Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “ASHES”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 757 records · Page 42
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Produced water softening using high-pH catholyte from brine electrolysis: reducing chemical transportation and environmental footprints

This study evaluates the benefits of using brine electrolysis for generating caustic soda (NaOH) and free chlorine for on-site produced water (PWs 1 ) treatment. A two-compartment electrochemical cell was shown to generate NaOH solutions (pH > 12, faradic efficiency 93%) and chlorine (faradic efficiency 32%) from a NaCl brine solution at a current density of 10 mA/cm2. The catholyte was used for softening field-collected PWs. The degree of Mg removal depends mostly on the catholyte/PW mixture pH with pH 11 achieving >90% removal. Ca removal is poor (<10%) due to low bicarbonate alkalinity in the PWs. Soda ash alone at a dose equivalent to the total hardness of the PWs helps CaCO3 precipitation and Ca removal (>90%). The combined treatment of the catholyte and a reduced quantity of soda ash achieves better or comparable Ca removal compared to the full stoichiometric amounts of soda ash alone. Ba and Sr removal patterns closely follow those of Ca, suggesting co-precipitation of these cations as the primary removal mechanism. Organic removal is negligible during chemical softening; however, activated carbon filtration achieves >90% of total organic carbon (TOC) removal in all PWs. A treatment scheme is proposed for field generation of caustic soda and chlorine from PW. The economic analysis demonstrates the significant cost-effectiveness of the approach compared to purchasing the NaOH.

42 ENGINEERING↗
DOE OSTI2022

Mass spectrometric investigations into 3D printed parts to assess radiopurity as ultralow background materials for rare event physics detectors

The mass concentrations of 232 Th and 238 U in several 3D printing filaments and printed polymer parts are reported as measures of their radiopurity. In order to minimize background signals in rare event physics detectors, radiopure polymers are necessary as dielectric and structural materials in their construction. New data are reported for polyvinylidene fluoride (PVDF), polyphenylene sulfide (PPS), and two forms of polyetherimide (PEI, branded ULTEM 1010 and 9085). Data for starting filaments and both simple and complex printed parts are reported. PVDF filaments and simple printed beads, were found to have values of approximately 30 and 50 pg g -1 for 232 Th and 238 U, respectively, while a more complex spring clip part had slightly elevated 232 Th levels of 65 pg g -1 , with 238 U remaining at 50 pg g -1 . PPS filament was found to have concentrations of 270 and 710 pg g -1 for 232 Th and 238 U, respectively, and were not chosen to be printed as those levels were already higher than other material options. ULTEM 1010 filaments and printed complex spring clip parts were found to have concentrations of around 5 and 7 pg g -1 for 232 Th and 238 U, respectively, illustrating no significant contamination from the printing process. ULTEM 9085 filaments were found to have concentrations of around 9 and 5 pg g -1 for 232 Th and 238 U, respectively, while the printed complex spring clip part was found to have slightly elevated concentrations of 25 and 7 pg g -1 for 232 Th and 238 U, respectively. All these results were obtained using a novel dry ashing method in crucibles constructed of ultralow background electroformed copper or, when applicable, microwave assisted wet ashing digestion. Samples and process blanks were spiked with 229 Th and 233 U as internal standards prior to dry/wet ashing and determinations were made by inductively coupled plasma mass spectrometry (ICP-MS). In order to maintain high radiopurity levels, pre-cleaning the filaments before printing and post-cleaning the parts is recommended, although the printing process itself has shown to contribute very minute amounts of radiocontaminants.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Life-Cycle Assessment of Sustainable Aviation Fuel Derived from Paper Sludge

