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DOE OSTI2020

Carbon Fiber Prepreg Recycling- Automated Perform Manufacturing Equipment (Final Technical Report)

Discontinuous fiber composites have a compelling business case as related to light metals such as aluminum and magnesium machined or die cast components. DFC’s have been in commercial production using carbon fiber/epoxy prepreg for both commercial aircraft and for military applications for a number of years and their usage is expanding into automotive and consumer goods components. Reasons for this include significantly lower cost as compared to continuous fiber composites easier design and understanding of the material by metal traditionalists, higher degree of part complexity with relatively simple and low cost molds when compared to high-pressure die casting, and potential for near zero waste. IACMI’s 10-year goals of reduction in carbon fiber reinforced plastics manufacturing cost by 25%, reduction in their embodied energy by 50%, and recyclability of 95% can all be advanced through robust recycling. With recycling We have shown that a 15% contribution in manufacturing cost reduction is feasible, that a significant reduction in embodied energy (over 90% for the recycled fraction) is achievable, and that when combined with primary pyrolysis recycling, the 95% target can be met. Large-scale application of advanced composites began with the aerospace industry, and CRTC’s location in Washington State provided access to a waste stream of nearly 900 tonnes/year that was going to landfill. As the aerospace industry has automated parts production, their material forms have become significantly easier to recycle, and some evidence of this exists for the future automotive and wind turbine components as well. CRTC decided to focus on re-purposing the carbon fiber/epoxy aerospace scrap streams through materials reformatting and reuse, and not on primary recycling (pyrolysis mainly) as this technology is commercially available. The main reasons for this were that it offers a route to effective use of the most widely available and consistent feedstock called edge-trim, as well as allows creation of complex and low-cost parts using rapid and cost-effective compression molding technologies. The reasons also include leading the way for potential automotive pre-preg recycling as the combination of roughly 85% virgin pre-preg and 15% recycled pre-preg directly supports IACMI’s goals and enables significant part cost reduction and a path to zero-waste composite manufacturing at the OEMs or Tier 1’s. The purpose of the project was to develop equipment and technology to transform continuous fiber pre-preg in roll forms into smaller chip-format DFC feedstock, and to determine impacts on moldability and performance based on lessons learned along the path. The availability of scrap from pre-preg manufacturers was a significant value to the program even though the aerospace pre-preg is designed to be autoclave molded thus has handling, tackiness, and processing factors that are not ideal for DFCs. The scope of the project was to develop a Phase 1 system that could identify and resolve some of the major hurdles, determine where to focus effort on building a commercial-scale Phase 2 system, and develop technology for handling a wide variety of incoming scrap materials to produce the most usable product. A chopping system was developed and reduced to practice via an experimental approach that enabled all forms of scrap coming from the pre-preg manufacturers and some forms of the scrap coming from OEM production lines to be very effectively re-purposed. The systems that were developed were not considered to be production robust but rather identified and resolved some of the major technical hurdles, and demonstrated the path towards effective full-scale commercialization.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Y-12 Groundwater Protection Program Monitoring Well Inspection and Maintenance Plan

This plan describes the systematic approach for: inspecting the physical condition of monitoring wells at Y-12, determining maintenance needs that extend the life of a well, and identifying those wells that no longer meet acceptable monitoring well design or well construction standards and require plugging and abandonment. The inspection and maintenance of groundwater monitoring wells is one of the primary management strategies of the Y-12 Groundwater Protection Program (GWPP) Management Plan, that is, the “proactive stewardship of the extensive monitoring well network at Y-12" (Consolidated Nuclear Security, L.L.C. [CNS], 2018). Effective stewardship, and a program of routine inspections of the physical condition of each monitoring well, ensures that representative water-quality samples and hydrologic data are obtained from the well network and protects the subsurface environment. In accordance with the Y-12 GWPP Monitoring Optimization Plan (MOP) for Groundwater Monitoring Wells at the Y-12 National Security Complex, Oak Ridge, Tennessee (CNS, 2017), the status designation (active or inactive) for each well determines the scope and extent of well inspections and maintenance activities. This plan, in conjunction with the above document, formalizes the GWPP approach to focus available resources on monitoring wells which provide the most useful data, and for that reason the GWPP inspects and performs maintenance on the wells sampled by the GWPP. This plan applies to groundwater monitoring wells installed at Y-12 and the related waste management facilities located within the three hydrogeologic regimes: (1) the Bear Creek Hydrogeologic Regime (Bear Creek Regime), (2) the Upper East Fork Poplar Creek Hydrogeologic Regime (East Fork Regime), and (3) the Chestnut Ridge Hydrogeologic Regime (Chestnut Ridge Regime). The Bear Creek Regime encompasses the section of Bear Creek Valley (BCV) immediately west of Y-12. The East Fork Regime encompasses most of the Y-12 process, operations, and support facilities in BCV west of Scarboro Road. The Chestnut Ridge Regime is directly south of Y-12 and encompasses a section of Chestnut Ridge that is bounded to the west by a surface drainage feature (Dunaway Branch, located immediately west of Industrial Landfill II) and by Scarboro Road to the east. The GWPP maintains an extensive database of geographic and construction details and related information for the monitoring wells in each hydrogeologic regime in the Updated Subsurface Database for Bear Creek Valley, Chestnut Ridge, and Parts of Bethel Valley on the U.S. DOE Oak Ridge Reservation (CNS, 2019). A detailed description of the hydrogeologic framework at Y-12 can be found in the GWPP Management Plan (CNS, 2018).

