Results for “raw materials” — Page 5

DOE OSTI2020

Integrating Clean Energy in Mining Operations: Opportunities, Challenges, and Enabling Approaches

The mining industry is a major source of raw materials for several industries such as manufacturing, transportation, construction, energy, and mining industry itself. It is anticipated that demand for raw materials is going to increase as the population growth and many low-income economies shift to middle-income countries. The increase in mineral demand accompanies by falling mineral ore grade is expected to increase energy demand raising concern of greenhouse gas emission (GHG). Renewable energy can provide mine operators with solutions to several of the challenges they face today, including energy costs, fossil fuel volatility, social license to operate, and meeting environmental, societal, and governance goals. However, the integration of wind, solar, storage, and other renewable technologies face several barriers that are generally not well understood. Many of these barriers will require further research, development, demonstration, and deployment before we see higher levels of renewables adoption in the mining industry. Thus, this report highlights renewable opportunities, barriers, and enabling approaches.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2020

Integrating Renewable Energy into Mining Operations

The mining industry is a major source of raw materials for several industries such as manufacturing, transportation, construction, energy, and mining industry itself. It is anticipated that demand for raw materials is going to increase as the population growth and many low-income economies shift to middle-income countries. The increase in mineral demand accompanies by falling mineral ore grade is expected to increase energy demand raising concern of greenhouse gas emission (GHG). Renewable energy can provide mine operators with solutions to several of the challenges they face today, including energy costs, fossil fuel volatility, social license to operate, and meeting environmental, societal, and governance goals. However, the integration of wind, solar, storage, and other renewable technologies face several barriers that are generally not well understood. Many of these barriers will require further research, development, demonstration, and deployment before we see higher levels of renewables adoption in the mining industry. Thus, this report highlights renewable opportunities, barriers, and enabling approaches.

clean energy↗

DOE OSTI2021

An investigation of hard-disk drive circularity accounting for socio-technical dynamics and data uncertainty

The installed data storage capacity in the U.S. will reach 2.2 Zettabytes by 2025, generating about 50 million units of end-of-life (EOL) hard-disk drives (HDDs) per year. Due to data security concerns, most EOL HDDs are currently shredded (even when still functioning), representing an economic loss. Moreover, raw material extraction linked to the increased demand for storage causes environmental impacts. Besides mitigating the threat posed by sudden restrictions of raw materials, the circular economy (CE) offers to maximize value retention in the economy and reduce the environmental impacts of human activities. Common CE strategies are reusing and recycling products. However, the reuse of hard disk drives is currently burdened by the lack of trust HDD end-users have toward other non-physical means of data removal than shredding. Here, an agent-based modeling (ABM) approach is proposed to explore how techno-economic and social factors affect end-users' decisions to adopt EOL management practices other than shredding. The proposed method also accounts for data uncertainty by applying a semi-quantitative approach. Results demonstrate how increased green procurement and more robust standards could spur end-users' trust toward data-wiping technologies. Even when accounting for uncertainty, HDDs' reuse brings better environmental and economic benefits than HDD shredding followed by material recovery. The semi-quantitative approach proposed in this study could be more universally applied in future ABM, especially given the often-stochastic nature of such models. The developed ABM is also the first to represent several HDD industry stakeholders and demonstrate how the HDD shredding lock-in situation could be resolved.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2024

Scalable electrified cementitious materials production and recycling

The production of Portland cement, the industry-standard cement, contributes ~8% of global CO 2 emissions through fossil-fuel heating and decomposition of limestone (the primary cement raw material). Decarbonization, e.g., via direct electrification, of this 200-year-old liming routine is extremely challenging at the industry scale. We propose a scalable electrochemical decarbonization approach to circumvent the limestone use by switching to carbon-free calcium silicates from abundant minerals and recycled concrete. Water electrolysis produces protons and hydroxides to drive a pH gradient that accelerates Ca 2+ ion leaching from calcium silicates and captures atmospheric CO 2 to form carbon-negative CaCO 3 , which serves as the feedstock for cement manufacturing or as the carbon-mineralized product for cement substitution with permanent carbon storage. Value-added co-products amorphous silica and green H 2 further enhance cement performance and supplant fossil fuels for net-zero transition, respectively. The products readily meet present-day regulatory standards and demands, and the approach readily synergizes with business-as-usual cement manufacturing and concrete construction, which are important for upscaling and structural safety, promising ready reception by the public and industries. Blended Portland cement produced through our approach with carbon-negative CaCO 3 and silica demonstrates enhanced resilience and achieves carbon neutrality or negativity when incorporating storage or circulation of CO 2 from cement plant flue gas, respectively. This low-cost, electrochemical cement production approach using abundant ubiquitous raw materials enables electrification, transition to clean fuel, and decarbonization at a gigaton scale.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Design and Optimization of the Direct Recycling of Spent Li-Ion Battery Cathode Materials