Converting waste paper sludge to sustainable aviation fuel (SAF) offers a circular economy strategy to decarbonize the aviation sector. Here, this study develops a life-cycle assessment (LCA) for converting high-ash paper sludge to SAF in the U.S. using a catalytic sugar upgrading system that consists of ash removal, enzymatic hydrolysis, dehydration, aldol condensation, and hydroprocessing. The LCA is coupled with a process simulation for an industrial-scale biorefinery based on experimental data. We quantified the carbon intensity as 35.7–41.8 gCO 2 eq MJ –1 SAF (–636 to –584 gCO 2 eq per dry kg paper sludge) with acetone as a solvent, renewable fuel, and biobased chemicals; this is further reduced to 5.1–11.1 gCO 2 eq MJ –1 (–925 to –873 gCO 2 eq per dry kg paper sludge) if ash is recycled and used for substituting cement. Converting 1 dry kg paper sludge to SAF with acetone, renewable fuel, and biobased chemicals (–925 to –584 gCO 2 eq) is more climate beneficial than landfilling without landfill gas recovery (791 gCO 2 eq) and with landfill gas recovery (–294 gCO 2 eq). More than 330 million gallons of SAF can be produced annually (>4 million dry t paper sludge/year in the U.S.), resulting in a reduction of 2–7 million tCO 2 eq.

09 BIOMASS FUELS↗
DOE OSTI2022

Identifying amyloid-related diseases by mapping mutations in low-complexity protein domains to pathologies

Proteins including FUS, hnRNPA2, and TDP-43 reversibly aggregate into amyloid-like fibrils through interactions of their low-complexity domains (LCDs). Mutations in LCDs can promote irreversible amyloid aggregation and disease. We introduce a computational approach to identify mutations in LCDs of disease-associated proteins predicted to increase propensity for amyloid aggregation. We identify several disease-related mutations in the intermediate filament protein keratin-8 (KRT8). Atomic structures of wild-type and mutant KRT8 segments confirm the transition to a pleated strand capable of amyloid formation. Biochemical analysis reveals KRT8 forms amyloid aggregates, and the identified mutations promote aggregation. Aggregated KRT8 is found in Mallory–Denk bodies, observed in hepatocytes of livers with alcoholic steatohepatitis (ASH). We demonstrate that ethanol promotes KRT8 aggregation, and KRT8 amyloids co-crystallize with alcohol. Lastly, KRT8 aggregation can be seeded by liver extract from people with ASH, consistent with the amyloid nature of KRT8 aggregates and the classification of ASH as an amyloid-related condition.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2024

Wildland–urban interface wildfire increases metal contributions to stormwater runoff in Paradise, California

The 2018 Camp Fire was a large late-year (November) wildfire that produced an urban firestorm in the Town of Paradise, California, USA, and destroyed more than 18 000 structures. Runoff from burned wildland areas is known to contain ash, which can transport contaminants including metals into nearby watersheds. However, due to historically infrequent occurrences, the effect of wildland-urban interface (WUI) fires, such as the Camp Fire, on surface water quality has not been well-characterized. Therefore, this study investigated the effects of widespread urban burning on surface water quality in major watersheds of the Camp Fire area. Between November 2018 and May 2019, 140 surface water samples were collected, including baseflow and stormflow, from burned and unburned watersheds with varying extent of urban development. Samples were analyzed for total and filter-passing metals, dissolved organic carbon, major anions, and total suspended solids. Ash and debris from the Camp Fire contributed metals to downstream watersheds via runoff throughout the storm season. Increases in concentration up to 200-fold were found for metals Cr, Cu, Ni, Pb, and Zn in burned watersheds compared to pre-fire values. Total concentrations of Al, Cd, Cu, Pb, and Zn exceeded EPA aquatic habitat acute criteria by up to 16-fold for up to five months after the fire. To assess possible transport mechanisms and bioavailability, a subset of 18 samples was analyzed using four filters with nominal pore sizes ranging from 0.22 to 1.2 μm to determine the particulate size distribution of metals. Trace and major metals (Al, Ba, Co, Cr, Cu, Fe, Hg, Mn, Ni, Pb, and Zn) were found mostly associated with larger grain sizes (>0.45 μm), and some metals (Al, Cr, Fe, and Pb) also included a substantial colloidal phase (0.22 to 0.45 μm). This study suggests that fires in the wildland–urban interface increase metal concentrations, mainly through particulate driven transport. The metals with the largest increases are likely from anthropogenic disaster materials, though biomass ash also is a major contributor to water quality. In conclusion, the increase in metals following WUI burning may have adverse ecological impacts.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2013

