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At least 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Reassessing early-age strength development of high-volume fly ash concretes for precast buildings

Increasing beneficial use of fresh or landfilled fly ash as a replacement for Portland cement can be more challenging for the construction of precast buildings or similar applications requiring rapid strength development. Therefore, the framework presented in this paper aims to reassess high-volume fly ash concretes but in the context of facilitating more sustainable precast buildings. More specifically, the framework was used to characterize strength development of concrete mixes with a target minimum 24-hour compressive strength of 24.1 MPa (3500 psi), selected as an example strength development metric to demonstrate the framework, and comprised of 40% Class C, Class F, and landfilled (harvested) fly ash – as a high-volume replacement of Type III or Type IL cement. High-early strength was driven by optimized dosages of commercial grade gypsum and accelerating admixtures, in addition to optimal aggregate packing and mix proportioning strategies. Early-age mechanical properties including compressive strength, modulus of rupture, and modulus of elasticity were reevaluated within 24 hours of batching with respect to common precast production demands. Simple data analyses were then used to highlight cases where currently accepted design provisions for the aforementioned properties are either overly-conservative or unconservative with respect to test data. Furthermore, the framework and demonstration of example mixes presented herein aim to promote confidence for using larger fractions of fresh or landfilled fly ashes for precast buildings to further enhance environmental benefits without sacrificing pertinent early-age structural performance.

42 ENGINEERING↗
DOE OSTI2025

Three-Dimensional Pore Networks in Miocene Stevens Sandstone of California: Implications for CO 2 Geologic Storage

The Miocene Stevens Sandstone in the San Joaquin Basin of California is increasingly recognized as a promising candidate for CO 2 geological storage due to the enormous storage capacity, proven sealing, and existing infrastructure. In this study, computed microtomography imaging and pore network modeling were employed to investigate the influence of pore geometry and wettability on the CO 2 injectivity and residual trapping. Image analysis revealed that a significant fraction of the cement and matrix consists of microporous regions. The microporosity can substantially increase the overall pore space, yet its contribution to permeability remains modest, particularly in samples with low permeability. The intrinsic heterogeneity of turbidite reservoirs further complicates the reservoir properties among different layers. Two-phase flow simulations under varying wettability conditions (water-wet, weak water-wet, and neutral-wet) demonstrated that the CO 2 injection is predominantly controlled by macropores. CO 2 invades microporous regions only after these larger pores are filled. The presence of microporosity leads to a decrease in both initial and residual CO 2 saturations, with the magnitude of the reduction being influenced by wettability. Neutral-wet scenarios exhibit higher CO 2 mobility and thus lower residual trapping than water-wet scenarios. The results imply that heterogeneity in pore geometry and cement distribution across different layers can result in stratified CO 2 flow pathways, complicating efforts to predict injection performance. Overall, the Stevens Sandstone shows considerable promise for CO 2 geologic storage, but effective implementation will require detailed characterization of the pore structure as well as the integration of reactive fluid flow to account for potential mineral dissolution and fines migration.

fluids↗
DOE OSTI2026

Effect of Lithium Doping on MgO Hydroxylation and Carbonation

Recovery of magnesium from brines can potentially be used to source MgO (periclase) as a CO 2 sorbent or for Mg-based cements. However, it is not clear how common impurities in brines, such as lithium, affect the resulting MgO reactivity. Here, to test the effect of lithium incorporation on MgO reactivity for hydration and carbonation, we combined computational simulations with experiments. Experimentally altered (Mg,Li)O with a low dopant concentration (0.012 ± 0.002% w/w Li) was characterized using synchrotron-based X-ray scattering and high-resolution electron microscopy to measure reaction layer formation on (Mg,Li)O. Single-crystal X-ray diffraction analysis of (Mg,Li)O demonstrates that the incorporation of lithium leads to the formation of oxygen vacancies. The presence of vacancies is likely causing faster hydroxylation rates as predicted by ab initio molecular dynamics simulations. However, the faster hydroxylation rates likely lead to faster passivation of the surface because we observe thinner reaction layers on (Mg,Li)O samples both over short time periods (30 days) and over long time periods (28 years). After 28 years, the reaction layer on the (Mg,Li)O sample was less than one-third of the thickness of that of the pure MgO sample. In addition, over 30 days, reaction layers on (Mg,Li)O samples primarily formed at steps rather than on terraces, in contrast to our previous observations on MgO. Based on our results, naturally occurring impurities in MgO modify its reactivity even at very low concentrations and need to be considered for accurate reaction rate prediction for application of MgO as a CO 2 sorbent or in cements.

