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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
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 OSTI2023

N2-to-NH3 conversion by excess electrons trapped in point vacancies on 5f-element dioxide surfaces

Ammonia (NH 3 ) is one of the basic chemicals in artificial fertilizers and a promising carbon-free energy storage carrier. Its industrial synthesis is typically realized via the Haber−Bosch process using traditional iron-based catalysts. Developing advanced catalysts that can reduce the N 2 activation barrier and make NH 3 synthesis more efficient is a long-term goal in the field. Most heterogeneous catalysts for N 2 -to-NH 3 conversion are multicomponent systems with singly dispersed metal clusters on supporting materials to activate N 2 and H 2 molecules. Herein, we report single-component heterogeneous catalysts based on 5 f actinide dioxide surfaces (ThO 2 and UO 2 ) with oxygen vacancies for N 2 -to-NH 3 conversion. The reaction cycle we propose is enabled by a dual-site mechanism, where N 2 and H 2 can be activated at different vacancy sites on the same surface; NH 3 is subsequently formed by H − migration on the surface via associative pathways. Oxygen vacancies recover to their initial states after the release of two molecules of NH 3 , making it possible for the catalytic cycle to continue. Our work demonstrates the catalytic activities of oxygen vacancies on 5 f actinide dioxide surfaces for N 2 activation, which may inspire the search for highly efficient, single-component catalysts that are easy to synthesize and control for NH 3 conversion.

36 MATERIALS SCIENCE↗
DOE OSTI2019

One-Nanometer-Thick Pt 3 Ni Bimetallic Alloy Nanowires Advanced Oxygen Reduction Reaction: Integrating Multiple Advantages into One Catalyst

Developing highly active as well as durable oxygen reduction reaction (ORR) electrocatalysts are still imperative for clean and efficient energy conversion device, such as fuel cells and metal-air battery. For this purpose and maximize the utilization of noble Pt, we present here a facile, yet scalable strategy for the high-precise synthesis of 1-nm-thick Pt 3 Ni bimetallic alloy nanowires (Pt 3 Ni BANWs). The seed-mediated growth mechanism of Pt 3 Ni BANWs was identified subsequently. As expected, the Pt 3 Ni BANWs delivered enhanced mass activity (0.546 A mgPt –1 , exceeding the 2020 target of DOE) in comparison to Pt nanowires assembly (Pt NWA, 0.098 A mgPt –1 ) and Pt/C (Pt, 0.135 A mgPt –1 ), because of the rational integration of multiple compositional and structural advantages. Moreover, the Pt 3 Ni BANWs displayed enhanced durability (37% MA retention) than Pt NWA and Pt after 50 000 potential cycles. All these results indicate that the ultrathin Pt 3 Ni BANWs are potential candidates for catalyzing ORR with acceptable activity and durability. In conclusion, the present work could not only provide a facile strategy but also a general guidance for the design of superb performance Pt-based nanowire catalysts for ORR.

