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All sourcesNASA NTRSDOE OSTI
DOE OSTI2013

Water Splitting by Thin Film Metal-Oxo Catalysts

The dropping price of silicon photovoltaics in the United States is causing load defection to solar supply at an accelerated pace. This conversion to solar and, more generally, other renewable energy sources has accordingly turned the energy research focus from generation to one of storage. Truly disruptive improvements in energy storage technologies are limited by energy density. This limitation, however, does not apply to fuels, which possess the energy density needed for large-scale energy storage. The first step of the basic science needed to drive such historic restructuring of the U.S. energy infrastructure begins with the solar-driven generation of hydrogen and oxygen from water. The solar-produced hydrogen may then be combined with carbon dioxide to deliver any number of fuels. Obviously, light does not directly act on water to engender its splitting into its elemental components. Hence, catalysts are needed to drive the oxygen evolution reaction (OER) and hydrogen evolution reaction (HER). Of these two reactions, the four-electron, four-proton oxidation of OER is the more kinetically challenging reaction, and therefore the development of energy efficient solar fuels processes demands that OER be accomplished at a minimal overpotential. The research completed in this program developed catalysts that drive OER and at the same time meet the important criteria of (1) using non-critical materials that (2) are easy to assemble and (3) accomplish OER under simple conditions. Research was designed to uncover the chemical principles that underlie the self-assembly of metal oxide oxygen evolving catalysts (M-OEC) from the metals of M = Mn, Co, and Ni. For example, a dogma of heterogeneous catalysis of any sort is that “edges” matter in promoting catalytic transformations. We provided a rationale for such dogma by showing that the OER in Co-OEC occurred at a dimensionally reduced dicobalt edge site. Edge site reactivity was clearly revealed analyzing 18O labeled OER with differential electrochemical mass spectrometry (DEMS) of Co-OEC. The OER mechanism of M-OECs was examined with complementary studies of model dicobalt compounds that captured the critical steps of the OER reaction. Additionally, the role of activating M-OECS with metal ion dopants was defined by developing structure–function relationships, guided by the principles of inorganic chemistry. We found that the M(IV) oxidation state in oxidic OER frameworks was correlated to the presence of the dopant metal, as assessed by coulometric titration and ICP-MS analysis. To investigate why greater M(IV) valence is beneficial to greater catalytic OER activity, we probed the influence of formal M valence on the electronic structure of oxygen ions in M-OECs by undertaking O and Ni K-edge spectroscopy, which revealed greater M-O covalency and hence M-oxyl radical character with M(IV) formation. Such oxyl radical character is consistent with increasing evidence for the role of oxygen radicals in O–O bond formation by a proton-coupled electron transfer mechanism involving water, to generate a hydroperoxide intermediate from which oxygen is generate. In accomplishing this science, the DOE program leveraged its expertise in spectroscopy and structural methods, inorganic and materials synthesis, and electrochemical characterization. The knowledge garnered from this proposed program enables the design of next generation catalysts with improved OER kinetics that operate over a wide range of conditions and environments.

25 ENERGY STORAGE↗
DOE OSTI2018

Final Report/Liox Power Inc.

The rechargeable lithium-oxygen battery has attracted attention due to its large theoretical energy density compared to modern lithium-ion batteries. This large energy density is attributed to the reaction of lithium with molecular oxygen to form lithium peroxide, which grows on the surface of the cathode. While this is a promising chemistry, there are many practical challenges that remain to be solved, such as the decomposition of organic electrolyte in the presence of superoxide anions and large overpotentials on charge.

25 ENERGY STORAGE↗
DOE OSTI2018

Multimetallic Systems for the Photocatalytic Production of Fuels from Abundant Sources

