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DOE OSTI2024

Bench-scale Development of a Transformational Graphene Oxide-based Membrane Process for Post-combustion CO 2 Capture

Graphene-based materials, such as graphene and graphene oxide (GO), have been considered as next-generation membrane materials. GTI Energy and The State University of New York at Buffalo (UB) have been developing a transformational GO-based membrane process (designated as GO2) that integrates a high CO 2 /N 2 selectivity membrane (GO-1) and a high CO 2 flux membrane (GO-2) for post-combustion CO 2 capture. An innovative membrane structure, consisting of GO nanochannels intercalated by single-walled carbon nanotube (SWCNT), was developed. The membrane prepared on hollow fiber substrate showed CO 2 permeance as high as 1,300 GPU with CO 2 /N 2 selectivity >200. The membranes were successfully scaled up to effective area of 50-100 cm 2 . The 50-100 cm 2 membranes showed CO 2 /N 2 selectivity ≥200 and CO 2 permeance ≥1,000 GPU for the GO-1 type, and CO 2 /N 2 selectivity ≥20 and CO 2 permeance ≥2,500 GPU for the GO-2 type. The CO 2 capture performance of the GO-based membranes was tested using a simulated flue gas. The testing results indicate that the GO-based membranes are stable in the presence of flue gas contaminants. The GO-based membranes were then further scaled up to a surface area of 1,000 cm 2 . Good stability was achieved during an integrated testing with GO-1 and GO-2 membranes using simulated flue gas. A bench-scale system was designed, constructed, and tested at the National Carbon Capture Center (NCCC). Good stability was achieved during testing of a single-stage process with >10 shutdowns/startups at NCCC. During the integrated testing, the membranes showed good stability at 50°C and 57°C. 70-90% CO 2 removal efficiencies and ≥95% CO 2 purity were validated during the steady state operation at NCCC. Techno-economic analysis indicates the GO2 membrane-based process technology provides a reduction in both the levelized cost of electricity (LCOE) and cost of capture when compared to the reference B12B case presented in the Cost and Performance Baseline for Fossil Energy Plants Volume 1: Bituminous Coal and Natural Gas to Electricity study prepared by the National Energy Technology Laboratory (NETL), before considering any system optimization or improvement opportunities. The benefits are primarily driven by a reduction in the equipment costs of the CO 2 capture process vs. the solvent-based reference process in NETL Case B12B as well as a decrease in the base plant size.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2021

Flattening the Radial Temperature Profile across the Transformational Challenge Reactor Core

The Transformational Challenge Reactor (TCR) program is demonstrating an agile development approach to advanced nuclear reactor design, which has traditionally utilized a linear design process. In leveraging artificial intelligence, additive manufacturing, advanced materials, and cutting-edge modeling and simulation, the TCR program aims to minimize the high cost and lengthy deployment timelines now standard in the nuclear industry. Within a relatively short period of time, a robust and mature advanced gas-cooled reactor was iteratively designed under the TCR program, using these cutting-edge technologies. The TCR is a 3 MWt gas-cooled microreactor fueled with uranium nitride (UN) tristructural isotropic (TRISO) fuel particles. Though manufactured via traditional means, these UN TRISO particles are loaded into additively manufactured silicon carbide (SiC) cans [4]. Once loaded with TRISO particles, the SiC cans are densified using a chemical vapor infiltration process. The additively manufactured SiC enables significantly more freedom in the design of the fuel form than could ever be achieved using traditionally manufactured SiC. The helium coolant, pressurized to 5 MPa, enters the core at 300°C and nominally exits it at 500°C. Typically, the most thermally limiting components in any reactor design are the fuel assemblies in the core center. To provide a wide thermal margin in these central fuel assemblies, the flow may be biased toward the center of the core to more effectively cool these fuel assemblies with more power deposition and flatten the core’s radial temperature distribution. An analytical fluid model of the TCR core was developed to explore methods for biasing the flow away from the cooler outer fuel assemblies and towards the hotter inner ones. Higher-fidelity models developed in STAR-CCM+ 2020.3.1, a computational fluid dynamics code, were then utilized to verify the analytical model’s findings.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2026

A mathematical design framework for membrane pre-concentration in energy-efficient recovery of fermentation products

