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DOE OSTI2022

Turbulent flow characteristics in an 84-pin rod bundle for typical and damaged spacer grids

Hexagonal rod bundles arranged in a tightly packed triangular lattice are extensively used for heat transfer and energy generation applications. Staggered spacer grids are used to maintain the structural integrity of gas-cooled fast reactor (GFR) fuel assemblies, while inducing localized turbulence in flow. Damage to these spacer grids results in a disruption of flow fields within these hexagonal fuel bundles. Experimental flow visualizations are critical to identify the differences in local flow properties that the structural damage may cause. This experimental research investigates the flow-field characteristics at a near-wall and center plane in a prototypical 84-pin GFR fuel assembly. Newly installed typical spacers and spacers subject to naturally occurring damage due to material degradation over prolonged experimentation were investigated. Velocity fields were acquired by utilizing the matched-index-of-refraction method to obtain time-resolved particle image velocimetry measurements for a Reynolds number of 12 000. Reynolds decomposition statistical results divulged differences in the time-averaged velocity, velocity fluctuations, flow anisotropy, and Reynolds stress distributions. Galilean decomposition demarcated the influence of spacer grid damage on the velocity fields. To extract turbulent structures and elucidate mechanisms of flow instabilities, proper orthogonal decomposition analysis was employed. Reduced order flow reconstructions enabled the application of vortex identification algorithms to determine the spatial and statistical characteristics of vortices generated. This research work provides unique experimental data on the spacer grid condition-dependent flow. The results offer a deeper understanding of fluid dynamics behavior to support GFR rod bundle design efforts and computational fluid dynamics model validation.

36 MATERIALS SCIENCE↗

DOE OSTI2023

A Better Method to Calculate Fuel Burnup in Pebble Bed Reactors Using Machine Learning

Burnup measurement is an important step in material control and accountancy (MC&A) at nuclear reactors, and may be done by examining gamma spectra of fuel samples. Traditional approaches rely on known correlations to specific photopeaks (e.g. 137 Cs) and operate via a standard linear regression method. However, the quality of these regression methods is limited even in the best case, and is significantly poorer at short fuel cool-down times, due to the elevated radiation background by short life-time isotopes, and self-shielding effect of the fuel. For practical operation of pebble bed reactors (PBRs), quick measurements (in minutes) and short cooling times (in hours) are required from a safety and security perspective. We investigated the efficacy and performance of machine learning (ML) methods to predict the burnup of the pebble fuel from full gamma spectra (rather than specific discrete photopeaks) and found a full-spectrum ML approach to far outperform baseline regression predictions in all measurement and cooling conditions - including in operational-like measurement conditions. We also performed model and data ablation experiments to determine the relative performance impact of our ML methods' capacity to model data nonlinearities and the inherent additional information in full spectra. Applying our ML methods, we found a number of surprising results, including improved accuracy at shorter fuel cooling times (the opposite of the norm), remarkable robustness to spectrum compression (via rebinning), and competitive burnup predictions even when using background signal only (i.e. explicitly omitting known isotope photopeaks).

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

DOE OSTI2024

The influence of laser focusing conditions on the direct laser acceleration of electrons

Direct laser acceleration of electrons during a high-energy, picosecond laser interaction with an underdense plasma has been demonstrated to be substantially enhanced by controlling the laser focusing geometry. Experiments using the OMEGA EP facility measured electrons accelerated to maximum energies exceeding 120 times the ponderomotive energy under certain laser focusing, pulse energy, and plasma density conditions. Two-dimensional particle-in-cell simulations show that the laser focusing conditions alter the laser field evolution, channel fields generation, and electron oscillation, all of which contribute to the final electron energies. The optimal laser focusing condition occurs when the transverse oscillation amplitude of the accelerated electron in the channel fields matches the laser beam width, resulting in efficient energy gain. Through this observation, a simple model was developed to calculate the optimal laser focal spot size in more general conditions and is validated by experimental data.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2026

Proteome-wide analysis of protein stability in Escherichia coli under acid stress

