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J.T. Padding

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Alternative fuels are essential to decarbonising maritime transport, provided they retain high energy and power density; hydrogen carriers fulfil these criteria and represent a promising fuel option. This research quantifies the power-energy trade-offs of four hydrogen carrier fuels: namely, sodium borohydride, ammonia borane, n-ethylcarbazole, and dibenzyltoluene. Each hydrogen carrier is combined with four energy converters: proton exchange membrane fuel cell (PEMFC), internal combustion engine (ICE), solid oxide fuel cell (SOFC), and gas turbine, respectively, resulting in 16 outcomes, which were assessed using Ragone plots. For each hydrogen carrier, one energy converter is selected as a case study. Four reference cases are also examined: marine diesel oil (MDO) and methanol combined with ICE, ammonia with SOFC, and liquid hydrogen with PEMFC. These 8 case studies (carrier and converter combinations) are evaluated for performance across several shipping applications. The results indicate that ammonia borane combined with ICE and sodium borohydride combined with a PEMFC offer energy and power density profiles suitable for various vessel types, including inland ships and ocean-going vessels. These combinations also show potential for specialised vessels such as fishing boats, dredgers, tugs, and ferries, which operate under unique load profiles and duty cycles. Compared with alternative fuels, such as ammonia, methanol, and liquid hydrogen, hydrogen carriers can demonstrate higher energy and power densities. Under specific circumstances, they may achieve performance comparable to MDO, highlighting their potential for zero-emission maritime propulsion. ...
While the Discrete Element Method (DEM) provides high-fidelity insights into granular processes like high-energy ball milling, its computational cost can become prohibitive when exploring extensive parameter spaces required for scale-up. This limitation hinders the rapid design and optimization cycles crucial for emerging applications, like mechanochemistry. Surrogate modeling offers a promising path to overcome these computational barriers, yet existing approaches often struggle to accurately represent the complex, moving boundary conditions typical of milling equipment. In this work, we leverage a Signed Distance Function Graph Neural Network (SGN) surrogate tailored to the high-energy, moving-boundary regime of the Emax mill. Trained on DEM data, the SGN jointly predicts particle kinematics for recursive roll-out and a mechanochemistry-relevant global quantity, the global dissipated energy. The model exhibits strong generalization to unseen motion trajectories and moderate jar-shape edits without retraining, while operating with a timestep over 100x larger than required by DEM. In a CPU-only comparison, it achieves a minimum of 6.6× wall-clock speedup. This approach provides a powerful and promising technique for the simulation, analysis, and design optimization of high-energy ball milling equipment. ...
The long-term operation of CO2 electrolyzers using membrane electrode assemblies (MEAs) is limited by challenges related to water management. However, the water balance in CO2 electrolyzer cells still has not been fully understood, and conflicting observations have been reported in the literature. In this study, a one-dimensional non-isothermal multiphysics model of an exchange MEA CO2 electrolyzer with a Tokuyama A201 anion exchange membrane is developed to investigate the role of different physical and chemical phenomena on the water balance. The relative contributions of these processes vary with current density and membrane transport properties, which shift the dominant water transport mechanism in the cell. Our results highlight the significant contribution of homogeneous reactions, particularly OH−, to the water balance across the membrane. At low currents (i < 130 mA cm−2), homogeneous buffer reactions dominate the water balance and result in net water production near the catalyst layer. At higher currents (i > 130 mA cm−2), the flux is governed by electro-osmotic drag and a temperature gradient over the cathode gas diffusion electrode (GDE) with their relative contributions depending on membrane properties. Homogeneous buffering can re-emerge as the dominant mechanism at high currents if the hydroxide ion concentration in the membrane increases, for example under CO2-limited cathode conditions, allowing hydroxide ions to react with depleted bicarbonate near the anode. ...
