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At least 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Rapid Assessment of Sulfate Resistance in Mortar and Concrete

Extensive research has been conducted on the sulfate attack of concrete structures; however, the need to adopt the use of more sustainable materials is driving a need for a quicker test method to assess sulfate resistance. This work presents accelerated methods that can reduce the time required for assessing the sulfate resistance of mixtures by 70%. Class F fly ash has historically been used in concrete mixtures to improve sulfate resistance. However, environmental considerations and the evolving energy industry have decreased its availability, requiring the identification of economically viable and environmentally friendly alternatives to fly ash. Another challenge in addressing sulfate attack durability issues in concrete is that the standard sulfate attack test (ASTM C1012) is time-consuming and designed for only standard mortars (not concrete mixtures). To expedite the testing process, accelerated testing methods for both mortar and concrete mixtures were adopted from previous work to further the development of the accelerated tests and to assess the feasibility of testing the sulfate resistance of mortar and concrete mixtures rapidly. This study also established criteria for interpreting sulfate resistance for each of the test methods used in this work. A total of 14 mortar mixtures and four concrete mixtures using two types of Portland cement (Type I and Type I/II) and various supplementary cementitious materials (SCMs) were evaluated in this study. The accelerated testing methods significantly reduced the evaluation time from 12 months to 21 days for mortar mixtures and from 6 months to 56 days for concrete mixtures. The proposed interpretation method for mortar accelerated test results showed acceptable consistency with the ACI 318-19 interpretations for ASTM C1012 results. The interpretation methods proposed for the two concrete sulfate attack tests demonstrated excellent consistency with the ASTM C1012 results from mortar mixtures with the same cementitious materials combinations. Metakaolin was shown to improve sulfate resistance for both mortar and concrete mixtures, while silica fume and natural pozzolan had a limited impact. Using 15% metakaolin in mortar or concrete mixtures with Type I/II cement provided the best sulfate resistance.

Chemistry↗
DOE OSTI2026

Global Carbon Budget 2025

Accurate assessment of anthropogenic carbon dioxide (CO 2 ) emissions and their redistribution among the atmosphere, ocean, and terrestrial biosphere in a changing climate is critical to better understand the global carbon cycle, support the development of climate policies, and project future climate change. Here we describe and synthesise datasets and methodologies to quantify the five major components of the global carbon budget and their uncertainties. Fossil CO 2 emissions (E FOS ) are based on energy and cement production data. Emissions from land-use change (E LUC ) are estimated by bookkeeping models based on land-use data. The global atmospheric CO 2 growth rate (G ATM ) is computed from changes in concentration measured at surface stations. The global net uptake of CO 2 by the ocean (S OCEAN ) is estimated with global ocean biogeochemistry models and observation-based fCO 2 -products. The global net uptake of CO 2 by the land (S LAND ) is estimated with dynamic global vegetation models. Additional lines of evidence are provided by atmospheric inversions, atmospheric oxygen measurements, ocean interior observation-based estimates, and Earth System Models. This year, we introduced corrections on the E LUC , S OCEAN and S LAND estimates. The sum of all sources and sinks results in the carbon budget imbalance (B IM ), a measure of imperfect data and incomplete understanding of the contemporary carbon cycle. All uncertainties are reported as ± 1σ. For the year 2024, E FOS increased by 1.1 % relative to 2023, with fossil emissions at 10.3 ± 0.5 GtC yr −1 (including the cement carbonation sink, 0.2 GtC yr −1 ), E LUC was 1.3 ± 0.7 GtC yr −1 , for total anthropogenic CO 2 emissions of 11.6 ± 0.9 GtC yr −1 (42.4 ± 3.2 GtCO2 yr −1 ). Also, for 2024, G ATM was 7.9 ± 0.2 GtC yr−1 (3.73 ± 0.1 ppm yr −1 ), 2.2 GtC above the 2023 growth rate. SOCEAN was 3.4 ± 0.4 GtC yr −1 and S LAND was 1.9 ± 1.1 GtC yr −1 , leaving a large negative B IM (−1.7 GtC yr −1 ), suggesting that the total sink or G ATM is strongly overestimated in 2024. The global atmospheric CO 2 concentration averaged over 2024 reached 422.8 ± 0.1 ppm. Preliminary data for 2025 suggest an increase in E FOS relative to 2024 of +1.0 % (0.2 % to 1.7 %) globally, and atmospheric CO 2 concentration increasing by 2.1 ppm reaching 425.6 ppm, 53 % above the pre-industrial level (around 278 ppm in 1750). Overall, the mean and trend in the components of the global carbon budget are consistently estimated over the period 1959–2024, with a near-zero overall budget imbalance, although discrepancies of up to around 1 GtC yr −1 persist for the representation of annual to decadal variability in CO 2 fluxes. Comparison of estimates from multiple approaches and observations shows: (1) a persistent large uncertainty in the estimate of land-use change emissions, (2) a low agreement between the different methods on the magnitude of the land CO 2 flux in the northern extra-tropics, and (3) a discrepancy between the different methods on the mean ocean sink. This living data update documents changes in methods and datasets applied to this most-recent global carbon budget as well as evolving community understanding of the global carbon cycle. The data presented in this work are available at https://doi.org/10.18160/GCP-2025 (Friedlingstein et al., 2025c).

