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DOE OSTI2021

Efforts and Innovations to Promote Data Sharing and Data Accessibility in the EGS Collab Experiments

Large-scale scientific research programs such as the EGS Collab experiments and the FORGE program play extremely important roles in advancing geothermal technologies. Such efforts involve a large number of researchers from multiple institutions, last multiple years, and generate large, complex datasets. The value of the research efforts is only realized when the datasets are used by a large community of researchers in the decades to come. A challenge is that due to the complexity of the data, it could require a user to devote a serious effort into understanding the data before the data can be effectively utilized. In the EGS Collab experiments, the team has devoted remarkable efforts and developed many innovative solutions to make the data more accessible to broader team members and future users. This paper documents the experience gained and lessons learned by the EGS Collab team in disseminating the data in the most informative and inspiring forms to maximize the value of this precious dataset. "Accessibility"in the title does not only mean making the raw data available for download. Particularly, we want to emphasize the importance of organizing, annotating, and presenting the data in ways to make it easy to digest by prospective consumers of the data.

circulation↗

DOE OSTI2021

ROP model for PDC bits in Geothermal drilling

Geothermal energy is a renewable source of energy, where heat extraction is preferentially balanced with the reservoir's natural heat recharge rate. The objective of this paper is to present and validate a novel rate of penetration (ROP) model for drilling hard and abrasive formations including granite formations for polycrystalline diamond compact (PDC) bits. The ROP model was developed based on a derived relationship of a threshold weight on cutter (WOC) and its corresponding depth of cut (DOC) for a single cutter. Laboratory data was used to scale the derived single cutter relationship to a full-hole ROP model for PDC bits. The ROP model includes a non-linear correlation for Phase I (inefficient drilling due to low WOB values) and a linear Phase II (efficient drilling) ROP response to WOB. The ROP model was verified using measured drilling parameter data from Utah FORGE well# 58-32 and data from Chocolate Mountains well # 17-8 in Southern California. When compared to oil and gas well drilling, geothermal drilling in granitic formations can be more difficult and complicated due to rock hardness and high temperatures. PDC bits can increase ROP and optimize drilling for these types of hard formations. This paper provides novel insight into the ROP response of PDC bits to drilling operational parameters.

15 GEOTHERMAL ENERGY↗

DOE OSTI2021

Field Experiments and Model Validation: The EGS Collab Project

Implementing enhanced geothermal systems (EGS) will require improvements in understanding stimulation of crystalline rock to create appropriate flow pathways, and the ability to effectively simulate both the stimulation and the flow and transport processes in the resulting fracture network. The US Department of Energy (DOE) is addressing these and other challenges at multiple scales. The EGS Collab project, addressed here, is performing tests and modeling at the 10 m scale. The FORGE project is performing tests at the full reservoir scale. The EGS Collab team created an underground testbed at the Sanford Underground Research Facility (SURF) in Lead, South Dakota, at a depth of approximately 1.5 km to examine hydraulic fracturing (Experiment 1). We are currently building a second testbed at SURF at a depth of about 1.25 km aimed at investigating shear stimulation (Experiment 2). In Experiment 1, we drilled eight boreholes in a well-characterized phyllite and installed geophysical sensors in six of them to create a well-instrumented testbed to allow careful monitoring of stimulation events and flow tests. Numerical simulation was used to answer key experimental design questions, to forecast fracture propagation trajectories and extents, and to analyze and evaluate results both in near-real-time and in detailed process studies. Stimulations performed in this testbed allowed quantification of processes occurring during stimulation and the examination of dynamic flow occurrences. Long-term ambient temperature and chilled water flow tests were performed in addition to many tracer tests to examine system behavior. Our second testbed, targeted at shear stimulation, is currently being built at the SURF Facility at a depth of about 1.25 km in amphibolite under a different set of stress and fracture conditions than Experiment 1.

artificial intelligence↗

DOE OSTI2020

Application of an Embedded Fracture and Borehole Modeling Approach to the Understanding of EGS Collab Experiment 1