Accurate non-invasive estimation of trans-stenotic pressure drops remains a challenge. In clinical practice, pressure drops are often estimated from velocity measurements using Bernoulli-based formulas, but these simplified relations do not explicitly account for how pressure losses change with the flow regime. Here, we introduce a modified Bernoulli (MB) formulation that incorporates regime-dependent pressure losses through a Reynolds-number-dependent loss coefficient. Steady in-vitro experiments were performed in an idealized stenosis model over physiologically relevant flow rates (0.65–3.9 L/min), combining direct pressure measurements with ultrasound imaging velocimetry (UIV) and phase-contrast magnetic resonance imaging (PC-MRI) to measure velocities. The MB model was calibrated from the measured pressure drops and then evaluated against the simplified Bernoulli (SB) and extended Bernoulli (EB) formulations. Over the tested flow regime, MB agreed best with the measurements (typically within about ±10%). SB and EB showed larger biases, with errors of roughly 10–55% (SB) and -15 to 25%−(EB), and overestimated the pressure drop in the clinically relevant range. We additionally quantified the effect of PC-MRI in-plane pixel size on MRI-based pressure estimates. Coarse in-plane pixel size of 1.33 mm, corresponding to only approximately 3–4 pixels across the 3.3 mm throat radius of the 6.6 mm stenosis throat, led to systematic underestimation of flow rate and bulk velocity (about − 34 to − 44%) and, consequently, of the MB-predicted pressure drop (about − 52 to − 62%). In contrast, the peak throat velocity was substantially less sensitive to pixel size, resulting in smaller estimation errors (about − 13 to − 18.7%) when used as input for the MB. Overall, the results demonstrate that accounting for flow-regime-dependent loss mechanisms enhances pressure drop estimation, and that sufficient sampling of the stenotic throat is crucial for MRI-based flow rate and pressure drop estimation. In addition, peak-velocity-based MB pressure drop estimations are less sensitive to pixel size. ...
The development of dewatering methods driven by electric fields offers significant potential to reduce the energy demand for these processes. Electro-osmotic dewatering relies on the application of an electric field across a porous matrix possessing a surface charge, inducing liquid transport through electrokinetic mechanisms. While the feasibility and energy efficiency of electro-osmotic dewatering have been demonstrated, a fundamental understanding of how the irregular, porous microstructure affects the uniformity of dewatering is lacking. In this work, we investigate electro-osmotic flow in porous media micromodels and directly compare it with conventional pressure-driven flow under controlled experimental conditions. The micromodel is designed and microfabricated to exhibit a controlled, heterogeneous microstructure. Pore-scale velocity fields are measured by using particle tracking velocimetry and characterized through velocity probability density functions. A multiphysics model, coupling ion transport, electrostatics, and hydrodynamics, is validated against the experiments. The results show that, in contrast to pressure-driven flow, which exhibits broader velocity distributions with preferential flow paths and stagnant regions, electro-osmotic flow produces a narrower velocity distribution, even in heterogeneous porous structures. These findings demonstrate the potential of electro-osmotic dewatering to achieve more uniform water removal in low-permeability materials and provide a predictive framework for optimizing electrically driven dewatering. ...
Journal article (2026) - M. C. van Benten, J. T. Padding, D. L. Schott
Sodium borohydride (NaBH4) is a promising hydrogen carrier for maritime applications due to its high gravimetric and volumetric energy densities compared to compressed or liquefied hydrogen. As a solid granular material, NaBH4 can be stored under atmospheric pressure and room temperature, eliminating the need for extreme pressures, or cryogenic conditions. Although NaBH4 is hygroscopic and can become cohesive when exposed to humid environments, when stored and handled sufficiently dry it remains free-flowing, which is essential for reliable conveying, storage, and discharge operations. Designing equipment for these processes requires an accurate understanding of NaBH4’s free-flowing behaviour, motivating the need for modelling tools. To address this, we model granular, free-flowing NaBH4 using the Discrete Element Method. Granular flow behaviour depends strongly on the flow regime—defined by the applied shear and confining pressure through the inertial number—and practical handling systems typically operate in the dense flow regime; consequently, this study focuses on dense-flow conditions. A standard calibration–verification–validation methodology is applied, using a ledge test and rotating drum for calibration and verification, and an inclined surface test for validation. In parallel, we evaluate the inertial number across all setups using a velocity-based approach to characterise both the global flow regime and locally occurring flow regimes within the flowing layer. Rather than assigning a single characteristic value per setup, we demonstrate that distinct segments exhibit different inertial numbers, indicating that the inertial number is spatially dependent. ...

