Search NASA⌕ Search

SEARCH · Search NASA

Results for “CATALYST”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Effects of Ink Formulation on the Structure and Performance of PGM-Free Catalyst Layer in PEMFCs

Platinum group metal (PGM) catalysts are the major electrocatalysts for oxygen reduction reaction (ORR) in the polymer electrolyte membrane fuel cells (PEMFCs). The cost becomes unaffordable if the PEMFC is in massive application. The PGM-Free catalyst shows very promising activity in rotation disk electrode (RDE) testing. The half-wave potential could reach 0.91 V versus standard hydrogen electrode (SHE). However, in a membrane electrode assembly (MEA), the performance of PGM-Free catalysts is not good enough to replace the PGM catalysts. Since the PGM-free catalysts are so different from the PGM catalysts in terms of catalytic activity, stability, surface conditions, particle size, etc., the fabrication of PGM-Free catalyst MEA cannot simply copy the method of making PGM MEA. Here we proposed a novel method of fabricating PGM-Free catalyst MEA, so that the intrinsic catalyst activity from RDE can be translated into MEA performance. The method is based on the catalyst coated membrane (CCM) method using optimized ionomer to carbon (I/C) ratio and solvent mixture of catalyst ink. Using this method, the PGM-free catalyst MEA achieved the current density 44.9 mA cm -2 at 0.9 V iR-free in H 2 /O 2 and 150 mA cm -2 at 0.8 V in H 2 /air, which surpassed the performance targets of US Department of Energy (DOE)for PGM-Free catalyst MEA. The property (solvent composition, dispersion of catalyst and ionomer in an ink), structure (pore structure) and the MEA performance have been characterized using, mercury intrusion porosimetry (MIP), MEA testing. A property-structure-performance relationship has been established.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

Understanding of catalytic transformation of shale gas and development of catalysts with high activity and selectivity through experimental exploration and theoretical simulation

Catalysis on transition metal oxides is equivalently important in contrast to that on metal catalysts in chemical and energy transformations. Understanding of catalytic reactions on early transition metal oxide catalysts is fundamentally intriguing and of great practical interest in efficient production of chemical and fuel feedstocks. Fundamental understanding of catalysis on transition metal oxide-based catalysts has been lagged behind catalysis on metals due to the complexity of chemistry and structure of surface and bulk of oxide catalysts and their structural flexibility in reactive environment at high temperatures. The funded DOE project explored surface chemistry of a few reducible oxides including CeO 2 - based, Co 3 O 4 -based, and CoO-based which are significant for heterogeneous catalysis. Through in-situ studies using ambient pressure X-ray photoelectron spectroscopy and high pressure scanning tunneling microscopy, we revealed phase transformation, the accompanying changes of surface chemistry and structure, and uncovered their correlations with catalytic activity and selectivity in catalytic reactions including reduction of NO with CO, water-gas shift, and chemical transformations of methane to methanol and acetic acid under mild conditions. Driven by the following two facts, we propose to pursue fundamental understanding of oxidative dehydrogenation of ethane and oxidative coupling of methane on oxide catalysts through both in-situ studies of catalyst surfaces during catalysis and computational studies in the renewal proposal. One driving force is the significance of oxidative dehydrogenation of ethane and oxidative coupling of methane for utilization of earth-abundant, relatively inexpensive energy resource and the urgent needs of efficient chemical processes to generate ethylene from shale gas. The other is that exploration of surface chemistry of oxide catalysts during catalysis has remained challenging though it is critical in deeply understanding catalysis on oxide catalysts and developing oxide-based catalysts toward high selectivity and activity. Therefore, the overall objective of the renewal proposal is to mechanistically understand the oxidative dehydrogenation of ethane and oxidative coupling of methane at a molecular level through building correlations between surface chemistry of catalysts during catalysis and the corresponding catalytic performances, and thus design catalysts with high selectivity and activity for production of ethylene with the guidance achieved from these fundamental studies. Experiments were designed to explore the influences of electronic states of cations supported on substrate oxides, cations of surface of the substrate oxides, and surface lattice oxygen atoms of the substrate oxides on their catalytic selectivity and activity. Surface chemistry, including oxidation state of the surface monomers and cations of substrate oxides and density of oxygen vacancies during catalysis, will be tracked with AP-XPS during catalysis. A correlation between surface chemistry of these catalysts at different temperatures and their corresponding catalytic selectivity for production of ethylene and activity will be built. Computational studies will calculate adsorption energies of reactant molecules and their dissociated species and intermediates on the catalyst surface, search transition states, and simulate reaction pathway close to experimental studies. By integrating the computational studies into these correlations to be built from experimental studies, fundamental understanding of the catalytic mechanisms of oxidative dehydrogenation of ethane and oxidative coupling of methane at a molecular level will be achieved. With these insights, new catalysts with high selectivity and activity will be developed.