MgO↗
DOE OSTI2025

Geo-Responsive Chemomechanics in Aluminum Oxyhydroxide via Alkali-Driven Dehydroxylation for Supercritical Geothermal Systems

Widespread use of enhanced geothermal systems can revolutionize global renewable electrical power access, yet its advancement is hindered by the inherent instability of Portland cement-based chemistries for geothermal well construction under high-temperature corrosive conditions. Here, in this work, we demonstrate the tunable mechanical performance of aluminum oxyhydroxides as cementitious materials through an alkali-controlled dehydroxylation reaction pathway for long-term applications under supercritical geothermal environments. Notably, the synthesized aluminum oxyhydroxides demonstrate remarkable stability, maintaining superior mechanical performance under supercritical conditions for over 30 days. Synchrotron X-ray diffraction, spectroscopy measurements and geochemical thermodynamic modeling uncover that the gibbsite dehydroxylation pathway functions as a key dial for tuning the chemomechanics, rendering the aluminum oxyhydroxide a strong cementitious material. By uncovering the mechanistic role of alkali-driven dehydroxylation, this work proposes a cementitious chemistry distinct from conventional Portland cement and geopolymer-dominated alkali-activated systems, laying the groundwork for developing next-generation cementitious materials for supercritical geothermal energy exploitation.

15 GEOTHERMAL ENERGY↗
DOE OSTI2025

Crystallographic Texture, Structure, and Stress Transmission in Nugget Sandstone Examined With X‐Ray Tomography and Diffraction Microscopy

Subsurface processes in sandstones are controlled by porosity, permeability, and deformation mechanisms, all of which are controlled by a complex interplay of crystallographic rock texture, structure, and micromechanics. Texture, structure, and micromechanics have historically been studied using optical and electron microscopy of thin-sections. Here, we employed a new combination of in situ X-ray tomography and ray diffraction microscopy to study crystallographic texture, structure, and grain stresses in 3D. We examined these features in a sample of Nugget sandstone, a sandstone constituting hydrocarbon reservoirs across the American West. Our aims are threefold. First, we demonstrate the utility of X-ray diffraction microscopy probes for revealing texture, structure, and stress transmission in 3D. Second, we apply these techniques to Nugget sandstone and discuss findings in the context of prior work. Third, we study grain stress tensor evolution during mechanical compression to examine whether their heterogeneity and orientation evolution reflect that of inter-particle forces in granular materials. Our results show: (a) larger grains featured higher intra-granular misorientations, possibly from an increased prevalence of cements; (b) pores closed parallel to the loading direction and opened normal to loading; (c) grain stresses featured heterogeneity and orientations similar to inter-particle forces in non-cohesive granular materials; (d) grains featured compressive stresses in the loading direction and tensile stresses orthogonal to the loading direction, the latter resisting sample dilation and grain separation. Our work demonstrates the first known application of multi-modal X-ray tomography and diffraction microscopy to sandstone, providing new 3D insight into the nature of quartz cement and stress evolution.

high energy diffraction microscopy↗
DOE OSTI2025

PyCMG-based Simulation of Volumetric Concrete Microstructure

Concrete is a complex, heterogeneous material with a microstructure composed of aggregates, cement paste, and pores spanning multiple length scales. Understanding this microstructure is critical for advancing the performance, durability, and modeling of concrete-based systems. While experimental imaging such as X-ray computed tomography (XCT) provides valuable insights, generating large datasets with detailed ground truth annotations is both costly and labor-intensive due to challenges in segmenting similar phases, such as aggregates and cement paste, that often share similar attenuation properties. To address this, we developed a pipeline to simulate realistic 3D concrete microstructures using the open-source Python package PyCMG. This simulation effort focuses on generating high-fidelity, annotated microstructures that can serve as training or benchmarking datasets for image analysis, segmentation algorithms, and machine learning models, particularly in scenarios where experimental data is scarce.