Investigation of SiO{sub 2}:Na{sub 2}O ratio as a corrosion inhibitor for metal alloys

The silicate is one of the potential compounds used as a corrosion inhibitor for metal alloys. The mixture between silica and sodium hydroxide (NaOH) succeeded to produce the silicate product. The formulation of a silicate product normally variable depended by the different ratio of SiO{sub 2}:Na{sub 2}O. This research utilized the agriculture waste product of paddy using its rice husk. In this study, the amorphous silica content in rice husk ash was used after rice husk burnt in a muffle furnace at a certain temperature. The X-ray diffraction (XRD) analysis was done to determine the existence of amorphous phase of silica in the rice husk ash. There are several studies that recognized rice husk as an alternative source that obtained high silica content. The X-ray fluorescence (XRF) analysis was carried out to clarify the percentage amount of Si and O elements, which referred the silica compound in rice husk ash. The preparation of sodium silicate formulation were differ based on the SiO{sub 2}:Na{sub 2}O ratio (SiO{sub 2}:Na{sub 2}O ratio = 1.00, 2.00 and 3.00). These silicate based corrosion inhibitors were tested on several testing samples, which were copper (99.9%), aluminum alloy (AA 6061) and carbon steel (SAE 1045). The purpose of this study is to determine the appropriate SiO{sub 2}:Na{sub 2}O ratio and understand how this SiO{sub 2}:Na{sub 2}O ratio can affect the corrosion rate of each metal alloys immersed in acidic medium. In order to investigate this study, weight loss test was conducted in 0.5 M hydrochloric acid (HCl) for 24 hours at room temperature.

36 MATERIALS SCIENCE↗
DOE OSTI2020

GaAs growth rates of 528 μm/h using dynamic-hydride vapor phase epitaxy with a nitrogen carrier gas

Herein we demonstrate record GaAs growth rates approaching 530 μm/h using nitrogen carrier gas and 400 μm/h using hydrogen carrier gas in a dynamic-hydride vapor phase epitaxy reactor. We measured root mean square surface roughness below 1 nm using a 1 μm × 1 μm atomic force microscopy scan for GaAs growth rates up to 483 μm/h using a nitrogen carrier gas and 400 μm/h using a hydrogen carrier gas. We performed computational fluid dynamics modeling to study the effect of the carrier gas choice on the thermal profile within the reactor and how that influences the degree of AsH 3 decomposition. The modeling suggests that the lower thermal conductivity of the nitrogen carrier gas minimizes the amount of AsH 3 that thermally decomposes before reaching the wafer surface and the heavier atomic mass decreases the likelihood that AsH 3 will reach the heated reactor walls, leading to a growth rate enhancement relative to the hydrogen carrier case in a hydride-enhanced growth regime.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2013

THE EFFECTS OF CURVATURE AND EXPANSION ON HELIUM DETONATIONS ON WHITE DWARF SURFACES

Accreted helium layers on white dwarfs have been highlighted for many decades as a possible site for a detonation triggered by a thermonuclear runaway. In this paper, we find the minimum helium layer thickness that will sustain a steady laterally propagating detonation and show that it depends on the density and composition of the helium layer, specifically {sup 12}C and {sup 16}O. Detonations in these thin helium layers have speeds slower than the Chapman-Jouget (CJ) speed from complete helium burning, v{sub CJ} = 1.5 × 10{sup 9} cm s{sup –1}. Though gravitationally unbound, the ashes still have unburned helium (≈80% in the thinnest cases) and only reach up to heavy elements such as {sup 40}Ca, {sup 44}Ti, {sup 48}Cr, and {sup 52}Fe. It is rare for these thin shells to generate large amounts of {sup 56}Ni. We also find a new set of solutions that can propagate in even thinner helium layers when {sup 16}O is present at a minimum mass fraction of ≈0.07. Driven by energy release from α captures on {sup 16}O and subsequent elements, these slow detonations only create ashes up to {sup 28}Si in the outer detonated He shell. We close by discussing how the unbound helium burning ashes may create faint and fast 'Ia' supernovae as well as events with virtually no radioactivity, and speculate on how the slower helium detonation velocities impact the off-center ignition of a carbon detonation that could cause a Type Ia supernova in the double detonation scenario.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2019