Knowledge of protein acid sensitivity remains sparse and is largely derived from low-throughput, enzyme-specific assays. We used a scalable framework to map acid stability across the Escherichia coli proteome to assess the acid stability of 1,675 unique proteins, estimating pH 50 values for over 90% of them. The parameter pH50 was defined as the pH value at which only 50% of the initial protein remains in solution following acid treatment. Proteome-wide pH 50 values ranged from 2.28 to 6.33 (median 5.11). Approximately 9% of detected proteins remained stable across all tested pH conditions. Our results align with published data and the assay of citrate synthase (GltA) performed here. Protein acid stability differed significantly by subcellular localization: periplasmic proteins were relatively more abundant in the acid-stable group, cytoplasmic proteins were abundant at pH 50 values 4.5–5.5, and inner membrane proteins at higher pH 50 between 5.5 and 6.0. Outer membrane proteins were too few to draw strong conclusions regarding enrichment within specific pH 50 groups. Notably, the periplasmic binding protein of the molybdate ABC transporter (ModA), was enriched after incubation at low pH. Estimated pH 50 values showed no correlation with protein isoelectric point and molecular weight. Together, this work provides the first proteome-wide map of protein acid stability and establishes a general framework for studying different chemical stressors.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

The distribution of [α/Fe] in the Milky Way disc

ABSTRACT Using a sample of red giant stars from the Apache Point Observatory Galactic Evolution Experiment (APOGEE) Data Release 16, we infer the conditional distribution $p([\alpha /{\rm Fe}]\, |\, [{\rm Fe}/{\rm H}])$ in the Milky Way disk for the α-elements Mg, O, Si, S, and Ca. In each bin of [Fe/H] and Galactocentric radius R, we model p([α/Fe]) as a sum of two Gaussians, representing ‘low-α’ and ‘high-α’ populations with scale heights $z_1=0.45\, {\rm kpc}$ and $z_2=0.95\, {\rm kpc}$, respectively. By accounting for age-dependent and z-dependent selection effects in APOGEE, we infer the [α/Fe] distributions that would be found for a fair sample of long-lived stars covering all z. Near the Solar circle, this distribution is bimodal at sub-solar [Fe/H], with the low-α and high-α peaks clearly separated by a minimum at intermediate [α/Fe]. In agreement with previous results, we find that the high-α population is more prominent at smaller R, lower [Fe/H], and larger |z|, and that the sequence separation is smaller for Si and Ca than for Mg, O, and S. We find significant intrinsic scatter in [α/Fe] at fixed [Fe/H] for both the low-α and high-α populations, typically ∼0.04-dex. The means, dispersions, and relative amplitudes of this two-Gaussian description, and the dependence of these parameters on R, [Fe/H], and α-element, provide a quantitative target for chemical evolution models and a test for hydrodynamic simulations of disk galaxy formation. We argue that explaining the observed bimodality will probably require one or more sharp transitions in the disk’s gas accretion, star formation, or outflow history in addition to radial mixing of stellar populations.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2020

Beam energy dependence of net- Λ fluctuations measured by the STAR experiment at the BNL Relativistic Heavy Ion Collider

The measurements of particle multiplicity distributions have generated considerable interest in understanding the fluctuations of conserved quantum numbers in the quantum chromodynamics (QCD) hadronization regime, in particular near a possible critical point and near the chemical freeze-out. Net-protons and net-kaons have been used as proxies for the net-baryon number and net-strangeness, respectively. We report the measurement of efficiency- and centrality-bin width-corrected cumulant ratios (C 2 /C 1 , C 3 /C 2 ) of net- Λ distributions, in the context of both strangeness and baryon number conservation, as a function of collision energy, centrality, and rapidity. The results are for Au + Au collisions at five beam energies ( √s NN = 19.6 , 27, 39, 62.4, and 200 GeV) recorded with the Solenoidal Tracker at RHIC (STAR). We compare our results to the Poisson and negative binomial (NBD) expectations, as well as to ultrarelativistic quantum molecular dynamics (UrQMD) and hadron resonance gas (HRG) model predictions. Both NBD and Poisson baselines agree with data within the statistical and systematic uncertainties. UrQMD describes the measured net- Λ C 1 and C 3 at 200 GeV reasonably well but deviates from C 2 , and the deviation increases as a function of collision energy. The ratios of the measured cumulants show no features of critical fluctuations. The chemical freeze-out temperatures extracted from a recent HRG calculation, which was successfully used to describe the net-proton, net-kaon, and net-charge data, indicate Λ freeze-out conditions similar to those of kaons. However, large deviations are found when comparing with temperatures obtained from net-proton fluctuations. The net- Λ cumulants show a weak but finite dependence on the rapidity coverage in the acceptance of the detector, which can be attributed to quantum number conservation.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2024