Ziabari, Amir [Oak Ridge National Laboratory; ORNL↗
DOE OSTI2024

Investigating Material Properties of Subsurface Rock Formations Modified by Engineering Mineral Precipitation (Final Scientific and Technical Report)

Montana State University’s (MSU) Energy Research Institute (ERI), in collaboration with the Center for Biofilm Engineering (CBE) and the Department of Civil Engineering (CE), has conducted a long‐term research program aimed at developing a novel cementing agent to address wellbore integrity and reduce the unwanted upward migration of fluids and greenhouse gases from the subsurface. The primary technology developed through this research program is known as ureolysis‐induced calcite precipitation (UICP), which harnesses bio‐chemical processes to precipitate calcium carbonate (CaCO 3 ). The same general process can also be called microbially-induced calcium carbonate precipitation (MICP) when microbes provide the process-catalyzing urease enzyme. Both terms are used in this report. Results have conclusively demonstrated that, if properly controlled, UICP can successfully seal fractures, high permeability zones, and compromised cement in the vicinity of wellbores and in nearby caprock. This technology has been successfully deployed to mitigate annular leakage in two test wells and over sixty commercial wells with a 100% success rate. This success in downhole deployment generates consideration of other subsurface applications where UICP could provide benefit to the energy sector, such as shale property modification for unconventional oil and gas recovery. The focus of this research project was to investigate fundamental material and mechanical properties of select shale cores and analyze how these properties change due to engineered mineral precipitation with the intent to control these properties to achieve a range of engineering objectives. Ultimately, the project aim was to identify valuable new areas where application of UICP might contribute to national energy security and environmental protection. The research workplan coupled UICP treatment of core samples, nuclear magnetic resonance (NMR) characterization, and mechanical strength testing at MSU with advanced X‐Ray micro-computed tomography (μCT) imaging and numerical modeling performed by collaborators at two national laboratories, the National Energy Technology Laboratory (NETL) and Lawrence Berkeley National Laboratory (LBNL). Experimental results are useful to inform geo-mechanical models which could be applied to predict mineralized rock formation behavior at field scale. Our findings suggest that NMR and μCT methods to detect and quantify biomineral formation in shale fractures are complementary and consistent with each other. Either could be used to estimate the volume of new mineral formed by UICP in shale fractures. The use of surfactants and guar gum to enhance biomineral precipitation in shale fractures merits further research. UICP can, under some conditions, increase the tensile strength of sealed shale fractures beyond that of the intact shale. These findings demonstrate that continued research in this area may be valuable to understanding and improving shale resource recovery techniques.

58 GEOSCIENCES↗
DOE OSTI2024

Coal Ash Beneficial Use at Savannah River Site

The Savannah River Site (SRS) has over 1.4 million cubic meters of coal ash and coal fines left over from coal-burning power plants that operated on site. Currently, the coal ash must be disposed of in an approved landfill or the coal ash-containing basins must be closed in place (i.e. consolidation, appropriate cover and liner system). Potential beneficial uses of the coal ash include geotechnical fill, such as backfill needed in the closure cap of the Z-area Saltstone Disposal Units (SDU), and use in cementitious material applications like thermal beneficiation or cement kiln feed, thereby reducing the environmental footprint of SRS. In this study, samples of coal ash from SRS were obtained and characterized for chemical and physical properties. Coal ash samples did not leach sulfates or heavy metals, so the coal ash is a candidate for geotechnical fill use. The samples also did not increase the acidity of the leachate during leaching tests, so it would not be detrimental to use as geotechnical fill near cementitious materials. The composition and energy potential of the coal ash makes it favorable for use as feed for external/off-site cement kilns or thermal beneficiation plants

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

April 2024 Semiannual Composite Salt Waste Processing Facility (SWPF) Decontaminated Salt Solution (DSS) Toxicity Characteristic Leaching Procedure (TCLP) Results

