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DOE OSTI2024

High-Efficiency and Low-Carbon Energy Storage and Power Generation System for Electric Aviation

This report summarizes the work performed by University of California San Diego (UCSD) – Honeywell Aerospace (Honeywell) team for the U.S. Department of Energy/Advanced Research Projects Agency-Energy (DOE/ARPA-E) under Phase 1 (April 2021 – October 2023) project, Cooperative Agreement DE-AR0001347 entitled “High-Efficiency and Low-Carbon Energy Storage and Power Generation System for Electric Aviation”. The main objective of this project is to develop and demonstrate an energy storage and power generation (ESPG) system operating on bio liquid natural gas (LNG) for electric aviation applications. The ESPG system concept in this project is a fuel cell, battery, and gas turbine hybrid system that incorporates an innovative solid oxide fuel cell (SOFC) technology. This SOFC technology has two main novel elements: (i) a lightweight and compact stack architecture that consists of cells and cell modules in electrical parallel and series connections (the module design) and (ii) exceptionally high performance, direct methane thin-film cells on porous substrate made by sputtering deposition process. This fuel cell has the specific power and volumetric power density suitable for electric aviation applications. Based on the current status of the SOFC technology, the Phase 1 work focused on the following activities: (i) ESPG System Modeling – to design and optimize an aircraft SOFC-based ESPG system concept that met the performance, weight and cost targets; (ii) Cell Material Development and Scaleup – to demonstrate scalability of the sputtering process for manufacture of thin-film SOFC cells of practical sizes, confirm the exceptional performance of sputtered cells, improve cell stability and durability for operation with hydrogen and methane fuel, and develop a suitable electrically conducting porous substrate to replace the current non-conducting ceramic substrate; (iii) Stack Development – to design and manufacture stack components for the stack architecture, evaluate and select a suitable sealant, and build and operate multi-cell stacks to demonstrate stack operation, and (iv) Technology to Market – to develop business models and commercialization plans, conduct various market and technology analysis and estimate SOFC and ESPG system costs.

25 ENERGY STORAGE↗
DOE OSTI2024

Electromagnetic Energy-Assisted Thermal Conversion of Fossil-Based Hydrocarbons to Low-Cost Hydrogen

The goal of this project was to develop and optimize catalysts for methane decomposition, particularly focusing on regeneration via an electromagnetic energy-assisted mechanism, to produce hydrogen more cost-effectively compared to electrolysis routes. To achieve this goal, the project pursued several key objectives. The project began with the preparation and testing of various catalysts. A nickel-silica based catalyst was identified as the most promising material for the pyrolysis of methane into carbon and hydrogen. Kinetic parameters for methane decomposition were determined, aiding in computational modeling efforts. Structured catalysts were investigated, highlighting the need for frequent cleaning or regeneration to maintain performance, with methane conversion rates exceeding 70% in tube furnace tests. Computational fluid dynamics modeling was employed to optimize reactor designs and electrode angles, leading the project team to propose a multi-compartment thermal conversion system for larger setups. This modeling work was important in understanding reaction characteristics, carbon deposition rates, and temperature profiles under various conditions. A bench-scale reactor system was assembled to evaluate catalyst regeneration using electromagnetic energy-assisted mechanisms. Experiments demonstrated the potential for carbon removal, though further optimization is needed. The carbon produced from the methane conversion process was evaluated for potential use in lithium-ion battery electrodes. The carbon exhibited properties similar to commercially available high-purity multi-walled carbon nanotubes and nanofibers, with a carbon content greater than 95%. Coin cell batteries assembled with this carbon showed that lower replacement levels (10% to 33%) outperformed the control group, improving specific capacity density and stability. However, higher replacement levels (100%) demonstrated poorer performance, suggesting that excessive carbon substitution negatively impacts battery performance. These findings indicate the potential marketability of the produced carbon as a component in lithium-ion batteries, though further testing is necessary to confirm long-term advantages and disadvantages associated with the use of the carbon product. These results however justified further technoeconomic assessments to determine if the process can provide low-cost hydrogen. The economic feasibility and technical performance of methane decomposition for hydrogen production were assessed, focusing on three plant configurations: 100E (electrically heated), 100C (combustion heated using produced hydrogen), and PE-Hybrid (a combination of pyrolysis (indicating decomposition) and electrolysis). The Levelized Cost of Hydrogen (LCOH) for the pyrolysis configurations was found to be approximately 25% lower than that of electrolysis. The 100E configuration had the lowest LCOH at $\$$3.12/kg. Including carbon product sales significantly improved the economics, with the 100C configuration achieving a negative LCOH of -$\$$0.35/kg. The PE-Hybrid configuration was not economically advantageous compared to pure pyrolysis plants due to its complexity and additional equipment requirements. Ultimately, methane pyrolysis presents a viable method for near carbon dioxide-free hydrogen production, with significant economic advantages over electrolysis, especially when considering the sale of carbon byproducts. The 100E and 100C configurations showed the most promise, with the choice between them ultimately depending on the prices of power and natural gas. In conclusion, this technology has the potential to lower hydrogen production costs by leveraging the methane decomposition process with the sale of valuable carbon byproducts. By optimizing catalyst performance and integrating electromagnetic energy-assisted regeneration, the process can achieve higher efficiency and economic viability, making it a competitive alternative to traditional hydrogen production methods.

