LTE-P-1 GDL Compressibility
Ex-situ measurement of the compressibility of Gas Diffusion Layer (GDL) materials for use as electrode materials in applications such as fuel cells, electrolyzers, and batteries.
08 HYDROGEN↗
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UAS-NAS Live Virtual Constructive Distributed Environment (LVC): LVC Gateway, Gateway Toolbox, Gateway Data Logger (GDL), SaaProc Software Design Description
This document provides the software design description for the two core software components, the LVC Gateway, the LVC Gateway Toolbox, and two participants, the LVC Gateway Data Logger and the SAA Processor (SaaProc).
software design↗
Numerical investigation and experimental validation of water condensation in the gas diffusion layer with different properties
Liquid water in porous media hinders the transport of reactant to catalyst layer, where the electrochemical reactions occur, which in turn, reduces performance and lifetime of a proton exchange membrane fuel cell (PEMFC). In this study, two types of gas diffusion layer (GDL) materials are used to study the two-phase saturation distribution in a PEMFC. The correlations between the effective and anisotropic transport properties and porosity of the two GDLs are solved by the pore scale model. In addition, the anisotropic liquid water permeability and the relationship between saturation pressure and capillary pressure is determined by using the Lattice-Boltzmann method. Fuel cell performance as well as liquid water distribution in the GDL using neutron radiography are obtained for validation. Under wet conditions, the cell with Freudenberg GDL performs better than that using Toray GDL, especially at high current densities. The results of the two-phase model simulation show that the peak water saturation for Toray GDL occurs in the catalyst layer and can reach 40%, while the peak water saturation for Freudenberg GDL occurs inside the GDL directly under the ribs and only reaches 25% saturation. The combined results provide key insights to enable high power density operation of a PEMFC through GDL material optimization.
42 ENGINEERING↗
Understanding the impact of the gas diffusion layer structure on catalyst utilization in the PEM water electrolyzer
A multiphysics half-cell model of a polymer electrolyte membrane water electrolyzer (PEMWE) was developed to probe impacts of the detailed 3-dimensional pore structure of the gas diffusion layer (GDL) on performance characteristics. We show that pores in the titanium GDL mesh led to significant underutilization of the catalyst layer (CL), with only 45% of the catalyst effectively utilized. This contradicts the assumption of uniform electron flow across the CL, as shown in graphical abstract (a), as near-zero current was observed near GDL pore regions and the current distribution in CL was influenced by GDL structure, as shown in graphical abstract (b). Instead, oxygen generation was primarily concentrated under the solid titanium regions, diffusing out around the pore walls. High current density peaks were also noted at the GDL-catalyst contact, correlating with degradation hotspots that were directly observed in companion experiments, as shown in graphical abstract (c). Collectively, these findings point to the critical importance of the heterogeneous GDL porous architecture not only for PEMWE efficiency but also for uneven degradation of the CL.
COMSOL↗
Natural fiber-derived gas diffusion layers for high performance, lower cost PEM fuel cells
The gas diffusion layer (GDL) is a critical component of proton exchange membrane fuel cells. GDL manufacture is dominated by the use of polyacrylonitrile (PAN) fibers, resulting in high production costs. Those costs contribute to the high cost of fuel cell stacks. Thus, reducing GDL manufacturing costs without sacrificing performance, should help reduce the overall cost of the fuel cell stack. Using inexpensive, natural fiber-based papers and fabric as substrates, here we examine the inherent performance these materials as GDLs, and the improvements enabled by the addition of a microporous layer, gas-phase hydrophobic treatment, and densification. The resulting GDLs achieve equivalent performance the commercial baseline GDL and demonstrate the potential of lower cost GDLs.