The aqueous waste from the Salt Waste Processing Facility (SWPF) is sampled semiannually for transfers to the Saltstone Production Facility (SPF). Salt solution is treated at SPF and disposed of in the Saltstone Disposal Facility (SDF). Per request of customer, X-TTR-Z-00027, Revision 0, one SDF waste form (saltstone) sample was prepared in the Savannah River National Laboratory (SRNL) from the SWPF Decontaminated Salt Solution (DSS) Waste Acceptance Criteria (WAC) sample and Z-area premix material for the April 2024 semiannual Toxicity Characteristic Leaching Procedure (TCLP) sample. The sample contained 60:40 (by weight) of slag and fly ash (referred to as the “Cement-Free grout sample”). Results from the technical report support Task 2: ‘Grout Leaching Analyses’ of the Task Technical Request (TTR) prepared by Savannah River Mission Completion (SRMC). After at least 28 days cured, a sample of the SDF waste form was collected and shipped to a certified laboratory for analysis using the Toxicity Characteristic Leaching Procedure (TCLP). The April 2024 semiannual Cement-Free grout sample met the South Carolina (SC) Code of Regulations for Hazardous Waste Management Regulations (HWMR) 61-79.261.24 and 61-79.268.48 requirements for a non-hazardous waste form with respect to the Resource Conservation and Recovery Act (RCRA) metals and Underlying Hazardous Constituents (UHCs), and met the SPF WAC that was in effect at the time of the tank sampling.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Developing a Prototype Methodology to Rank CO2-EOR Wells and Assess Their Reuse Potential for Geologic Carbon Sequestration

This study presents a prototype methodology for evaluating the reuse potential of Class II CO₂-enhanced oil recovery (CO₂-EOR) wells as Class VI wells for geologic carbon sequestration. The approach focuses on assessing wellbore construction materials—casing, cement, tubing, and packers—based on U.S. Environmental Protection Agency (EPA) Class VI well conversion guidelines. Utilizing Python scripts and JSON representations, the methodology automates checks on digitized Texas Railroad Commission (TRRC) data to rank wells based on regulatory and integrity criteria. Key factors include casing integrity, cementing techniques, tubing compatibility, and packer selection. Due to limitations in digitized data, manual verification is required for certain sections. Future enhancements include incorporating non-digitized data via web scraping and machine learning. This research provides a practical framework for well owners and regulators, supporting informed decision-making for sustainable CO₂ storage.

carbon sequestration↗
DOE OSTI2025

October 2024 Semiannual Composite Salt Waste Processing Facility (SWPF) Decontaminated Salt Solution (DSS) Toxicity Characteristic Leaching Procedure (TCLP) Results

The aqueous waste from the Salt Waste Processing Facility (SWPF) is sampled semiannually for transfers to the Saltstone Production Facility (SPF). Salt solution is treated at SPF and disposed of in the Saltstone Disposal Facility (SDF). Per request of customer, X-TTR-Z-00027, Revision 0, one SDF waste form (saltstone) sample was prepared in the Savannah River National Laboratory (SRNL) from the SWPF Decontaminated Salt Solution (DSS) Waste Acceptance Criteria (WAC) sample and Z-area premix material for the October 2024 semiannual Toxicity Characteristic Leaching Procedure (TCLP) sample. The sample contained 60:40 (by weight) of slag and fly ash (referred to as the “Cement-Free grout sample”). Results from the technical report support Task 2: ‘Grout Leaching Analyses’ of the Task Technical Request (TTR) prepared by Savannah River Mission Completion (SRMC). At 64 days cured, a sample of the SDF waste form was collected and shipped to a certified laboratory for analysis using the Toxicity Characteristic Leaching Procedure (TCLP). The October 2024 semiannual Cement-Free grout sample met the South Carolina (SC) Code of Regulations for Hazardous Waste Management Regulations (HWMR) 61-79.261.24 and 61-79.268.48 requirements for a non-hazardous waste form with respect to the Resource Conservation and Recovery Act (RCRA) metals and Underlying Hazardous Constituents (UHCs), and met the SPF WAC that was in effect at the time of the sample collection at SWPF.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Light, High Performance and Scalable Coal-Derived Composites for Construction: Precast and Cast-in-Place Applications

