Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Process design”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
DOE OSTI2015

Streamlining NIF Design Engineering Processes

As a new project and facility, the National Ignition Facility (NIF) located a Lawrence Livermore National Laboratory (LLNL), adopted a design standard that incorporated a safety criteria process that all equipment was to be designed with thorough design documentation and a level of safety evaluation that guaranteed tractability and success in the commissioning of this new asset. The documentation is in the form of a Mechanical Engineering Safety Note (MESN) or Engineering Note (EN), which is a complete stand-alone review document of each design, with backup support, detailed analysis, drawings and a full review committee signoff. The design safety review process was given conservative Factors of Safety (FS) and guidance to evaluated design adequacy, leading to robust support structures. The MESN, EN, FS and guidance requirements were primarily driven by a need for confidence in the early success of the facility and the importance of personnel safety concerns. As the NIF facility and operations have matured and design loads, usage and risks have been become well defined and empirically validated, and we now have an opportunity to streamline the design process by not requiring such strict adherence to historical practice, specifically for non-personnel safety related requirements. This streamlining helps support a congressional review that was performed on NIF to determine cost saving opportunities in all areas of operation and development. This proposed NIF design guidance design approach would save design time, schedule and material costs. The new design approach includes reductions in FS and reduction in formal documentation, and will be implemented through the release of a NIF Design Guidance Document. This document will be used actively by designers, project engineers, structural analysts, safety engineers, scientists and engineering management to prepare, evaluated and approve designs for NIF experiments. This document will also be used as a general supporting reference for all design reviews involving the active stakeholders. The active stakeholders will gain through a faster design cycle time, from requirements, to concept, to final design, using less expensive materials and fewer design iterations. The passive stakeholders will gain through lighter weight equipment, easier to acquire materials, easier to manufacture parts and shorter schedules to get equipment in the hands of the user.

42 ENGINEERING↗
DOE OSTI2012

Modular Design of Processing and Storage Facilities for Small Volumes of Low and Intermediate Level Radioactive Waste including Disused Sealed Sources - 12372

There are a number of IAEA Member States generating relatively small quantities of radioactive waste and/or disused sealed sources in application of nuclear techniques in medicine, industry and research and in nuclear research centres having small research reactors. At present many of these Member States do not have facilities for processing and storing their radioactive wastes; notably in those countries with small quantities of generated radioactive wastes. In other Member States the existing waste processing and storage facilities (WPSF) are in need of varying degrees of upgrading in order to address new waste streams, incorporate new waste processing technologies, or expand interim storage capacities. The IAEA has developed a modular design approach for a WPSF that is based on a variety of modules for different waste stream treatment and conditioning processes. The modular WPSF design is elaborated in a substantial Design Engineering Package that will be published by IAEA as a technical report. The Design Engineering Package enables users to select the optimum waste processing and storage modules to meet their needs, and to specify the requirements for procurement of individual modules and their integration into a waste processing and storage facility. The Design Engineering Package is planned for publication by the IAEA in 2012 and is presented as: - A Design Engineering Package Summary document. - A supporting CD that contains: - Process module general specifications. - Process module interface specifications. - Design Engineering Package for process modules. - Sample technical specifications for design and construction of modular processing facility. - Design Engineering Package for storage modules. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Safeguards Modeling for Advanced Nuclear Facility Design.

Future nuclear fuel cycle facilities will see a significant benefit from considering materials accountancy requirements early in the design process. The Material Protection, Accounting, and Control Technologies (MPACT) working group is demonstrating Safeguards and Security by Design (SSBD) for a notional electrochemical reprocessing facility as part of a 2020 Milestone. The idea behind SSBD is to consider regulatory requirements early in the design process to provide more optimized systems and avoid costly retrofits later in the design process. Safeguards modeling, using single analyst tools, allows the designer to efficiently consider materials accountancy approaches that meet regulatory requirements. However, safeguards modeling also allows the facility designer to go beyond current regulations and work toward accountancy designs with rapid response and lower thresholds for detection of anomalies. This type of modeling enables new safeguards approaches and may inform future regulatory changes. The Separation and Safeguards Performance Model (SSPM) has been used for materials accountancy system design and analysis. This paper steps through the process of designing a Material Control and Accountancy (MC&A) system, presents the baseline system design for an electrochemical reprocessing facility, and provides performance metrics from the modeling analysis. The most critical measurements in the electrochemical facility are the spent fuel input, electrorefiner salt, and U/TRU product output measurements. Finally, material loss scenario analysis found that measurement uncertainties (relative standard deviations) for Pu would need to be at 1% (random and systematic error components) or better in order to meet domestic detection goals or as high as 3% in order to meet international detection goals, based on a 100 metric ton per year plant size.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2017