25 ENERGY STORAGE↗
Structural Tuning of Self‐Conductive Polymer as Gas Diffusion Layer for Electrocatalytic Reactions at High Current
Electrocatalytic conversions offer a promising route for sustainable chemical production using renewable energy. Gas diffusion layers (GDLs) enable selective product formation at high current densities but suffer from electrolyte flooding, and polytetrafluoroethylene (PTFE)-based GDLs typically require metal conductive layers, which constrain catalyst development. A recently developed GDL configuration, electropolymerized poly(3,4-ethylenedioxythiophene) (PEDOT)-coated PTFE, demonstrates notable flooding resistance, but suffers from gas diffusion limitations at elevated currents due to limited gas diffusion through the PEDOT layer. Here, different dopants in PEDOT are exploited to modify the physical properties and enhance gas transport. ClO 4 − -doped PEDOT exhibits superior performance due to optimized physical structure, leading to increased gas permeance and faradaic efficiency (FE) for CO production during electrocatalytic CO 2 reduction. Further optimization of coverage and thickness achieved by adjusting charge density led to an optimal configuration at 33 mC cm −2 . This GDL supports various metal electrocatalysts and demonstrates FE CO of > 90% for over 150 h at −200 mA cm −2 using a commercial silver electrocatalyst. This work highlights the importance of GDL engineering in enhancing performance and durability for long-term electrocatalytic processes.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Differentiable modeling and optimization of non-aqueous Li-based battery electrolyte solutions using geometric deep learning
Electrolytes play a critical role in designing next-generation battery systems, by allowing efficient ion transfer, preventing charge transfer, and stabilizing electrode-electrolyte interfaces. In this work, we develop a differentiable geometric deep learning (GDL) model for chemical mixtures, DiffMix, which is applied in guiding robotic experimentation and optimization towards fast charging battery electrolytes. In particular, we extend mixture thermodynamic and transport laws by creating GDL-learnable physical coefficients. We evaluate our model with mixture thermodynamics and ion transport properties, where we show improved prediction accuracy and model robustness of Diff-Mix than its purely data-driven variants. Furthermore, with a robotic experimentation setup, Clio, we improve ionic conductivity of electrolytes by over 18.8% within 10 experimental steps, via differentiable optimization built on DiffMix gradients. By combining GDL, mixture physics laws, and robotic experimentation, DiffMix expands the predictive modeling methods for chemical mixtures and enables efficient optimization in large chemical spaces.
25 - ENERGY STORAGE↗
Local microenvironment tuning induces switching between electrochemical CO 2 reduction pathways
Gas diffusion layers (GDL) have become a critical component in electrochemical CO 2 reduction (CO 2 R) systems because they can enable high current densities needed for industrially relevant productivity. Besides this function, it is often assumed that the choice of catalyst and electrolyte play much more important roles than the GDL in influencing the observed product selectivity. Here, we show that tuning of the GDL pore size can be used to control the local microenvironment of the catalyst and hence, effect significant changes in catalytic outcomes. This concept is demonstrated using sputtered Ag films on hydrophobic PTFE substrates with 6 different pore sizes. Although Ag is known to be a predominantly CO generating catalyst, we find that smaller pore sizes favor the generation of formate up to a faradaic efficiency of 43%. Combined experimental and simulation results show that this is due to the influence of the pore size on CO 2 mass transport, which alters the local pH at the electrode, resulting in reaction pathway switching between CO and formate. Importantly, our results highlight the importance of the local microenvironment as an experimental knob that can be rationally tuned for controlling product selectivity: a key consideration in the design of CO 2 R systems.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Conducting polymer transforms hydrophobic porous membranes into robust gas diffusion layers in electrochemical applications
A new self-conductive all-polymer GDL configuration, using a conductive polymer layer and hydrophobic layer, overcomes the most prominent obstacles of existing carbon-based and PTFE-based GDLs, representing a next-generation GDL technology.