36 MATERIALS SCIENCE↗
NASA NTRS2010

Reactivation of a Tin-Oxide-Containing Catalyst

The electrons in electric-discharge CO2 lasers cause dissociation of some CO2 into O2 and CO, and attach themselves to electronegative molecules such as O2, forming negative O2 ions, as well as larger negative ion clusters by collisions with CO or other molecules. The decrease in CO2 concentration due to dissociation into CO and O2 will reduce the average repetitively pulsed or continuous wave laser power, even if no disruptive negative ion instabilities occur. Accordingly, it is the primary object of this invention to extend the lifetime of a catalyst used to combine the CO and O2 products formed in a laser discharge. A promising low-temperature catalyst for combining CO and O2 is platinum on tin oxide (Pt/SnO2). First, the catalyst is pretreated by a standard procedure. The pretreatment is considered complete when no measurable quantity of CO2 is given off by the catalyst. After this standard pretreatment, the catalyst is ready for its low-temperature use in the sealed, high-energy, pulsed CO2 laser. However, after about 3,000 minutes of operation, the activity of the catalyst begins to slowly diminish. When the catalyst experiences diminished activity during exposure to the circulating gas stream inside or external to the laser, the heated zone surrounding the catalyst is raised to a temperature between 100 and 400 C. A temperature of 225 C was experimentally found to provide an adequate temperature for reactivation. During this period, the catalyst is still exposed to the circulating gas inside or external to the laser. This constant heating and exposing the catalyst to the laser gas mixture is maintained for an hour. After heating and exposing for an appropriate amount of time, the heated zone around the catalyst is allowed to return to the nominal operating temperature of the CO2 laser. This temperature normally resides in the range of 23 to 100 C. Catalyst activity can be measured as the percentage conversion of CO to CO2. In the specific embodiment described above, the initial steady-state conversion percentage was 70 percent. After four days, this conversion percentage decreased to 67 percent. No decrease in activity is acceptable because the catalyst must maintain its activity for long periods of time. After being subjected to the reactivation process of the present invention, the conversion percentage rose to 77 percent. Such a reactivation not only returned the catalyst to its initial steady state but resulted in a 10-percent improvement over the initial steady state value.

Hess, Robert↗
DOE OSTI2021

Effects of Ink Formulation on Construction of Catalyst Layers for High-Performance Polymer Electrolyte Membrane Fuel Cells

Rational design of catalyst layers in a membrane electrode assembly (MEA) is crucial for achieving high-performance polymer electrolyte membrane fuel cells. Establishing a clear understanding of the property (catalyst ink)–structure (catalyst layer)–performance (MEA) relationship lays the foundation for this rational design. Here, a synergistic approach was taken to correlate the ink formulation, the microstructure of catalyst layers, and the resulting MEA performance to establish such a property–structure–performance relationship. The solvent composition (n-PA/H 2 O mixtures) demonstrated a strong influence on the performance of the MEA fabricated with an 830-EW (Aquivion) ionomer, especially polarization losses of cell activation and mass transport. The performance differences were studied in terms of how the solvent composition affects the catalyst/ionomer interface, ionomer network, and pore structure of the resulting catalyst layers. The ionomer aggregates mainly covered the surface of catalyst aggregates acting as oxygen reduction reaction active sites, and the aggregate sizes of the ionomer and catalyst (revealed by ultrasmall angle X-ray scattering and cryo-transmission electron microscopy) were dictated by tuning the solvent composition, which in turn determined the catalyst/ionomer interface (available active sites). In n-PA/H 2 O mixtures with 50~90 wt % H 2 O, the catalyst agglomerates could be effectively broken up into small aggregates, leading to enhanced kinetic activities. The boiling point of the mixed solvents determined the pore structure of ultimate catalyst layers, as evidenced by mercury porosimetry and scanning electron microscopy. For mixed solvents with a higher boiling point, the catalyst–ionomer aggregates in the ink tend to agglomerate during the solvent evaporation process and finally form larger catalyst–ionomer aggregates in the ultimate catalyst layer, resulting in more secondary pores and thus lower mass transport resistance. Both the enlarged catalyst/ionomer interface and appropriate pore structure were achieved with the catalyst layer fabricated from an n-PA/H 2 O mixture with 90 wt % H 2 O, leading to the best MEA performance.