Due to the dilute nature of products manufactured via fermentation and cell-free bioprocessing, dewatering is a common unit operation in downstream processing (DSP) for bioproduct recovery, but it is typically energy intensive. To improve DSP energy efficiency for bio-based small molecules, integrating high-pressure membrane pre-concentration is a promising process option. However, this approach is typically constrained by a tradeoff between concentration factor (CF) and product recovery (PR), namely increasing the CF typically results in greater product loss, and vice versa. Here we developed a model that enables process design guidelines to: (i) identify scenarios in which the additional energy consumption and product loss from membrane pre-concentration are justified for use in DSP, and (ii) determine the optimal CF that minimizes process specific energy consumption. We compared the energy consumption of high-pressure membrane-integrated processes to evaporation-only processes and applied the model to an experimental case study for the separation and purification of butyric acid from Clostridium tyrobutyricum fermentation using an in situ product recovery (ISPR) process. The model estimated that integrating a tangential-flow reverse osmosis (RO) pre-concentration unit could reduce process energy consumption up to 45%. The use of advanced membrane pre-concentration technologies, such as negative rejection membranes and organic solvent reverse osmosis (OSRO), have the potential to further reduce the overall process specific energy consumption up to 96%, projected based on modeling. Overall, membrane pre-concentration, especially when strategically integrated prior to an evaporation step with optimized process conditions, holds significant potential for improving DSP energy efficiency, particularly in applications requiring substantial solvent removal for product recovery from dilute mixtures.

09 BIOMASS FUELS↗

DOE OSTI2026

Fluorescence Signatures of Rare Earth Metals during Precipitation in Various Conditions

Fluorescence spectroscopy is a widely used sensor methodology that analyzes light emitted from a compound or element as it decays from an excited state. This technique is very sensitive and selective, which is ideal to characterize analytes at lower limits of detection. Key example targets of significant industry and research interest include rare earth elements (REEs) such as dysprosium (Dy) and europium (Eu). These are widely used in advanced technologies including semiconductors, electric vehicle motors, lasers, and permanent magnets. Identifying new sources and responsible reutilization of REEs is essential, and new approaches to extract and recycle REEs could be notably enhanced through the integration of on-line sensors. The sensors can support faster process design, informed scale-up, and cost-effective deployment. This study covers the initial exploration of applying fluorescence-based on-line monitoring to REEs within a precipitation process. This study demonstrates the successful scale-up of a fluorescence -based sensing approach, from stationary cuvettes and small-volume microfluidic devices to continuous flow systems operating at the bench scale (10-25mL). This work also provides initial insight into the challenges of signal’s effects and utility within a turbid environment. Using a modular design for monitoring flowing solutions in a flow tube, fluorescence can be characterized for a variety of analytical targets. In this study, detection performance parameters between the cuvette and flow tube system were compared. Additionally, the response of Dy during precipitation by sodium bicarbonate in the two measurement designs was explored. This letter represents a starting point to bridge the gap between traditional fluorescence sensor measurements in a cuvette to future developments that explore the ability to integrate fluorescence sensors into extraction and separation processes at industrially relevant scales.

fluorescence↗

DOE OSTI2023

Design, scaling and cost evaluations of circulating fluidized-bed systems for biomass pyrolysis

To generate updated and transparent capital cost estimates for biomass fast pyrolysis equipment, refinery fluidized catalytic cracking design and sizing principles are examined and extended to pyrolysis of woody biomass. Capital costs for the sized equipment are estimated with process-industry software. A one-dimensional flow simulation with pyrolysis kinetics is leveraged to validate the fluidization conditions and thermal energy balance. After successful sizing and a system cost estimate of $\$$2.8 M (in 2016 US$\$$) at the biorefinery scale of 1000 metric tons per day (MTD), these methods were exercised for even smaller equipment at the distributed pyrolysis scale with modifications to the process design constraints, and not directly comparable with the 1000 MTD case, arriving at capital cost estimates of $\$$1.2 M for a 500 ton/day system and $\$$0.9 M for a 200 ton/day system. Here in this work, It is noted that this work only estimates purchased equipment costs at the ±50% accuracy level; there are significant other custom factors applicable to each installation based on location, maturity, scale, complexities during installation, engineering and licensing costs, etc. that need to be added on to these estimates to derive investment costs.

09 BIOMASS FUELS↗

DOE OSTI2020

Microgrid Design Toolkit (MDT) User Guide. Software v1.3.

