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At least 253 records · Page 14

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DOE OSTI2019

Low-Energy, Low-Cost Ethylene Production by Low-Temperature Oxidative Coupling of Methane

Ethylene, one of the highest volume production chemicals in the U.S. and globally, is an essential chemical building block that is used to manufacture countless products, from packaging to antifreeze to tires. Most ethylene is produced via a process called steam cracking, where the feedstock (mostly ethane, sometimes naphtha or propane) is heated to high temperatures over a catalyst. The naphtha feedstock typically comes from petroleum refineries, while ethane is becoming increasingly used as a feedstock in the U.S. due to the rise in domestic natural gas production from shale resources. However, steam cracking is energy intensive and occurs in large- scale facilities. Low-temperature oxidative coupling of methane (LT-OCM) is an alternative ethylene production method that converts methane (natural gas) and optionally ethane to ethylene in a single-step, energy-producing conversion system using an innovative process. While OCM has been studied for over 30 years due to its potential to reduce ethylene production cost, past efforts did not result in a viable catalyst with performance needed for commercialization. These catalysts, while at times achieving promising yield and selectivity, were hampered by very high operating temperatures, low activities, and short lifetimes on the order of hours to days. Recognizing this, Siluria applied a combination of new innovations in catalyst development and a thorough definition and understanding of the problem to develop unique catalysts that enable commercialization of OCM. The OCM catalysts operate at significantly lower temperature (several hundreds of degrees lower) and practical operating pressures (5-10 atmospheres), have high activities and standard lifetimes of years under said conditions. In addition, the simple process provides excellent scalability and flexibility, especially when compared to today’s mega-scale steam crackers, thus enabling small- volume “distributed scale” reactors for on-demand ethylene production for applications such as on-site conversion of ethylene to high value polymer derivatives.

02 PETROLEUM↗

DOE OSTI2017

High temperature efficient, stable Si wafer-based selective solar absorbers

Creating selective solar absorber systems using simple, stable structures capable of surviving high temperatures is essential for widespread adoption of efficient, high-temperature solar thermal technologies. In this study, semiconductor-metal tandem selective solar absorbers based on commercially available Si wafers are fabricated and measured at different high temperatures. High selectivity of the devices is obtained at temperature as high as 490 °C, and the structure is demonstrated to be mechanically and thermally stable even at slightly higher temperatures (up to 535 °C). Increased free carrier absorption and lattice absorption of Si are observed at elevated temperatures, which raise thermal re-radiation dramatically. In order to mitigate this effect, a thin Si film-based selective absorber has also been computationally designed and optimized, which is predicted to exhibit even higher thermal transfer efficiency (60–70%) at a wide range of solar concentrations (20–100 suns). In conclusion, the simple structure combined with the mechanical and thermal stability enables the low-cost Si substrate-based selective solar absorber to find wide applications in solar thermal energy conversion systems.

14 SOLAR ENERGY↗

DOE OSTI2025

Low Carbon Intensity Formic Acid Chemical Synthesis from Direct Air Captured CO 2 Utilizing Chemical Plant Waste Heat - Final Technical Report

The primary objective of Low Carbon Intensity Formic Acid Chemical Synthesis from Direct Air Captured CO 2 Utilizing Chemical Plant Waste Heat (ChemFADAC) is to execute and complete a FEED study for an integrated direct air capture (DAC) and carbon conversion system (together, the DACUS system) co-located at a Nutrien nitric acid production facility in Kennewick, WA capable of capturing and converting a minimum of 5,000 MT/year net atmospheric CO 2 to low carbon intensity formic acid (FA) using industrial waste heat and renewable electricity. The goal will be achieved through the completion of four objectives using a collaborative approach with community stakeholders. Objective 1. Conduct a FEED study and Class 3 project cost estimate for the proposed DACUS system that maximizes use of thermal energy from the Nutrien KFO host site to produce low carbon intensity FA from atmospheric CO 2 . Objective 2. Perform a cradle-to-gate life-cycle analysis of the DACUS system to determine the environmental sustainability and carbon intensity (CI) of the proposed project and product from the results of the FEED study. Objective 3. Perform a business case analysis from results of the LCA, FEED study and cost estimate to justify investment to build the DACUS project at the Nutrien KFO site. Objective 4. Quantify how deployment of the proposed technology will promote and prepare a ready workforce for clean energy and manufacturing jobs and coordinate with community stakeholders to perform an environmental justice and a preliminary economic revitalization and job creation outcomes analysis.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

