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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

A high-performance oxygen evolution catalyst in neutral-pH for sunlight-driven CO 2 reduction

The efficiency of sunlight-driven reduction of carbon dioxide (CO 2 ), a process mimicking the photosynthesis in nature that integrates the light harvester and electrolysis cell to convert CO 2 into valuable chemicals, is greatly limited by the sluggish kinetics of oxygen evolution in pH-neutral conditions. Current non-noble metal oxide catalysts developed to drive oxygen evolution in alkaline solution have poor performance in neutral solutions. Here we report a highly active and stable oxygen evolution catalyst in neutral pH, Brownmillerite Sr 2 GaCoO 5 , with the specific activity about one order of magnitude higher than that of widely used iridium oxide catalyst. Using Sr 2 GaCoO 5 to catalyze oxygen evolution, the integrated CO 2 reduction achieves the average solar-to-CO efficiency of 13.9% with no appreciable performance degradation in 19h of operation. Our results not only set a record for the efficiency in sunlight-driven CO 2 reduction, but open new opportunities towards the realization of practical CO 2 reduction systems.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Nanocluster and single-atom catalysts for thermocatalytic conversion of CO and CO 2

In this Minireview, we discuss recent advances in understanding nanocluster and single-atom catalysts for CO and CO 2 emissions control applications. Through analyzing thermocatalytic CO oxidation and CO 2 reduction, two fundamentally and industrially important reactions, we compare representative nanocluster and single-atom catalytic systems from perspectives of intrinsic chemistry and reaction engineering. Generally, nanoclusters and single atoms display different catalytic performances (i.e., activity, selectivity, and stability) for these reactions depending on the synthesis methods, support materials, and reaction conditions. Key observations of activity and selectivity tradeoffs between nanoclusters and single-atom catalysts are highlighted. Here, the dynamic structural responses of these catalytic species under CO oxidation or CO 2 reduction reaction conditions are also discussed. Synthetic control and detailed experimental and computational characterization of single-atom and nanocluster catalysts for CO and CO 2 conversion have led to exciting progress over the past decade. Still, more efforts are needed to understand and develop catalysts that meet the environmental, energy, and technical requirements to power a sustainable global economy.

03 NATURAL GAS↗
DOE OSTI2021

Higher Energy-Content Jet Blending Components Derived from Ethanol (CRADA 467)

This project aims to develop a new sustainable aviation fuel (SAF) that comprises favorable properties, such as high energy density, excellent thermal stability, and favorable cold fold properties. Through catalyst development, this work will provide a route to control the cycloalkane/n-alkane/iso alkane content of a next-generation fuel with minimal or no aromatic content. Combining n-alkane and iso-alkane streams (high specific energy, MJ/kg) with cycloalkanes (higher energy density, MJ/L), is expected to enable at least a 4% net increase in combined (specific (MJ/kg) and volumetric (MJ/L)) energy content without impacting ‘drop-in’ fuel requirements, such as seal swelling. PNNL and LanzaTech have already demonstrated a sustainable, non-petroleum, route to isoalkanes. However, economically attractive cycloalkane production from waste and biomass is challenged by large hydrogen requirements, preferential selectivity to aromatic compounds and low yields to jet fuel range components. Many gaps in understanding cycloalkane properties and performance in complex jet fuel mixtures remain. The close tie and integration of Purdue’s fuel property analysis, with PNNL’s process development, can lead to an economically attractive process. The fuel analysis and testing by Purdue will enable a robust understanding of the properties and behavior of the cycloalkanes produced to inform process development. Additionally, seal-swelling analysis will quantify the ability of fuel blends with zero or minimal aromatics content to satisfy the seal swell requirement of O rings. Lastly, Purdue’s system-level analysis will lead to the development of a roadmap for deployment in key regions that considers system pressures such as hydrogen, water, energy efficiency, and ease of infrastructure access.

