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603 records · Page 34
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Modernization of Technical Requirements for Licensing of Advanced Non-Light Water Reactors: Risk-Informed and Performance-Based Evaluation of Defense-in-Depth Adequacy

This document supports the work contained in Nuclear Energy Institute (NEI) 18-04 “Risk-Informed Performance-Based Technology Inclusive Guidance for Advanced Reactor Licensing Basis Development” Revision 0. NEI 18-04 presents a modern, technology-inclusive, risk-informed, and performance-based (TI-RIPB) process for selection of Licensing Basis Events (LBEs); safety classification of structures, systems, and components (SSCs) and associated risk-informed special treatments; and determination of defense-in-depth (DID) adequacy for non-LWRs. The NEI guidance document provides one acceptable means for addressing the aforementioned topics as part of demonstrating a specific design provides reasonable assurance of adequate radiological protection. This report provides the framework and associated methodology guidelines and discussion for establishing, then evaluating, confirming, and documenting the adequacy of defense-in-depth (DID) for advanced non-light-water reactor technologies. It was developed as part of the Licensing Modernization Project led by Southern Company and cost-shared by the United States Department of Energy and has benefited from considerable NRC formal reviews and public workshops. The methodology converts the DID philosophy into a structured process that is implementable, embraces existing United States and international definitions and philosophies of DID that set the foundation for the process. It builds on the DID framework developed in the Department of Energy Next Generation Nuclear Plant Project and earlier works on this subject. The approach to establishing DID adequacy involves the incorporation of DID attributes into the plant capabilities and programmatic elements of DID. The integrated evaluation of DID adequacy includes both quantitative elements to incorporate risk-informed and performance-based (RIPB) considerations and qualitative elements that address uncertainties and limitations in the quantitative models and supporting data. Demonstration of DID adequacy ensures that there are multiple layers of defense for risk-significant challenges to the design and that the plant capabilities and programs that support each layer are provided in a manner that minimizes dependencies among these layers. The focus of this report is assurance of DID adequacy with respect to protection of the public from radiological exposures resulting from accidental releases of radioactive material. While other hazards are not specifically addressed, this methodology is expected to be beneficial for determining DID adequacy for them as well. Risk-informed evaluation of DID considers the integrated performance of all plant SSCs and associated programs to manage daily operational activities, transients, and accidents, including the evaluation of strategies for accident prevention and mitigation. The RIPB LBE scenario methodology used in this evaluation defines the challenges to the plant safety features included in the plant design basis and beyond, and the scope of all deterministic and probabilistic safety evaluations. By examining event sequences across the whole spectrum of LBEs, a systematic assessment of DID can be accomplished.

42 ENGINEERING↗
DOE OSTI2025

Process design and techno-economic analysis for bio-based graphite and liquid hydrocarbons production from lignocellulosic biomass

The worldwide demand for graphite, as the main anode material for Li-ion batteries, is expected to double by 2028 since it supports the use of electricity, including transient renewable sources, for energy storage, sustainable mobility, and automation. However, the dependence on non-renewable and external resources jeopardizes the world supply chain. This study explores the technical and economic performance of transforming lignocellulosic biomass into biographite and fuel-grade hydrocarbons through pyrolysis bio-oil upgrading. According to simulation results, the total power demand for the biorefinery reached 10,784 kWh per tonne of biographite, of which 36 % can be supplied by the heat integration network and power plant. Sensitivity and risk analyses were conducted to evaluate the economics, with process yields identified as the most relevant indicators to the minimum selling price (MSP). The analysis revealed a promising cost-competitive range for biographite MSP against fossil-based graphite (medium quality synthetic graphite Chinese market price ~$\$$4.2/kg). Case D, which includes biofuels as a byproduct, presents the best metrics, reaching a MSP of $\$$3.3/kg of anode-grade biographite with a profit margin of 27 %. While including biofuels in the product slate provides the best economic performance, the uncertainty associated with the big capital investment makes its risk 13 % higher to attain an IRR >20 % than the case in which biographite is produced as a standalone product. Overall, this study demonstrates that integrated biorefineries can produce a cost-competitive bio-based anode material for Li-ion batteries.