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Wellbore Stability and Mud Loss Management in Geothermal Drilling: Optimizing Mud Weight to Mitigate Tensile Wellbore Fracturing at The Geysers, California

As part of a U.S. Department of Energy (DOE) Geothermal Technologies Office-funded initiative, Geysers Power Company, LLC, a subsidiary of Calpine Corporation, has been working to enhance drilling performance at the world’s largest geothermal field, The Geysers, in northern California. In a recent drilling operation of the GDC-36 well, excessive mud losses were encountered, initially addressed through repeated but largely ineffective cement plugging. Ultimately, the most effective strategy was to drill blind through the loss zones, made feasible by the high rate of penetration (ROP) achieved with PDC bits, allowing significant progress before the mud tanks were depleted and water-sensitive argillic formation layers could collapse. In response to these challenges, the project team explored alternative methods to minimize downtime and risks associated with cement plugging and continuous mud loss and to contemplate the driving mechanisms for the losses. Wellbore imaging using Formation MicroImager (FMI) and Ultrasonic Borehole Imager (UBI) tools revealed longitudinal tensile fractures, which were attributed to mud weights exceeding the minimum circumferential stress resulting from the native stress field and formation pressure. This study examines the mud losses encountered and leverages wellbore imaging data to understand the mechanisms behind mud induced tensile fracturing in specific rock facies. Understanding fracture behavior across different lithologies is crucial, as fractures within the reservoir can enhance steam migration throughout the system. The reservoir at The Geysers lies within the Mesozoic Franciscan Assemblage, a tectonic mélange formed by subduction. It consists of metamorphosed turbidite sandstone (greywacke) and mudstone (argillite), oceanic upper crust (including greenstone and chert), and serpentinized ultramafic rocks - each exhibiting distinct geomechanical fracturing properties. The structural fabric of the Franciscan Assemblage was shaped by low-angle Mesozoic thrust faulting and later overprinted by sub-vertical strike-slip structures related to the Pacific-North American plate boundary. A wellbore stability model was developed using core measurements and logs to simulate fracturing scenarios during drilling under varying stress conditions. These simulations guided the development of an optimized mud weight management strategy that should enable adaptive adjustments during drilling, reducing the likelihood of tensile fracturing and mud losses, ultimately improving operational efficiency.

15 GEOTHERMAL ENERGY↗
DOE OSTI2024

Sorption of Metals and Radionuclides in Cementitious Leachate Impacted Sediments from the Savannah River Site

Performance assessments (PAs) are calculations used to establish the risk posed by radioactive waste disposal facilities in the Savannah River Site (SRS). The distribution coefficient (Kd; solid/liquid concentration ratio; Csolid/liquid) is one of the key geochemical parameters used in the PA to provide a measure of how strongly the dissolved contaminants bind to solid phases; the greater the Kd value, the greater the tendency to bind to the solids. The overall purpose of this study was to measure this key parameter for several constituents of concern in the cementitious leachate impacted SRS sediment environments. Particular attention was directed at quantifying the influence of cementitious leachate from various stages of cement aging on the sorption of radioactive waste and heavy metals on SRS sediments.