25 ENERGY STORAGE↗
DOE OSTI2023

Activated carbon supported Ni, Fe, and bimetallic NiFe catalysts for CO x -free H 2 production by microwave methane pyrolysis

The goal of this study was to test the effect of metal-impregnated carbon-based catalysts on the conversion of methane to hydrogen gas and solid carbon using microwave reactor technology. Monometallic and bimetallic catalysts on activated carbon supports (Ni/AC, Fe/AC, Ni-Fe/AC) are compared during methane pyrolysis testing. Catalytic methane pyrolysis was carried out in a microwave reactor at reaction temperatures of 600 °C and 800 °C. For comparison, one of the catalysts (Ni-Fe/AC) was tested in a conventionally heated reactor at 800 °C. The prepared catalysts were characterized by X-ray diffraction (XRD), while post-reaction catalysts were characterized by XRD and SEM. During reaction testing, the monometallic Ni/AC catalyst exhibited the best catalytic activity (CH 4 conversion: 46.0 and H 2 yield: 46.9%) when reacted in the microwave reactor, however, it suffered from rapid deactivation from carbon deposition (carbon yield: 0.39 gC/g catalyst). The bimetallic Ni-Fe/AC catalyst was slightly less active (CH 4 conversion: 36.9 and H 2 yield: 40.5%) but it was more resistant to carbon formation (carbon yield: 0.27 gC/g catalyst) suggesting it may have greater long-term stability. The Ni-Fe/AC catalyst was also the most energy efficient as it required the least microwave power to maintain the 800 °C reaction temperature compared to the other catalysts tested. Methane conversion of the bimetallic Ni-Fe/AC at 800 °C under microwave irradiation was three times the conversion under conventional heating at the same reaction temperature. Finally, this work demonstrates the use of microwave-specific catalysts for catalytic methane pyrolysis in a microwave reactor, and can be used as a foundation for further methane pyrolysis process and catalyst optimization for CO x -free H 2 production.

08 HYDROGEN↗
DOE OSTI2021

Structure-Activity Relationships of Hydrothermally Aged Titania-Supported Vanadium-Tungsten Oxide Catalysts for SCR of NOx Emissions with NH3

Supported V2O5-WO3/TiO2 materials employed as selective catalytic reduction (SCR) catalysts for NOx emission control from power plants. Fresh SCR catalysts usually receive exposure to harsh treatments in industry to accelerate catalyst activation (calcination in air at 650oC) and catalyst aging (hydrothermal aging at 650oC) in a way that represents various points in the catalyst/product lifetime. The present study investigates the catalyst structural and chemical changes occurring during such harsh treatments. Three series of supported V2O5-WO3/TiO2 catalysts were prepared by incipient-wetness impregnation of aqueous ammonium metavanadate and metatungstate precursors. The catalysts were subsequently dried and calcined at 550oC in O2, 650oC in O2, and hydrothermal conditions (10% O2, 8% H2O, 7% CO2 and 75% N2) at 650oC. The resulting catalysts were physically characterized by numerous techniques (in situ Raman, in situ IR, in situ High Field-High Spinning solid-state 51V MAS NMR, in situ EPR, XRD, BET surface area and ICP) and chemically probed with adsorbed ammonia, SCR-TPSR, and the SCR reaction. The surface WOx sites on the TiO2 support behave as a textural promoter that stabilizes the TiO2 (anatase) phase from sintering and transforming to the undesirable crystalline TiO2 (rutile) phase that can lead to formation of a Ti1-xVxO2 (rutile) solid solution with reduced V4+ cations (~7-15%). The surface VOx sites are mostly oligomerized as surface V+5Ox sites (~50-85% oligomers) and the extent of oligomerization tends to increase with surface WOx coverage and calcination temperature. A major difference between the calcined and hydrothermally treated catalysts was the low concentration of surface NH3* species on Lewis acid sites for the hydrothermally treated catalysts, yet the SCR activity was almost comparable for both catalysts. This finding suggests that surface NH4+*, primarily associated with the surface VOx sites, are able to efficiently perform the SCR reaction. Given that multiple catalyst parameters were simultaneously varying during these treatments, it was difficult to correlate the SCR activity with any single catalyst parameter. A correlation, however, was found between the SCR TOF/activity and the sum of the surface NH3* and NH4+* species, which is dominated by the surface NH4+* species.

SCR, NO, NH3, catalyst, V2O5, WO3, TiO2, promotion↗
DOE OSTI2025

The Development of Catalysts for Upgrading of Pyrolysis Vapor for Refinery Feedstocks and Intermediates (CRADA Final Report)

