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At least 235 records · Page 13

All sources NASA NTRS DOE OSTI

DOE OSTI2023

Demonstration of the Blending of the H-Canyon 2nd U Cycle with Natural U to Produce a HALEU Solution

Continued growth in the demand for high assay low enriched uranium (HALEU) is projected to support the conversion of US high performance research reactors from high to low enrichment and the development and deployment of a new generation of advanced reactors. Current options to meet the growing US need for HALEU include (1) blend-down of excess of highly enriched uranium (HEU) from the nuclear weapons programs, (2) blend-down of HEU metal from other stockpiles, or (3) recycle of irradiated HEU recovered from spent nuclear fuel (SNF). The recycle of HEU from SNF has been performed at the Savannah River Site (SRS) H-Canyon facility for nearly two decades to produce 4.95 wt % U-235 for sale and subsequent use in fuel for Tennessee Valley Authority (TVA) reactors. The HALEU produced in H-Canyon will not exceed the U-236 concentration limit in the ASTM C1462 standard for U metal enriched to more than 15% and less than 20% U-235, which applies to advanced reactors.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Performance Testing of a Moving-Bed Gasifier Using Coal, Biomass, and Waste Plastic Blends to Generate White Hydrogen

The objective of this DOE-funded project by the Electric Power Research Institute, Inc. (EPRI), Hamilton Maurer International (HMI) and Sotacarbo S.p.A. (Sotacarbo), is to qualify coal, biomass, and plastic waste blends based on performance testing of selected pellet recipes in a pilot-scale updraft moving-bed gasifier. The testing provides relevant data to advance the commercial-scale design of the moving-bed gasifier to be able to successfully use these feedstocks to produce hydrogen. In particular, the effects of the waste plastics on feedstock development (i.e., blending and pelletizing) and the resulting products (i.e., syngas compositions, organic condensate production, and ash characteristics) are a focus. The gasifier is Hamilton Mauer International, Inc. (HMI)’s moving-bed gasifier, which has been proven capable of gasifying nearly all coal ranks. It has also shown the ability in prior testing work to gasify wood chips. However, mixtures of these fuels with plastic wastes had not yet been prepared and gasified together. The feedstocks were prepared by California Pellet Mill (CPM) under contract to HMI.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2023

Demonstration of In Situ Down Blending During ZIRCEX Process

The Material Recovery Pilot Plant has successfully demonstrated in situ down-blending of HEU fuel to support INL’s commitment to HALEU production technologies. Depleted uranium pellets, along with an HEU fuel piece were placed in the hydrochlorinator and subsequently declad and oxidized. UOx product was recovered, analyzed, and demonstrated to have reduced enrichment within the targeted range of 20 – 30 % U-235. This first attempt at in situ down-blending will be followed by continued process refinement over the remaining fuel operations at MRPP.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Research to Address Technical Barriers to Expanded Markets for Biodiesel and Biodiesel Blends (CRADA Final Report)

NREL and the Clean Fuels Alliance America (CFAA) will work cooperatively to assess the effects of biodiesel blends on the performance of modern diesel engines. This work will include research to understand the impact of biodiesel blends on the operation and durability of particle filters and NO x control sorbents/catalysts, to quantify the effect on emission control systems performance, and to understand effects on engine component durability. This research was performed at NREL Renewable Fuels and Lubricants (REFUEL) laboratory (an engine testing laboratory) as well as at third party labs paid directly by CFAA with NREL as part of the project management team. Also, research to develop appropriate ASTM standards for biodiesel quality and stability was conducted in NREL’s bench scale fuel chemistry laboratory. The cooperative project involved laboratory testing and research at NREL using biodiesel from a variety of sources and in collaboration with a broad range of other stakeholders. In addition, NREL will work with NBB to set up an Industrial Steering Committee to design the scope for the various tasks and to provide technical oversight to these projects. NREL and NBB will cooperatively communicate the study results to as broad an audience as possible. This research benefits the public by expanding markets for a domestically produced low-carbon intensity fuel for use in diesel engines.