The Microgrid Design Toolkit (MDT) supports decision analysis for new ("greenfield") microgrid designs as well as microgrids with existing infrastructure. The current version of MDT includes two main capabilities. The first capability, the Microgrid Sizing Capability (MSC), is used to determine the size and composition of a new, grid connected microgrid in the early stages of the design process. MSC is focused on developing a microgrid that is economically viable when connected to the grid. The second capability is focused on designing a microgrid for operation in islanded mode. This second capability relies on two models: the Technology Management Optimization (TMO) model and Performance Reliability Model (PRM).

42 ENGINEERING↗

DOE OSTI2023

Semi-Annual Report for Horizontal Compact High Temperature Gas Reactor (HC-HTGR) Development during Performance Period October 2022-March 2023

Horizontal Compact High Temperature Gas Reactor (HC-HTGR) is being designed by a multi-disciplinary team of nuclear, mechanical, and structural engineers under the support of a DOE-NE Advanced Reactor Demonstration Program’s Advanced Reactor Concepts-20 (ARC-20) award. The objective of this ARC-20 project is to deliver a conceptual design for the proposed HC-HTGR in 3 years and support its commercialization as a safe, low-cost HTGR. Argonne National Laboratory (Argonne) is responsible for the design and analysis of the reactor cavity cooling system (RCCS) as a safety system for passive decay heat removal of the reactor concept. Additionally, Argonne is providing analysis of the primary heat transport system to ensure temperatures in the reactor systems, structures and components with significant safety margins during normal operation and design basis accident scenarios. This third semi-annual report summarized the progress made at Argonne on the two tasks during the first half of FY23. As a part of the RCCS design task, a design process for the water panel and the system configuration was performed to improve the thermal performance of the RCCS. The updated water panel design had achieved enhanced thermal performance with 0.96 MWth capability with major design updates made in structural interfaces with the RPV and initial configuration of the water tanks. The loop configuration of the RCCS has been proposed to have two independently working loops for system redundancy. A water panel material study was performed focusing on the use of carbon steel in water systems. Additional modeling strategies of primary system thermal fluids analyses were developed to meet modeling needs that are not well suited for the 1D-3D assembly level approach. The first of these is a reduced order assembly model, in which fuel centered unit cells are used to represent a fuel assembly. The 2D approach used in this model is much more computationally efficient, making this model useful for full core transient scenarios where fuel to coolant heat transfer is still the dominant flow path. The next model is the 3D core conduction model to be used to analyze decay heat removal in loss of primary system flow scenarios. Because these scenarios require a large domain to be modeled, a homogenized core model is being pursued to reduce the required computational costs. To accurately model decay heat scenarios it is necessary to couple a RCCS model to the 3D core conduction model. A simplified case is presented to demonstrate how the coupling methodology will be applied to the full core 3D conduction model.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2023

Gas Separation Membrane Module Modeling: A Comprehensive Review

Membrane gas separation processes have been developed for diverse gas separation applications that include nitrogen production from air and CO2 capture from point sources. Membrane process design requires the development of stable and robust mathematical models that can accurately quantify the performance of the membrane modules used in the process. The literature related to modeling membrane gas separation modules and model use in membrane gas separation process simulators is reviewed in this paper. A membrane-module-modeling checklist is proposed to guide modeling efforts for the research and development of new gas separation membranes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Life Cycle Analysis of Electrofuels: Fischer–Tropsch Fuel Production from Hydrogen and Corn Ethanol Byproduct CO 2

Electrofuels from renewable H 2 and waste CO 2 streams are of increasing interest because of their CO 2 emissions reduction potentials compared to fossil counterparts. This study evaluated the well-to-wheel (WTW) greenhouse gas (GHG) emissions of Fischer-Tropsch (FT) fuels from various electrolytic H 2 pathways and CO 2 sources, using various process designs (i.e., with and without H 2 recycle) and system boundaries. Two systems with different boundaries were considered: a stand-alone plant (with CO 2 from any source) and an integrated plant with corn ethanol production (supplying CO 2 ). The FT fuel synthesis process was modeled using Aspen Plus, which showed that 45% of the carbon in CO 2 can be fixed in the FT fuel, with a fuel production energy efficiency of 58%. Using nuclear or solar/wind electricity, the stand-alone FT fuel production from various plant designs can reduce WTW GHG emissions by 90-108%, relative to petroleum fuels. When integrating the FT fuel production process with corn ethanol production, the WTW GHG emissions of FT fuels are 57-65% lower compared to petroleum counterparts. This study highlights the sensitivity of the carbon intensity of FT fuels to the system boundary selection (i.e., stand-alone vs integrated), which has different implications under various GHG emission credit frameworks.