09 BIOMASS FUELS↗
DOE OSTI2021

Big Adaptive Rotor Phase I (Final Report)

The Big Adaptive Rotor (BAR) project was initiate by DOE in 2018 with the goal of identifying novel technologies that can enable large (>100m) blades for low specific power (SP) turbines. Five distinct tasks were completed to achieve this goal: 1. Assess trends, impacts, and value of low-SP turbines, 2. Wind turbine blade cost reduction roadmap study, 3. Research and Development (R&D) opportunity screening, 4. Detailed design and analysis, and 5. Low-cost carbon fiber. These tasks were completed by the national lab team consisting of Sandia National Laboratories (SNL), the National Renewable Energy Laboratory (NREL), and Lawrence Berkeley National Laboratory (LBNL). The objective of Task 1 was to assess the historical trends of low-SP of onshore deployments, and to assess the impact and value of low-SP turbines. Analysis under this task showed that there is significant value for low-SP turbines, especially in markets where there is a higher saturation of wind energy on the grid. This has to do with the fact that low-SP turbines have increased capacity factors, and can contribute more reliable energy to the grid, even in lower wind conditions. This bodes well as higher renewable scenarios are likely in the coming years. Task 2 was a detailed analysis on the logistical challenges of deploying very large (>100m) onshore blade. This work was completed by experts at DNV-GL. The report looked at various ways to get around the current transportation constraints which are estimated to be around 75m in length. The report concluded that there are viable solutions to this issue including: segmented blades (which the industry is already pursuing), lighter than air (LTA) transportation, on-site manufacturing, and controlled bending of blades on rail. The final option was recommended for further analysis and study by DOE and the national labs because keeping a single piece blade reduces manufacturing and operations and maintenance (O&M) costs. Task 3 focused on identifying novel concepts that are capable of enabling a cost effective 5MW 206m rotor for onshore deployment. The findings from the first two tasks were considered in the analysis, in that the concepts identified must be able to overcome the transportation logistics challenges. Around 20 concepts were identified and evaluated by experts within the industry. Additionally, science and engineering challenges were identified for each concept. Based on these evaluations six concepts were deemed the most impactful and were selected for further analysis in Task 4. The concepts were: highly flexible rail transportable blades, downwind rotors, distributed aerodynamic control (DAC) devices, inflatable blade, bi-wing blade, and 4/5 bladed rotors. Task 4 conducted detailed design, optimization, and analysis on the selected BAR concepts. A modeling gaps analysis was conducted, and modeling improvements were implemented that allowed for the study and design of the novel concepts. The BAR team established a set of baseline designs by which to compare the selected designs through a technoeconomic analysis. It was found that the highly flexible rail transportable blade, the downwind rotor, and the DAC devices have the most promise to deliver the BAR targets. A Phase II for BAR has been proposed to further mature these concepts and address the open science and engineering challenges identified in Task 3. Task 5 conducted research on optimized carbon fiber materials that were used throughout the BAR Phase I project. Overall, the BAR project has identified low-SP turbines as important to continued LCOE reductions for onshore turbines. Furthermore, the project has identified viable solutions to the technical and logistical challenges to realizing these goals. The most promising technologies that were identified in Phase I of the project will be further matured and de-risked in Phase II of the BAR project.

17 WIND ENERGY↗
NASA NTRSDate not supplied

Towards an Aviation Large Language Model by Fine-tuning and Evaluating Transformers