Relief Zones Enhance the Durability of Ultrathin Membranes in Electrochemical Conversion Devices

Premature failures in electrochemical conversion systems often result when membrane electrode assemblies (MEAs) use ultrathin (≤15 μm-thick) polymer electrolyte membranes, susceptible to mechanical degradation from stress concentrations arising from device-level integration. Herein, relief zones were developed to mitigate mechanical degradation by alleviating excess and nonuniform compression across active areas. Relief zones, created through ablation of carbonaceous diffusion media, enable seamless adaptation across MEA dimensions without need for hardware modifications. Demonstrated using fuel cells as a case study, accelerated stress tests revealed a 6-fold lifetime improvement (∼1500 h) compared to conventional edge-protected MEAs, decoupling device-level engineering effects from material limitations.

accelerated stress test↗

DOE OSTI2015

In service inspection and repair of sodium cooled ASTRID prototype

In the frame of the large R and D work which is performed for the future ASTRID sodium cooled prototype, In Service Inspection and Repair (ISI and R) has been identified as a major issue to be taken into account in order to enlarge the plant safety, to consolidate its availability and to protect the associated investment. After the first part of pre-conceptual design phase (2008-2012), the running second part of pre-conceptual phase (2013-2015) allows to increase the ISI and R tool ability for immersed sodium structures of ASTRID, at about 200 deg. C, on the basis of consolidated specifications and thanks to their qualification through more and more realistic laboratory tests and simulation with CIVA code. ISI and R items are being developed and qualified during a pluri-annual program which mainly deals with the reactor block structures, the primary components and circuit, and the Power Conversion System. It ensures a strong connection between the reactor designers and inspection specialists, as the optimization of inspectability and repairability is looked at: this already induced specific rules for design, in order to shorten and ease the ISI and R operations, which have been merged into RCC-MRx rules. In the frame of increasing technology readiness level with corresponding performance demonstration, this paper presents R and D dealing with the ISI and R items: it highlights the sensor development (both ultrasonic and electromagnetic concepts, compatible with sodium at 200 deg. C), then their applications for ASTRID structure control (under sodium telemetry, imaging and NDE). Activity for repair is also presented (a single laser tool for sodium sweeping, machining and welding), and finally the effort for associated robotic (generic program for ASTRID applications, specific technological tools for sodium medium, tight immersed bell). The main results of testing and simulation are given for telemetry, vision, NDE applications, laser process repair and under sodium sealing. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2023

Hot carrier extraction from 2D semiconductor photoelectrodes

Hot carrier-based energy conversion systems could double the efficiency of conventional solar energy technology or drive photochemical reactions that would not be possible using fully thermalized, “cool” carriers, but current strategies require expensive multijunction architectures. Using an unprecedented combination of photoelectrochemical and in situ transient absorption spectroscopy measurements, we demonstrate ultrafast (<50 fs) hot exciton and free carrier extraction under applied bias in a proof-of-concept photoelectrochemical solar cell made from earth-abundant and potentially inexpensive monolayer (ML) MoS 2 . Our approach facilitates ultrathin 7 Å charge transport distances over 1 cm 2 areas by intimately coupling ML-MoS 2 to an electron-selective solid contact and a hole-selective electrolyte contact. Our theoretical investigations of the spatial distribution of exciton states suggest greater electronic coupling between hot exciton states located on peripheral S atoms and neighboring contacts likely facilitates ultrafast charge transfer. Our work delineates future two-dimensional (2D) semiconductor design strategies for practical implementation in ultrathin photovoltaic and solar fuel applications.