Catalytic fast pyrolysis (CFP) is a versatile technology platform to convert biomass into fungible hydrocarbon transportation fuels and chemical co-products. Key technical barriers to reaching this goal include increasing the product yields and achieving the desired fuel properties for gasoline, diesel, and jet range fuels or blendstocks that would be suitable for introduction into existing refinery unit operations. Overcoming these barriers will require durable catalysts that are effective at upgrading and stabilizing biomass pyrolysis vapors. Towards these goals, this CRADA leveraged NREL experience as a leader in biomass pyrolysis research and Johnson Matthey's (JM) experience as a leader in the production of advanced catalytic materials. The scope spanned CFP catalyst development, characterization, multi-scale reaction testing, and computational modeling. CRADA benefits to DOE, Participant, and U.S. Taxpayer: Assists laboratory in achieving programmatic scope, Uses the laboratory’s core competencies. The purpose of this CRADA was to develop and deploy catalysts for biomass CFP to help achieve cost-competitive biofuels and bio-based products. This was accomplished through a close collaboration between biomass conversion researchers at NREL and catalyst development researchers at JM. Summary of Research Results: Focus Area 1. Foundational research on catalytic conversion and deactivation: Key interactions between pyrolysis vapors and heterogeneous catalysts were probed through catalyst characterization, model compound reaction testing, and atomistic-scale computational modeling. Catalyst development focused on multifunctional materials, which include zeolites, oxides, carbides, and nitrides. Computational modeling identified reaction mechanisms and elucidated surface chemistry to test hypotheses regarding mechanisms of deoxygenation, coupling, cracking, dehydration, coke formation, hydrogen transfer, and aromatic ring reactions. This information was used to design multifunctional catalysts to increase product yields, control product selectivity, and reduce deactivation during CFP and downstream processing steps. The results served to increase fundamental understanding of key catalyst attributes and durability features for the upgrading of biomass pyrolysis vapors. Model compound experiments confirmed the importance of metal-acid bifunctionality for the deoxygenation of lignin-derived phenolic species under hydrodeoxygenation conditions. This insight led to the development of catalysts such as Pt/TiO2 and Mo2C, which were confirmed as high-performing materials during subsequent bench-scale experiments using biomass-derived pyrolysis vapors. This focus area also led to the identification of important catalyst deactivation mechanisms associated with the deposition of inorganic contaminants such as potassium. The molecular-level insight from model compound experiments and computational modeling, shown in Figure 1, informed the development of regeneration procedures that have been shown to be effective for restoration of > 90% of initial catalyst activity. This understanding has subsequently been translated to other catalyst systems, including zeolite materials that can be operated without requirements for co-fed hydrogen.

09 BIOMASS FUELS↗
DOE OSTI2020

Reformulated Red mud: a robust catalyst for in situ catalytic pyrolysis of biomass

Biomass feedstocks contain inorganic compounds generally classified as ash. The ash consists of compounds of potassium, calcium, magnesium, silicon, phosphorous and other elements. These elements have been reported to influence both the pyrolysis reactions as well as destabilizing the pyrolysis oils during storage. The inorganic elements have also been reported to deposit on catalyst surfaces during in situ catalytic pyrolysis leading to the eventual deactivation of acidic catalysts such as zeolites. The deposition of inorganic elements and their effect on formulated red mud (FRM) catalyst during in situ catalytic pyrolysis of pinyon juniper wood was investigated. The inorganic elements were measured for the fresh, coked, and regenerated catalysts. The BET specific surface area of the FRM catalyst decreased from 76 m2/g for the fresh catalyst to 53 m2/g for the stable regenerated catalyst. After three regenerations, the BET specific surface area stabilized at 53 m2/g and remained constant after all other regenerations. Potassium, calcium, magnesium, and phosphorous were deposited on the catalyst. Potassium deposition was linear with the number of regenerations while magnesium and calcium depositions were initially rapid but leveled off after three regenerations of the catalyst. Phosphorous deposition was almost linear, but the data were more scattered compared to potassium. The potassium deposition was attributed to physical phenomenon whereas calcium and magnesium depositions were more akin to chemical reactions related to the loss of BET surface area of the catalyst. The deposition of these elements on the surface of the catalyst did not deactivate it. After each catalyst regeneration, the oil yield was not significantly affected and the oil oxygen content and viscosity decreased slightly. This clearly showed that formulated red mud is a robust catalyst suitable for in situ catalytic fast pyrolysis of biomass.

Agblevor, Foster↗
DOE OSTI2024

Core-Shell Oxidative Aromatization Catalysts for Single Step Liquefaction of Distributed Shale Gas (Final Technical Report)