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

Intrinsic mechanical properties and seeding effect of tobermorite synthesized in supercritical water

This publication reports for the first time the physiochemical, the intrinsic mechanical properties and the seed effect of anomalous Al-substituted 11 Å tobermorite synthesized via the innovative supercritical hydrothermal flow process at 400 °C and 25 MPa. This approach allows synthesizing highly crystalline tobermorite fibers in only 8 s, with characteristics very close to the natural tobermorite. The anomalous 11 Å tobermorite exhibits aluminosilicate chains with a high polymerisation degree and a less defective structure compared to materials produced via the conventional hydrothermal method. Furthermore, the intrinsic mechanical properties of Al-tobermorite synthesized in supercritical water are investigated for the first time by High-Pressure XRD. This Al-substituted 11 Å tobermorite is characterised by higher incompressibility along the b-axis and bulk modulus K0 in comparison with what is commonly observed for other synthetic tobermorite. The tobermorite acts as nucleation points to trigger the quick formation of the hydration product in Portland cement paste.

Calcium silicate hydrate↗
DOE OSTI2026

A rapid embodied carbon assessment tool for priority materials

Embodied carbon limits within building materials are a driving factor in global trade, generating new research and analysis tools in industry. These product assessments, which require utilizing life-cycle assessment (LCA) across broad supply chains, can be expensive, time and data-intensive, and subject to significant variations. Existing methods and tools, such as specific environmental product declarations, typically do not capture these variations and dynamics in supply and manufacturing. Moreover, models and tools must enable stakeholders to assess customized supply chains and future scenarios. In this study, we present the Rapid Embodied Carbon Assessment and Target-setting for Emissions-intensive Materials (REDuCE) tool for building materials. We developed a tool that allows users to select production technologies, transportation mode and distances, concrete carbonation, fuel sources, and regional electricity mixes to supply customization for cement and concrete produced and consumed in California. We generated and integrated a material demand model using residential building stock projections. We provide the user with a wide range of mitigation alternatives through low-carbon production pathways, material use efficiency, transportation modes, and projected electricity grid mixes. In a case study application through four mitigation scenarios, we find emission savings up to 80% by maximizing user mitigation alternatives, primarily driven by reductions in material use intensities. This work represents a foundation for expanding LCA and embodied carbon tools to better enable stakeholders to rapidly and accurately assess customized supply chains while meeting trade requirements.

building materials↗
DOE OSTI2025

Coal-derived graphene materials for industrial applications

The project (Award DE-FEO-0032274), led by Iowa State University in collaboration with the University of Wyoming, sought to improve the production and utility of graphene oxide (GO), reduced graphene oxide (rGO), and related advanced materials from coal char. The three overall objectives of this project were: 1) to improve production of graphene oxide using Powder River Basin (PRB) coal as feedstock; 2) to continue testing and improvement of a hard carbon sodium-ion battery prototype and test device; and 3) to determine properties and performance of concrete using GO and rGO as a concrete additive or cement replacement.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2026

Trash to Treasure: Waste Carbon into Construction Materials

Mineralization of industrial waste and earth-abundant CO2 into value-added products is a powerful method of utilizing domestic resources to produce value from waste. Carbonate minerals formed from Ca and Mg rich waste streams are key constituents in cement and concrete, which are in demand at the gigaton-scale every year. While thermodynamically favorable, CO2 mineralization is hindered by slow kinetics, and traditional thermochemical routes are too expensive to scale. Here, we demonstrate the advantages of an electrochemical method of waste valorization, which eliminates this limitation and improves kinetics. We highlight this method's ability to initiate crystallization under favorable local conditions, producing carbonates from mining waste at mildly acidic pH. We highlight the effects of key constituents in mining waste on the mineralization process.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2026

