Ultrathin coatings of nanoporous materials as property enhancements for advanced functional materials.

This report summarizes the findings of a five-month LDRD project funded through Sandia's NTM Investment Area. The project was aimed at providing the foundation for the development of advanced functional materials through the application of ultrathin coatings of microporous or mesoporous materials onto the surface of substrates such as silicon wafers. Prior art teaches that layers of microporous materials such as zeolites may be applied as, e.g., sensor platforms or gas separation membranes. These layers, however, are typically several microns to several hundred microns thick. For many potential applications, vast improvements in the response of a device could be realized if the thickness of the porous layer were reduced to tens of nanometers. However, a basic understanding of how to synthesize or fabricate such ultra-thin layers is lacking. This report describes traditional and novel approaches to the growth of layers of microporous materials on silicon wafers. The novel approaches include reduction of the quantity of nutrients available to grow the zeolite layer through minimization of solution volume, and reaction of organic base (template) with thermally-oxidized silicon wafers under a steam atmosphere to generate ultra-thin layers of zeolite MFI

The oxidation of aluminum at high temperature studied by Thermogravimetric Analysis and Differential Scanning Calorimetry.

The oxidation in air of high-purity Al foil was studied as a function of temperature using Thermogravimetric Analysis with Differential Scanning Calorimetry (TGA/DSC). The rate and/or extent of oxidation was found to be a non-linear function of the temperature. Between 650 and 750 %C2%B0C very little oxidation took place; at 850 %C2%B0C oxidation occurred after an induction period, while at 950 %C2%B0C oxidation occurred without an induction period. At oxidation temperatures between 1050 and 1150 %C2%B0C rapid passivation of the surface of the aluminum foil occurred, while at 1250 %C2%B0C and above, an initial rapid mass increase was observed, followed by a more gradual increase in mass. The initial rapid increase was accompanied by a significant exotherm. Cross-sections of oxidized specimens were characterized by scanning electron microscopy (SEM); the observed alumina skin thicknesses correlated qualitatively with the observed mass increases

Novel catalysts for hydrogen fuel cell applications:Final report (FY03-FY05).

The goal of this project was to develop novel hydrogen-oxidation electrocatalyst materials that contain reduced platinum content compared to traditional catalysts by developing flexible synthesis techniques to fabricate supported catalyst structures, and by verifying electrochemical performance in half cells and ultimately laboratory fuel cells. Synthesis methods were developed for making small, well-defined platinum clusters using zeolite hosts, ion exchange, and controlled calcination/reduction processes. Several factors influence cluster size, and clusters below 1 nm with narrow size distribution have been prepared. To enable electrochemical application, the zeolite pores were filled with electrically-conductive carbon via infiltration with carbon precursors, polymerization/cross-linking, and pyrolysis under inert conditions. The zeolite host was then removed by acid washing, to leave a Pt/C electrocatalyst possessing quasi-zeolitic porosity and Pt clusters of well-controlled size. Plotting electrochemical activity versus pyrolysis temperature typically produces a Gaussian curve, with a peak at ca. 800 C. The poorer relative performances at low and high temperature are due to low electrical conductivity of the carbon matrix, and loss of zeolitic structure combined with Pt sintering, respectively. Cluster sizes measured via adsorption-based methods were consistently larger than those observed by TEM and EXAFS, suggesting , that a fraction of the clusters were inaccessible to the fluid phase. Detailed EXAFS analysis has been performed on selected catalysts and catalyst precursors to monitor trends in cluster size evolution, as well as oxidation states of Pt. Experiments were conducted to probe the electroactive surface area of the Pt clusters. These Pt/C materials had as much as 110 m{sup 2}/g{sub pt} electroactive surface area, an almost 30% improvement over what is commercially (mfg. by ETEK) available (86 m{sup 2}/g{sub pt}). These Pt/C materials also perform qualitatively as well as the ETEK material for the ORR, a non-trivial achievement. A fuel cell test showed that Pt/C outperformed the ETEK material by an average of 50% for a 300 hour test. Increasing surface area decreases the amount of Pt needed in a fuel cell, which translates into cost savings. Furthermore, the increased performance realized in the fuel cell test might ultimately mean less Pt is needed in a fuel cell; this again translates into cost savings. Finally, enhanced long-term stability is a key driver within the fuel cell community as improvements in this area must be realized before fuel cells find their way into the marketplace; these Pt/C materials hold great promise of enhanced stability over time. An external laser desorption ion source was successfully installed on the existing Fourier transform ion-cyclotron resonance (FT-ICR) mass spectrometer. However, operation of this laser ablation source has only generated metal atom ions, no clusters have been found to date. It is believed that this is due to the design of the pulsed-nozzle/laser vaporization chamber. The final experimental configuration and design of the two source housings are described