EGS Collab is a series of meso-scale experiments and associated numerical simulation activities being funded by the United States Department of Energy, Geothermal Technologies Office (GTO) to investigate enhanced geothermal system processes under in-situ stress and slightly elevated temperature conditions. This project is designed to provide scientists and engineers with immediate access to impermeable rock at scales larger than possible in the laboratory, but generally smaller than those for commercial production. Immediate access to rock is provided via the existing drifts of the former Homestake Gold Mine, now operated as the Sanford Underground Research Facility in Lead, South Dakota. The objectives of the EGS Collab project are to develop well controlled fracture networks between injector and producer boreholes using normal and shear stimulation for permeability enhancement. The first experimental site was located off the West Access drift on the 4850 Level (4850 feet below ground surface) in phyllite of the Precambrian Poorman formation, and involved the creation of a fracture network comprising a combination of hydraulic and natural fractures. A second experimental site is now being considered near the battery alcove on the 4100 Level in amphibolite and rhyolite of the Yates Unit. Data generated during these experiments will be compared against predictions of a suite of computer codes specifically designed to solve problems involving coupled thermal, hydrological, geomechanical, and geochemical processes. Comparisons between experimental and numerical simulation results will provide code developers with direction for improvements and verification of process models, build confidence in the suite of available numerical tools, and ultimately identify critical future development needs for the geothermal modeling community. Moreover, conducting thorough comparisons of models, modelling approaches, measurement approaches and measured data, via the EGS Collab project, will serve to identify techniques that are most likely to succeed at the Frontier Observatory for Research in Geothermal Energy (FORGE), the GTO’s flagship EGS research effort. Experiment 1 has comprised a series of successful tests, including a long-term chilled-water circulation test, but the testbed has two atypical EGS elements. Active ventilation in the adjacent drift over a 50-year period cooled the testbed rock mass and hydraulic fracturing intersected monitoring boreholes making them conduits for fluid flow. Numerical simulations executed in support of the design of the EGS Collab Experiment 1, computed a radial temperature distribution and stress gradient orthogonal to the drift axis, resulting in the forecast of an oblong hydraulic fracture geometry, extended in the direction of the drift from the stimulation borehole. This paper describes the numerical simulation of long-term chilled-water circulation test with an embedded fracture and borehole modeling approach. The principal objective of the simulation work is show agreement between experimental observations in terms of production fluid temperatures, monitoring borehole temperatures, injection and production pressures, and tracer recoveries using a single conceptual model for the fracture network, using characterization and monitoring data generally available for EGS. A secondary objective is to improve the numerical simulation result comparisons with additional data available from the broader monitoring equipment within the testbed versus deeper, hotter, and more remote EGS. One complicating factor for comparisons between the numerical simulation results and experimental observations, is the Joule-Thomson heating associated with large pressure drops across the fracture network.

numerical simulation, embedded fractures and boreh↗

DOE OSTI2023

Deep Learning for Modeling Enhanced Geothermal Systems

Enhanced Geothermal Systems (EGS) offer a vast potential to expand the use of geothermal energy. Heat is extracted from this engineered system by injecting cold water into a subsurface fractures, which are in contact with the hot dry rock, and pulled through the production wells. Creating EGS requires improving the natural permeability of hot crystalline rocks. To develop economically viable EGS reservoirs, significant technical barriers (e.g., better stimulation technologies without adequate water and/or permeability) and non-technical barriers (e.g., land access and permitting) must be overcome. In this short conference paper, we present a workflow to address a part of this challenge – “How to develop economically viable EGS using existing technologies?”. Our workflow called the GeoThermalCloud (GTC) for EGS, leverages recent advances in machine learning, deep learning, and cloud computing. This GTC framework is open-source and available at https://github.com/SmartTensors/GeoThermalCloud.jl. The GTC framework provides trained deep learning (DL) models to estimate the net present value of a given EGS design scenario. The Geothermal Design Tool (https://github.com/GeoDesignTool/GeoDT.git), a fast and simplified multi-physics solver, is used to develop a database for training DL models. The database consists of EGS design parameters (inputs to DL model) and their net present value (output of DL model) in uncertain geologic systems. The EGS design parameters for constructing this training database are based on Utah FORGE but include the options of more wells and deeper depths. The DL models are trained by ingesting the EGS design parameters and estimating the corresponding net present value. Such an emulation allows us to screen various EGS designs quickly and identify good development strategies by coupling them with optimization techniques. Our preliminary results show promise in DL emulation of net present value. However, a lot more work is needed to improve the predictive capability of DL models (i.e., extensive hyperparameter tuning is necessary). This will be the primary focus of our future work.

