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At least 73 records · Page 4

NMPC for Setpoint Tracking Operation of a Solid Oxide Electrolysis Cell System

Solid oxide electrolysis cells (SOECs) are a promising technology to generate hydrogen through water electrolysis. However, intermittent renewable energy requires SOECs to transition between hydrogen production setpoints as the price of electricity fluctuates. A well-functioning control system is important to avoid cell degradation during setpoint tracking operation. In this work, we apply nonlinear model predictive control (NMPC) to an SOEC module and supporting equipment and compare NMPC performance to classical PI control while ramping between hydrogen production setpoints. We find that these control methods provide similar performance in many metrics, but NMPC significantly reduces cell thermal gradients during the setpoint transition.

Allan, Douglas↗

Methanol from Integrated Direct Air Capture and Ceramic Electrolysis (MIDACE)

The Methanol from Integrated Direct Air Capture and Ceramic Electrolysis (MIDACE) project advanced a novel system concept for integrating pressurized co-electrolysis of steam and crude carbon dioxide captured directly from ambient air using a sorbent technology. The co-electrolysis produced syngas provides feedstock for a gas-to-liquid methanol synthesis reactor. The system recovers waste heat from the reactor and electrolyzer into regenerating the direct air capture sorbent. The purpose of the project was to demonstrate critical integration elements of the design and perform a technical study illustrating how a large-scale installation could achieve the $800/ton program target for green methanol production. The concept addresses the program objective to consolidate operations by combining crude CO 2 cleanup, hydrogen production, and partial CO 2 reduction steps within a carbon tolerant high temperature electrolyzer. The design lowers costs by simplifying the methanol recovery cycle, reducing carbon losses from venting, reducing sensitivity to catalyst selectivity, and avoiding syngas compression.

10 SYNTHETIC FUELS↗

Techno-Economic Analysis of Large-Scale Hydrogen Production from Solid Oxide Electrolysis Cell Systems

The objective of this study is to establish a detailed techno-economic analysis to assess the effectiveness of incremental technology improvements needed for solid oxide electrolysis cell (SOEC) technology to achieve the U.S. DOE’s Hydrogen Shot goal of hydrogen production at less than $1 per kilogram. The pathway considers incremental technology improvements to key system parameters, with system performance and cost assessed for each pathway step. Briefly, the steps include cell voltage degradation rate improvements, operational current density increases, operating temperature reduction, improved steam utilization, increased system capacity factor, and reduced cell/stack capital costs. Each step is assessed at both atmospheric and pressurized (8 bar) operating conditions. To supplement assessment at each of these discrete stepwise improvements, sensitivity studies are conducted to understand the relative impact of each parameter and identify avenues for additional cost reductions. System efficiency and levelized costs of hydrogen (LCOH) for each case are presented. For the end-of-pathway case, which includes all the incremental research and development improvements, the cost of hydrogen produced is reduced by 50 percent from the state-of-the-art case.

08 HYDROGEN↗

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↗

Electrochemical Conversion of Carbon Dioxide to Alcohols

The vast quantities of fossil fuels used by our society have led to unprecedented atmospheric carbon dioxide levels with widespread climate impacts. Electrochemical conversion of carbon dioxide to valuable fuels and chemicals is a promising technology to utilize carbon dioxide emitted from coal-fired power plants. In this project, the team developed an integrated electrolyzer system that takes the flue gas from the power plant and produce C2/C3 alcohols (i.e., ethanol and n-propanol) through a two-stage electrolysis process. The pretreated carbon dioxide from the flue gas is converted into carbon monoxide by the first stage carbon dioxide electrolysis, followed by the second stage where the produced carbon monoxide is further converted into liquid C2/C3 alcohols with a high selectivity and energy efficiency. Impact and anticipated fate of flue gas contaminants, such as sulfur dioxide and nitrogen oxides, on the proposed technology was also evaluated. Furthermore, a full analysis of economics and life-cycle of the carbon dioxide electrolysis technology for carbon dioxide emissions mitigation from coal-fired power plants was conducted to evaluate the economic feasibility and carbon dioxide mitigation potential of the proposed technology.