First Simultaneous Measurement of Differential Muon-Neutrino Charged-Current Cross Sections on Argon for Final States with and without Protons Using MicroBooNE Data

We report the first double-differential neutrino-argon cross section measurement made simultaneously for final states with and without protons for the inclusive muon neutrino charged-current interaction channel. The proton kinematics of this channel are further explored with a differential cross section measurement as a function of the leading proton’s kinetic energy that extends across the detection threshold. These measurements use data collected with the MicroBooNE detector from 6.4 × 10 20 protons on target from the Fermilab booster neutrino beam with a mean neutrino energy of ∼ 0.8 GeV . Extensive data-driven model validation utilizing the conditional constraint formalism is employed. This motivates enlarging the uncertainties with an empirical reweighting approach to minimize the possibility of extracting biased cross section results. The extracted nominal flux-averaged cross sections are compared to widely used event generator predictions revealing severe mismodeling of final states without protons for muon neutrino charged-current interactions, possibly from insufficient treatment of final state interactions. These measurements provide a wealth of new information useful for improving event generators which will enhance the sensitivity of precision measurements in neutrino experiments. Published by the American Physical Society 2024

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2023

Modeling and Rapid Prototyping of Integrated Transmission-Distribution OPF Formulations with PowerModelsITD.jl

Conventional electric power systems are composed of different unidirectional power flow stages of generation, transmission, and distribution, managed independently by transmission system and distribution system operators. However, as distribution systems increase in complexity due to the integration of distributed energy resources, coordination between transmission and distribution networks will be imperative for the optimal operation of the power grid. However, coupling models and formulations between transmission and distribution is non-trivial, in particular due to the common practice of modeling transmission systems as single-phase, and distribution systems as multi-conductor phase-unbalanced. To enable the rapid prototyping of power flow formulations, in particular in the modeling of the boundary conditions between these two seemingly incompatible data models, we introduce PowerModelsITD.jl, a free, open-source toolkit written in Julia for integrated transmission-distribution (ITD) optimization that leverages mature optimization libraries from the InfrastructureModels.jl-ecosystem. The primary objective of the proposed framework is to provide baseline implementations of steady-state ITD optimization problems, while providing a common platform for the evaluation of emerging formulations and optimization problems. In this work, we introduce the nonlinear formulations currently supported in PowerModelsITD.jl, which include AC-polar, AC-rectangular, current-voltage, and a linear network transportation model. Results are validated using combinations of IEEE transmission and distribution networks.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2026

Multi‐Model Ensembles in Ecosystem Modeling: Challenges and Best Practices for Decision‐Making