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

CONVERSION OF COAL WASTES AND MUNICIPAL SOLIDS MIXTURES BY PYROLYSIS TORREFACTION AND ENTRAINED FLOW GASIFICATION

Hundreds of millions of tons of underutilized high-ash, low-energy-density bituminous and anthracite waste coal can be found in the U.S. These stockpiles contribute to water pollution from leaching that is harmful to waterways downstream of the piles. Conventional circulating fluidized combustion power plants use this coal to generate energy but emit toxic trace metals into groundwater (e.g., lead, mercury, arsenic). In addition, refuse-derived fuel (RDF) including municipal solid waste (MSW), biomass, waste plastics, and industrial waste are an enormous and untapped resource that is currently filling landfills or incinerated for low-quality energy with poor emissions. Mainstream Engineering has developed a combined pyrolysis torrefaction entrained flow gasification (PT-EFG) process that utilizes combined waste coal and RDF to create an alternative energy source, increasing energy independence and security and reducing the environmental burden from coal mines and processing facilities. Mainstream’s self-sustaining PT process converts RDF into feedstocks that can be pulverized and handled like conventional coal, enabling combined RDF-waste coal co-feeding into an EFG. The EFG operates at temperatures high enough to slag the ash completely, destroying any residual polycyclic aromatic hydrocarbons (PAHs), converting ash into nonporous vitrified slag or non-leachable ash, and generating high-hydrogen syngas for power generation or liquid fuels. During Phase II, Mainstream successfully demonstrated PT of biomass and MSW into a coal-like feedstock, which was co-gasified with waste coal in an EFG in a combined PT EFG process

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Exploring Electrocatalysis of Methane on Transition Metal Surfaces

Methane is a potent greenhouse gas because it has a heat-absorbing ability that is 20 times stronger than the better-known carbon dioxide. It is also the dominant component of nature gas (>70%). Its current greenhouse effect is only second to carbon dioxide largely because of its relatively low atmospheric concentration. Alarmingly, however, the latter has seen a 1.5-time increase since 1750, mainly due to anthropogenic livestock farming, coal and natural gas mining, and organic matter decomposing in waste landfills. Mitigating such a trend effectively and efficiently is therefore highly desirable and intensely sought for. This final technical report describes some exciting research progresses made over the last three years supported financially by the aforementioned award. The research conducted focused on exploring electrochemical direct methane to methanol (DMTM) conversion under mild conditions. The goal of research was to explore the possibility of developing potentially game-changing electrocatalysts and electrocatalysis that can convert methane directly to methanol in a most sustainable way for curbing its effect on global warming. Progress has been made in the following three directions. First, by adapting a hydrogen fuel-cell configuration that enables gaseous methane to be transported directly to the electrocatalyst surface, we have overcome the perennial difficulty in measuring activity of methane electro-oxidation at low temperature and ambient pressure that has prevented any meaningful studies of electrocatalysis of methane conversion thus far. Second, we have developed a novel and operational in situ electrochemical infrared (IR) spectral cell for studying electrocatalysis of direct methane to methanol conversion. This novel cell is also expected to alleviate the measuring difficulty caused by low solubility of methane in aqueous electrolyte and low sticking coefficient for methane adsorption onto transition metal surface. It will improve significantly the IR’s signal to noise ratio. Third, we have successfully synthesized nano-sizing copper (Cu) exchanged zeolite mordenite (Cu-ZMOR) and coated it with carbon that enabled electrochemical access to the encaged Cu ions. This opens a door to unravel the chemistry of Cu ions in catalyzing direct methane to methanol conversion under mild experimental conditions. Altogether, these progresses achieved have laid a solid foundation for further exploring electrocatalysis of direct methane to methanol conversion in general where there exists “a plenty of room” for new discoveries and developments.

