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At least 847 records · Page 47
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Development of an In-Situ Method for Cable Condition Monitoring in Nuclear Power Plants (SBIR Phase IIB Final Report)

This is the final report of a Small Business Innovation Research (SBIR) project that Analysis and Measurement Services Corporation (AMS) has conducted for the U.S. Department of Energy (DOE) over a seven-and-a-half year period (February 2013 through April 2020 with the awards of Phase I, Phase II and Phase IIB projects). The goal of the project was to design, develop, validate, and demonstrate a technique for in-situ testing of cable insulation polymers that will identify, locate, and provide the degree of aging for cables commonly used in nuclear power plants. During the Phase I project, AMS established that the frequency domain reflectometry (FDR) technique can successfully identify and measure cable insulation degradation that can be trended with aging. In Phase II, AMS performed extensive cable aging studies to correlate FDR measurements with other laboratory condition monitoring techniques and developed aging condition categories to quantify the severity of insulation degradation. In Phase IIB, the project expanded the research to include a wider variety of cable polymers that are used in the commercial nuclear power industry. This work also involved developing acceptance criteria to objectively assess age-related cable degradation while sharing the results of this research with industry, academia, and national laboratories to advance the state of the art in cable aging management technologies. The products developed under this research project provide the nuclear industry with an effective condition monitoring tool to support safe and long-term plant operation. Throughout the project, collaborations and support were received from a variety of industry organizations and individuals including DOE National Laboratories as well as nuclear plant utilities and several other industry experts and cable manufacturers. Contributions from these organizations included the donation of new cables, naturally aged cables, and research collaboration. The validation and commercialization of the products of this project were achieved through opportunities to test and demonstrate the technologies’ capabilities on-site at nuclear power generation and research facilities as well as in the laboratory alongside industry peers and cable testing service companies. The research resulted in a technology that can be used to identify, locate, and quantify age-related degradation in several types of cable polymers. This included developing software and hardware as well as the methodology for using the FDR technique to assess age-related degradation of installed cables. The technology developed under this project can provide nuclear plant management, engineers, and technicians with an in-situ electrical test method to determine if in-service cables need to be replaced, monitored on a periodic basis, or show no evidence of significant age-related degradation that may require action. Near the end of this Phase IIB project, the FDR product was sold to a nuclear power utility in South Korea. This sale of a dedicated aging assessment tool is the beginning of a comprehensive contract with the expectation of twelve (12) units sold to that country. Additionally, the FDR technology has been sold to several industry organizations including a nuclear research institute and the Diablo Canyon nuclear power plant. This technology is also being leased by other nuclear industry service companies for incorporation into aging management programs. The cable testing technology that was developed under this project was also integrated into a comprehensive cable aging assessment service that is being offered to the nuclear industry at the request of U.S. nuclear utilities and is currently part of onsite testing services provided by AMS.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2023

AGR-5/6/7 Irradiation Disassembly and Metrology First Look

The Advanced Gas Reactor (AGR) Fuel Development and Qualification Program was established to perform research and development on tristructural isotropic (TRISO)-coated particle fuel to support deployment of high-temperature gas-cooled reactors (HTGRs), which are graphite-moderated nuclear reactors cooled with helium. This work continues as part of the Advanced Reactor Technologies (ART) TRISO Fuel Program. The overarching program goal is to provide a baseline fuel qualification data set to support licensing, deployment, and operation of HTGRs in the United States. To achieve these goals, the program includes fuel fabrication, irradiations of TRISO fuels and high-temperature materials (e.g., graphite), safety testing and post-irradiation examination (PIE), fuel performance modeling, and fission product transport and source term determination. The ART AGR program has conducted four distinct fuel irradiation experiments in the Advanced Test Reactor (ATR) at Idaho National Laboratory (INL). The first of these irradiation tests, designated AGR-1, began in ATR in December of 2006 and ended in November 2009. This experiment was primarily to act as a shakedown test of the multi-capsule test train design and to provide early data on fuel performance that would be used in fuel fabrication process development. AGR-1 fuel kernels were produced on an engineering scale, but the TRISO coatings and cylindrical fuel compacts were fabricated on a laboratory scale. The AGR-1 PIE was completed and the final report was published in 2015. The second irradiation test, AGR-2, started in ATR in June 2010 and ended in October 2013. The AGR-2 irradiation test was designed to provide fuel performance data for coated particles fabricated on an engineering-scale pilot line using a coater with an internal chamber diameter of 150 mm (6 in.). The final PIE report was published in 2021. AGR-3/4, a single irradiation that combined what were originally conceived as the third and fourth tests, was to support the refinement of fission product transport models and to assess the effects of sweep gas impurities on fuel performance and fission product transport. PIE of the AGR-3/4 experiment is still in progress as of this writing. The subject of this report is AGR-5/6/7, the final qualification test of AGR TRISO fuel made entirely at the engineering scale.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