10 SYNTHETIC FUELS↗
DOE OSTI2024

Slashing Platinum Group Metals (PGM) in Catalytic Converters: An Atoms-to-Autos Approach

Platinum group metals (PGMs) are used in three-way catalysts (TWCs) for stoichiometric gasoline engine vehicles to simultaneously convert carbon monoxide, hydrocarbons, and nitrogen oxides into nitrogen, carbon dioxide and water. For US light duty gasoline vehicles, about 3-8 grams of PGMs are used in each catalytic converter system and the PGM loading is expected to increase for future vehicles, driven by increasingly stringent emissions standards, potentially lower engine exhaust temperatures, and higher emission control system durability requirements. The technical necessity for the current high PGM loadings is largely driven by: 1) poor atomic efficiency (or metal dispersion) of PGMs on catalyst supports with the current synthesis approaches, and 2) severe deactivation of unstable PGM nanoparticles in high temperature engine exhaust. Therefore, the project team will develop catalyst technologies that not only maximize the PGM atom efficiency and intrinsic activity in the fresh state, but also maintain the benefits during aging with extended exposure in engine exhaust.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Catalytic deconstruction of organic additive-containing plastics

Plastics waste ends up in landfills, oceans, and incinerators, posing major environmental and human health threats. Catalytic deconstruction is emerging as a key technological solution to handle complex plastics and has successfully converted virgin polymers into various products. Here, we investigate the resilience of chemical deconstruction technologies to organic additives, which are ubiquitous in plastics. We study catalyst-additive interactions experimentally and via first-principles calculations for plastics additives representative of entire classes. We reveal two deactivation mechanisms and demonstrate that many recently developed catalysts are inadequate for polyolefin conversion due to poisoning caused by the strong adsorption of most additives or their small fragments. Furthermore, we also identify conditions and catalysts that can circumvent the challenge of deconstruction in the presence of additives challenge.

10 SYNTHETIC FUELS↗
DOE OSTI2021

Dual active site tandem catalysis of metal hydroxyl oxides and single atoms for boosting oxygen evolution reaction

We report the high voltage in oxygen evolution reaction (OER) often causes structural change in electrocatalysts and forms multiple active sites. Therefore, exploring the synergy of various active sites is extremely significant to develop catalysts for OER with multiple elementary steps. Herein, we adopt the physically adsorbed metal ions method to successfully synthesize a highly-efficient electrocatalyst containing the dual active sites of Fe-NiOOH and NiC4 single atoms (marked as Ni SAs/Fe-NiOOH). The Ni SAs/Fe-NiOOH displays outstanding OER performance with an overpotential of 269 mV to deliver current density of 10 mA/cm 2 that shows 55 mV superior to commercial IrO 2 /CB at the same condition. Experiments and density functional theory calculations indicate that the excellent OER activity of Ni SAs/Fe-NiOOH catalyst is attributed to the synergy of dual active sites of NiC 4 SAs and Fe-NiOOH. A tandem catalysis mechanism is also proposed to reveal the synergism of two active centers, which makes the potential-determining step more facile and accordingly decreases the OER overpotential. This work offers a new concept of tandem catalysis to develop the electrocatalysts with many elemental steps, like OER and oxygen reduction reaction catalysts.

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

Photocatalysis and Photoelectrocatalysis Methods of Nitrogen Reduction for Sustainable Ammonia Synthesis

Abstract Ammonia (NH 3 ) is one of the essential chemicals as a fertilizer and as a starting reagent for various chemicals with a production expectation of 200 million tonnes for 2018. With the development of renewable energy technologies such as hydrogen fuel cells, hydrogen also has emerged as an innovative clean energy source. Ammonia is a suitable hydrogen fuel carrier since a molecule of ammonia can carry up to three atoms of hydrogen. Recently, photochemical synthesis via nitrogen reduction has gained considerable attention as a sustainable method for the production of ammonia. The performance of the photoreduction of nitrogen lies in the developments of the photocatalysts and photoelectrocatalysts. Therefore, it is essential to understand the fundamentals of nitrogen reduction processes along with apprehending the challenges that limit the progress of catalysts. In this review, the basic understanding of photoreduction of nitrogen is highlighted, emphasizing on the challenges and effective methods to control defects, structures, and morphologies of materials for the catalyst development. The methods for ammonia detection and uncertainties in calculating the efficiency of the photochemical process are also addressed.