08 HYDROGEN↗
DOE OSTI2019

Roll-to-Roll SOFC Manufacturing for Low Cost Energy Generation

Oak Ridge National Laboratory (ORNL) and Redox Power Systems, LLC. collaborated on this project to develop an integrated, continuous roll-to-toll (R2R) manufacturing processes to produce solid oxide fuel cells (SOFCs). SOFCs are ceramic-based electrochemical devices that efficiently produce electricity from hydrogen-containing fuels, including natural gas. Standard processes for manufacturing SOFCs include tape casting of the anode and electrolyte, followed by stacking of the layers, and lamination using a uniaxial press or isostatic press. After high temperature firing, the cathode and electrical contact are screen printed and fired once again to complete the cell. This effort aimed to further develop R2R tape fabrication processes for green cell fabrication with the DOE Battery Manufacturing Facility (BMF) at ORNL as next generation improvements to current methods, focusing on R2R calendering and slot die coating for lower cost, high volume approaches for multilayer green cell fabrication. Two paths were investigated in parallel in this project. The first path was to optimize R2R processing using traditional tape cast materials from the Redox production chain on the BMF’s heated calender for compressing and laminating multilayer materials. The second path was to use BMF’s pilot-scale slot-die coater for R2R manufacturing as an alternative to tape casting of some or all of the layers in the green cell. Processes have been developed and and process conditions have been identified. Additionally, basic process economics were estimated for comparison to Redox current manufacturing approaches for the applicable process modules. The SBV program results will enable Redox to advance lower cost R2R manufacturing processes to produce millions of green cells per year on a single production line. As a result of this work, one invention disclosure has been submitted. In addition, one paper is under preparation for submission to a peer-reviewed journal.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2018

Brazings for Metal-Ceramic Joining in Sodium Thermal Electrochemical Converter (Na-TEC) Devices

Sodium thermal electrochemical converters (Na-TECs) offer a high efficiency advancement for converting thermal energy into electrical energy without moving parts. Since the cell operates using a Na pressure difference between the high temperature evaporator and the lower temperature condenser, a hermetic seal capable of maintaining that pressure difference is essential. This study looked at brazing of the ceramic electrolyte used in these cells, which is a β”-alumina solid-electrolyte referred to as BASE. Since a literature search found no papers pertaining to brazing of BASE, knowledge from ceramic to metal brazing called widegap brazing was used. Specifically, the widegap brazing of α-alumina to nickel-based alloys. Initial brazing trials used a traditional inert atmospheric brazing technique with an Ar-H2 gas mixture. However, the very low pO2 atmosphere resulted in the destruction of the BASE layers due to the diffusion of carbon to the outer surface of the electrolyte during brazing. A new and radically different brazing technique called air brazing was then attempted. This brazing technique proved successful using the brazing alloy Ag-8CuO. Both Ag and Cu are not deleteriously affected by Na corrosion; thus, Ag-8CuO were a good choice for the braze alloy. Leak tests were performed on these cells to establish their hermeticity. This cell structure and brazing technique proved to be successful. Air brazing is an exciting joining operation for these types of cells.