Direct regeneration of spent Li-ion batteries based on the hydrothermal relithiation of cathode materials is a promising next-generation recycling technology. In order to demonstrate the feasibility of this approach at a large scale, we systematically design and optimize the process parameters to minimize both energy and raw material costs. Specifically, the effects of regenerative processing parameters on the composition, structure, and electrochemical performance of the regenerated cathode materials are investigated via systematic characterization and testing. From this analysis, it was found that the raw material costs can be substantially reduced by either replacing the typically employed 4 M LiOH solution by a cost-effective mixture of 0.1 M LiOH and 3.9 M KOH or recycling of the concentrated 4 M LiOH for continuous relithiation processes. Finally, life cycle analysis suggests that this strategy results in reduced energy consumption and greenhouse gas emissions, leading to an increased potential revenue, particularly when compared with hydro- and pyrometallurgical recycling methods.

25 ENERGY STORAGE↗

DOE OSTI2022

Regional analysis of aluminum and steel flows into the American automotive industry

Aluminum and steel represent the two most dominant metals in light duty vehicles, yet the flows of these materials into the American automotive industry have not been well characterized. This study proposes and implements a method for analyzing the flow of these metals into the automotive industry. We create a framework for performing regionally linked, sector specific material flow analyses and use this framework to trace flows of aluminum and steel entering the American automotive industry, focusing on flows downstream from raw material production. We show that automotive aluminum sheet and extrusions are sourced primarily from the NPCC (23%), SERC (20%), MRO (18%), and RFC (13%) NERC regions and a spatially unresolved Local region within the U.S. and Canada (18%). We determine that primary aluminum is largely from Canada (70%), nearly all from Quebec (69%). Further upstream, alumina and bauxite originate mostly from Brazil, Australia, and Jamaica. We also show that finished automotive steel is sourced primarily from the RFC (63%) and SERC (20%) regions. The crude steel supply similarly originates mainly from the RFC (69%) and SERC (7%) regions. Upstream raw materials including coke, coking coal, iron ore, lime, and steel scrap are primarily sourced from the U.S. with only direct reduced iron and pig iron used in electric arc furnace steel production coming mostly from outside the U.S. The framework developed here allows for increased spatial resolution of material flows, which can be used to develop more specific life cycle impact factors for life cycle assessments.

aluminum↗

NASA NTRS1996

Cost Models for MMC Manufacturing Processes

The quality cost modeling (QCM) tool is intended to be a relatively simple-to-use device for obtaining a first-order assessment of the quality-cost relationship for a given process-material combination. The QCM curve is a plot of cost versus quality (an index indicating microstructural quality), which is unique for a given process-material combination. The QCM curve indicates the tradeoff between cost and performance, thus enabling one to evaluate affordability. Additionally, the effect of changes in process design, raw materials, and process conditions on the cost-quality relationship can be evaluated. Such results might indicate the most efficient means to obtain improved quality at reduced cost by process design refinements, the implementation of sensors and models for closed loop process control, or improvement in the properties of raw materials being fed into the process. QCM also allows alternative processes for producing the same or similar material to be compared in terms of their potential for producing competitively priced, high quality material. Aside from demonstrating the usefulness of the QCM concept, this is one of the main foci of the present research program, namely to compare processes for making continuous fiber reinforced, metal matrix composites (MMC's). Two processes, low pressure plasma spray deposition and tape casting are considered for QCM development. This document consists of a detailed look at the design of the QCM approach, followed by discussion of the application of QCM to each of the selected MMC manufacturing processes along with results, comparison of processes, and finally, a summary of findings and recommendations.

Elzey, Dana M.↗

NASA NTRS1978

High-purity silicon for solar cell applications

The article discusses the production of solar cells from high-purity silicon. The process consists of reducing the level of impurities in the raw materials, preventing material contamination before and after entering the furnace, and performing orders-of-magnitude reduction of metal impurity concentrations. The high-purity raw materials are considered with reference to carbon reductants, silica, and graphite electrodes. Attention is also given to smelting experiments used to demonstrate, in an experimental-scale furnace, the production of high-purity SoG-Si. It is found that high-purity silicon may be produced from high-purity quartz and chemically purified charcoal in a 50-kVA arc furnace. The major contamination source is shown to be impurities from the carbon reducing materials.