20 FOSSIL-FUELED POWER PLANTS↗

Performance and community structure dynamics of microbial electrolysis cells operated on multiple complex feedstocks

Microbial electrolysis is a promising technology for converting aqueous wastes into hydrogen. However, substrate adaptability is an important feature, seldom documented in microbial electrolysis cells (MECs). In addition, the correlation between substrate composition and community structure has not been well established. This study used an MEC capable of producing over 10 L/L-day of hydrogen from a switchgrass-derived bio-oil aqueous phase and investigated four additional substrates, tested in sequence on a mature biofilm. The additional substrates included a red oak-derived bio-oil aqueous phase, a corn stover fermentation product, a mixture of phenol and acetate, and acetate alone. The MECs fed with the corn stover fermentation product resulted in the highest performance among the complex feedstocks, producing an average current density of 7.3 ± 0.51 A/m 2 , although the acetate fed MECs outperformed complex substrates, producing 12.3 ± 0.01 A/m 2 . 16S rRNA gene sequencing showed that community structure and community diversity were not predictive of performance, and replicate community structures diverged despite identical inoculum and enrichment procedure. The trends in each replicate, however, were indicative of the influence of the substrates. Geobacter was the most dominant genus across most of the samples tested, but its abundance did not correlate strongly to current density. High-performance liquid chromatography (HPLC) showed that acetic acid accumulated during open circuit conditions when MECs were fed with complex feedstocks and was quickly degraded once closed circuit conditions were applied. The largest net acetic acid removal rate occurred when MECs were fed with red oak bio-oil aqueous phase, consuming 2.93 ± 0.00 g/L-day. Principal component analysis found that MEC performance metrics such as current density, hydrogen productivity, and chemical oxygen demand removal were closely correlated. Net acetic acid removal was also found to correlate with performance. However, no bacterial genus appeared to correlated to these performance metrics strongly, and the analysis suggested that less than 70% of the variance was accounted for by the two components. This study demonstrates the robustness of microbial communities to adapt to a range of feedstocks and conditions without relying on specific species, delivering high hydrogen productivities despite differences in community structure. The results indicate that functional adaptation may play a larger role in performance than community composition. Further investigation of the roles each microbe plays in these communities will help MECs to become integral in the 21st-century bioeconomy to produce zero-emission fuels.

09 BIOMASS FUELS↗

Insights into catalyst degradation during alkaline water electrolysis under variable operation

Energy conversion technologies that are key to decarbonization efforts face significant durability challenges due to variable operation. Understanding the impact of variable operation on catalytic stability and identifying the key variables that dictate degradation is crucial for developing robust technologies. Here, we present a comprehensive investigation of the effects of variable operation on liquid alkaline water electrolysis. Our findings reveal that variable operation induces severe degradation of Ni, Fe, and Co catalytic films that is not observed during steady-state operation. By systematically interrogating the electrode discharge during simulated shutdown tests using Raman spectroscopy and mass spectrometry techniques, we uncover significant alterations caused by reverse currents in real time. These include changes in crystal structure, composition, film thickness, electronic conductivity, and dissolution rates. Lab-scale electrolyzer experiments further highlight the impact of variable operation on catalyst materials under relevant conditions. Finally, we provide guidelines for leveraging these insights to advance electrocatalysis research. This work underscores the importance of integrating realistic stressors into stability testing and offers practical guidelines for catalyst design, performance evaluation, and industrial implementation. Collectively, insights from this study will drive the development of more resilient energy conversion technologies.

Marquez, Raul A. [Univ. of Texas, Austin, TX (Unit↗

A novel green hydrogen production using water-energy nexus framework

The transformation of electrical energy to hydrogen via water electrolysis consumes considerable amount of fresh water and a productive use of nontraditional water sources enhances the reliability and resilience of energy and water systems. In this study, we have designed a solid oxide electrolysis cell (SOEC) system which is an evolving hydrogen production technology at high temperatures for water electrolysis. Here, the SOEC uses steam generated from flue gas as its feedstock and is fully integrated with numerous power production units, including coal and natural gas-fired power plants as its energy feedstock. While there is a hasten global shift away from fossil fuel, integrating its asset into this technology helps limit the risk and future losses of stranded assets and reduce the cost of investment in the new technologies. But high capital expenditures and doubt concerning the future cost and efficiency upgrade are obstacles to investing in water electrolysis. Such a detailed Levelized cost of hydrogen and techno-economic analysis is conducted to show the viability and environmental impacts of this novel technology. The results show SOEC efficiency of 97.4 % and 56.3 % as thermal-to-hydrogen efficiency of the system with a daily hydrogen production of 242,400 kg at $2.9–3.5/kg H 2 . The estimates show a positive gain prospect in this technology and techno-economic challenges.