In the aviation domain, there are many applications for machine learning and artificial intelligence tools that utilize natural language. For example, there is a desire to know the commonalities in written safety reports such as voluntary post incidents reports or aerial wildfire operations reports to better understand the risks present. Another use-case is the possibility of extracting airspace procedures and constraints currently written in documents such as Letters of Agreement. These applications can benefit from the use of state-of-the-art natural language processing techniques when adapted to the language/phraseology specific to the aviation domain. This paper evaluates the viability of adaptation of NLP tools to the aviation domain by fine-tuning transformer based models using aviation data sets. In 2018, a novel language model based on neural units (also called transformers) was created and became known as “Bidirectional Encoder Representations from Transformers” or BERT. This architecture combined with large amounts of English training data and innovative semi-supervised training tasks set the standard for what would later emerge as Large Language Models. The performance of these models was further improved by hyperparameter tuning and refinement of the semi-supervised training task and resulted in “Robustly Optimized BERT Pre-training Approach through hyperparameter tuning” or RoBERTa models. These pre-trained Large Language Models proved to be useful for a wide variety of natural language processing tasks such as text classification and question answering through a process called fine-tuning. The transformer architecture with pre-trained weights served as the basis with the last few layers replaced with layers fine-tuned to perform a new task e.g., a layer that provides a label for the entire input text. This process of fine-tuning can also be used to adapt the models to new domains; e.g., BioBERT started with the pre-trained BERT model and was completed by additional fine-tuning and training on biomedical documents. Transformer-based architectures can also be used to create rich representations of text called embeddings which can serve as the input to other machine learning models. This allows simpler algorithms such as logistic regression to use context-rich representations of the text while still remaining quick to train and evaluate. In the world of aviation, there is a growing demand for natural language processing and understanding but the domain presents unique challenges. Due to the technical content (and specialized language) of most aviation documents, fine-tuning pre-trained Large Language Models to specific tasks has not met the benchmark on natural language processing tasks set by simpler models trained from scratch on the data. To address this deficiency, this paper evaluates the improvements from fine-tuning a Large Language Model on a large set of aviation documents using the original semi-supervised training tasks before performing specific natural language tasks. In fine-tuning, a domain-specific dataset is used on the original training task but with the pre-trained Large Language Model instead of starting from a random initialization. This approach allows the model to be adapted to the specific domain language without discarding the information gained from training on general English data. This paper utilized two major dataset types to train and assess the RoBERTa fine-tuning performance. The first are 7,057 Letters of Agreement which are Federal Aviation Administration (FAA) documents that formalize airspace operations across the national airspace system. They contain many examples of ‘aviation English’ using domain specific terminology and phrasing which serves as a representative basis to perform the semi-supervised fine-tuning. The second type is the 494 document classification labels to be used for evaluation. This down-stream evaluation aims to show the performance of the fine-tuned model, better understand how much data is needed for an effective fine-tuning, and how fine-tuning can be adapted for different applications in-the domain. After semi-supervised training, evaluation begins by encoding the documents for classification using the fine-tuned RoBERTa model. Then a logistic regression classifier is trained to label the document type and compared against our ground truth labels. This currently leads to a 82.8% accuracy on 10-fold cross validation showing improvement over baseline RoBERTa which achieved 81.0%. We plan to measure the improvements on additional tasks and it is expected that these improvements will lead to more robust models that can tackle the natural language processing challenges present in aviation datasets.

ATM↗
DOE OSTI2020

Risk to Ecological Resources on Burial Waste Sites on the Hanford Site, Washington - 20248

The US and other nations have a large nuclear and chemical waste remediation task remaining from World War II, the Cold War, and industrial activities. The US Department of Energy (DOE) has the largest task in the U.S., with Hanford (Washington State) being the most contaminated site, with the longest and most costly cleanup program projected to extend to the end of the century. One of the greatest remediation problems at Hanford are the burial waste facilities, some of which are inside the 200 Areas on the Central Plateau, while others are outside the 200 Areas. These areas are associated with waste sites, pipes, and contaminated trenches, posing technical cleanup challenges to meet DoE's remediation goals, including protection of human health and the environment commensurate with Tri- Party Agreement and current regulatory requirements. In this paper we select one of the legacy waste sites (the BC Cribs and Trenches) as a case study to explore how risk to ecological resources varies during and as a consequence of remediation on sites primarily considered legacy waste sites. We used the risk methodology developed by the Consortium for Risk Evaluation with Stakeholder Participation (CRESP) during the Hanford Site-wide Risk Review. The CRESP methodology included evaluating the risk to receptors, including human health, the Columbia River, groundwater, and ecological and cultural resources. The risk evaluation process for ecological receptors included defining the boundaries of each evaluation unit (EU) to be remediated, definition of a suitable buffer area that might be affected, and consideration of the known resource value based on field work. This information, coupled with known remediation options or strategies, allowed us to develop a risk rating for ecological resources. Site risks were evaluated on a scale of 'not discernible' to 'very high' risk. Consideration of the risks at the buried waste sites was complicated by uncertainties in remediation methods and the degree of restoration that would occur as part of the remediation process. We use the BC Cribs and Trenches as a case study to explore why the risks are low currently but increase during remediation. The current 'not discernible to low' risk rating is due to the lack of high quality ecological resources on the BC Cribs and Trenches EU, except for edge areas (with some state-listed species). During remediation the risks increase to 'medium', mainly due to high quality resources on adjacent buffer lands, which could be disrupted during active remediation. Medium and high quality resources on the edge of the site are continuous with higher quality native shrub-steppe habitat on the buffer. Ecological resources on some of the areas surrounding the 200 East and West Areas are some of the highest quality shrub-steppe areas on the Hanford Site, and risk to these resources could be prevented by planning before and during remediation to minimize disruption. For example, lay down areas for the BC Cribs and Trenches can be minimized by careful planning. Heavy truck and other vehicular traffic can be minimized. Spread of the noxious weeds now on some of the site can be prevented, and the spread of invasive species into the site (particularly near undisturbed shrub-steppe habitat) can be reduced. Further, the areas around and between the 200 East and West Areas have been largely undisturbed and can serve as a source of seeds and propagules for any revegetation that occurs as part of the remediation process. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Distribution Grid Impact Study in Highland Park, Michigan: Understanding Rooftop Solar, Behind-the-Meter Energy Storage, Electric Vehicle Charging, and Building Electrification [Slides]