The reported findings herein are a result of a collaboration between the groups of Claudia Turro at The Ohio State University (DE-SC0010542) and Kim R. Dunbar at Texas A&M University (DE-SC0010721). The Turro and Dunbar groups jointly discovered that cationic d 7 –d 7 Rh 2 (II,II) complexes bridged by electron-donating formamidinate (form) ligands possess redox-active excited states that are relatively long-lived and can engage in charge transfer reactions. As part of the present grant we designed new complexes that exhibit strong absorption from the UV to ~800 nm. The Rh 2 (II,II) complexes under investigation are poised to undergo catalytic reduction of substrates because they are robust to changes in metal oxidation state, the two metals and the two diimine ligands, together with the non-innocent bridges, can be used to store redox equivalents, making these complexes capable of coupling one-electron events with multi-electron transformations. We discovered the electrocatalytic reduction of H + and CO 2 by complexes that are able to electrocatalytically reduce H + to H 2 with high turnover frequencies (TOFs) and overpotentials, η, of ~0.5 V,8 as well as to reduce CO 2 to HCOOH. We now have experimental evidence that both the production of H 2 from H + and HCOOH. The molecular catalysts are stable after the acid and/or CO 2 is consumed since electrocatalysis is restored at the same rate upon the addition of substrate to the cell.8,9 Moreover, we showed that the catalysis is not a result of a decomposition product deposited on the electrode, since placing an electrode from an active electrocatalytic solution into one that does not contain catalyst completely shuts down the reactivity. We are currently exploring the reactivity of these complexes in hydride transfer reactions with other substrates and in the presence of CO 2 and reducing agents, as well as attempting to grow single crystals for x-ray diffraction.

14 SOLAR ENERGY↗
DOE OSTI2019

High Energy Storage Capacity Low Cost Iron Flow Battery

A new flow battery was proposed that utilizes low cost materials: iron as the only active element, cheap aqueous electrolytes, and inexpensive separators. During charging, ferrous iron (Fe 2+ ) is oxidized to ferric iron (Fe 3+ ) at the positive electrode while it (Fe 2+ ) is reduced to form iron metal (Fe 0 ) at the negative electrode. Because iron is plated at the negative electrode during charging, conventional electrode structures couple the energy storage capacity and the power rating of the battery. In order to decouple the energy and power ratings and regain the economic advantages of a flow battery, a slurry electrode design was proposed for use as the negative electrode. The slurry electrode is made by flowing electrically conductive particles in an electrolyte containing the dissolved iron species. On charging, iron is plated onto the particles. The particles can then carry the iron metal out of the cell to be stored in external reservoirs. This project looked to develop a slurry for the negative electrode of the all-iron flow battery that can operate at 200 mA/cm 2 with <100 mV overpotential, be pumped with parasitic energy costs < 10%, and promote plating on the particles. A scalable and stackable cell design of 1100 cm 2 was developed. The project was initially under contract in mid-January 2013. The project was converted from a one-year proof of concept seedling to an additional two-year program, then extended with an 18-month plus-up, and finally with an additional 6-month approved cost-overrun. During the seeding project, the concept of plating on carbon particles in a slurry was demonstrated. However, this was accomplished with high-cost multi-walled carbon nanotubes as the slurry material. The following two-year program discovered several low-cost carbon blacks that could also be used in this application. These findings were supported by an analysis that demonstrated the effectiveness of the carbon that takes into account not just the effective electronic conductivity of the slurry, but also the surface area per volume of the slurry. It was demonstrated that stable, flowable slurries could be created with these carbons, even when the carbons where fully loaded with iron during charging. During the two-year program, laboratory-scale 50 cm 2 single-cells demonstrated charge-discharge cycling at current densities of 150 mA/cm 2 and energy efficiencies of >50%. Meanwhile, cost modeling continued to show promise for this energy storage approach. Following the conversion period, the overall objective of the nominally 18-month plus up period was to close the technical gap of a 25X scale-up and reduce risk to enable commercial investment required to develop a slurry iron flow battery product. A specific objective was to demonstrate 150 cycles of performance exceeding 70% energy efficiency with a 10-cell stack of 1156 cm 2 cells operating at 100 mA/cm 2 . The 10-cell short stack was designed to have a power delivery rating of approximately 1 kW, which represents a size commensurate with the requirements of our commercialization partner at that time. A complete battery support system for the full-size cell was designed, fabricated, and tested. This includes pumps (multiple types were considered, and constant volume hose pumps were found to be acceptable for performance and cost), electrolyte rebalance reactor, and sensors and control systems. The support system proved to be well-behaved and worked well. A new low-cost membrane was developed for this system based on a microporous polymer support with a layer of hydrogel polymer. The membrane had low resistivity, and significantly reduced pressure driven fluid flow across the membrane (as compared to the un-coated microporous support). This membrane approach was scaled-up in conjunction with a commercial toll coating company, and a large amount of membrane was manufactured to support large cell and stack testing. A new concept for an electrolyte rebalance reactor to react hydrogen gas from the negative electrolyte (from plating inefficiency) with excess ferric ion in the positive electrolyte was developed. This design was very simple, low cost, and effective. The full scale 1156 cm 2 single-cell was designed, modeled, fabricated and tested. Modeling showed that uniform flow-distribution should be obtained with the designed flow distributor. The design took into consideration the need to stack the cells, and components were fabricated for a ten-cell stack. Testing of the cell for charge and discharge demonstrated current densities of 50 mA/cm 2 with efficiencies of 50%. However, optimization and long cycling could not be accomplished because the slurry electrode would plug within the cell and block the flow. This would shut down the cell after several charge-discharge cycles. Various approaches were pursued to address this problem with some progress. However, there was not adequate time to find solutions to the problem although several promising approaches were identified for future work. The final deliverable for this proposed 18-month effort was to be a 1 kW, 6 kWh slurry flow battery, with complete balance of plant, ready for testing at an ARPA-E ‘Charges’ site with an estimated capital cost less than $\$ $45/kWh for a six-hour system (excluding power electronics). The deliverable milestone was not achieved for reasons mentioned above related to the slurry plugging. At the completion of this project, it was determined that the cost targets are achievable. The cost estimate for a 1 MW system with a one-hour capacity was estimated at $\$ $140/kWh (including power electronics) and for a six-hour system was estimated at $\$ $40/kWh (including power electronics). These costs include the battery, the balance of plant, the power conditioning and a concrete pad. This program resulted in three patents including the slurry-based iron flow battery, the rebalance reactor, and the membrane separator. At the time of this report, slurry-based iron flow battery patents have been issued in the US, China, Japan, Korea, and Europe. The other patent applications were under various stages of examination. A licensee was identified and the company initiated a scale-up and development program to take this technology to the marketplace, and CWRU staff have transferred their know-how and knowledge base to the company. This technology will enhance the economic and energy security of the United States by enabling the use of intermittent renewable energy technology, such as wind and solar power, as dispatchable resources. This report summarizes the results of this research and development program.