BETO 2021 Peer Review - Strategic Analysis Support WBS 4.1.1.30

Strategic Analysis Support. The objective of the NREL strategic support project is to provide sound, unbiased, and consistent analyses to inform the strategic direction of the DOE BETO office. This project addresses key technological questions, provides critical data needed to inform strategy, and highlights barriers, gaps and data needs in support of the DOE BETO's mission to improve the affordability of bio-based fuels and products. This task employs various quantitative (techno-economic analysis, TEA) and qualitative (gap analysis) approaches to allow for direct comparisons of biomass conversion technologies across a wide slate of processing platforms and products. Furthermore, this project develops and utilizes novel analyses beyond traditional biorefinery focused TEA/LCAs to identify both technical (e.g., in sustainable design) and non-technical (e.g., in value proposition) barriers, as well as to outline mitigation strategies and R&D needs for emerging technologies. Additionally, the project is tasked with evaluating drivers that support the growing bio-economy, which is achieved by the development and public release of tools to advance the understanding and facilitate comparisons of socio-economic impacts along the supply chain. Critical to the success of this project is the development of defensible methodologies, analyses, and tools that are publicly available to support stakeholders and bioeconomy growth. To develop such high-quality analyses, the biggest challenge to this project, as with most analysis focused projects, is the availability and reliability of the underlying data. Therefore, the project team works extensively with key stakeholders (e.g., policy makers, bioenergy technology developers, and investors) in developing and reviewing the results of these analyses to overcome this challenge. Any remaining uncertainties associated with the analysis efforts are clearly defined and quantified.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2020

Calcium Phosphate Catalysts for Ethanol Coupling to Butanol and Butadiene

The catalytic conversion of ethanol to butanol and butadiene at 633 K and atmospheric pressure (7 vol% ethanol) was studied over calcium phosphate materials pretreated over a wide temperature range. For calcium phosphate pretreated at or below 923 K, the resulting solid had an apatite structure identified by X-ray diffraction and strong acid sites probed by triethylamine (TEA) adsorption microcalorimetry. The low temperature pretreated materials were not effective at ethanol coupling reactions but instead were highly selective to acid-catalyzed products ethene and diethyl ether. Pretreatment of calcium phosphate at 973 K transformed the apatite structure to β-tricalcium phosphate, which exposed both acid and base sites evaluated by TEA and CO 2 adsorption microcalorimetry. In conclusion, high temperature pretreated calcium phosphate catalysts formed the coupling products butanol and butadiene during ethanol reaction. The butadiene selectivity was improved by supporting calcium phosphate on zirconia.

09 BIOMASS FUELS↗
DOE OSTI2022

Dynamic and single cell characterization of a CRISPR-interference toolset in Pseudomonas putida KT2440 for β-ketoadipate production from p -coumarate

We report Pseudomonas putida KT2440 is a well-studied bacterium for the conversion of lignin-derived aromatic compounds to bioproducts. The development of advanced genetic tools in P. putida has reduced the turnaround time for hypothesis testing and enabled the construction of strains capable of producing various products of interest. Here, we evaluate an inducible CRISPR-interference (CRISPRi) toolset on fluorescent, essential, and metabolic targets. Nuclease-deficient Cas9 (dCas9) expressed with the arabinose (8K)-inducible promoter was shown to be tightly regulated across various media conditions and when targeting essential genes. In addition to bulk growth data, single cell time lapse microscopy was conducted, which revealed intrinsic heterogeneity in knockdown rate within an isoclonal population. The dynamics of knockdown were studied across genomic targets in exponentially-growing cells, revealing a universal 1.75 ± 0.38 hour quiescent phase after induction where 1.5 ± 0.35 doublings occur before a phenotypic response is observed. To demonstrate application of this CRISPRi toolset, β-ketoadipate, a monomer for performance-advantaged nylon, was produced at a 4.39 ± 0.5 g/L and yield of 0.76 ± 0.10 mol/mol from p-coumarate, a hydroxycinnamic acid that can be derived from grasses. These cultivation metrics were achieved by using the higher strength IPTG (1K)-inducible promoter to knockdown the pcaIJ operon in the βKA pathway during early exponential phase. This allowed the majority of the carbon to be shunted into the desired product while eliminating the need for a supplemental carbon and energy source to support growth and maintenance.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2022

