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NASA NTRS1989

Electrochemical incineration of wastes

A low temperature electrolysis process has been developed for the treatment of solid waste material and urine. Experiments are described in which organic materials are oxidized directly at the surface of an electrode. Also, hypochlorite is generated electrochemically from chloride component of urine. Hypochlorite can act as a strong oxidizing agent in solution. The oxidation takes place at 30-60 C and the gaseous products from the anodic reaction are carbon dioxide, nitrogen, oxygen. Hydrogen is formed at the cathode. Carbon monoxide, and nitrogen oxides and methane were not detected in the off gases. Chlorine was evolved at the anode in relatively low amounts.

Kaba, L.↗

DOE OSTI2022

Formation of carbon and oxygen rich surface layer on high purity magnesium by atmospheric carbon dioxide plasma

Carbon and oxygen-rich corrosion barrier layer formed on Mg by a simple and scalable CO 2 atmospheric plasma (CO 2 -AP) process. The reactive CO 2 -AP interacts with the Mg surface and forms a unique layered structure with the top MgCO 3 /MgO-intermixed particulates pillars and the bottom dense layer. The surface features were simultaneously formed on the nano-/micro-structured MgO layer by carbonate molecules, plasma-active CO 2 molecules, and/or other volatile organic compounds on the nano-/micro-structured MgO particle layer. The resulting surfaces after CO 2 -AP were either hydrophobic or hydrophilic and exhibited lower anodic current or high resistance for Mg corrosion. For the hydrophobic surfaces of CO 2 -AP treated Mg, molecular dynamic simulations were performed to understand the origin of hydrophobicity and identified that the amorphous carbon layers formed on the Mg surface are the source. The environmentally benign abundant-gas-based process enables the cost reduction associated with waste treatment, generation of by-product, and supply of raw material.

36 MATERIALS SCIENCE↗

NASA NTRS2003

JSC Metal Finishing Waste Minimization Methods

THe paper discusses the following: Johnson Space Center (JSC) has achieved VPP Star status and is ISO 9001 compliant. The Structural Engineering Division in the Engineering Directorate is responsible for operating the metal finishing facility at JSC. The Engineering Directorate is responsible for $71.4 million of space flight hardware design, fabrication and testing. The JSC Metal Finishing Facility processes flight hardware to support the programs in particular schedule and mission critical flight hardware. The JSC Metal Finishing Facility is operated by Rothe Joint Venture. The Facility provides following processes: anodizing, alodining, passivation, and pickling. JSC Metal Finishing Facility completely rebuilt in 1998. Total cost of $366,000. All new tanks, electrical, plumbing, and ventilation installed. Designed to meet modern safety, environmental, and quality requirements. Designed to minimize contamination and provide the highest quality finishes.

Sullivan, Erica↗

DOE OSTI2025

Nano- and Earth-Science-inspired Electric Vehicle Battery Recycling to Secure Battery Supply Chain

With the expected growth of electric vehicles (EV) in the transportation sector, recycling or upcycling spent battery materials will be required to reduce EV costs, lessen waste, and ease critical material supply chain pressure for EV battery applications. “Direct” recycling or upcycling is an alternative to current industrial approaches. Many challenges remain for viable direct battery upcycling, including upgrading the transition metal ratio in the costliest component (cathode oxide); separation of transition metal ions in the exit stream; battery disassembly; improving cathode exfoliation which can lead to a new way of direct recycling; and lithium metal anode recycling -- including safety concerns. We devise and deploy a suite of methods to deal with these challenges. The results pave the way to future work on battery recycling, in areas of technological/commercial readiness level ranging from basic research to large-scale commercialization.