Cementless Concrete: Advancing Alkali-Activated Slag Composites with Black Liquor

This project explores the use of black liquor, a byproduct of sustainable aviation fuel production, as an alkaline activator for industrial byproducts such as steel slags to produce alkali-activated composites (AACs). The resulting cementless concrete cures at ambient temperature, demonstrates comparable performance to conventional cement, and offers a safer, lower-energy alternative for durable construction materials.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Mitchell FEED Study Summary Report (Unlimited Rights Version) (Rev. D)

Heidelberg Materials (HM), Sargent & Lundy (S&L), and Mitsubishi Heavy Industries (MHI) completed a Front End Engineering Design (FEED) study for deployment of an amine-based CO 2 capture system at the Mitchell Cement Plant in Indiana. The project includes compression of captured CO 2 to a supercritical state for geological sequestration. The flue gases from 7,000 mtpd clinker plant combined with auxiliary boiler flue gases into the capture system. Auxiliary boiler supplies steam for solvent regeneration. The study developed an AACE Class 3 capital cost estimate (+30%/-20%) at approximately 30% design completion to evaluate the technical and economic feasibility of capturing up to 2 million tonnes of CO 2 per year.

42 ENGINEERING↗
DOE OSTI2024

Detection and Signal Processing for Near-Field Nanoscale Fourier Transform Infrared Spectroscopy

Researchers from a broad spectrum of scientific and engineering disciplines are increasingly using scattering-type near-field infrared spectroscopic techniques to characterize materials non-destructively with nanoscale spatial resolution. However, a sub-optimal understanding of a technique's implementation can complicate data interpretation and act as a barrier to entering the field. Here the key detection and processing steps involved in producing scattering-type near-field nanoscale Fourier transform infrared spectra (nano-FTIR) are outlined. The self-contained mathematical and experimental work derives and explains: i) how normalized complex-valued nano-FTIR spectra are generated, ii) why the real and imaginary components of spectra qualitatively relate to dispersion and absorption respectively, iii) a new and generally valid equation for spectra which can be used as a springboard for additional modeling of the scattering processes, and iv) an algebraic expression that can be used to extract an approximation to the sample's local extinction coefficient from nano-FTIR. The algebraic model for weak oscillators is validated with nano-FTIR and attenuated total reflectance Fourier transform infrared (ATR-FTIR) spectra on samples of polystyrene and Kapton and further provides a pedagogical pathway to cementing some of the technique's key qualitative attributes.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Mercury sequestration in alkaline salt low-level radioactive waste

Liquid low-level radioactive waste at the Savannah River Site contains several species of mercury, including inorganic, elemental and methylmercury. This waste is solidified and stabilized in a cementitious waste form referred to as saltstone. Soluble mercury is stabilized as β-cinnabar, HgS as the result of reaction between the mercury and sulfur present in blast furnace slag, one of the cementitious regents. In this investigation, Mersorb®, a commercial granular activated carbon impregnated with sulfur, was evaluated as a pretreatment to remove mercury from the solution prior to cementation. Mersorb® was found to remove more than 96 mass percent of the methylmercury in simulated tank waste solution when the mass ratio of Mersorb® to mercury was above 2.5. Slag sequestered relatively more inorganic mercury than organic mercury in simulated tank waste after 24 hours of contact. This is likely due to the mercury-carbon bond being more covalent than the mercury-oxygen bond and therefore more difficult to break and slower to form HgS.