14 SOLAR ENERGY↗
DOE OSTI2016

Strongly correlated perovskite fuel cells

Fuel cells convert chemical energy directly into electrical energy with high efficiencies and environmental benefits, as compared with traditional heat engines(1-4). Yttria-stabilized zirconia is perhaps the material with the most potential as an electrolyte in solid oxide fuel cells (SOFCs), owing to its stability and near-unity ionic transference number(5). Although there exist materials with superior ionic conductivity, they are often limited by their ability to suppress electronic leakage when exposed to the reducing environment at the fuel interface. Such electronic leakage reduces fuel cell power output and the associated chemo-mechanical stresses can also lead to catastrophic fracture of electrolyte membranes(6). Here we depart from traditional electrolyte design that relies on cation substitution to sustain ionic conduction. Instead, we use a perovskite nickelate as an electrolyte with high initial ionic and electronic conductivity. Since many such oxides are also correlated electron systems, we can suppress the electronic conduction through a filling-controlled Mott transition induced by spontaneous hydrogen incorporation. Using such a nickelate as the electrolyte in free-standing membrane geometry, we demonstrate a low-temperature micro-fabricated SOFC with high performance. The ionic conductivity of the nickelate perovskite is comparable to the best-performing solid electrolytes in the same temperature range, with a very low activation energy. The results present a design strategy for high-performance materials exhibiting emergent properties arising from strong electron correlations.

Zhou, You↗
DOE OSTI2020

Diversity in Photoprotection and Energy Balancing in Terrestrial and Aquatic Phototrophs

The evolution of oxygenic photosynthesis enabled organisms to use sunlight as an energy source, allowing them to colonize new niches. At the same time, life (as we know it) places severe constraints on photosynthesis. For example, the initial reactions of photosynthesis involve highly energetic intermediates that, if not controlled, can generate highly toxic side products (especially reactive oxygen species, ROS), that can damage other essential components of the organisms it powers. Photosynthesis must therefore be tightly regulated to balance the need for efficient energy conversion with the necessity of avoiding photodamage (Gust D, Kramer D, Moore A, Moore T, Vermaas W, Mater Res Bull 33:383–389, 2008). A related constraint on photosynthesis is the need to precisely balance how much energy is stored in ATP and NADPH to precisely meet biochemical demands. If this balancing does not occur, the system will fail, leading to photodamage (Kramer DM, Evans JR, Plant Physiol 155:70–78, 2011). Consideration of these requirements is essential for efforts to improve the efficiency of photosynthesis by introducing CO 2 concentrating mechanisms, altering metabolism or biosynthetic pathways to shunt energy to alternative products (Kramer DM, Evans JR, Plant Physiol 155:70–78, 2011). These balancing processes must be extremely robust to contend with the rapid and unpredictable fluctuations in environmental conditions and metabolic demands that occur in nature. A large body of work has come from model systems, especially terrestrial higher plants and the green alga Chlamydomonas reinhardtii, leading to a model for the regulation of light reactions that involves 1) sensing of the pH gradient component of the thylakoid proton motive force (pmf), and 2) the redox state of the plastoquinone- and stromal pools. Over the short term, these sensors trigger regulation of light capture by altering the activity of ATP synthase leading to adjustments in lumen pH, which fine tunes light capture through nonphotochemical quenching (NPQ) and control of electron flow by adjusting the rate of PQH 2 oxidation at the b 6 f complex. Simultaneously, this system controls the balance of ATP/NADPH by adjusting electron flux to linear and cyclic electron flow pathways to balance ATP/NADPH. This integrated “pmf paradigm” model explains much of the existing data on plants and green algae, but may not extend to other diverse organisms. This review considers how advances in our understanding of photosynthesis over the past 7–8 years, particularly in the discoveries of diverse biochemical/biophysical mechanisms in aquatic photosynthetic species, affects the view of energy balance, including the shunting of electrons to O 2 through the flavodiiron proteins (FLV), the plastid terminal oxidase, the dissipation of electric field by ion movements, and the activation of alternative electron sinks. Furthermore, we will introduce the basic model that has been developed for higher plant chloroplasts, then contrast these with selected aquatic systems, focusing on how the differences impact the needs to re-balance both energy input and its partitioning into energy currencies.