25 ENERGY STORAGE↗
DOE OSTI2020

Recent developments in catalyst-related PEM fuel cell durability

Cost and durability remain the two major barriers to the widespread commercialization of polymer electrolyte membrane fuel cell (PEMFC)-based power systems, especially for the most impactful but challenging fuel cell electric vehicle (FCEV) application. Commercial FCEVs are now on the road; however, their PEMFC systems do not meet the cost targets established by the U.S. Department of Energy, primarily due to the high platinum loading needed on the cathode to achieve the requisite performance and lifetime. Furthermore, while the activities of a number of commercial Pt-based alloy cathode catalysts exceed the beginning-of-life (BOL) targets, these activities, and the overall cathode performance, degrade via a variety of mechanisms described herein. Degradation is mitigated in current FCEVs by utilizing a cathode catalyst with a lower BOL activity (e.g., much lower transition metal alloy content and larger BOL nanoparticle size), necessitating higher catalyst loadings, and through the utilization of system controls that avoid conditions known to exacerbate degradation processes, such as limiting the fuel cell stack voltage range. The design and development of active and robust materials and eliminating the need for vehicle mitigation strategies would greatly simplify the operating system, allowing for greater transient operation, avoiding large hybridization, and curtailing of fuel cell power. Although system mitigation strategies have provided the near-term pathway for FCEV commercialization, material-specific solutions are required to further reduce costs and improve operability and efficiency. Future material developments should focus on stabilization of the electrode structure and minimization of the catalyst particle susceptibility to dissolution caused by oxide formation and reduction over PEMFC cathode-relevant operating potentials plus minimization of support corrosion. Ex situ accelerated stress tests have provided insight into the processes responsible for material and performance degradation and will continue to provide useful information on the relative stability of materials and benchmarks for robust and stable materials-based solutions not requiring system mitigation strategies to achieve adequate lifetime.

25 ENERGY STORAGE↗
DOE OSTI2023

Research tool development for catalyst, catalyst/ionomer, and ionomer characterization above 100°C (CRADA Final Report)

There is a need to develop experimental tools that address the catalyst and ionomer interface under high-temperature proton-exchange-membrane (HT-PEM) operating conditions (dry, >100°C). These conditions mean traditional water-based measurements for membrane and ionomer properties are insufficient; new ex-situ techniques are required to address and characterize expected novel materials. In this project we develop a microelectrode cell for high temperature kinetics and gas transport properties and ex-situ ionomer thin-film characterization under these conditions. We use baseline Nafion and phosphoric-acid imbibed membranes as prototype materials for measuring the membrane/acid/ionomer systems with Pt microelectrodes and demonstrate feasibility of the tools.

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

HydroGEN Seedling: High-Temperature Reactor Catalyst Material Development for Low-Cost and Efficient Solar-Driven Sulfur-Based Processes

The HyS process, driven by solar power, has great potential to reach high-efficiency and low-cost hydrogen production without greenhouse gas emissions. The high-temperature section of the HyS cycle, which operates the catalytic decomposition of sulfuric acid into sulfur dioxide, oxygen, and water, is a fundamental part of the cycle affecting the overall plant efficiency and cost. Therefore, a high-performance catalyst (i.e., low cost, high catalytic activity, and low degradation catalyst) is of critical importance to achieve high efficiency and low hydrogen cost. Research and development has highlighted that a Pt-based monometallic catalyst had unacceptable catalytic activity and performance degradation for a high-efficiency and low-cost hydrogen production process. A high-efficiency solar receiver-reactor system, which incorporates the new catalyst, also needs to be developed to achieve the required plant efficiency and cost. Greenway Energy (GWE) and the University of South Carolina (USC), partnering with HydroGEN node laboratories Idaho National Laboratory (INL), Savannah River National Laboratory (SRNL), and National Renewable Energy Laboratory (NREL), propose the development of a new catalyst formulation, included in a novel solar receiver-reactor concept, to be tested experimentally in the last part of the project.

08 HYDROGEN↗
DOE OSTI2021

Roads less traveled: Nitrogen reduction reaction catalyst design strategies for improved selectivity

Direct electrochemical nitrogen reduction for ammonia production is necessary to reduce the use of fossil fuels from conventional Haber–Bosch methods. Applications of nitrogen reduction electrocatalysts remain inhibited by slow reaction kinetics and low faradaic efficiencies because of competitive H2 production pathways. Current strategies to address this challenge in selectivity have focused on catalyst design, reactor configuration, and electrolyte conditions. This brief review discusses the thermodynamic and kinetic challenges in the field as well as current underused approaches for selective catalyst development including bimetallic catalysts, transition metal nitrides, and carbon supports.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2017

Combining theory and experiment in electrocatalysis: Insights into materials design