Summary report : universal fuel processor.

The United States produces only about 1/3 of the more than 20 million barrels of petroleum that it consumes daily. Oil imports into the country are roughly equivalent to the amount consumed in the transportation sector. Hence the nation in general, and the transportation sector in particular, is vulnerable to supply disruptions and price shocks. The situation is anticipated to worsen as the competition for limited global supplies increases and oil-rich nations become increasingly willing to manipulate the markets for this resource as a means to achieve political ends. The goal of this project was the development and improvement of technologies and the knowledge base necessary to produce and qualify a universal fuel from diverse feedstocks readily available in North America and elsewhere (e.g. petroleum, natural gas, coal, biomass) as a prudent and positive step towards mitigating this vulnerability. Three major focus areas, feedstock transformation, fuel formulation, and fuel characterization, were identified and each was addressed. The specific activities summarized herein were identified in consultation with industry to set the stage for collaboration. Two activities were undertaken in the area of feedstock transformation. The first activity focused on understanding the chemistry and operation of autothermal reforming, with an emphasis on understanding, and therefore preventing, soot formation. The second activity was focused on improving the economics of oxygen production, particularly for smaller operations, by integrating membrane separations with pressure swing adsorption. In the fuel formulation area, the chemistry of converting small molecules readily produced from syngas directly to fuels was examined. Consistent with the advice from industry, this activity avoided working on improving known approaches, giving it an exploratory flavor. Finally, the fuel characterization task focused on providing a direct and quantifiable comparison of diesel fuel and JP-8

Ion exchange studies of microporous solids

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The oxidation of aluminum at high temperature studied by Thermogravimetric Analysis and Differential Scanning Calorimetry.

The oxidation in air of high-purity Al foil was studied as a function of temperature using Thermogravimetric Analysis with Differential Scanning Calorimetry (TGA/DSC). The rate and/or extent of oxidation was found to be a non-linear function of the temperature. Between 650 and 750 %C2%B0C very little oxidation took place; at 850 %C2%B0C oxidation occurred after an induction period, while at 950 %C2%B0C oxidation occurred without an induction period. At oxidation temperatures between 1050 and 1150 %C2%B0C rapid passivation of the surface of the aluminum foil occurred, while at 1250 %C2%B0C and above, an initial rapid mass increase was observed, followed by a more gradual increase in mass. The initial rapid increase was accompanied by a significant exotherm. Cross-sections of oxidized specimens were characterized by scanning electron microscopy (SEM); the observed alumina skin thicknesses correlated qualitatively with the observed mass increases

Ultrathin coatings of nanoporous materials as property enhancements for advanced functional materials.

