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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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At least 739 records · Page 41
All sourcesNASA NTRSDOE OSTI
DOE OSTI2010

Challenges for Numerical Modeling of Enhanced Geothermal Systems

A recent guest editorial by Wood (2009) pointed out the potential of enhanced geothermal systems (EGS) as a future source of “green” energy and suggested that EGS offers research opportunities for hydrogeologists seeking to become involved in the world’s energy future. Although EGS may have a bright future as a sustainable, low-carbon emission energy source, significant technical challenges must be overcome before this promising energy resource can be commercially viable. Because pilot EGS projects in the United States face very different economic constraints than current European projects, there is a real need to make technological advances to improve the return on capital investment. In this article, we amplify on Wood’s excellent editorial by describing some of the challenges that exist for the simulation of EGS.

15 GEOTHERMAL ENERGY↗
DOE OSTI2017

Long‐Term Structural Evolution of an Intercalated Layered Semiconductor

Intercalated molecules can dramatically modify the electronic band structure of layered semiconductors, significantly altering the optical properties of the material. In the layered monochalcogenide Gallium Telluride (GaTe), exposure to air induces a nearly 1 eV reduction of its band gap due to the interlayer diffusion and chemisorption of oxygen. The effect of oxygen chemisorption at the Te‐terminated surfaces on the structure of GaTe, however, is much less known. To better understand the structure–property relationship of intercalated GaTe, a systematic, long‐term, X‐ray diffraction study has been performed on GaTe exfoliated crystals exposed to ambient conditions. It is observed that the structural changes are not limited to a previously observed short‐term increase in lattice expansion. Over the course of months and even years after exfoliation, the oxygen adsorbates continue to modify the structure of GaTe, inducing significant disorder and grain reorientation. It is estimated that approximately one out of every two grains is slightly displaced by the intercalating oxygen, demonstrating a significant increase in grain mosaicity, while still maintaining the original {−2 0 1} out‐of‐plane texture. Correlating these structural transformations to observed changes in electrical and optical properties will enable capitalization of the use of adsorbates to engineer novel properties in these layered materials.

Chew, Annabel R.↗
DOE OSTI2023

Progresses and Perspectives of All‐Iron Aqueous Redox Flow Batteries

Abstract Redox flow batteries (RFBs) are a promising option for long‐duration energy storage (LDES) due to their stability, scalability, and potential reversibility. However, solid‐state and non‐aqueous flow batteries have low safety and low conductivity, while aqueous systems using vanadium and zinc are expensive and have low power and energy densities, limiting their industrial application. An approach to lower capital cost and improve scalability is to utilize cheap Earth‐abundant metals such as iron (Fe). Nevertheless, all‐iron RFBs have many complications, involving voltage loss from ohmic resistance, side reactions such as hydrogen evolution, oxidation, and most significantly electrode plating, and dendrite growth. To address these issues, researchers have begun to examine the effects of various alterations to all‐iron RFBs, such as adding organic ligands to form Fe complexes and using a slurry electrode instead of common materials such as graphite or platinum rods. Overall, progress in improving aqueous all‐iron RFBs is at its infant stage, and new strategies must be introduced, such as the utilization of nanoparticles, which can limit dendrite growth while increasing storage capacity. This review provides an in‐depth overview of current research and offers perspectives on how to design the next generation of all‐iron aqueous RFBs.

Belongia, Shawn↗
DOE OSTI2024

Charge‐Programmable Photopolymers for 3D Electronics via Additive Manufacturing

Charge‐programmed 3D printing enables the fabrication of 3D electronics with lightweight and high precision via selective patterning of metals. This selective metal deposition is catalyzed by Pd nanoparticles that are specifically immobilized onto the charged surface and promises to fabricate a myriad of complex electronic devices with self‐sensing, actuation, and structural elements assembled in a designed 3D layout. However, the achievable property space and the material‐performance correlation of the charge‐programmed printing remain unexplored. Herein, a series of photo‐curable resins are designed for unveiling how the charge and crosslink densities synergistically impact the nanocatalyst‐guided selective deposition in catalytic efficiency and properties of the 3D printed charge‐programmed architectures, leading to high‐quality 3D patterning of solid and liquid metals. The findings offer a wide tunability of the structural properties of the printed electronics, ranging from stiff to extreme flexibility. Capitalizing on these results, the printing and successful application of an ultralight‐weight and deployable 3D multi‐layer antenna system operating at an ultrahigh‐frequency of 19 GHz are demonstrated.