Through the Communities LEAP (Local Energy Action Program) Pilot, the National Renewable Energy Laboratory (NREL) engaged the Highland Park Stakeholder Coalition to scope four technical assistance work areas to address their energy needs and goals. This slide deck addresses the highlighted tasks under work area "B" related to policy analysis, due diligence, and case studies for removing barriers and providing best practices for local clean energy development. Highland Park community members face frequent, long-duration power interruptions due largely to the aging distribution system serving the area and the legacy design standards used in its construction. While degrading physical infrastructure such as poles, crossarms, and transformers can result in this substandard reliability, another notable characteristic of this legacy system is the lower, 4.8 kV, voltage class. This is a legacy construction standard which many utilities, DTE included, are phasing out in favor of higher, 15 or 25 kV, voltage classes instead. The existing 4.8 kV distribution system serving Highland Park may limit significant adoptions of clean-energy technologies like high percentages of building electrification or electric vehicle adoption. The following analysis seeks to quantify these limitations under a variety of clean-energy technology adoption scenarios. It compares the overall system risks of the present system to those of a hypothetical, upgraded 13.2 kV system, using NREL-developed risk metrics and offers upgrade cost considerations. The legacy 4.8 kV voltage class serving Highland park is not, as we have modeled it, a major limitation to the widespread adoption of cost-optimal rooftop solar and/or behind-the-meter energy storage. Within our modeling framework, these technologies namely impact secondary, low-voltage assets, which may be remedied without the need for a system-wide upgrade to a 13.2 kV voltage class. Our model of the current 4.8kV system indicates it is not capable of supporting community-wide electrification efforts. Widespread building electrification, and the resulting large increase in wintertime load, dramatically increases the prevalence of voltage violations and thermal overloading on the current 4.8 kV distribution system. These impacts illustrate the need for system-wide upgrades to a 13.2 kV voltage class to accommodate these technologies. Low to Moderate DER adoption does not adversely impact the grid but does improve undervoltage and asset overloading issues. However, these benefits are insufficient to defer grid upgrades. Higher DER penetration is shown to increase overvoltage and asset overloading in future electrification scenarios.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
NASA NTRSDate not supplied

Assessments of Physiology and Cognition in Hybrid-Reality Environments (APACHE)