09 BIOMASS FUELS↗

DOE OSTI2025

Development of Calcined Clay/Calcium Sulfate Blends for Robust Performance of LC3 Concrete

This report documents the development of robust blends of calcined clays (CCs) with calcium sulfate (gypsum) for application in limestone calcined clay cement (LC3) systems. The U.S. cement industry faces supply chain constraints and high energy intensity, motivating the need for alternative supplementary cementitious materials. Calcined clays are abundant and highly reactive when properly processed, but their variable physical and chemical characteristics can negatively impact hydration balance, rheology, and admixture demand in LC3 concretes. To address this, five calcined clays, two Portland cements, ground limestone, gypsum, and a polycarboxylate dispersant were procured. Isothermal calorimetry and mini-cone flow tests were used to determine sulfate and dispersant demand. Results show that the addition of approximately 6.7% gypsum, relative to the calcined clay weight, consistently balanced sulfate consumption across the LC3 systems studied. Dispersant demand, however, varied significantly with clay source, demonstrating the need for tailored admixture strategies. These findings confirm that supplying CC–gypsum blends directly to concrete producers is a viable approach to overcoming current manufacturing constraints, enabling reliable fresh and hardened performance of LC3 concretes, and supporting broader adoption of calcined clays in the U.S. market.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Storage Stability of 50% Biodiesel Blends and Neat Biodiesel Produced in North America

This study investigated aging of two petroleum diesel, seven B100, three B20 blends, and 14 B50 blends representing the full range of fuels in the North American market for 12-weeks at 43 degrees Celsius under the ASTM D4625 accelerated aging protocol. Twelve-weeks under D4625 aging represents approximately 12 months of storage time in clean, dry conditions. Samples were taken every two weeks for measurement of Rancimat induction period (IP), peroxide content, and TAN; and total insoluble were measured at the end of the 12-week test.

09 BIOMASS FUELS↗

DOE OSTI2021

Reburning of Animal Waste Based Biomass with Coals for NO x Reduction, Part II: Dairy Biomass (DB) and Coal–DB Blends

Concentrated animal feeding operations (both slaughter and dairy cattle) lead to land, water, and air pollution if waste storage and handling systems are not effectively managed. At the same time, cattle biomass (CB), which includes both slaughter/feedlot biomass (FB) and dairy biomass (DB), have the potential to be a source of green energy at coal-fired power plants. Part I presented results on NOx reductions with pure FB or Coal: FB blends as reburn fuels. Part II deals with results from reburning with pure DB or Coal: DB blends as reburn fuels. A mixture of NG with a small amount of NH3 was used to generate the baseline NOx of 400–420 ppm (or 185–194 g/GJ). NOx emissions were found to be reduced by as much as 96% when reburning with FB. The effects of reburn fuel type, equivalence ratio (ER RBZ ) in the reburn zone, vitiated air, several injection configurations of reburn fuel and initial NO concentrations on NOx emissions were investigated. The ER RBZ shows a significant effect on the NOx reduction. The 20% heat input by reburning was the better operating condition for the long-term operation due to its ash production. The results reveal that reburn with DB fuels is an effective technology for NOx emission control when the initial NOx emission is higher than 275 ppm (or 127 g/GJ or 0.3 lb/MMBtu).

09 BIOMASS FUELS↗

DOE OSTI2023

A Theoretical Study of NH 2 Radical Reactions with Propane and Its Kinetic Implications in NH 3 -Propane Blends’ Oxidation