Kanazawa, Atsuko↗
DOE OSTI2023

Boosting the performance of reversible solid oxide electrochemical cells with a novel hybrid oxygen electrode, Pr 1.39 Ba 0.14 Sr 0.53 Co 1.48 Fe 0.76 O 6- δ -Ba 0.66 Sr 0.34 CoO 3- δ

Solid oxide electrochemical cells (SOECs) stand out as a highly promising clean energy technology that offers several benefits, showing significant potential to play a pivotal role in the transition towards a sustainable and low-carbon energy future. SOECs can efficiently convert the chemical energy stored in fuels to electricity in fuel cell mode, and produce various chemicals from abundant feedstocks (e.g., CO 2 , H 2 O) and intermittent solar/wind-based renewable electricity. Despite extensive efforts that have been devoted to designing novel materials and optimizing SOEC manufacturing processes, aiming to achieve enhanced energy efficiency, the current SOECs still suffer from poor performance, which is mainly due to the sluggish oxygen reduction reaction (ORR) and oxygen evolution reaction (OER) kinetics. To address this challenge, in this work, we have successfully designed an in situ formed hybrid oxygen electrode material (Pr 1.39 Ba 0.14 Sr 0.53 Co 1.48 Fe 0.76 O 6- δ -Ba 0.66 Sr 0.34 CoO 3- δ ), which significantly improves the surface oxygen exchange coefficient and bulk oxygen-ion diffusion coefficient, enhancing the OER and ORR electrocatalytic activities. Further, the SOECs equipped with this newly developed oxygen electrode achieved exceptional performance for power generation using both hydrogen and propane as the fuels. At 750 °C, a peak power density of 2.4 W cm -2 was obtained with H 2 as the fuel. Additionally, the SOECs attain unprecedented performance in steam electrolysis mode. A current density of 4.4 A cm -2 was achieved at 1.3 V and 750 °C, which represents the highest performance among all yttria-stabilized zirconia (YSZ) electrolyte-based SOECs. The SOECs also deliver remarkable stability during the accelerated stability testing, highlighting the great potential of Pr 1.39 Ba 0.14 Sr 0.53 Co 1.48 Fe 0.76 O 6- δ -Ba 0.66 Sr 0.34 CoO 3- δ as a high-performance oxygen electrode for next generation SOECs.

08 HYDROGEN↗
DOE OSTI2024

Electrochemical Conversion of CO 2 to Methyl Formate in a Flow Electrolyzer with Mixed Propylene Carbonate/Methanol Catholyte

Despite the promise of electrochemical carbon dioxide reduction as a technology for the production of clean fuels and decarbonization of the chemical industry, research has mostly focused on aqueous systems with a relatively limited set of products that have been achieved via electrosynthesis. Increasingly, CO 2 electroreduction in nonaqueous solvents is being pursued to develop new avenues for expanding the suite of products that can be made with high selectivity. CO 2 reduction in alcohols coupled with in situ esterification to produce esters is one such route that utilizes nonaqueous electrolyte. To be practical, such electrochemical syntheses need to be translated to a high-performance reactor such as a flow electrolyzer. However, many organic solvents, such as alcohols, wet and flood porous electrodes, thus impeding reactor performance. In this work, methanol was mixed with propylene carbonate as a catholyte for a gas-fed CO 2 flow electrolyzer that avoided cathode flooding. Simultaneously, a dual aqueous anolyte was used for water oxidation as a scalable and sustainable anodic half-reaction. The performance effect of methanol concentration, catholyte acidity, CO 2 flow rate, and dilute water in the catholyte were investigated. With 10 vol % methanol in 90 vol % propylene carbonate, 63% faradaic efficiency for methyl formate ester product was sustained without cathode flooding. However, improvements are still needed to lower the cell resistance and further increase the operating current density.