Microstrip patch antenna for simultaneous temperature sensing and superstrate characterization

This paper investigates a microstrip patch antenna for measuring the thickness and dielectric constant of the medium above the antenna (i.e. the superstrate) as well as the temperature. The intended application is simultaneous sensing of ash accumulation and temperature inside a boiler, with the aim of enhancing safety, improving efficiency, and reducing downtime associated with maintenance. A patch antenna, consisting of a dielectric substrate, a radiation patch, and a ground plane, functions as an electromagnetic resonator with specific fundamental frequencies. A dielectric medium placed above the patch antenna changes its effective dielectric constant and thus its resonant frequencies. Meanwhile, temperature also influences the antenna frequencies because of the thermal expansion of the conductors (i.e. the radiation patch and ground plane), and the dielectric constant of dielectric materials due to their temperature dependency. Since a rectangular patch antenna has two fundamental frequencies, it enables determining these two parameters simultaneously. Once the temperature and superstrate thickness are determined, the dielectric constant of the superstrate and its temperature dependency can also be extracted. To demonstrate this capability, a dual-frequency patch antenna was designed, fabricated, and characterized with a superstrate of various thicknesses and at different temperatures. By fitting the antenna resonant frequencies as functions of the superstrate thickness and temperature, these two parameters were inversely determined from the measured antenna frequencies. Using ash from charcoal briquettes as a superstrate, the measurement uncertainties were determined to be ±0.58 °C and ±58.05 μ m for the temperature and the superstrate thickness respectively. The dielectric constant of the ash was found to be 2.64 at room temperature and its thermal coefficient of dielectric constant (TCD k ) was found to be 918 ppm °C –1 .

36 MATERIALS SCIENCE↗
DOE OSTI2015

Rapid Analysis of Inorganic Species in Herbaceous Materials Using Laser-Induced Breakdown Spectroscopy [plus supplemental information]

Inorganic compounds in biomass, often referred to as ash, are known to be problematic in the thermochemical conversion of biomass to bio-oil or syngas and, ultimately, hydrocarbon fuels because they negatively influence reaction pathways, contribute to fouling and corrosion, poison catalysts, and impact waste streams. The most common ash-analysis methods, such as inductively coupled plasma-optical emission spectrometry/mass spectrometry (ICP-OES/MS), require considerable time and expensive reagents. Laser-induced breakdown spectroscopy (LIBS) is emerging as a technique for rapid analysis of the inorganic constituents in a wide range of biomass materials. This study compares analytical results using LIBS data to results obtained from three separate ICP-OES/MS methods for 12 samples, including six standard reference materials. Analyzed elements include aluminum, calcium, iron, magnesium, manganese, phosphorus, potassium, sodium, and silicon, and results show that concentrations can be measured with an uncertainty of approximately 100 parts per million using univariate calibration models and relatively few calibration samples. These results indicate that the accuracy of LIBS is comparable to that of ICP-OES methods and indicate that some acid-digestion methods for ICP-OES may not be reliable for Na and Al. These results also demonstrate that germanium can be used as an internal standard to improve the reliability and accuracy of measuring many elements of interest, and that LIBS can be used for rapid determination of total ash in biomass samples. Key benefits of LIBS include little sample preparation, no reagent consumption, and the generation of meaningful analytical data instantaneously.

09 BIOMASS FUELS↗
DOE OSTI2018

Mass measurement of 51 Fe for the determination of the 51 Fe($p, γ$) 52 Co reaction rate