25 ENERGY STORAGE↗

NASA NTRS2003

From Oxygen Generation to Metals Production: In Situ Resource Utilization by Molten Oxide Electrolysis

For the exploration of other bodies in the solar system, electrochemical processing is arguably the most versatile technology for conversion of local resources into usable commodities: by electrolysis one can, in principle, produce (1) breathable oxygen, (2) silicon for the fabrication of solar cells, (3) various reactive metals for use as electrodes in advanced storage batteries, and (4) structural metals such as steel and aluminum. Even so, to date there has been no sustained effort to develop such processes, in part due to the inadequacy of the database. The objective here is to identify chemistries capable of sustaining molten oxide electrolysis in the cited applications and to examine the behavior of laboratory-scale cells designed to generate oxygen and to produce metal. The basic research includes the study of the underlying high-temperature physical chemistry of oxide melts representative of lunar regolith and of Martian soil. To move beyond empirical approaches to process development, the thermodynamic and transport properties of oxide melts are being studied to help set the limits of composition and temperature for the processing trials conducted in laboratory-scale electrolysis cells. The goal of this investigation is to deliver a working prototype cell that can use lunar regolith and Martian soil to produce breathable oxygen along with metal by-product. Additionally, the process can be generalized to permit adaptation to accommodate different feedstock chemistries, such as those that will be encountered on other bodies in the solar system. The expected results of this research include: (1) the identification of appropriate electrolyte chemistries; (2) the selection of candidate anode and cathode materials compatible with electrolytes named above; and (3) performance data from a laboratory-scale cell producing oxygen and metal. On the strength of these results it should be possible to assess the technical viability of molten oxide electrolysis for in situ resource utilization on the Moon and Mars. In parallel, there may be commercial applications here on earth, such as new green technologies for metals extraction and for treatment of hazardous waste, e.g., fixing heavy metals.

Khetpal, Deepak↗

NASA NTRS1994

Space-based bacterial production of hydrogen

This paper deals with the electrochemical production of hydrogen by depolarizing the oxygen evolution reaction using human feces and urine, which contains 30-40% bacteria and yeast. The electroactivity of graphite, tungsten carbide, perovskite and RuO2-coated Ebonex (Ti4O7) as anode materials are compared. The scale-up of the process in a laboratory-scale three-dimensional packed bed cell is discussed.

NASA Discipline Life Support Systems↗

DOE OSTI2025

Electrocatalytic oxidation of hydrothermal liquefaction-derived aqueous phase for on-site wastewater treatment and H 2 production

Electrocatalytic oxidation (ECO) is a promising method for generating molecular hydrogen (H 2 ) while simultaneously treating the aqueous phase (AP) from hydrothermal liquefaction (HTL) of biomass-derived feedstocks such as algae, food waste, sludge, and wood. This study highlights the impact of HTL-AP composition on ECO performance, mainly activity, stability, and efficiency in a batch and flow electrolyzer. We demonstrated current efficiency (CE) for chemical oxygen demand (COD) removal ranges from 14% to 85% in the flow electrolyzer with electrode stability increasing from 20 to ≥2,800 h. Decreasing the applied potential enhances the CE. High ammonium content can accelerate deactivation, yet chloride ions appear to aid oxidation of organic compounds and enhanced anode stability. A preliminary energy and H 2 balance for an HTL sewage sludge plant shows that the HTL-AP contains sufficient COD to produce all the H 2 needs for bio-oil hydrotreating, with a 26% surplus available for other uses.

Electrolysis↗

DOE OSTI2023

Room Temperature Electrorefining of Rare Earth Metals from End-of-use Nd-Fe-B Magnets

Recovering rare earth elements (REE) from used permanent magnets, which contains about 30 wt.% of rare earth elements, has been persistent technological challenge. Current recycling methods relies on pyrometallurgical or hydrometallurgical processes which are energy- and chemical- intensive and not economically and environmentally viable for rare earth containing magnets. Enabling efficient and simplistic recovery and refining of REEs contained in End-of-Use (EoU) products, such as Neodymium-Iron-Boron (Nd-Fe-B) based magnets will play an important and complementary role in the total supply of REEs in the future. We designed a new electrochemical method and demonstrated a room temperature one-pot process that concurrently separates and electroplates REE from commercial Nd-Fe-B magnets. By establishing selective oxidation and reductive potential as electrochemical control parameter along with electrochemically compatible non-aqueous electrolyte system, we demonstrated selective electroleaching of lanthanides (Nd and Preseodymium (Pr)) from anode and concurrent plating as alloy at Pt cathode. The morphological and chemical evolution of the Nd-Fe-B magnets during electroleaching reveals the electrochemical stimuli and rate of dissolution depends on microstructural complexities of the Nd-Fe-B magnet. The concomitant electroplating process leads to Nd-Pr based alloy which can be used as raw metallic alloy for manufacturing new permanent magnet and other devices. Our study demonstrates a scalable separation and refining methodology, based on widely available organic electrolyte system and without any consumptive chemical use, for selective lanthanide recovery from waste magnets.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Electrodialysis: An effective methodology to purify the leachate of spent Li-ion batteries