Lignite-plus-Biomass to Synthetic Jet Fuel with CO2 Capture and Storage: Design, Cost, and Greenhouse Gas Emissions Analysis for a Near-Term First-of-a-Kind Demonstration Project and Prospective Future Commercial Plants

We report on a 30-month design study for a first-of-a-kind (FOAK) demonstration plant that would be built at a site near Meridian, Mississippi, to coprocess lignite coal and woody biomass into jet fuel. The design uses an oxygen-blown TRIG™ gasifier developed by KBR and Southern Company. Fischer-Tropsch conversion of the syngas produces synthetic paraffinic kerosene (SPK) as the primary product, plus naphtha. Other co-products include electricity sold to the grid and CO 2 sold for use in enhanced oil recovery (EOR). Previous studies have identified coprocessing of various coals and biomass with CO 2 capture as promising options for cost-competitive production of low net lifecycle greenhouse gas (GHG) emissions synthetic fuels. The effort reported here goes beyond earlier studies in the level of detail in process design and cost estimation with the aim of improving the understanding of the economic prospects for lignite and woody biomass coprocessing systems. Key objectives in the design of the FOAK lignite/biomass-to-jet (LBJ) plant were to achieve net lifecycle GHG emissions for the SPK that are less than for conventional petroleum-derived jet fuel and to make process design and equipment selections such that the plant could be built and operated in the near term, e.g., before 2025. The process design was developed by researchers at Princeton University and the University of Queensland and validated by engineers at the WorleyParsons Group (WP). Commercial vendors provided design and cost estimates for several major plant components. Bare-erected capital costs and operating and maintenance costs were estimated by WP. The primary objective in building and operating the FOAK plant would be to demonstrate the technical viability of the LBJ concept as an essential first step toward launching commercial-scale plants in the longer term. With this in mind, the project team developed a set of principles to help guide the process design: the total plant cost should be less than 2 billion USD (to limit investment risk); the level of input biomass should be both proportionally significant to reflect biomass/lignite co-gasification and sufficient to achieve GHG emissions goals; process design decisions and vendor/equipment selections should prioritize the likelihood of technical success over minimizing the cost of jet fuel production. The resulting FOAK plant design capacity is 1,551 metric t/d (45.5% moisture) lignite and 556 t/d (43.3% moisture) biomass, for a total input of 295 MW HHV , of which 25% is biomass. The design output is 1,252 actual barrels per day of liquids, of which 80% is SPK (62.3 MW LHV ) and 20% is naphtha (13.9 MW LHV ). It exports 15 MW e of electricity after satisfying a 38 MW e onsite auxiliary load. Additional products are 1,326 t/d of pressurized pipeline-quality CO 2 and 49 t/day of sulfuric acid (93 wt% H 2 SO 4 ). With thinnings from sustainably-managed southern pine plantations as the biomass, and with captured CO 2 stored underground via EOR, the net lifecycle emissions for the SPK product are estimated to be about one-quarter of those for petroleum-derived jet fuel. The bare-erected cost (BEC) estimated by WP for this plant is 588 million USD (2015). The authors’ best estimate of total plant cost (TPC) is 1,230 million USD, arrived at by assuming engineering, procurement and construction management services (20% of BEC), process 5 contingencies (35% of BEC), and project contingencies (35% of the sum of all other costs, i.e., 35% of 1.55xBEC). Not surprisingly, an annual discounted cash flow (DCF) analysis determined that it would be impossible to generate a positive net present value (NPV) over a wide range in key input assumptions. An SPK production cost subsidy of nearly 400/bbl USD over a 20-year plant life would be required to achieve zero NPV under a baseline set of assumptions (including 3% real weighted average cost of capital and a levelized crude oil price of 80/bbl USD). Alternatively, a capital grant in excess of the TPC value would also achieve zero NPV. The poor financial results reflect the small scale of the plant, the design principle to prioritize technical success, the levels of contingencies appropriate for the relatively early stage of project development, and the first-of-a-kind nature of the plant. Technology innovations, learning via construction and operating experience, alternative plant configurations, and larger scale should improve economics of future plants. To help understand these prospects, a preliminary analysis of N th -of-a-kind (NOAK) plants was developed, but with the limitation that plants would use only equipment components that for the most part are already commercial today: consideration of advanced, not-yet-commercial technologies and of R&D-driven improvements in existing technologies were beyond the scope of this analysis. The analysis found that a variety of NOAK plant designs that coprocess lignite and woody biomass to make jet fuel are unlikely to be economically competitive without subsidy even in the presence of a high future carbon tax or equivalent greenhouse gas mitigation policy. This conclusion applies to process configurations and input biomass/lignite ratios that result in net GHG emissions as high as those for petroleum-derived jet fuel and as low as zero. In contrast, encouraging results were found for plants processing only biomass. The economics of these “BECCS” plants (biomass energy with CCS) improve dramatically with the strength of carbon mitigation policies because of their strongly negative net GHG emissions. These findings do not imply that coal/biomass coprocessing strategies for making synfuels with CCS are not economically promising – only that, in the case of lignite, much more than a 25% biomass coprocessing rate would be needed. However, our analysis shows that all such systems are unlikely to be economic in the absence of a strong carbon mitigation policy. Future R&D driven technological innovations could modify this conclusion. Among other R&D priorities, an emphasis on better understanding and reducing plant auxiliary loads is warranted.