The objective of this project was to design and demonstrate a core-shell structured multifunctional catalyst to convert the light (dry) components of shale gas into liquid aromatic compounds (primarily benzene and toluene) in a single step. Operated in a modular oxidative aromatization system (OAS) under a cyclic redox scheme, the novel catalyst and process can significantly improve the value and transportability of distributed shale gas. Since the project started, each quarter addressed a different set of tasks related to the completion of the milestone detailed in the project award. The yearly summaries of these tasks are summarized below: Q1-Q4: • Conducted project planning and literature search. • Investigated a number of SHC redox catalysts using thermogravimetric analysis and fixed-bed reactor experiments. • Initiated process modeling towards generating two process models for the methane DHA base case and OAS process. • Developed DHA catalysts capable of producing >500 g/kg-cat-hr aromatics at 80% or greater aromatics selectivity at 700°C. Q5-Q8: • Developed alternative approaches with sequential bed configurations to enhance the aromatic yields based on OCM+DHA • Improved the zeolite synthesis efficiency by using the microwave-assisted technique and investigated the synthesis conditions on the zeolite yield, crystalline structure and morphology • Constructed a set of Aspen Plus process models with significant energy savings for OAS as compared to the base case non-oxidative DHA. • Adapted conventional hydrothermal method to be applicable to the microwave synthesizer unit for more efficient catalyst synthesis. • Studied the structure of the OCM catalyst and the dispersion of the carbonate in the redox reactions and in methane flow with Raman Spectroscopy. Q9-Q12: • Scaled up the catalyst synthesis with the microwave synthesis method. Based on its performance, procedural characterizations and catalytic performance testing were further conducted for the new microwave synthesized catalysts with the newly-developed product analysis procedure. • Developed the reaction system setup for the C2-DHA or OCM+DHA reaction product and achieved a better product collection-analysis method for the aromatic products with an improved carbon balance. The product from the OCM reaction exhibited complicated effects on the DHA catalyst. • Conducted additional OCM catalyst characterization using Near Ambient Pressure X-ray Photoelectron Spectroscopy and in situ Raman characterization • Validated the significant energy savings for OAS as compared to the base case non-oxidative DHA. Successfully set up the simulation model for the OCM+DHA+SHC reaction system based on the updated experimental results from NCSU. Q13-End of project: • Synthesized new zeolite catalysts by the microwave method, conducted characterizations (XRD, SEM, and TEM) and catalytic behavior testing. • Explored the “wet” C 2 H 6 and C 2 H 4 DHA reactions with using steam co-feed. A subsequent reduction as the regeneration step can regenerate the DHA catalyst and recover 99% activity of the fresh performance. • Achieved a 15.3% single-pass aromatic yield from methane by rationally combining the OCM and DHA at different temperatures. • Conducted a 105-hour stability test with an improved regeneration procedure, with an average aromatic yield of 13.8%. • Developed new catalyst and achieved a record-high 23.2% yield.

03 NATURAL GAS↗
NASA NTRS1999

Catalyst Development for Hydrogen Peroxide Rocket Engines

The development of various catalysts of hydrogen peroxide was conducted for the applications of liquid rocket engines. The catalyst development includes silver screen technology, solid catalyst technology, and homogeneous catalyst technology. The silver screen technology development was performed with 85% (by weight) hydrogen peroxide. The results of this investigation were used as the basis for the catalyst design of a pressure-fed liquid-fueled upper stage engine. Both silver-plated nickel 200 screens and pure silver screens were used as the active metal catalyst during the investigation, The data indicate that a high decomposition efficiency (greater than 90%) of 85% hydrogen peroxide can be achieved at a bed loading of 0.5 lbm/sq in/sec with both pure silver and silver plated screens. Samarium oxide coating, however, was found to retard the decomposition process and the catalyst bed was flooded at lower bed loading. A throughput of 200 lbm of hydrogen peroxide (1000 second run time) was tested to evaluate the catalyst aging issue and performance degradation was observed starting at approximately 400 seconds. Catalyst beds of 3.5 inch in diameter was fabricated using the same configuration for a 1,000-lbf rocket engine. High decomposition efficiency was obtained with a low pressure drop across the bed. Solid catalyst using precious metal was also developed for the decomposition of hydrogen peroxide from 85% to 98% by weight. Preliminary results show that the catalyst has a strong reactivity even after 15 minutes of peroxide decomposition. The development effort also includes the homogeneous catalyst technology. Various non-toxic catalysts were evaluated with 98% peroxide and hydrocarbon fuels. The results of open cup drop tests indicate an ignition delay around 11 ms.

Morlan, P. W.↗
DOE OSTI2020

Raspberry colloid-templated approach for the synthesis of palladium-based oxidation catalysts with enhanced hydrothermal stability and low-temperature activity

It is becoming increasingly urgent to develop and utilize novel, more efficient and stable materials for mobile and stationary emission control applications as the deleterious consequences of anthropogenic air pollution are becoming more evident and pressing. Tightening regulations, particularly related to automotive exhaust treatment, together with continued improvements in engine design, that result in lowering the engine operating temperatures and inadvertently lead to the release of an overwhelming proportion of pollutants during the cold start, present new challenges for materials design, specifically for oxidation catalysts. In particular, improvements in the low-temperature activity while maintaining catalyst stability at high temperatures are required from the next-generation catalyst. Typical catalysts for removal of pollutants from automotive exhaust streams incorporate platinum group metals (PGMs). They tend to be inefficient at low temperatures (below 250 °C), thus accounting for the cold start problem, yet sinter and lose their activity at high temperatures that are frequently encountered during catalyst operation. High PGM loadings are often employed to compensate for catalyst inefficiencies and fast degradation, ultimately resulting in high-cost catalytic converters. Here, we have developed a new approach for the design and formation of catalytic materials that allows for both significantly more efficient PGM incorporation and improved overall catalyst performance at reduced PGM loadings. The method provides control over the composition and geometry of the support through self-assembly of sacrificial composite template — “raspberry” polymeric colloids decorated with catalytic particles — accompanied by infiltration with metal-oxide precursor and subsequent removal of the colloids. This method simultaneously structures the porous network and organizes the catalytic particles within it. Uniquely, the resulting catalytic particles are partially embedded in the support matrix and partially exposed to the pore interior, producing catalytic sites that are both stable and accessible. Herein, the feasibility of this novel and versatile approach for automotive catalytic conversion is demonstrated: the studies include testing alumina-based raspberry-colloid-templated (RCT) catalysts containing Pd nanoparticles (RCT Pd/Al2O3) for oxidation of propane and carbon monoxide under simulated diesel exhaust conditions and hydrothermal aging at 800 °C for 50 h in the simulated stream. The RCT Pd/Al2O3 catalysts exhibit exceptional activity toward CO oxidation, reduced reaction onset temperature, and high stability to elevated temperatures (demonstrated through prolonged exposure to temperatures up to 950 °C) and reactive gas streams, without migration, sintering or loss of the precious metal NPs. Notably, the novel catalyst shows the same or slightly better performance than the commercial catalysts even when the PGM load is reduced by ~80 % compared to the commercial counterparts. These results provide confidence for the utilization of the RCT approach for the fabrication of robust nanostructured catalysts for next-generation, energy-efficient catalytic converters with improved performance at low and high temperatures and reduced costs. The RCT methodology is, in addition, highly generalizable, and can thus be applied for the design of a wide range of catalytic systems in the automotive sector and beyond.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Computational catalyst discovery: Active classification through myopic multiscale sampling