NASA is planning to return to the Moon in the mid-2020s as a stepping stone to Mars missions in the 2030s. Spacewalks, or extravehicular activities (EVAs), performed on the Moon and Mars will differ in a variety of ways from those that have been performed in decades past. NASA has identified multiple risks to human health and performance associated with a crewed mission to Mars, especially those associated with exploration EVAs which are expected to be a primary mission activity. Crew may be expected to conduct up to 24 hours of EVA per person per week, where the likelihood of injury and/or mental mistakes are increased compared to ground-based training or current microgravity EVAs and the consequences of which can be catastrophic. Current test environments for exploration EVA research and technology development are large, costly facilities that are limited in their availability or capabilities. Spacesuit testing in a reduced gravity environment such as NASA’s Neutral Buoyancy Laboratory, while a good representation of the crew’s physical workload during exploration EVAs, typically has small datasets and is difficult to integrate physiological sensors or other types of crew performance measures. Meanwhile, scientific field-based testing such as NASA’s Desert Research and Technology Studies offers an operationally relevant environment for exploration EVAs, particularly for cognitive workload, but is also limited by small datasets, lack of a pressurized spacesuit, and obtrusive measures. The limitations of current analogs for exploration EVAs identify a need for a new test environment that can approximate both the physical and cognitive demands associated with exploration EVAs to enable rapid, controlled, and repeatable evaluations of human health and performance risks of exploration missions. In response, the Human Physiology, Performance, Protection, and Operations Laboratory (H-3PO) at NASA Johnson Space Center has developed a hybrid reality exploration EVA analog named the Assessments of Physiology And Cognition in Hybrid-reality Environments (APACHE) to address these limitations using a combination of virtual, physical, and hybrid reality techniques. The APACHE facility resides at NASA Johnson Space Center and serves as a large “sandbox” for EVA research and simulation. At its center is a roughly 15x20ft space surrounded by a 14” tall sandbox partially filled with lunar regolith simulant to emulate the physical feeling of walking on a planetary surface and to allow for simulated geology operations. Nearby, a curved passive treadmill (Skillmill Connect, Technogym, Fairfield, NJ) and an omnidirectional treadmill (Infinadeck, Infinadeck, Rocklin, CA) are included to enable exploration of these large virtual environments while also imposing the physical demands, representative timelines, and cognitive burdens required to navigate and traverse these distances during exploration EVA. A 6DOF motion platform is used to simulate rover operations and supports various human performance evaluations and associated risks. Lastly, APACHE can support two extravehicular (EV) crewmembers working in tandem. A computer workstation is located nearby and also supports an intravehicular (IV) crewmember as part of a full mission simulation. The IV crewmember has direct video and audio communication with the EV crew in VR to provide operational and procedural support. The software used in APACHE was created by the JSC Engineering Directorate, in partnership with Buendea, powered by a custom Unreal Engine 5 (UE5.3, Epic Games) project. APACHE currently utilizes the HTC Vive Pro Eye in a wireless configuration for VR simulations. There are two virtual environments that subjects can explore within APACHE, a Lunar and Martian surface. The virtual Lunar surface was created from LIDAR data of the Lunar South Pole to create roughly 16 sq km of explorable terrain. The virtual Martian surface contains roughly 400 sq km of explorable terrain derived from Mars Reconnaissance Orbiter LIDAR data of the Jezero Crater. The immersion and related cognitive burdens of conducting a planetary EVA is simulated through a series of EVA-relevant tasks performed in the VR environment, using these high-fidelity visual representations. Additionally, APACHE includes biosensor driven informatics, such as real-time heart rate monitoring and/or derived values from model simulations, for active monitoring by the EV crew and added cognitive demand. A “Wizard of Oz” control panel enables test operators to activate contingency events such as simulated spacesuit malfunctions, loss of communications, and/or limited visibility. Embedded performance measures such as accuracy, completeness, and execution time have been developed for various exploration tasks to objectively quantify crew performance during an EVA and compare impacts to performance when different environmental stressors, both physical and cognitive, are added to or removed from the simulation. Additionally, validated cognitive and operational performance measures such as the Digit Symbol Substitution Task have been recreated and embedded in VR for direct and relatively unobtrusive measurement of motor perception. The APACHE environment currently supports multiple research studies at NASA. Examples include the CHAPEA project, a series of simulated year-long missions on Mars by a 4-person crew; and the CO2 Contingency Walk Back Study, an investigation of elevated CO2 exposure on crew performance during a contingency EVA scenario. APACHE also provides a test environment to support the development of the Crew State and Risk Model, which is a collection of individualized, mathematical models of crew physical and cognitive state; and the Personalized EVA Informatics and Decision Support system, an operational tool for flight controllers, and eventually a self-reliant Martian crew, to make biomedically-informed decisions in real-time to optimize the EVA planning and execution with respect to crew health and performance. Some technical challenges associated with developing the APACHE environment, as well as current limitations, include VR limitless natural walking with a hybrid spacesuit simulator, optimizing performance for wireless PC VR streaming while maintaining a high degree of visual fidelity, and the integration of various physiological (metabolic masks) and psychometric (eye tracking) sensors with the VR headset.

