Synthesis of NaAlH4-based hydrogen storage material using milling under low pressure hydrogen atmosphere

The present study highlights the advantages of milling NaH/Al under moderate hydrogen pressure as a favourable production step for NaAlH₄-based hydrogen storage materials. Firstly, it is demonstrated that NaAlH₄ can be obtained by applying a moderate hydrogen pressure (6–12 bar) during milling of NaH and Al with and without the presence of an inexpensive catalyst (TiCl₄). The yield of NaAlH₄ depends critically on process parameters, such as hydrogen pressure and milling time. A fully converted product is capable of reversible hydrogen storage without any activation procedure. Under optimized conditions, a capacity of 4.2 wt.% was achieved and kinetics in the first desorption are comparable to NaAlH₄ doped with TiCl₃. Secondly, the synthesis has been optimized towards shorter milling times. By applying a few absorption/desorption cycles to material that was partially converted during milling, almost full reversible storage capacity can be reached. In addition, kinetics is extremely enhanced. For example, such material exhibits an optimum capacity already after two sorption cycles at 100 bar and 125 °C and allows to absorb 80% of the reversible hydrogen content within a few minutes.