Background: The 51 Fe(p, γ) 52 Co reaction lies along the main rp-process path leading up to the 56 Ni waiting point. The uncertainty in the reaction Q value, which determines the equilibrium between the forward protoncapture and reverse photodisintegration 52 Co(γ,p) 51 Fe reaction, contributes to considerable uncertainty in the reaction rate in the temperature range of interest for Type I x-ray bursts and thus to an ≈10% uncertainty in burst ashes lighter than A = 56. Purpose: With a recent Penning trap mass measurement of 52 Co reducing the uncertainty on its mass to 6.6 keV [Nesterenko et al., J. Phys. G 44, 065103 (2017)], the dominant source of uncertainty in the reaction Q value is now the mass of 51 Fe, reported in the 2016 atomic mass evaluation to a precision of 9 keV [Wang et al., Chin.Phys. C 41, 030003 (2017)]. A new, high-precision Penning trap mass measurement of 51 Fe was performed to allow the determination of an improved precision Q value and thus new reaction rates. Method: 51 Fe was produced using projectile fragmentation at the Coupled Cyclotron Facility at the National Superconducting Cyclotron Laboratory, and separated using the A1900 fragment separator. The resulting secondary beam was then thermalized in the beam stopping area before a mass measurement was performed using the LEBIT 9.4T Penning trap mass spectrometer. Results: The new mass excess, ME = -40189.2(1.6) keV, is sixfold more precise than the current AME value, and 1.6σ less negative. This value was used to calculate a new proton separation energy for 52 Co of 1431(7) keV. New excitation levels were then calculated for 52 Co using the NUSHELLX code with the GXPF1A interaction, and a new reaction rate and burst ash composition was calculated. Conclusions:With a new measured Q value, the uncertainty on the 51 Fe(p, γ ) reaction rate is dominated by the poorly measured 52 Co level structure. Finally, reducing this uncertainty would allow a more precise rate calculation and a better determination of the mass abundances in the burst ashes.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2025

Computational Study of a Cryopump Design for Fusion Exhaust Gas Purification Using Direct Simulation Monte Carlo

Cryopump-based direct internal recycling (DIR) of fusion fuel is an attractive prospect because it provides pumping of helium ash from a reactor along with separation of helium and other impurities from the fuel. Previous studies have demonstrated a continuously regenerating cryopump, referred to as the Snail pump, that separates helium ash from fusion fuel for reactor-relevant flow rates. Here, in this study, a conceptual cryopump was designed as a proof-of-principle study to target other impurities, besides helium ash, from the fusion exhaust that would complement the Snail pump. The impurity-removal cryopump consists of four sets of chevron fins, two sets operating at 80 K and the other two at 30 K. A computational study using direct simulation Monte Carlo (DSMC) was performed with a gas mixture of 96.5% D2, 2.0% He, and 0.5% each of CO2, N2, and CH4. In this configuration, 80 K chevron fin sets are capable of capturing CO2 and 30 K sets capable of capturing CO2, N2, and CH4. The computational study showed that the cryopump is capable of reducing the impurity content by more than two orders of magnitude from the flow.

Adhikari, Nirajan [Oak Ridge National Laboratory (↗
DOE OSTI2012

Relationship between Particle Size Distribution of Low-Rank Pulverized Coal and Power Plant Performance

The impact of particle size distribution (PSD) of pulverized, low rank high volatile content Alaska coal on combustion related power plant performance was studied in a series of field scale tests. Performance was gauged through efficiency (ratio of megawatt generated to energy consumed as coal), emissions (SO 2 , NO x , CO), and carbon content of ash (fly ash and bottom ash). The study revealed that the tested coal could be burned at a grind as coarse as 50% passing 76 microns, with no deleterious impact on power generation and emissions. The PSD’s tested in this study were in the range of 41 to 81 percent passing 76 microns. There was negligible correlation between PSD and the followings factors: efficiency, SO 2 , NO x , and CO. Additionally, two tests where stack mercury (Hg) data was collected, did not demonstrate any real difference in Hg emissions with PSD. The results from the field tests positively impacts pulverized coal power plants that burn low rank high volatile content coals (such as Powder River Basin coal). These plants can potentially reduce in-plant load by grinding the coal less (without impacting plant performance on emissions and efficiency) and thereby, increasing their marketability.