Human Performance↗
NASA NTRS2023

Automated Fluidics Device for Extraction and Quantification of miRNA Biomarkers From Blood

Radiation Assessment DuRing Exposure And long-Duration Spaceflight (RADREADS) demonstrates space-compatible point-of-care technology for quantitative biological monitoring of blood miRNA biomarkers in response to long-term low dose radiation exposure. This individualized monitoring approach will inform targeted treatment strategies to maximize medical resource utilization by accounting for individual susceptibility to radiation-related illnesses. As human spaceflight progresses beyond Earth’s magnetic shielding, radiation exposure poses a significant risk to astronaut health and safety. Extended operation in this environment comes with an increased risk of radiation exposure, leading to higher risks of radiation sickness, cancer, central nervous system effects, and degenerative diseases. While conventional physical dosimetry techniques capture radiation dose, individualistic susceptibility to radiation damage is varied. Multiple characteristics, including age, body weight, sex, genetics, and immune status, have been found to influence radiosensitivity (Liu et al. 2011, and Bouffler 2016). This differential response necessitates individualized monitoring and targeted treatment strategies to maximize medical resource utilization; however, a practical diagnostic platform for quantifying long-term, low dose radiation-induced tissue damage does not currently exist. MicroRNAs (miRNAs) are a class of small, non-coding RNAs that regulate gene expression by mediating the degradation of messenger RNA. The levels of particular miRNAs are influenced by biological processes such as inflammation and serve as biomarkers for a variety of conditions including cancer (Singh et al. 2017). MicroRNAs are found in various bodily fluids and are amenable to collection via liquid biopsies, providing a minimally invasive and easily quantifiable readout for a variety of radiosensitive reporters. A preliminary signature of 15 spaceflight sensitive miRNA has been identified in rodent and human studies, including miR-21-5p, miR-24-3p, miR-92a-3p, miR-17-5p, miR-16a-3p, miR-34a-3p, and miR-223-3p. These targets generally increased expression with radiation dose and linear energy transfer, though variation between individuals is not yet described. Current gaps in the field include a lack of understanding of longitudinal biological responses to long-term, low dose radiation exposure and the absence of space-compatible point-of-care technology for quantitative biological monitoring. In this body of work, we aim to develop an automated bleed-to-read system to process whole blood for the detection of miRNA biomarkers in order to monitor individualistic responses to radiation exposure. This will be achieved via separating serum (or plasma) from whole blood, followed by extraction, amplification, and quantification of the miRNA using a RT-qPCR reaction. Previously, the WetLab-2 hardware enabled execution of a RT-qPCR reaction aboard ISS; however, it is a manual system that requires crew manipulation and bulky components (Parra et al. 2017). To address these issues, automated fluid handling hardware was developed for each stage of sample preparation. Extraction of total RNA is achieved by sequentially pumping reagents through an off-the-shelf nucleic acid binding column (miRNeasy Serum/Plasma Advanced Kit, Qiagen). This approach eliminates several manual pipetting and centrifuging steps and limits the use of toxic chemicals commonly found in other sample processing techniques. The resulting elution will then be automatically dispensed for RT-qPCR analysis using a compact rotary qPCR (Mic qPCR Cycler, Bio Molecular Systems) that will improve spaceflight compatibility by removing bubbles from the detection region, another challenge highlighted by WetLab-2 (Parra et al. 2017). Efforts are also being made to simplify the RT-qPCR reaction to a 1-step air-dryable mix to improve long-term reagent stability at room temperature and reduce system complexity. By automating the RT-qPCR processes via microfluidic manipulation, RADREADS will reduce crewmember hands-on time and enable the personalized detection of radiation-induced tissue damage during long duration missions. Minimally invasive, longitudinal monitoring of individual’s response to radiation exposure will inform how the physiological system responds to long-term low dose space radiation and enables development of targeted countermeasures by the medical team. Ultimately, this portable technology will require minimal technical expertise and can also be used to monitor miRNA biomarkers associated with other diseases.

