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DOE OSTI2021

Analysis of Various Polysulfone-nanodiamond Mixed-Matrix Membranes

Historically, coal combustion systems have contributed to the extensive network of energy production across the world. Oxycombustion has been shown to be more energy efficient and can facilitate carbon capture from fossil energy utilization. The challenge for small modular deployment of coal combustion or gasification systems is that current O2 enrichment technologies do not scale downward cost-effectively. Fortunately, membrane processes have been developed to offer a more viable polymer-based technology for this application. The central focus is to deliver a high-performance polymer membrane capable of enriching O2 to 90-95% in oxycombustion systems for small modular coal-based power or gasification plants. To accomplish this, various properties of polysulfone-nanodiamond mixed-matrix membrane are examined to determine the appropriate conditions for applicable use. The polymers are infused with nanoparticles to increase the mechanical functionality of the structure which in turn alters the permeability and selectivity of the membrane. Furthermore, the thermal history can also impact the functionality and characteristics of these polymer systems. This study primarily discusses the structure and function of these assorted membranes in terms of permeability and thermomechanical characteristics.

01 COAL, LIGNITE, AND PEAT↗

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↗

NASA NTRS2017

Temperature-Driven Shape Changes of the Near Earth Asteroid Scout Solar Sail

Near Earth Asteroid Scout (NEA Scout) is a NASA deep space Cubesat, scheduled to launch on the Exploration Mission 1 flight of the Space Launch System. NEA Scout will use a deployable solar sail as its primary propulsion system. The sail is a square membrane supported by rigid metallic tapespring booms, and analysis predicts that these booms will experience substantial thermal warping if they are exposed to direct sunlight in the space environment. NASA has conducted sunspot chamber experiments to confirm the thermal distortion of this class of booms, demonstrating tip displacement of between 20 and 50 centimeters in a 4-meter boom. The distortion behavior of the boom is complex and demonstrates an application for advanced thermal-structural analysis. The needs of the NEA Scout project were supported by changing the solar sail design to keep the booms shaded during use of the solar sail, and an additional experiment in the sunspot chamber is presented in support of this solution.

Stohlman, Olive R.↗

DOE OSTI2021

BETO 2021 Peer Review - Continuous Enzymatic Hydrolysis Development (CEHD) WBS 2.4.1.101

The Continuous Enzymatic Hydrolysis Development (CEHD) project aims to reduce the cost and commercialization scale-up risks of biorefinery sugar-lignin production through development of a deployable continuous enzymatic hydrolysis (CEH) process. Through the use of external cross flow membrane filtration loops coupled to enzymatic hydrolysis (EH) reactors, pretreated biomass solids and enzymes are retained for reaction while solubilized product sugars are removed in situ, with high extents of conversion achieved through a series of reactor-membrane unit stages. The CEHD project is focused on advancing CEH as a transformational, process-intensified, lower-cost method for producing soluble clarified biomass sugars and insoluble lignin-rich streams than traditional batch enzymatic hydrolysis (BEH). The project's primary objective is to reduce the cost of CEH to be compellingly lower than conventional BEH, 10% lower in year 1 and 20% lower in year 3 (end of project). A related objective is to expand CEH's operating envelope to increase process efficiency. Through more thorough de-risking and demonstration of CEH, in conjunction with building a suite of modeling and optimization tools that allow for more facile rigorous in silico evaluation of novel CEH designs and modalities, this project intends to elevate industry interest in adopting CEH as an improvement over conventional batch processing. This project was merit reviewed in FY20. It's now in its first year of a new 3-year plan spanning FY21-FY23.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2024