The electrification of transportation and the transition of society towards low or net-zero carbon emissions has led to a skyrocketing global demand for Li-ion batteries. After a service life of three to ten years, Li-ion batteries have less than 80 % of their initial capacities and draw near to the end of their lives for practical utilization. Due to potential supply chain shortages and the value embodied in Li-ion batteries, it is imperative to recycle them, to recover the materials, and to improve the circularity and the sustinability of the industry. How to cost-effectively purify spent batteries while reducing time, energy, and waste emissions is a challenge faced by Li-ion battery recyclers. The first electrochemical membrane reactor reported in our group hasa high selectivity towards lower Cu 2+ , Al 3+ and Fe 3+ ions (<5 ppm) and retains >95% of the Ni 2+ , Co 2+ and Mn 2+ ions in the leachate. An advanced electrochemical membrane reactor was developed in this study. Further, not only does the new reactor have the same selectivity as the original reactor, but other advantages including a faster leachate processing rate (up to 10X faster). The advanced reactor can also directly generate acid at the anode side; eliminating the reactor restoration step. The prominent advantages that this electrodialysis technology has over chemical-precipitation methods include: (1) ion recovery efficiencies do not diminish after removing the impurities, Ni 2+ , Co 2+ and Mn 2+ , even at a higher initial Ni 2+ ion concentrations; in comparison, chemical precipitation has Ni 2+ , Co 2+ and Mn 2+ ion recovery efficiencies reduced significantly when the initial Ni 2+ , Co 2+ and Mn 2+ ion concentrations increase. (2) electrodialysis does not change the concentrations of Ni 2+ , Co 2+ and Mn 2+ ions significantly, but chemical precipitation could reduce Ni 2+ and Co 2+ ions to less than half of their initial values. Through electro-dialyzing the leachate, the H 2 evolution reaction mechanism was found to switch from the Volmer-acid Heyrovsky mechanism to the Volmer-alkaline Heyrovsky mechanism at a pH of around 3.7.

25 ENERGY STORAGE↗

DOE OSTI2024

Hard carbon with an opened pore structure for enhanced sodium storage performance

The pore structure of hard carbon has a significant impact on its Na + storage capacity. Herein, a waste wood-derived hard carbon with opened pores (OP-HC) was fabricated with polyvinyl pyrrolidone (PVP) as an additive. Ex situ SAXS and HR-TEM testing results indicate that OP-HC with opened pores and enlarged d 002 interlayer spacing facilitates the reversible (de)sodiation of Na + ions. In situ TEM and XRD testing results demonstrate that OP-HC shows excellent structure stability during the (de)sodiation process. Thus, OP-HC delivers a high reversible charge capacity of 350.7 mA h g −1 at 0.05 C and an ultra-high initial Coulombic efficiency (ICE) of 94.9%. Moreover, OP-HC exhibits excellent cycling stability, and the assembled 18650 full cell with an OP-HC anode can achieve a high capacity retention of 94.5% after 400 cycles at 1.0 A. Furthermore, the excellent electrochemical performance and deep insights into OP-HC with opened pores and increased d 002 interlayer spacing offer a new strategy to design high-performance HC anodes for SIBs.