08 HYDROGEN↗

HydroGEN Consortium: Advancements in Hydrogen Production

HydroGEN Energy Materials Network (EMN) is an U.S. Department of Energy (DOE) EERE Hydrogen and Fuel Cell Technologies Office (HFTO)-funded consortium that aims to accelerate the discovery and development of advanced water splitting materials (AWSM) for clean, low-cost hydrogen production. Materials innovations are key to enhancing performance, durability, and cost of hydrogen generation technologies. HydroGEN is focused on low technology readiness level AWS technologies, including low- (alkaline exchanged membrane electrolysis) and high-temperature electrolysis (proton-conducting solid oxide electrolysis), photoelectrochecmical (PEC) and thermochemical (TCH) water splitting. The AWS technologies in this consortium study proton conduction in solid oxide electrolysis and hydroxide conduction in polymer electrolysis, and proton transport in photoelectrochemical water splitting. This presentation will provide an overview of the HydroGEN EMN and technical highlights of a few lab-led and DOE-awarded "seedling" R&D projects. HydroGEN continues to grow its community of industry, university, and national laboratories, forming a national innovation ecosystem focused on renewable hydrogen production.

08 HYDROGEN↗

HydroGEN Consortium

HydroGEN Energy Materials Network (EMN) is an U.S. Department of Energy (DOE) EERE Hydrogen and Fuel Cell Technologies Office (HFTO)-funded consortium that aims to accelerate the discovery and development of advanced water splitting materials (AWSM) for clean, low-cost hydrogen production. Materials innovations are key to enhancing performance, durability, and cost of hydrogen generation technologies. HydroGEN is focused on low technology readiness level AWS technologies, including low- (alkaline exchanged membrane electrolysis) and high-temperature electrolysis (proton-conducting solid oxide electrolysis), photoelectrochecmical (PEC) and thermochemical (TCH) water splitting. The AWS technologies in this consortium study proton conduction in solid oxide electrolysis and hydroxide conduction in polymer electrolysis, and proton transport in photoelectrochemical water splitting. This presentation will provide an overview of the HydroGEN EMN and technical highlights of a few lab-led and DOE-awarded "seedling" R&D projects. HydroGEN continues to grow its community of industry, university, and national laboratories, forming a national innovation ecosystem focused on renewable hydrogen production.

08 HYDROGEN↗

(Invited) Utilization of Bio-CO 2 and Bio-Methane for Fuel Production: Integration Solid Oxide Electrolyzer, Low Energy Plasma Reformer with Fischer-Tropsch Synthesis

Transition to renewable energy is essential to achieve climate protection objectives. Besides storing electricity for later use, fuel production using renewable energy is an essential part of reducing fossil dependance. The highest value application in current markets is the production of liquid transportation fuels such as sustainable aviation fuels (SAF) from sustainable, ideally biogenic carbon resources. A system is presented for processing anaerobic digester gas for liquid hydrocarbon production. Bio-CO 2 is processed through a solid oxide electrolysis cell and bio-CH 4 through a low energy plasma reformer. The combined synthesis gas is supplied to a Fischer-Tropsch reactor for the production of liquid hydrocarbons. The combination of technologies nearly doubles the yield of biofuel by utilizing the bio-CO 2 in addition to the bio-CH 4 . Here, the product fuel is all bio-carbon but it also embodies renewable electric energy in a high-value, storable and transportable liquid hydrocarbon.