03 NATURAL GAS↗

DOE OSTI2021

Igiugig Site Visit Report

The National Renewable Energy Laboratory (NREL) team conducted a site visit during January 23-25, 2019 with the Igiugig Village Council (IVC) and other stakeholders to assist the community of Igiugig in refining their long-term energy strategy. The agenda included a tour of the village, data collection, presentations, long-term visioning exercises, identification of energy scenarios, and a school presentation. Participants in the site visit activities spanned a range of local, regional, government, and industry participation. There were 24 attendees at the all-day community workshop on Thursday, January 24th, with participants from the IVC, NREL, Bristol Bay Native Association (BBNA), Bristol Bay Native Corporation (BBNC), Lake and Peninsula Borough, Alaska Energy Authority, Intergrid, ORPC, Deer Stone Consulting, the Southwest Alaska Municipal Conference, and University of Alaska Fairbanks - Alaska Center for Energy and Power. Igiugig is a well-organized rural Alaskan community, with a leadership team that appears to have broad community support. The use of consensus-based decision making is one tangible example of how the leadership team actively invokes and promotes community-focused thinking. The NREL team observed anecdotal evidence of how this approach seems to be strengthening the community: active participation in the visioning exercise, a student hosted fund-raiser dinner at the school, a clean and organized landfill, and well-maintained roads and buildings. Igiugig has wind, solar, and river hydrokinetic resources readily available within the community. Wind has shown to be a promising resource in the region, and has been integrated into microgrids around the state, but the community has had mixed success with wind technologies: some devices failed quickly and others continue to operate. The economics of solar energy are improving in Alaska, and economical solar projects are being installed around the state. Considering that economic activity in Igiugig peaks during the summer sport fishing season, solar could prove to be a valuable supplement to the electrical system. Igiugig has been a test site for two different river hydrokinetic devices, and they have began a third project to operate ORPC's RivGen device, which is delivering valuable device performance data, operations and maintenance experience, and design refinement information. Already, this device has made over 7-million revolutions, and delivered over 8 MWh of power to the community. Igiugig's river resource is fairly unique because it is available year-round and has the potential to provide reliable base-load power for months at a time. A preliminary investigation of this diverse resource mix suggests that Igiugig could achieve very high levels (70% or more) of annual renewable generation contributions. A critical step in pursuing this path is identifying the mix of energy assets (generation and storage) that best meets the community's budget, needs, and goals. The assets that a community installs early in their grid-modernization initiative can constrain the options that are economical at later stages, which may lead to sub-optimal solutions. This is where technical and economic analysis of potential scenarios (i.e., distinct mixes of energy assets) can be useful in identifying the most promising pathways so that a community can make informed and strategic decisions about the assets they install. These analyses are most accurate and informative when they are based on actual technology performance and cost data. As the RivGen project continues to operate and generate this data, we will be better prepared to evaluate the technology's long-term viability and to identify research areas that would improve it. Igiugig's energy projects are at the cutting edge of two intersecting technology areas: 1) deploying an operational river hydrokinetic turbine, and 2) integrating renewable energy sources to achieve very high percent renewables. If these projects are successful, the lessons learned and technologies developed could be valuable for other microgrids around the world. Igiugig's unique resource mix make it an ideal location for this work, and the community's organizational strength make it an ideal partner in this ground-breaking work. Ongoing support for technical assistance to manage and address technical challenges along the way will maximize the probability of project success.

