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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Pathway to Complete Energy Sector Decarbonization with Available Iridium Resources using Ultralow Loaded Water Electrolyzers

We present ultralow Ir-loaded (ULL) proton exchange membrane water electrolyzer (PEMWE) cells that can produce enough hydrogen to largely decarbonize the global natural gas, transportation, and electrical storage sectors by 2050, using only half of the annual global Ir production for PEMWE deployment. This represents a significant improvement in PEMWE's global potential, enabled by careful control of the anode catalyst layer (CL), including its mesostructure and catalyst dispersion. Using commercially relevant membranes (Nafion 117), cell materials, electrocatalysts, and fabrication techniques, we achieve at peak a 250× improvement in Ir mass activity over commercial PEMWEs. An optimal Ir loading of 0.011 mg Ir cm -2 operated at an Ir-specific power of ~100 MW kg Ir -1 at a cell potential of ~1.66 V versus RHE (85% higher heating value efficiency). Here, we further evaluate the performance limitations within the ULL regime and offer new insights and guidance in CL design relevant to the broader energy conversion field.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1993

Recent advances in SPE (tm) water electrolyzer

A new cell structure has been introduced into the SPE Water Electrolyzer which has improved overall characteristics significantly. Weight, reliability, and efficiency are the characteristics that are improved the most, with volume having a second order improvement. This paper discusses the capabilities of the new cell structure and the impact it would have in various space applications.

Mcelroy, James F.↗
DOE OSTI2024

Constructing Highly Porous Low Iridium Anode Catalysts Via Dealloying for Proton Exchange Membrane Water Electrolyzers

Iridium (Ir) is the most active and durable anode catalyst for the oxygen evolution reaction (OER) for proton exchange membrane water electrolyzers (PEMWEs). However, their large-scale applications are hindered by high costs and scarcity of Ir. Lowering Ir loadings below 1.0 mgcm -2 causes significantly reduced PEMWE performance and durability. Therefore, developing efficient low Ir-based catalysts is critical to widely commercializing PEMWEs. Herein, an approach is presented for designing porous Ir metal aerogel (MA) catalysts via chemically dealloying IrCu alloys. In this study, the unique hierarchical pore structures and multiple channels of the Ir MA catalyst significantly increase electrochemical surface area (ECSA) and enhance OER activity compared to conventional Ir black catalysts, providing an effective solution to design low-Ir catalysts with improved Ir utilization and enhanced stability. An optimized membrane electrode assembly (MEA) with an Ir loading of 0.5 mg Ir cm -2 generated 2.0 A cm -2 at 1.79 V, higher than the Ir black at a loading of 2.0 mg Ir cm -2 (1.63 A cm -2 ). The low-Ir MEA demonstrated an acceptable decay rate of ≈40 µV h -1 during durability tests at 0.5 (>1200 h) and 2.0 A cm -2 (400 h), outperforming the commercial Ir-based MEA (175 µV h -1 at 2.0 mg Ir cm -2 ).

36 MATERIALS SCIENCE↗
DOE OSTI2026

Cyclic olefin copolymer-based reinforced anion exchange membranes for water electrolyzers

Anion exchange membranes (AEMs) have emerged as a promising technology for water electrolysis in hydrogen production since they offer significant cost reduction in choices of electrocatalysts and bipolar plates. However, AEMs satisfying multiple requirements of high ionic conductivity, good chemical stability, robust mechanical properties, scalable synthesis, and low manufacturing costs are rare. Herein, we introduce quaternary ammonium functionalized cyclic olefin copolymers (COCs) as a new class of chemically stable and low-cost AEM materials. To further enhance the mechanical robustness, we prepared reinforced composite AEMs by impregnating the ionically functionalized COC into a mechanically robust matrix. The resulting reinforced composite membrane exhibits a high hydroxide conductivity of 127 mS cm −1 and excellent mechanical strength. In water electrolyzers, the MEA demonstrated outstanding performance, achieving a current density of 2.24 A cm −2 at 1.8 V, attributable to high conductivity, enhanced mechanical properties, and good alkaline stability of the composite membrane. These results indicate that the COC-based AEMs demonstrate good potential for application in AEM electrolyzers.