36 MATERIALS SCIENCE↗
DOE OSTI2025

A Simple Route for Open Fluidic Devices with Particle Walls

Open fluidics, allowing liquid in a flow channel to interact with the external environment, is a revolutionary concept. However, fabricating a highly stable open fluidic device of arbitrary complexity, while maintaining reconfigurability, is still a challenge. This is achieved by the use of a patterned substrate and liquids that are covered with functional, readily available hydrophobic particles, providing great flexibility in the construction and use of open fluidic structures. Decorated with a coating of modified carbon nanotubes (CNTs) to encapsulate the fluids, the study capitalizes on the photothermal characteristics of CNTs to fabricate a device to probe the effects of temperature on tumor chemotherapy. The strategy substantially increases the availability and potential use of open fluidic devices.

Liu, Heng↗
DOE OSTI2017

Scalable Dry Printing Manufacturing to Enable Long-Life and High Energy Lithium-Ion Batteries

Slurry casting method dominates the electrode manufacture of lithium-ion batteries. The entire procedure is similar to the newspaper printing that includes premixing of cast materials into solvents homogeneously, and continuously transferring and drying the slurry mixture onto the current collector. As a market approaching US $80 billion by 2024, the optimization of manufacture process is crucial and attractive. However, the organic solvent remains irreplaceable in the wet method for making slurries, even though it is capital-intensive and toxic. In this paper, an advanced powder printing technique is demonstrated that is completely solvent-free and dry. Through removing the solvent and related procedures, this method is anticipated to statistically save 20% of the cost at a remarkably shortened production cycle (from hours to minutes). The dry printed electrodes outperform commercial slurry cast ones in 650 cycles (80% capacity retention in 500 cycles), and thick electrodes are successfully fabricated to increase the energy density. Furthermore, microscopy techniques are utilized to characterize the difference of electrode microstructure between dry and wet methods, and distinguish dry printing's advantages on controlling the microstructure. Finally, this study proves a practical fabrication method for lithium-ion electrodes with lowered cost and favorable performance, and allows more advanced electrode designs potentially.

25 ENERGY STORAGE↗
DOE OSTI2024

Technoeconomic and Emissions Analysis of the Hybrid Redox Process for the Production of Acetic Acid with CO 2 Utilization

The production of oxygenated hydrocarbons, such as acetic acid, using captured CO 2 is a promising pathway to reduce greenhouse gas emissions in the chemical industry. The use of a chemical looping‐based hybrid redox process (HRP) is proposed to convert CO 2 and natural gas into separate CO and syngas streams that can be used to produce various commodity oxygenates, while allowing the beneficial utilization of captured CO 2 . Here, a detailed technoeconomic analysis of HRP applied to the production of acetic acid is presented. Emissions and energy analyses show the ability of HRP to lower the CO 2 emissions for acetic acid synthesis by 74% compared to a conventional steam and autothermal reforming route. HRP also offers a potential 34% reduction in capital costs. Compared to a dry reforming based acetic acid production route, HRP has the potential for significantly lower costs. If integrated with a low carbon energy source, HRP has the potential to achieve a negative emission of greenhouse gas (‐0.50 kg CO 2 per kg acetic acid).