08 HYDROGEN↗

DOE OSTI2023

PacWave South SeaRAY k2 Risk Registers

The SeaRAY is a deployable power system for maritime sensors, monitoring equipment, communications, unmanned underwater vehicles, and other similar payloads. This project is to design, deliver, and test a prototype low-power WEC that lowers the total cost of ownership and provides robust, new capabilities for customers in the maritime environment. Failure Modes, Effects, and Criticality Analysis (FMECA) is conducted to systematically identify all potential failure modes and their effects on the system, and to analyze the criticality of each risk based on the likelihood of the event and the severity of the impact. Actions may then be recommended to mitigate the criticality of a risk, either by reducing the likelihood of the risk or the severity of its impact. Risk assessment is executed iteratively as an integral part of the design process. By incorporating risk assessment early in the development cycle, mitigation of risk can be achieved cost effectively. The actions recommended to mitigate risk may be subsequently executed, and as the design progresses the risk assessment is reviewed and revised. Review of the risk assessment is integrated into structured design reviews, ensuring that critical risks are comprehended and that the Project will not progress to e.g. fabrication while intolerable risks remain. The risk assessment process results in the population and maintenance of Risk Registers (RRs). Each major system (and as needed, subsystem) will have a distinct RR. This allows each system or subsystem to be assessed individually, rendering the RRs to a manageable size for review.

16 TIDAL AND WAVE POWER↗

DOE OSTI2023

A Simplified Method to Evaluate Energy Life Cycle Cost Effectiveness for Electron Ion Collider Infrastructure Design

The new DOE Order 436.1A approved on April 25 th provides instructions to incorporate principles of sustainability early in the project planning and design process. Integral to the principles of sustainability is life cycle cost effectiveness Life Cycle Cost (LCC) Analysis is vital to the sustainable energy efficient design and construction of the Electron Ion Collider (EIC). Reducing energy consumption has a direct impact on reducing life cycle operating costs with benefits to the environment. The early stages of the project are the most influential where design decisions and so life-cycle considerations during this stage can result in significant impacts to the energy footprint of the design. For example, when comparing between various options, it is necessary to compare the energy savings in $\frac{US$}{kWh}$ to the capital cost in US$. And although uncertain by nature, it is important to factor in the expected inflation and discount of future spendings to compare with the cost of immediate capital investment. This tech note presents a tool that engineers can readily use to analyze energy operating costs using an incremental life cycle cost method when comparing different design alternative.

43 PARTICLE ACCELERATORS↗

DOE OSTI2020

ANDRA's Underground Research Laboratory in Bure: Major Role in the Cigeo Development - 20005

The Industrial Center for Geological Disposal, also called Cigeo, is the deep geological disposal facility project developed by Andra since 1991. It is intended for the final disposal of High-Level Waste (HLW) and Intermediate Level Waste-Long Lived (ILW-LL) generated in France by the nuclear industry. Cigeo is located in the east of France (Meuse/Haute-Marne site). The disposal will be implemented in a 140 to 160 m thick clay layer at about 500 m depth. The license application file will be submitted in 2020. If the license is granted, the construction of the pilot phase of Cigeo (ramp, shafts, drifts, initial disposal vaults) could start in 2025 at the earliest. Since 2000, the development of the safety case of Cigeo for post closure has been supported by a three-stage construction, design, and scientific and technological experiment program performed in the French Underground Research Laboratory (URL) in Bure. These stages of the URL activities supported the iterative interactions between the knowledge acquired by scientific and technological R and D program, the design process and the safety assessment. The stages focused on assessing the suitability of the disposal concept, providing the basis for safety options and construction design, and preparing for licensing using large scale demonstrations. Recently, Andra launched the fourth development stage of the URL to implement a new set of technological experiments aiming at consolidating the design options of disposal cells and galleries for the pilot phase of Cigeo and at assessing monitoring technologies. Recently, Andra launched the fourth development stage of the URL to implement a new set of technological experiments aiming at consolidating the design of the pilot phase of Cigeo and at assessing design options and monitoring technologies. Removal of a segment ring, construction of an X drift crossing, improved construction techniques for HLW vaults, and construction of an ILW-LL prototype disposal vault are example activities during the fourth phase. In the future, the URL in Bure will remain a unique location to carry out research on promising technical solutions, to reduce Cigeo's construction and operation risks and strengthen the long-term safety assessment. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2023