The reaction of NH 2 radicals with C 3 H 8 is crucial for understanding the combustion behavior of NH 3 /C 3 H 8 blends. In this study, we investigated the temperature dependence of the rate coefficients for the hydrogen abstraction reactions of C 3 H 8 by NH 2 radicals using high-level theoretical approaches. The potential energy surface was constructed at the CCSD(T)/cc-pV(T, Q)//M06-2X/aug-cc-pVTZ level of theory, and the rate coefficients were computed using conventional transition state theory, incorporating the corrections for quantum tunneling and hindered internal rotors (HIR). The computed rate coefficients showed a strong curvature in the Arrhenius behavior, capturing the experimental literature data well at low temperatures. However, at T > 1500 K, the theory severely overpredicted the experimental data. The available theoretical studies did not align with the experiment at high temperatures, and the possible reasons for this discrepancy are discussed. At 300 K, the reaction of NH 2 with C 3 H 8 predominantly occurs at the secondary C-H site, which accounts for approximately 95% of the total reaction flux. However, the hydrogen abstraction reaction at the primary C-H site becomes the dominant reaction above 1700 K. A composite kinetic model was built, which incorporated the computed rate coefficients for NH 2 + C 3 H 8 reactions. The importance of NH 2 + C 3 H 8 reactions in predicting the combustion behavior of NH 3 /C 3 H 8 blends was demonstrated by kinetic modeling.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Electromagnetic Design Optimization Integrated with Mechanical Stress Analysis of PM-Assisted Synchronous Reluctance Machine Topologies Enabled with a Blend of Magnets

Permanent Magnet-Assisted Synchronous Reluctance Machines (PMASynRM) provide a low-cost alternative to Surface PM Machines due to the use of relatively lower grades of rare-earth (RE) or RE-free magnets, as the performance degradation due to weaker magnets is compensated by the presence of reluctance torque. However, the weaker magnets suffer from a high risk of demagnetization, leading to unreliable motor operation. Using a blend of RE and RE-free magnets has the potential to overcome this issue. This paper proposes to blend different grades of various rare-earth (RE) and rare-earth-free (RE-free) magnets in six different combinations and utilizes them in two-layer and three-layer U-shaped PMASynRM topologies with both eight-pole and six-pole variations. The rotor of the various designs is then optimized using a differential evolution (DE) based optimization algorithm to obtain low-cost designs with reduced RE magnet volume and minimum demagnetization risk. The optimization of each design is also integrated with the evaluation of mechanical stresses in the rotor laminations so as to maintain the stresses below the material yield strength. Furthermore, the various performance metrics, such as toque–speed/power–speed characteristics, demagnetization, and efficiency maps, are evaluated for each of the optimized and mechanically feasible designs. A quantitative comparison of the various optimized designs is also obtained to highlight the various trade-offs. The results indicate the feasibility of meeting the baseline torque requirement across the entire speed range, even with a 100% reduction in RE magnet volume and less than 5% demagnetization risk, while achieving a cost reduction exceeding 50%. Moreover, the two-layer, eight-pole designs exhibit relatively higher performance, whereas the three-layer, eight-pole designs are found to be the most economical option.

design optimization↗

DOE OSTI2020

A Review on Metallic Alloys Fabrication Using Elemental Powder Blends by Laser Powder Directed Energy Deposition Process

The laser powder directed energy deposition process is a metal additive manufacturing technique, which can fabricate metal parts with high geometric and material flexibility. The unique feature of in-situ powder feeding makes it possible to customize the elemental composition using elemental powder mixture during the fabrication process. Thus, it can be potentially applied to synthesize industrial alloys with low cost, modify alloys with different powder mixtures, and design novel alloys with location-dependent properties using elemental powder blends as feedstocks. This paper provides an overview of using a laser powder directed energy deposition method to fabricate various types of alloys by feeding elemental powder blends. At first, the advantage of laser powder directed energy deposition in manufacturing metal alloys is described in detail. Then, the state-of-the-art research and development in alloys fabricated by laser powder directed energy deposition through a mix of elemental powders in multiple categories is reviewed. Finally, critical technical challenges, mainly in composition control are discussed for future development.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Water-Dependent Blending of Pectin Films: The Mechanics of Conjoined Biopolymers