25 ENERGY STORAGE↗
DOE OSTI2019

Metal-Metal Interactions in Heterobimetallic Complexes as a Strategy to Promote Multielectron Redox And Small Molecule Activation Processes

Recent attention in the chemical community has been focused on the energy efficient and environmentally benign conversion of abundant small molecules (CO 2 , H 2 O, etc.) to useful liquid fuels. This project addressed these goals by examining fundamental aspects of catalyst design to ultimately access small molecule activation processes under mild conditions. Specifically, Thomas and coworkers constructed heterobimetallic complexes that feature metal centers with vastly different electronic properties, dictated both by their respective positions on the periodic table and their coordination environment. Unlike homobimetallic complexes featuring identical or similar metals, the bonds between metals in early/late heterobimetallics are more polarized, with the more electron-rich late metal center donating electron density to the more electron-deficient early metal center. While metal-metal bonds pose an interesting strategy for storing redox equivalents and stabilizing reactive metal fragments, the polar character of metal-metal bonds in heterobimetallic complexes renders these molecules ideally poised to react with small molecule substrates via cleavage of energy-rich single and double bonds. This research project further explored such bond activation processes. In addition, metal-metal interactions were shown to dramatically affect redox potentials and promote multielectron redox activity, and it was demonstrated that metal-metal interactions provide a mechanism to tune redox potentials and access substrate reduction/activation at mild overpotentials. This research project provided a better fundamental understanding of how interactions between transition metals can be used as a strategy to promote and/or control chemical transformations related to the clean production of fuels. While this project focused on the study of homogeneous systems, the broad conclusions drawn from these investigations are applicable to heterogeneous catalysis as well, particularly to heterogeneous processes that occur at interfaces in multicomponent systems.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Electrochemical CO 2 Utilization: Scalable System Operation for Formic Acid Production