Pure-Water-Fed Forward-Bias Bipolar Membrane CO 2 Electrolyzer

Coupling renewable electricity to reduce carbon dioxide (CO 2 ) electrochemically into carbon feedstocks offers a promising pathway to produce chemical fuels sustainably. While there has been success in developing materials and theory for CO 2 reduction, the widespread deployment of CO 2 electrolyzers has been hindered by challenges in the reactor design and operational stability due to CO 2 crossover and (bi)carbonate salt precipitation. Herein, we design asymmetrical bipolar membranes assembled into a zero-gap CO 2 electrolyzer fed with pure water, solving both challenges. By investigating and optimizing the anion-exchangelayer thickness, cathode differential pressure, and cell temperature, the forward-bias bipolar membrane CO 2 electrolyzer achieves a CO faradic efficiency over 80% with a partial current density over 200 mA cm –2 at less than 3.0 V with negligible CO 2 crossover. In addition, this electrolyzer achieves 0.61 and 2.1 mV h –1 decay rates at 150 and 300 mA cm –2 for 200 and 100 h, respectively. Postmortem analysis indicates that the deterioration of catalyst/polymer– electrolyte interfaces resulted from catalyst structural change, and ionomer degradation at reductive potential shows the decay mechanism. Furthermore, all these results point to the future research direction and show a promising pathway to deploy CO 2 electrolyzers at scale for industrial applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Grooved electrodes for high-power-density fuel cells

Proton exchange membrane fuel cells (PEMFCs) are leading candidates to decarbonize the transport sector, but widespread deployment will require improvements in lifetime, fuel economy and cost. Here we present the grooved electrode, an alternative electrode structure that enhances PEMFC performance and durability by coupling high ionomer (ion-conducting binder) content for improved H + transport with grooves for rapid O 2 transport. Grooved electrodes provide up to 50% higher performance than state-of-the-art conventional electrodes under standard operating conditions. Fuel cell diagnostics combined with multiphysics modelling demonstrate that grooved electrodes provide facile O 2 transport despite their high ionomer content, enabling improved reaction rate uniformity. Grooved electrodes also provide improved durability, with less performance loss after carbon corrosion compared with baseline electrodes. Machine learning analysis demonstrates the potential to further optimize grooved structures for next-generation PEMFCs with enhanced performance and durability, enabling smaller and cheaper fuel cell stacks with higher fuel efficiency.

25 ENERGY STORAGE↗

DOE OSTI2024

Multi-functional Sorbent Technology (MUST) for the Recovery/Removal of Critical/Heavy Metals from Fossil-Related Wastewater

A collection of remediation and recovery technologies like those predicated on photocatalytic-, electric-, chemical-, membrane-, and adsorptive-based processes currently exists in different stages of development or deployment between these methods of water management. Among these technologies, solid sorbent processes embody an optimal balance between cost-effectiveness, environmental friendliness, and technological maturity. The U.S. Department of Energy’s National Energy Technology Laboratory developed a suit of cross-linked, functionalized silica sorbents tailored to eliminate the most toxic metals regulated by the U.S. Environmental Protection Agency (EPA); critical metals identified by the U.S. Geological Survey (USGS); and harmful organics like the infamous perfluoroalkyl and polyfluoroalkyl substances (PFAS). An array of laboratory and field tests proved that the MUST sorbents removed ppb-level lead from drinking water, selenium from FGD wastewater below EPA limits, aqueous dyes and PFAS; and fractionated low ppm-level critical metals (CM) from AMD and simulated produced water. Proof-of-concept for commercial CM recovery was verified through obtaining milligram-quantities of purified Al solids from a sorbent multi-bed AMD field-site test. Commercial efficacy was further supported by achieving purified fractions of adsorbed Mn upon treating both the AMD and synthetic produced water with the laboratory multi-bed test unit.