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

Solar Bankability Data to Advance Transactions and Access (SB-DATA) Final Technical Report

The DOE project “Solar Bankability Data to Advance Transactions and Access”, known in the solar industry and referred to in this report as “Orange Button”, had project objectives of convening key stakeholder participants in the solar project lifecycle to develop a data taxonomy that meets to the solar industry’s needs for standardized data types for use in solar projects. Additional Orange Button deliverables included the development of an online data exchange to act as a clearinghouse of data that conformed to the data standard and additional solar industry data, and a Solar Data Translation Platform that could transform legacy solar project data to conform to the Orange Button data standard. All of these objectives were achieved. The Smart Electric Power Alliance (SEPA) provided program management, industry participant recruiting and convening, worked with the solar industry to define the scope of the Orange Button data taxonomy, and documented and delivered the taxonomy data requirements to funded project partners to develop both the taxonomy and the data conversion tools. Further efforts included performing extensive industry outreach and awareness to encourage adoption of the Orange Button taxonomy by the solar industry by enumerating the cost saving benefits of using the taxonomy and the public benefit of the increased use of solar energy due to increased bankability and viability of solar development projects. Solar PV panel and component prices have fallen in the last decade, while soft costs have remained stubbornly high and can account for as much as 64% of the total cost of a new solar system. Part of the U.S. Department of Energy SunShot Initiative, Orange Button enabled the creation and adoption of industry-led open data standards for rapid and seamless information exchange across the solar value chain, from origination to decommissioning. Standardizing data will reduce soft costs by making it easier to share solar data and speeding up processes. The taxonomy is a product of solar industry participants convening to identify the pain points caused by incompatible data, and to agree on and standardize data types to be used by the actors in the solar project lifecycle. This report focuses on the SEPA led first phase of Orange Button project that included industry outreach and recruiting participants for five industry working groups, widespread industry outreach to increase awareness and encourage eventual adoption of the taxonomy, and the definition of the scope, use cases, and supporting data types of the Orange Button taxonomy. The solar industry has been receptive of the completed Orange Button taxonomy. In SEPA’s work, 401 solar industry participants facilitated by SEPA defined the scope, use cases, and requirements for the taxonomy leading to over 150 taxonomy early adopters incorporating the taxonomy into their software products serving the solar industry, and several large investors and banks have started projects to enable them to utilize the taxonomy to gain back-office efficiencies. Moving forward, as the solar industry more widely embraces the Orange Button taxonomy and begins realizing the tangible benefits of adoption at scale, we expect further pressure on solar soft costs and increases in the bankability of solar projects.

14 SOLAR ENERGY↗
DOE OSTI2018

Heat Storage Options for Sodium, Salt and Helium Cooled Reactors to Enable Variable Electricity to the Grid and Heat to Industry with Base-Load Reactor Operations

Electricity markets are changing rapidly because of (1) the addition of wind and solar and (2) the goal of a low-carbon electricity grid. These changes result in times of high electricity prices and very low or negative electricity prices. California has seen its first month where more than 20% of the time (mid-day) the wholesale price of electricity was zero or negative. This creates large incentives for coupling heat storage to advanced reactors to enable variable electricity and industrial-heat output (to maximize revenue) while the reactor operates at base load (minimize cost). Recent studies have examined coupling various types of heat storage to Rankine and Brayton power cycles. However, there has been little examination of heat-storage options between (1) the reactor and (2) the power-conversion system or industrial customer. Heat-storage systems can be incorporated into sodium , helium-, and salt-cooled reactors. Salt-cooled reactors include the fluoride-salt-cooled high-temperature reactor (FHR) with its solid fuel and clean coolant and the molten salt reactor (MSR) with its fuel dissolved in the salt. For sodium and salt reactors, it is assumed that a heat-storage system would be in the secondary loop between the reactor and power cycle. For helium-cooled reactors, heat storage can be in the primary or secondary loop. This report is a first look at the rational and the heat storage options for deploying gigawatt-watt hour heat-storage systems with GenIV reactors. Economics and safety are the primary selection criteria. The leading heat-storage candidate for sodium-cooled systems (a low-pressure secondary system with small temperature drop across the reactor core) is sodium coolant stored in large steel tanks, with the coolant transferring heat in channels. The design minimizes sodium volume in the storage and, thus, the risks and costs associated with sodium. For helium systems (high-pressure with large temperature drop across the core), the leading heat storage options are (1) varying the temperature of the reactor core, (2) steel or alumina firebrick in a secondary pressure vessel and (3) nitrate or hot-rock/firebrick at atmospheric pressure. For salt systems (low pressure, high temperatures, and small temperature drop across the reactor core) the leading heat-storage systems are secondary salts. In each case, options are identified and questions to be addressed are identified. In some cases there is a strong coupling between the heat-storage technology and the power cycle. The leading sodium heat-storage technology may imply changes in the power cycle. High-temperature salt systems couple efficiency to Brayton power cycles that may create large incentives for the heat storage to remain within the power cycle rather than in any intermediate heat transfer loop.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Anodized Aluminum Oxide Membrane Ionic Memristors

