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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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This report examines the development and use of coal-plastic composite (CPC) materials for use in building applications. CPC formulations were developed at bench scale and evaluated for decking applications. CPC decking boards were designed, manufactured, and evaluated. Techno-economic and lifecycle analyses for CPC decking are also reported.
Abstract not provided.
Project Motivation: Uranium corrosion susceptible and highly catalytic; Exposure thickens oxide impacting material performance. This worsens with time; Sigma is uniquely positioned to tackle R&D challenges with Uranium processing. Possible Solutions: 1) Make new material for each weld. Occupational exposure, difficult to align resources ; 2) Coatings? Coating adds foreign material: can this be minimized?
Lithium (Li) is one of the critical industrial materials and an indispensable component in manufacturing Li batteries. However, Li resource is limited and geographically uneven in earth’s crust and its mining is not sustainable due to the low efficiency and complicated separation and refining processes. In this work, we develop a one-step technology to electrochemically extract Li from low concentration solutions (brines, seawater or used Li-ion batteries) into a form to directly produce commercial battery materials, eliminating the costly Li separation/purification steps. By using this approach, Li was selectively extracted and converted into battery cathodes (e.g., spinel LiMn 2 O 4 and layered LiNi x Mn y Co z O 2 ) through heat treatment. With the importance of Li-ion batteries to the overall decarbonization strategy, the demonstration of a one-step Li-extraction to a ready-to-use material could expand the access to Li resources at a lower cost by eliminating processing steps.
Advanced materials design often leads to new complex compositions that can bring challenges to manufacturing processes. Melt processing of a novel alloy with a tight chemistry range revealed a 25% Ta loss after manufacturing. Vacuum induction melting (VIM) and electroslag remelting (ESR) were performed using industry practices at a laboratory scale and the loss occurred from the VIM electrode to the ESR ingot. Several tools were used for characterization, including combustion analysis, scanning electron microscopy, and electron probe microanalysis for observation of the precipitate and inclusion phases. Additionally, computational modeling of the ESR process was performed to predict macrosegregation and inclusion travel. It was found that a significant amount of Ta2O5 inclusions formed during VIM and were transferred to the slag during ESR. This led to a 95% decrease in density of inclusions explaining to Ta loss. Pathways to better control advanced alloy chemistries during melt processing will be discussed.
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Traditionally, metal powders have been produced through methods such as grinding, atomization, and electrolysis. In contrast to these techniques, Metal Powder Works, Inc. has pioneered a methodology based on metal cutting. This innovative approach utilizes a vibrating cutting tool to machine metal particles, in the form of chips, from a workpiece. This technique allows for control of powder particle size, morphology, and avoids any thermally induced material changes. This collaboration aims to elucidate metal cutting characteristics and assess performance on tough materials like Inconel alloys. Computational models, using FEA and SPH techniques, will be developed initially, focusing on aluminum alloy (Al 7075-T6) for studying mesh sensitivity, cutting forces, and chip morphology.
Traditionally, metal powders have been produced through methods such as grinding, atomization, and electrolysis. In contrast to these techniques, Metal Powder Works, Inc. has pioneered a methodology based on metal cutting. This innovative approach utilizes a vibrating cutting tool to machine metal particles, in the form of chips, from a workpiece. This technique allows for control of powder particle size, morphology, and avoids any thermally induced material changes. This collaboration aims to elucidate metal cutting characteristics and assess performance on tough materials like Inconel alloys. Computational models, using FEA and SPH techniques, will be developed initially, focusing on aluminum alloy (Al 7075- T6) for studying mesh sensitivity, cutting forces, and chip morphology.
Catalytic fast pyrolysis (CFP) is a versatile technology platform to convert biomass into fungible hydrocarbon transportation fuels and chemical co-products. Key technical barriers to reaching this goal include increasing the product yields and achieving the desired fuel properties for gasoline, diesel, and jet range fuels or blendstocks that would be suitable for introduction into existing refinery unit operations. Overcoming these barriers will require durable catalysts that are effective at upgrading and stabilizing biomass pyrolysis vapors. Towards these goals, this CRADA leveraged NREL experience as a leader in biomass pyrolysis research and Johnson Matthey's (JM) experience as a leader in the production of advanced catalytic materials. The scope spanned CFP catalyst development, characterization, multi-scale reaction testing, and computational modeling. CRADA benefits to DOE, Participant, and U.S. Taxpayer: Assists laboratory in achieving programmatic scope, Uses the laboratory’s core competencies. The purpose of this CRADA was to develop and deploy catalysts for biomass CFP to help achieve cost-competitive biofuels and bio-based products. This was accomplished through a close collaboration between biomass conversion researchers at NREL and catalyst development researchers at JM. Summary of Research Results: Focus Area 1. Foundational research on catalytic conversion and deactivation: Key interactions between pyrolysis vapors and heterogeneous catalysts were probed through catalyst characterization, model compound reaction testing, and atomistic-scale computational modeling. Catalyst development focused on multifunctional materials, which include zeolites, oxides, carbides, and nitrides. Computational modeling identified reaction mechanisms and elucidated surface chemistry to test hypotheses regarding mechanisms of deoxygenation, coupling, cracking, dehydration, coke formation, hydrogen transfer, and aromatic ring reactions. This information was used to design multifunctional catalysts to increase product yields, control product selectivity, and reduce deactivation during CFP and downstream processing steps. The results served to increase fundamental understanding of key catalyst attributes and durability features for the upgrading of biomass pyrolysis vapors. Model compound experiments confirmed the importance of metal-acid bifunctionality for the deoxygenation of lignin-derived phenolic species under hydrodeoxygenation conditions. This insight led to the development of catalysts such as Pt/TiO2 and Mo2C, which were confirmed as high-performing materials during subsequent bench-scale experiments using biomass-derived pyrolysis vapors. This focus area also led to the identification of important catalyst deactivation mechanisms associated with the deposition of inorganic contaminants such as potassium. The molecular-level insight from model compound experiments and computational modeling, shown in Figure 1, informed the development of regeneration procedures that have been shown to be effective for restoration of > 90% of initial catalyst activity. This understanding has subsequently been translated to other catalyst systems, including zeolite materials that can be operated without requirements for co-fed hydrogen.