Wilfong, Walter C.↗

NASA NTRS2000

Solar Power System Evaluated for the Human Exploration of Mars

The electric power system is a crucial element of any mission for the human exploration of the Martian surface. The bulk of the power generated will be delivered to crew life support systems, extravehicular activity suits, robotic vehicles, and predeployed in situ resource utilization (ISRU) equipment. In one mission scenario, before the crew departs for Mars, the ISRU plant operates for 435 days producing liquefied methane and oxygen for ascent-stage propellants and water for crew life support. About 200 days after ISRU production is completed, the crew arrives for a 500-day surface stay. In this scenario, the power system must operate for a total of 1130 days (equivalent to 1100 Martian "sols"), providing 400 MW-hr of energy to the ISRU plant and up to 18 kW of daytime user power. A photovoltaic power-generation system with regenerative fuel cell (RFC) energy storage has been under study at the NASA Glenn Research Center at Lewis Field. The conceptual power system is dominated by the 4000- m2 class photovoltaic array that is deployed orthogonally as four tent structures, each approximately 5 m on a side and 100-m long. The structures are composed of composite members deployed by an articulating mast, an inflatable boom, or rover vehicles, and are subsequently anchored to the ground. Array panels consist of thin polymer membranes with thin-film solar cells. The array is divided into eight independent electrical sections with solar cell strings operating at 600 V. Energy storage is provided by regenerative fuel cells based on hydrogen-oxygen proton exchange membrane technology. Hydrogen and oxygen reactants are stored in gaseous form at 3000 psi, and the water produced is stored at 14.7 psi. The fuel cell operating temperature is maintained by a 40-m2 deployable pumped-fluid loop radiator that uses water as the working fluid. The power management and distribution (PMAD) architecture features eight independent, regulated 600-Vdc channels. Power management and distribution power cables use various gauges of copper conductors with ethylene tetrafluoroethylene insulation. To assess power system design options and sizing, we developed a dedicated Fortran code to predict detailed power system performance and estimate system mass. This code also modeled the requisite Mars surface environments: solar insolation, Sun angles, dust storms, dust deposition, and thermal and ultraviolet radiation. Using this code, trade studies were performed to assess performance and mass sensitivities to power system design parameters (photovoltaic array geometry and orientation) and mission parameters (landing date and landing site latitude, terrain slope, and dust storm activity). Mission analysis cases were also run. Power results are shown in this graph for an analysis case with a September 1, 2012, landing date; 18.95 North latitude landing site; two seasonal dusts storms; and tent arrays. To meet user load requirements and the ISRU energy requirement, an 8-metric ton (MT) power system and 4000-m2 photovoltaic array area were required for the assumed advanced CuInS2 thin-film solar cell technology. In this figure, the top curve is the average daytime photovoltaic array power, the middle curve is average daytime user load power, and the bottom curve is nighttime power. At mission day 1, daytime user power exceeds 120 kW before falling off to 80 kW at the end of the mission. Throughout the mission, nighttime user power is set to the nighttime power requirement. In this analysis, "nighttime" is defined as the 13- to 15-hr period when array power output is below the daytime power requirement. During dust storms, power system capability falls off dramatically so that by mission day 900, a daily energy balance cannot be maintained. Under these conditions, the ISRU plant is placed in standby mode, and the regenerative fuel cell energy storage is gradually discharged to meet user loads.

Kerslake, Thomas W.↗

NASA NTRS1985

Electrostatic forming and testing of polymer films on a 16-foot diameter test fixture

The large space systems technology program investigated different forms of large, lightweight, deployable structures which could be carried on the Space Shuttle. Different forms and concepts of antennas as a type of large space system were investigated. The electrostatically controlled membrane reflector made of metallized material concept was chosen. The concept is a good candidate for creating an antenna with high surface quality and has the ability to be packaged and deployed from the Shuttle with a significant reduction in weight compared to other antenna types.

Goslee, J. W.↗

DOE OSTI2026

Sparsely Dispersed CeO x ‑Stabilized Pt Nanoparticles Overcome Pt Loading–Durability Trade-Off for Highly Durable Heavy-Duty Fuel Cells

Proton-exchange-membrane fuel cells (PEMFCs) are clean and sustainable mobile power sources for transportation. Recently, their deployment in heavy-duty vehicles (HDVs) has attracted growing interest owing to their high energy scalability and lower infrastructure requirements. However, to meet the stringent requirements for efficiency and long-term durability for HDV applications, PEMFCs typically employ a relatively high platinum group metal (PGM) loading (>0.2 mg PGM /cm 2 ). This elevated PGM loading significantly increases the stack and system costs, surpassing the U.S. Department of Energy (DOE) target of $\$ 60$/kW for commercial viability. Reducing PGM loading while maintaining performance and durability remains a central challenge for HDV fuel cells. Here we exploit metal oxide–Pt interactions and utilize the strong CeO x –Pt interaction to design a CeO x @Pt catalyst structure with exceptional durability. At a low total PGM loading (0.1 mg PGM /cm 2 ), the CeO x @Pt/C catalyst demonstrates high fuel cell performance (8.8 kW/g PGM ) and stability (power retention >90%) after the challenging HDV durability testing (90,000 accelerated-stress-test cycles). With the CeO x @Pt/C catalyst, we showcase over 70% reduction in Pt cost from the M2FCT target (to $\$ 9$/kW), highlighting its promising potential for enabling stable and cost-effective fuel cell systems for heavy-duty applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2003