Fabrication and accelerated long-term stability test of asymmetrical hollow fiber-supported thin film oxygen separation membrane

Asymmetrical hollow fiber-supported thin film membrane may provide microstructural advantages for air separation and oxygen production. The fabrication of such a membrane is usually very difficult, particularly the sintering behaviors and thermal expansion coefficient (TEC) mismatch among multiple layers. This directly affects the reliability and long-term stability of the membrane. Here, in this research, the sintering behaviors of a set of simple oxides are systematically studied and ZnO is identified as a material component for composite substrate La 0.6 Sr 0.4 Co 0.2 Fe 0.8 O 3-δ (LSCF)-ZnO. The LSCF-ZnO ratios are further optimized by trading off several factors, e.g., matching the sintering behaviors and TECs of the LSCF-ZnO composite with those of LSCF thin film separation layer while enhancing the substrate strength. With the identified LSCF-ZnO ratio, the LSCF-ZnO composite hollow fiber substrate precursor is formed through slurry spinning process with porous microstructure being formed via phase inversion process. The thin film LSCF dense separation layer is then dip-coated on the substrate followed by co-sintering process. A thin, porous PrBaCo(Fe 0.6 Zr 0.2 Y 0.2 )O 5+δ (PBCFZY) catalyst layer is fabricated on the dense LSCF separation layer with dip-coating and sintering process, forming an asymmetrical membrane device LSCF-ZnO/LSCF/PBCFZY. Oxygen permeation test of the device is systematically conducted, and the fundamental mechanisms are analyzed. An accelerated long-term stability test of the membrane is also conducted (~550h, 46 thermal cycling loads), demonstrating excellent robustness and durability. The device is characterized and analyzed before and after the test. By replacing a considerable amount of high cost LSCF with low cost ZnO in the substrate, it not only enhances the stability but also reduces the capital cost of the membrane for practical applications.

42 ENGINEERING↗
DOE OSTI2023

Climate vs Energy Security: Quantifying the Trade-offs of BECCS Deployment and Overcoming Opportunity Costs on Set-Aside Land

Bioenergy with carbon capture and storage (BECCS) sits at the nexus of the climate and energy security. We evaluated trade-offs between scenarios that support climate stabilization (negative emissions and net climate benefit) or energy security (ethanol production). Our spatially explicit model indicates that the foregone climate benefit from abandoned cropland (opportunity cost) increased carbon emissions per unit of energy produced by 14–36%, making geologic carbon capture and storage necessary to achieve negative emissions from any given energy crop. The toll of opportunity costs on the climate benefit of BECCS from set-aside land was offset through the spatial allocation of crops based on their individual biophysical constraints. Dedicated energy crops consistently outperformed mixed grasslands. We estimate that BECCS allocation to land enrolled in the Conservation Reserve Program (CRP) could capture up to 9 Tg C year –1 from the atmosphere, deliver up to 16 Tg CE year –1 in emissions savings, and meet up to 10% of the US energy statutory targets, but contributions varied substantially as the priority shifted from climate stabilization to energy provision. Furthermore, our results indicate a significant potential to integrate energy security targets into sustainable pathways to climate stabilization but underpin the trade-offs of divergent policy-driven agendas.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

Active Sites in a Heterogeneous Organometallic Catalyst for the Polymerization of Ethylene