You, Shunzhang↗

DOE OSTI2023

Piezo-electrocatalytic oxidation of methanol with UV-ozone treated wurtzite zinc oxide nanostructures

Leveraging mechanically-induced piezoelectric polarization, piezocatalysis emerges as a viable mechanism for enhancing the efficiency of catalytic processes. Nanostructured, catalytically active, rationally designed piezoelectric semiconductors can achieve high-performance catalysts for various applications using cost-effective electrocatalytic pathways, such as mechanical stimuli. We design and demonstrate for the first time a cost-effective, high-performance piezo-electrocatalyst for anodic methanol oxidation, which is crucial for the practical application and deployment of direct methanol fuel cells in a variety of emerging clean energy technologies. We synthesized wurtzite ZnO nanorods and nanosheets treated with UV-O 3 to characterize and compare their efficacy for piezo-electrocatalytic methanol oxidation. The generation of piezoelectric polarization charges in nanostructured semiconducting ZnO catalysts significantly increased their electrocatalytic performance. By elucidating the charge transfer between mechanically-deformed ZnO nanostructures and methanol molecules, we identified the underlying mechanism for the piezo-electrocatalytic process for methanol oxidation. The facile synthesis of high-quality ZnO nanostructures enables low-cost, scalable manufacture and direct integration into electrocatalysts whose performance could be enhanced by harvesting mechanical energy that would otherwise be wasted in the working environment.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2023

Electrochemical Reduction of Flue Gas Carbon Dioxide to Commercially Viable C2-C4 Products (Final Report)

This is the final scientific/technical report for a DOE project focused on the electrochemical conversion of CO 2 in non-aqueous solvents to novel products. Electrochemical reduction of CO 2 provides an attractive route to produce valuable fuels and chemicals that can simultaneously lower greenhouse gas emissions when powered by renewable electricity. While recent technological advances have shown the feasibility of industrial CO 2 electroreduction, many challenges remain to improve this technology and expand the list of economically viable products. The vast majority of electrochemical CO 2 reduction research has been conducted in aqueous media under neutral to alkaline conditions, leading to commonly reported products including carbon monoxide, formic acid, methane, methanol, ethylene, acetic acid, and ethanol. In comparison, non-aqueous media for CO 2 reduction has been underexplored but represents a possible avenue to yield new products and improved operating conditions. The aim of the project was to convert waste CO 2 in the form of flue gas to a multicarbon C2 - C4 chemical product in a reactor designed to achieve economically competitive values of current density and selectivity. The project strived to advance the technology readiness of an electrochemical CO 2 reduction process in alcohol solvents from the proof-of-concept stage to a device capable of meeting performance metrics for commercial viability. In the initial plan, the University of Louisville researchers were to focus on investigating the electrochemical process and improving the faradaic efficiency for novel C2 – C4 species, while also working on a parallel effort to build a practical electrolysis reactor to markedly increase the CO 2 reduction current density. The reactor development effort also aimed to engineer a dual-electrolyte feed strategy with non-aqueous catholyte and aqueous anolyte to promote water oxidation as the coupling anodic half-reaction to enable a sustainable and economical overall process. At the outset, the University of North Dakota was to investigate the feasibility of operating directly from coal-derived flue gas without separate capture and purification. The research team sought to determine impurity effects and test mitigation strategies, as well as engineer the gaseous feed system for high reactor tolerance to lower CO 2 concentration. In the last half year of the project, the focus was planned to shift to integrating the advances in the catalysis, electrochemical conditions, reactor design, and flue gas compatibility into a fully functional device and improve it for maximum current density and faradaic efficiency for C2 – C4 species. Knowledge of the full system components, constraints, and maximum performance was then to be used as the basis for a thorough technoeconomic analysis (TEA) and life cycle analysis (LCA) at the end of the project.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2021

Refinement of Salt Dissolution Inhibitor Requirements (Final Report)