Rollable Thin-Shell Nanolaminate Mirrors

A class of lightweight, deployable, thin-shell, curved mirrors with built-in precise-shape-control actuators is being developed for high-resolution scientific imaging. This technology incorporates a combination of advanced design concepts in actuation and membrane optics that, heretofore, have been considered as separate innovations. These mirrors are conceived to be stowed compactly in a launch shroud and transported aboard spacecraft, then deployed in outer space to required precise shapes at much larger dimensions (diameters of the order of meters or tens of meters). A typical shell rollable mirror structure would include: (1) a flexible single- or multiple-layer face sheet that would include an integrated reflective surface layer that would constitute the mirror; (2) structural supports in the form of stiffeners made of a shape-memory alloy (SMA); and (3) piezoelectric actuators. The actuators, together with an electronic control subsystem, would implement a concept of hierarchical distributed control, in which (1) the SMA actuators would be used for global shape control and would generate the large deformations needed for the deployment process and (2) the piezoelectric actuators would generate smaller deformations and would be used primarily to effect fine local control of the shape of the mirror.

Hickey, Gregory↗

DOE OSTI2020

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

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

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2000

Design and Flight Testing of an Inflatable Sunshield for the NGST

The Next Generation Space Telescope (NGST) mission is scheduled to launch in 2007 and be stationed at L2 for a mission life of ten years. The large aperture mirror and optical detectors aboard NGST require shielding from the constant solar energy seen at this orbit. The government reference NGST design, called the Yardstick, baselined a sunshield using an inflation deployment system. During the formulation phase, NGST is spending approximately 25% of the overall budget to foster the development of new technology. The goal is to develop and demonstrate enabling or enhancing technology and provide innovative solutions for the design of the NGST observatory. Inflatable technology falls in the category of enhancing technology due to its advantages in weight, stowed volume and cost. The Inflatable Sunshield in Space (ISIS) flight experiment will provide a realistic space flight demonstration of an inflatable sunshield. The supporting technology development program will provide an information base for the design, manufacture, assembly and testing of large thin membranes and inflatable structural elements for space structures. The ISIS experiment will demonstrate the feasibility of using inflatable technology to passively cool optical systems for NGST and provide correlation between analytical predictions and on orbit results. The experiment will be performed on a Hitchhiker/Space Shuttle mission in late 2001. The ISIS mission is an effort to address several major technical challenges of the NGST inflatable sunshield, namely controlled inflation deployment, plenarity and separation of large stretched membranes, space rigidization of inflatable booms, and dynamic modeling and simulation. This paper will describe the design of the flight experiment and the testing to be performed on-orbit.

Adams, Michael L.↗

DOE OSTI2024

Updated Manufactured Cost Analysis for Proton Exchange Membrane Water Electrolyzers

Enabling rapid and extensive decarbonization within the electric power and industrial sectors is likely to require high levels of renewable energy deployment, supported by technologies that store and transform renewable electricity into other useful forms. Within hard to decarbonize sectors such as organic chemicals and heavy-duty transportation, the use of low-carbon intensity hydrogen as a fuel and chemical building block is emerging as a near-term alternative to reduce their fossil-fuel dependency. Water splitting electrolysis to produce hydrogen requires only water and electricity as inputs, eliminating the use of natural gas in steam methane reforming, which is the conventional hydrogen production pathway. When powered by low-carbon electricity, electrolysis represents an important pathway towards cross-sectoral decarbonization.

08 HYDROGEN↗

DOE OSTI2021

Development of an Advanced Hydrogen Energy Storage System using Aerogel in a Cryogenic Flux Capacitor (CFC)