Tristen Head↗
DOE OSTI2023

Laboratory-Scale Coal-Derived Graphene Process (Final Report)

The Energy & Environmental Research Center (EERC) conducted a laboratory-scale coal-derived graphene (CDG) project focused on developing a technological process for making graphene from four U.S. domestic coal or coal wastes, including lignite from North Dakota, subbituminous coal from Wyoming, bituminous coal from Utah, and anthracite from Pennsylvania. The project was divided into two performance or budget periods (BPs), with BP1 comprising the up-front laboratory experiments to make graphene materials from coal beginning on May 1, 2020, to April 30, 2022. BP2 was conducted from May 1, 2022, to April 30, 2023, and was focused on analyzing the CDG process economic feasibility and the technical gaps for technological scale-up and commercialization. During this project, a few different coal-derived high-value products have been demonstrated, including graphite, graphene oxide (GO), reduced graphene oxide (rGO), and graphene quantum dots (GQDs). A new graphite microstructure was discovered and named “croissant graphite” because of the exterior morphological and textural resemblance to croissant food items sold in commercial groceries stores. The new graphite structure and the associated preparation from coal or coal waste feedstocks has been the subject of a U.S. patent application. The systematic experimental processes involving coal cleaning, upgrading, and conversion to high-value carbon products culminated into a developed upgraded coal-to-products (UCP) technology that is being pursued for potential fast-track commercialization, if funding is available. It is envisioned that commercialization of the UCP technology would increase consumption of U.S. domestic coals or coal wastes to make environmentally sustainable high-value products for the electronics industry, high-energy-storage applications, and clean energy technologies such as electric vehicle (EV) lithium-ion batteries (LIBs), for which graphite has become a critical mineral commodity. Croissant graphite microstructures, when observed by field emission scanning electron microscopy (FESEM), display wavy surface morphology and often grow from a base that is made of graphitized particles with honeycomb-like layers, which are believed to be graphene layers. While more studies are needed to fully ascertain the mechanisms of the croissant graphite microstructure formation, it is postulated that their growth may begin from curling of the graphene sheets into ribbon-like structures, and continuous growth and densification of the ribbon-like structures forms croissant microstructures. Additional studies are ongoing to evaluate the electrochemical performance of croissant graphite for LIB applications and to determine the experimental conditions necessary to tune on/off croissant formation so that it can be either optimized or suppressed depending on performance evaluation results. In addition to the discovery of croissant graphite, the graphitization process from the four coal ranks in general was successful. X-ray diffraction (XRD) analysis showed that the degree of graphitization (DoG) ranged from 12% to 80% in an early sample set, and further optimization on lignite coal produces a DoG of about 92%, which was spectacular to see as lignite is the lowest-rank coal. Thus, it is expected that the graphitization performance for higher-rank coals will be similar or better when optimized as well. The coal-derived graphite was used to make GO and rGO. Analytical characterization, e.g., by methods such as Raman spectroscopy, XRD, Fourier transform infrared (FTIR) spectroscopy and FESEM, showed that the sequence of converting the coal to graphite, exfoliating it to GO, and then chemically reducing the GO to rGO was successful. Although coal naturally contains aromatic compounds and some relatively small-sized condensed aromatic units, it does not contain graphene sheets. In the UCP process, the aromatic domains in the coals, particularly low-rank coals, are concentrated and condensed further into graphene sheets, which are ordered into a 3D stack during graphitization. The synthesized graphite is then unpacked by methods such as exfoliation to various graphene products. GQDs were synthesized from all four coal types, and their optical properties were demonstrated to be tunable by the coal precursor preprocessing treatments. In all four coal types, enhanced optical properties were observed for the produced GDQs with incremental improvements made to the coal precursors. GQDs produced from raw coal samples displayed lower ultraviolet–visible (UV–Vis) spectroscopy absorbance intensity compared to those obtained from cleaned and upgraded coal residues. The photoluminescence (PL) intensities also varied with pretreatment conditions and with the concentration of GQDs in aqueous solutions. GQDs obtained from anthracite show longer emission wavelengths and can be excited by visible light as opposed to GQDs derived from the other coal ranks. UV fluorescence 3D maps and spectra revealed that the emission wavelength at which the GQDs solutions display the highest intensity was slightly redshifted based on the coal precursor pretreatments. In low-rank coal (lignite and subbituminous) samples, two clusters were observed in the maps for