We report the recent boom in computational chemistry has enabled several projects aimed at discovering useful materials or catalysts. We acknowledge and address two recurring issues in the field of computational catalyst discovery. First, calculating macro-scale catalyst properties is not straightforward when using ensembles of atomic-scale calculations [e.g., density functional theory (DFT)]. We attempt to address this issue by creating a multi-scale model that estimates bulk catalyst activity using adsorption energy predictions from both DFT and machine learning models. The second issue is that many catalyst discovery efforts seek to optimize catalyst properties, but optimization is an inherently exploitative objective that is in tension with the explorative nature of early-stage discovery projects. In other words, why invest so much time finding a “best” catalyst when it is likely to fail for some other, unforeseen problem? We address this issue by relaxing the catalyst discovery goal into a classification problem: “What is the set of catalysts that is worth testing experimentally?” Here, we present a catalyst discovery method called myopic multiscale sampling, which combines multiscale modeling with automated selection of DFT calculations. It is an active classification strategy that seeks to classify catalysts as “worth investigating” or “not worth investigating” experimentally. Our results show an ~7–16 times speedup in catalyst classification relative to random sampling. These results were based on offline simulations of our algorithm on two different datasets: a larger, synthesized dataset and a smaller, real dataset.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

The Development of Catalysts for Upgrading of Pyrolysis Vapor for Refinery Feedstocks and Intermediates: Cooperative Research and Development, CRADA Number CRD-12-00497 (Final Report)

Fast pyrolysis of biomass with vapor phase upgrading (VPU) can produce refinery feedstocks or intermediates that can meet the Department of Energy’s goal of cost-competitive hydrocarbon fuels by 2017. A key technical barrier for this technology is the lack of selective, cost effective catalysts that can produce high yields of fuel-appropriate hydrocarbons from the pyrolysis vapors. In overcoming this barrier, it will be important to engage leading catalyst development companies to devote their resources and expertise to the development of these materials. Thus, we propose a Cooperative Research and Development Agreement (CRADA) between the National Renewable Energy Laboratory (NREL), a world leader in biomass pyrolysis research and Johnson Matthey (JM), a world leader in the production of advanced catalyst materials to develop and test novel catalysts for efficient VPU. Through its Intercat Inc. subsidiary in Savannah, Ga., Johnson Matthey is internationally recognized as a leader in zeolite-based vapor phase upgrading in refinery duties and an emerging developer of biomass conversion technologies. The research and development efforts described in the proposed work will build upon existing collaborations between NREL and JM and play to the strengths of both institutions. NREL will analyze the composition of pyrolysis vapors as an input to catalyst design, screen and test catalysts, characterize the resulting oil and conduct techno-economic analysis. Catalyst samples will be produced and funded by JM. JM will design and synthesize catalysts, characterize fresh and used catalysts and develop catalyst supports needed to achieve commercially meaningful lifetimes. The project will span catalyst development and testing from the fundamental stage using quantum mechanical modeling and chemical reaction analysis to catalyst screening to integrated pilot studies.