13 HYDRO ENERGY↗

DOE OSTI2021

Preliminary Environmental and Financial Viability Analysis of Circular Economy Scenarios for Satisfying PV System Service Lifetime

PV deployment has grown rapidly in recent decades, and this growth is expected to continue. At the same time, the rapid increase in PV panel efficiencies offers the opportunity to repower/revamp existing installations - replacing operational, lower-efficiency panels before the end of their 30-year service lifetime with newer, higher-efficiency panels. As a result, an increasing volume of PV panels could be decommissioned well before reaching the end of their 30-year service lifetime. Two broad strategies can be applied to manage the expected increase in decommissioned PV panels: (i) recycle prematurely decommissioned panels, and (ii) prevent recycling of these panels by satisfying the typical service lifetime of 30 years through circular economy strategies such as repair and reuse. Each strategy presents an environmental and economic trade-off. Retaining and satisfying the lifetime of the older, lower-efficiency panels avoids environmental burdens from recycling or landfilling but incurs burdens from additional repair and forgoing the opportunity to install newer panels with greater electricity-generation capabilities. This study assesses whether satisfying the expected service lifetime of a PV system through circular economy scenarios generates a greater environmental and financial benefit than recycling used panels and installing newer panels with higher efficiencies. The circular economy scenarios include repair and reuse of the PV system. Specifically, the study determines whether it is better for the environment to keep a PV panel in use for its 30-year service life after accounting for potential repair and additional transportation, or to replace older panels with more efficient new ones. In addition, we explore whether satisfying the service lifetime of PV panels proves competitive with the recycling route from a financial perspective.

14 SOLAR ENERGY↗

DOE OSTI2022

High Yield, Economical and Environmentally Benign Production of Rare Earth Elements from Coal Ash [Abstract]

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2022

Multiple Stream Low-Cost Recycling Method

The global composite industry generates large quantities of waste and which mostly end as landfill due to lack of meaningful end-use applications for the multiple waste streams. In a recent report by the Electric Power Research Institute (EPRI), waste generated by the wind industry could reach 370,000 tons a year of composite wind energy blades being decommissioned and scrapped. Wind energy is just one major industry utilizing composite materials. The waste generated by industry includes End-of-Life (EoL) materials and manufacturing process scrap. GreenTex Solutions has developed a unique and innovative technology to recycle the composite waste streams in a range of forms made from production waste and EoL materials. This includes manufacturing waste materials such as dry chopped fiber tow, loose fibers, shredded fibers from reinforcement fabrics, cured/semi-cured prepregs, and it also includes fully-cured composite structure waste (such as edge trims from cured parts) from manufacturing aircraft, automobiles, wind blades, boats, and composite cylinders (tanks). Current recycling methods involve recovering the structural fiber by removing the matrix resin through methods such as pyrolysis. The resulting fibers are used in injection molding or wet laid nonwoven mats and other usable forms. The GreenTex technology bypasses these intermediate steps to create the lowest possible recycling processing costs and the lowest embodied energy/CO2 emissions. The end-product from the GreenTex technology is a finished industrial composite part/application versus intermediate fibers or fabrics. The GreenTex manufacturing process enables cross-industry reuse of recycled feedstock by taking waste from multiple industries (wind energy, aerospace, marine, etc.) and recycles the waste into a product used in other industries. The initial target market application is structural flooring for intermodal shipping containers and truck bodies. One of the team’s key partners is Wabash National which produced 29,000 truck bodies in 2019. The current flooring system is comprised of solid oak “butcher board” laminated panels. Additionally, Mediterranean Shipping Containers (MSC) transports over 1.8 million twenty-foot equivalent units per year in intermodal shipping containers. The current container floor is laminated hardwood that is harvested from the rain forests of Central and South America. The project is to develop a flooring system made from recycled composites that can be qualified for both companies (Wabash and MSC). Initial prototypes validated that the recycled composites panels are lighter and thinner with much higher mechanical strength. These results suggest a typical truck trailer would have 20% lower tare weight. The GreenTex technology is not limited to flooring and is widely applicable to other transportation elements such as walls, roof elements, cab areas and related structural components. Under this project different composite waste streams were evaluated and then combined to develop a formulation that would meet the targeted performance criteria for a flooring system. Wet compression molding was used to fabricate plaques at different tonnage using various composite waste streams. The plaques were tested for flexure and impact.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Highly Recyclable Thermosets for Lightweight Composites: CRADA 517 [Abstract only]