Biodegradable pectin polymers have been recommended for a variety of biomedical applications, ranging from the delivery of oral drugs to the repair of injured visceral organs. A promising approach to regulate pectin biostability is the blending of pectin films. To investigate the development of conjoined films, we examined the physical properties of high-methoxyl pectin polymer-polymer (homopolymer) interactions at the adhesive interface. Pectin polymers were tested in glass phase (10–13% w/w water content) and gel phase (38–41% w/w water content). The tensile strength of polymer-polymer adhesion was measured after variable development time and compressive force. Regardless of pretest parameters, the adhesive strength of two glass phase films was negligible. In contrast, adhesion testing of two gel phase films resulted in significant tensile adhesion strength (p < 0.01). Adhesion was also observed between glass phase and gel phase films—likely reflecting the diffusion of water from the gel phase to the glass phase films. In studies of the interaction between two gel phase films, the polymer-polymer adhesive strength increased linearly with increasing compressive force (range 10–80 N) (R 2 = 0.956). In contrast, adhesive strength increased logarithmically with time (range 10–10,000 s) (R 2 = 0.913); most of the adhesive strength was observed within minutes of contact. Fracture mechanics demonstrated that the adhesion of two gel phase films resulted in a conjoined film with distinctive physical properties including increased extensibility, decreased stiffness and a 30% increase in the work of cohesion relative to native polymers (p < 0.01). Scanning electron microscopy of the conjoined films demonstrated cross-grain adhesion at the interface between the adhesive homopolymers. These structural and functional data suggest that blended pectin films have emergent physical properties resulting from the cross-grain intermingling of interfacial pectin chains.

62 RADIOLOGY AND NUCLEAR MEDICINE↗

DOE OSTI2022

Evaluating Class 6 Delivery Truck Fuel Economy and Emissions Using Vehicle System Simulations for Conventional and Hybrid Powertrains and Co-Optima Fuel Blends

The US Department of Energy’s Co-Optimization of Engine and Fuels Initiative (Co-Optima) investigated how unique properties of bio-blendstocks considered within Co-Optima help address emissions challenges with mixing controlled compression ignition (i.e., conventional diesel combustion) and enable advanced compression ignition modes suitable for implementation in a diesel engine. Additionally, the potential synergies of these Co-Optima technologies in hybrid vehicle applications in the medium- and heavy-duty sector was also investigated. In this work, vehicles system were simulated using the Autonomie software tool for quantifying the benefits of Co-Optima engine technologies for medium-duty trucks. A Class 6 delivery truck with a 6.7 L diesel engine was used for simulations over representative real-world and certification drive cycles with four different powertrains to investigate fuel economy, criteria emissions, and performance. Comparisons were made between ultralow-sulfur diesel and a blend of 25% hexyl hexanoate with diesel. Model validation data were informed by 2019 model year Cummins ISB 6.7 L diesel engine maps and transient validation data in a pre-production hybrid configuration and a direct dyno coupled configuration with diesel fuel and a blend of 25% hexyl hexanoate with diesel.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2022

Ethanol Blends: Providing a Renewable Fuel Choice

More than 21 million vehicles on U.S. roads are flexible-fuel vehicles (FFVs) as of August 2022. These vehicles can operate on either gasoline or blends of gasoline and ethanol up to E85 (a gasoline-ethanol blend containing 51% to 83% ethanol). As a renewable fuel, ethanol offers significant advantages. It is produced predominantly in the United States, made from home-grown feedstocks, and burns cleaner than gasoline.

ethanol, E85, flexible fuel vehicles↗

DOE OSTI2022

Fuel and fuel blend for internal combustion engine

A fuel or fuel blending agent for an internal combustion engine includes a ketone compound that is a C 4 to C 10 branched acyclic ketone, cyclopentanone, or a derivative of cyclopentanone. The ketone compound may be blended with a majority portion of a fuel selected from the group consisting of: gasoline, diesel, alcohol fuel, biofuel, renewable fuel, Fischer-Tropsch fuel, or combinations thereof. The ketone compound may be derived from biological sources. A method for powering an internal combustion engine with a fuel comprising the ketone compound is also provided.

