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The state-of-the-art thermochemical conversion pilot plant includes several configurable, complementary unit operations for testing and developing various reactors, filters, catalysts, and other unit operations. NREL engineers and scientists as well as clients can test new processes and feedstocks in a timely, cost-effective, and safe manner to obtain extensive performance data on processes or equipment.
Air Products has developed a potentially ground-breaking technology – Sour Pressure Swing Adsorption (PSA) – to replace the solvent-based acid gas removal (AGR) systems currently employed to separate sulfur containing species, along with CO 2 and other impurities, from gasifier syngas streams. The Sour PSA technology is based on adsorption processes that utilize pressure swing or temperature swing regeneration methods. Sour PSA technology has already been shown with higher rank coals to provide a significant reduction in the cost of CO 2 capture for power generation, which should translate to a reduction in cost of electricity (COE), compared to baseline CO 2 capture plant design. The objective of this project is to test the performance and capability of the adsorbents in handling tar and other impurities using a gaseous mixture generated from the gasification of lower rank, lignite coal. The results of this testing are used to generate a high-level pilot process design, and to prepare a techno-economic assessment evaluating the applicability of the technology to plants utilizing these coals.
The research activities presented in this report are intended to address the most critical technical challenges pertaining to coal-biomass briquette feedstocks. Several detailed investigations were conducted using a variety of coal and biomass feedstocks on the topics of (1) coal-biomass briquette production and characterization, (2) gasification of coal-biomass mixtures and briquettes, (3) combustion of coal-biomass mixtures and briquettes, and (4) conceptual engineering design and economic feasibility of briquette production. The briquette production studies indicate that strong and durable co-firing feedstocks can be produced by co-briquetting coal and biomass resources commonly available in the United States. It is demonstrated that binderless coal-biomass briquettes produced at optimized conditions exhibit very high strength and durability, which indicates that such briquettes would remain competent in the presence of forces encountered in handling, storage and transportation. The gasification studies conducted demonstrate that coal-biomass mixtures and briquettes are exceptional gasification feedstocks, particularly with regard to the synergistic effects realized during devolatilization of the blended materials. The mixture combustion studies indicate that coal-biomass mixtures are exceptional combustion feedstocks, while the briquette combustion study indicates that the use of blended briquettes reduces NO x , CO 2 , and CO emissions, and requires the least amount of changes in the operating conditions of an existing coal-fired power plant. Similar results were obtained for the physical durability of the pilot-scale briquettes compared to the bench-scale tests. Finally, the conceptual engineering and feasibility analysis study for a commercial-scale briquetting production facility provides preliminary flowsheet and cost simulations to evaluate the various feedstocks, equipment selection and operating parameters.
This project was sponsored by the US DOE Global Initiatives for Proliferation Prevention. The object was for Ukrainian and US partners, including Argonne, AETC, and Dontech to develop special carbon materials and factory production equipment with the goal of making better car batteries to achieve DOE's goals for all-electric and plug-in hybrid electric vehicles. Carbon materials are used in designs for lithium-ion batteries and metal-air batteries, both leading contenders for future electric cars. Specifically, the collaborators planned to use the equipment derived from this project to develop a rechargeable battery system that will use the carbon materials produced by the innovative factory process equipment. The final outcome of the project was that the Ukrainian participants consisting of the Kharkov Institute of Physics and Technology (KIPT), the Institute of Gas of National Academy of Sciences of Ukraine and the Materials Research Center, Ltd. designed, built, tested and delivered 14 pieces of processing equipment for pilot scale carbon production lines at the AETC, Arlington Heights facilities. The pilot scale equipment will be used to process materials such as activated carbon, thermally expanded graphite and carbon coated nano-particles. The equipment was shipped from Ukraine to the United States and received by AETC on December 3, 2013. The equipment is on loan from Argonne, control # 6140. Plug-in hybrid electric vehicles (PHEV) and all-electric vehicles have already demostrated success in the U.S. as they begin to share the market with older hybrid electric designs. When the project was conceived, PHEV battery systems provided a ~40 mile driving range (2011 figures). DOE R&D targets increased this to >100 miles at reduced cost less than $250/kWh (2011 figures.) A 2016 Tesla model S has boasted 270 miles. The project object was to develop pilot-production line equipment for advanced hybrid battery system that achieves cycle life of 1000, an energy density of 280 Wh/kg and specific density of 600Wh/l. This project delivers factory equipment to produce these advanced battery materials.
The U.S. Department of Energy (DOE), the world's largest buyer and user of supercomputers, awarded IDC Research, Inc. a grant to create two macroeconomic models capable of quantifying, respectively, financial and non-financial (innovation) returns on investments in HPC resources. Following a 2013 pilot study in which we created the models and tested them on about 200 real-world HPC cases, DOE authorized us to conduct a full-out, three-year grant study to collect and measure many more examples, a process that would also subject the methodology to further testing and validation. A secondary, "stretch" goal of the full-out study was to advance the methodology from association toward (but not all the way to) causation, by eliminating the effects of some of the other factors that might be contributing, along with HPC investments, to the returns produced in the investigated projects.