09 BIOMASS FUELS↗
DOE OSTI2015

Prototype Laboratory Concept

The prototype laboratory concept was developed to simplify the laboratory design process, and should be considered for use as a new laboratory design methodology. Many developing countries lack adequate public and animal health laboratories and typically do not have the economic means and the design and construction expertise to build a laboratory on their own. These countries rely on international sponsors to provide the funds necessary to design and construct a laboratory. However, these international sponsors are often located far away, making travel back and forth difficult, which leads to an increase in overall costs and delays for the project. The prototype laboratory concept and design methodology were developed to streamline the design process, saving time and money, while also minimizing the number of errors that typically arise using a traditional design process by providing well considered design decisions in advance of the project. By solving numerous detailed design issues early, this methodology will allow the time, attention and energies of the design team to be focused on addressing the specific needs of the end users, the unique design challenges related to a given site and scientific program, and the biosafety and biosecurity risks associated with the scientific activities planned to be conducted in the facility. While the concept could be expanded to cover other types of laboratories to date, it has primarily focused on supporting the implementation of good laboratory design best practices for infectious disease diagnostic and research laboratories for both the human and animal health sectors. This report presents the laboratory design concept and details associated with the modular layouts. It builds on the work previously provided in the interim prototype laboratory concept report delivered to the Cooperative Biological Engagement Program (CBEP) at the Defense Threat Reduction Agency (DTRA) in 2014. This report includes a number of revised and additional module layouts, more detailed information regarding laboratory finishes and equipment, engineering service information, electrical and lighting layouts, plumbing service information and two mechanical service options for each prototype module. Additionally, this report also includes a description of a cost estimating tool that will accompany this report and allow funding agencies to generate an approximate cost for the construction of a laboratory that utilizes the prototype laboratory concept modules. This report is intended to serve a complete document and includes all relevant information from the 2014 prototype laboratory concept report.

42 ENGINEERING↗
DOE OSTI2012

MCNP6 for Criticality Accident Alarm Systems – A Primer

MCNP6 is a Los Alamos National Laboratory (LANL) developed, general-purpose Monte Carlo radiation transport simulation package. The code is capable of transporting a broad range of particles for numerous applications. MCNP6 has continuous-energy neutron and photon physics that make it suitable for both criticality and shielding problems. The analysis of a criticality accident alarm system (CAAS) combines methodologies and techniques for both classes of problems, and the requisite knowledge for both is quite different in some areas. For this reason, a primer has been created with the focus on teaching criticality safety practitioners the Monte Carlo techniques needed to analyze a CAAS. This primer specifically focuses on the Monte Carlo transport techniques for CAAS design. The use of radiation transport codes is a small portion of the overall design process, which is preceded and followed by many other design calculations and decisions. Those readers unfamiliar with the design of CAAS systems are directed to a PNNL report by Greenfield, which gives a thorough overview of the CAAS design process. This document gives reference to applicable standards and regulatory requirements and how to meet them, which is not the subject of this primer. The PNNL report explains where radiation transport codes such as MCNP play a role in this process, and this primer is meant to provide a more in-depth set of lessons for this portion of the design process.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2025