Process limiting steps investigated by micro-scale modeling

Journal article (2026) - V. Murugesan, Remco Hartkamp, Johan T. Padding
The advancement of microbial electrosynthesis systems (MES) towards industrialization is currently hindered by a limited understanding of the fundamental constraints affecting selective production of high-value chemicals. To address this challenge, we develop a comprehensive computational model that integrates microbial, electrochemical, and acid–base reactions with pore-scale transport processes within a three-dimensionally resolved biofilm. This study investigates the H2-mediated CO2 fixation pathway to acetate, butyrate, and caproate. The effect of applied cathode potential and biofilm thickness on macroscopic parameters, such as efficiency and selectivity, is analyzed based on local concentrations and electrochemical and biochemical fluxes. Among the limiting factors, the availability of CO2 emerges as the main limitation for biochemical reactions due to its low solubility and high half-saturation constant. Additionally, hydrogen – serving as the electron mediator – limits the reaction rate at low current densities and reduces electron transfer efficiency at higher current densities. A key insight from our study is the identification of an optimal electrode potential for each biofilm thickness, balancing both H2 transfer and CO2 consumption efficiencies. Furthermore, carbon selectivity shifts with increasing biofilm thickness: net acetate production declines while caproate production increases. This trend is attributed to the prolonged residence time of metabolic intermediates within thicker biofilms, promoting chain elongation pathways. Thus, our work takes an important step towards a fundamental understanding of caproate selectivity across different biofilms, which can be used to optimize the electrode structure and operating conditions to control the local biofilm thickness. ...
To reduce global emissions, hydrogen is increasingly considered as an energy carrier for renewable energy storage. However, traditional storage methods for hydrogen such as compression or liquefaction require high pressures, extremely low temperatures, and still result in a low volumetric energy density. As a solution, sodium borohydride (NaBH4) is proposed as an alternative method to store hydrogen. NaBH4 is a granular material that can be stored using ambient temperature and pressure, and has a relatively high volumetric and gravimetric energy density compared to traditional hydrogen storage. This paper explores the application of NaBH4 as a fuel in the maritime industry, and elaborates on how the use of NaBH4 leads to a circular bunkering (refuelling) process. By using hydrolysis to extract hydrogen from NaBH4 during vessel operation, a so called spent fuel remains and needs to be stored on the vessel until next port call. Additionally, examples of various bunkering equipment that can be used to design the circular bunkering process of NaBH4 are presented. Moreover, it explains how design of bunkering equipment depends on the mechanical characteristics of the fuel and spent fuel. The main finding of this work is that NaBH4 is a promising solution for a sustainable future. Before NaBH4 can be used as a fuel, vessels and ports need to be adapted to facilitate circular bunkering with such a novel solid-state energy carrier. ...
High-energy ball milling is a versatile method utilized in mechanochemical reactions and material transformations. Understanding and characterizing the relevant mechanical variables is crucial for the optimization and up-scaling of these processes. To achieve this, the present study delves into differentiating the contributions of normal and tangential interactions during high-energy collisions. Using Discrete Element Method (DEM) simulations, we characterize how operational parameters influence these energy dissipation modes, emphasizing the significance of tangential interactions. Our analysis also reveals how different operational parameters such as ball size, fill ratio, and rotational speed affect the mechanical action inside the milling jar giving rise to multiple operating zones where different modes of energy dissipation can thrive. Finally, we present master curves that generalize findings across a wide range of configurations, offering a tool for characterizing and predicting mechanochemical processes beyond the presented cases. These results provide a robust framework for improving mechanochemical reaction efficiency, and equipment design. ...