Lightweight composites are of increasing need to enable reduced fuel usage, reduced carbon emissions and increased range in air and ground transportation. The superior weight savings of carbon fiber thermoset composites are impeded by material and production costs and the limited options available for composite repair and recycle. The materials recovery and recycling sector is currently overwhelmed by an abundance of low-value materials and limited market opportunities for downcycled content, rendering landfilling a more attractive alternative. Vitrimers represent a new paradigm for repairable and recyclable thermosets, but this relatively new technology will require development, including government investment, to reduce risks for its adoption by aerospace and automotive OEMs. The overall goal of the project is to create recyclable carbon fiber composites using vitrimer resins that are more energy efficient to produce and have improved properties over baseline technology. The targeted composites will retain their tensile strength after multiple recycling and reprocessing steps. In addition, monomer will be recoverable through depolymerization and re-usable carbon fibers will be retrieved.

36 MATERIALS SCIENCE↗

DOE OSTI2022

High Yield, Economical and Environmentally Benign Production of Rare Earth Elements from Coal Ash (Phase II Final Summary Report)

Fly ash stored in landfills and ponds across the United States is an attractive, abundant domestic resource for the cost-effective recovery of rare earth elements (REE) and other critical minerals (CM). Physical Sciences Inc. (PSI) and its team members, Winner Water Services (WWS) and University of Kentucky/Center for Applied Energy Research (UK/CAER) successfully executed a multiphase program that developed technologies and their implementation in a pilot plant. We demonstrated plant operations for cost-effective and environmentally-friendly production of rare earth element oxide (REO) concentrates, and the critical minerals scandium and aluminum (in the forms of salts or oxide products), from coal ash. We also constructed and demonstrated a research-scale (0.5 kg/day) micropilot facility to validate the key physical and chemical processing operations, predict yields, and troubleshoot process bottlenecks. The project team then designed, constructed and operated two decoupled pilot plants: (1) an operational pilot plant for physical separation processes with capacity of 0.4 metric tons per day (tpd), where we optimized processes to produce selected ash fractions as the feedstock for chemical processing and as valuable byproducts such as cenospheres, magnetic ash, and secondary fuel carbon, and (2) an operational pilot plant for chemical ash processing with a capacity of 0.5 tpd that developed optimized processes for the production of: (a) REO concentrates, (b) critical minerals (Sc, Al), and (c) beneficiated ash as a valuable byproduct suitable for cement applications. In Phase I, the project team (with Equinox Chemicals in place of WWS) developed and demonstrated the feasibility of the physical and chemical separation processes, developed the design of a pilot plant, and began the development of a preliminary techno-economic model. In the baseline (initial) Phase II program, the project team developed and demonstrated the above pilot scale plant, producing salable REE concentrates, including Y and Sc (REYSc), plus commercially viable byproducts, using environmentally safe and high-yield physical and chemical enrichment processes. The team successfully demonstrated chemical pilot design, construction, shakedown, and operations of the plant. We produced the Phase II deliverable REYSc concentrate ((50 g of >60 wt.% purity REYSc salts on elemental basis), generated the feed for the Phase II follow-on program, identified processing challenges for future optimizations, and refined the techno-economic model. In the Phase II follow-on program, the project team: (1) developed and demonstrated processes to increase the REE amount by 3X (content basis) and convert the Phase II REE salt mixture to an oxide mixture, (2) produced/delivered >38 g of REO mixture with >85 wt.% purity (elemental basis); (3) developed processes to recover critical minerals scandium and aluminum from intermediate streams; (4) produced/delivered > 1 g of scandium salt mixture with >85 wt. % purity (elemental basis); (5) produced/delivered > 100 g of aluminum oxide type material with >70% wt. purity (elemental basis); and (6) updated the techno-economic model from the baseline Phase II program to assess CAPEX and OPEX of a commercial operation. This program has developed extensive databases on process chemistry, unit operations, plant engineering, and techno-economics that will enable further scale-up toward commercial plant design. Specific future developments will be focused on achieving dramatic savings in energy, reagent usage, and operating costs. The combined results will contribute significantly for maturing the technologies of REE recovery from coal byproducts and promote the establishment of domestic REE and CM supply chains.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2022

Life Cycle Analysis and Life Cycle Costing for Municipal Solid Waste (MSW) Management and Materials Redeployment to Support ARPA-E’s Potential Program on Waste to Energy and Materials