Ithisuphalap, Kemakorn↗
DOE OSTI2021

Revealing the Nanostructure of Mesoporous Fuel Cell Catalyst Supports for Durable, High-Power Performance

Achieving high power performance and durability with low Pt loadings are critical challenges for proton exchange membrane fuel cells. PtCo catalysts developed on new carbon black supports show promise by simultaneously providing good oxygen reduction kinetics and local oxygen transport. We investigate the role of nanoscale morphology in the performance of these catalysts supported on accessible (HSC-e and HSC-f) and conventional (Ketjen Black) porous carbons using 3D electron tomography, nitrogen sorption, and electrochemical performance measurements. We find that the accessible porous carbons have hollow interiors with mesopores that are larger and more numerous than conventional porous carbons. However, mesopore-sized openings (>2 nm width) are too rare to account for significant oxygen transport. Instead we propose the primary oxygen transport pathway into the interior is through 1–2 nm microporous channels permeating the carbon. The increased mesoporosity in the accessible porous carbons results in a shorter diffusion pathlength through constrictive, tortuous micropores in the support shell leading to lower local oxygen transport resistance. In durability testing, the accessible porous carbons show faster rates of electrochemical surface area loss, likely from fewer constrictive pores that would mitigate coarsening, but maintain superior high current density performance at end of test from the improved local oxygen transport.

Electrochemistry↗
DOE OSTI2019

CatCost™ (Catalyst Cost Estimation Tool) [SWR-18-74]

CatCost™ is a state-of-the-art cost estimation tool designed to reduce the cost uncertainty associated with pre-commercial catalyst materials. The tool combines industry-standard cost estimation methods and resources into an intuitive suite of tools to bring actionable cost insight to every step of catalyst research and development. CatCost™ allows the rapid development of comprehensive catalyst cost estimates. It incorporates detailed insight into manufacturing methods, especially for pre-commercial catalysts, without requiring any process design experience. The tool has been designed from the ground up with a number of user-selectable estimation methods, pricing libraries, and ease-of-use features to tailor an estimate to a user's skill level and need for customization, empowering researchers of all skill-levels to make better R&D decisions throughout the catalyst development cycle. Our costing methods are fully transparent and enable power-users the ability to adjust any estimate to the economic realities of their operation. The tool has been designed from the ground up with a number of user-selectable estimation methods, pricing libraries, and ease-of-use features to tailor an estimate to a user's skill level and need for customization, empowering researchers of all skill-levels to make better R&D decisions throughout the catalyst development cycle. Our costing methods are fully transparent and enable power-users the ability to adjust any estimate to the economic realities of their operation. Features include: Raw materials pricing: Libraries of common chemicals, cost scaling indices, guidance for obtaining bulk quotes, and methods for extrapolating laboratory-scale prices to bulk. Simplified step method for synthesis by a contract manufacturer: All-in hourly cost for process equipment using methods and data from tollers. (Excel-only in v1.0)

Baddour, Frederick↗
DOE OSTI2023

Recent advancements in high performance polymer electrolyte fuel cell electrode fabrication – Novel materials and manufacturing processes

The global effort to introduce polymer electrolyte fuel cells for clean and renewable energy to the market is increasing the demand for high performance, robust and affordable membrane electrode assemblies (MEAs). There is not yet a standard method for large scale production of MEAs, or the methods employed are generally unsatisfactory in terms of quality and performance. A large number of published data of newly developed catalyst and electrolyte materials, claim to improve the state of the art, but are often not fully comparable due to different experimental studies and experimental designs. This article summarizes the trends in material developments and emerging MEA-manufacturing techniques. The materials and techniques are systematically compared in terms of cell performance and scalability. Current and future scientific challenges are identified and analysed based on published findings over the past five years. Finally, the results of the cited papers have been quantitatively compared to each other and to the internal benchmarks used in each cited work to provide a complete picture of the state of the art in PEFC MEA manufacturing.

25 ENERGY STORAGE↗
DOE OSTI2021

BETO 2021 Peer Review - Catalytic Upgrading of Biochemical Intermediates (CUBI) 2.3.1.101-104

The Catalytic Upgrading of Biochemical Intermediates (CUBI) project is a multi-lab effort within ChemCatBio (CCB) that is focused on improving the catalytic upgrading of intermediates from biochemical deconstruction and/or biological conversion (i.e. fermentation) to fuels and chemical co-products. This is accomplished by developing catalysts with improved performance and durability, mitigating the impact of biogenically-derived inhibitors (including water), and evaluating intensified processes to reduce separations requirements and improve carbon utilization. Specific catalytic upgrading routes being developed are: 1) fermentation-derived 2,3-butanediol (BDO); 2) fermentation-derived carboxylic acids; and 3) lignocellulosic sugar-derived furfurals. These routes represent key technology pathways being investigated within BETO's biochemical conversion portfolio. By utilizing experimental and characterization capabilities and modeling tools across the 4 CUBI labs and collaborations with CCB Enabling Projects, the CUBI project is advancing catalytic upgrading process performance and robustness. Its impact is already well-established by several high-impact journal articles and patent publications, along with industrial engagement in related, competitively-awarded collaborations. The CUBI project will result in >25% MFSP cost reduction in the catalytic upgrading section of integrated biochemical conversion routes, as quantified by ongoing TEA modeling.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2019