Ecosystem models are increasingly central to the decision-making for environmental policy, conservation planning, and climate-related investments. Yet, the growing reliance on Multi-Model Ensembles (MMEs) of ecosystem models by practitioners and policymakers, sometimes under tight timelines and imperfect information, has frequently outpaced the scientific rigor required to ensure ensemble reliability. Here, MMEs refer to approaches that combine targeted predictions from multiple models with the expectation of improving robustness and quantifying predictive uncertainty. Poorly designed MMEs may create a false sense of confidence and lead to suboptimal policy and market decisions. This perspective argues that robust decision-making-relevant MMEs must be grounded on two pillars: (1) rigorous Model Intercomparison Projects (MIPs), which identify inter-model agreement and disagreement, characterize model uncertainties, and evaluate robustness with observationally based benchmarks—MIPs' diagnostic evaluation is so critical that it must be needed to drive MME's decision in model selection and weighting, especially when only a limited number of models available; and (2) co-design by both stakeholders and scientists to ensure that scenarios, metrics and uncertainty requirements provide decision-relevant information. Building upon the past success and lessons from the existing MIPs-MMEs efforts (e.g., climate/Earth system/crop), we derived the theoretical basis for MMEs, addressed their specific challenges in ecosystem modeling, and highlighted proper consideration of model numbers and diversity, risk of model inter-dependence, effective calibration of model parameters, possible overdue of some ecosystem model development, critical roles of open benchmark data across a wide range of conditions, and suggested use of Artificial Intelligence to support MIPs-MMEs. We highlighted the under-recognized opportunity for MIPs and MMEs to drive scientific progress and innovation through identifying better performing models, systematic benchmarking, feedback loops, and targeted model improvement. By following actionable best practice guidelines, MMEs can evolve from ad hoc aggregation of models into a trusted backbone of environmental policy and decision-making.

ecosystem modeling↗

DOE OSTI2023

Solubility behavior and thermodynamic modeling of sodium monosulfoaluminate (“U‐phase”) in cementitious systems

Abstract The “U‐phase,” a sodium‐containing (alumino‐ferrite‐monosubstituent) AFm phase, has been observed to form in sodium‐enriched highly alkaline cementitious systems, for example, of relevance to nuclear waste, and saline industrial brine management. But, minimal information is available of the U‐phase's (e.g., solubility or thermodynamic properties) due to its limited stability and its tendency to transform into ettringite or monosulfoaluminate. Herein, the U‐phase was systematically synthesized at four temperatures (5, 15, 25, and 50°C) and fully characterized in terms of its thermochemical properties. The average composition of the synthesized U‐phase (4CaO·Al 2 O 3 ·1.85SO 3 ·0.85Na 2 O·12H 2 O) deviates slightly from typical disclosures in the literature. The solubility product of the U‐phase formation was measured from conditions of oversaturation. The measured thermodynamic data accurately predicted experimental observations of U‐phase formation in cementitious environments. In general, it was noted that the U‐phase forms and persists (i.e., remains stable) at pH > 13.7 and [Na + ] concentrations superior to 1 mol/L.

Materials Science↗

DOE OSTI2020

Effects of Riser Diameter on Solids Holdup and Particle Velocity Profiles in Circulating Fluidized Bed Riser Systems

Tests were performed in a 0.1-m diameter small circulating fluidized bed (SCFB) and 0.3 m diameter cold flow circulating fluidized bed (CFCFB) riser systems located at the National Energy Technology Laboratory (NETL) to study the effects of riser diameter on the riser hydrodynamics. These tests were performed at solids circulation rates of G s = 20 and 75 kg/m 2 s and superficial gas velocities of U g = 5.8 and 6.5 m/s using high-density polyethylene (HDPE) pellets with a density of 0.863 g/cm 3 , particle size range of 600–1400 µm (with a Sauter mean diameter of 871 µm, placing them in the Geldart B classification). Comparisons of riser axial pressure and solids fraction profiles, radial particle velocity profiles, and radial profiles of higher statistical moments and select chaos analysis parameters were considered. The results showed that for a given U g and G s , the smaller diameter riser exhibited characteristics associated with more dilute solids flow than that observed in the larger diameter riser. Additionally, the larger diameter riser exhibited a downward flow of solids near the wall under all test conditions, whereas the smaller diameter riser data exhibited little or no indications of solids downflow near the wall. Overall, these findings suggest that, from an industrial standpoint, a direct scaleup of small-scale tests cannot readily be accomplished as the solids holdup and the solids velocity profiles in small units (those normally tested in the laboratory) are not similar to those of large units and the performance of large units can therefore not be predicted from small-scale tests.