Heterogeneous derivatives of catalysts developed by Ziegler and Natta are important for the industrial production of polyolefin plastics. However, the interaction between precatalysts, alkylaluminum activators, and oxide supports to form catalytically active materials is poorly understood. This is in contrast to homogeneous or well-defined heterogeneous catalysts that 20 contain resolved molecular structures that relate to activity and selectivity in polymerization reactions. This study describes the reactivity of triisobutylaluminum with high surface area aluminum oxide and a zirconocene precatalyst. Triisobutylaluminum reacts with the zirconocene precatalyst to form hydrides and passivates –OH sites on the alumina surface. The combination of passivated alumina and zirconium hydrides formed in this mixture generate ion-pairs that 25 polymerize ethylene.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Proof of principle study: synchrotron X-ray fluorescence microscopy for identification of previously radioactive microparticles and elemental mapping of FFPE tissues

Biobanks containing formalin-fixed, paraffin-embedded (FFPE) tissues from animals and human atomic-bomb survivors exposed to radioactive particulates remain a vital resource for understanding the molecular effects of radiation exposure. These samples are often decades old and prepared using harsh fixation processes which limit sample imaging options. Optical imaging of hematoxylin and eosin (H&E) stained tissues may be the only feasible processing option, however, H&E images provide no information about radioactive microparticles or radioactive history. Synchrotron X-ray fluorescence microscopy (XFM) is a robust, non-destructive, semi-quantitative technique for elemental mapping and identifying candidate chemical element biomarkers in FFPE tissues. Still, XFM has never been used to uncover distribution of formerly radioactive micro-particulates in FFPE canine specimens collected more than 30 years ago. In this work, we demonstrate the first use of low-, medium-, and high-resolution XFM to generate 2D elemental maps of ~ 35-year-old, canine FFPE lung and lymph node specimens stored in the Northwestern University Radiobiology Archive documenting distribution of formerly radioactive micro-particulates. Additionally, we use XFM to identify individual microparticles and detect daughter products of radioactive decay. The results of this proof-of-principle study support the use of XFM to map chemical element composition in historic FFPE specimens and conduct radioactive micro-particulate forensics.

62 RADIOLOGY AND NUCLEAR MEDICINE↗
DOE OSTI2021

Guide field effects on the distribution of plasmoids in multiple scale reconnection

The effects of a finite guide field on the distribution of plasmoids in high-Lundquist-number current sheets undergoing magnetic reconnection in large plasmas are investigated with statistical models. Merging of plasmoids is taken into account either assuming that guide field flux is conserved resulting in nonforce-free profiles in general, or that magnetic helicity is conserved and Taylor relaxation occurs to convert part of the summed guide field flux into reconnecting field flux toward minimum energy states resulting in force-free profiles. It is found that the plasmoid distribution in terms of reconnecting field flux follows a power law with index 7/4 or 1 depending on whether merger frequencies are independent of or dependent on their relative velocity to the outflow speed, respectively. This result is approximately the same for the force-free and nonforce-free models, with nonforce-free models exhibiting indices of 2 and 1 for the same velocity dependencies. Distributions in terms of guide field flux yield indices of 3/2 for the nonforce-free model regardless of velocity dependence. This is notably distinct from the indices of 11/8 and 1 for the force-free models independent of and dependent on velocity, respectively. At low guide field fluxes, the force-free models exhibit a second power law index of 1/2 due to nonconstant flux growth rates. The velocity-dependent force-free model predicts the production of slightly more rapidly moving large guide field flux plasmoids which are supported by observational evidence of flux ropes with strong core fields. Implications are discussed on particle acceleration via Fermi processes.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Anolyte Enhances Catalyst Utilization and Ion Transport Inside a CO 2 Electrolyzer Cathode

Electrochemical CO 2 reduction is a promising technology to capture and convert CO 2 to valuable chemicals. High Faradaic efficiencies of CO 2 reduction products are achieved with zero-gap alkaline CO 2 electrolyzers with a supporting electrolyte at the anode (anolyte). Herein, we investigate the effect of anolyte on the electrode properties such as catalyst utilization, ionic accessibility etc. of a CO 2 reduction cathode using electrochemical techniques and cell configurations that avoid the complexities related to co-electrolysis. Using 1M KOH as the anolyte and a Cu gas-diffusion-electrode with low Nafion content as the model CO 2 reduction electrode, we find that electrode capacitance (proxy for electrochemically active surface area) and ionic conductivity inside the cathode increase approximately 4 and 447 times, respectively, in presence of KOH. Liquid anolyte wets the electrode’s pore structure more efficiently than capillary condensation of feed water vapor. The ionomer coverage is very low, and its distribution inside the electrode is highly fragmented. Surface ion conduction mechanisms inside the electrode are orders of magnitude lower than the bulk ion conduction in presence of anolyte. This study shows that when an anolyte (e.g., KOH) is used, catalyst utilization and ionic accessibility inside the electrode increase significantly.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2020