Modified Solution Combustion Synthesis (SCS) of nickel oxide, NiO sphere clusters using glucans and sodium salts: Application for electrocatalytic decomposition of urea

The application of metabolites from the modern clinic (patient care environments including hospitals and medical facilities) has become an important part of energy research as these materials are readily available at low-cost and are non-toxic to handle in large quantities for catalyst development in the chemical industry. A modified Solution Combustion Synthesis (SCS) route was utilized in the preparation of nickel oxide, NiO nanomaterials using Dextran/Trisodium Citrate Dihydrate and Dextran/Sodium Carboxymethyl Cellulose (Na-CMC). The catalysts were then applied towards the electrocatalytic decomposition of urea, a metabolite from human and animal urine for Direct Urea Fuel Cell (DUFC) technology. Results from the catalysis demonstrated that the sample prepared via Dextran/Trisodium Citrate Dihydrate had the greatest Electroactive Surface Area (ESA) of 146 $\frac{cm^2}{mg}$, potentially a result of the well-defined clusters produced using the citrate coordinating species to produce individual particles.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Tailoring a Three-Phase Microenvironment for High-Performance Oxygen Reduction Reaction in Proton Exchange Membrane Fuel Cells

Despite tremendous progress in catalyst development for rate-limiting cathodic oxygen reduction reaction (ORR), reducing Pt usage while meeting performance requirements in practical proton exchange membrane fuel cells (PEMFCs) remains a challenge. The ORR in PEMFCs occurs at a catalyst–electrolyte–gas three-phase interface. A desirable interface should exhibit highly active and available catalytic sites, as well as allow efficient oxygen and proton feeding to the catalytic sites and timely removal of water to avoid interface flooding. In this work, we report the design of a three-phase microenvironment in PEFMCs, showing that carbon surface chemistry can be tuned to modulate its interaction with the ionomers and create favorable transport paths for rapid delivery of both reactants and products. With such an elaborate interfacial design, for the first time we have demonstrated PEMFCs with all key ORR catalyst performance metrics, including mass activity, rated power, and durability, surpassing the US Department of Energy targets.

25 ENERGY STORAGE↗
NASA NTRS2011

Alternative Fuel Research in Fischer-Tropsch Synthesis

NASA Glenn Research Center has recently constructed an Alternative Fuels Laboratory which is solely being used to perform Fischer-Tropsch (F-T) reactor studies, novel catalyst development and thermal stability experiments. Facility systems have demonstrated reliability and consistency for continuous and safe operations in Fischer-Tropsch synthesis. The purpose of this test facility is to conduct bench scale Fischer-Tropsch (F-T) catalyst screening experiments while focusing on reducing energy inputs, reducing CO2 emissions and increasing product yields within the F-T process. Fischer-Tropsch synthesis is considered a gas to liquid process which reacts syn-gas (a gaseous mixture of hydrogen and carbon monoxide), over the surface of a catalyst material which is then converted into liquids of various hydrocarbon chain length and product distributions1. These hydrocarbons can then be further processed into higher quality liquid fuels such as gasoline and diesel. The experiments performed in this laboratory will enable the investigation of F-T reaction kinetics to focus on newly formulated catalysts, improved process conditions and enhanced catalyst activation methods. Currently the facility has the capability of performing three simultaneous reactor screening tests, along with a fourth fixed-bed reactor used solely for cobalt catalyst activation.