42 ENGINEERING↗

DOE OSTI2022

To Fail or not to Fail: An Exploration of Machine Learning Techniques for Predictive Maintenance

Predictive maintenance refers to the ability to predict when machinery or systems need to be maintained. Making an accurate prediction is quite challenging given the costs for both over-estimating (unnecessary maintenance and reduction in availability of assets) and under-estimating (untimely breakdowns and possible loss of equipment or lives). To address these challenges researchers were able to develop new approaches for analyzing oil samples taken extracting samples from oil-wetted machinery that may provide information critical to developing predictive capabilities. We consider the problem from both supervised (though data limited) and unsupervised approaches and provide a first look into a data driven approach for identification of condition indicators. Through this work we identify a collection of candidate features that can form the basis of condition indicators for both a high level discrimination of failure vs. normal operation as well as a set for potential failure mode identification. Finally, we present an anomaly detection framework for detecting failures which can be a viable solution for an onboard analysis tool in deployed systems.

predictive maintenance, anomaly detection, Laserne↗

DOE OSTI2024

Communication Lower Bounds and Optimal Algorithms for Multiple Tensor-Times-Matrix Computation

Multiple tensor-times-matrix (Multi-TTM) is a key computation in algorithms for computing and operating with the Tucker tensor decomposition, which is frequently used in multidimensional data analysis. Here, we establish communication lower bounds that determine how much data movement is required (under mild conditions) to perform the Multi-TTM computation in parallel. The crux of the proof relies on analytically solving a constrained, nonlinear optimization problem. We also present a parallel algorithm to perform this computation that organizes the processors into a logical grid with twice as many modes as the input tensor. We show that, with correct choices of grid dimensions, the communication cost of the algorithm attains the lower bounds and is therefore communication optimal. Finally, we show that our algorithm can significantly reduce communication compared to the straightforward approach of expressing the computation as a sequence of tensor-times-matrix operations when the input and output tensors vary greatly in size.

HBL-inequalities↗

DOE OSTI2023

Doppler Lidar Measurements of Wind Variability and LLJ Properties in Central Oklahoma during the August 2017 Land–Atmosphere Feedback Experiment

Abstract Low-level jets (LLJs) are an important nocturnal source of wind energy in the U.S. Great Plains. An August 2017 lidar-based field-measurement campaign [the Land–Atmosphere Feedback Experiment (LAFE)] studied LLJs over the central SGP site in Oklahoma and found nearly equal occurrences of the usual southerly jets and postfrontal northeasterly jets—typically rare during this season—for an opportunity to compare the two types of LLJs during this month. Southerly winds were stronger than the northeasterlies by more than 4 m s −1 on average, reflecting a significantly higher frequency of winds stronger than 12 m s −1 . The analysis of this dataset has been expanded to other SGP Doppler-lidar sites to quantify the variability of winds and LLJ properties between sites of different land use. Geographic variations of winds over the study area were noted: on southerly wind nights, the winds blew stronger at the highest, westernmost sites by 2 m s −1 , whereas on the northeasterly flow nights, the easternmost sites had the strongest wind speeds. Lidar measurements at 5 sites during August 2017, contrasted to the 2016–21 summertime data, revealed unusual wind and LLJ conditions. Temporal hodographs using hourly averaged winds at multiple heights revealed unorganized behavior in the turbulent stable boundary layer (SBL) below the jet nose. Above the nose, some nights showed veering qualitatively similar to inertial oscillation (IO) behavior, but at amplitudes much smaller than expected for an IO, whereas other nights showed little veering. Vertical hodographs had a linear shape in the SBL, indicating little directional shear there, and veering above, resulting in a hook-shaped hodograph with height. Significance Statement Doppler-lidar measurements at the Atmospheric Radiation Measurement (ARM) Southern Great Plains (SGP) were used to quantify the variability of winds and low-level jet (LLJ) properties between five sites of different land use and wind regimes across this area. Knowledge of wind and LLJ structure and dynamics is important for many applications, and strong southerly LLJ winds at night are an important resource for wind energy. The analysis of multiyear (2016–21) summertime LLJ parameters provided insight into the LLJ climatology in this part of the Great Plains.