This report summarizes the findings of a five-month LDRD project funded through Sandia's NTM Investment Area. The project was aimed at providing the foundation for the development of advanced functional materials through the application of ultrathin coatings of microporous or mesoporous materials onto the surface of substrates such as silicon wafers. Prior art teaches that layers of microporous materials such as zeolites may be applied as, e.g., sensor platforms or gas separation membranes. These layers, however, are typically several microns to several hundred microns thick. For many potential applications, vast improvements in the response of a device could be realized if the thickness of the porous layer were reduced to tens of nanometers. However, a basic understanding of how to synthesize or fabricate such ultra-thin layers is lacking. This report describes traditional and novel approaches to the growth of layers of microporous materials on silicon wafers. The novel approaches include reduction of the quantity of nutrients available to grow the zeolite layer through minimization of solution volume, and reaction of organic base (template) with thermally-oxidized silicon wafers under a steam atmosphere to generate ultra-thin layers of zeolite MFI

Thermochemical cycle of a mixed metal oxide for augmentation of thermal energy storage in solid particles

Solid particle heat transfer and storage media have been shown to be able to operate at temperatures \u3e1000°C in concentrated solar power (CSP) applications, much higher than the operational limit of 600°C for current state-of-the-art molten nitrate salt heat transfer fluid. Solid particles can be endothermically reduced by direct exposure to concentrated solar energy, thus absorbing and storing thermal energy beyond that possible with sensible heating alone. The particles can then be oxidized exothermically at a later time, releasing the stored chemical heat and effectively augmenting the thermal energy storage capacity of the solid particles. A mixed metal oxide spinel material that reduces in the temperature range of interest (1000-1200°C) has been examined for applicability to this thermochemical energy storage concept. A description of this application, prospective materials, and details of the thermochemical cycle are presented. The heats of reduction and oxidation for the thermochemical cycle have been determined for various operating conditions to evaluate the amount of thermal energy that may be stored. Various possible implementations of this augmented storage concept are considered, and alternate means of controlling the thermochemical cycle are explored

Formation of Ba3Nb0.75Mn2.25O9-6H during thermochemical reduction of Ba4NbMn3O12-12R

The resurgence of interest in hydrogen-related technologies has stimulated new studies aimed at advancing lesser-developed water-splitting processes, such as solar thermochemical hydrogen production (STCH). Progress in STCH has been largely hindered by a lack of new materials able to efficiently split water at a rate comparable to ceria under identical experimental conditions. BaCe0.25Mn0.75O3 (BCM) recently demonstrated enhanced hydrogen production over ceria and has the potential to further our understanding of two-step thermochemical cycles. A significant feature of the 12R hexagonal perovskite structure of BCM is the tendency to, in part, form a 6H polytype at high temperatures and reducing environments (i.e., during the first step of the thermochemical cycle), which may serve to mitigate degradation of the complex oxide. An analogous compound, namely BaNb0.25Mn0.75O3 (BNM) with a 12R structure was synthesized and displays nearly complete conversion to the 6H structure under identical reaction conditions as BCM. The structure of the BNM-6H polytype was determined from Rietveld refinement of synchrotron powder X-ray diffraction data and is presented within the context of the previously established BCM-6H structure

A revolution in micropower : the catalytic nanodiode.

Our ability to field useful, nano-enabled microsystems that capitalize on recent advances in sensor technology is severely limited by the energy density of available power sources. The catalytic nanodiode (reported by Somorjai's group at Berkeley in 2005) was potentially an alternative revolutionary source of micropower. Their first reports claimed that a sizable fraction of the chemical energy may be harvested via hot electrons (a 'chemicurrent') that are created by the catalytic chemical reaction. We fabricated and tested Pt/GaN nanodiodes, which eventually produced currents up to several microamps. Our best reaction yields (electrons/CO{sub 2}) were on the order of 10{sup -3}; well below the 75% values first reported by Somorjai (we note they have also been unable to reproduce their early results). Over the course of this Project we have determined that the whole concept of 'chemicurrent', in fact, may be an illusion. Our results conclusively demonstrate that the current measured from our nanodiodes is derived from a thermoelectric voltage; we have found no credible evidence for true chemicurrent. Unfortunately this means that the catalytic nanodiode has no future as a micropower source