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At least 703 records · Page 39
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Catalytic Upgrading of Pyrolysis Condensables from Postconsumer Polyolefins Using HZSM-5

The conversion of plastic wastes to monomeric olefins is an attractive means for achieving a plastic circular economy. In our study, a fluidized bed reactor converts post-consumer waste high-density polyethylene (HDPE) and polypropylene (PP) to mostly condensed pyrolysis waxes and some oils, preventing carbon loss to gases. The pyrolysis condensables were upgraded to light olefins (C 2 –C 5 ) at carbon yields greater than 76 wt % using the HZSM-5 zeolite catalyst at a post pyrolysis process that employed a micropyrolyzer. These results were comparable to olefin monomer yields from direct ex situ catalytic pyrolysis of the original waste plastics without condensing the vapors, highlighting the potential applicability of this approach in plastic waste recycling. Our results suggest that a centralized catalytic upgrading facility fed by pyrolysis condensables sourced from distributed thermochemical processing plants is a promising pathway to a circular economy. Such an approach enables utilization of available catalytic cracking infrastructure while focusing on setting up distributed thermochemical processing plants close to material recovery facilities. As a result, the energy-dense pyrolysis waxes are more suitable for transportation, contributing to the overall scalability and economic viability of the proposed distributed approach.

10 SYNTHETIC FUELS↗
DOE OSTI2015

Evaluation of Biomass-Derived Distillate Fuel as Renewable Heating Oil

The utilization of advanced biofuels in stationary applications, such as home heating, is considered as an early entry point for biomass-derived fuels into the distillate fuel market sector. Two renewable fuels produced by a biomass fluidized catalytic cracking (BFCC) process, followed by hydroprocessing and fractionation, were tested. The evaluation was performed on a pure (100%) distillate fraction, 50% blend of the distillate fraction with petroleum-based heating oil, and 20% blend of a heavier gas oil fraction. Combustion experiments were carried out in a transparent quartz chamber and a typical oil-fired residential boiler. The flame stability, size, and shape produced by the fuels were examined. The flue gas was analyzed for O 2 , CO, NO x , and smoke. The elastomer compatibility test was performed with nitrile slabs at 43 °C for 1 month. Fuel stability was examined at 80 °C for 1 week. The results from the combustion studies suggest that the distillate fuel blends could be used as alternative fuels to No. 2 heating oil, even up to 100% without any operational issues. The distillate fuels were found to be stable. and the nitrile slab volume swell (~10%) suggests that the fuel could be compatible to legacy elastomers.

09 BIOMASS FUELS↗
DOE OSTI2025

Thermal Oxo-degradation and Catalytic Upgrading of Plastic Waste to Light Olefins for a Circular Economy

The commercialization of conventional pyrolysis of plastic in an inert atmosphere has been hindered by large thermal requirements stemming from long reaction rates. The rate of thermal depolymerization of waste plastics can be accelerated by the addition of oxygen in a process known as thermal oxo-degradation (TOD). This study offers the prospect of TOD to upcycle postconsumer waste rapidly and efficiently. Using moderate temperatures and small amounts of air in a fluidized bed reactor, we demonstrated that waste high-density polyethylene and polypropylene are rapidly deconstructed to condensable products. These condensable products were catalytically upgraded in a micropyrolysis reactor using commercially available zeolite (HZSM-5) to monomeric olefins. The olefin yields proved to be greater than those achieved through the catalytic upgrading of condensable products from (nonoxidative) the pyrolysis of the same plastic wastes. The coupling of TOD with catalytic upgrading proves to be an energy-efficient pathway in a plastics circular economy for the production of light olefins from wastes.