Electrocatalysis plays a central role in clean energy conversion, enabling a number of sustainable processes for future technologies. This review discusses design strategies for state-of-the-art heterogeneous electrocatalysts and associated materials for several different electrochemical transformations involving water, hydrogen, and oxygen, using theory as a means to rationalize catalyst performance. By examining the common principles that govern catalysis for different electrochemical reactions, we describe a systematic framework that clarifies trends in catalyzing these reactions, serving as a guide to new catalyst development while highlighting key gaps that need to be addressed. Here, we conclude by extending this framework to emerging clean energy reactions such as hydrogen peroxide production, carbon dioxide reduction, and nitrogen reduction, where the development of improved catalysts could allow for the sustainable production of a broad range of fuels and chemicals.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2017

Best Practices and Testing Protocols for Benchmarking ORR Activities of Fuel Cell Electrocatalysts Using Rotating Disk Electrode

Abstract Thin-film-rotating disk electrodes (TF-RDEs) are the half-cell electrochemical system of choice for rapid screening of oxygen reduction reaction (ORR) activity of novel Pt supported on carbon black supports (Pt/C) electrocatalysts. It has been shown that the magnitude of the measured ORR activity and reproducibility are highly dependent on the system cleanliness, evaluation protocols, and operating conditions as well as ink formulation, composition, film drying, and the resultant film thickness and uniformity. Accurate benchmarks of baseline Pt/C catalysts evaluated using standardized protocols and best practices are necessary to expedite ultra-low-platinum group metal (PGM) catalyst development that is crucial for the imminent commercialization of fuel cell vehicles. We report results of evaluation in three independent laboratories of Pt/C electrocatalysts provided by commercial fuel cell catalyst manufacturers (Johnson Matthey, Umicore, Tanaka Kikinzoku Kogyo—TKK). The studies were conducted using identical evaluation protocols/ink formulation/film fabrication albeit employing unique electrochemical cell designs specific to each laboratory. The ORR activities reported in this work provide a baseline and criteria for selection and scale-up of novel high activity ORR electrocatalysts for implementation in proton exchange membrane fuel cells (PEMFCs).

Kocha, Shyam S.↗
DOE OSTI2020

Energetic decomposition yields efficient bimetallic Cu MOF-derived catalysts

Metal–organic frameworks (MOFs) have recently emerged as efficient self-sacrificial templates to fabricate porous carbon-supported metal nanoparticles (NPs). Due to observed increased activity, catalysts containing bimetallic NPs represent an active frontier for heterogeneous catalyst development. A strategy to synthesize active catalysts with highly dispersed bimetallic metal/metal oxides within a porous carbon matrix via rapid MOF decomposition using dopants is presented in this paper. A 2,4,6-trinitrotoluene (TNT) additive enhances the rapid thermolysis of the metal-doped Cu-based MOFs to minimize particle aggregation. Catalyst characterization reveals that a secondary metal increases dispersion of both metals over the carbon composite support. The catalyst preparation method influences both the metal particle size and oxidation state. Catalytic performance shows increased rates for 4-nitrophenol reduction even with <1 wt% of added secondary metal. Among the synthesized catalysts, the Ni–CuO@C bimetallic catalyst exhibits outstanding activity. This synthetic strategy is useful for creating highly efficient, robust, non-noble metal catalysts for development of sustainable chemical processes.

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

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

This report describes our effort in developing catalysts for the conversion of syngas to light olefins and oxygenates. We have developed a series of metal/zeolite catalysts and tested their activity towards the conversion of syngas to light olefins. Light olefins produced in our case mostly comprised of C 2 /C 3 . A series of multimetallic catalyst also synthesized and their performance was evaluated for the conversion of syngas to the production of oxygenates. In case of oxygenates, our specific focus was to maximize the selectivity of C 2+ oxygenates which is a precursor for fuel or can be used as high value chemicals. In this direction, we have identified several Rh based catalysts that are specifically shows superior activity towards oxygenates formation.