The Cryogenic Flux Capacitor (CFC) is a cold, dense fluid storage core with integrated design features that afford the designer flexibility and provide new possibilities for the storage and discharge of energy. The stored energy, in this case, is represented by hydrogen physically bonded within the nanoscale pores within the aerogel composite blanket material, and the process of bonding or debonding is governed by principles of physical adsorption (physisorption) and thermodynamics. The large surface area afforded by the nanoporous aerogel (~1,000 m2/g) allows for storage densities close to, or in some cases exceeding, that of normal boiling point liquids. Its performance easily exceeds what can be achieved via ambient temperature, high-pressure gas storage for an equivalent volume. CFC storage is predicted to be easily scalable, is constructed from readily available commercial materials, lends itself to a range of pressure applications, and is geometry insensitive. They can also be used in modular designs, affording even more flexibility for potential deployment. In addition to the aerogel adsorbent within the blanket material, a CFC includes thermally-conductive membrane layered with the aerogel, which acts as a large-area, quick-response thermal management system. The system conducts heat throughout the volume to discharge the unit quickly. This same thermal management system can also be connected to a refrigeration system, or cold fluid such as liquid nitrogen (LN2), to facilitate the charging up of the CFC. The charging and discharging can be performed as fast or as slow as desired by controlling the cooling or heating supplied to the CFC.

08 HYDROGEN↗

NASA NTRS2013

Extreme low frequency acoustic measurement system

The present invention is an extremely low frequency (ELF) microphone and acoustic measurement system capable of infrasound detection in a portable and easily deployable form factor. In one embodiment of the invention, an extremely low frequency electret microphone comprises a membrane, a backplate, and a backchamber. The backchamber is sealed to allow substantially no air exchange between the backchamber and outside the microphone. Compliance of the membrane may be less than ambient air compliance. The backplate may define a plurality of holes and a slot may be defined between an outer diameter of the backplate and an inner wall of the microphone. The locations and sizes of the holes, the size of the slot, and the volume of the backchamber may be selected such that membrane motion is substantially critically damped.

Shams, Qamar A.↗

NASA NTRS2017

Extreme Low Frequency Acoustic Measurement System

Shams, Qamar A.↗

NASA NTRS2006

Hybrid Deployable Foam Antennas and Reflectors

Hybrid deployable radio antennas and reflectors of a proposed type would feature rigid narrower apertures plus wider adjoining apertures comprising reflective surfaces supported by open-cell polymeric foam structures (see figure). The open-cell foam structure of such an antenna would be compressed for compact stowage during transport. To initiate deployment of the antenna, the foam structure would simply be released from its stowage mechanical restraint. The elasticity of the foam would drive the expansion of the foam structure to its full size and shape. There are several alternatives for fabricating a reflective surface supported by a polymeric foam structure. One approach would be to coat the foam with a metal. Another approach would be to attach a metal film or a metal-coated polymeric membrane to the foam. Yet another approach would be to attach a metal mesh to the foam. The hybrid antenna design and deployment concept as proposed offers significant advantages over other concepts for deployable antennas: 1) In the unlikely event of failure to deploy, the rigid narrow portion of the antenna would still function, providing a minimum level of assured performance. In contrast, most other concepts for deploying a large antenna from compact stowage are of an "all or nothing" nature: the antenna is not useful at all until and unless it is fully deployed. 2) Stowage and deployment would not depend on complex mechanisms or actuators, nor would it involve the use of inflatable structures. Therefore, relative to antennas deployed by use of mechanisms, actuators, or inflation systems, this antenna could be lighter, cheaper, amenable to stowage in a smaller volume, and more reliable. An open-cell polymeric (e.g., polyurethane) foam offers several advantages for use as a compressible/expandable structural material to support a large antenna or reflector aperture. A few of these advantages are the following: 3) The open cellular structure is amenable to compression to a very small volume - typically to 1/20 of its full size in one dimension. 4) At a temperature above its glass-transition temperature (T(sub g)), the foam strongly damps vibrations. Even at a temperature below T(sub g), the damping should exceed that of other materials. 5) In its macroscopic mechanical properties, an open-cell foam is isotropic. This isotropy facilitates computational modeling of antenna structures. 6) Through chemical formulation, the T(sub g) of an open-cell polyurethane foam can be set at a desired value between about - 100 and about 0 C. Depending on the application, it may or may not be necessary to rigidify a foam structure after deployment. If rigidification is necessary, then the T(sub g) of the foam can be tailored to exceed the temperature of the deployment environment, in conjunction with providing a heater to elasticize the foam for deployment. Once deployed, the foam would become rigidified by cooling to below T(sub g). 7) Techniques for molding or machining polymeric foams (especially including open-cell polyurethane foams) to desired sizes and shapes are well developed.

Rivellini, Tommaso↗