Ganguli, Rajive↗
DOE OSTI2011

Evaluation of the Relative Merits of Herbaceous and Woody Crops for Use in Tunable Thermochemical Processing

This report summarizes the work and findings of the grant work conducted from January 2009 until September 2011 under the collaboration between Ceres, Inc. and Choren USA, LLC. This DOE-funded project involves a head-to-head comparison of two types of dedicated energy crops in the context of a commercial gasification conversion process. The main goal of the project was to gain a better understanding of the differences in feedstock composition between herbaceous and woody species, and how these differences may impact a commercial gasification process. In this work, switchgrass was employed as a model herbaceous energy crop, and willow as a model short-rotation woody crop. Both crops are species native to the U.S. with significant potential to contribute to U.S. goals for renewable liquid fuel production, as outlined in the DOE Billion Ton Update (http://www1.eere.energy.gov/biomass/billion_ton_update.html, 2011). In some areas of the U.S., switching between woody and herbaceous feedstocks or blending of the two may be necessary to keep a large-scale gasifier operating near capacity year round. Based on laboratory tests and process simulations it has been successfully shown that suitable high yielding switchgrass and willow varieties exist that meet the feedstock specifications for large scale entrained flow biomass gasification. This data provides the foundation for better understanding how to use both materials in thermochemical processes. It has been shown that both switchgrass and willow varieties have comparable ranges of higher heating value, BTU content and indistinguishable hydrogen/carbon ratios. Benefits of switchgrass, and other herbaceous feedstocks, include its low moisture content, which reduce energy inputs and costs for drying feedstock. Compared to the typical feedstock currently being used in the Carbo-V® process, switchgrass has a higher ash content, combined with a lower ash melting temperature. Whether or not this may cause inefficiencies in the process, needs to be verified by long term test runs. Currently, there are not sufficient operational test data available for the Carbo-V® process for the utilization of higher ash content feedstocks. The application of currently evolving biomass pretreatment technologies, such as pelletization and torrefaction, will be able to expand the portfolio of biomass varieties and species acceptable in gasification processes. Tests showed that 6 mm diameter pellets of switchgrass were superior to 8 mm diameter pellets produced in a flat dye press, and that torrefaction of switchgrass produced an excellent (but currently costly) feedstock that could be handled, crushed, and combusted in a manner compatible with any coal-fed gasification facility. Ceres will use this information in the development of high yielding, dedicated energy crops specifically tailored for thermochemical conversion. CHOREN will make use of the information for improvement or development of low cost, highly efficient biomass gasification processes that convert a wide variety of biomass feedstocks to fuels, chemicals, heat and power via the production of tar free green syngas on an industrial scale.

09 BIOMASS FUELS↗
DOE OSTI2017

Low–Cost Bio-Based Carbon Fiber for High-Temperature Processing

GrafTech International Holdings Inc. (GTI), worked with Oak Ridge National Laboratory (ORNL) under CRADA No. NFE-15-05807 to develop lignin-based carbon fiber (LBCF) technology and to demonstrate LBCF performance in high-temperature products and applications. This work was unique and different from other reported LBCF work in that this study was application-focused and scalability-focused. Accordingly, the executed work was based on meeting criteria based on technology development, cost, and application suitability. The focus of this work was to demonstrate lab-scale LBCF from at least 4 different precursor feedstock sources that could meet the estimated production cost of $5.00/pound and have ash level of less than 500 ppm in the carbonized insulation-grade fiber. Accordingly, a preliminary cost model was developed based on publicly available information. The team demonstrated that 4 lignin samples met the cost criteria, as highlighted in Table 1. In addition, the ash level for the 4 carbonized lignin samples were below 500 ppm. Processing asreceived lignin to produce a high purity lignin fiber was a significant accomplishment in that most industrial lignin, prior to purification, had greater than 4X the ash level needed for this project, and prior to this work there was not a clear path of how to achieve the purity target. The lab scale development of LBCF was performed with a specific functional application in mind, specifically for high temperature rigid insulation. GTI is currently a consumer of foreignsourced pitch and rayon based carbon fibers for use in its high temperature insulation products, and the motivation was that LBCF had potential to decrease costs and increase product competitiveness in the marketplace through lowered raw material costs, lowered energy costs, and decreased environmental footprint. At the end of this project, the Technology Readiness Level (TRL) remained at 5 for LBCF in high temperature insulation.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Low-Cost Bio-Based Carbon Fibers for High Temperature Processing