Dosaj, V. D.↗

DOE OSTI2021

Using diglycolamides to improve rare-earth element separation

The family of 17 elements known as the “rare earth elements” are difficult to produce economically. Despite this, they are described as “critical raw materials” because of their unique properties and their various technological applications. This means their use is accelerating globally. Separation of these elements is a fundamental challenge, but this does not daunt Dr Santa Jansone-Popova and her team at Oak Ridge National Laboratory. In recovering praseodymium from neodymium using a variety of ligands known as diglycolamides, she has been demonstrating potentially game-changing advances in liquid-liquid separations that could realise more of these in-demand materials.

Jansone-Popova, Santa↗

NASA NTRS1979

Solar silicon via the Dow Corning process

Technical feasibility for high volume production of solar cell-grade silicon is investigated. The process consists of producing silicon from pure raw materials via the carbothermic reduction of quartz. This silicon was then purified to solar grade by impurity segregation during Czochralski crystal growth. Commercially available raw materials were used to produce 100 kg quantities of silicon during 60 hour periods in a direct arc reactor. This silicon produced single crystalline ingot, during a second Czochralski pull, that was fabricated into solar cells having efficiencies ranging from 8.2 percent to greater than 14 percent. An energy analysis of the entire process indicated a 5 month payback time.

Hunt, L. P.↗

NASA NTRSDate not supplied

Reusable TPS Materials Development Activities at NASA Ames

Recent developments in low-cost access to low-earth orbit (LEO) and hypersonic flight are driving renewed demand in reusable thermal protection systems (RTPS) that have not had broad application since the Space Shuttle era. Modern systems will need to consider full cycle cost (lower cost raw materials, manufacturing, integration, and refurbishment) in addition to improved performance to enable this new generation of space flight. NASA Ames Research Center (ARC) has a long history of RTPS development including modern state-of-the-art materials like Alumina Enhanced Thermal Barrier (AETB), and multi-component systems like Toughened Uni-piece Fibrous Reinforced Oxidation-resistant Composite (TUFROC). Now, ARC is supporting the growing commercial space field through internal research and development efforts for high-risk low TRL materials and collaboration with commercial partners including technology transfer. This talk will discuss the current development efforts at ARC that span updating legacy insulating systems with modern raw materials and processes to totally novel designs for heat pipes with various low-TRL activities in between. It will also discuss Ames’ recent re-investment in experimental capabilities to enable characterization and material testing.

Adam Caldwell↗

NASA NTRS1985

Characterization of ZrO2-Y2O3 thermal spray powder systems

The overall objective is to establish the interrelation between the raw material in the coating process and the performance of the coating deposit. It is anticipated that these interrelations will help establish more precise specifications for the procurement of the raw materials. Some of the preliminary results of the program are presented.

Mantkowski, Thomas E.↗

NASA NTRSDate not supplied

New Development Activities at NASA Ames in Reusable TPS Materials

Over the last few years, new activities in rapid, low-cost access to low-earth orbit (LEO) and hypersonic flight have refreshed interest in reusable thermal protection systems (RTPS) that have not had broad application since the Space Shuttle era. Development of novel systems having a greater consideration of full cycle cost (lower cost raw materials, manufacturing, integration, and refurbishment) in addition to improved performance are needed to enable this new generation of space flight. NASA Ames has a long history of RTPS development including invention of flexible blankets such as Advanced Flexible Reusable Surface Insulation (AFRSI), rigid ceramic tiles like Fibrous Refractory Composite Insulation (FRCI) and Alumina Enhanced Thermal Barrier (AETB), and multi-component systems like Toughened Uni-piece Fibrous Reinforced Oxidation-resistant Composite (TUFROC). In much more recent times, NASA Ames is supporting the growing commercial space field through internal research and development efforts for high-risk low TRL materials and collaboration with commercial partners including technology transfer. This talk will discuss the current development efforts that span broadly from updating legacy insulating systems with modern raw materials and processes to totally novel designs for heat pipes with various low-TRL activities in between. It will also discuss Ames’ recent re-investment in experimental capabilities to enable characterization and material testing.

Reusable thermal protection materials↗

NASA NTRSDate not supplied

New Development Activities at NASA Ames in Reusable TPS Materials

Over the last few years, new activities in rapid, low-cost access to low-earth orbit (LEO) and hypersonic flight have refreshed interest in reusable thermal protection systems (RTPS) that have not had broad application since the Space Shuttle era. Development of novel systems having a greater consideration of full cycle cost (lower cost raw materials, manufacturing, integration, and refurbishment) in addition to improved performance are needed to enable this new generation of space flight. NASA Ames has a long history of RTPS development including invention of flexible blankets such as Advanced Flexible Reusable Surface Insulation (AFRSI), rigid ceramic tiles like Fibrous Refractory Composite Insulation (FRCI) and Alumina Enhanced Thermal Barrier (AETB), and multi-component systems like Toughened Uni-piece Fibrous Reinforced Oxidation-resistant Composite (TUFROC). In much more recent times, NASA Ames is supporting the growing commercial space field through internal research and development efforts for high-risk low TRL materials and collaboration with commercial partners including technology transfer. This talk will discuss the current development efforts that span broadly from updating legacy insulating systems with modern raw materials and processes to totally novel designs for heat pipes with various low-TRL activities in between. It will also discuss Ames’ recent re-investment in experimental capabilities to enable characterization and material testing.