08 HYDROGEN↗
DOE OSTI2026

The Impact of Operational Strategies and Load Fluctuations on Anion Exchange Membrane Water Electrolyzer Degradation

This study reports on the durability of anion exchange membrane water electrolyzers (AEMWEs) at the cell level in a supporting electrolyte (1 M) and the impact of operational profiles on cell degradation. While constant load shows significant voltage loss, including a current hold at 1 A cm −2 and a potential hold at 2 V, it generally occurs in the first 70 h of testing. These losses are likely due to passivation altering site reactivity and cell kinetics, and are largely recoverable upon load cycling and diagnostics at the end of test. Furthermore, square and triangular-wave cycling do not show cell degradation and indicate that AEMWEs are not vulnerable to load cycling. When operating outside of this potential window (1.45–2 V), cell voltage decay rates markedly increase and the losses are not recoverable. This includes a current density hold at 4.0 A cm −2 with high cell voltages (>2.4 V for test duration) and cycling between 0 and 2 V to simulate start–stop, where more than a 50% loss in current density occurs over 50 h. The findings presented here demonstrate the high durability of AEMWEs, particularly when operating with load fluctuations, and may allow for durability advantages compared to iridium and proton exchange membrane systems.

08 HYDROGEN↗
DOE OSTI2022

Low-Cost, High Performance Catalyst Coated Membranes for PEM Water Electrolyzers (Final Technical Report)

In this project, the objective was to develop reduced-cost manufacturing techniques capable of producing proton exchange membrane water electrolyzer (PEMWE) catalyst coated membranes (CCMs) with further improved performance relative to then-current 3M CCM technology. Processes to be developed would enable 1) production of 0.5 m wide CCMs (approximately 2x wider than produced by the current laboratory/pilot-scale processes) and 2) 3x higher net-effective linear rates (lineal-meters of CCM produced per cumulative process time) than the baseline CCM process. In combination, the wider width CCM and increased net-effective linear rates would result in a 6-fold decrease in CCM manufacturing cost (defined as cumulative machine and labor time) per m 2 of CCM produced. PEMWE CCMs produced with these optimized processes were targeted to produce 1) 0.25 A/cm 2 or greater at 1.5 V, 2) 2.0 A/cm 2 or greater at 1.75 V and 3) 4 A/cm 2 or greater at 1.95V, 4) with total catalyst platinum-group metal (PGM) loadings of ≤ 0.50 mg/cm 2 , measured in a cell with 50 cm 2 active area (or larger) at 80°C cell temperature and ambient outlet pressures.

08 HYDROGEN↗
DOE OSTI2020

High-performance and cost-effective membrane electrode assemblies for advanced proton exchange membrane water electrolyzers: Long-term durability assessment

In this work, improved activity and durability performance of a two-cell (86 cm 2 ) proton exchange membrane water electrolyzer (PEMWE) stack is reported for the first time. Both membrane electrode assemblies (MEAs) contain one order of magnitude lower platinum group metal (PGM) loadings compared to the state-of-the-art PEMWEs and incorporate novel Pt recombination layers. The high-performance and cost-effective MEAs are fabricated by the unique reactive spray deposition technology (RSDT). This advanced methodology allows for one-step fabrication of MEAs and ensures precise control and distribution of the catalyst composition and loading. The RSDT-fabricated MEAs contain only 0.2 and 0.3 mg PGM cm –2 loading in the cathode and anode electrodes, respectively, and demonstrate excellent activity and durability for over 3000 h of operation at industrially-relevant operating conditions without showing significant loss in performance. This novel work shows that a significant cost reduction for PEMWEs is achieved while maintaining excellent durability, high catalysts activities, and low hydrogen cross-over.