Cementitious Material↗
DOE OSTI2024

Transfer learning for probabilistic localization of hidden cracks in concrete structures

Abstract The utility of discriminative supervised learning models built using multiple training-data sources is investigated for hidden crack localization in concrete. Feed-forward neural network (FFNN) is chosen as the model architecture, and transfer learning is used to assimilate the information obtained from different sources (computational physics simulations and laboratory experiments). The labeled training data consists of values of a damage index and the known locations of hidden cracks. The classification models need to learn how the presence of damage (hidden cracks) affects the damage index at different sensors for different test conditions. To this end, diagnostic FFNN models are built by sequentially adding and training new hidden layers to assimilate labeled information from computer models (different model geometries, test conditions, crack lengths, crack locations) and laboratory experiments on a plain cement slab. These transfer learning-based models are then used to localize damage in concrete specimens that reflect real-world conditions (i.e., specimens with steel reinforcement and randomly distributed aggregate). The actual damage state in these specimens is determined by extracting cores and performing petrographic studies on the extracted cores. The damage probability estimated by transfer learning-based models is compared with the petrographic damage rating index (DRI) to identify the most suitable approach to train the diagnostic models. The transfer learning-based diagnostic methodology shows promise and could be used in various structural health monitoring applications, where sufficient labeled data are typically not available from a single data source.

Miele, S.↗
DOE OSTI2025

UR 2 : Ultra-rapid reactivity test for real-time, low-cost quality control of calcined clays

To reduce cement's carbon footprint, there is growing interest in commercial adoption of sustainable SCMs such as calcined clays. However, the existing ASTM standard (R 3 test, C1897) to test the reactivity of such clays takes up to 7 days and cannot be used for real-time quality control in an industrial setting. We address this issue by introducing a 5-min Ultra-Rapid Reactivity (UR 2 ) test. By dissolving 47 clay specimens in 4 M NaOH solutions at 90°C, we report that a dissolution index of 1.54Al + Si correlates strongly to the 7-day R 3 heat (R 2 = 0.92, RMSE = 94.1 J/g). This dissolution index also correlates to the 28-day compressive strength for 14 clay mixtures (R 2 = 0.94, RMSE = 1.7 MPa). This UR 2 test relies on colorimetry and can be conducted via off-the-shelf, low-cost cameras. Overall, our new UR 2 test opens a pathway for real-time, low-cost quality control of calcined clays.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Characterizing the combined impact of nucleation-driven precipitation and secondary passivation on carbon mineralization

The evolution of mineral reactive surface area is one of the primary phenomena controlling the progression and extent of mineral carbonation. The CO 2 mineralization begins with nucleation of crystals that provide initial surface area for subsequent growth of the mineral. However, many reactive transport models (RTMs) for CO 2 mineralization do not include the nucleation process. The few RTMs that do include it are yet to be validated against experimental data. Similarly, many RTMs ignore passivating effects of the secondary mineral, which coats the surface of the dissolving mineral, slow down the reaction process, and reduce the total extent of carbonation. Furthermore, the combined impact of nucleation and passivation on carbon mineralization is yet to be properly characterized. In this study, we consider the coupled effects of passivation and nucleation on the mineralization extent. The nucleation-driven precipitation model relies on the formation of nuclei to provide a surface area for crystal growth, while a new model is proposed to account for passivation effects. Our analysis shows that (i) omission of nucleation leads to overestimation of extent of mineralization, and (ii) omission of passivation leads to overestimation of host rock reactivity. The model was evaluated via comparison with CO 2 mineralization data from the literature and models that ignore these processes. We observed that including nucleation and passivation lead to closer predictions of the CO 2 mineralization extent. Therefore, this study highlights the importance of including the coupled nucleation-driven precipitation and secondary passivation in RTMs. Here, the findings from the study can be applied in various scientific and engineering applications such as petroleum production, cement carbonation, CO 2 sequestration, chemical weathering, and concrete degradation.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Peridynamic modeling of cementitious materials for nuclear waste management

Radioactive and hazardous waste generated from fuel processing plants, nuclear reactors, and hospitals, requires effective management strategies. Cementitious materials are widely applied for these needs, serving as structural materials, reactive barriers, or waste forms. In these applications cracking poses a significant risk to performance, driven by inconsistent shrinkage of the components and the varying strength and permeability of their interfaces. Traditional modeling approaches face challenges in representing the complex fracture behavior of cementitious materials due to the reliance on spatial derivatives and difficulties with mesh generation. Here, to overcome these limitations, we employ peridynamics, a novel continuum mechanics formulation that uses integrals to describe mechanical equilibrium, avoiding discontinuities associated with traditional methods. Through incorporation of a bi-linear softening model and quasistatics, an experimentally validated model for Portland cement concrete samples was created. Mechanical parameters, including compressive strength and elastic modulus were validated and variation due to aggregate packing was evaluated. Additionally, sensitivity analysis of the peridynamic parameters to the bulk material properties was established. The results lay the groundwork for evaluating the impact of unique conditions of cementitious waste forms that can be assessed to improve the reliability of waste management strategies.