2D materials↗

DOE OSTI2026

A Relief Zone Architecture for Enhanced Durability of Ultrathin Membranes in Electrochemical Conversion Devices

Premature cell failures in electrochemical conversion systems often result when membrane electrode assemblies (MEAs) are prepared with ultra-thin (= 15 micrometer-thick) polymer electrolyte membranes (PEMs). These high-performance PEMs are susceptible to mechanical degradation from stress concentrations arising from component and device-level integration. Herein, a relief zone was developed to mitigate mechanical degradation by alleviating excess and non-uniform compression across the active area. Relief zones, created through the ablation of carbonaceous diffusion material achieves a seamless adaptation across a range of MEA dimensions and electrochemical applications without need for costly hardware modifications. This concept was demonstrated using fuel cells as a case study. Accelerated stress test (AST) validations yielded a 6-fold improvement for MEAs prepared with relief zones (i.e., lifetime approximately 1500 h) compared to those fabricated using conventional edge-protection techniques, showcasing the utility of this technique in decoupling integration and device-level engineering effects from intrinsic material limitations for durable electrochemical devices.

14 SOLAR ENERGY↗

DOE OSTI2024

Inverse Consequences of the SnO 2 Protection Layers on Pt/C Catalysts in Proton-Exchange Membrane Fuel Cells

Proton-exchange membrane fuel cells (PEMFCs) are promising energy-conversion systems, offering an appealing blend of high energy efficiency and low environmental impact. However, carbon corrosion of PEMFCs is known to significantly degrade their performance, remaining a critical challenge to overcome. In this study, we applied a Nb-doped SnO 2 (Nb-SnO 2 ) nanoparticle coating on Pt/C catalysts as a protective layer, with the Sn/C ratio in the precursors varying from 0.25:1 to 2.0:1. Contradictory behaviors of the coated Pt/C catalysts were observed at different Sn/C ratios. The Sn/C = 1.0 sample exhibited improved electrochemically active surface area retention after 500 cycles of accelerated stress testing (AST) but with more significant polarization and resistance increase observed in the polarization curves. In addition, agglomeration of Nb-SnO 2 particles was observed at a higher Sn/C ratio in the AST of a membrane electrode assembly, with less shrinkage of the total thickness of the Nb-SnO 2 -coated Pt/C electrode. We speculate that formation of Nb-SnO 2 agglomerates occurs once the protective layer is broken down or the unprotected carbon surface is corroded and that these Nb-SnO 2 agglomerates increase the tortuosity of the electron pathways and significantly increase the cell polarization.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2011

Influence of Hold Time on Creep-Fatigue Behavior of an Advanced Austenitic Alloy

An advanced austenitic alloy, HT-UPS (high temperature-ultrafine precipitate strengthened), is a candidate material for the structural components of fast reactors and energy-conversion systems. HT-UPS provides improved creep resistance through a composition based on 316 stainless steel (SS) with additions of Ti and Nb to form nano-scale MC precipitates in the austenitic matrix. The low cycle fatigue and creep-fatigue behavior of a HT-UPS alloy has been investigated at 650 C, 1.0% total strain, and an R ratio of -1 with hold times as long as 9000 sec at peak tensile strain. The cyclic deformation response of HT-UPS is compared to that of 316 SS. The cycles to failure are similar, despite differences in peak stress profiles and the deformed microstructures. Cracking in both alloys is transgranular (initiation and propagation) in the case of continuous cycle fatigue, while the primary cracks also propagate transgranularly during creep-fatigue cycling. Internal grain boundary damage as a result of the tensile hold is present in the form of fine cracks for hold times of 3600 sec and longer and substantially more internal cracks are visible in 316 SS than HT-UPS. The dislocation substructures observed in the deformed material are different. An equiaxed cellular structure is observed in 316 SS, whereas tangles of dislocations are present at the nanoscale MC precipitates in HT-UPS and no cellular substructure is observed.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2017

Photophysical properties of [Ru(2,2′-bipyridine){sub 3}]{sup 2+} encapsulated within the Uio-66 zirconium based metal organic framework