Meteorology & Atmospheric Sciences↗

DOE OSTI2026

Machine learning of factors for improving oyster hatchery production

Oyster aquaculture and restoration in the Chesapeake Bay are vital, yet hatcheries frequently struggle with inconsistent larval growth and sudden mass mortality events. Unpredictable disruptions in larval production cause large economic losses, represent a perceived risk to growers, and impede industry expansion. To better understand associations between production yield and its potential predictors, we applied machine learning (random forest, and neural network) and statistical (generalized additive model) models to a comprehensive dataset of environmental, water quality, and operational parameters from a Maryland oyster hatchery, aiming to identify key yield predictors and develop a robust forecasting tool. We used recursive Boruta algorithm for variable selection, pinpointing critical predictors, and employed cross-validation to fine-tune model settings. Shapley value analysis offered crucial insights into model interpretations, highlighting week number, Normalized Difference Vegetation Index, salinity, turbidity, and fecundity as primary drivers of yield variability. For low-yield cases, salinity-related variables were particularly important. Our findings provide an early warning system for potential production downturns, empowering hatchery operators to make data-driven decisions for optimizing water conditions, feeding schedules, and broodstock management. By boosting predictability and efficiency, this research directly supports economic stability of the oyster industry and ecological health of the Chesapeake Bay.

Vishwakarma, Srishti [Oak Ridge National Laborator↗

DOE OSTI2024

Vegetation Warming Experiment: Leaf Mass Area, Leaf Carbon and Nitrogen Content, Utqiagvik (Barrow), Alaska, 2017

Leaf mass per area (LMA), leaf carbon and nitrogen content of vegetation (Petasites frigidus) within warming chambers and paired control plots. See related datasets for plant physiology, phenology and environmental conditions. The files included in this data package are in .csv format, and include 2 data files and 4 metadata files.These data were collected in 2017 as part of a series of single-season warming experiments on tundra vegetation on the Barrow Environmental Observatory (BEO), Utqiagvik, Alaska. A different plant species was targeted each year, over four experimental years from 2017–2021. Each year, five warming chambers and paired ambient control plots were deployed from around the time of snowmelt in mid-June through to mid-September. Average seasonal warming of 3–4°C was achieved using Zero Power Warming (ZPW) chambers (Lewin et al, 2017). The Next-Generation Ecosystem Experiments: Arctic (NGEE Arctic), was a research effort to reduce uncertainty in Earth System Models by developing a predictive understanding of carbon-rich Arctic ecosystems and feedbacks to climate. NGEE Arctic was supported by the Department of Energy's Office of Biological and Environmental Research. The NGEE Arctic project had two field research sites: 1) located within the Arctic polygonal tundra coastal region on the Barrow Environmental Observatory (BEO) and the North Slope near Utqiagvik (Barrow), Alaska and 2) multiple areas on the discontinuous permafrost region of the Seward Peninsula north of Nome, Alaska. Through observations, experiments, and synthesis with existing datasets, NGEE Arctic provided an enhanced knowledge base for multi-scale modeling and contributed to improved process representation at global pan-Arctic scales within the Department of Energy's Earth system Model (the Energy Exascale Earth System Model, or E3SM), and specifically within the E3SM Land Model component (ELM).