GQDs, which may suggest that there are potentially two types of fluorophores in solution or two main size populations. The ability to tune the properties of GQDs based on processing methods can be exploited to make GQDs for various optical display or optoelectronics applications. The results also highlight the importance of removing coal-borne impurities to improve the quality of the coal precursor for preparation of graphene products. Coal and/or coal wastes preprocessing methods were developed and applied to clean and upgrade the coal precursors prior to graphitization and subsequent conversion to graphene products. The preprocessing methods involve high specific-gravity separations, mineral acid cleaning (no hydrofluoric acid), and subsequent upgrading by reducing the coal-borne heteroatom (nitrogen, sulfur, and oxygen) content using proprietary chemical agents. Analytical characterization revealed that the preprocessing steps were successful, with ash reductions that range from 38% to 80% and residual ash content that was below the 5 wt% initial target. Based on proximate and ultimate analysis, the heteroatom reduction reactions produced upgraded coal residues with the oxygen content reduced by 8% to 24%, with additional reductions in the nitrogen and sulfur contents. An initial assessment of the waste streams from the UCP process shows very small to negligible environmental impact due to CO 2 , NO x , and SO x because most process steps are performed under inert atmosphere with argon. Consequently, reactive oxygen environments that tend to create these species are avoided. The inorganic and potentially hazardous species are released into aqueous waste streams that are easy to handle for proper disposal. The liquid waste streams were found to contain low-level concentrations of rare-earth elements (REEs), which could be concentrated and recovered as value-added by-products. Additionally, the volatile and gaseous fractions from carbonization and heat treatment contain useful organic compounds that can also be recovered as potential valuable by-products. Thus, the UCP technology is considered an environmentally sustainable and promising emerging technology for making high-value products from coal and coal wastes, with potential additional value-added by-products. Analysis of potential markets for the coal-derived carbon products shows a strong demand in both niche market sectors and across a wide variety of other industrial sectors. Graphite is currently considered a critical mineral commodity that has a large and growing demand in the LIB industry for EV applications. Based on data from Fortune Business Insights (2022) and Marketwatch (2023) reports, the average global graphite market is projected to reach about 33 billion by 2028, growing at a compound annual growth rate (CAGR) of about 7%, with much of this growth expected to be in the LIB industry. GO and rGO have strong market potentials in various application areas, such as coatings for anticorrosion, anti-icing, and antimicrobial protection, thermal barriers, wear resistance, sensors, additive manufacturing such as 3D inks, and others. GQDs are the emerging key player in the bioimaging, photovoltaics, and light-emitting diodes (LEDs) applications, with the potential to replace traditional semiconductor quantum dots (SQDs), which are based on metallic systems that are more toxic and more expensive. Biomedical applications of GQDs are becoming more attractive because of low to no toxicity and extremely low cost compared to SQDs. The major challenges for scale-up and commercialization of coal-derived carbon products such as graphene vary from the inherent attributes of graphene itself to reluctance to accept graphene in new manufacturing processes because of the uncertainty of the unknown. The 2D nature of graphene materials with a thickness of one atom presents significant challenges to proper handling/processing, and process scale-up becomes difficult because it requires high-end, expensive equipment, even for routine handling and analysis for quality assurance and control. Pristine graphene can also be extremely difficult to work into other matrices, thus hindering downstream processibility, especially at large scale. Currently, the cost of graphene and graphene products is still high and presents an economic risk that tends to slow down investment in scaling up emerging technologies. The lack of a standard for graphene materials for quality assurance and quality control poses a great challenge not only for the markets but also for commercialization efforts. A first-look economic feasibility analysis of the UCP technology provided valuable information that suggests the UCP process would be feasible, especially when it is scaled to a pilot scale and could be more competitive at the full scale. Graphitization was found to be the most energy-consuming and most capital-intensive step in the overall process. In small laboratory- and bench-scale experiments, labor is a significant contributor to the total process costs. Although these energy, capital, and labor constraints contribute to a higher selling price for the product, a preliminary economic model suggests that the process would be feasible at large scale when the process is fully integrated, optimized, and automated.

01 COAL, LIGNITE, AND PEAT↗