Mixed-Integer Linear Programming Formulation with Embedded Machine Learning Surrogates for the Design of Chemical Process Families

In previous work, we introduced process family design. The main idea is to design a platform of common elements, and, allowing us to capture additional cost savings, simultaneously design a family of processes, and reducing both engineering and deployment timelines. We formulate this as an optimization problem, specifically a nonlinear generalized disjunctive program (GDP). We have proposed two approaches for reformulating and solving this problem: one based on full-discretization of the design space and one that uses Machine Learning (ML) surrogates to replace the nonlinear process models. Using ML surrogates to predict required system costs and performance indicators allows us to reformulate the nonlinearities in the GDP generate an efficient MILP formulation. In this work, we apply the ML surrogate approach to two case studies. One case study involves designing a family of carbon capture systems to cover a set of different flue gas flow rates and inlet CO 2 concentrations, where we consider the absorber and stripper as common unit module types. The second case study focuses on a water-desalination process, where we design a family of these processes for a variety of salt concentrations and flow rates. In both of these case studies, we demonstrate a scalable optimization approach that enables the design of multiple processes simultaneously, reducing the time-to-market and overall costs by maximizing the cost savings due to both economies of scale and economies of numbers.

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

Transforming the Process Industries through Electrification: Challenges and Opportunities

For the more than 70 years, the process industries have provided essential fuels and materials for global growth. Increased manufacturing production comes with substantial environmental impact. Reducing environmental impact through process electrification, carbon capture, and other emerging technologies would require large changes throughout the process industries. We review opportunities and challenges related to electrification, focusing on technical, operational, and economic considerations. Here, we conclude that electrification could completely eliminate scope 1 CO 2 emissions, increase product quality, and reduce the equipment size and cost. On the other hand, it calls for a significant expansion of power generation capacity, as well as new paradigms for process design and operations.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Decomposition and Algorithmic Approaches for Solving Large-Scale Process Family Design Problems

Our most recent work expands the water desalination case study from 76 variants to 10,897 variants using the equation-oriented model built in Pyomo as part of the PARETO project. Using the discretization formulation presented in Stinchfield (2024a), rather than solving for all 10,897 variants simultaneously, we decompose the formulation into subproblems containing subsets of variants from the process family. We solve the overall problem with Progressive Hedging (PH) deployed in parallel on a distributed HPC cluster using the open-source Python package mpi-sppy (Knueven et al., 2023). This approach allowed us to solve this process family design problem to ~1.5% relative optimality gap in about 5 hours; in comparison, Gurobi reached ~50% relative optimality gap in about 6 hours (Stinchfield et al., 2024b). However, this approach still requires discretization of the common unit module design ranges; additionally, PH acts as a heuristic for MILP’s with gap-closing capabilities. Ideally, we would not have to use ML surrogates or discretization to solve this problem, instead solving the process family design problem with the equation-oriented model directly to achieve the most accurate results. However, recall that we did not consider solving the MINLP directly due to complexity and size. In this work, we aim to decompose and solve this large-scale MINLP using a Structured Nonlinear Global Optimization algorithm presented by Cao and Zavala (2019).