Proton exchange membrane water electrolyzer↗
DOE OSTI2025

Stable Metal–Organic Electrocatalysts for Anion-Exchange Membrane Water Electrolyzers by Defect Engineering

Developing efficient and durable catalysts for the alkaline oxygen evolution reaction (OER) is vital to achieving practical anion-exchange membrane water electrolyzers (AEMWE) for green hydrogen production. In this work, we break the activity-stability trade-off of electrocatalysis by defect engineering of Ni-based metal-organic electrocatalysts (Ni-benzene dicarboxylate; Ni-BDC) through coordinating ferrocenecarboxylates (Fc) to the metal sites. Experimental results collectively reveal that the defect MOF (Ni-BDC:Fc_5:1) exhibits a high OER turnover frequency of 0.75 O 2 s -1 at 300 mV overpotential. Operando Raman spectroscopy and isotope-labelling electrochemical mass spectrometry measurements indicate the structure of Ni-BDC:Fc_5:1 is also more stable in service than that of pure Ni-BDC. The high activity and stability could be attributed to the moderate defects (i.e., unsaturated Ni sites) in the structure that not only increase the intrinsic activity and stability of the local active environment by inhibiting lattice oxygen exchange, but also electrochemically activates the bulk of the catalysts by creating a porous network that facilitates internal H 2 O/OH - conduction with enhanced electronic conduction. Accordingly, an AEMWE employing Ni-BDC:Fc_5:1 as the OER catalyst delivers an industrial-level current density of 1 A cm -2 at 1.73 V cell and can be steadily operated for more than 120 hours.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

La–Sr–Co oxide catalysts for oxygen evolution reaction in anion exchange membrane water electrolyzer: The role of electrode fabrication on performance and durability

Anion exchange membrane water electrolysis is an attractive technology for low-cost generation of “green” hydrogen by combining the use of noble metal-free catalysts with pure water feed. By thus addressing main drawbacks of the liquid alkaline electrolysis and proton exchange membrane water electrolysis, anion exchange membrane water electrolysis stands an excellent chance of replacing the two technologies. The development of active and stable platinum group metal (PGM)-free catalysts for oxygen evolution reaction (OER) is crucial for making anion exchange membrane water electrolyzers (AEMWEs) practical. For this work, we synthesized, characterized and tested two La–Sr–Co oxide-based OER catalysts. First, we characterized the catalysts by XRD, SEM, and N 2 physisorption and assessed their OER activity in a three-electrode cell. Next, we focused on electrode fabrication, demonstrating the importance of catalyst-ink application to the porous transport layers (PTLs) and a key role of adding a binder to the catalyst ink to prevent the catalyst detachment from the PTL in pure water. We tested three membrane electrode assemblies prepared using different formulations of the anode catalyst ink. The results show that the optimum ink formulation is essential for the performance on pure-water feed by maximizing OH - conductivity of the catalyst layer and catalyst-membrane interface.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

Degradation Effects at the Porous Transport Layer/Catalyst Layer Interface in Polymer Electrolyte Membrane Water Electrolyzer

The porous transport layer (PTL)/catalyst layer (CL) interface plays a crucial role in the achievement of high performance and efficiency in polymer electrolyte membrane water electrolyzers (PEMWEs). This study investigated the effects of the PTL/CL interface on the degradation of membrane electrode assemblies (MEAs) during a 4000 h test, comparing the MEAs assembled with uncoated and Ir-coated Ti PTLs. Our results show that compared to an uncoated PTL/CL interface, an optimized interface formed when using a platinum group metal (PGM) coating, i.e., an iridium layer at the PTL/CL interface, and reduced the degradation of the MEA. The agglomeration and formation of voids and cracks could be found for both MEAs after the long-term test, but the incorporation of an Ir coating on the PTL did not affect the morphology change or oxidation of IrO x in the catalyst layer. In addition, our studies suggest that the ionomer loss and restructuring of the anodic MEA can also be reduced by Ir coating of the PTL/CL interface. Optimization of the PTL/CL interface improves the performance and durability of a PEMWE.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2023

Pathways Toward Efficient and Durable Anion Exchange Membrane Water Electrolyzers Enabled By Electro‐Active Porous Transport Layers