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Phase I Final Technical Report
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Microbial conversion of lignocellulosic substrates to fuel and platform chemical intermediates offers a sustainable route to establish a viable bioeconomy. However, such approaches face a series of key technical, economic, and sustainability hurdles, including: incomplete substrate utilization, lignocellulosic hydrolysate, and/or end-product toxicity, inefficient product recovery, incompatible cultivation requirements, and insufficient productivity metrics. Development of a production host with native traits suitable for high productivity conversion of lignocellulosic substrates under process-relevant conditions offers a means to bypass the above-described hurdles and accelerate the development of microbial biocatalyst deployment. Clostridium tyrobutyricum , a native producer of short chain fatty acids, displays a series of characteristics that make it an ideal candidate for conversion of lignocellulosic substrates and thus represents a promising host for microbial production of diverse carboxylate-derived product suites. Herein, recent progress and future directions in the development of this bacterium as an industrial microbial cell factory, with emphases on the utilization of lignocellulosic substrates and metabolic engineering approaches, is reviewed.
Few life cycle assessments (LCAs) on willow biomass production have investigated the effects of key geographically specific parameters. This study uses a spatial LCA model for willow biomass production to determine spatially explicit greenhouse gas (GHG) emissions and energy return on investment (EROI), including land use conversion from pasture and cropland or grassland. There were negative GHG emissions on 92% of the land identified as suitable for willow biomass production, indicating this system’s potential for climate change mitigation. For willow planted on cropland or pasture, life cycle GHG emissions ranged from −53.2 to −176.9 kg CO2eq Mg-1. When willow was grown on grassland the projected decrease in soil organic carbon resulted in a slightly positive GHG balance. Changes in soil organic carbon (SOC) associated with land use change, transportation distance, and willow yield had the greatest impacts on GHG emissions. Results from the uncertainty analysis exhibited large variations in GHG emissions between counties arising from differences in these parameters. The average EROI across the entire region was 19.2. Willow biomass can be a carbon negative or low-carbon energy source with a high EROI in regions with similar infrastructure, transportation distances, and growing conditions such as soil characteristics, land cover types, and climate.
The economic impact of obtaining biomass could become significant to U.S. rural economies via the establishment of a bioeconomy. In 2023, the Bioenergy Technologies Office (BETO) and Oak Ridge National Laboratory provided a road map to obtain over a billion tons of biomass for conversion to bioenergy and other products. Using information from this roadmap, this study estimates the potential positive and negative economic impacts that occur because of land use change, along with increased technological advances. This is achieved by using the input–output model, IMPLAN, and impacting 179 Bureau of Economic Analysis regions in the conterminous United States. Biomass included in the analysis comprises dedicated energy crops, crop residues, and forest residues. The analysis found that managing pastures more intensively could result in releasing land to produce dedicated energy crops on 30.8 million hectares, resulting in the production of 361 million metric tons of biomass. This, coupled with crop residues from barley, corn, oats, sorghum, and wheat (162 million metric tons), plus forest residues (41 million metric tons), provide 564 million dry metric tons of biomass. Assuming the price for biomass in 2023 dollars was USD 77 per dry metric-ton, this additional production results in an economic benefit for the nation of USD 619 billion, an increase from the Business As Is scenario (Baseline) of almost USD 100 billion per year, assuming a mature biomass industry. An additional 700,000 jobs are required to grow, harvest/collect, and transport the biomass material from the land.
Global waste generation is a ubiquitous challenge, driving a paradigm shift towards viewing waste as a valuable resource for a circular economy across diverse sectors. While innovative waste-to-resource pathways are crucial, rigorous Life Cycle Assessment (LCA) is essential to ensure the pathways are an important part of current practices. However, LCA application to waste valorization varies, leading to incomparable results due to differing methodological choices. This paper examines three key nuances in waste-as-resource LCAs: the zero-burden assumption, the biogenic carbon neutrality assumption, and the benchmark assumption for emissions avoidance. Using a waste gasification to hydrogen case study, we demonstrate how these methodological decisions impact LCA outcomes. Our findings reveal that waste composition significantly influences the results and highlight challenges associated with biogenic carbon accounting under various system boundary assumptions. Emissions avoidance accounting requires multi-functional unit perspectives and robust benchmark selection. This paper clarifies these accounting approaches, empirically illustrates their influence, and discusses broad implications for accurate sustainability assessment, emphasizing the critical role of transparent LCA choices for effective policy and investment in circular economy solutions.