Memory effect in ion transport (IT) at the solid–solution interface is uniquely attractive in that the conductance depends on or “memorizes” the previous states. Hysteretic and rectified transport properties offer exciting potential to developing advanced iontronics and neuromorphic functions, improving the efficiency of energy conversion and electrochemical processes, and overcoming the selectivity-throughput bottleneck in the enrichment of low abundant species for environment- and energy-friendly separations, among others. Herein, memory effects are discovered in the rectified electrokinetic IT through anodized aluminum oxide (AAO) membranes containing densely packed highly ordered nanochannels (10 10 per cm 2 ). Characteristic memristor responses of pinched current–potential loops are resolved in voltammetric experiments and successfully reproduced through finite element simulation. Excitatory and inhibitory conductance states are shown to arise from the enrichment and depletion of mobile charge carriers. Structurewise, the transport symmetry is broken by the barrier oxide layer (BOL) on the one end of the cylindrical nanochannels across the AAO membranes. Charge selectivity is attributed to the gradient(s) of the space charge density across the BOL characterized by depth profiling via X-ray photoelectron spectroscopy analysis. The space charge gradient(s) overcomes the fundamental limitation of widely exploited surface charge effects to enable intense rectification and hysteresis prevailing at very high ionic concentrations up to 1–2 M. A new strategy is developed for controlling the preferential IT direction and selectivity via counterion intercalation and extraction/exchange. Mechanistic understanding is further confirmed through parameter variations such as potential scan rate and ionic strength, which also demonstrates convenient controls of the related functions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2015

Monitoring of WEEE plastics in regards to brominated flame retardants using handheld XRF

Highlights: • Specification of an empirical factor for conversion from bromine to PBB and PBDE. • The handheld XRF device was validated for this particular application. • A very large number of over 4600 pieces of monitor housings was analysed. • The recyclable fraction mounts up to 85% for TV but only 53% of PC waste plastics. • A high percentage of pieces with bromine contents of over 50,000 ppm was obtained. - Abstract: This contribution is focused on the on-site determination of the bromine content in waste electrical and electronic equipment (WEEE), in particular waste plastics from television sets (TV) and personal computer monitors (PC) using a handheld X-ray fluorescence (XRF) device. The described approach allows the examination of samples in regards to the compliance with legal specifications for polybrominated biphenyls (PBBs) and polybrominated diphenyl ethers (PBDEs) directly after disassembling and facilitates the sorting out of plastics with high contents of brominated flame retardants (BFRs). In all, over 3000 pieces of black (TV) and 1600 pieces of grey (PC) plastic waste were analysed with handheld XRF technique for this study. Especially noticeable was the high percentage of pieces with a bromine content of over 50,000 ppm for TV (7%) and PC (39%) waste plastics. The applied method was validated by comparing the data of handheld XRF with results obtained by GC–MS. The results showed the expected and sufficiently accurate correlation between these two methods. It is shown that handheld XRF technique is an effective tool for fast monitoring of large volumes of WEEE plastics in regards to BFRs for on-site measurements.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Lithium Recovery and Conversion from Wastewater Produced by Recycling of Li-Ion Batteries via Two-Stage Electrodialysis

Electrodialysis (ED) is a membrane separation technique that has been well-established in various applications such as desalination, drinking water production, wastewater treatment, and lithium salt production. A limited number of studies have explored its application in lithium salt production, especially from secondary resources like wastewater. This study investigated a route to recover lithium from wastewater generated from the recycling of end-of-life Li-ion batteries. Two electrodialysis methods, namely standard electrodialysis (ED) and bipolar-membrane electrodialysis (BPED), were combined to concentrate lithium ions and convert them to lithium hydroxide (LiOH), a valuable product that can be fed back into the supply chain for manufacturing Li-ion batteries. Lithium (Li⁺) concentration in recycling wastewater was successfully increased by 58% using ED and converted to LiOH (>96% purity) with a further increase in Li⁺ concentration by 67% using BPED. The Coulombic efficiency of the experiments was 91.0 and 92.2%, with specific energy consumption of 1 and 2.5 kWh/kg, and a production rate of 1.01 and 0.14 kg/h/m 2 for the ED and BPED processes, respectively. In addition, preliminary techno-economic and environmental impact analyses show a significant improvement (GHG emission reduction by 77% and total energy reduction by 53%) by producing LiOH via electrodialysis compared to conventional lithium production via brine extraction. The process was assessed to be beneficial for lithium extraction from secondary resources and to enhance overall battery recycling efforts.