Stinchfield, Georgia↗
DOE OSTI2022

Process-informed adsorbent design guidelines for direct air capture

Direct air capture using solid adsorbents is a proven technology critical to reducing our net greenhouse gas emissions to zero and beyond. Currently, academic research into the technology mainly focuses on the development of new adsorbents. However, there is a discord between the adsorbent design and process performance. Many materials scientists focus on maximising metrics such as the CO 2 capacity of their adsorbent. Here, we combine detailed process modelling, machine learning, and extensive global sensitivity analysis, which entails varying all of the model parameters together, on a direct air capture process to show that the dry CO 2 adsorption capacity does not influence process performance for an amine-functionalised adsorbent operating in a temperature vacuum swing adsorption (TVSA) process, while it is important in a steam-assisted TVSA (S-TVSA) process. In fact, adsorption kinetics, density, and thermal conductivity are all critical attributes to obtaining a low energy penalty and reduced costs. The analysis also highlights the importance of heat transfer, directing process engineers to (alternative) adsorber designs that maximise this. By an in-depth evaluation of how process performance indicators are affected by materials properties and process operating parameters, this work provides guidance to both material scientists and process engineers towards the design of a “unicorn adsorbent” and intensified DAC processes. This will improve the performance of solid adsorbent direct air capture and help drive down the costs of this vital technology to avert the worst impacts of climate change.

42 ENGINEERING↗
DOE OSTI2024

LENS: Learning Enabled Network Synthesis

RTRC and UMD have developed novel machine learning based methods under the ARPA-E DIFFERENTIATE program for rapid acceleration of hypothesis generation in complex architecture design spaces involving both discrete choices of component inclusion and interconnection and continuous parametric decisions. The project named Learning Enabled Network Synthesis (LENS) further demonstrated the developed methods on challenging electrical power converter design problems by identifying the most suitable circuit topologies and simultaneously selecting the most appropriate components to achieve optimized design of power converter with improved performances. We demonstrated that LENS could enable exploration of very large design space of circuit topologies and components by addressing the limitations of conventional design process in non-linear, high switching speed, multi-dimensional power converter design and optimization. The key innovation developed in LENS is the seamless integration of statistical learning and logical reasoning techniques and building on the individual strengths of these techniques for rapid hypothesis discovery. The main component of LENS comprises of: 1) Graph Reasoning Engine (GRE) to enforce composition rules that rapidly reject all discrete architectures that are composed incorrectly and generates an adaptive database of feasible designs which can be used by ML modules, 2) Graph Generative Learning module which is a deep neural network based generative model for graph architectures which can enable design space exploration beyond the dataset generated by the GRE, 3) Graph Reduced Order Model (ROM) for graph domains for accelerating computation of output metrics, and 4) Active learning and Rule Discovery module for sample efficient learning and extracting logical rules from the learned ML models which will be integrated in the GRE to enhance the filtering effectiveness. LENS approach can be applied to any design domains where designs can be represented as multi-attribute graphs. The LENS team integrated the various technical innovations listed above into an optimization pipeline and exercised the optimization pipeline on the converter design problem. The LENS project demonstrated that the developed AI/ML technologies can be used to generate novel converter circuits >45x faster than experts on chosen use-cases. This can enable faster design space exploration and identification of new designs which are not considered by experts due to the increasing design space complexity. This has significant potential impact on the public and energy needs of the country. It is currently estimated that 30% of all electrical powers generated passes through power converters. The future estimate is that 80% of all power generated would be passing through converters. LENS fills a critical gap in this space since by accelerating the design process the designers would be able to generate more efficient converters which can lead to significant energy savings for the country.

42 ENGINEERING↗
DOE OSTI2019

Methodology for designing grism stretchers for idler-based optical parametric chirped-pulse-amplification systems

Powerful ultrafast lasers with wavelengths above 1 mm are in demand to create attosecond pulses and ultra-intense laser sources. A promising technology to achieve these laser sources uses the by-product from an optical parametric chirped-pulse amplifier, known as the idler. Compression of the idler to high peak powers requires a grism stretcher and a grating compressor. Grism stretchers have many more design parameters than conventional stretchers, complicating the design process. This paper presents a method for designing a grism stretcher and grating compressor that logically navigates the design process. This method was applied to design a grism stretcher for the optical parametric amplifier line that is under construction at the Laboratory for Laser Energetics to produce a 50-mJ, 115-fs pulse at 1170 nm.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

Design and processing for high performance Li ion battery electrodes with double-layer structure

A two-layer LiNi 0.8 Mn 0.1 Co 0.1 O 2 (NMC811) cathode has been designed and fabricated containing a “power layer” and “energy layer”, with corresponding porosity and particle size prescribed to each layer to achieve best utilization of electrode material (maximum integrated depth of discharge across the electrode thickness) at high applied current. The cathode showed a 17% improvement in capacity when tested in symmetric cells. When applying the design to a full cell, where both positive and negative electrodes contain power and energy layers, a 74% increase in discharge capacity at 2C was achieved compared to the cell with conventional electrodes. Furthermore, this demonstrates an avenue to increase energy and power density of lithium–ion batteries and enable fast charging capability.