Enthalpy↗
DOE OSTI2016

Thermal Stability of Fractionated Bio-Oil from Fast Pyrolysis

A method was developed to simulate the rapid heating bio-oil fractions will undergo if upgraded using conventional petroleum refining processes. Bio-oil fractions were produced via fluidized bed fast pyrolysis of southern yellow pine sawmill residue. Thermal processing of the bio-oil fractions was evaluated at three temperatures (100, 200, and 300 °C) and two heating times (60 and 120 s). Thermal stability was defined as the increase in average relative molecular weight (RMW) of bio-oil samples after thermal treatment. The effect of moisture content and total acid number (TAN) on thermal stability was also investigated. Changes in chemical structures were observed via Fourier transform infrared spectroscopy (FTIR). Bio-oil fractions exhibited considerable instability at temperatures above 100 °C with substantial increases in average RMW for both 60 and 120 s heating times. Finally, the initial concentration of acids, as measured by TAN and ion chromatography (IC), was found to be the strongest predictor of thermal instability.

09 BIOMASS FUELS↗
DOE OSTI2024

Prioritization of Early-Stage Research and Development of a Hydrogel-Encapsulated Anaerobic Technology for Distributed Treatment of High Strength Organic Wastewater

This study aims to support the prioritization of research and development (R&D) pathways of an anaerobic technology leveraging hydrogel-encapsulated biomass to treat high-strength organic industrial wastewaters, enabling decentralized energy recovery and treatment to reduce organic loading on centralized treatment facilities. To characterize the sustainability implications of early-stage design decisions and to delineate R&D targets, an encapsulated anaerobic process model was developed and coupled with design algorithms for integrated process simulation, techno-economic analysis, and life cycle assessment under uncertainty. Across the design space, a single-stage configuration with passive biogas collection was found to have the greatest potential for financial viability and the lowest life cycle carbon emission. Through robust uncertainty and sensitivity analyses, we found technology performance was driven by a handful of design and technological factors despite uncertainty surrounding many others. Hydraulic retention time and encapsulant volume were identified as the most impactful design decisions for the levelized cost and carbon intensity of chemical oxygen demand (COD) removal. Encapsulant longevity, a technological parameter, was the dominant driver of system sustainability and thus a clear R&D priority. Ultimately, we found encapsulated anaerobic systems with optimized fluidized bed design have significant potential to provide affordable, carbon-negative, and distributed COD removal from high strength organic wastewaters if encapsulant longevity can be maintained at 5 years or above.

Anaerobic Treatment↗
DOE OSTI2021

Development of a Filtered CFD-DEM Drag Model with Multiscale Markers Using an Artificial Neural Network and Nonlinear Regression

Here, the accuracy of coarse-grained Euler-Lagrangian simulations of fluidized beds heavily depends on the mesoscale drag models to account for the influences of the unresolved sub-grid structures. Traditional filtered drag models are regressed with mesoscale markers such as voidage and slip velocities. In this research, a filtered drag was regressed with both mesoscale and macro-scale markers using fine grid Computational Fluid Dynamics - Discrete Element Method (CFD-DEM) simulations. The traditional non-linear regression method was compared with machine learning regression using an Artificial Neural Network (ANN) implemented in PyTorch and coupled with MFiX. The new drag showed higher accuracy than the Wen-Yu drag and another filtered drag derived from the two-fluid model. The nonlinear regression shows slightly better results than ANN regression in cases with similar R 2 values. The utilization of the gas inlet velocity as an additional macro-scale marker reduced the errors by up to 55.3% in the tested cases.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

Kinetics of Dechlorination of Molten Chloride Salt Using Protonated Ultrastable Y Zeolite

Investigation of the kinetics of the ion exchange between protonated ultrastable Y-type (USHY) and surrogate electrorefiner (ER) waste salt was performed to optimize the dechlorination process. The kinetics of the ion exchange reaction was investigated by measuring the amount of unreacted Cl. In theory, the kinetics of the ion exchange reaction in porous media will be limited by diffusion- or reaction-controlled mechanisms. Therefore, second order kinetics and diffusion-limited rate models have been derived and compared to experimental data to elucidate the rate-limiting step and develop a predictive model for the apparent rate of reaction. Ion exchange experiments were performed with varying zeolite particle sizes (up to 600 μm) at 625 °C. The experiments were performed with both unfluidized and continuously fluidized zeolite particles in static and rotating tube furnaces. Finally, it was concluded that the process is limited by reaction kinetics inside the zeolite crystals, and a second order kinetic model best fits the experimental data. Given that the zeolite is not stable at higher temperatures, further increase in the extent of dechlorination for a given batch reaction time requires an increase of the zeolite-to-salt ratio, which has the undesirable effect of increasing the volume of generated waste per amount of salt.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2015