Municipal solid waste infrastructure in the United States contains complex supply chains to transport, sort, and sequester waste. This project developed models to estimate the environmental and economic costs of waste infrastructure in the U.S. using data from several municipalities. Life cycle costing (LCC) models were developed for waste management relevant supply chain steps, including waste collection, sorting, landfilling, waste-to-energy, ash processing, and recycling. A waste-to-materials and energy (WTM&E) life cycle analysis (LCA) and LCC dashboard was developed in collaboration with Argonne National Laboratory (ANL) and an LCC tool was developed for additional analysis.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2021

The Institute for Advanced Composites Manufacturing and Innovation Circular Economy for Wind Workshop Report

Wind turbine blade waste is anticipated to amount to approximately 2.2 million tons or more by 2050 (more than the equivalent weight of 6 empire state buildings). However, no existing recycling technologies for the composites in wind turbines are currently at cost-parity with landfilling. As such, there is little industrial drive to recycle these materials, so they are currently buried. If it were possible to develop a circular economy for wind blades it could directly reduce material feedstock costs for many composites industries, facilitate the tremendous, anticipated growth of the domestic off-shore wind energy sector, and help the U.S. achieve net-zero manufacturing and energy generation. However, to enable circular economies for wind blades, several questions need to be answered.

17 WIND ENERGY↗

DOE OSTI2022

Wastewater Recycling Using a Hygroscopic Cooling System

This project by the Energy & Environmental Research Center (EERC), Baltimore Aircoil Company (BAC), and Great River Energy (GRE) evaluated the concept of recycling wastewater at a coal-fired power plant using a hygroscopic cooling system, which is an evaporative cooling technology analogous to conventional cooling towers, except that sparingly soluble dissolved solids are precipitated and removed as waste solids instead of purging them with a liquid blowdown stream. This technology can maximize the use of plant makeup water by obtaining useful evaporative cooling from wastewater while minimizing the volume of wastes needing disposal. Experimental activities were conducted in two phases, a laboratory-based evaluation of the properties of wastewater from the host site, GRE’s Coal Creek Station near Underwood, North Dakota, and a field test of a small pilot hygroscopic cooling system at the host site power plant. Findings from the laboratory study informed the design of the pilot system and the system’s field test performance served as the basis for a techno-economic analysis (TEA) of the hygroscopic recycling concept. At the preferred operating conditions identified during the TEA, the wet-bulb approach temperature of the tower was 7.3°C (13°F) and the volume of blowdown produced by the plant was reduced to 5.4% of its incoming volume. Waste solids produced during field testing were classified as nonhazardous waste based on the measured hazardous element content and evaluation of their leaching potential. However, to qualify as a solid for landfill disposal i.e., as determined by the U.S. Environmental Protection Agency’s paint filter test, it appears that a dewatering step beyond hydrocyclone separation is needed. The baseline levelized cost of wastewater disposal (LCWD) for hygroscopic wastewater recycling was estimated to be $\$ $3.69–$\$ $3.72 per m3 of plant blowdown. Capital cost was estimated to contribute over 54% to the LCWD, and parameters that impact capital cost such as the heat exchange coil material of construction and the tower’s wet-bulb approach temperature were identified as having the greatest impact on overall LCWD. A LCWD estimate prepared for the same application but using thermomechanical brine evaporation was almost 40% higher than that calculated for hygroscopic cooling, despite recovering distilled-quality water for reuse, while the LCWD for disposal-only, deep well injection was estimated to be 30% lower compared to hygroscopic wastewater recycling.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2022