In recent years, research into the electrochemical reduction of CO 2 has grown exponentially. Formic acid (FA) has become a particular value product from CO 2 due to its versatility [1], optimal atom economy [2], and thermodynamic favorable [3]. FA can be produced electrochemically via a direct two-electron transfer process involving CO 2 with a proton source, requiring less energy input and fewer reaction steps than the conventional Kemira process. However, product selectivity, electrode stability, and low faradic efficiency due to increased resistance under constant current, remain key issues for CO 2 reduction to FA [4]. University of Kentucky’s Center for Applied Energy Research (UK CAER) is currently investigating reactor designs to address the challenges associated with electrochemical CO 2 conversion to FA [5]. The current reactor system employs: (1) an organic-based charge carrier which shuttles charge directly to the catalyst to enable CO 2 reduction to FA; (2) novel electrode materials to mitigate large voltages and improve conductivity; and (3) a flow system which not only allows for the volumetric scale-up of both charge carrier and catalyst, but also decouples the charger carrier re-energized and FA production processes to protect the catalyst’s stability due to overpotential. Through careful adjustment of electrode, charge carrier, and electrolyte selection, cell resistances have decreased by over 15%, facilitating conduction necessary for effective CO 2 reduction to FA. The system uses a highly specific engineered catalyst, which has produced over 100 mM FA at a rate of over 10 mM FA/hour following the aforementioned electrode/charge carrier changes. System design considerations (flow rate, bulk volume) and modeling of the system will also be discussed.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2019

Process Intensification for Electrochemical Utilization of CO 2

The conversion of CO 2 to value-added products is an attractive approach for reducing the cost of CO 2 capture. Formic acid (FA) is a multipurpose industrial chemical feedstock for formic acid fuel cells, additives in the textile and agricultural sectors, cleaning products, and corrosion inhibitors. FA can be produced directly from CO 2 via a two-electron process facilitated with DC electricity supplied via renewable/intermittent power sources [1]. The state-of-the-art method for industrial FA production is the Kemira process, which uses methanol, sodium methoxide, and CO to produce methyl formate that is subsequently hydrolyzed to formic acid. Conversely, an electrochemical approach reduces the number of chemical input for FA production, but conventional electrochemical processes for CO 2 reduction to FA continue to suffer from selectivity issues where the electrocatalyst produces a wide range of products. These competing products include FA, hydrogen, carbon monoxide, methanol, and methane that reduce faradaic efficiency by up to 50% [2]. The CAER-Andora process features an enzymatic catalyst with high selectivity for FA production with turn-over-frequency >85 s-1. The CAER-Andora process combines an electrochemical cell that features graphite electrodes and an electrochemically facile charge mediator, combined with an immobilized proprietary catalyst inside a FA production cell. These processes work together to 1) reduce faradaic inefficiencies by producing only FA, 2) protect the valuable catalyst from deactivation by overpotentials, and 3) provide a modular system configuration that facilitates independent optimization of the electrochemical and production cells. Operating at <3 V, the CAER-Andora process currently produces ~1 mM FA/hour with >90% CO2 to FA conversion in the production cell, and progress towards the intensification of the CO 2 utilization process will be discussed.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2021

Nanostructured, Targeted Layered Metal Oxides as Active and Selective Heterogeneous Electrocatalysts for Oxygen Evolution

Oxygen evolution reaction (OER) is an important chemical transformation that governs the performance of technologically relevant energy conversion and storage processes, such as electrochemical water splitting in electrolyzers and metal-air batteries. This reaction involves the evolution of oxygen gas from (i) oxygen ions formed from water splitting at high temperatures, (ii) oxygen containing species (i.e., OH, OOH) formed from water splitting at low temperatures, and (iii) metal-oxide discharge products (M x O 2 ) in metal-air batteries. One of the main challenges with OER is that it is catalyzed at low temperatures by noble metal-based electrocatalysts, which are expensive (making this process economically unviable), or at high temperatures by metal-oxide based electrocatalysts that are inefficient and lead to high overpotential losses. Our preliminary results, as well as other results in the literature, show that non-noble metal-based oxide electrocatalysts with layered structures, known as nickelate oxides, exhibit promising OER activity. Nickelate oxides (A 2 MO 4+δ ) belong to the Ruddlesden-Popper series composed of alternating perovskite-like and rocksalt-like layers. They are promising OER electrocatalysts due to their high oxygen transport/exchange properties compared to the state-of-the-art perovskite-type oxides. Unfortunately, these materials are fairly unexplored and little is known about the properties that govern their OER activity. Our preliminary studies, where we combine density functional theory (DFT) calculations, selective synthesis and characterization, show that engineering their nanocrystalline structure can significantly impact their catalytic activity.