artificial neural networks, geothermal↗

DOE OSTI2022

Techno-Economic Performance of Eavor Loop 2.0

This project evaluated techno-economic performance for a sample Eavor-Loop 2.0 design for electricity production and direct-use heating. The Eavor-Loop 2.0 design investigated is a 7.5-km deep closed-loop geothermal system consisting of 12 laterals for a total of more than 90 km of downhole well and lateral length. Both a high geothermal gradient scenario of 60 degrees C/km and a low geothermal gradient scenario of 30 degrees C/km were considered. With pure water injected at 60 degrees C and 80 kg/s, reservoir simulations with the Slender-Body Theory simulator indicate average production temperatures over a 30-year lifetime of ~125 degrees C and ~210 degrees C for the low and high geothermal gradient scenario, respectively. These correspond to heat production of ~22 M Wth and ~51 M Wth, respectively. Using IPSEpro simulations, we find average power production of ~2.2 M We and ~8.6 M We, respectively, for a subcritical organic Rankine cycle power plant with air-cooled condensers. Cost estimates indicate the overall capital and levelized costs are dominated by the lateral drilling cost. Obtaining a levelized cost of electricity below $70/M Wh requires a geothermal gradient of 60 degrees C/km, a discount rate below 9%, and lateral drilling cost below $400/m. A well cost model indicates that ~$400/m for the Eavor-Loop 2.0 design investigated can be obtained for a drilling rate of penetration about 40 ft/hr (with bit life of 50 hours), and omitting casing and cement. Traditional (geothermal) well drilling has achieved these drilling rate conditions, including the Utah FORGE project where the rate of penetration has exceeded 50 ft/hr in granite. However, it is unclear if these conditions are still valid for drilling the Eavor-Loop 2.0 laterals (i.e., ~82 km of laterals at 4 to 7.5-km vertical depth with rock temperatures up to 460 degrees C), as such downhole completion has never been developed before. Competitive levelized cost of heat values ($1.2-$8.2/GJ) are calculated, even for the low geothermal gradient scenario (30 degrees C/km) and lateral drilling cost of $600/m.

advanced geothermal system↗

DOE OSTI2023

High conductivity magnesium alloy

A castable, moldable, or extrudable magnesium-based alloy that includes one or more insoluble additives. The insoluble additives can be used to enhance the mechanical properties of the structure, such as ductility and/or tensile strength. The final structure can be enhanced by heat treatment, as well as deformation processing such as extrusion, forging, or rolling, to further improve the strength of the final structure as compared to the non-enhanced structure. The magnesium-based composite has improved thermal and mechanical properties by the modification of grain boundary properties through the addition of insoluble nanoparticles to the magnesium alloys. The magnesium-based composite can have a thermal conductivity that is greater than 180 W/m-K, and/or ductility exceeding 15-20% elongation to failure.

Sherman, Andrew J.↗

DOE OSTI2023

High conductivity magnesium alloy

Sherman, Andrew J.↗

DOE OSTI2023

Report on FY 2023 Experimental Results in Developing the Fabrication Parameters for Alloy 709 in Different Product Forms