In this study we investigate the mechanochemical regeneration of sodium borohydride (NaBH4) from a system comprising hydrated sodium metaborate ( [Formula presented] ) and magnesium hydride (MgH2). We explore the individual and joint impact of key operational parameters (rotational speed, milling time, ball-to-powder ratio (BPR), and molar ratio) on the regeneration yield. Furthermore, a method for quantifying chemical conversion is introduced relying only on water and thus, offering environmental benefits. This approach additionally facilitates the production and storage of a “ready-to-use” NaBH4 solution with minimal losses at room temperature. Notably, a yield of 90% is achieved, with a 20% reduction in rotational speed compared to prior literature. This research contributes to sustainable hydrogen storage and presents practical advancements in mechanochemical processes. ...
Journal article (2025) - S. Garrido Nuñez, D.L. Schott, J.T. Padding
Mechanochemical synthesis faces reproducibility and scale-up challenges due to complex parameter interactions. This study employs machine learning (ML) to predict NaBH4 regeneration yield, integrating chemical experimental data and DEM (Discrete Element Method) derived invariant mechanical descriptors (Ēn, Ēt, fcol/nball). Various algorithms were evaluated, including a two-step modeling strategy to isolate the dominant effect of milling time in our process. Results demonstrate that a two-step Gaussian Process Regression (GPR) model achieves good predictive performance (R2 = 0.83), significantly outperforming single-stage models and providing valuable uncertainty estimates. Tree-based ensembles (XGBoost, RF) also benefit from the two-step approach and can enhance interpretability. This work establishes a framework for using ML to optimize mechanochemical processes, reducing experimental cost and offering a method to link mechanical milling conditions to chemical outcomes, thereby enabling predictive mechanochemistry. ...
Journal article (2025) - M.C. van Benten, J.T. Padding, D.L. Schott
Sodium borohydride (NaBH4) is increasingly considered as an alternative fuel for maritime vessels due to its relatively high energy density. When stored in dry solid form, it is a granular material, similar to coal, starch, and iron ore. As NaBH4 is historically used in the chemical industry in aqueous solutions, virtually no details regarding its behaviour as a solid granular material are known. Therefore, after determining particle properties such as size, shape, and density, this study characterises granular NaBH4 in three flow regimes using three experimental setups. Ring shear tests are used for the quasi-static regime, ledge tests for the dense flow regime, and rotating drum tests characterise both dense and gaseous flow, depending on the rotational speed. Various operational conditions, including temperature, humidity, time consolidation, and handling stresses, are taken into account. Experimental results demonstrate that above a threshold temperature and humidity, NaBH4 readily absorbs moisture from ambient air but remains free-flowing for most scenarios. However, time consolidation can transform this free-flowing material into a very cohesive substance. While this cohesiveness is reversible, requiring minimal agitation, the transformation from free-flowing to cohesive is accelerated by elevated moisture contents and a reduced particle size. Additionally, handling stresses were found to have minimal effect on the flow behaviour and characteristics of NaBH4. These findings are ultimately used to derive implications for the design of handling and storage equipment for NaBH4, enabling its use as an alternative fuel for maritime vessels. ...