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2013

Nanoporous Polytetrafluoroethylene/Silica Composite Separator as a High-Performance All-Vanadium Redox Flow Battery Membrane

Driven by the motivation of searching for low-cost membrane alternatives, a novel nanoporous polytetrafluoroethylene/silica composite separator has been prepared and evaluated for its use in all-vanadium mixed-acid redox flow battery. This separator consisting of silica particles enmeshed in a polytetrafluoroethylene fibril matrix has no ion exchange capacity and is featured with unique nanoporous structures, which function as the ion transport channels in redox flow battery operation, with an average pore size of 38nm and a porosity of 48%. This separator has produced excellent electrochemical performance in the all-vanadium mixed-acid system with energy efficiency delivery comparable to Nafion membrane and superior rate capability and temperature tolerance. The separator also demonstrates an exceptional capacity retention capability over extended cycling, offering additional operational latitude towards conveniently mitigating the capacity decay that is inevitable for Nafion. Because of the inexpensive raw materials and simple preparation protocol, the separator is particularly low-cost, estimated to be at least an order of magnitude more inexpensive than Nafion. Plus the proven chemical stability due to the same backbone material as Nafion, this separator possesses a good combination of critical membrane requirements and shows great potential to promote market penetration of the all-vanadium redox flow battery by enabling significant reduction of capital and cycle costs.

all-vanadium redox flow battery↗
DOE OSTI2025

Cathode Upcycling for Direct Recycling of Lithium‐Ion Batteries Using a Precipitation Approach

With the increased production of electric vehicles to reduce carbon emissions, the lithium-ion battery market to supply those vehicles has grown dramatically. To enhance battery sustainability and circularity, direct recycling methods aim to recover intact cathode materials. However, end-of-life cathode materials are typically 15–20 years old and often have lower energy density compared to current cathode materials. To address this challenge, a rapid precipitation process is developed to boost energy density by converting low Ni-compositions, LiNi 0.33 Co 0.33 Mn 0.33 O 2 (NMC111), into higher Ni-compositions (NMC622). This process forms a Ni-rich coating on cathode particles that diffuses into the core upon high-temperature relithiation, increasing compositional homogeneity. The upcycling process leverages existing infrastructure, offering low capital cost and minimal additional chemical input. Through ex situ tomographic transmission X-ray microscopy (TXM), 3D Ni:Co elemental mixing is quantified, confirming that elemental content evens at the secondary particle level with a mean NMC622 composition upon relithiation. However, elemental gradients remain in the single crystalline primary particles. Ex situ high-resolution and in situ wide-angle X-ray diffraction reveals concurrent structural changes during the relithiation process. These findings provide key insights into the structural and chemical mechanisms of elemental diffusion to obtain further improvements of increased capacity and retention through compositional conversion of cathode materials.

Cathode Upcycling↗
DOE OSTI2025

Battery‐Grade Lithium Materials: Virgin Production and Recycling, a Techno‐Economic Comparison

Lithium has been identified as an essential mineral to the economic and national security of the United States. It is vital for rechargeable batteries that surround us daily from the personal electronics to large-scale energy storage. With a comprehensive techno-economic analysis, the cost of battery-grade lithium compounds production, i.e., lithium carbonate (LC) is evaluated and lithium hydroxide monohydrate (LHM), from both virgin (spodumene ore and brine) and recycled feedstocks (spent lithium-ion batteries). The goal of this study is to inform about the economics of lithium compounds production with comprehensive insights into differences in manufacturing routes and pave a pathway to explore more innovative, domestic manufacturing processes in future for their cost competitiveness and environmental impact. The study includes details on mining and extraction operations as well as unit level operation in the refining process. Moreover, process level information has been collected for pyrometallurgical and hydrometallurgical battery recycling routes. This analysis shows that brine and direct lithium extraction are the cheapest pathways to produce LC or LHM (between $\$3.39$ and 6.20 kg −1 ). The cost of production in the ore and recycling routes can range between $\$4.17$ and $\$53.41$ kg −1 and is highly depending on capital equipment investment, plant location, and the price of spodumene concentrate SC6.0.

battery recycling↗
DOE OSTI2011

Optimal design of sustainable cellulosic biofuel supply chains: Multiobjective optimization coupled with life cycle assessment and input-output analysis