At Savannah River Site (SRS), High-Level Waste is stored in below-grade carbon steel tanks. This waste in part consists of sludge, salt cake, and/or supernate. Preparation of this waste for future processing involves dissolution of the salt cake layer. The salt dissolution process can create conditions that leave the carbon steel tanks susceptible to localized corrosion. The salt to be dissolved contains high concentrations of nitrate, that once released, create an environment that may be conducive to pitting corrosion and/or stress corrosion cracking (SCC) of carbon steel. The salt dissolution process also liberates interstitial liquid trapped between the salt crystals. This liquid is initially high in nitrite and hydroxide concentration. High pH and greater ratios of nitrite to nitrate act as inhibitors to minimize corrosion of carbon steel in high nitrate environments. However, as dissolution proceeds, the concentration of nitrate will increase, while the hydroxide and nitrite concentration of the interstitial liquid will deplete and become insufficient to prevent the onset of corrosion attack. Tank blending and addition of inhibitors are used to ensure adequate concentrations of hydroxide and nitrite. However, this is not desirable during salt dissolution as it can reduce process efficiency and increase the amount of waste that needs processing. It has been proposed that these corrosion control limits be revisited to evaluate the corrosion susceptibility of carbon steel in environments that more closely resemble current operating conditions at SRS. An experimental matrix was designed to evaluate the use of the pitting factor for supernate chemistries characteristic to SRS, particularly during the salt dissolution process. Two electrochemical methods were identified to determine the susceptibility of A537 and A285 low-carbon steels to pitting corrosion with this chemistry envelope at temperatures up to 75 °C. The predominant electrochemical test method was Cyclic Potentiodynamic Polarization (CPP) studies. Through CPP, the pitting factor was used, based on Hanford Site corrosion studies, to accurately identify pitting susceptibility within the compositional range studied with some conservatism. Additionally, sulfate was determined to have no statistically significant influence, at concentrations up to 0.6 M, on pitting behavior in more concentrated solutions where other aggressive species govern pitting susceptibility. Where CPP was inconclusive, Modified ASTM G192 was successfully used to evaluate pitting susceptibility conditions and allowed for a pass/fail result to be determined. In all cases, the pitting factor was determined to be applicable to the simulants tested, with this metric accurately predicting incidences in which pitting occurred. Based upon the findings in this work, a pitting factor of 1.2 is being proposed to build in a safety factor and remain consistent with the Hanford Site approach. Additionally, a minimum pH limit of 12 is proposed to ensure carbon steel passivity and localized corrosion the primary degradation mechanism. Susceptibility to SCC was evaluated using a reduced matrix of tests at 75 °C. No failures due SCC were observed at open circuit. In addition, tests polarized anodically by 200 mV only resulted in failures for trials with pitting factors less than 0.86. However, a test with a passing condition based upon the pitting factor metric (pitting factor = 1.40) did exhibit a failure with an applied potential of +300 mV vs. OCP. This result is contrary to the prediction based upon the pitting factor, however, a polarization of 300 mV, or even 200 mV, from open circuit is substantial. The relationship between these testing parameters and service environment/conditions and the desired level of conservatism in the metric should be further evaluated in the determination of the significance of this result. While the pitting factor accurately predicted susceptibility to SCC at temperatures up to 75 °C and with positive overpotentials up to 200 mV, the relatively small sample matrix and failure of a passing pitting factor with a 300 mV polarization resulted in an inconclusive determination of whether the pitting factor may be used for predicting susceptibility to SCC at temperatures between 50 °C and 75 °C. As such, additional testing is recommended to evaluate the validity of the pitting factor for SCC susceptibility prediction at temperatures between 50 °C and 75 °C.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2024

Flow field design for zero-gap microbial electrolysis cells using synthetic and real wastewater

Increasing performance in microbial electrolysis cells (MECs) requires the development of optimized reactor configurations with minimal internal resistance and capable to operate with real wastewater. Here, the impact of two different flow fields (serpentine and circular) was examined in zero-gap MECs with synthetic and real wastewaters. The serpentine flow field enabled a uniform distribution of the electrolyte in the anode chamber, resulting in larger current densities at lower flow rates compared to the circular flow field. Electrochemical tests using synthetic media with high buffer capacity revealed more stable and higher performance with the serpentine flow field compared to the circular flow path, producing larger current density (23.7 ± 0.8 A/m 2 vs 21.9 ± 5.6 A/m 2 ), hydrogen production rate (75.8 ± 4.1 L/L-d vs 54.3 ± 2.4 L/L-d), cathodic coulombic efficiency (>91 % vs >50 %), and an overall lower internal resistance (12.5 ± 0.5 mΩm 2 vs 14.8 ± 3.7 mΩm 2 ). Continuous operation for over 30 days with real wastewater indicated higher tolerance of the MECs with serpentine flow field toward media with large concentration of suspended solids, producing a current density of 5.4 ± 1.1 A/m 2 and a hydrogen production rate of 22.2 ± 6.2 L/L-d. Furthermore, the results presented here underscore the importance of reactor design and architecture in optimizing MEC performance for hydrogen production from liquid wastes.