Reusable thermal protection materials↗

NASA NTRS1980

Coal gasification systems engineering and analysis. Appendix A: Coal gasification catalog

The scope of work in preparing the Coal Gasification Data Catalog included the following subtasks: (1) candidate system subsystem definition, (2) raw materials analysis, (3) market analysis for by-products, (4) alternate products analysis, (5) preliminary integrated facility requirements. Definition of candidate systems/subsystems includes the identity of and alternates for each process unit, raw material requirements, and the cost and design drivers for each process design.

Source record↗

DOE OSTI2024

Manufacturing and Additive Design of Electric Machines by 3D Printing (MADE3D) (Final Technical Report)

As the U.S clean energy transition hinges on the growth of offshore wind, this is expected to be a major driver for innovations in manufacturing, material and design advancements to enable robust and cost-competitive wind turbines. The race to build larger and taller turbines rated 10 megawatts (MW) and beyond, has intensified pressure on OEMs in terms of logistics of handling and transporting large wind components, securing critical raw material as well as scaling up necessary domestic production infrastructure to meet the demand. There is increased interest in building lightweight, more efficient, and high-power dense drivetrains that will ease the burden on installation, minimize the raw material demand, increasing domestic sourceability. Despite good efficiency and reliability, existing drivetrain technologies such as direct-drive permanent magnet generators are heavy (> 300 tons), expensive, and often rely on large quantities of rare-earth permanent magnets (PMs), steel and copper.

17 WIND ENERGY↗

NASA NTRS1994

Preparation and Dielectric Measurements of the Rare Earth Green Phases R2BaCuO(5-x) (R = Y, Sm, Gd, Dy, Ho, Er, Yb)

It has been demonstrated that R2BaCuO(5-x) (R = Y, Sm, Gd, Dy, Ho, Er, Yb) does not undergo significant densification unless the sintering temperatures are near the incongruent melting point or the sintering times are long. Good quality powders of Y2BaCuO(5-x) have been synthesized by using oxide raw materials or precursors such as acetates and nitrates. The acetates- and the nitrates-derived yttrium green phase resulted in finer particle sizes, acceptable dielectric properties and lower melting temperatures than those processed via oxide raw materials. The hot pressing technique has been employed to produce a dense R2BaCuO(5-x) (R=Y,Gd) substrate with satisfactory dielectric properties. Reactivity to reducing conditions, i.e. graphite die, limited the optimization of the properties. A high sensitivity to the annealing atmosphere has been demonstrated in Y2BaCuO,.,,. Oxygen treatment at 950 OC has been shown to improve the dielectric properties while treatment in nitrogen, at the same temperature, degraded desirable properties. A high sensitivity to the annealing atmosphere has been demonstrated in Y2BaCuO(5-x). Oxygen treatment at 950 C has been shown to improve the dielectric properties while treatment in nitrogen, at the same temperature, degraded desirable properties. The dielectric constants of the rare earth green phases R2BaCuO(5-x) were found to be low. Relaxation peaks were detected at low temperatures (T less than 150 K) and at high temperatures (150 less than T greater than 420 K). The dielectric losses and conductivities at 77 K were measured to be in the range of 10(exp -4) and 10(exp -12) (Omega-cm)(exp -1), respectively. Many parameters were found to exhibit dependencies on the rare earth cation sizes.

Gonzalez-Titman, Carlos↗

NASA NTRS1978

Process feasibility study in support of silicon material task 1

Initial results for gas thermal conductivity of silicon tetrafluoride and trichlorosilane are reported in respective temperature ranges of 25 to 400 C and 50 to 400 C. For chemical engineering analyses, the preliminary process design for the original silane process of Union Carbide was completed for Cases A and B, Regular and Minimum Process Storage. Included are raw material usage, utility requirements, major process equipment lists, and production labor requirements. Because of the large differences in surge tankage between major unit operations the fixed capital investment varied from $19,094,000 to $11,138,000 for Cases A and B, respectively. For the silane process the original flowsheet was revised for a more optimum arrangement of major equipment, raw materials and operating conditions. The initial issue of the revised flowsheet (Case C) for the silane process indicated favorable cost benefits over the original scheme.

Fang, C. S.↗