This article addresses the optimal design and planning of cellulosic ethanol supply chains under economic, environmental, and social objectives. The economic objective is measured by the total annualized cost, the environmental objective is measured by the life cycle greenhouse gas emissions, and the social objective is measured by the number of accrued local jobs. A multiobjective mixed-integer linear programming (mo-MILP) model is developed that accounts for major characteristics of cellulosic ethanol supply chains, including supply seasonality and geographical diversity, biomass degradation, feedstock density, diverse conversion pathways and byproducts, infrastructure compatibility, demand distribution, regional economy, and government incentives. Aspen Plus models for biorefineries with different feedstocks and conversion pathways are built to provide detailed techno-economic and emission analysis results for the mo-MILP model, which simultaneously predicts the optimal network design, facility location, technology selection, capital investment, production planning, inventory control, and logistics management decisions. The mo-MILP problem is solved with an e-constraint method; and the resulting Pareto-optimal curves reveal the tradeoff between the economic, environmental, and social dimensions of the sustainable biofuel supply chains. The proposed approach is illustrated through two case studies for the state of Illinois.

09 BIOMASS FUELS↗
DOE OSTI2014

An Ionic Liquid Reaction and Separation Process for Production of Hydroxymethylfurfural from Sugars

There has been world-wide interest to making plastics out of renewable biomass feedstock for recent years. Hydroxymethylfurfural (HMF) is viewed as an attractive alternate to terephthalic acid (TPA) for production of polyesters (PET) and polyamides. Conversion of sugars into HMF has been studied in numerous publications. In this work, a complete ionic liquid reaction and separation process is presented for nearly stoichiometric conversion of fructose into HMF. Different adsorbent materials are evaluated and silicalite material is demonstrated effective for isolation of 99% pure HMF from actual ionic liquid reaction mixtures and for recovery of the un-converted sugars and reaction intermediate along with the ionic liquid. Membrane-coated silicalite particles are prepared and studied for a practical adsorption process operated at low pressure drops but with separation performances comparable or better than the powder material. Complete conversion of fresh fructose feed into HMF in the recycled ionic liquid is shown under suitable reaction conditions. Stability of HMF product is characterized. A simplified process flow diagram is proposed based on these research results, and the key equipment such as reactor and adsorbent bed is sized for a plant of 200,000 ton/year of fructose processing capacity. The proposed HMF production process is much simpler than the current paraxylene (PX) manufacturing process from petroleum oil, which suggests substantial reduction to the capital cost and energy consumption be possible. At the equivalent value to PX on the molar basis, there can be a large gross margin for HMF production from fructose and/or sugars.

Liu, Wei↗
DOE OSTI2019

Biomass‐based chemical production using techno‐economic and life cycle analysis

Abstract Furfural has been selected as one of the top 30 biomass derived platform compounds by the U.S. Department of Energy based on several indicators including the raw material used for production, estimated processing cost, technical complexity, and market potential. In this work, several high value chemicals such as butadiene, surfactants, jet‐fuels, and lubricants are produced from furfural. The paper proposes the integrated flowsheet to produce those chemical and techno‐economic and life cycle analysis is performed to compare the minimum selling price and environmental impacts of the integrated process. The capital and operating cost for production of lubricants and surfactants is the highest when compared with other products. Production of surfactants performs the best in terms of environmental impacts except in water depletion when compared with other processes while butadiene production performs the worst regarding the environmental effects.

Athaley, Abhay↗
DOE OSTI2022

Minimum reflux calculation for multicomponent distillation in multi‐feed, multi‐product columns: Mathematical model

Abstract Multi‐feed, multi‐product distillation columns are ubiquitous in multicomponent distillation systems. The minimum reflux ratio of a distillation column is directly related to its energy consumption and capital cost. Thus, it is a key parameter for distillation systems design, operation, and comparison. In this series, we present the first accurate shortcut based algorithmic method to determine the minimum reflux condition for any general multi‐feed, multi‐product (MFMP) distillation column separating any ideal multicomponent mixture. The classic McCabe‐Thiele or Underwood method is a special case of this general approach. Compared with existing techniques, this method does not involve any rigorous tray‐by‐tray calculation, nor does it require guessing of key components. In this first part of the series, we present the mathematical model for a general MFMP column, derive constraints for feasible separation and minimum reflux condition, discuss their geometric interpretations, and present an illustrative example to demonstrate the effectiveness of our approach.