flow path↗

DOE OSTI2020

Safe, Low-Cost, High Energy-Density, Solid-State Li-Ion Batteries

We developed intrinsically safe, robust, low-cost, high-energy-density solid-state Li-ion batteries, by integrating high conductivity garnet-type solid Li ion electrolytes and several different cathodes in tailored microstructures, fabricated by low-cost supported thin-film ceramic techniques, to overcome the primary technological barriers to next generation battery technology. In this ARPA-E project we employed Li-garnet solid-state electrolytes pioneered by one of the co-investigators (Thangadurai) which has room temperature (RT) conductivity of ~10 -3 S cm -1 . The highly stable garnet SSE allowed the use of S, NMC, and other cathodes with Li metal anodes without stability or flammability concerns. We studied the garnet’s stability when exposed to CO 2 and humidity (with or without an ALD coating) and showed that the material can be processed in ambient air for most steps prior to battery assembly, significantly reducing production costs. We extensively studied and scaled up the synthesis of the powder and explored external suppliers of garnet to determine the best pathway for commercial success. We used low-cost and scalable tapecasting fabrication methods to create porous-dense-porous “trilayer” solid electrolyte microstructures with a ~20 μm separating dense layer, and >70% porosity porous layers to host the electrodes. These scalable multilayer ceramic fabrication techniques, without need for dry rooms or vacuum equipment, also provide for dramatically reduced manufacturing costs. The tailored microstructured electrode supports (scaffold) increased interfacial area ~50x, overcoming the high impedance typical of planar geometry SSLiBs, resulting in record-setting 10 mA/cm 2 lithium cycling in a symmetric cell. We expanded our tapecasting ability and showed tapes >25m in length by the end of the project. We demonstrated the ability to sinter garnet without the use of a garnet powderbed, which could have been a major obstacle and waste of material at scale. At the same time, we expanded the size of our trilayers from coin cells (0.7 cm 2 ) to the full format design (30 cm 2 ). To develop full cells, we demonstrated 250 Wh/kg at room temperature with commercial NMC electrode films in a bilayer configuration. Similarly, we demonstrated 280 Wh/kg trilayer Li-S cells at room temperature with >90% capacity retention over 300 cycles. At 90°C we demonstrated 350 Wh/kg with a Li-S trilayer. The high thermal stability of the garnet electrolyte also enabled extended cycling (400 cycles) of a Li-TiS 2 cell at 150 °C, showcasing the exceptional safety and nonflammability of the solid-state trilayer batteries. Ion Storage Systems has taken this technology and knowledge to produce trilayer garnet electrolytes and is building out facilities to commercialize high performance solid state batteries. ISS has hired a strong staff, identified and communicated with a large number of potential partners, and successfully secured follow-on funding.

