2 V cell potential. Using a single-junction solar cell-powered BAWE, 15 mA H 2 is generated at 1 Sun, resulting in 4.8% solar-to-hydrogen efficiency, equivalent to 35% when the energy of H 2 relative to H 2 O (without biochar) is assumed.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