25 ENERGY STORAGE↗
DOE OSTI2023

Phase Stability, Band Gap Tuning, and Rashba Splitting in Selenium-Alloyed Bournonite: CuPbSb(S 1– x Se x ) 3

Recently, bournonite (CuPbSbS 3 ) has been identified as a potential ferroelectric photovoltaic (PV) material with a 1.3 eV band gap, which falls in an appropriate range for single junction PV devices. Progress in applying bournonite has yielded several studies reporting successful thin-film processing, the most recent of which demonstrated a 2.65% power conversion efficiency for a bournonite-based PV device. In an effort to explore bournonite band gap engineering for PV and other prospective applications (e.g., thermoelectric, spintronic), we here consider the solid-state synthesis of selenium-alloyed bournonite, CuPbSb(S 1-x Se x ) 3 , across the full range of x (0.0 ≤ x ≤ 1.0), and report phase purity for 0.0 ≤ x ≤ 0.5. We characterize the crystal structure and band gap of the samples using X-ray diffraction and diffuse reflectance spectroscopy, determining a band gap decrease for single-phase samples from 1.25 eV at x = 0.0 to 1.06 eV at x = 0.5. Formation energies determined using dispersion corrected hybrid density functional theory (DFT) support experimental findings and are consistent with the stability (instability) of the x = 0.5 (x = 1.0) structure relative to starting materials. The computed band structures show a decreasing trend in the band gap with increasing x, again consistent with experiment, with the states at the conduction (valence) band minima (maxima) being principally derived from Pb (S/Se) states. Spin texture analysis and detailed comparison of spin splitting parameters show that Se-alloying modifies the band gap while maintaining Rashba spin splitting character within the electronic structure. Rashba splitting is most pronounced for the conduction band minimum along the Γ-X path in the Brillouin zone. Energy separation between spin states is maintained at ΔE~0.2 eV for the various Se contents, with σz as the spin direction. Furthermore, a smaller spin splitting occurs along Γ-Z (decreasing value with increasing x), with σ x as the spin direction.

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

Photoionization of seeded combustion products as a method of enhancing the efficiency of magnetohydrodynamic power generators

Here, in this study, we performed an experimental and computational investigation into the feasibility of utilizing photoionization to enhance the electrical conductivity of seeded oxy-fuel combustion products and improve the performance of magnetohydrodynamic (MHD) power generators. We applied a variety of optical and microwave diagnostics to study the ionization and recombination processes of potassium excited by an excimer laser in a high-velocity oxy-fuel free jet. Computational fluid dynamic (CFD) simulations were performed to model the thermophysical properties and species densities of the free jet. The CFD results were validated with position-dependent potassium concentration measurements. Electron recombination exponential lifetimes were measured through time-resolved microwave transmission. The experimental electron lifetimes were compared with lifetimes calculated from CFD-predicted species densities and literature recombination rates. It was determined that K + or O 2 are the most likely recombination partners for photoionized electrons. Time-resolved fluorescence measurements provided evidence of an ionization pathway involving a two-photon ionization of KOH . Finally, a zero-dimensional chemical kinetic model was developed to assess the fundamental viability of inducing a non-equilibrium electron population to provide a net energy return in combustion-driven MHD power generators. We determined that a high energy return is feasible for targeting electrode boundary layers with ultraviolet photoionization. We also found that photoionization could potentially lower the required temperature of the bulk gas flow.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2025

200 h of discharge cycling with an all-aqueous copper thermally regenerative ammonia battery