Dec, John E.↗

DOE OSTI2023

Fuel and fuel blend for internal combustion engine

Dec, John E.↗

DOE OSTI2025

Recent Advances in Pipeline Integrity for Transporting Blended Hydrogen-Natural Gas

To achieve US decarbonization goals, hydrogen is being considered as an alternative energy source to reduce carbon emissions. Blending hydrogen into existing natural gas pipelines is an intuitive first step to enable near term emission reductions. However, there are numerous challenges and uncertainties that complicate the transition to transporting hydrogen long-distance through existing natural gas pipelines. The main challenge is hydrogen embrittlement (HE), which reduces the ductility, fracture toughness and fatigue resistance of pipeline steels. This work delivers a technical review on HE effects on the material properties of pipeline carbon steels, such as Grade B, X52, X65, X70, X80, and X100. An important aspect of laboratory tests to capture the HE effect is the hydrogen test environment. This includes hydrogen pre-charged specimens tested in air and specimens tested in a hydrogen gas environment. A review of the mechanical properties of pipeline steel in different hydrogen environments determined through tensile testing is given first, which includes HE effects on yield strength, ultimate tensile strength, and ductility for blended hydrogen-natural gas pipelines. Then, the HE effects on fracture toughness and fatigue crack growth resistance are discussed. Last, impacts of HE to pipeline integrity and major technical challenges are discussed.

: Hydrogen Embrittlement↗

DOE OSTI2021

Synergistic Enzyme Mixtures to Realize Near-Complete Depolymerization in Biodegradable Polymer/Additive Blends

Embedding catalysts inside of plastics affords accelerated chemical modification with programmable latency and pathways. Nanoscopically embedded enzymes can lead to near-complete degradation of polyesters via chain-end mediated processive depolymerization. The overall degradation rate and pathways have a strong dependence on the morphology of semicrystalline polyesters. Yet, most studies to date focus on pristine polymers instead of mixtures that contain additives and other components despite their nearly universal use in plastic production. Here, for this study, additives are introduced to purposely change the morphology of polycaprolactone (PCL) by increasing the bending and twisting of crystalline lamellae. These morphological changes immobilize chain ends preferentially at the crystalline/amorphous interfaces and limit chain-end accessibility by the embedded processive enzyme. This chain-end redistribution reduces the polymer-to-monomer conversion from >95% to less than 50%, causing formation of highly crystalline plastic pieces, including microplastics. By synergizing both random chain scission and processive depolymerization, it is feasible to navigate morphological changes in polymer/additive blends and to achieve near-complete depolymerization. The random scission enzymes in the amorphous domains create new chain ends that are subsequently bound and depolymerized by processive enzymes. Present studies further highlight the importance to consider how the host polymer's morphologies affect the reactions catalyzed by embedded catalytic species.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Synthesis of precipitation-strengthened Al-Sc, Al-Zr and Al-Sc-Zr alloys via selective laser melting of elemental powder blends

Selective laser melting is used to create Al-1.5Sc, Al-1.5Zr and Al-0.75Sc-0.75Zr (at.%) alloys from blends of elemental Al, Sc, and Zr powders. This study investigates elemental alloying elements (Sc and Zr) which are high-melting and highly reactive, unlike previous work which focused on more concentrated elemental additions of lower-melting, lower-reactivity Cu and Si to aluminum. High-speed in situ synchrotron x-ray imaging and diffraction show that the 20–30 μm Al, Sc, and Zr powders fully melt and sufficiently mix in the molten state to create, on solidification, a homogeneous distribution of primary, micron-size L12 precipitates (Al 3 Sc, Al 3 Zr, and Al 3 (Sc,Zr), respectively) and nucleate micron-size Al matrix grains, as confirmed by SEM imaging of cross-sections. Here, a second laser pass, simulating a realistic additive-manufacturing build condition, fully remelts the initial volume which shows, after solidification, the same Al 3 (Sc,Zr) L1 2 primary micro-precipitates and very fine Al grains. After aging at 300–400°C, the alloys show large increases in hardness, consistent with an exceptionally high number density (1.4 × 10 24 m –3 ) and volume fraction (2.5%) of secondary Al 3 (Sc,Zr) nano-precipitates with a Sc-rich core and Zr-rich shell, as measured via atom-probe tomography.

36 MATERIALS SCIENCE↗