The ability to encapsulate photo-active guest molecules within the pores of metal organic frameworks (MOFs) affords the opportunity to develop robust photocatalysts as well as solar energy conversion systems. An important criteria for such systems is stability of the new materials towards moisture, high temperatures, etc which preclude the use of many MOF frameworks. Here, the ability to encapsulate [Ru(II)(2,2′-bipyridine){sub 3}]{sup 2+}([Ru(bpy){sub 3}]{sup 2+}) into the cavities of the zirconium based MOF Uio-66 as well as the photophysical properties of the complex are reported. The X-ray powder diffraction data of the orange Uio-66 powder are consistent with the formation of Uio-66 in the presence of [Ru(bpy){sub 3}]{sup 2+}. The steady state emission exhibits a significant bathochromic shift from 603 nm in ethanol to 610 nm in Uio-66. The corresponding emission decay of the encapsulated [Ru(bpy){sub 3}]{sup 2+} complex is biexponential with a fast component of 128 ns and a slower component of 1176 ns (20 deg C). The slow component is consistent with encapsulation of [Ru(bpy){sub 3}]{sup 2+} into cavities with restricted volume that prevents the population of a triplet ligand field transition that is anti-bonding with respect to the Ru-N bonds. The origin of the fast component is unclear but may involve interactions of the [Ru(bpy){sub 3}]{sup 2+} encapsulated within large cavities formed through missing ligand defect sites within the Uio-66 materials. Co-encapsulated quenchers contained within these larger cavities gives rise to the reduced lifetimes of the [Ru(bpy){sub 3}]{sup 2+} complexes. - Graphical abstract: One-pot synthesis of Ru(II)tris(2,2-bipyridine)@Uio-66 (left) and the effects of encapsulation on the excited state energy levels and decay pathways of the Ru(II)tris(2,2-bipyridine) complex (right).

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2012

Preliminary studies on the heat exchanger option for S-CO{sub 2} power conversion cycle coupled to water cooled SMR

For more than a half century, the steam Rankine cycle had been the major power conversion cycle for a nuclear power plant. However, as the interest on the next generation reactors grows, a variety of alternative power conversion systems have been studied. Among them, the S-CO{sub 2} cycle (Supercritical carbon dioxide Brayton cycle) is considered as a promising candidate due to several benefits such as 1) Relatively high thermal efficiency at relatively low turbine inlet temperature, 2) High efficiency with simple lay-out 3) Compactness of turbo-machineries. 4) Compactness of total cycle combined with PCHE (Printed Circuit Heat Exchanger). According to the conventional classification of heat exchangers (HE), there are three kind of HE, 1) Tubular HEs, 2) Plate-type HEs, 3) Extended surface HEs. So far, the researcher has mostly assumed PCHE type HE for the S-CO{sub 2} cycle due to its compactness with reasonably low pressure drop. However, PCHE is currently one of the most expensive components in the cycle, which can have a negative effect on the economics of the cycle. Therefore, an alternative for the HE should be seriously investigated. By comparing the operating condition (pressure and temperature) there are three kind of HE in the S-CO{sub 2} cycle, 1) IHX (Intermediate Heat exchanger) 2) Recuperator and 3) Pre-cooler. In each heat exchanger, hot side and cold side coolants are different, i.e. reactor coolant to S-CO{sub 2} (IHX), S-CO{sub 2} to S-CO{sub 2}(Recuperator), S-CO{sub 2} to water (Pre-cooler). By considering all the attributes mentioned above, all existing types of heat exchangers are compared to find a possible alternative to PCHE. The comparing factors are 1) Size(volume), 2) Cost. Plate fin type HEs are considered to be the most competitive heat exchanger regarding the size and the cost after some improvements on the design limit are made. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2021

Enhancing Oxygen Reduction Activity and Cr Tolerance of Solid Oxide Fuel Cell Cathodes by a Multiphase Catalyst Coating