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

PastoralScape: An Environment-Driven Model of Vaccination Decision Making Within Pastoralist Groups in East Africa

Economic and cultural resilience among pastoralists in East Africa is threatened by the interconnected forces of climate change, contagious diseases spread and evolving national and international trade. A key factor in the resilience of livestock that communities depend on is human decision making regarding vaccination against prevalent diseases such as Rift Valley fever and Contagious Bovine Pleuropneumonia. This paper describes an agent-based model that couples models of disease propagation, animal health, human decision making, and external GIS data sources capturing measures of foraging condition. We describe the design of the sub-models, their coupling, and demonstrate the sensitivity of the model to parameters that relate to controllable factors such as government and NGO information sources that can influence human decision making patterns. This model is intended to form the basis upon which richer economic and human factor models can be built.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2020

Advanced sorbents for modular oxygen production for REMS gasifiers

Under a DOE funded effort, Thermosolv LLC has been developing a sorbent-based oxygen production technology for gasification and oxy-combustion applications. The sorbents utilize oxygen-storage properties of certain perovskites to (1) selectively adsorb oxygen at moderate temperature from compressed air and (2) release the adsorbed oxygen into a vacuum or a sweep gas such as CO2 and/or steam. Through cyclic operations of multiple sorbent beds such a process can be made continuous. Pressure drop across the sorbent bed and other similar design considerations dictate that the sorbent be in the form of a high surface-area-to-volume pellet and yet still possess sufficient crush strength and integrity. Process efficiency is determined by the sorption and desorption kinetics and sorbent capacity. Typical process involves cycle times in the order of 100 seconds, a time too short to fully utilize the full volume of the sorbent and the sorption capacity of the sorbent pellets. As a part of this project, Thermosolv LLC undertook the development of oxygen sorbents as a high-surface area supported sorbent on a light-weight inert support to (1) reduce the cost, (2) increase the productivity, and (3) reduce the overall weight of the reactor. Using a previously developed perovskite (LSCF 1991) with its well-characterized performance, composite sorbent pellets each consisting of an inert core coated by a thin layer of the functional perovskite material were produced. Several low-density, inexpensive inert solids supports in the 1/8”-1/4” size were selected to keep the pressure drop across the sorbent bed in the acceptable range. A number of commercial technologies including spray coating, dip coating, incipient impregnation of porous substrate followed by thermal annealing at various temperatures and duration were employed and tested to produce robust composite supported sorbent pellets. A sense of optimum coating thickness was developed by testing sorbent pellets of various increasing diameter pellets. LSCF-1991extrudates ranging in size from 1/32” to 3/16” were tested in a TGA and in a fixed-bed pressure swing test set-up for sorption/desorption cycles of interest. The data show that for the operational conditions of interest the coating thickness for a supported sorbent pellet needs to be approximately 1/32” (about 0.8 mm). Subsequent work thereby concentrated on developing composite pellets of various substrates, shapes and sizes with coating layer of about this size range. Candidate support materials were chosen based on cost, inertness, mechanical strength, thermal expansion and chemical stability with sorbent material, and in a size range to give an acceptable pressure drop in fixed-bad reactor configurations. Coating application methods used for application of the sorbent onto the support included precipitation, spray coating and dip coating from sorbent slurries and sol gels. For all coated supports where we could successfully apply a uniform coating of desired thickness with an acceptable handling performance in terms of exfoliation, TGA-based cyclic sorption/desorption testing was performed to determine cycling capacity of oxygen. Among nearly twenty different support materials tested, best adhesion performance was obtained from stainless saddle supports. In the bench-scale fixed-bad tests stainless steel saddle support composite pellets with a coating thickness in the 0.6 mm or so range, the composite sorbent pellet performance approached up to 95% of that of the 2 mm parent material pellets. In a parallel approach to reducing the cost of the sorbent, alternate sorbent formulations replacing/reducing the amount of cobalt in the LSCF family were also investigated. Successful formulations that could match the performance of LSCF 1991 were identified based on TGA cyclic tests as LSCF 1919 and LSF 1910. In the range of operational envelop of cycle times and other relevant process operating conditions, the reduced Co formulations showed comparable performance in the bench-scale fixed-bad cyclic operations. As a part of this project, we also attempted substitution of La and Sr with Ca and Ba, and Co with Mn, Ni and Cu with little success, but the overall project goal of reducing sorbent cost in terms of raw material and manufacturing expenses was successful.

01 COAL, LIGNITE, AND PEAT↗