The overall objective of this project was to produce a coal-based construction material that has up to ~95 weight percent (wt. %) coal with physical, chemical, and thermal properties exceeding those of ordinary Portland cement (OPC)-based construction materials. Additionally, the project aimed to minimize external binders by implementing novel mixing techniques, while exceeding the performance/cost ratio of OPC. Finally, the project was to demonstrate production of precast products via the design and fabrication of products via a bench scale process. Consistent with some of these objectives, the project successfully fabricated samples of coal-based composite materials with >80 wt% coal with physical, chemical and thermal properties on par with cement-based concrete. Select samples demonstrated compressive strengths with >7,000 psi and flexural strength of >420 psi. The composite materials minimized external binders and also demonstrated durability, as evidenced by resistance to acidic and basic solutions. Finally, larger slab and beam type samples were produced using a process developed by the Recipient, although, the process was not semicontinuous in nature. Taken together, the results of this project suggest that domestic coal has potential to serve as a replacement for cementitious materials utilized in incumbent construction technologies, which could significantly reduce the energy and emissions of the construction industry

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

Electrochemical Production of Calcium Hydroxide from Calcium Carbonate [Poster]

Cement production involves the decomposition of limestone (calcium carbonate) at high temperatures (~900°C) to produce CaO, a major constituent in Portland cement (60-70%). Our unique approach will eliminate the high temperature process and introduce a low-temperature electrochemical process to produce Ca(OH) 2 which can be converted into CaO through dehydration process. This program will allow SRNL to become a leading organization in an open and unexplored field that addresses many of the technical challenges.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Electrochemical Production of Calcium Hydroxide from Calcium Carbonate

Calcium hydroxide is electrochemically synthesized to address SRNL core competency of Creating Manufacturing & Energy Solutions. This process is energy efficient compared to high temperature calcium carbonate decomposition to produce calcium oxide for the cement industry. Ultrasonic dehydration coupled with induction heating can further reduce the energy need for cement production.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

CRADA Number NFE-22-09375 with Vitriform3D, Inc. (CRADA Final Report)

Each year, roughly 8 million tons of glass are landfilled in the United States. Vitriform3D, in collaboration with Oak Ridge National Laboratory through the Innovation Crossroads program, is developing an additive manufacturing approach to transform post-consumer glass into engineered stone building materials. A custom UV-curable binder jetting system was commissioned to enable recycled glass printing without energy-intensive oven curing. While this printer is still under development, the team pursued a parallel research track using ORNL equipment and a polyethyleneimine (PEI) binder. Printed parts were thermally post-cured and infiltrated with epoxy, with the resulting material exceeding fiber cement board performance. Silane treatment of the glass particles further improved glass–epoxy adhesion, yielding an additional 24% strength gain over the epoxy-glass composite, achieving nearly 3x the fiber cement benchmark. Ongoing research is focused on reducing epoxy content to improve cost and recycled content while retaining mechanical performance. This work demonstrates a scalable, low-carbon pathway to convert glass waste into high-value, locally produced construction materials.

36 MATERIALS SCIENCE↗
DOE OSTI2025

April 2025 Semiannual Composite Salt Waste Processing Facility (SWPF) Decontaminated Salt Solution (DSS) Toxicity Characteristic Leaching Procedure (TCLP) Results

The aqueous waste from the Salt Waste Processing Facility is sampled semiannually for transfers to the Saltstone Production Facility. Salt solution is treated at the Saltstone Production Facility and disposed of in the Saltstone Disposal Facility. Per request of customer, X-TTR-Z-00027, Revision 0, one Saltstone Disposal Facility waste form was prepared at Savannah River National Laboratory using the Salt Waste Processing Facility Decontaminated Salt Solution and Z-area premix material for the April 2025 semiannual Toxicity Characteristic Leaching Procedure sample. The sample contained 60:40 (by weight) of slag and fly ash (referred to as the “Cement-Free grout sample”). Results from the technical report support Task 2: ‘Grout Leaching Analyses’ of the Task Technical Request prepared by Savannah River Mission Completion. At 43 days cured, the Saltstone sample was collected and shipped to a certified laboratory for analysis using the Toxicity Characteristic Leaching Procedure. The April 2025 semiannual Cement-Free grout sample met the South Carolina Code of Regulations for Hazardous Waste Management Regulations 61-79.261.24 and 61-79.268.48 requirements for a non-hazardous waste form with respect to the Resource Conservation and Recovery Act metals and Underlying Hazardous Constituents, and met the Saltstone Production Facility Waste Acceptance Criteria that was in effect at the time of the sample collection at the Salt Waste Processing Facility.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2026