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

Sensing and arresting metal corrosion in molten chloride salts at 800 degrees Celsius

Originally this was planned as a 5 task, 3 year project, starting in May 2019. Task 1 Detecting oxidants and metal corrosion in molten chloride salt at 800°C. Task 2 Effectiveness of Zr getter using head gas sensors of inlet and outlet gases. Task 3 Cathodic protection of metal in molten salt at reducing potential. Task 4 Find reduction potential of metals in molten chloride salts & quantum modeling. Task 5 Develop corrosion test sections integrated into molten salt flow loop. After Q4, the project was scaled back and the reorganized SOPO was reduced to 3 tasks to be completed at the end of Q7 on 01/05/2021. The 3 SOPO tasks are: Task 1 Sense oxidants and the metal corrosion in molten Na-K-Mg-Cl salt at 800°C. Task 3 Cathodically protect H230 alloy in molten Na-K-Mg-Cl salt at 800C by making H230 alloy the cathode of a power supply with a chromium-rich-metal as the anode. Task 4 Find the reduction potential of Cr metal in molten Na-K-Mg-Cl salt at 800°C. The total timeline was reduced from 12 to 7 quarters with the end date being, January 5, 2021. This amounted to task 1,3 and 4 being done in Q5,6 and 7 of an extended year 1, ending on January 5, 2021. Task 1, 3 and 4 were completed. For task1) the increase of oxidants in molten salt is detected by two things: i) a positive shift of the electrode potential for a Haynes 230 alloy (H230) metal coupon versus a silver/silver-chloride reference electrode (SSE) and ii) an increase in the corrosion rate of a H230 electrode at 800C. For task 3) applying a cathodic potential (negative overpotential) to a H230 electrode versus SSE arrested the corrosion of the cathodically protected H230 compared to an unprotected “spectator H230 electrode” in the same molten chloride salt. Lastly, for task 4) the reduction potential of chrome and chrome rich, and nickel metal electrodes were measured. The most valuable outcome of this work is that a power supply can arrest metal corrosion for metal in molten chloride salt when the power supply applies a cathodic potential to bare metal, like H230, in molten chloride salts, like ternary Mg-K-Na-chloride salt. H230 is a high strength metal for containing molten chloride salt and ternary Mg-K-Na-chloride salt is used as heat transfer fluids in concentrating solar power plants. When to use cathodic protection for protecting metal in molten chloride salts? Two scenarios are envisioned: 1) for protecting high-valued components, like solar collectors and heat exchangers and 2) for protecting the bare surface in holidays (point defects) of corrosion inhibitors that are to intended to cover the entire surface of metal.

14 SOLAR ENERGY↗
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 OSTI2023

Development of an All-Aqueous Thermally Regenerative Redox Flow Battery to Support Fossil Fuel Assets

Low-temperature thermal energy, a largely untapped resource, holds significant promise for large-scale electrical power generation globally. Various stationary sources, including industrial entities and thermal power plants, emit considerable low-temperature heat that currently remains unutilized. This energy is often overlooked because its low temperature renders it unsuitable for efficient power generation using conventional methods. However, current research is exploring diverse technologies capable of converting low-temperature heat into grid-scale power, aiming to enhance grid efficiency, further decarbonization initiatives, and facilitate a shift toward more decentralized power systems. One such innovative technology is the thermally regenerative battery (TRB), noted for its high power and energy densities compared to similar technologies, positioning it as a potential game-changer in power generation. TRBs integrate two scalable and well-established unit operations: a redox flow battery and a distillation column. This integration suggests that once an effective TRB chemistry is established, the pathway to commercialization could be expedited. The copper-based thermally regenerative ammonia battery (Cu aq -TRAB) stands out as the first TRB that circumvents electrodeposition/dissolution reactions, stabilizing Cu(I) and Cu(II) within the electrolyte and maintaining stability of all electroactive species in an aqueous phase. This stabilization has led to improvements in coulombic efficiency, open circuit potential, and copper solubility, thereby enhancing power density, energy density, and overall energy efficiency. Preliminary tests were conducted to determine the effects of various electrolyte species on the performance metrics of the battery, both theoretically and experimentally. These tests revealed that the solubility of copper in the Cu aq -TRAB electrolyte was constrained by the Cu(I)-NH 3 complex. Adjusting the background electrolyte to 5 M NH4Br and the ligand concentration to 4 M NH 3 enabled the copper concentration to reach a maximum of 0.6 M. This modification led to an estimated theoretical maximum energy density of 9.5 Wh L -1 for the Cu aq -TRAB. Additionally, full cell testing indicated a tradeoff between peak power and energy density with varying copper and ammonia concentrations. Increasing the applied current density during discharge linearly raised the average power output, with a minimal reduction in energy density due to a balance between higher ohmic overpotential and reduced time for undesirable ammonia crossover. Furthermore, a comprehensive numerical sensitivity analysis of the complete Cu aq -TRAB system was performed. This analysis aimed to assess how the battery and the distillation column responded to changes in system input parameters, providing insights into optimal research directions for enhancing system performance. The analysis revealed that at room temperature, battery power was significantly more sensitive to ohmic losses than to mass transfer, with reaction rates having minimal impact. This trend continued even at higher temperatures. Also, the thermal energy required for ammonia separation was studied, showing that increased temperatures generally reduced energy requirements, except in low-pressure scenarios above 65 °C. An investigation into membrane performance in the Cu aq -TRAB was undertaken, given the significant impact of ammonia transport control and ohmic losses on system performance. Various membranes were evaluated to identify key performance metrics. Among the tested membranes, Selemion CMVN exhibited the highest performance, with a peak power density of 84 mW cm -2 and average values of 26 ± 6.8 mW cm -2 for power density and 2.9 Wh L -1 for energy density at an applied current density of 50 mA cm -2 . An economic assessment indicated a levelized cost of storage at $410 per MWh under optimal conditions, highlighting the commercial potential of the Cu aq -TRAB when utilizing cost-effective, readily available materials.