RELOG

RELOG is a supply chain optimization package focusing on reverse logistics and reverse manufacturing. For example,the package can be used to determine where to build recycling plants, what sizes should they have and which customers should be served by which plants. The package supports customized reverse logistics pipelines, with multiple types of plants, multiple types of product and multiple time periods.

ILOEJE, CHUKWUNWIKE↗
DOE OSTI2023

Data for Climate vs Energy Security: Quantifying the Trade-offs of BECCS Deployment and Overcoming Opportunity Costs on Set-Aside Land

Bioenergy with carbon capture and storage (BECCS) sits at the nexus of the climate and energy security. We evaluated trade-offs between scenarios that support climate stabilization (negative emissions and net climate benefit) or energy security (ethanol production). Our spatially explicit model indicates that the foregone climate benefit from abandoned cropland (opportunity cost) increased carbon emissions per unit of energy produced by 14–36%, making geologic carbon capture and storage necessary to achieve negative emissions from any given energy crop. The toll of opportunity costs on the climate benefit of BECCS from set-aside land was offset through the spatial allocation of crops based on their individual biophysical constraints. Dedicated energy crops consistently outperformed mixed grasslands. We estimate that BECCS allocation to land enrolled in the Conservation Reserve Program (CRP) could capture up to 9 Tg C year–1 from the atmosphere, deliver up to 16 Tg CE year–1 in emissions savings, and meet up to 10% of the US energy statutory targets, but contributions varied substantially as the priority shifted from climate stabilization to energy provision. Our results indicate a significant potential to integrate energy security targets into sustainable pathways to climate stabilization but underpin the trade-offs of divergent policy-driven agendas.

Field Data↗
DOE OSTI2021

The Energizer Bunny: Dual-Use Photovoltaic and Pasture-Raised Rabbit Farms (Final Report)

This case study project lays the groundwork for the broader realization of agrivoltaics by considering the techno-economic, environmental, and social aspects of system development and assessing a novel rabbit-based concept. Research on the social and political barriers to agrivoltaic development is sparse, which emphasizes the importance of this project as it provides key insight into the consequential socio-political challenges that may hinder the diffusion of agrivoltaic technology. Additionally, the rabbit agrivoltaic concept is novel and has not been applied in experimental or commercial applications to date. This project advances our understanding of the viability of this co-location scheme through empirical assessment of integrating grazing rabbits with solar. A total of five manuscripts (3 published in peer-reviewed journals, 2 under review) have resulted from this project. The techno-economic component of the project included a) a pilot test study investigating the feasibility of the rabbit agrivoltaic concept and b) an economic analysis of the advantages available to solar operators who leverage grazing animals for lawn maintenance and a dual-revenue stream. Our calculations indicate that the co-location of solar and rabbit farms is a viable form of agrivoltaics, increasing overall site revenue by 2.5%-24.0% above projected electricity revenue. The environmental component of the project entailed an ISO 14040 and 14044 compliant life cycle assessment to quantify the impacts of the rabbit agrivoltaic concept. The results indicate pasture-based agrivoltaic systems provide a dual synergy that produces 69.3% less emissions and demands 82.9% less fossil energy per functional unit of cumulative MWh output of electricity and cumulative kg of meat compared to non-integrated production. The social component of the project included conducting two separate interview studies with agriculture and solar industry professionals and the distribution of a public survey. The interview findings identify the key socio-political opportunities for agrivoltaics include: the retention of agricultural land and rural interests, and increased local level acceptance of solar development. The key barriers to agrivoltaics include: ensuring long term agricultural productivity is not compromised, and subnational zoning strategies. The survey results indicate that support for local solar projects increase by 10% when an agricultural function is incorporated. Survey respondents prefer agrivoltaic projects that are a) designed to provide economic opportunities for farmers and the local community b) located on private property or existing agricultural land, and c) do not threaten local interests. Cumulatively, this project can inform agrivoltaic decision making, solar development practices, rabbit-based applications, land use management, and policy making in a way that supports the furtherance of the renewable energy transition, conserves arable land, and utilizes innovative solar photovoltaic technologies.