25 ENERGY STORAGE↗
DOE OSTI2013

Acoustic Array Development for Wind Turbine Noise Characterization

This report discusses the design and use of a multi-arm, logarithmic spiral acoustic array by the National Renewable Energy Laboratory (NREL) for measurement and characterization of wind turbine-generated noise. The array was developed in collaboration with a team from the University of Colorado Boulder. This design process is a continuation of the elliptical array design work done by Simley. A description of the array system design process is presented, including array shape design, mechanical design, design of electronics and the data acquisition system, and development of post-processing software. System testing and calibration methods are detailed. Results from the initial data acquisition campaign are offered and discussed. Issues faced during this initial deployment of the array are presented and potential remedies discussed.

17 WIND ENERGY↗
DOE OSTI2012

Modular Energy Storage System for Alternative Energy Vehicles

An electrical vehicle environment was established to promote research and technology development in the area of high power energy management. The project incorporates a topology that permits parallel development of an alternative energy delivery system and an energy storage system. The objective of the project is to develop technologies, specifically power electronics, energy storage electronics and controls that provide efficient and effective energy management between electrically powered devices in alternative energy vehicles plugin electric vehicles, hybrid vehicles, range extended vehicles, and hydrogen-based fuel cell vehicles. In order to meet the project objectives, the Vehicle Energy Management System (VEMS) was defined and subsystem requirements were obtained. Afterwards, power electronics, energy storage electronics and controls were designed. Finally, these subsystems were built, tested individually, and integrated into an electric vehicle system to evaluate and optimize the subsystems performance. Phase 1 of the program established the fundamental test bed to support development of an electrical environment ideal for fuel cell application and the mitigation of many shortcomings of current fuel cell technology. Phase 2, continued development from Phase 1, focusing on implementing subsystem requirements, design and construction of the energy management subsystem, and the integration of this subsystem into the surrogate electric vehicle. Phase 2 also required the development of an Alternative Energy System (AES) capable of emulating electrical characteristics of fuel cells, battery, gen set, etc. Under the scope of the project, a boost converter that couples the alternate energy delivery system to the energy storage system was developed, constructed and tested. Modeling tools were utilized during the design process to optimize both component and system design. This model driven design process enabled an iterative process to track and evaluate the impact of design alternatives and the impact of changes. Refinement of models was accomplished through correlation studies to measured data obtained from functioning hardware. Specifically, correlation and characterization of the boost converter resulted in a model that was effectively used to determine overall VEMS performance. The successful development of the boost converter can be attributed to utilization of previously proven technologies and adapting to meet the VEMS requirements. This program provided significant improvement in development time of various generations of boost converters. The software strategies and testing results support the development of current energy management systems and directly contribute to the future of similar, commercial products at Magna E-Car Systems. Because of this development project, Magna E-Car Systems is able to offer automotive customers a boost converter system with reduced time to market and decreased product cost, thus transferring the cost and timing benefits to the end use consumer.

25 ENERGY STORAGE↗
DOE OSTI2026

Large Scale Granulator Development Designed to Process Reclaimed Feedstock for Sustainable Additive Manufacturing Applications

This CRADA between UT-Battelle, LLC (Contractor) and re:3D Inc. (Participant) aims to develop an affordable large-scale granulator system designed to process reclaimed plastic feedstock suitable for additive manufacturing applications. The 24-month project will focus on testing, prototyping, and optimizing a shredder/granulator system. This project also focuses on the processing steps (e.g. washing and sorting) that can convert waste plastics, like discarded water bottles, into flake/granules which can be 3D printed using re:3D’s Fused Granular Fabrication (FGF) 3D printers. If successful, this could enable more localized 3D printing using recycled plastics, reducing waste and feedstock costs.