Elucidating Arsenic and Selenium Speciation in Coal Fly Ashes

Coal fly ash (CFA) is produced during the coal combustion process and contains trace elements (<100 ppm) including selenium (Se) and arsenic (As), both detrimental for environmental and human health. Existing management strategies for CFAs involve disposal in landfills and ash ponds, as well as beneficial usage in other applications such as in concrete. Both the direct disposal and beneficial usage of CFA raise concerns for environmental hazards due to the potential leaching of Se and As. CFAs were classified as reusable material by the U.S. Environmental Protection Agency (EPA) with the first federal regulation (Disposal of Coal Combustion Residuals from Electric Utilities, CCR) for its disposal established six years ago. During coal combustion process, parameters such as furnace firing type, emissions controls, coal rank, use of additives, and particulate matter controls, could contribute to significant variability in As/Se concentrations and their speciation. Although there have been a handful of studies on As/Se speciation on small sets of samples, they do not fully represent the current state of coal-fired electrical generating units. Little information exists on the detailed speciation (e.g. oxidation state, complexation state) of As/Se in large set of fly ash samples. To better investigate the role of the potential contributing parameters, a large-scale survey study with representative samples of typical coal source and combustion conditions is highly desired. The overall goal of this research is to systematically characterize As and Se speciation of representative coal fly ash samples using state-of-the-art synchrotron based spectroscopic and microscopic techniques, in order to develop a correlation between coal source/type, operation condition, As/Se speciation, and As/Se mobility. A detailed survey study was conducted documenting the current state-of-knowledge on fossil power generating units as a function of coal type/source, operating conditions, environmental control systems, additive use, and fly ash handling methods. Based on this survey, a matrix of fly ash samples representing a range of conditions were chosen and collected. The collected ash samples were analyzed for bulk characteristics such as elemental composition, microstructure, chemical and mineralogical composition, surface area, and particle size distribution. State-of-the-art synchrotron X-ray microscopy and spectroscopy techniques were applied to reveal the molecular scale speciation information of As and Se, such as oxidation state, association with other elements/minerals, and complexation states.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2022

Performance and Cost Potential for Exemplar Direct Supercritical Carbon Dioxide Natural Gas Plants

This report presents the techno-economic analysis (TEA) optimization results of natural gas-fired utility-scale power plants based on the direct supercritical carbon dioxide (sCO 2 ) power cycle. To identify optimum plant configuration, the study also considered three different cases (Case A, Case B, Case C) with varying levels of thermal integration with the plant air separation unit (ASU). A fourth case (Case D), which is based on a patent from 8 Rivers, was also considered and includes thermal integration with the ASU as well as compressed recycle carbon dioxide (CO 2 ) gas. The four direct sCO 2 power plants offered similar or slightly higher plant efficiencies than the reference NGCC plants based on an F-class gas turbine with carbon capture and storage (CCS). LCOE of the direct sCO 2 plants is 13.5–17.2 percent higher than the reference NGCC plants with CCS due to higher capital costs associated with the ASU and sCO 2 power block. Recuperators make up over 50 percent of the power cycle costs. Consequently, any research and development (R&D) efforts to reduce the recuperator capital costs will be beneficial for the technology commercialization. The study also investigated the impact of co-firing landfill gas (LFG) and natural gas on plant efficiency, LCOE, and CO 2 emissions. Increasing the LFG co-firing from 0 percent to 50 percent (mass basis), decreased the plant efficiency by 0.3 percentage points and increased the LCOE by 3 percent. Due to high inherent CO 2 capture rates, direct sCO 2 plants have strong potential to achieve net-zero CO 2 emissions with LFG and natural gas co-firing.

03 NATURAL GAS↗

DOE OSTI2023

Idaho National Laboratory’s FY 2021 Greenhouse Gas Report

A greenhouse gas (GHG) inventory is a systematic approach to account for the production and release of certain gases generated by an institution from various emission sources. The gases of interest are those that climate science has identified as related to anthropogenic global climate change. This document presents an inventory of GHGs generated during Fiscal Year (FY) 2021 by Idaho National Laboratory (INL)—a Department of Energy (DOE) sponsored entity located in southeastern Idaho. In recent years, concern has grown about the environmental impact of GHGs. This, together with a desire to decrease harmful environmental impacts, would be enough to encourage the calculation of an inventory of the total GHGs generated at INL. Additionally, INL has a desire to see how its emissions compare with similar institutions, including other DOE national laboratories. Executive Order 13834 requires that federal agencies and institutions track and report GHG emissions where required. INL’s GHG inventory was calculated according to methodologies identified in federal GHG guidance documents using operational control boundaries. It measures emissions generated in three scopes: (1) INL emissions produced directly by stationary or mobile combustion and by fugitive emissions, (2) the share of emissions generated by entities from which INL purchased electrical power, and (3) indirect or shared emissions generated by outsourced activities that benefit INL (occurring outside INL’s organizational boundaries but are a consequence of INL’s activities). This inventory found that INL generated 81,185.05 metric tons (MT) of CO 2 equivalent (CO 2 e) emissions during FY 2021. The following conclusions were made from looking at the results of the individual contributors to INL’s FY 2021 GHG inventory: Electricity (including the associated transmission and distribution losses) is the largest contributor to INL’s GHG inventory, with over 50% of the CO 2 e emissions; Other sources with high emissions were mobile combustion (fleet fuels), employee commuting, stationary combustion (facility fuels), and waste disposal (fugitive emissions from the onsite landfill); Sources with low emissions were waste disposal (contracted disposal), fugitive emissions from refrigerants, wastewater treatment (onsite and contracted), and business ground travel (in personal and rental vehicles). This report details the methods behind quantifying INL’s GHG inventory and discusses lessons learned on better practices by which information important to tracking GHGs can be tracked and recorded. It is important to note that because this report differentiates between those portions of INL that are managed and operated by Battelle Energy Alliance, LLC (BEA) and those managed by other contractors, it includes only INL’s activities overseen by BEA. It is assumed that other contractors will provide similar reporting for those activities they manage, where appropriate.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Idaho National Laboratory’s FY 22 Greenhouse Gas Report