25 ENERGY STORAGE↗
DOE OSTI2024

Catalyst design for small molecule activation of energy consequence

This project targets the conversion of ubiquitous small molecules (e.g. NO, CO, H 2 O) into viable precursors to synthetic fuels. Current state of the art catalyst design has not directly targeted transition metal complexes capable of mediating the multi-electron redox processes necessary to reduce the overpotential (energy loss) required achieve efficient activation of small molecule substrates. In this vein, a new strategy has been developed for the assembly of polynuclear architectures; allowing for the construction of tunable polymetallic centers that assemble easily within a pre-organized template (conferring stability, selectivity and tunability) that can effect multi-electron redox processes for reactions. Catalyst development has commenced with the following target design elements: (1) catalysts featuring multiple transition metal ions in the same reaction space to greatly expand accessible molecular redox capabilities; (2) catalysts are assembled in a polynucleating ligand framework that permits control over the cluster morphology as well as the local steric and electronic environment of the transition metal ions within the cluster. The high-tunability of the catalyst composition (metal content) and geometric flexibility has permitted a rigorous assessment of electronic-structure-to-function relationship to be developed, further guiding synthetic efforts to realize more potent catalysts. The numerous permutations possible showcase the high degree of generality to this approach with many synthetic handles to tune redox and reaction chemistry. Trinuclear complexes have been synthesized featuring homo- and hetero-trinuclear cores featuring a variety of first row transition metal ions (Cr→Ni). The molecular clusters have been shown to successfully mediate multi-electron redox processes in a cooperative fashion without requiring strong chemical reductants or oxidants. The reactive molecular complexes are being utilized to activate and breakdown the robust bonds within typical waste stream small molecules (e.g., greenhouse gases) and convert them into value-added commodity chemicals. Ultimately, the catalysts developed by this approach will be required to convert energy acquired via renewable resources (e.g., solar or wind) into synthetic fuels as an energy storage mechanism.

10 SYNTHETIC FUELS↗
DOE OSTI2024

Toward a better understanding of Ni coarsening in solid oxide cells: NiH on Ni (111) examined at the level of density-functional theory (and KMC)

Ni coarsening in the fuel electrode of solid oxide cells (SOCs) is known to be significantly faster under a humid atmosphere. In this talk, density-functional theory and kinetic Monte Carlo methods are used to explore the hypothesis that the surface diffusion of NiH on Ni may promote Ni coarsening in the SOC operated in electrolysis cell mode. Defining the surface diffusivity as the product of the fractional surface coverage and single-molecule surface diffusivity, the surface diffusivity of NiH on Ni (111) is found to be large enough under a significant overpotential to support the above hypothesis. However, as NiH could dissociate on Ni (111), more work is needed to show that NiH may promote Ni coarsening.