09 BIOMASS FUELS↗
DOE OSTI2019

Methane and Ethane Steam Reforming over MgAl2O4-Supported Rh and Ir Catalysts: Catalytic Implications for Natural Gas Reforming Application

Solar concentrators employed in conjunction with highly efficient micro- and meso-channel reactors offer the potential for cost-effective upgrading of the energy content of natural gas, providing a near-term path towards a future solar-fuel economy with reduced carbon dioxide emissions. To fully exploit the heat and mass transfer advantages offered by micro- and meso-channel reactors, highly active and stable natural gas steam reforming catalysts are required. In this paper, we report the catalytic performance of MgAl2O4-supported Rh (5 wt.%), Ir (5 wt.%), and Ni (15 wt.%) catalysts used for steam reforming of natural gas. Both Rh- and Ir-based catalysts are known to be more active and durable than conventional Ni-based formulations, and recently Ir has been reported to be more active than Rh for methane steam reforming on a turnover basis. Thus, the effectiveness of all three metals to perform natural gas steam reforming was evaluated in this study. Here, the Rh- and Ir-supported catalysts both exhibited higher activity than Ni for steam methane reforming. However, using simulated natural gas feedstock (94.5% methane, 4.0% ethane, 1.0% propane, and 0.5% butane), the Ir catalyst was the least active (on a turnover basis) for steam reforming of higher hydrocarbons (C2+) contained in the feedstock when operated at <750 °C. To further investigate the role of higher hydrocarbons, we used an ethane feed and found that hydrogenolysis precedes the steam reforming reaction and that C–C bond scission over Ir is kinetically slow compared to Rh. Catalyst durability studies revealed the Rh catalyst to be stable under steam methane reforming conditions, as evidenced by two 100-hour duration experiments performed at 850 and 900 °C (steam to carbon [S/C] molar feed ratio = 2.0 mol). However, with the natural gas simulant feed, the Rh catalyst exhibited catalyst deactivation, which we attribute to coking deposits derived from higher hydrocarbons contained in the feedstock. Increasing the S/C molar feed ratio from 1.5 to 2.0 reduced the deactivation rate and stable catalytic performance was demonstrated for 120 h when operated at 850 °C. However, catalytic deactivation was observed when operating at 900 °C. While improvements in steam reforming performance can be achieved through choice of catalyst composition, this study also highlights the importance of considering the effect of higher hydrocarbons contained in natural gas, operating conditions (e.g., temperature, S/C feed ratio), and their effect on catalyst stability. The results of this study conclude that a Rh-supported catalyst was developed that enables very high activities and excellent catalytic stability for both the steam reforming of methane and other higher hydrocarbons contained in natural gas, and under conditions of operation that are amendable to solar thermochemical operations.

03 NATURAL GAS↗
DOE OSTI2019

Enhanced catalytic performance of Zr modified CuO/ZnO/Al 2 O 3 catalyst for methanol and DME synthesis via CO 2 hydrogenation

Zirconium (Zr) modified CuO/ZnO/Al 2 O 3 (CZA) catalysts with different aluminum (Al) and Zr contents were synthesized by the co-precipitation method. The synthesized CuO/ZnO/ZrO 2 /Al 2 O 3 (CZZA) catalysts were comprehensively characterized and studied for methanol synthesis via CO 2 hydrogenation. The CZZA catalyst showed the highest methanol yield of 12.4 % at 220 °C and 2.76 MPa with an optimized catalyst composition of Cu/Zn/Zr/Al (atomic ratio) at 4:2:1:0.5. The CZZA catalyst showed better activity than that of the CZA catalyst and a superior stability for methanol synthesis. There was no decrease in the BET surface area and very little coke formation for the spent CZZA catalyst, after 300 h of methanol synthesis. Bifunctional catalysts, composed of CZZA and HZSM-5, were investigated for dimethyl ether (DME) synthesis directly from CO 2 hydrogenation, and a maximum DME yield of 18.3 % was obtained at a reaction temperature of 240 °C and a pressure of 2.76 MPa. The stability of the bifunctional CZZA and HZSM-5 catalyst during the DME synthesis also significantly improved, as compared to that of the CZA and HZSM-5. A significant decrease in the BET surface area and an increase in coking on the spent CZZA catalyst were observed after 100 h of DME synthesis, indicating a detrimental effect on CZZA stability when a HZSM-5 catalyst was present. The changes in structural properties (e.g., BET surface area and crystallinity) and coking for HZSM-5 could be responsible for the deactivation of the bifunctional catalyst.

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

Conversion of Syngas and CO2 to Light Olefins using Multi-Functional Catalysts

This report describes our effort in developing a novel zeolite encapsulated metal nanoparticle catalyst for the conversion of syngas to light olefins. We have adopted a ligand assisted synthesis protocol in which first metal-amine was prepared using metal salts and suitable amine ligands. The stable metal-amine complex thus prepared was then used as the seed for the growth of zeolite in alkaline solution. We have optimized the synthesis condition as well as different amine ligand to identify the condition to obtain stable metal-amine complex. Upon synthesis of zeolite, metal particles are encapsulated inside the zeolite in a confined space. We have synthesized both Fe and Co catalyst inside silicalite and chabazite zeolite. Catalytic activity of these catalysts were evaluated for syngas conversion reaction and compared with a baseline catalyst. The activity trend of zeolite encapsulated catalyst show very different activity trend compared to the baseline catalyst. While a distribution of products with different carbon number was obtained with baseline catalyst, zeolite encapsulated catalyst show ethylene as the major product. While ~73% selectivity to C 2 -C 6 products were obtained with cahabazite encapsulated Fe catalyst, only 53% selectivity was obtained for the corresponding products with silica-alumina supported Fe catalyst. Not only higher selectivity, Fe-chabazite also produces only C 2 products (ethylene/ethane) while a distribution of products was obtained with Fe-SiAl catalyst. The significantly different reactivity associated with the chabazite encapsulated Fe catalyst was attributed to the confinement effect. We hypothesized that due to the small size of the pore, only ethylene was obtained as the product.