A greenhouse gas (GHG) inventory is a systematic approach to account for the production and release of certain gases generated by an institution from various emission sources. The gases of interest are those that climate science has identified as related to anthropogenic global climate change. This document presents an inventory of GHGs generated during fiscal year (FY) 2022 by Idaho National Laboratory (INL)—a Department of Energy (DOE) sponsored entity located in southeastern Idaho. In recent years, concern has grown about the environmental impact of GHGs. This, together with a desire to decrease harmful environmental impacts, would be enough to encourage the calculation of an inventory of the total GHGs generated at INL. Additionally, INL has a desire to see how its emissions compare with similar institutions, including other DOE national laboratories. Executive Order 14057 requires that federal agencies and institutions track and report GHG emissions where required. INL’s GHG inventory was calculated according to methodologies identified in federal GHG guidance documents using operational control boundaries. It measures emissions generated in three scopes: (1) INL emissions produced directly by stationary or mobile combustion and by fugitive emissions, (2) the share of emissions generated by entities from which INL purchased electrical power, and (3) indirect or shared emissions generated by outsourced activities that benefit INL (occurring outside INL’s organizational boundaries, but are a consequence of INL’s activities). This inventory found that INL generated 75,572.42 metric tons (MT) of CO2 equivalent (CO2e) emissions during FY 2022. The following conclusions were made from looking at the results of the individual contributors to INL’s FY 2022 GHG inventory: • Electricity (including the associated transmission and distribution losses) is the largest contributor to INL’s GHG inventory, with over 50% of the CO2e emissions. • Other sources with high emissions were mobile combustion (fleet fuels), employee commuting, stationary combustion (facility fuels), and waste disposal (fugitive emissions from the onsite landfill). • Sources with low emissions were waste disposal (contracted disposal), fugitive emissions from refrigerants, wastewater treatment (onsite and contracted), and business ground travel (in personal and rental vehicles). This report details the methods behind quantifying INL’s GHG inventory and discusses lessons learned on better practices by which information important to tracking GHGs can be tracked and recorded. It is important to note that because this report differentiates between those portions of INL that are managed and operated by Battelle Energy Alliance, LLC (BEA) and those managed by other contractors, it includes only INL’s activities overseen by BEA. It is assumed that other contractors will provide similar reporting for those activities they manage, where appropriate.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Organic Evaporation, Oxidation, and Hydrolysis Testing in Support of Hanford Sample-and-Send

The Hanford site has approximately 56 million gallons of radioactive mixed waste stored in 156 unretrieved underground storage tanks. The Hanford Waste Treatment and Immobilization Plant (WTP) is being built to treat and immobilize the tank waste. The baseline method for immobilization of Low Activity Waste (LAW) through the WTP is vitrification, but additional immobilization capacity is needed to supplement the initial LAW melters. An alternative cementitious waste form is being investigated for that future immobilization method. However, one impediment to a cementitious waste form is the presence of Land Disposal Restricted (LDR) organic chemicals in tank waste, which are regulated on a concentration-based standard in the final waste form. Hence, if the quantity of organics in LAW is high enough, they must be destroyed or removed to make a waste form compatible with disposal in a mixed low level waste landfill. This work evaluates potential avenues for treatment of LDR organics to eliminate the impediment and permit possible use of a cementitious waste form.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