Approaches for Synthesis and Deployment of Controller Models on Automated Vehicles for Car-following in Mixed Autonomy

This paper describes the software design patterns and vehicle interfaces that were employed to transition vehicle controllers from simulation environments to open-road field experiments. The approach relies on a life cycle that utilizes model-based design and code generation, along with agile software development, and both software and hardware-in-the-loop testing, with additional safety margins. Autonomous designs should consider the dynamics of mixed autonomy in traffic to safely operate among humans. The software that provides a vehicle’s behavior intelligence is often developed through simulation, which may have a mismatch between dynamics, or as a result of a reinforcement learning workflow, which may be a black box with challenges to analyze. In each of these cases, it is important to have research interfaces that provide strongly typed data streams accessible to researchers who are not software experts while continuing to satisfy safety and liveness constraints. This paper describes how we design the hardware platform interfaces and software design process for a mixed autonomy traffic experiment with a leader-follower scenario. Controller synthesis for these vehicles requires clearly articulated vehicle interfaces and software design patterns for successful onboard deployment. Testing strategies for such controllers are also described before algorithms are transitioned to full-scale field experiments with safety operators for the vehicles. Testing strategies include software-in-the-loop simulation testing, hardware-in-the-loop simulation, ghost-car testing, and read-only testing in live traffic. With our approach, we were not only able to validate our controller synthesized in scripts and simulation, but also able to scale deployment to multiple vehicles.

Bhadani, Rahul↗

DOE OSTI2026

Bench-Scale Development of Promoted High-Capacity Structured Sorbents (Final Technical Report)

The project objective was to develop high-capacity structured sorbent capable of achieving low CO 2 removal from air. The sorbent framework consists of an amine-functionalized onto hydrophobic polymer backbone with an added promoter. The functionalized amine provides high CO 2 capacity and adsorption rates and the polymer backbone to reduce water uptake. For the sorbent development, multiple functionalized amines and promoters were assessed to select a candidate that achieved high CO 2 capacity, high adsorption rate, and high stability. A sorbent-coated filter design was selected as the structured sorbent, which provides high sorbent loading capacity and contains an electrically conductive nonwoven filter substrate that can be Joule-heated to provide efficient utilization of available electricity for sorbent regeneration. A commercial partner operated a pilot filter manufacturing line to produce the filter panels coated with the developed sorbent. A 1 kg CO 2 /day bench unit was designed and fabricated to test the structured filter sorbent. The key achievements from the structured sorbent development activity were demonstrating that existing filter industrial-scale processes can be used for manufacturing Susteon’s structured sorbent and completing a proof-of-concept demonstration of the commercially manufactured structured sorbent filters for CO 2 capture from air with direct, Joule-heated regeneration. A techno-economic assessment with sensitivity analysis was conducted on a 100,000 TPY facility with 85% operating capacity. Through sorbent optimization and process design improvements, it is estimated that the cost of capture was reduced from $\$$349/tCO 2 to $\$$241/tCO 2 . The TEA projects further reductions to $165/tCO 2 through enhancements in CO 2 adsorption rate and sorbent capacity and reducing manufacturing and scale up risks. A life cycle analysis was conducted on the same 100,000 TPY facility and confirmed that the facility’s electricity demand drives its greenhouse gas impact. It was determined that electricity supplied through the current grid mix would result in net-positive CO 2 emissions and that achieving net-negative emissions is only possible by powering the system with renewable electricity or fossil fuel sources equipped with carbon capture and sequestration.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Aerodynamic Sensitivities over Separable Shape Tensors

Here, we present a comprehensive aerodynamic sensitivity analysis of airfoil parameterization informed by separable shape tensors. This parameterization approach uniquely benefits the design process by isolating various well-studied shape characteristics, such as airfoil thickness, and providing a well-regulated low-dimensional parameter domain for aerodynamic designs. Exploring the aerodynamic sensitivities of this novel parameterization can provide valuable insights for more robust designs and future manufacturing efforts. We construct a data-driven parameter space of airfoils using principal geodesic analysis of separable shape tensors informed by a curated database containing almost 20,000 suitable engineering airfoils. Analyzing the shape reconstruction error and the maximum mean discrepancy between joint distributions of aerodynamic quantities, we study the dimensionality of the learned parameter space. This simple numerical experiment demonstrates a dramatic dimension reduction that retains design effectiveness and promotes regularity of the shape representations. Finally, we generate new airfoils and use the HAM2D Reynolds-averaged Navier–Stokes solver to predict lift, drag, and moment coefficients. We compute multiple sensitivity metrics to quantify and assert the consistency of parameter influence on the aerodynamic quantities. We also explore low-dimensional polynomial ridge approximations to motivate physical intuitions and offer explanations of the approximated sensitivities.