Surgenor, Angela D.↗
DOE OSTI2025

Modular Processing of Flare Gas for Carbon Nanoproducts

This project demonstrated the technical viability and economic promise of a modular system for converting flared natural gas into valuable carbon nanoproducts (CNPs) through catalytic chemical vapor deposition (CVD). All major project milestones were successfully completed, including reactor design and commissioning, catalyst development, process optimization, technoeconomic analysis, and application testing in concrete systems. The overarching goal was to create a scalable, field-deployable process that valorizes stranded methane by producing high-value carbon materials for use in cementitious composites. At the lab scale, the team designed and built a fluidized bed reactor optimized for use with silica fume-supported nickel catalysts synthesized via atomic layer deposition (ALD). A statistically designed sintering study enabled precise tuning of nickel nanoparticle size, identifying the influence of oxygen partial pressure, time, and temperature on catalyst morphology and performance. These insights allowed the team to target catalyst conditions that maximize carbon nanofilament growth. Subsequent CVD experiments achieved up to 31.8 wt% carbon deposition under optimized conditions, with TEM confirming the presence of nanofilament structures and sustained hydrogen evolution during reaction. Reactor upgrades and empirical fluidization studies supported the development of reliable, repeatable experimental protocols. The modular pilot-scale skid reactor was fully constructed, instrumented, and commissioned. Capable of operating at 675–800°C and pressures up to 290 psig, the system was designed for continuous operation at a carbon production rate of 1 kg/hr. Initial demonstration runs confirmed solids handling, thermal control, and system leak-tightness, although a critical reactor component (the downfeed tube) was inadvertently omitted during final assembly. This omission limited gas–solid contact and prevented meaningful carbon deposition during pilot-scale CVD runs. Nonetheless, the system operated safely under design conditions, and the root cause of performance limitations was clearly identified. Complementary work on UHPC formulations demonstrated that small additions of carbon nanoproducts, including those derived from flare gas, can significantly enhance mechanical performance while preserving workability. A comprehensive study of CNF dispersion techniques and mix design optimization led to a clear protocol for integrating these nanomaterials into concrete. Incorporation of CNPs improved flexural toughness and reduced porosity, supporting their use in high-performance infrastructure applications. A technoeconomic analysis (TEA) confirmed that this process can produce CNP-loaded catalyst material at a levelized cost below $\$$7/kg across a range of catalyst loadings and reaction yields. With estimated market values for the carbon composite product ranging from $\$$14 to over $\$$60/kg, and the ability to blend CNPs into concrete at sub-percent levels with less than 10% added cost, the system presents a compelling economic case. While additional engineering work is needed to optimize fluidization and heat transfer at scale, this project establishes a strong foundation for commercial development. The process is not only technically sound but also economically promising, representing a viable pathway for flare gas mitigation through modular carbon nanomaterial production.

03 NATURAL GAS↗
DOE OSTI2022

Atomically Dispersed Platinum in Surface and Subsurface Sites on MgO Have Contrasting Catalytic Properties for CO Oxidation

Atomically dispersed metals on metal oxide supports are a rapidly growing class of catalysts. Developing an understanding of where and how the metals are bonded to the supports is challenging because support surfaces are heterogeneous, and most reports lack a detailed consideration of these points. In this work, we report two atomically dispersed CO oxidation catalysts having markedly different metal–support interactions: platinum in the first layer of crystalline MgO powder and platinum in the second layer of this support. Structural models have been determined on the basis of data and computations, including those determined by extended X-ray absorption fine structure and X-ray absorption near edge structure spectroscopies, infrared spectroscopy of adsorbed CO, and scanning transmission electron microscopy. The data demonstrate the transformation of surface to subsurface platinum as the temperature of sample calcination increased. Catalyst performance data demonstrate the lower activity but greater stability of the subsurface platinum than of the surface platinum.

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

Selective Butanol Production from Ethanol over an Atomically Dispersed Cu on Mixed Oxide Catalyst

The maturation of the ethanol industry has led to more readily available pathways toward renewable fuels. However, the presence of the “blendwall” problem, as well as the shift in focus toward heavier fuels, has resulted in a need for processes that can use ethanol as a building block for more valuable fuels and chemical products. Concurrently, numerous processes are being developed for the conversion of ethanol into a wide range of value-added products. One such process, the Guerbet reaction, is a well-known chemistry for coupling alcohols that has resurfaced as a promising pathway toward producing 1-butanol and other valuable higher alcohols. Though the general chemistry for Guerbet coupling is largely agreed upon, recent research interest has been focusing on developing catalysts that can achieve both high selectivities and yield. This work focused on hydrotalcite based catalysts, which are layered double hydroxide (LDH) formed by co-precipitation of divalent and trivalent metals in solution and then calcined to form the integrated mixed oxide structure. Changing the ratio of +2/+3 metals is a facile method for tuning the acid-base nature of the catalyst, and these metals can be further substituted to form ternary or quandary structures with additional characteristics. This flexible synthesis allows for the design of catalysts that have the strong-base, weak-acid sites shown to be beneficial to ethanol C-C coupling reaction to produce butanol and higher alcohol.

Guo, Mond F.↗