GrafTech International Holdings Inc. (GTI), under Award No. DE-EE0005779, worked with Oak Ridge National Laboratory (ORNL) under CRADA No. NFE-15-05807 to develop lignin-based carbon fiber (LBCF) technology and to demonstrate LBCF performance in high-temperature products and applications. This work was unique and different from other reported LBCF work in that this study was application-focused and scalability-focused. Accordingly, the executed work was based on meeting criteria based on technology development, cost, and application suitability. High-temperature carbon fiber based insulation is used in energy intensive industries, such as metal heat treating and ceramic and semiconductor material production. Insulation plays a critical role in achieving high thermal and process efficiency, which is directly related to energy usage, cost, and product competitiveness. Current high temperature insulation is made with petroleum based carbon fibers, and one goal of this protect was to develop and demonstrate an alternative lignin (biomass) based carbon fiber that would achieve lower cost, CO2 emissions, and energy consumption and result in insulation that met or exceeded the thermal efficiency of current commercial insulation. In addition, other products were targeted to be evaluated with LBCF. As the project was designed to proceed in stages, the initial focus of this work was to demonstrate lab-scale LBCF from at least 4 different lignin precursor feedstock sources that could meet the estimated production cost of $5.00/pound and have ash level of less than 500 ppm in the carbonized insulation-grade fiber. Accordingly, a preliminary cost model was developed based on publicly available information. The team demonstrated that 4 lignin samples met the cost criteria. In addition, the ash level for the 4 carbonized lignin samples was below 500 ppm. Processing as-received lignin to produce a high purity lignin fiber was a significant accomplishment in that most industrial lignin, prior to purification, had greater than 4X the ash level needed for this project, and prior to this work there was not a clear path of how to achieve the purity target. The lab scale development of LBCF was performed with a specific functional application in mind, specifically for high temperature rigid insulation. GTI is a consumer of foreign-sourced pitch and rayon based carbon fibers for use in its high temperature insulation products, and the motivation was that LBCF had potential to decrease costs and increase product competitiveness in the marketplace through lowered raw material costs, lowered energy costs, and decreased environmental footprint. At the end of this project, the Technology Readiness Level (TRL) remained at 5 for LBCF in high temperature insulation.

09 BIOMASS FUELS↗
DOE OSTI2018

Novel Membrane and Electrodeposition-Based Separation and Recovery of Rare Earth Elements from Coal Combustion Residues (Final Report)

This project developed a hydrometallurgical-based technology to extract and concentrate rare earth elements (REEs) from a representative group of coal combustion residuals (CCRs) from major coal sources in the United States. The approach for REE recovery comprises two general components: (1) Leaching of REEs from CCRs and (2) Separation of REEs from other major ions in the CCR leachate. The leaching step entails acid leaching with nitric or hydrochloric acid, and in some cases, pretreatment of CCRs with alkaline roasting prior to acid leaching. The follow-up REE recovery steps involve a series of membrane-based methods to separate and concentrate rare earth ions from other major ions in acid leachates of CCRs. These methods include liquid emulsion membranes, supported liquid membranes and electrodeposition with carbon nanotube electrochemical filters. The advantage of these separation approaches (relative to conventional approaches such as solvent extraction) is a reduction in the usage of solvents and other costly chemicals and a reduction of hazardous waste products that are challenges in conventional REE separation methods. In the testing of our process, we selected a representative set of CCR samples from our collection and performed a suite of characterization measurements (total REE content and major mineralogy). The major results of this work demonstrated that heated acid leaching could efficiently extract REEs from PRB-based coal fly ashes while the Appalachian and Illinois Basin CCRs required alkaline roasting with NaOH prior to acid leaching at room temperature. The supported liquid membrane (SLM) configuration and electrochemical deposition (ED) system yielded the most promising methods of REE recovery from the acid leachates of fly ash. Our most concentrated product to date comprised 1 wt.% (dry basis) REEs produced from an Appalachian-based fly ash leached and purified by SLM. The SLM separation process was more selective for heavy REEs over the light REEs. When SLM was combined with ED, preliminary results demonstrated that a final product of >2 wt.% REEs was possible.

36 MATERIALS SCIENCE↗