25 ENERGY STORAGE↗

DOE OSTI2026

Cathodic Protection Modeling for Hanford Underground Double-Shell Tank Farms

Hanford stores millions of gallons of radioactive and chemically hazardous waste from the production of weapon materials in tank farms consisting of underground carbon-steel storage tanks surrounded by reinforced concrete. Six of these Hanford tank farms use double-shell storage tanks (DSTs). The DST farms were constructed from 1968 to 1986 with a planned 40–50 year design life, so some are already operating beyond their initial life expectancy. Ultrasonic testing (UT) has indicated significant thinning on the bottom of the secondary (outer) liner of these tanks, believed to arise from groundwater intrusion driving concrete side corrosion. There is no direct access to the steel/concrete interface between the tank and the concrete pad, making it difficult to apply a chemical-based mitigation strategy or to conduct repairs, but cathodic protection (CP) is a possible method to inhibit further concrete-side corrosion. Hanford already uses CP to protect below grade steel piping within the tank farms and connected to the tanks, but this system was not designed to protect the tank bottoms. CP design must account for the structures surrounding the DSTs, including the steel reinforcing bars (rebar) within the concrete pad and vault, various process lines, and the existing CP system. In this study, finite element analysis (FEA) modeling was carried out to simulate CP protection of 1) a single tank and CP anode to develop options for modeling the rebar and to compare to a simpler circuit model and 2) the entire Hanford AN tank farm as a representative example consisting of seven tanks, associated piping, and both existing and new CP anodes. Both circuit and FEA models predict that significant protective current could be delivered to the bottoms of the tanks with the addition of tank-protection anodes below the depth of the tanks. Simulations with only the existing pipe-protection anodes active confirmed that only a very small current to the tank bottoms is predicted under present conditions. Multiple simplified representations of the dome and wall rebar were tested to reduce the computational complexity of the tank-farm simulations, resulting in modeling the rebar as edge elements with a prescribed effective circumference that matches the real rebar surface area. The geometry of the rebar is also simplified into horizontal hoops around the tank walls and radial rebar over the dome with increased effective circumference to retain the target surface area. This simplification was found to greatly reduce the complexity and solution time of the models without large changes in current distributions, especially to the tank bottom. A range of values were tested for model parameters such as soil and concrete resistivities and polarization resistance to investigate their impact on the current and electric potential distributions. Depending on the parameters used, FEA simulations predict some risk of overprotection, particularly on the piping system; since overprotection can also lead to surface damage associated with hydrogen gas generation at the interface (e.g. hydrogen embrittlement or damage to coatings), this needs to be considered when refining the design of the new CP system. Comparison between the FEA models and the circuit model representation demonstrated that the circuit model could not match the predicted FEA current distribution, even when using the exact same surface areas. This discrepancy appeared to be at least partly attributable to the impact of the relative positions of the tank components and anodes to each other and to the ground surface. The FEA model accounts for the relative positions since it solves the governing equations in three dimensions, but the circuit model cannot account for the positioning. In particular, the circuit model underpredicts the current to the tank bottom and overpredicts the current to the dome compared to FEA for the baseline geometry. The FEA models omitted the electrically isolated rebar in the bottom concrete slab. However, a circuit based stray current model estimated that only 2.1% of the total current through the slab would stray into the rebar, corresponding to ~0.21 A for a target current density of 2 mA/ft2 to the tank bottom. The estimated corrosion driven by this amount of stray current is predicted to yield a lifetime of >400 years for the minimum rebar diameter, assuming an acceptable cross-section area loss of 10%.

d'Entremont, Anna [Savannah River National Laborat↗

DOE OSTI2022

Process intensification for generating and decomposing formic acid, a liquid hydrogen carrier

We preview two processes that facilitate using formic acid (HCOOH) as a liquid hydrogen carrier to store renewably-generated electrical energy and then release it to generate electrical power cleanly for backup or emergency applications. First, we show that simultaneously oxidizing an organic solute (typically a waste stream) can assist the electrochemical synthesis of formic acid by lowering the cell potential. The electrolyser comprises a hybrid 3-chamber PEM stack that reduces CO₂ via a gas-diffusion cathode boosted by the oxidation of aqueous methanol. However, the extent of the boosting needs to be optimized across the whole operation of the cell. Next, we present results from an intensified reactor for decomposing formic acid back into H₂ and CO₂ at elevated pressure so that the H₂ can be used in a fuel cell. The reactor combines three operations: Vaporization of the formic acid, its decomposition, and separation of the product stream. Their close coupling affords energy savings and a compact design that could be mounted on a mobile skid. We briefly discuss the electrode catalyst that facilitates the first process and two thermally activated catalysts (Ir supported on covalent triazine framework and Pd supported on carbon) that enable the second process.

25 ENERGY STORAGE↗