10 SYNTHETIC FUELS↗
DOE OSTI2020

Isotopic Studies for Tracking Biogenic Carbon during Co-processing of Biomass and Vacuum Gas Oil

Co-processing bio-oils with petroleum-derived feeds in the existing multitrillion dollar refining and distribution infrastructure is an attractive option for introducing renewable energy into the fuels marketplace. Considerable research on co-processing bio-oils and vacuum gas oil (VGO) in fluid catalytic cracking units (FCC) using equilibrium catalysts (E-Cats) demonstrated that biomass-derived molecules decreased activity of and increased carbon laydown on E-Cat. In this work, 13 C-labeled biomass was co-processed with VGO using either an E-Cat or a proprietary zeolite Johnson Matthey catalyst (CP758), which is optimzed for upgrading biomass vapors in a riser reactor, to evaluate the fate of biogenic carbon in FCC products. The results from both catalysts indicate that biogenic carbon was incorporated into alkenes and aromatic hydrocarbons. While no biogenic carbon was found in linear alkanes, it was observed in cycloalkanes during experiments with E-Cat but not with CP758. All produced CO2 was biogenic as was most of the carbon laydown on the catalysts. Several partially deoxygenated biomass compounds, such as alkylphenols and benzofurans, unexpectedly contained small amounts of carbon from VGO. Although this study was conducted with labeled biomass and not bio-oil, it provides insights to reaction mechanisms for co-processing bio-oil and VGO in an FCC, which is required to develop catalysts that efficiently convert bio-oil components during FCC co-processing. This work also demonstrates that comprehensive catalyst development utilizing both biomass- and fossil-derived feeds is required to maximize the incorporation of biogenic carbon into transportation fuels.

09 BIOMASS FUELS↗
DOE OSTI2021

Introduction to (Photo)electrocatalysis For Renewable Energy

Humanity is facing a significant and growing energy demand, necessitating a new energy paradigm built on clean and abundant renewable energy.1 Within this context, electrocatalysis and (photo)electrocatalysis hold great promise for enabling renewable energies such as solar and wind power to overcome the transient nature of their energy output.2-6 Developing catalysts that operate efficiently and selectively, and that are also robust, has been the focus of much research. This special issue brings together the latest advances in the fundamental and applied science addressing the synthesis, characterization, mechanisms, and performance of (photo)electrocatalysts for energy storage and conversion of small molecules into useful specialty and commodity chemicals and fuels. The electrocatalysts and (photo)electrocatalysts highlighted in this issue include metalloenzymes, homogeneous and supported molecular catalysts, and diverse heterogeneous nanoparticulate and thin film systems. The reports span across basic and applied studies and encompass both experimental and theoretical investigations.

Dey, Abhishek↗
DOE OSTI2023

Microwave-assisted depolymerization of PET over heterogeneous catalysts

The accumulation of plastic waste in the environment is rising and poses a significant environmental and health threat. Polyethylene terephthalate (PET), used mainly in single-use plastic bottles, accounts for a substantial fraction of this waste. The currently employed recycling strategies are inadequate to deal with the global plastic waste problem. PET glycolysis is a promising depolymerization method but has mainly been conducted using homogeneous catalysts; developing active and sustainable catalysts, and more energy-efficient processes remain challenges. Here, in this work, we implement microwave heating in PET glycolysis and identify ZnO as an excellent heterogeneous catalyst. We demonstrate the influence of ZnO's particle size and facet and hydrogen bonding on its activity. Finally, we demonstrate excellent performance for real-world post-consumer PET waste deconstruction with rapid depolymerization into bis(2-hydroxyethyl) terephthalate (BHET), achieving > 95% yields in less than 10 min. Cradle-to-gate life cycle assessment also indicates that BHET produced by ZnO-catalyzed glycolysis has lower global warming potential than the petrochemical-based production and homogeneously-catalyzed glycolysis.