October 2025 Semiannual Composite Salt Waste Processing Facility Decontaminated Salt Solution Toxicity Characteristic Leaching Procedure Results

The aqueous waste from the Salt Waste Processing Facility is sampled semiannually for transfers to the Saltstone Disposal Facility. Salt solution is treated at the Saltstone Production Facility and disposed of in the Saltstone Disposal Facility. Per request of customer, X-TTR-Z-00027, Revision 0, one Saltstone Processing Facility Decontaminated Salt Solution and Z area premix material for the October 2025 semiannual Toxicity Characteristic Leaching Procedure sample. The sample contained 60:40 (by weight) of slag and fly ash (referred to as the “Cement-Free grout sample”). Results from the technical report support Task 2: ‘Grout Leaching Analyses’ of the Task Technical Request prepared by Savannah River Mission Completion. At 51 days cured, the Saltstone sample was collected and shipped to a certified laboratory for analysis using the Toxicity Characteristic Leaching Procedure. The October 2025 Semiannual Cement-Free grout sample met 61 79.268.48 requirements for a non-hazardous waste form with respect to the Resource Conservation and Recovery Act metals and Underlying Hazardous Constituents and met the Saltstone Production Facility Waste Acceptance Criteria that was in effect at the time of the sample collection at the Salt Waste Processing Facility.

Hsieh, Madison [Savannah River National Laboratory↗
DOE OSTI2025

Diagenesis is key to unlocking outcrop fracture data suitable for quantitative extrapolation to geothermal targets

Exceptionally large, well-exposed sandstone outcrops in New York provide insights into folds, deformation bands, and fractures that could influence permeability, heat exchange, and stimulation outcomes of geothermal reservoir targets. Cambrian Potsdam Sandstone with <5% porosity contains decimeter-scale open, angular-limbed monoclines <0.5 km apart with associated low-porosity mm-wide cataclastic deformation bands. Crossing and abutting relationships among sub-vertical opening-mode fractures show four chronological Sets A–D, striking NNW, NE, NW, and ENE, respectively. Fracture lengths and heights range from millimeters to tens of meters. Sets A and C macro-fractures, and possibly B and D, contain quartz deposits. All sets have abundant associated quartz cemented microfractures that also record set orientations and crosscutting relations. Quartz cement deposits—evidence of diagenesis—are the key to identifying attributes of outcrop fractures suitable for extrapolation to geothermal targets in sandstones because they show which fractures formed in the subsurface. Set A fluid inclusion homogenization temperatures (120°C–129°C) are compatible with fracture at >3 km depth. Fractures are stiff and those ≥0.05 mm (Set C) and ≥0.1 mm (Set A) are open and potentially conducive to flow. Sets A and D are abundant in outcrops with close fracture spacing—0.18 m and 0.68 m, respectively—and define a rectangular connectivity network dominated by crossing and abutting X and Y nodes. Set A aperture distributions follow a power law with slope –0.8 up to 0.15 mm; other sets have lognormal distributions. Set A and D microfractures are weakly clustered, while macro-fractures commonly have 1D anticlustered (regular or periodic) arrangements at shorter length scales (<0.2 m). Sub-horizontal fractures are barren and may have formed near the surface. Fracture heights, lengths, and spatial arrangements show good trace connectivity but low open connectivity. For geothermal applications, outcrop results predict low initial well-test permeabilities owing to quartz disconnecting open fractures, but stimulation of closely spaced microfractures and partly open macro-fractures could yield high surface area for heat exchange. Quantitative extrapolation of key fracture attributes like abundance, orientation, spatial arrangement, length, and open fracture connectivity is possible from outcrops to fractured reservoirs if differing thermal histories and diagenesis are accounted for.

02 PETROLEUM↗