Noh, Hwiyoon [Charles D. Davidson School of Chemic↗
A Tandem Electrolysis Process for Multi-Carbon Chemical Production from Carbon Dioxide (Final Technical Report)
a two-step CO 2 electroreduction process for selective production of acetate and ethylene was successfully developed at the kW-scale. The CO 2 and CO electrolyzers were first investigated individually on the Watt-scale to achieve high current densities and more durable operation by using a reinforced GDL. High CO 2 conversion was obtained in the first CO 2 electrolyzer to produce a CO-dominant gas stream with minimal CO 2 , and highly pure acetate stream was produced in the second CO electrolyzer by using NiFe anode, which promoted alcohol oxidation to carboxylates. The two-step process operated stably for 200 h with acetate and ethylene as the major C 2+ products. Degradation mechanism study revealed that the flooding and the salt formation in the GDL is likely the biggest contributor to the performance degradation for both CO 2 and CO electrolyzers. A 1,000 cm 2 CO electrolyzer stack was then designed, fabricated, and operated up to a total current of 300 A along with a 500 cm 2 CO 2 electrolyzer stack which was operated up to a total current of 100 A. The CO electrolyzer stack demonstrated good stability at 300 A for at least 125 h at a carbon selectivity >96%. The impact of CO 2 , O 2 , N 2 , SO x , and NO x gas impurities on the CO electrolyzer stack was studied and a relatively high resistance to these contaminants was demonstrated. Electroreduction of CO 2 into acetic acid was also demonstrated to be environmentally favorable when compared to the traditional production of acetic acid when powered by renewable electricity. Additionally, electricity cost was identified as the primary source of cost sensitivity indicating substantial economic improvements could be achieved by continuing to drive down the cost of renewable electricity. Overall, the presented approach demonstrates the feasibility of the two-step electrochemical CO 2 reduction process for the effective production of C 2+ products at the kW-scale which should inspire future scaling efforts accelerating commercialization.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
CalTestBed - Twelve Benefit Co - Understanding Degradation of Water Management Properties in Gas Diffusion Layers (CRADA Final Report)
The research between Lawrence Berkeley National Lab and Twelve Benefit Co. enhanced Twelve’s understanding of how chemical changes to the gas diffusion layer lead to failure of their CO 2 electrolyzers. During the CRADA period, LBNL team tested Twelve’s gas diffusion layer samples (GDL), some with microporous layer (MPL) and some without MPL using the water-air capillary pressure setup. LBNL team also tested microporous layer samples using the fuel cell test stands and compared those results with commercial GDL and MPL. Understanding the hydrophobicity of the material, along with electrochemical performance is the key to determining Twelve’s ability to scale their platform. Further improvements to Twelve’s CO 2 electrolyzer can enhance the net zero emissions with their technology.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Gasdynamic lasers and photon machines.
The basic operational highlights of CO2-N2 gasdynamic lasers (GDL's) are described. Features common to powerful gas lasers are indicated. A simplified model of the vibrational kinetics of the system is presented, and the importance of rapid expansion nozzles is shown from analytic solutions of the equations. A high-power pulsed GDL is described, along with estimations of power extraction. A closed-cycle laser is suggested, leading to a description of a photon generator/engine. Thermodynamic analysis of the closed-cycle laser illustrates in principle the possibility of direct conversion of laser energy to work.
Christiansen, W. H.↗
Preheated, combustion-driven gasdynamic lasers
The effect of preheated nitrogen on the available laser specific energy is examined for two classes of combustion-driven gasdynamic lasers (GDLs). The analysis combines a nonequilibrium model of the relevant GDL processes with a simplified nondissociating combustion model handling a variety of candidate GDL fuels. For a more comprehensive evaluation of the capabilities of preheating, an optimization routine is added to the combined laser/combustion models. The effectiveness of preheating to enhance laser specific energy is demonstrated, although preheating may impose unacceptable hardware requirements. The application of numerical optimization techniques appears to offer a means to improve laser design.
Saunders, R. C., III↗
Bond Energies of UO + and UC + : Guided Ion Beam and Quantum Chemical Studies of the Reactions of Uranium Cation with O 2 and CO
Here, guided ion beam tandem mass spectrometry was used to examine the kinetic energy dependent reactions of U + with O 2 and CO. In the reaction of U + with O 2 , the UO + product is formed in a barrierless and exothermic process with a reaction efficiency at low energies of k/k col =1.1±0.2, but increases at higher collision energies. Formation of both UO + and UC + in the reaction of U + with CO is endothermic. 0 K bond dissociation energies (BDEs) of D 0 (U + -O)=7.88±0.09 eV and D 0 (U + -C)=4.03±0.13 eV were determined by analyzing the kinetic energy dependent cross sections in the latter endothermic reactions. These values are within experimental uncertainty of previously reported experimental values. Additionally, the electronic states of UO + and UC + and the potential energy surfaces for the reactions were explored by quantum chemical calculations. The former include a full Feller-Peterson-Dixon composite approach with correlation contributions up to CCSDT(Q) for UO and UO + , yielding D 0 (U-O)=7.82 eV and D 0 (U + -O)=7.99 eV, as well as more approximate CCSD(T) calculations where a semi-empirical model was used to estimate spin-orbit energy contributions, which are generally found to improve the agreement with experiment. Both experimental BDEs are observed to be close to those of their transition metal congeners, ScL + , YL + , and GdL + (L=O and C).