The Advanced Reactor Technologies (ART) Program has established a multi-year plan to develop Alloy 709 advanced stainless steel (A709), generate the data package and develop material-specific design parameters in qualifying it as a new structural material for Class A construction in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Division 5, High Temperature Reactors (ASME 2023). In collaboration with material vendors, the Advanced Materials Development activities under ART have successfully scaled the A709 plate form production from a laboratory heat of 500 pounds to commercial heats totaling 133,000 pounds of A709 plate fabricated from three heats. The goal of the overall A709 development program is to establish the necessary microstructural and mechanical properties relationship for A709 to ultimately develop fabrication parameters for other product forms such as bars, pipes, and forgings using the available ART A709 materials. The objective of this A709 development work in FY 2023 is to experimentally determine grain coarsening behavior for the A709 heats and to experimentally generate the continuous cooling precipitation (CCP) diagram for A709 using the as-rolled commercial heat plate materials. Integral to this work is the characterization of the as-rolled materials and the determination of an effective solution-annealing process, which was reported in Y. Wang et al., 2023. This report summarizes the results of the high-speed dilatometry project to develop the CCP diagram using the commercial heat 58776-3RB fabricated by G. O. Carlson and heat 529900-02 fabricated by Allegheny Technologies Incorporated (ATI) Specialty Rolled Products.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Evaluation of Physics-Based Limiter Redesign Drilling and Alternative Bit Design at The Geysers

As part of a U.S. DOE Geothermal Technologies Office funding opportunity, Geysers Power Company, LLC, an indirect subsidiary of Calpine Corporation, partnered with Sandia National Labs, EGI at the University of Utah, and Texas A&M University to demonstrate increased drilling performance at The Geysers Geothermal Field. The performance target in the drilling demonstrations is at least a 25% improvement in rates of penetration with increased time on bottom for each bit. The project will leverage advances in oil and gas drilling technologies including PDC bits, along with the physics-based limiter redesign techniques championed in drilling demonstrations conducted at the Utah FORGE geothermal site. The planned drilling demonstrations are being conducted as part of an existing drilling campaign intended to enhance reservoir utilization. The wells are typically drilled to the top of the reservoir with mud and then air-drilled to total depth (TD) through fractured zones at temperatures ≥ 450°F. A major goal of the project is to assess the effectiveness of implementing mechanical specific energy (MSE) and drilling dysfunction diagnosis and remediation in these challenging environments, as well as alternate bit technologies. The first demonstration well has been completed, with a total of 15 PDC bit runs in the 17.5”, 12.25” and 8.5” sections. Initial analysis shows ROP gains in all three hole sections, especially in the 17.5” and 12.25” sections, compared with conventional roller cone bit runs in the demonstration well and offset wells. However in the 8.5” hole, wear and damage to the PDC bits resulted in relatively short bit runs. Analysis is underway to take advantage of the positive results and remediate the challenges.

15 GEOTHERMAL ENERGY↗

DOE OSTI2024

Decarbonization Dilemmas: Deliberating Difficult Decisions in Laboratory Design

Dive into the depths of design and decision-making, while we discuss the decarbonization of laboratory buildings! Delve into the dense domain of laboratory design and operations, where every development presents a diverse array of dilemmas and delights. Join us for these dynamic sessions focused on decoding the secrets of sustainable success. Dig deep into the dynamic world of heat pump designs and the delicate balance of heating and cooling loads. Debate between constant and variable fume hood designs, where these decisions determine outcomes. Discover the divergent paths of HVAC system implementation, from the deployment of chilled beams to the diverse array of different terminal unit types. But don't delay; decisive action is demanded for these goals! Dare to dream of decarbonization as we direct discussions on retrofitting existing building stock versus innovative new design approaches. Delve into the depths of debate and emerge with a decisive strategy for sustainable success. Discuss recent discoveries in development from experts associated with existing laboratory buildings with decarbonization goals. These insights and lessons learned will help determine the path forward in our industry's drive for decarbonization designs. Decarbonization is no easy task, but with determination, dedication, and devotion, we can defy the odds and forge a brighter future for laboratory design and operations. Let's dare to decarbonize together!