Electrochemical conversion of CO2 to hydrocarbons is limited by the low solubility and slow transport of CO2 in aqueous systems. We demonstrate that we can reach partial current densities for CO2-to-CO of 40 mA/cm2 in fully aqueous systems, without the use of gas diffusion electrodes. We alleviate the mass transfer limitation by combining a suspension of catalytically active silver nanoparticles (Ag NPs) with a flow-through current collector. This extends the reactive area into the electrolyzer channel and improves the accessibility of dissolved CO2 in a larger volume of electrolyte. The flow-through electrode system also outperforms a fully suspended electrode (based on carbon black particles), due to enhanced electric conductivity and smaller carbon area to minimize parasitic side-reactions. Additionally, we show that the distribution of the Ag NPs is pivotal for high CO2 conversion rates, demonstrated by the highest CO current density obtained when a suspension of Ag NPs and SDS as surfactant is flowing through the 3D electrodes as pre-treatment. A stable CO current density can be sustained for more than 4 h. Although the conversion rate is still moderate compared to gas-fed CO2 electrolzyers, the partial current density for flow-through electrodes is more than an order of magnitude larger than for planar flow systems. This work shows that CO2 conversion in aqueous systems can be enhanced considerably by exploiting larger electrolyte volumes via smart electrode designs, such as a flow-through principle. ...
Electrochemical reactors, such as water electrolyzers, CO2 electrolyzers, fuel cells, and flow batteries, will be essential in electrifying industry as part of the global transition towards a defossilized and sustainable economy. These technologies require further optimization to enhance efficiency and reduce costs for widespread adoption. Hydrodynamics and mass transfer at electrode–electrolyte interfaces significantly affect electrochemical conversion reactions by influencing the reactant availability and pH in the local reaction environment. 3D electrodes, such as flow-through foams and suspension electrodes, hold a great advantage over 2D electrodes as they moderate pH changes and reactant depletion by spreading the current over a larger electrode area and electrolyte volume. We study the diffusion boundary layer in operando around a single mm-sized particle, representing an element of a 3D electrode. We visualize the local and transient pH with Fluorescence Lifetime Imaging Microscopy (FLIM) during H2O reduction at various current densities and electrolyte flow velocities at a resolution down to 9 μm and 2 Hz. In addition, we apply an intermittent current to investigate how long the capacitive electric double layer of a suspension electrode particle can maintain an electrochemical reaction during their time of non-contact with a current collector, mimicking applications with Faradaic charge transfer (i.e. flow batteries, microbial fuel cells, capacitance-based electrolyzers). We demonstrate that the diffusion boundary layer is not symmetrical, but depend on the direction of the electric field, the current density and the flow conditions. The substantial pH gradients and boundary layer formation at the scale of hundreds of micrometers underline the importance of controlling flow in or around electrodes, making 3D electrodes an important asset for creating suitable reaction conditions in mass transport-limited electrochemical conversions. ...
We investigated the evaporative crystallization of aqueous glycine sessile droplets on hydrophilic glass, hydrophobic Teflon surfaces, and hydrophobic Teflon surfaces, where the contact angle is manipulated dynamically with electrowetting. Microscopy experiments and analytical characterization revealed that the size, morphology, and polymorphic form (α, β, and γ) of the glycine crystals are influenced by the surface wettability as well as the amplitude and frequency of electrowetting. On a hydrophilic glass surface, a coffee-stain-shaped residue composed of a mixture of bipyramidal α and needle-like β crystals was observed. On a hydrophobic Teflon surface, the droplets evaporated with minimum contact line pinning, producing hemispherical residue shapes, and bipyramidal α crystals smaller than 100 μm were formed. On a Teflon surface with electrowetting, glycine could be manipulated to crystallize into distinct polymorphic forms (β and γ) and residue shapes not observed on hydrophilic glass and hydrophobic Teflon surfaces. The frequency and amplitude of electrowetting were optimized to produce single large crystals. We observed the highest chance of producing single-millimeter-scale crystals at a frequency of 1 kHz and a voltage amplitude of 80 Vrms. We attribute this observation to a combination of nucleation at lower bulk supersaturation compared to the experiment on Teflon surfaces and electrowetting-induced mixing most prominent at 1 kHz. Our results highlight the opportunities arising from the dynamic manipulation of surface wettability ...