Mantz, Yves↗
DOE OSTI2025

Probing the Sustainable Reduction of CO 2 , N 2 and NO 3 to Fuels and Chemicals using Non-Traditional Porphyrinoid Catalysts

For the last several decades, numerous strategies have been proposed to be able to interconvert electricity and commodity fuels for transportation and other applications. Even as solar and wind energy become more widely available, these renewable energy sources are not always available where the population is most dense or during peak times of energy demand. One plausible solution to the issue of electricity storage and transport is to use electricity to drive the formation of high-energy compounds and chemical fuels. As a result, the electrochemical conversion of CO 2 into chemical fuels has received major attention as a multi-pronged approach for electricity coversion, storage, and transport. Similar strategies are also attractive for conversion of N 2 and NO x into value added compounds such as ammonia. Metalloporphyrin and metallocorrole complexes are comprised of aromatic tetrapyrrole scaffolds and have been extensively studied as homogeneous catalysts for critical catalytic processes like the electrochemical CO 2 reduction reaction (eCO 2 RR) to generate CO as feedstock for the Fischer–Tropsch process to generate a variety of hydrocarbons as chemical fuels. Despite their significance and impact, efficiently driving such catalytic reduction processes is challenging for multiple reasons. Such processes require multiple-electron transfer events, as opposed to single-electron redox chemistry that forms high-energy singly-reduced intermediates. In addition, these electron transfer events must be coupled to proton-transfer steps and avoid application of high overpotentials where proton (H + ) reduction to generate H 2 (as well as other side-reactions) can lower the selectivity and energy efficiency of the eCO 2 RR process. Certain Fe(III) aromatic tetrapyrroles (e.g., porphyrins and corroles) have been reported to overcome these challenges, but are often difficult to synthesize and modify, and have a tendency to support single-electron redox chemistry at the metal as opposed to multielectron redox involving the ligand and metal in concert. Other families of tetrapyrroles in which all four meso-carbons are reduced (i.e., sp 3 -hybridized) are also known in the literature. These non-aromatic tetrapyrroles are known as porphyrinogens and support multi-electron redox chemistry which has been elaborated by several groups, prompting researchers to consider whether these scaffolds may improve the kinetics and efficiencies of multi-electron steps attendant to activation of thermodynamically stable small-molecule substrates such as CO 2 , N 2 , NO 3 − , and NO 2 − . Although porphyrinogens support multi-electron redox properties, the four sp 3 -hybridized meso-carbons inherent to the tetrapyrrole core completely disrupt π-conjugation between pyrrolic units, which compromises the photochemical properties of porphyrinogens in comparison to that of traditional porphyrinoids. Moreover, the highly reducing nature of porphyrinogens predisposes these platforms to extreme air and water sensitivity. Accordingly, such metalated porphyrinogens are often pyrophoric and/or incompatible with many common organic solvents (CH 2 Cl 2 , CHCl 3 , CH 3 CN, EtOAc, etc.). Hence, reports of efficient small-molecule activation or catalysis supported by porphyrinogens have been limited. To overcome the instability of porphyrinogens while retaining the scaffold’s attractive multi-electron redox properties, we have directed attention to establishing less-well studied groups of non-aromatic tetrapyrroles (i.e., phlorins, biladienes, and isocorroles). These non-traditional tetrapyrroles each contain just a single sp 3 -hybridized meso-carbon, which ablates the platforms aromaticity but still provides an extended π-framework. In addition to developing innovative platforms that may be used to sustainably generate value-added chemicals, fuels, and ammonia via either photo- or electrocatalytic approaches our work also has significantly broadened our understanding of how to prepare and modulate the properties of non-aromatic tetrapyrroles for other applications. Our efforts entailed a synergistic partnership and active collaborations with Drs. David C. Grills and Mehmed Z. Ertem (both of Brookhaven National Lab) to better characterize isocorroles (and related non-aromatic tetrapyrroles) using a variety of advanced spectroscopic and theoretical methods. Our combined efforts have shown that the combination of properties that isocorroles (and related tetrapyrroles) provide results in good chemical stability paired with unique redox and photochemical characteristics that are not typically supported by simple and/or unadorned aromatic tetrapyrroles. Beside redox chemistry, the photochemistry of isocorroles and other non-aromatic tetrapyrroles containing one sp 3 -hybridized meso-carbon is also appealing due to their absorption in the long-visible to near-IR regions, which are essential for photocatalysis and related applications that benefit from direct excitation at these wavelengths. The results reported vastly improve our understanding of non-aromatic tetrapyrrole synthesis, properties and utility for activation of small molecule substrates such as O 2 and CO 2 in the presence of weak cationic organic acids.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Examining Ni Coarsening in Solid Oxide Electrolysis Cells by Characterizing NiH on Ni (111) Using a Combined Theoretical Approach