Controlled Formation of Mixed Nanoscale Domains of High Capacity Fe 2 O 3 –FeF 3 Conversion Compounds by Direct Fluorination

In this paper, we report a direct fluorination method under fluorine gas atmosphere using a fluidized bed reactor for converting nanophase iron oxide (n-Fe 2 O 3 ) to an electrochemically stable and higher energy density iron oxyfluoride/fluoride phase. Interestingly, no noticeable bulk iron oxyfluoride phase (FeOF) phase was observed even at fluorination temperature close to 300 °C. Instead, at fluorination temperatures below 250 °C, scanning transmission electron microscopy coupled with electron energy loss spectroscopy (STEM-EELS) and X-ray photoelectron spectroscopy (XPS) analysis showed surface fluorination with nominal composition, Fe 2 O 3-x F 2x (x < 1). At fluorination temperatures of 275 °C, STEM-EELS results showed porous interconnected nanodomains of FeF 3 and Fe 2 O 3 coexisting within the same particle, and overall the particles become less dense after fluorination. We performed potentiometric intermittent titration and electrochemical impedance spectroscopy studies to understand the lithium diffusion (or apparent diffusion) in both the oxyfluoride and mixed phase FeF 3 + Fe 2 O 3 composition, and correlate the results to their electrochemical performance. Finally and further, we analyze from a thermodynamical perspective, the observed formation of the majority fluoride phase (77% FeF 3 ) and the absence of the expected oxyfluoride phase based on the relative formation energies of oxide, fluoride, and oxyfluorides.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2017

Catalyst Residence Time Distributions in Riser Reactors for Catalytic Fast Pyrolysis. Part 2: Pilot-Scale Simulations and Operational Parameter Study

Here, wsing the validated simulation model developed in part one of this study for biomass catalytic fast pyrolysis (CFP), we assess the functional utility of using this validated model to assist in the development of CFP processes in fluidized catalytic cracking (FCC) reactors to a commercially viable state. Specifically, we examine the effects of mass flow rates, boundary conditions (BCs), pyrolysis vapor molecular weight variation, and the impact of the chemical cracking kinetics on the catalyst residence times. The factors that had the largest impact on the catalyst residence time included the feed stock molecular weight and the degree of chemical cracking as controlled by the catalyst activity. Lastly, because FCC reactors have primarily been developed and utilized for petroleum cracking, we perform a comparison analysis of CFP with petroleum and show the operating regimes are fundamentally different.

09 BIOMASS FUELS↗
DOE OSTI2017

One-dimensional biomass fast pyrolysis model with reaction kinetics integrated in an Aspen Plus Biorefinery Process Model

A biomass fast pyrolysis reactor model with detailed reaction kinetics and one-dimensional fluid dynamics was implemented in an equation-oriented modeling environment (Aspen Custom Modeler). Portions of this work were detailed in previous publications; further modifications have been made here to improve stability and reduce execution time of the model to make it compatible for use in large process flowsheets. The detailed reactor model was integrated into a larger process simulation in Aspen Plus and was stable for different feedstocks over a range of reactor temperatures. Sample results are presented that indicate general agreement with experimental results, but with higher gas losses caused by stripping of the bio-oil by the fluidizing gas in the simulated absorber/condenser. Lastly, this integrated modeling approach can be extended to other well-defined, predictive reactor models for fast pyrolysis, catalytic fast pyrolysis, as well as other processes.