One of the most promising energy carriers for transport applications are hydrogen-based energy carriers. NaBH4 is a hydrogen energy carrier and produces hydrogen bubbles when it is dissolved in water. The formation of hydrogen bubbles hinders experimental measurements of the thermodynamic and transport properties of aqueous NaBH4 solutions at elevated temperatures. Accurate knowledge of these properties is essential for the NaBH4 hydrolysis reactor modeling and design. Molecular dynamics (MD) simulations provide the option to study the thermodynamic and transport properties of NaBH4 aqueous solutions without hindering hydrogen bubble formation. In this work, a new force field is developed for BH4-, namely, the Delft force field of BH4- (DFF/BH4-), which, combined with additional force fields, can accurately describe experimental densities and viscosities of 0 to 5 m (mol salt/kg water) NaBH4, 0 to 3 m NaB(OH)4, and 1 m NaOH aqueous solutions at 295 K within 1.8% and 10.8% maximum deviation, respectively. Empirical fitting correlations are created for densities, viscosities, and self-diffusivities obtained from the MD simulations of 0 to 5 m NaBH4, 0 to 5 m NaB(OH)4, and 0 to 1 m NaOH aqueous solutions at 295-363 K for NaBH4 hydrolysis reactor modeling and design purposes. ...
We compare the influence of tangential (shear) and normal (compressive) stress events on the mechanochemical regeneration of sodium borohydride NaBH4 from hydrated sodium metaborate [Figure presented] and magnesium hydride MgH2. Discrete element method (DEM) mechanical descriptors are used to design experiments that either maintain the mill at a constant rotational speed or maintain a constant total dissipation power, thereby separating stress distribution from net power input. Under constant power operation, a tangential rich regime achieves a record 94% conversion yield with 37.5% shorter milling time, 40% lower ball-to-powder ratio, and 34% reduced speed. However, this high yield requires such a substantial power consumption that the converted mass per Watt drops to only 0.090 gW−1, below both balanced (0.113 gW−1) and normal-bias (0.108 gW−1) cases. By contrast, a tangential bias at half the power (3 W) still delivers 84% yield and peaks at 0.185 gW−1, illustrating the often disregarded trade-off between absolute conversion and energetic productivity in mechanochemistry. Specific yield (conversion per Watt) likewise peaks at 0.28 W−1 and declines linearly with fill ratio (R2>0.99). Mechanochemical energy leverage analysis reveals that, at most, 1.7–3.7% of input mechanical work is theoretically recoverable on an enthalpy basis, 2.1–4.4% on a Gibbs free energy basis, and 4–8.7% when considering the fuel value of all available hydrogen. Our mill-agnostic framework provides a transferable blueprint for cross-platform optimization of mechanochemical processes. ...
Hydrogen carriers are attractive alternative fuels for the shipping sector. They are zero-emission, have high energy densities, and are safe, available, and easy to handle. Sodium borohydride, potassium borohydride, dibenzyltoluene, n-ethylcarbazole, and ammoniaborane are hydrogen carriers with high theoretical energy densities. The energy density is paramount to implementing hydrogen carriers as a high energy density enables compact and lightweight storage. The effective energy density depends on integrating heat and masses with energy converters. This combination defines the energy efficiency and, thus, the energy density of the system. This paper addresses the effective energy density of the hydrogen carriers, including the dehydrogenation process. Using a 0D model, we combined the five carriers with two types of fuel cells, namely proton exchange membrane (PEM) and solid oxide fuel cells (SOFC), an internal combustion engine and a gas turbine. N-ethylcarbazole and dibenzyltoluene offer medium energy densities, reaching almost 4 MJ/kg. However, the effective energy density of sodium borohydride and ammoniaborane is very high, up to 15 MJ/kg, including the energy converter. This is similar to the energy density of marine diesel oil combined with an internal combustion engine. Thus, we conclude hydrogen carriers are alternative fuels that deserve more attention because of their strong potential to make shipping zero-emission. ...