Ni coarsening in the fuel electrode of solid oxide cells (SOCs) is an important degradation mechanism. In this talk, density-functional theory and kinetic Monte Carlo methods are used to explore the hypothesis that the surface diffusion of NiH on Ni may promote Ni coarsening in the SOC operated in electrolysis cell mode. Using both methods and defining the diffusivity as the product of the surface coverage and single-molecule diffusivity, the diffusivity of NiH on Ni (111) is found to be sufficiently large under a significant overpotential to support the above hypothesis. Also, the time between the formation and dissociation of NiH on Ni (111) is predicted to be short at low coverages of H on Ni (111). Thus, significant progress is made toward developing a model of Ni coarsening considering both molecular and dissociated forms of NiH on Ni (111).

density functional theory (DFT)↗
DOE OSTI2025

3D Multiphysics Model for Large Scale Planar Cell: Inductance Investigation in Impedance Analysis

Developed a comprehensive 3D multiphysics model to analyze impedance behavior in large-scale planar Solid Oxide Fuel Cells (SOFCs). The model investigates how impedance varies across operating conditions and cell components, with a particular focus on inductive loops or negative capacitance at the air electrode. It was found that the Inductive loop disappears in the low-frequency zone when the activation overpotential or faradic current is not temperature-dependent. These findings offer new insights into SOFC impedance behavior.

impedence analysis↗
DOE OSTI2026

Measurement of Local Impedance Characteristics of In-Plane PEM Electrolyzer Component Features via Segmented Cell

Segmented cells are a class of advanced diagnostic devices that enable the measurement of current distribution within the active area of an electrochemical cell, allowing for the evaluation of localized impacts from operating conditions, flow fields and component inhomogeneities. Segmented cell devices have been applied to support R&D efforts for the advancement of polymer electrolyte membrane fuel cell technologies and more recently proton exchange membrane water electrolysis (PEMWE). Beyond current density distributions, segmented cells have been successfully deployed to collect the distribution of other relevant parameters such as high frequency resistance and electrode potentials. Very recently, a promising impedance method has been reported for water electrolysis where a one-dimensional segmented cell is coupled to a multichannel potentiostat, to enable the measurement of local cell impedances, further expanding the diagnostic capabilities of the segmented cell. In this study, we will present recent efforts to accurately measure local impedance characteristics for a PEMWE cell using a two-dimensional segmented cell device coupled with a multichannel potentiostat. The distribution of local resistances, i.e. high frequency, charge transfer, mass transport and catalyst layer, and iR-free overpotentials were successfully measured after eliminating sources of random and systematic error. We will discuss the application of this diagnostic on a cell containing a 1 cm feature simulating an ionomer skin. The results from these tests give insights if such an irregularity needs to be classified as a defect, and highlight the usefulness of coupling impedance spectroscopy with segmented cells for holistic spatial diagnostics of electrochemical devices.

08 HYDROGEN↗
DOE OSTI2026

Designing carbon wetting layers with inorganic salts as additives for enhanced adhesion and molten sodium wettability in electrochemical application

ß” alumina solid-state electrolyte (BASE) is considered one of the most promising materials for sodium batteries due to its high ionic conductivity and exceptional stability with molten sodium. However, at lower operating temperatures, the poor physical contact at the liquid-solid interface between molten sodium and BASE results in high interfacial resistance. In this study, we explore the optimization of carbon wetting layers with various salt additives to enhance adhesion and improve molten sodium wettability. Using a spray-coating method, carbon layers incorporating sodium hexametaphosphate (Na6(PO3)6, SHMP) as an additive demonstrate superior adhesion, mechanical stability, and enhanced wettability with molten sodium. Scanning Electron Microscopy (SEM) analysis reveals that SHMP preserves the porous carbon network required for efficient sodium transport while minimizing structural defects such as cracks and voids. Electrochemical testing using Na symmetric cells confirms that SHMP-modified layers significantly reduce interfacial resistance and overpotential, outperforming No salts counterparts. These findings highlight that the strategic incorporation of suitable additives, such as SHMP, in the design of microscale carbon layers could significantly enhance the performance of molten sodium batteries at lower operating temperatures.

Han, Henry H.↗