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Innovative Method for Reliable Measurement of PEM Water Electrolyzer Component Resistances
Understanding the sheet resistance of porous electrodes is essential for improving the performance of polymer electrolyte membrane (PEM) water electrolyzers and related technologies. Despite its importance, existing methods often fail to provide reliable and comprehensive data, especially for porous materials with complex morphologies and non‐uniform thicknesses. This study introduces a robust and straightforward method for determining the sheet resistance of porous electrodes using a novel probe concept based on industrial printed circuit board (PCB) technology. This probe measures resistance across ten distances, ranging from 250 µm to 2500 µm, enabling local mapping of resistance. The study focuses on the sheet resistance of key components in PEM water electrolyzers, including the gas diffusion layer (GDL), porous transport layer (PTL), and catalyst layers deposited on a membrane. Additionally, an image‐processing‐based method is presented to obtain the thickness distribution of the studied catalyst layers, facilitating a detailed analysis of the electrical in‐plane resistivity with thickness variations. Overall, this methodology has the potential to expedite material integration and bridge the gap between electrode engineering and single‐cell testing, thereby advancing the development of PEM water electrolyzers.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Establishment of a Vertically Integrated Domestic Manufacturing Process for Production of Substrates Needed for Manufacture of Gas Diffusion Layers
In this project, AvCarb, LLC evaluated the baseline performance metrics of commercial carbon veils and their corresponding Gas Diffusion Layers (GDLs) with the goal of establishing an optimized, vertically integrated production system for wet-laid nonwoven substrates used in gas diffusion media for electrochemical energy storage and conversion devices. Mechanical testing and microstructural characterization were conducted and used to develop a multiscale computational model capable of simulating and predicting the performance of GDLs in fuel cells. Although the project successfully generated foundational transport and modeling data, it was terminated prior to identifying the critical GDL design parameters necessary for full optimization. The program aimed to improve carbon veil fabrication through enhanced fiber dispersion, fiber-fiber adhesion control, and improved web formation, enabling the production of high-quality, uniform substrates. Simulations were intended to guide mixing and solution delivery system design and process conditions, followed by production-scale trials to evaluate fiber dispersion, web uniformity, and mechanical robustness. At full deployment, the proposed production line would have been capable of producing approximately 650,000 m² of carbon veil annually. This capability remains strategically important, as the United States currently lacks a domestic source of wet-laid nonwoven carbon substrates that satisfy the stringent quality requirements for fuel-cell GDLs and electrolyzers representing an ongoing supply-chain vulnerability. Beyond supply-chain benefits, the project established a robust benchmarking dataset for existing commercial carbon veils while advancing next-generation material concepts targeting improved performance and manufacturing consistency.
Olson, Cynthia Lemay↗
Closed-cycle gas dynamic laser design investigation
A conceptual design study was made of a closed cycle gas-dynamic laser to provide definition of the major components in the laser loop. The system potential application is for long range power transmission by way of high power laser beams to provide satellite propulsion energy for orbit changing or station keeping. A parametric cycle optimization was conducted to establish the thermodynamic requirements for the system components. A conceptual design was conducted of the closed cycle system and the individual components to define physical characteristics and establish the system size and weight. Technology confirmation experimental demonstration programs were outlined to develop, evaluate, and demonstrate the technology base needed for this closed cycle GDL system.
Ketch, G. W.↗
Numerical optimization of gasdynamic lasers
A sophisticated numerical optimization procedure has been coupled to a detailed theoretical model of the carbon dioxide gasdynamic laser (GDL) for the purpose of systematically evaluating the performance of these systems. The integrated model was used to predict the performance of a wide variety of combustion-driven gasdynamic lasers and was then used to maximize the theoretical available specific energy of these lasers. Up to six design variables and three nonlinear constraints were used in these optimizations, although the method is not limited to this number. Results are presented to show the performance of typical lasers before and after optimization. Improvements approaching a factor of two in the available specific energy are found, suggesting that numerical optimization techniques are valuable in improving the design of gasdynamic lasers.
Saunders, R. C., III↗