Intermediate temperature solid oxide fuel cells (IT-SOFCs) are cost-effective and efficient energy conversion systems. Here, the sluggish oxygen reduction reaction (ORR) and the degradation of cathodes are critical challenges to the commercialization of IT-SOFCs. Here, a highly efficient multiphase (MP) catalyst coating, consisting of Ba 1–x Co 0.7 Fe 0.2 Nb 0.1 O 3–δ (BCFN) and BaCO 3 , to enhance the ORR activity and durability of the state-of-the-art lanthanum strontium cobalt ferrite (La 0.6 Sr 0.4 Co 0.2 Fe 0.8 O 3–δ , LSCF) cathode is reported. The conformal MP catalyst-coated LSCF cathode shows a polarization resistance (R p ) of 0.048 Ω cm 2 at 650 °C, about one order of magnitude smaller than that of the bare LSCF. In an accelerated Cr-poisoning test, the degradation rate of the catalyst-coated LSCF electrode is 10 –3 Ω cm 2 h –1 (0.59% h –1 ) over 200 h, only one fifth of the degradation rate of the bare LSCF electrode at 750 °C. In addition, anode-supported single cells with the MP catalyst-coated LSCF cathode show a dramatically enhanced peak power density (1.4 W cm –2 vs 0.67 W cm –2 at 750 °C) and increased durability against Cr and H 2 O. Both experimental results and density functional theory-based calculations indicate that the BCFN phase improves the ORR activity while the BaCO 3 phase enhances the stability of the LSCF cathode.

solid oxide fuel cells↗

DOE OSTI2025

Enhancing Metal‐Support Interactions of Ru Catalysts via Relaxation of Oxygen Vacancies for Hydrogen Production

The stability of Ru-based catalysts under harsh electrochemical conditions is a critical challenge limiting their practical application in energy conversion systems. In this study, Ru catalysts supported on ZrO 2-x , CeO 2-x , and ZrCeO 2-x are synthesized via pyrolysis of metal-organic frameworks (MOFs) and systematically evaluated to elucidate the role of support interactions on catalytic performance and durability. Advanced characterization techniques, including HR-TEM, XRD, XPS, and EXAFS, revealed that Ru-ZrCeO 2-x exhibited superior structural stability compared to Ru-ZrO 2-x and Ru-CeO 2-x , particularly under high-potential sweep (HPS) conditions. The incorporation of Ce into ZrO 2-x is shown to stabilize oxygen vacancies and enhance the interaction between Ru catalyst and the support, thereby mitigating catalyst degradation. Density functional theory (DFT) calculations further confirmed that Ce doping decreases formation energy of the oxygen vacancy, providing a thermodynamically favorable environment for Ru stabilization. This work demonstrates the promise of ZrCeO 2-x as a robust support material for Ru-based catalysts, advancing their potential for durable and efficient energy applications.

hydrogen evolution reaction↗

DOE OSTI2023

Single‐Step Deformation Processing of Ultrathin Lithium Foil and Strip

Abstract Next‐generation, high‐efficiency energy storage and conversion systems require development of lithium metal batteries. But the high cost of production and constraints on thickness of lithium (anode) foils continue to limit adoption for integration into battery cell architectures. Here, a novel lithium anode manufacturing solution is demonstrated – single‐step production of ultrathin gauge foil formats directly from solid ingot. Hybrid cutting‐based deformation processes, involving large plastic strains and strain rates, produce foil to sub‐10 µm thickness, with surface quality even superior to present Li anode processing routes. Energy analysis shows the single‐stage processing is ≈50% more efficient than conventional processing by extrusion‐rolling. Through in situ force measurements and high‐speed imaging of the cutting it also characterize – for the first time – the flow stress of Li to strain rates of 800 sec −1 , revealing a power‐law relationship. The results present a paradigm shift in manufacturing and integration of solid lithium anodes for energy applications.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2018

Fabrication of Sub-Micrometer-Thick Solid Electrolyte Membranes of β-Li 3 PS 4 via Tiled Assembly of Nanoscale, Plate-Like Building Blocks

Here solid electrolytes represent a critical component in future batteries that provide higher energy and power densities than the current lithium-ion batteries. The potential of using ultrathin films is among the best merits of solid electrolytes for considerably reducing the weight and volume of each battery unit, thereby significantly enhancing the energy density. However, it is challenging to fabricate ultrathin membranes of solid electrolytes using the conventional techniques. Here, a new strategy is reported for fabricating sub-micrometer-thick membranes of β-Li 3 PS 4 solid electrolytes via tiled assembly of shape-controlled, nanoscale building blocks. This strategy relies on facile, low-cost, solution-based chemistry to create membranes with tunable thicknesses. The ultrathin membranes of β-Li 3 PS 4 show desirable ionic conductivity and necessary compatibility with metallic lithium anodes. The results of this study also highlight a viable strategy for creating ultrathin, dense solid electrolytes with high ionic conductivities for the next-generation energy storage and conversion systems.