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

Modular–scale ethane to liquids via chemical looping oxidative dehydrogenation: Redox catalyst performance and process analysis

The difficulties in the liquefaction and transportation of ethane in shale gas has led to significant rejection, via reinjection or flaring, of this valuable hydrocarbon resource. Upgrading this low–value, isolated ethane into easily transportable liquid fuels is a promising solution to this supply glut. In this study, we present a modular system that can potentially be operated economically at geographically isolated gas–processing facilities. The modular ethane–to–liquids (M–ETL) system uses a chemical looping–oxidative dehydrogenation (CL–ODH) technology to efficiently convert ethane and natural gas liquids into olefins (primarily ethylene) via cyclic redox reactions of highly effective redox catalyst particles. The resulting olefins are then converted to gasoline and mid–distillate products via oligomerization. CL–ODH eliminates air separation and equilibrium limitations for olefin generation. It also simplifies the process scheme and reduces energy consumption. Here, we present experimental proof–of–concept data on CL–ODH conversion of ethane to ethylene. Using the CL–ODH performance data at 750°C, we show that a simple, single–pass configuration can be economically viable at distributed sites. We identify that economic factors such as the capital cost, price of ethane feed, and value of electricity byproduct have strong effects on the required selling price of the liquids. It is also noted that the economic viability of the M–ETL system is relatively insensitive to the liquid yield under a low ethane price scenario. In conclusion, the demand and value of electricity at distributed locations, on the other hand, can play an important role in the optimal process configuration and economics.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

The scaling economics of small unit operations

We present a correlation that represents the capital costs of the components of even very small modular facilities. Conversion of distributed feedstocks (eg, associated natural gas, biomass, and carbonaceous wastes) could provide a small fraction of the liquid fuels now used for transportation in the U.S. (~6%),or nearly half of the chemical products now made from petroleum. However, those resources tend to be available at small geographically distributed sites, and they are difficult or expensive to transport to a distant processing center. Modular, and likely intensified, processes that can be numbered up promise to enable utilizing such distributed resources. Early stage economics evaluation of those processes requires cost estimates for the components, which are likely smaller in scale than can be accommodated by the 0.6 power law typically used in chemical engineering

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Specialty chemicals production case study: Economic analysis of modular chemical process intensification versus conventional stick‐built approaches

Abstract The beneficial synergies of chemical process intensification and plant modularization present a unique step‐wise advancement opportunity for many chemical manufacturers, but economic case studies are needed to raise awareness of such opportunities. The primary objective of this case study is to better understand the business case economics of a specialty chemical plant using modular chemical process intensification (MCPI), by comparing it with that of a conventional stick‐built (CSB) plant that produces the same product at the same production capacity. When comparing MCPI against CSB approaches for a plant project strategy decision, analysts should thoroughly understand and model the differences and similarities in scope bases. The MCPI approach for this case study benefitted from dramatic reductions in capital expenditures (CAPEX). A sizeable reduction in plant spatial volume likely explains some of these reductions. Sizeable operational expenditure (OPEX) reductions with the MCPI plant appear to be associated with the reduced operator staffing required from converting a labor‐intensive batch process into an automated, continuous flow process. Traditional project investment economic measures strongly favored the MCPI case for the design, construction, and operation of the specialty chemical plant. The net present value for the MCPI case was nearly twice that for the CSB case over a ten‐year period, and the payback period for the CSB case was nearly five times longer than that of the MCPI case. The opinion‐based perspective of the study participant identified significant contributors to superior MCPI economic performance for this case study. With the two conditions of low MCPI CAPEX and high product profit margin, economic analysis indicates that incorporation of a backup MCPI train, for operational redundancy when downtime occurs, is a very beneficial strategy.

O'Connor, James T.↗