decarbonization↗

DOE OSTI2025

Physics-Based Limiter Redesign and Bit Performance Analysis at The Geysers

As part of a U.S. DOE Geothermal Technologies Office funding opportunity, Geysers Power Company, LLC (GPC), an indirect subsidiary of Calpine Corporation, partnered with Sandia National Labs, EGI at the University of Utah, and Texas A&M University to demonstrate increased drilling performance at The Geysers Geothermal Field. The performance target in the drilling demonstrations is at least a 25% improvement in rates of penetration, with increased footage on bottom for each bit coupled with increased bit life and time drilling. The project leverages advances in oil and gas drilling technologies including PDC bits, along with the physics-based limiter redesign techniques championed in drilling demonstrations conducted at the Utah FORGE geothermal site. The planned drilling demonstrations are being conducted as part of an existing drilling campaign intended to enhance reservoir utilization. The wells are typically drilled to the top of the reservoir with mud and then air-drilled to total depth (TD) through fractured zones at temperatures ≥ 450°F. A major goal of the project is to assess the effectiveness of implementing mechanical specific energy (MSE) and drilling dysfunction diagnosis and remediation in these challenging environments, as well as alternate rock reduction technologies. The first demonstration well has been completed, with 15 PDC bit runs in the 17.5”, 12.25” and 8.5” sections. Initial analysis shows ROP gains in all three sections, especially in the 17.5” and 12.25” sections, compared with conventional roller cone bit runs in the demonstration well and offset wells. However, in the 8.5” hole, wear and damage to the PDC bits resulted in relatively short bit runs. Analysis is underway to take advantage of the positive results and remediate the challenges. This paper provides updates on drilling activities conducted since the Phase 1 demonstration well at GDC-36 which was drilled from November 2023-January 2024. Additional analysis of the bit performance has been conducted. Furthermore, in subsequent wells drilled by GPC, PDC bits have been used extensively, building on the gains realized at GDC-36. GPC has continued to work with bit vendors to identify designs that last longer in the harsh, air-drilled 8.5” portions of the wells. Planning for the Phase 2 demonstration at Prati-44 is ongoing.

15 GEOTHERMAL ENERGY↗

DOE OSTI2025

Wire Arc Additive Manufacturing of Multi-material Parts Using H-13 Tool Steel

H-13 tools steel’s relative hardness, resistance to thermal fatigue, and high tolerance of thermal shock, make it very desirable for use in forging, pressing, casting, and extrusion processes[1]. H-13 is however typically quite expensive when compared to many other steel compositions. It is therefore desirable to encase a lower cost steel composition with H-13. This configuration allows for the benefits of H-13 tooling to be realized, at a considerably reduced cost. To demonstrate the viability of this concept, a casting tool was fabricated using a Wire Arc Additive Manufacturing (WAAM) process. Initial materials testing was conducted on a multi-material wall which consisted of one section of H-13 tool steel, and one section of 410NiNmo. These tests included scanning electron microscopy, energy dispersive X-ray spectroscopy, and hardness testing. This testing generated favorable results and subsequently a casting tool was fabricated for evaluation. Utilization of a Multi-Material WAAM process to fabricate large tooling in this manner could yield significant improvements in material cost, manufacturing agility, and supply chain complexity.

Lambert, Nathan [ORNL] (ORCID:0009000324134206)↗

DOE OSTI2025

Controlled phosphate doping into nanoscopic SiO 2 proton conducting membranes

This article describes a method to introduce phosphate (PO 4 ) into SiO 2 atomic layer deposition (ALD) films in a self-limiting fashion. The method involves the use of a less common phosphate precursor, trimethyl phosphite [P(OMe) 3 ], to introduce PO 4 as a low-level dopant, <1 at. %, into a SiO 2 ALD process using bis(ethylmethylamino)silane and a modified O 3 conversion. P(OMe) 3 does not deposit a film with typical oxygen sources but incorporates as PO 4 in an ABC-type ALD scheme at deposition temperatures ranging from 100 to 300 °C. Addition of up to ∼1 at. % of PO 4 does not significantly impact the film density or concentrations of carbon and nitrogen impurities, which are both <0.4 at. %. Despite the relatively low dopant concentrations, PO 4 incorporation is shown to have a large impact on transport properties of the film. When explored as proton (H + )-conducting membranes, undoped SiO 2 ALD films showed H + conductivities (3 × 10 −6 –8 × 10 −5 S cm −1 ) and low H 2 permeabilities (<10 −9 cm 2 s −1 ) when measured at room temperature. The addition of PO 4 is shown to increase H + conductivity to 2 × 10 −4 S cm −1 , while maintaining low H 2 permeability of <10 −9 cm 2 s −1 . The ratio of H + conductivity to H 2 permeability, a key performance metric for H + -conducting membranes used in water electrolyzers, exceeds that of commercial Nafion-117 membranes. Here, the moderate H + conductivity and very low H 2 permeability of PO 4 -doped SiO 2 films make them promising candidates as fluorine-free replacements for Nafion in applications such as water electrolysis, hydrogen fuel cells, and redox flow batteries.