09 BIOMASS FUELS↗
DOE OSTI2017

Techno-economic and Life Cycle Analysis for Bioleaching Rare-Earth Elements from Waste Materials

A bioleaching process to extract rare earth elements (REE) from fluidized catalytic cracking (FCC) catalysts was optimized using a heterotrophic bacterium Gluconobacter oxydans to produce organic acids from glucose. Parameters optimized included agitation intensity, oxygen levels, glucose concentrations and nutrient additions. Biolixiviants from the optimized batch process demonstrated REE leaching efficiencies up to 56%. A continuous bioreactor system was subsequently developed to feed a continuous leach process and demonstrated leaching efficiencies of 50%. A techno-economic analysis showed glucose to be the single largest expense for the bioleach process constituting 37.8% of the total cost. The bioleaching plant described here was found profitable although the margin was small. Lower cost carbon and energy sources for producing the biolixiviant and improved leaching efficiencies would improve profitability as well as sourcing FCC catalysts with higher levels of REE. In conclusion, a life cycle analysis showed that electricity generation and glucose production required for the bioreactor had the largest potential for environmental impacts.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2018

An Efficient, Solvent-Free Process for Synthesizing Anhydrous MgCl 2

A new efficient and solvent-free method for the synthesis of anhydrous MgCl2 from its hexahydrate is proposed. Fluidized dehydration of MgCl 2 ·6H 2 O feedstock at 200 °C in a porous bed reactor yields MgCl2·nH2O (0 < n < 1), which has a similar diffraction pattern as activated MgCl2. The MgCl 2 ·nH 2 O is then ammoniated directly using liquefied NH 3 in the absence of solvent to form MgCl 2 ·6NH 3 . Calcination of the hexammoniate complex at 300 °C then yields anhydrous MgCl 2 . Both dehydration and deammoniation were thoroughly studied using in situ as well as ex situ characterization techniques. Specifically, a detailed understanding of the dehydration process was monitored by in situ PXRD and in situ FTIR techniques where formation of salt with nH 2 O (n = 4, 2, 1, <1) was characterized. Given the reduction in thermal energy required to produce dehydrated feedstock with this method compared with current strategies, significant cost benefits are expected. Overall, the combined effect of activation, macroporosity, and coordinated water depletion allows the formation of hexammoniate without using solvent, thus minimizing waste formation.

Motkuri, Radha K.↗
DOE OSTI2018

Experimental Measurement of the Solid Particle Concentration in Geophysical Turbulent Gas-Particle Mixtures

Dilute gas-particle mixtures in which the particles are carried by the turbulent fluid are found in various geophysical contexts, from cold snow avalanches to hot pyroclastic density currents. Though previous studies suggest that such mixtures have maximum particle concentrations of a few volume percent, the dependence of this maximum concentration on the Reynolds number is unclear. We addressed this issue through laboratory experiments in a vertical pipe, where dilute gas-particle mixtures were created by injecting a turbulent air flow from below. Nearly monodisperse mixtures of glass beads of different grain sizes (77 to 1,550 μm) were used with varying bulk concentrations from 0.025 to 8 vol. %. To create quasi-static mixtures, the mean air velocity matched the terminal settling velocity for the grain sizes investigated. The maximum Reynolds numbers of the mixtures were ~104–106. The air pressure indicated full support of the particle weight at concentrations down to 0.025 vol. %. Above a critical particle concentration, at which all the particles were suspended, subsequent additional particles were not maintained in the mixture and led to the formation of clusters that settled downward in the pipe to form a dense fluidized bed. Maximum mean particle concentrations of the dilute mixtures increased from ~1 to ~2.8 vol. % and reached a plateau at increasing mixture Reynolds number. These results give insights into the maximum particle concentrations of geophysical turbulent gas-particle mixtures and may serve to constrain observations as well as the input and output data of models.