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

Nanoporous Iridium Nanosheets for Polymer Electrolyte Membrane Electrolysis

The growth of the hydrogen economy is predicated on advancements in electrochemical energy technologies, with water electrolysis as a key component to the technological portfolio. Much of the focus on anode catalyst development for polymer electrolyte membrane water electrolyzers (PEMWE) is centered on activity as controlled by compositional and morphological impacts on reactant/intermediate/product adsorption. However, the effectiveness of this strategy is found to be limited upon integration of these materials into PEMWE membrane electrode assemblies (MEA). Regardless of catalyst activity, the combination of electrode inhomogeneity, ionomer integration, and high density of oxide-oxide interfaces yields significant performance losses associated with poor catalytic electrode conductivity. Here many of these limitations are addressed through the development of a unique catalyst morphology composed of nanoporous Ir nanosheets (npIr(x)-NS) that exhibit high catalytic activity for the anodic oxygen evolution reaction and superior electrode electronic conductivity in comparison to a commercial IrO2 nanoparticle catalyst. The utility of the npIr(x)-NS is demonstrated through incorporation into PEMWE MEAs where their performance exceeds that of commercial catalyst coated membranes at loadings as low as 0.06 mg(Ir) cm(-2) while exhibiting a negligible loss in performance following 50 000 accelerated stress test cycles.

Polymer Electrolyte Membrane Electrolysis↗
DOE OSTI2018

Trends in the Catalytic Activity of Hydrogen Evolution during CO 2 Electroreduction on Transition Metals

During CO 2 electroreduction (CO 2 R), the hydrogen evolution reaction (HER) is a competing reaction. We present a combined experimental and theoretical investigation of the HER activity of transition metals under CO 2 R conditions. Experimental HER polarization curves were measured for six polycrystalline metal surfaces (Au, Ag, Cu, Ni, Pt, and Fe) in the presence of CO 2 gas. We found that the HER activity of the transition metals is significantly shifted, relative to the CO 2 -free case. Density functional theory (DFT) calculations suggest that this shift arises from adsorbate–adsorbate interactions between *CO and *H on intermediate and strong binding metals, which weakens the *H binding energy. Using a simple model for the effect of *CO on the *H binding energy, we construct an activity volcano for HER in the presence of CO 2 gas that is consistent with experimental trends. In conclusion, the significant changes in HER activity in the presence of CO 2 gas is an important consideration in catalyst design and could help develop catalysts that are more selective for CO 2 R than the HER.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

Development of activity–descriptor relationships for supported metal ion hydrogenation catalysts on silica

With the increasing attention on single-site heterogeneous catalysts on account of their high specific activity, more effective catalyst design strategies are necessary. We demonstrate a first-principles-calculation-guided active-site design strategy for alkene hydrogenation using silica-supported single-atom single-site heterogeneous catalysts (SSHCs, i.e., M/SiO2). An activity-descriptor relationship for propylene hydrogenation was established using representative catalysts (i.e., Ga3+, Zn2+, Mn2+ and Ti4+/SiO2), correlating the computational activity descriptor (i.e., the reaction free energy of the metal hydride formation) with the experimental reaction rates. Microkinetic modeling confirmed the predicted reaction mechanisms and further explained the rationale of the activity-descriptor relationship. This relationship was then used to predict the trend of activities of a variety of isolated ions on silica, and an In3+/SiO2 catalyst was identified as the most promising candidate based on its predicted activity and synthetic feasibility. The monodispersed In3+/SiO2 catalyst was then synthesized, for the first time, and showed higher propylene hydrogenation activity than the other four single-atom SSHCs, as predicted. Detailed spectroscopic characterization (XAS, XPS, DRIFTS and DRUV-Vis) provided insights into coordination environments and oxidation states of the catalysts, as well as evidence for the hydride intermediate. The successful discovery of the In3+/SiO2 catalyst for propylene hydrogenation using the first-principles-calculations-guided design strategy opens up new opportunities for efficient development of single-atom SSHCs.

DFT↗