Abstract Green hydrogen, produced via water electrolysis using renewable electricity, will play a crucial role in decarbonizing industrial and heavy‐duty transportation sectors. Anion exchange membrane water electrolyzers (AEMWEs) can overcome many of the performance and cost limitations of incumbent technologies, however, still suffer from durability challenges due to oxidative instability of anion‐exchange ionomers. Herein, the use of an electro‐active porous transport layer as anode (PTL‐electrode) is demonstrated to enable efficient and durable AEMWEs. The stainless‐steel PTL‐electrodes are shown to have superior performance and durability compared to traditional catalyst layers containing ionomer and nanoparticle catalysts. An AEMWE cell operating at 2 A cm −2 for over 600 h exhibited a degradation rate of just 5 µV h −1 . During operation, the surface composition of the stainless steel transforms into a mixture of iron and nickel oxyhydroxides, contributing to enhanced oxygen‐evolution reaction activity. The combination of experimental work and modeling elucidates how the bulk structure of the PTL‐electrode offers an additional design dimension to further improve electrolyzer performance. Lastly, a surface modification strategy is applied to a PTL‐electrode to achieve an even higher performing AEMWE (2.3 vs 2.0 A cm −2 at 1.8 V). Overall, this work lays out pathways toward more efficient, durable, and affordable AEMWEs.

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

CalTestBed - EvolOH - Testing of Hydroxide Exchange Membrane Water Electrolyzers and their Components (CRADA Final Report)

EvolOH is a Hydroxide Exchange Membrane Water Electrolyzer (HEMWE) company located in Menlo Park. LBNL helped EvolOH optimize MEA performance and durability through in/ex-situ materials characterization techniques. The finding of this project was used to develop an understanding of the performance limitations and component characterization toward commercializing HEMWE technology.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Zinc treatment to enhance nickel electrode performance for liquid alkaline water electrolyzers

Raney Ni treatment is introduced to the surface of Ni mesh anode electrodes, enhancing liquid alkaline water electrolyzer performance. The surface of the Ni mesh is alloyed with Zn, deposited by either an aqueous infiltration of Zn salt or direct reaction with Zn foil. The extent of alloying is controlled by a heat treatment step. For both processes, fine porosity and enhanced surface area are obtained after leaching the Zn out of the surface alloy layer. The observed electrode surface structure and performance is quite sensitive to the thermal treatment temperature. The enhanced surface area improves full cell performance by 90 mV for infiltrated Zn treated at 600 °C and by 185 mV for Zn foil reacted at 425 °C (at 2 A cm −2 and 80 °C). In conclusion, the Zn treatment methods produce stable operating performance, exhibiting no decay after 150 h for the infiltrated Zn treated at 600 °C, and a decay rate of 4.6 μV h −1 over 100 h for the Zn foil reacted at 425 °C (at 1 A cm −2 and 80 °C).

LAWE↗
DOE OSTI2021

Elucidating the Role of Hydroxide Electrolyte on Anion-Exchange-Membrane Water Electrolyzer Performance

Many solid-state devices, especially those requiring anion conduction, often add a supporting electrolyte to enable efficient operation. The prototypical case is that of anion-exchange-membrane water electrolyzers (AEMWEs), where addition of an alkali metal solution improves performance. However, the specific mechanism of this performance improvement is currently unknown. This work investigates the functionality of the alkali metal solution in AEMWEs using experiments and mathematical models. The results show that additional hydroxide plays a key role not only in ohmic resistance of the membrane and catalyst layer but also in the reaction kinetics. The modeling suggests that the added liquid electrolyte creates an additional electrochemical interface with the electrocatalyst that provides ion-transport pathways and distributes product gas bubbles; the total effective electrochemical active surface area in the cell with 1 M KOH is 5 times higher than that of the cell with DI water. In the cell with 1 M KOH, more than 80% of the reaction current is associate with the liquid electrolyte. These results indicate the importance of high pH of electrolyte and catalyst/electrolyte interface in AEMWEs. The understanding of the functionality of the alkali metal solution presented in this study should help guide the design and optimization of AEMWEs.