14 SOLAR ENERGY↗
DOE OSTI2021

Manufacture of Carbon Foam in Continuous Process at Atmospheric Pressure

CFOAM LLC has been manufacturing CFOAM® vitreous carbon foam from coal in panel form for several years. The process is currently set up in batch mode as two steps, where the first step is conducted at very high pressure. In order to reduce cost and increase capacity, a new process for making carbon foam is being developed that can be performed at atmospheric pressure. This advance in turn would enable the development of a continuous manufacturing process, which is also being pursued. Both carbon foam panels and light weight aggregates are being investigate. Progress on the evolution of the pilot scale manufacturing plant and initial results of processing, microstructure, properties and performance of carbon foam products made using this new process will be discussed. This project is being supported by a cooperative agreement with the Department of Energy – National Energy Technology Laboratory (DE-FOA-0002185, Area of Interest 4: Coal-Derived Carbon Foam Produced via a Continuous Process, award number DE-FE-0031992).

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

Exploratory Synthesis for Reactive f-Element Separations without Solvent

Solvent extraction is commonly used to separate different f-metals found in spent nuclear fuel, but this process results in large volumes of highly contaminated liquid waste that must be remediated or stored at significant expense. The project funded under this award was aimed at addressing solvent-related issues encountered in conventional f-metal separations. Our strategy focused on using solvent-free mechanochemical reactions to prepare lanthanide and actinide borohydride complexes so that they could be separated based on differences in their volatility. Key deliverables described in this report include proof-of-principle results demonstrating that borohydrides called aminodiboranates can be used for volatile lanthanide/lanthanide and lanthanide/uranium separations, as we proposed. Moreover, exploration of a closely related class of borohydrides called phosphinodiboranates allowed us to identify underlying chemical factors that control the volatility of trivalent lanthanide and uranium borohydride complexes with identical structures. Details of published and pending research products are provided, and these include comprehensive synthesis and characterization efforts required to support fundamental studies related to the proposed separations. These technical efforts supported the training of nine graduate students and three undergraduate researchers, and they established air-sensitive transuranic capabilities at the University of Iowa to enhance radiochemical workforce development.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Manufacture of Carbon Foam in Continuous Process at Atmospheric Pressure

CFOAM LLC has been manufacturing vitreous carbon foam from coal in panel form for several years. The process is currently set up in batch mode as two steps, where the first step is conducted at very high pressure. In order to reduce cost and increase capacity, a new process for making carbon foam is being developed that can be performed at atmospheric pressure. This advance in turn would enable the development of a continuous manufacturing process, which is also being pursued. Both carbon foam panels and light weight aggregates are being investigate. Progress on the evolution of the pilot scale manufacturing plant and initial results of processing, microstructure, properties and performance of carbon foam products made using this new process will be discussed. This project is being supported by a cooperative agreement with the Department of Energy – National Energy Technology Laboratory (DE-FOA-0002185, Area of Interest 4: Coal-Derived Carbon Foam Produced via a Continuous Process, award number DE-FE-0031992).

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Manufacture of Carbon Foam in Continuous Process at Atmospheric Pressure

CFOAM LLC has been manufacturing vitreous carbon foam from coal in panel form for several years. The process is currently set up in batch mode as two steps, where the first step is conducted at very high pressure. In order to reduce cost and increase capacity, a new process for making carbon foam is being developed that can be performed at atmospheric pressure. This advance in turn would enable the development of a continuous manufacturing process, which is also being pursued. Both carbon foam panels and light weight aggregates are being investigate. Construction of the pilot scale manufacturing plant has been completed and results of processing, microstructure, properties and performance of carbon foam products made using this new process will be discussed. This project is being supported by a cooperative agreement with the Department of Energy – National Energy Technology Laboratory (DE-FOA-0002185, Area of Interest 4: Coal-Derived Carbon Foam Produced via a Continuous Process, award number DE-FE-0031992).

01 COAL, LIGNITE, AND PEAT↗