09 BIOMASS FUELS↗

Editorial: Advanced water splitting technologies development: Best practices and protocols

As the level of deployment and utilization of renewable energy sources, including wind and solar, continues to rise, large-scale, long-term energy storage technologies that could accommodate weekly and seasonal energy fluctuations will play a significant role in the overall deployment of renewable energies in the future. Harnessing and storing renewable energy resources via electrochemical, photoelectrochemical, or thermochemical processes by converting renewable energy into sustainable (energy storage) fuels have the potential to meet the long-term, terawatt scale energy storage challenge. Renewable hydrogen production is the cornerstone for sustainable fuel production and deep decarbonization of multiple sectors in our society. Cost-competitive clean hydrogen provides value to applications, such as 1) in the transportation sector for fuel cell vehicles, 2) in the electric grid sector for system stability and load balancing, and 3) in the industrial sector with metal refineries, cement production, and biomass upgrading (carbon-free fertilizer production). In addition, coupling clean renewable hydrogen with the carbon and nitrogen cycles enables known and well-established thermal-chemical processes to generate renewable hydrocarbon fuels and ammonia. The Advanced Water Splitting Technologies (AWST): low temperature electrolysis (LTE), high temperature electrolysis (HTE), photoelectrochemical (PEC) and solar thermo-chemical hydrogen (STCH) provide four unique and parallel approaches to produce low cost, low greenhouse gas (GHG) emission hydrogen at scale (Figure 1). Cost competitive clean hydrogen production using these four technologies is a current high priority focus for governments and industry. In June of 2022, the U.S. Department of Energy (DOE) launched the first in a series of Earthshot Initiatives. The Hydrogen Shot, “1 1 1” aims to reduce the cost of clean hydrogen by more than 80% to one dollar per one kilogram in 1 decade ($\$$1/kg H 2 ). The European Green Deal and the International Energy Agency (IEA) have implemented a strong focus on green hydrogen production for a clean and secure energy future.

benchmarking, low temperature electrolysis↗

Voltage cycling as a dynamic operation mode for high temperature electrolysis solid oxide cells

Solid Oxide Electrolysis Cells (SOECs) have emerged as a promising technology for the efficient production of H2 via high-temperature electrolysis. However, power input from dynamic energy sources remains a significant challenge for their long-term stability. It is important to analyze the tolerance of cells under dynamic operation conditions. This study focuses on evaluating the impact of voltage cycling on the performance and durability of electrode-supported SOECs. We explore the operational limits and degradation mechanisms of SOECs subjected to various voltage conditions and find that the cells have high tolerance for dynamic voltage. Voltage cycling between 1.3 V and 1.5 V for 9000 cycles does not damage the cell. Conversely, cycling to higher voltages (≥1.7 V) results in accelerated degradation. Advanced characterization is used to screen for various degradation modes post operation. Within the oxygen electrode, XRD and STEM EDS find compositional and phase evolution in all voltage cycled samples including increased decomposition of the air electrode resulting in cation migration. Microstructural analysis of the fuel electrode from nano-CT data shows minimal change throughout the sample set and no evidence of Ni migration, indicating the fuel electrode is stable and not impacted by cycling to higher voltages within the timeframe studied.

Zhu, Zhikuan↗

The Feasibility of Direct CO2 Conversion Technologies on Impacting Mid-Century Climate Goals

Recent IPCC modeling suggests that to limit global warming below 2 degrees C, "unprecedented" reductions in CO2 emissions will be required during the 2030-2050 time frame. The direct conversion of CO2 to fuels and chemicals using renewable electricity has garnered interest as one route to draw down emissions with the ability to synthesize products at a significantly lower carbon footprint than conventional methods. However, most direct CO2 conversion pathways are only in the early stages of development and face technical and market hurdles prior to scale-up, bringing into question what role they may play in influencing global CO2 emissions within this critical two-decade window. In this perspective, we highlight low-temperature electrolysis as a promising technology for direct CO2 conversion, including discussion on the products that could most impact global emission levels, and importantly, offer insight into the timeline, required advancements, and specific technical targets needed to successfully scale and deploy these technologies at the commercial level.

chemicals↗

Current research in low temperature proton exchange membrane-based electrolysis and a necessary shift in focus

While hydrogen has limited use in energy markets today, significant growth is possible in grid storage and as an energy carrier in other sectors. Along with lower electricity prices, further hydrogen cost reduction can enable electrochemical water splitting, particularly as the use of intermittent, renewable power sources increases and the quantity and duration of storage requirements limit electrical storage options. With the improved viability of large-scale hydrogen production, research in low temperature electrolysis has dramatically increased. The overwhelming majority of research efforts within proton exchange membrane-based systems has focused on catalyst development, although a smaller set have developed transport layers as well. As proton exchange membrane-based electrolysis shifts into higher technology readiness levels, however, there is a growing need for work optimizing materials integration, developing component-specific and device-level accelerated stress tests, and addressing manufacturing considerations. These areas directly impact electrolyzer performance, durability, and cost, and are critical to advancing hydrogen’s value and electrochemical water splitting.