Atomic layer deposition↗

DOE OSTI2026

Proton Conducting Silicon Oxide Membranes as a Fluorine Free Alternative to Nafion for Low Temperature Water Electrolysis

Driven by environmental and health concerns related to per- and polyfluoroalkyl substances (PFAS), there has been growing interest in developing fluorine-free proton (H + ) exchange membrane (PEM) materials for fuel cells and water electrolyzers. In this study, we present a side-by-side comparison of the key transport properties of submicron thick, PFAS-free amorphous silicon dioxide (SiO 2 ) membranes to Nafion, a fluorinated polymer electrolyte membrane that represents the industry standard for PEM fuel cells and electrolyzers. Here, measurements of proton (H + ) conductivity (σ H + ), hydrogen (H 2 ) permeability (P H 2 ), and electrical resistivity (ρ e – ) were conducted using model thin films comprised of SiO 2 membranes deposited by atomic layer deposition (ALD). Although the H + conductivity of the SiO 2 membranes is 2–3 orders of magnitude lower than Nafion, the addition of phosphorus dopants (PO x ) improves H + conductivity such that the area specific membrane resistance of thin (<50 nm) PO x -doped SiO 2 membranes is more than an order of magnitude lower than Nafion-117. Importantly, the safe operation of such nanoscale membranes within a PEM electrolyzer is feasible thanks to the low H 2 permeability of dense SiO 2 -based membranes, which are predicted to limit H 2 crossover rates to acceptable levels for pressures up to ≈ 100 bar. As a proof-of-principle demonstration, a chip-scale water electrolyzer based on 100 nm thick PO x -SiO 2 membrane is shown to achieve a current density of 2 A cm –2 at a potential of 2.5 V. If this technology can be successfully scaled up, H + conducting oxide membranes offer an attractive PFAS-free alternative to Nafion for efficient and durable water electrolysis and fuel cell technologies.

Nafion↗

DOE OSTI2025

Nanoscopic Plugs Block Hydrogen Crossover in Submicron Thick Proton-Conducting SiO 2 Membranes for Water Electrolysis

Zero-gap electrolyzers based on submicron thick proton-conducting oxide membranes (POMs) represent a promising approach to increasing the efficiency of H 2 production from water electrolysis while moving away from conventional perfluorosulfonic acid (PFSA) membranes. A critical barrier to the commercialization of such electrolyzers is that the ultrathin nature of POMs, which is necessary to achieve low cell resistance, makes them more susceptible to defects that can lead to unacceptably high rates of H 2 crossover. Herein, we demonstrate an approach to mitigate this problem through selective deposition of carbon-containing silicon oxide (SiO x C y ) “nanoplugs” into the defects of submicron thick SiO 2 membranes using a facile electrochemically mediated deposition process. Selective deposition of nanoplugs within the defects was verified by multiple characterization techniques, while scanning electrochemical microscopy (SECM) was used to confirm selective plugging of H 2 -crossover hotspots associated with defects at identical locations. Thanks to the use of nanoplugs, the H 2 permeance of 250 nm thick SiO 2 membranes was reduced by 5 to 6 orders of magnitude compared to the unmodified atomic layer deposition (ALD) SiO 2 membranes while having negligible impact on the ionic resistance of the membrane. These plug-modified membranes also enabled safe and stable operation of a zero-gap full cell electrolysis cell, in contrast to cells lacking nanoplugs that produced anode effluent streams having H 2 concentrations near or exceeding the lower flammability limit (LFL) of H 2 . Furthermore, beyond water electrolysis, this defect-sealing strategy has the potential to be broadly implemented in other applications, such as fuel cells and flow batteries, offering a versatile solution to mitigate crossover-related performance losses.