25 ENERGY STORAGE↗
DOE OSTI2026

Impact of Porous Transport Layer Morphology on the Performance of Proton Exchange Membrane Water Electrolyzers with Ultra-Low Iridium Loadings

Reducing Ir loadings in proton exchange membrane water electrolyzer anodes is critical for lowering capital expenses. Loading reduction could be achieved by improving the Ir activity via doping/alloying and/or the development of advanced microstructures. However, the anode porous transport layer (PTL) is a comparatively simple component whose properties also impact Ir utilization. Therefore, well-designed PTLs may also enable reduced Ir loadings. In this work, we survey eight PTLs from various manufacturers to observe their impact on cell performance at low (0.4 mg Ir cm -2 ) and ultralow (0.1 mg Ir cm -2 ) Ir loadings. The PTLs were characterized by their microstructural properties, including porosity, particle size distribution, and pore size distribution. Electrochemical cell performance was correlated to PTL morphology, and it was found that PTLs with lower porosities and smaller particle and pore radii enabled good performance even at ultralow Ir loadings. 1000-h durability testing indicated that using lower porosity PTLs can significantly improve durability behavior. A runaway voltage phenomenon was observed during durability testing of cells with ultralow Ir loadings, which was caused by increases in both anode and cathode overpotentials. Furthermore, we observed that the beginning of test performance of 0.1 mg Ir cm -2 cells correlates to the 1000-h degradation rates of 0.4 mg Ir cm -2 cells, suggesting that for the Ir catalyst used in this work, short-term testing at ultralow loadings can be used as an indicator of long-term degradation at higher loadings.

08 HYDROGEN↗
DOE OSTI2025

Comparing Intrinsic Catalytic Activity and Practical Performance of Ni- and Pt-Based Alkaline Anion Exchange Membrane Water Electrolyzer Cathodes

The stringent cost and performance requirements of renewable hydrogen production systems dictate that electrolyzers benefit from the use of nonprecious catalysts only if they deliver the same level of activity and durability as their precious metal counterparts. Here we report on recent work to understand interrelationships between the intrinsic activity of Ni- and Pt-based electrolyzer cathode catalysts and their performance in zero-gap alkaline water electrolyzer assemblies. Our results suggest that nanoparticulate Ni–Mo exhibits HER activity that is roughly 10-fold lower than Pt–Ru on the basis of turnover frequency under low (≤100 mV) polarization conditions. We further found that the HER activity of Ni–Mo/C cathodes is inhibited by aryl piperidinium anionexchange ionomers bearing bicarbonate counter-anions. After addressing this poisoning effect, we produced electrolyzer assemblies based on Ni–Mo/C cathodes that delivered indistinguishable current density vs cell potential relationships compared to otherwise identical assemblies with Pt–Ru cathodes. This result indicates that the contribution of the cathode to the total cell polarization is small, even for the less active Ni–Mo/C catalyst, and further implies that Pt-based cathodes can indeed be replaced by nonprecious alternatives with no loss in performance.

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

EWTN: Quantifying Mass Transport to Enable Water Electrolyzer Architectures with Low Flow-Rate Sensitivity

To develop cost-effective and high-performing polymer electrolyte water electrolyzers (PEWEs) for gigawatt-scale applications, researchers have focused on reducing precious metal catalyst loadings and optimizing porous transport layers. However, the performance of PEWEs is also affected by system architecture. Mass transport losses are dependent on localized architecture and material interactions. In-situ measurements, such as current density distribution maps have demonstrated advantages in understanding the intricate characteristics and influence of two-phase flow within PEWEs. This study proposes the parameter of effective water transport number (EWTN) as a quantitative tool to investigate such current density distribution (CDD) measurements for PEWEs. Results show that higher flow-rates have EWTN values of 0.95 and above, indicating no mass transport limitations; while lower flow-rates with large gradients CDD have EWTN values between 0.6-0.8, indicating mass transport limited conditions. The new analysis also identified a correlation between mass transport losses due to bubble accumulation, membrane hydration, and ohmic overpotentials. To address these limitations, an unitized pin-type LGDL/flow-field design was developed, which effectively prevents local gas phase accumulation, resulting in improved mass transport characteristics. The results of this work show reduced flow-rate sensitivity with the pin-type architecture and ∼13% increased performance at 0.24 ml / min / cm 2 .

Electrochemistry↗