08 HYDROGEN↗

Critical Review of Platinum Group Metal-Free Materials for Water Electrolysis: Transition from the Laboratory to the Market : Earth-abundant borides and phosphides as catalysts for sustainable hydrogen production

To combat the global problem of carbon dioxide emissions, hydrogen is the desired energy vector for the transition to environmentally benign fuel cell power. Water electrolysis (WE) is the major technology for sustainable hydrogen production. Despite the use of renewable solar and wind power as sources of electricity, one of the main barriers for the widespread implementation of WE is the scarcity and high cost of platinum group metals (pgms) that are used to catalyse the cathodic hydrogen evolution reaction (HER) and the anodic oxygen evolution reaction (OER). Hence, the critical pgm-based catalysts must be replaced with more sustainable alternatives for WE technologies to become commercially viable. This critical review describes the state-of-the-art pgm-free materials used in the WE application, with a major focus on phosphides and borides. Several emerging classes of HER and OER catalysts are reviewed and detailed structure-property correlations are comprehensively summarised. The influence of the crystallographic and electronic structures, morphology and bulk and surface chemistry of the catalysts on the activity towards OER and HER is discussed.

Chemistry↗

Linking structure to performance: Characterization of porous transport layers for high-pressure water electrolysis

Proton exchange membrane (PEM) water electrolysis is a promising technology to produce cost-efficient hydrogen. PEM electrolyzers offer a large current density range and the ability to operate at differential pressure which can be used to minimize both capital and operational expenditures. However, directly producing pressurized hydrogen at the cathode results in pushing the membrane against the anode porous transport layer (PTL). This can lead to detrimental effects, such as membrane deformation or ruptures, which depend on membrane properties as well as PTL material properties such as pore size, structure, and morphology. In this work, a range of sinter and felt-based commercial PTLs are evaluated for their contributions to the cell's electrochemical and H 2 crossover performance at cathode pressures up to 30 bar. X-ray tomography and post-operando optical microscopy are used to assess the morphology of the PTLs, and the PTL induced deformation experienced by the catalyst coated membrane (CCM), respectively. PTL samples with lower porosity were found to reduce both the cell voltage and the amount of H 2 permeating from the cathode to the anode exhaust, which was ascribed to improved catalyst layer contact and reduced membrane deformation, respectively. The best performing PTLs improved electrolyzer efficiency by ~1.5 kWh/kg H2 . Specifically, 1 kWh/kg H2 was gained due to reducing membrane deformation and decreasing H 2 crossover. The remainder 0.5 kWh/kg H2 were achieved by improving the electrical contact at the electrode/PTL interface which decreased cell voltage.

08 HYDROGEN↗

The impacts of membrane pinholes on PEM water electrolysis

Polymer electrolyte membrane (PEM) water electrolysis is a promising technology to efficiently produce green hydrogen. Irregularities in membrane electrode assembly (MEA) component materials caused by manufacturing, processing, handling, or operation can lead to performance loss and failure. One example is the presence of pinholes in the membrane, which can cause increased gas transport (crossover) and lead to electrical shorting. This work investigates the effects of intentionally introduced pinholes with various sizes up to 350μm in diameter. The presence of the pinholes resulted in minimal impacts on the cell voltage (±30 mV at 4Acm -2 ). However, the pinholes significantly increased H 2 crossover, which decreased hydrogen production efficiency and increased the minimum current density for safe operation. The impacts of the pinhole on the H 2 crossover and efficiency are more severe for open pinhole features than tear-like pinhole features. In conclusion, this research demonstrates that even small pinholes cannot be disregarded from a safety, efficiency, and operating strategy perspective.

08 HYDROGEN↗