58 GEOSCIENCES↗
DOE OSTI2024

Origin of biogeographically distinct ecotypes during laboratory evolution

Resource partitioning is central to the incredible productivity of microbial communities, including gigatons in annual methane emissions through syntrophic interactions. Previous work revealed how a sulfate reducer (Desulfovibrio vulgaris, Dv) and a methanogen (Methanococcus maripaludis, Mm) underwent evolutionary diversification in a planktonic context, improving stability, cooperativity, and productivity within 300-1000 generations. Here, we show that mutations in just 15 Dv and 7 Mm genes within a minimal assemblage of this evolved community gave rise to co-existing ecotypes that were spatially enriched within a few days of culturing in a fluidized bed reactor. The spatially segregated communities partitioned resources in the simulated subsurface environment, with greater lactate utilization by attached Dv but partial utilization of resulting H 2 by low affinity hydrogenases of Mm in the same phase. The unutilized H 2 was scavenged by high affinity hydrogenases of planktonic Mm, producing copious amounts of methane. Our findings show how a few mutations can drive resource partitioning amongst niche-differentiated ecotypes, whose interplay synergistically improves productivity of the entire mutualistic community.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2015

Hydrocarbon liquid production via the bioCRACK process and catalytic hydroprocessing of the product oil

Continuous hydroprocessing of liquid phase pyrolysis bio-oil, provided by BDI-BioEnergy International bioCRACK pilot plant at OMV Refinery in Schwechat/Vienna Austria was investigated. These hydroprocessing tests showed promising results using catalytic hydroprocessing strategies developed for unfractionated bio-oil. A sulfided base metal catalyst (CoMo on Al2O3) was evaluated. The bed of catalyst was operated at 400 °C in a continuous-flow reactor at a pressure of 12.1 MPa with flowing hydrogen. The condensed liquid products were analyzed and found that the hydrocarbon liquid was significantly hydrotreated so that nitrogen and sulfur were below the level of detection (<0.05), while the residual oxygen ranged from 0.7 to 1.2%. The density of the products varied from 0.71 g/mL up to 0.79 g/mL with a correlated change of the hydrogen to carbon atomic ratio from 2.1 down to 1.9. The product quality remained high throughout the extended tests suggesting minimal loss of catalyst activity through the test. These tests provided the data needed to assess the quality of liquid fuel products obtained from the bioCRACK process as well as the activity of the catalyst for comparison with products obtained from hydrotreated fast pyrolysis bio-oils from fluidized-bed operation.

09 BIOMASS FUELS↗
DOE OSTI2015

Role of precursor chemistry in the direct fluorination to form titanium based conversion anodes for lithium ion batteries

In this study, a new synthetic route for the formation of titanium oxydifluoride (TiOF 2 ) through the process of direct fluorination via a fluidized bed reactor system and the associated electrochemical properties of the powders formed from this approach are reported. The flexibility of this synthetic route was demonstrated using precursor powders of titanium dioxide (TiO 2 ) nanoparticles, as well as a reduced TiO x N y . An advantage of this synthetic method is the ability to directly control the extent of fluorination as a function of reaction temperature and time. The reversible capacity of TiOF 2 anodes was found to depend greatly upon the precursor employed. The TiOF 2 synthesized from TiO 2 and TiO x N y showed reversible capacities of 300 mAh g -1 and 440 mAh g -1 , respectively, over 100 cycles. The higher reversible capacity of the TiOF 2 powders derived from TiO x N y likely relate to the partial reduction of the Ti in the fluorinated electrode material, highlighting a route to optimize the properties of conversion electrode materials.

25 ENERGY STORAGE↗
DOE OSTI2015

Dynamics and yielding of binary self-suspended nanoparticle fluids

Yielding and flow transitions in bi-disperse suspensions of particles are studied using a model system comprised of self-suspended spherical nanoparticles. An important feature of the materials is that the nanoparticles are uniformly dispersed in the absence of a solvent. Addition of larger particles to a suspension of smaller ones is found to soften the suspensions, and in the limit of large size disparities, completely fluidizes the material. We show that these behaviors coincide with a speeding-up of de-correlation dynamics of all particles in the suspensions and are accompanied by a reduction in the energy dissipated at the yielding transition. We discuss our findings in terms of ligand-mediated jamming and un-jamming of hairy particle suspensions.

Agrawal, Akanksha↗