Aggregates↗
DOE OSTI2025

Hydrothermal liquefaction of wastewater-grown algae to produce synthetic aviation fuel: A combined experimental study and techno-economic assessment

Large-scale algae farms may someday become a consistent source of biomass feedstock for biofuels. Near-term supplies of algal biomass are available at certain water resource recovery facilities as algae cultivation is used as a method for nutrient recovery from specific effluent streams. Algae grown as a service shifts the value to the service rather than its sole use as a feedstock, which could enable the provision of algal biomass at low to no cost to biofuel producers. Hydrothermal liquefaction (HTL) can readily upgrade wet feedstock slurries, such as algae, to produce a carbon-enriched biocrude. The HTL biocrude can be hydrotreated and distilled, producing a variety of distillate fuels, including synthetic aviation fuel (SAF). We present a pathway, showing the experimental production of SAF from wastewater-grown algae via HTL, along with a techno-economic assessment to identify opportunities for process improvements. Critical quality attributes of the SAF, such as density, viscosity, surface tension, and freeze point, were estimated within the expected fuel experience ranges when compared against petroleum jet fuel. The average minimum fuel selling price of fuels from wastewater-grown algae for breakeven economics was $\$9.04$ per gasoline gallon equivalent (GGE). The sale of co-products such as struvite fertilizers and cement additives can add revenue to reduce the net cost. Ultimately, the selling price is influenced by the scale of the HTL processing facility. Adjusting estimations in the process scale, algae yield, and capital cost estimation can lower the price to $\$6.51$/GGE or raise it to $13.07/GGE.

Biofuels↗
DOE OSTI2025

Laboratory evaluation of cyclic underground hydrogen storage in the Temblor sandstone of the San Joaquin Basin, California

Underground Hydrogen Storage (UHS) in depleted oil and gas reservoirs could provide a cost-effective solution to balance seasonal fluctuations in renewable energy generation. However, data and knowledge on UHS at subsurface conditions are limited so it is difficult to estimate how effective this type of storage could be. In this study, we perform high pressure experiment to measure the effectiveness of cyclic hydrogen (H 2 ) storage in a specimen of Temblor sandstone retrieved from the San Joaquin Basin of California. Our experiment mimics reservoir pressure conditions to measure H 2 -brine relative permeability and fluid-rock interactions over the course of ten charging and discharging cycles. Initial gas breakthrough occurred at 15 % to 25 % H2 saturation in the specimen with 3 % NaCl brine as the resident fluid. Continuing injecting to 4 pore volumes (PV) of H 2 yielded an asymptotic H 2 saturation of 38 % to 41 %, a level often referred to as the irreducible gas saturation based on two-phase flow. The boundary condition in this study mimics the near wellbore region, which experiences bi-directional H 2 flow. This bi-directional flow led to evaporative drying of the specimen resulting in 94 % H 2 saturation at the end of 10th cycle. This indicates that cyclic flow and evaporative drying can lead to more efficient reservoir storage where a larger fraction of the reservoir porosity is usable to store H 2 . The produced gas stream consisted of H 2 mixed with 8 % to 22 % H 2 O, indicating formation dry-out by evaporation. Meanwhile, produced water chemistry indicated calcite and silicate dissolution, with calcite sourced from fossil fragments. This led to a loss of cementation and weakened the rock sample. Combined, our results indicate dry-out, compaction, increased H 2 saturation, rock weakening, and permeability loss during cyclic UHS. Overall, we anticipate that the combined effects should lead to higher than anticipated UHS storage efficiency per volume of sandstone reservoir rock.

08 HYDROGEN↗