Thermally regenerative ammonia batteries (TRABs) offer an approach to energy storage and electricity generation by harnessing low-grade heat (T < 150 °C). A TRAB discharge resembles that of a flow battery, where electrochemical reactions produce electrical power from energy stored within aqueous electrolytes. While there are many types of TRABs, the all-aqueous copper TRAB (Cu aq -TRAB) has produced the largest power and energy storage densities. Despite many improvements to TRAB performance, most tests have only lasted a few hours, which are not representative of operation times expected of these devices. Herein, we operated a Cu aq -TRAB for 200 h of constant current discharging to assess battery performance and component stability. After 200 h of testing, the average power density increased slightly to 7.2 mW cm -2 , which was within 0.01 % of starting conditions. Likewise, the average energy density for the final cycle was only 0.03 % lower than the initial cycle. The overall insensitivity of the power cell to cycling represents a major milestone in the advancement of TRAB systems. In conclusion, energy dispersive X-ray spectroscopy provides evidence to suggest that these small changes in power and energy density are likely to the membrane acclimating to TRAB electrolytes.

25 ENERGY STORAGE↗
DOE OSTI2025

Orthorhombic Structures as Inorganic Halide Perovskite Models for High-Throughput DFT Investigations

Although high-symmetry Pm-3m space group cubic models are computationally efficient for high-throughput density functional theory (DFT) calculations of inorganic ternary (ABX 3 ) halide perovskites (HPs), they frequently predict band gaps (E g ) that disagree with experiment. Conversely, while low-symmetry cubic polymorphous networks (PN) comprised of 160 to 320 atoms incur significantly greater computational cost, they predict E g ’s that are more closely aligned with experiment. Here, in this study, we compare the DFT total energies and E g ’s predicted by four high-symmetry structure models (Pnma orthorhombic, R3m trigonal, P4/mbm tetragonal, and Pm-3m cubic) to cubic PNs for 5 experimentally characterized ternary HPs and find that the orthorhombic model computes Eg’s with the smallest MAD of 0.23 eV relative to the PNs. Pair distribution functions and DFT-computed total energies show that octahedral tilting, which is present in the 20-atom orthorhombic and 160-atom cubic PN models but not in the 5-atom cubic models, stabilizes all 5 compositions in our benchmarking set. We also find that imposing PN constraints when generating and optimizing these orthorhombic structures by fixing the unit cell lattice vectors and displacing the atoms prior to ionic relaxation with DFT, which we call the orthorhombic surrogate model (OSM), lowers the MAD of E g predictions to 0.09 eV. Our OSM predicts the PN band gaps of an additional 95 theoretical inorganic ternary HPs with MAD of 0.08 eV, supporting its usage in high-throughput DFT investigations to closely estimate PN band gaps with much less computational expense.

14 SOLAR ENERGY↗
DOE OSTI2017

Enhanced Materials Based on Submonolayer Type-II Quantum Dots

We have investigated a nanostructured material known as sub-monolayer type-II QDs, made from wide bandgap II-VI semiconductors. Our goal is to understand and exploit their tunable optical and electrical properties by taking advantage of the type-II band alignment and quantum confinement effects. Type-II ZnTe quantum dots (QDs) in a ZnSe host are particularly interesting because of their relatively large valence band and conduction band offsets. In the current award we have developed new materials based on sub-monolayer type-II QDs that may be advantageous for photovoltaic and spintronics applications. We have also expanded the structural characterization of these materials by refining the X-ray diffraction methodologies needed to investigate them. In particular, we have 1) demonstrated ZnCdTe/ZnCdSe type-II QDs materials that have ideal properties for the development of novel high efficiency “intermediate band solar cells”, 2) we developed a comprehensive approach to describe and model the growth of these ultra-small type-II QDs, 3) analysis of the evolution of the photoluminescence (PL) emission, combined with other characterization probes allowed us to predict the size and density of the QDs as a function of the growth conditions, 4) we developed and implemented novel sophisticated X-ray diffraction techniques from which accurate size and shape of the buried type-II QDs could be extracted, 5) a correlation of the shape anisotropy with polarization dependent PL was observed, confirming the QDs detailed shape and providing insight about the effects of this shape anisotropy on the physical properties of the type-II QD systems, and 6) a detailed “time-resolved Kerr rotation” investigation has led to the demonstration of enhanced electron spin lifetimes for the samples with large densities of type-II QDs and an understanding of the interplay between the QDs and Te-isoelectroic centers, a defect that forms in the spacer layers that separate the QDs.

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