Wang, Peter [Oak Ridge National Laboratory (ORNL),↗
DOE OSTI2021

Synthesis and Processing by Design of High-Nickel Cathode Materials

The high demand of lightweight, high energy density batteries for energy storage promotes new materials discovery and development. Despite the large number of battery materials being discovered, very few of them have been commercially deployed, mostly bottlenecked by synthesis and processing – namely, making certain phases with the desired structure and properties to meet the multifaceted performance requirements. Alternative to the traditional trial and error, we present here an in situ study aided synthesis- and processing-by-design approach. With specific examples, we illustrate how to use the approach to identify reaction pathways in synthesis and processing of high-Nickel (Ni) cathode materials for next-generation lithium-ion batteries, thereby ensuring precise control of their structure, morphology, and surface properties. Furthermore, perspectives are provided on the wide applicability of the approach to solving critical issues inherent to high-Ni cathodes and the new directions and opportunities in the area.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Direct Air Capture Using Trapped Small Amines in Hierarchical Nanoporous Capsules on Porous Electrospun Fibers (Final Technical Report)

This report summarizes the carbon capture research and development conducted by The State University of New York at Buffalo (UB) and GTI Energy (GTI) for award “DE-FE0031969: Direct Air Capture Using Trapped Small Amines in Hierarchical Nanoporous Capsules on Porous Electrospun Fibers” sponsored by the U.S. Department of Energy (DOE). The objective of this project is to develop an innovative sorbent structure of trapped small amines in HNC embedded in PEF for DAC. This involves tailoring both sorbent and PEF materials to achieve a compact system for DAC with high capacity for CO 2 at concentrations typically available in air and at near ambient conditions. An innovative sorbent structure of trapped small amines in hierarchical nanoporous capsules (HNC) embedded in porous electrospun fibers (PEF) was developed for direct air capture (DAC). This involves tailoring both sorbent and PEF materials to achieve a compact system for DAC with high capacity for CO 2 at concentrations typically available in air and at near ambient conditions. An interfacial polymerization process was developed, which utilized loaded amines inside mesoporous silica and trimesoyl chloride (TMC) dissolved in organic solvents as the precursors, to generate a polyamide (PA) coating layer on mesoporous silica and thus trap amines. Reaction conditions, including TMC concentration, organic solvents, reaction time, etc., for interfacial polymerization were optimized to effectively trap loaded amines, and cyclic heating-cooling operation was conducted to evaluate the coating quality. Larger pore volume mesoporous silica was also synthesized to increase amine loading and thus increase CO 2 capacity. The optimized sorbent material exhibited CO 2 capacity as high as 4.88 mmol/g under humid DAC conditions and negligible loss (<1%) during 10 cyclic heating-cooling operations. The optimized PA-coated sorbent also showed fast adsorption and desorption kinetics, with <20% t1/2 increase compared to uncoated sorbent. PEF fabrication conditions, including organic solvents for dissolving core and shell polymers, voltage, distance from the nozzle to the collection panel, etc. were adjusted to better incorporate HNC. After incorporating the optimized sorbent material into PEF, the structured sorbent had a CO 2 capacity of approximately 4.0 mmol/g under humid DAC conditions, with capacity loss of 0.17% per cycle and t1/2 increase less than 10%. A techno-economic analysis (TEA) for the process design for a DAC system based on our developed sorbent structure of trapped small amines in HNC embedded in PEF was conducted. The process design included process description and major equipment sizing and energy and mass balances in addition to scale-up research results and estimated capture cost. Aspen Adsorption Simulator was used to fit the experimentally measured breakthrough curves and extract equilibrium and kinetic data of the optimized sorbent. Our results indicated that for a DAC plant with CO 2 productivity of 3,000 tonne/year, the levelized cost of CO 2 capture was $\$$612/tonne, with the largest contribution of 44.33% from the fixed operation cost. Increasing CO 2 productivity, while maintaining similar fixed operation cost, is expected to significantly reduce the CO 2 capture cost. A sensitivity study was also conducted to understand the influence of total plant cost, sorbent cost, CO 2 concentration in the feed, sorbent mat lifetime, sorbent regeneration electricity, and adsorption blower pressure drop on the levelized cost of CO 2 capture, revealing a capture cost range of $\$$520-870/tonne.

36 MATERIALS SCIENCE↗