25 ENERGY STORAGE↗

DOE OSTI2018

Rational Design of Hierarchically Open-Porous Spherical Hybrid Architectures for Lithium Ion Batteries

Controlling the internal microstructure and overall morphology of building blocks used to form hybrid materials is crucial for the realization of deterministically designed architectures with desirable properties. Here, we demonstrate an integrative spray-frozen (SF) assembly for forming hierarchically structured open-porous microspheres (hpMSs) composed of Fe 3 O 4 and reduced graphene oxide (rGO). The SF process drives the formation of a radially-aligned microstructure within the sprayed colloidal droplets and also controls the overall microsphere morphology. The Fe 3 O 4 /rGO hpMSs contain interconnected open-pores and spherical morphology, which, when used as a lithium-ion battery anode, enables then to provide gravimetric and volumetric capacities of 1069.7 mAh g -1 and 686.7 mAh cm -3 , much greater than those of samples with similar composition and different morphologies. The hpMSs have good rate and cycling performances, retaining 78.5% from 100 to 1000 mA g -1 and 74.6% over 300 cycles. Using in-situ synchrotron x-ray absorption spectroscopy, the reaction pathway and phase evolution of the hpMSs are monitored observing the very small domain size and highly disordered nature of Fe x O y . Here, the reduced capacity fading relative to other conversion systems is due to the good electrical contact between the pulverized Fe x O y particles and rGO, the overall structural integrity of the hpMSs, and interconnected openporosity.

25 ENERGY STORAGE↗

DOE OSTI2025

Impact of Advances in Anion Exchange Membranes and Ionomers on Alkaline Fuel Cells

Abstract The operation of low‐temperature electrochemical energy conversion systems (fuel cells, electrolyzers) at high pH values is of perennial interest due to the possibility of moving away from expensive platinum group metal catalysts and reducing cost. Historically, the anion exchange membranes (AEMs) and ionomers have been hampered by performance (ionic conductivity, mechanical strength) and chemical stability issues. In this context, select developments over the past decade in alternate AEM chemistries, water management methods, and production of membrane electrode assemblies (MEAs) that have enabled a significant leap in performance of alkaline fuel cells are examined. These developments are linked to performance improvements in alkaline H 2 /O 2 fuel cells and also consider developments in alkaline fuel cells using nitrogen‐containing fuels (ammonia, hydrazine), carbon‐containing fuels (alcohols, glycols), and boron‐containing fuels (sodium borohydride, ammonia borane). Finally, current challenges and bottlenecks are identified, and potential solutions are proposed.

Chemistry↗

DOE OSTI2015

When small is big: the role of impurities in electrocatalysis.

Improvements in the fundamental understanding of electrocatalysis have started to revolutionize the development of electrochemical interfaces for the efficient conversion of chemical energy into electricity, as well as for the utilization of electrons to produce new chemicals that then can be re-used in energy conversion systems. Here, some facets of the role of trace level of impurities (from 10-7 to 10-6 M) in electrocatalysis of the oxygen reduction reaction, hydrogen oxidation and evolution reactions, and CO oxidation reactions are explored on well-characterized platinum single crystal surfaces and high surface area materials in alkaline and acidic environments. Of particular interest is the effect of anions (e.g., Cl-, NO3-) and cations (i.e., Cu2+) present in the supporting electrolytes as well as surface defects (i.e., ad-islands) that are present on metal surfaces. The examples presented are chosen to demonstrate that a small level of impurities may play a crucial role in governing the reactivity of electrochemical interfaces.

Strmcnik, Dusan↗