ALD SiO2↗

DOE OSTI2025

Extremely Durable Concrete using Methane Decarbonization Nanofiber Co-products with Hydrogen

This project successfully developed a scalable, low-cost co-production process for hydrogen (H₂) and carbon nanofibers (CNFs) using methane through catalytic chemical vapor deposition (CVD). CNFs are high-value materials with exceptional mechanical, electrical, and chemical properties, while hydrogen is a critical clean energy resource. By leveraging vapor deposition to create highly dispersed metal catalysts, this work addressed the dual challenge of producing low-cost hydrogen and enhancing the durability of concrete using co-produced CNFs. Unlike prior approaches, which required separating the carbon product from the catalyst, this innovative method integrated the carbon product, catalyst, and silica support as a crack-bridging additive for Portland cement. This novel application aimed to advance the performance of high-performance concrete (HPC) by improving its flexural toughness, durability, and resistance to environmental degradation.

08 HYDROGEN↗

DOE OSTI2025

Modular Processing of Flare Gas for Carbon Nanoproducts

This project demonstrated the technical viability and economic promise of a modular system for converting flared natural gas into valuable carbon nanoproducts (CNPs) through catalytic chemical vapor deposition (CVD). All major project milestones were successfully completed, including reactor design and commissioning, catalyst development, process optimization, technoeconomic analysis, and application testing in concrete systems. The overarching goal was to create a scalable, field-deployable process that valorizes stranded methane by producing high-value carbon materials for use in cementitious composites. At the lab scale, the team designed and built a fluidized bed reactor optimized for use with silica fume-supported nickel catalysts synthesized via atomic layer deposition (ALD). A statistically designed sintering study enabled precise tuning of nickel nanoparticle size, identifying the influence of oxygen partial pressure, time, and temperature on catalyst morphology and performance. These insights allowed the team to target catalyst conditions that maximize carbon nanofilament growth. Subsequent CVD experiments achieved up to 31.8 wt% carbon deposition under optimized conditions, with TEM confirming the presence of nanofilament structures and sustained hydrogen evolution during reaction. Reactor upgrades and empirical fluidization studies supported the development of reliable, repeatable experimental protocols. The modular pilot-scale skid reactor was fully constructed, instrumented, and commissioned. Capable of operating at 675–800°C and pressures up to 290 psig, the system was designed for continuous operation at a carbon production rate of 1 kg/hr. Initial demonstration runs confirmed solids handling, thermal control, and system leak-tightness, although a critical reactor component (the downfeed tube) was inadvertently omitted during final assembly. This omission limited gas–solid contact and prevented meaningful carbon deposition during pilot-scale CVD runs. Nonetheless, the system operated safely under design conditions, and the root cause of performance limitations was clearly identified. Complementary work on UHPC formulations demonstrated that small additions of carbon nanoproducts, including those derived from flare gas, can significantly enhance mechanical performance while preserving workability. A comprehensive study of CNF dispersion techniques and mix design optimization led to a clear protocol for integrating these nanomaterials into concrete. Incorporation of CNPs improved flexural toughness and reduced porosity, supporting their use in high-performance infrastructure applications. A technoeconomic analysis (TEA) confirmed that this process can produce CNP-loaded catalyst material at a levelized cost below $\$$7/kg across a range of catalyst loadings and reaction yields. With estimated market values for the carbon composite product ranging from $\$$14 to over $\$$60/kg, and the ability to blend CNPs into concrete at sub-percent levels with less than 10% added cost, the system presents a compelling economic case. While additional engineering work is needed to optimize fluidization and heat transfer at scale, this project establishes a strong foundation for commercial development. The process is not only technically sound but also economically promising, representing a viable pathway for flare gas mitigation through modular carbon nanomaterial production.

03 NATURAL GAS↗