17 WIND ENERGY↗

DOE OSTI2023

Understanding the Uncertainty in the Technical Performance Level Assessment for Wave Energy

In recent years, the design and development of wave energy converters (WECs) has been explored with intense interest, with highly varying design concepts emerging globally across both research enterprises and industry. The design space for WECs is vast - many concepts ranging in functionality, control systems, power development systems, materials, and scale have been ideated and prototyped, but WEC technology has yet to converge. One critical element of the technology trajectory that governs the speed of adoption is the performance of a WEC concept. In analogous but more-established industries (such as aerospace, and environmentally sustainable electronics design), performance assessment is a quantitative method, based on historical data, that is used as an iterative tool to improve the design of these systems early on in the design process. Though more nascent than these approaches, in wave energy R&D, WEC performance has been assessed using the Technology Performance Level (TPL) assessment, which provides designers with a quantitative score, situating a grid-scale WEC concept on a scale from 1-9 (1 being the lowest performance, and 9 being the highest, trending with the oft-used Technology Readiness Level, or TRL). The TPL assessment is designed to be used during design iteration, when a WEC concept is fully ideated, to enable designers to consider potential means of improving the downstream performance of the concept. One concern that may be slowing the adoption of TPL among WEC developers is the inherent uncertainty in the assessment, and how uncertainty in the individual questions asked as part of the assessment may contribute to perceived inaccuracies in the final score. In this work, we explore the uncertainty present in the assessment and quantify this uncertainty using both traditional mathematical operations and a Monte Carlo simulation. Results imply areas of improvement of the TPL assessment, where reducing uncertainty will be most helpful to end users, enabling both TPL practitioners and users to understand with more accuracy those design elements that can be improved to impact device performance most substantively.

techno-economic analysis↗

DOE OSTI2025

Incorporation of Oxygen Carrier Recycle into Large-Scale Production of Cu-Based Oxygen Carriers

One of the greatest challenges in the chemical looping combustion (CLC) of solid fuels is developing an oxygen carrier material that is reactive and attrition resistant and can be prepared at a reasonable cost. Recent efforts in oxygen carrier development have followed two primary approaches: (1) using natural ores, such as ilmenite, or (2) developing highly attrition-resistant and reactive synthetic materials. Both approaches have shortcomings, namely, the low reactivity and incompatibility of ores with solid fuel CLC and the high cost and low durability of synthetic materials. Here, a different approach is taken where attrition is assumed inevitable and the recycling of spent oxygen carrier materials is incorporated into oxygen carrier manufacture. For solid fuel CLC, Cu-based oxygen carriers are attrited and are collected with fly ash. Copper oxides are more reactive with nitric acid than most ash materials, meaning that a copper-nitrate-rich leachate can be generated. This copper nitrate stream could then be reused in oxygen carrier synthesis by impregnation. For proof of concept, leaching experiments were conducted to verify that copper oxides are selectively leached from ash-containing spent oxygen carriers. Several cases for process design are proposed based on the composition of spent materials, as the degree of copper oxidation and type of solid fuel dictate leaching residence times and general processing intensity. The four stages proposed here include impurity removal, copper leaching and recovery, solid–liquid separation, and evaporation/concentrating. The resulting process should be able to recover up to 95% of copper while minimizing inclusion of undesirable ash-based impurities.

anions↗

DOE OSTI2024

A mixed integer linear programming approach for the design of chemical process families

Tackling climate change goals requires widespread deployment of process technology variants across many decentralized sites with different geographical, environmental, and operational requirements. Conventional engineering approaches focus on unique designs for each installation (process variant), while missing opportunities for manufacturing standardization. Here, instead we seek to optimize a process platform of common unit designs while simultaneously designing an entire family of process variants that make use of that platform. This reduces engineering effort, deployment timelines, and manufacturing costs. We propose a nonlinear generalized disjunctive programming formulation and convert this to an efficient mixed-integer linear programming (MILP) formulation through discretization of the design space. We formulate our optimization in Pyomo with costing from IDAES, and we demonstrate the computational performance and solution quality on a water treatment desalination system from the PARETO framework and a carbon capture system built in Aspen Plus as part of CCSI2.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