10 SYNTHETIC FUELS↗
NASA NTRS2002

Evaluation of the Effect of Water Vapor On the Performance of NASA's NMRO Catalysts for Carbon Monoxide Oxidation

The Noble Metal Reducible Oxide (NMRO) catalysts for the low temperature oxidation of carbon monoxide were developed by NASA for the reoxidation of carbon monoxide which forms by the dissociation of carbon dioxide during the operation of sealed carbon dioxide lasers. The NMRO catalyst, which consists of a noble metal in conjunction with a reducible metal oxide, was evaluated under conditions that will be encountered in a CO2 laser operation, namely temperatures in the range 298 to 373 K and no significant reaction gas components other than CO, CO2 and O2. The NMRO catalysts may have significant potential for spin-off applications such as the prevention of carbon monoxide build-up in closed spaces as in space vehicle cabins or submarines, and the elimination of the cold start-up problem of automobile exhaust catalysts. The most significant difference in the conditions of these possible future applications is the high moisture content of the gases to be processed. Lack of understanding of the effects of water vapor and high temperature on catalyst activity and operation for extended periods are currently the main stumbling blocks for the transfer of this NASA technology to be used for commercial purposes. In the original proposal the following objectives were stated: To obtain experimental data on the adsorption, desorption and reaction characteristics of CO and CO2 the catalysts under high moisture conditions; to collect evidence on the presence of carbonate and hydroxyl surface species and their involvement in the CO oxidation mechanism; and to model the reaction system using a Monte-Carlo simulation to gain insight on the various steps involved. After the work has commenced the NASA technical monitor Mr. David Scheyer informed us that there was increased interest in the possible use of the NMRO catalysts as automobile exhaust catalysts and therefore NASA wanted to know whether the catalysts can operate at high temperatures as well as with high moisture gases. At that meeting it was decided that investigation of the high temperature performance of the NMRO catalysts should be given priority and replace the Monte-Carlo simulation objective. As a result, the modified objectives of the investigation were taken as the investigation of the high-temperature activity of the NMRO catalysts, and the effect of water vapor on the performance of these catalysts.

Akyurtlu, Ates↗
DOE OSTI2020

Effect of Dispersion Medium Composition and Ionomer Concentration on the Microstructure and Rheology of Fe–N–C Platinum Group Metal-free Catalyst Inks for Polymer Electrolyte Membrane Fuel Cells

In this paper, we present an investigation of the microstructure and rheological behavior of catalyst inks consisting of Fe–N–C platinum group metal-free catalysts and a perfluorosulfonic acid ionomer in a dispersion medium (DM) of water and 1-propanol ( n PA). The effects of the ionomer-to-catalyst (I/C) ratio and weight percentage of water (H 2 O %) in the DM on the ink microstructure were studied. Steady-shear and dynamic-oscillatory-shear rheology, in combination with synchrotron X-ray scattering, was utilized to understand interparticle interactions and the level of agglomeration of the inks. In the absence of the ionomer, the inks were significantly agglomerated, approaching a gel-like microstructure for catalyst concentrations as low as 2 wt %. The effect of H 2 O % in the DM on particle agglomeration was found to vary with particle concentration. In concentrated inks (≥2 wt % catalyst), increasing H 2 O % was found to increase agglomeration because of the hydrophobic nature of the catalysts. In dilute inks (<1 wt % catalyst), the trend was reversed with increasing H 2 O %, suggesting that electrostatic interactions are dominating the behavior. In inks with 5 wt % catalyst, the addition of an ionomer was found to significantly stabilize the catalyst against agglomeration. Maximum stability was observed at 0.35 I/C for all DM H 2 O % studied. At high ionomer concentrations (I/C > 0.35), interesting differences were observed between n PA-rich inks (H 2 O % ≤ 50%) and H 2 O-rich (82% H 2 O) inks. The n PA-rich inks remained predominantly stable—ink viscosity only weakly increased with I/C and the Newtonian behavior was maintained for I/C up to 0.9. In contrast, the H 2 O-rich inks exhibited a significant increase in viscoelasticity with increasing I/C, suggesting flocculation of the catalyst by the ionomer. These differences suggest that the nature of the interactions between the ionomer and catalyst is highly dependent on the H 2 O % in the DM.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