When Solstice began working in the community solar industry, it quickly became clear that there was a wide disparity along race and class lines in terms of what kind of household traditional solar offerings benefited. Solstice is an organization that aligns itself to the principles of a Just Transition, or the concept that a transition to a green economy should benefit and prioritize historically marginalized groups of people. Given that low-income communities are disproportionately burdened by our current polluting fossil fuel economy, Solstice set out to investigate the root causes of the exclusion of low to moderate income (LMI) households in the community solar market. As we worked more and more with financiers, developers, and LMI households, we recognized that significant barriers to entry in a developer-owned project were credit threshold requirements. A FICO score of 750 and higher discriminates against LMI households that are not financially stable enough to take on multiple lines of credit (or who may not have been deemed credit worthy enough to access a line of credit) yet who may have been reliable utility customers. As Solstice began looking further into preliminary data and speaking to community-based organizations (CBOs) that serve LMI households, we found our hypothesis to be worth investigating; there was indeed a subset of LMI households with poor FICO scores (or no FICO score at all) that had perfect bill payment history. Though initially Solstice was intent on gathering a body of data to prove or disprove this hypothesis, we were also concerned that all this proof of a financially stable and reliable customer was not being incorporated into FICO, and wondered if such a score would be possible. After preliminary research into the existence of alternative scores, Solstice realized that many mission-driven lending institutions rely on alternative metrics that are formulated for their specific industry. However, we also realized that community solar did not have an alternative credit underwriting mechanism, though there was great need from solar financiers for one. We anticipated that the creation of an EnergyScore would contribute to financiers’ need to qualify more people, as these entities are desperately looking for ways to lower the cost of customer acquisition. FICO turns away nearly 50% of potential customers (according to our own acquisition experience), and much of the community solar industry is realizing that FICO is not the perfect qualifying mechanism. Additionally, with a grounding in energy justice, just transitions, and climate justice, Solstice recognizes the need for a solution that addresses a more urgent need for LMI households to access renewable energy savings and relieve energy burdens. With funding from the Department of Energy, we gathered the data necessary to build the EnergyScore, reached out to mission-driven developers willing to test the metric, and secured several demonstration projects to pilot the EnergyScore. After acquiring customers for these demo projects using the EnergyScore, we will be continuously collecting customer payment behavior data. Though it goes beyond the scope of this project, we plan to disseminate this de-identified data with the wider community solar industry, which includes not only financiers and developers, but other mission-driven nonprofits, solar cooperatives, community-based organizations, environmental justice activists, and academics. While we intend to disprove the notion that LMI households cannot be included in projects without acutely increasing the risk to project finances, we also hope the data can be used to negotiate better pricing of systems and terms of ownership for community groups seeking to build inclusive projects.
Anthropogenic sources of carbon dioxide are generated from a number of sources, but the key among these are ordinary Portland cement (OPC) production and combustion of fossil fuels. Cement production is the largest global CO 2 source from the mineral decomposition of carbonates. Combination of the limestone decomposition and thermal requirements of the clinkering process causes cement production to contribute 8-9% of annual global CO 2 emissions. Combustion of fossil fuels (coal, oil and gas) was shown to contribute a much larger portion of global CO 2 emissions. As of 2018, combustion of fossil fuels accounted for 65% of global CO 2 , where 41% was derived from stationary sources for electricity and heat generation and the other 24% was related to transport. To reduce these contributions, key steps forward in CO 2 utilization technologies are required. The purpose of this project is to demonstrate the feasibility of the Reversa process evolving from a TRL-3 technology at the bench-scale up to TRL-6 technology at the pilot-scale. The reliability of the Reversa technology was tested to prove the effective production of concrete masonry units (CMUs) at bench scale, where the units exceeded the required 13.8 MPa compressive strength requirements. The overall goal of this project was to accelerate the development of a CO 2 mineralization process that synergistically utilizes CO 2 in flue gas and coal combustion residues (CCRs) to synthesize carbonated concrete, a functional replacement for traditional concrete. The culmination of this work resulted in 12 successful production runs at the Integrated Test Center (ITC), Gillette, WY using coal flue gas as a CO 2 source. This was followed by 6 production runs which were completed at the National Carbon Capture Center (NCCC), Wilsonville, AL, using coal-fired and natural gas (NG) flue gas as the CO 2 source. Over the course of the production runs at NCCC and ITC, the CO 2 utilization as a function of time, 24-h CO 2 uptake, electricity usage, and 28-d net area compressive strength recorded for each run. The ITC and NCCC demonstrations achieved an average of 0.19 and 0.1 g CO 2 /g reactant, respectively. Both demonstrations exceeded the project’s target goals of uptake > 0.05 g CO 2 /g reactant. Average compressive strength of the ITC blocks was 18.24 MPa at 28-days. This exceeded the target strength of 13.8 MPa specified by ASTM C90. ITC and NCCC produced an average CO 2 utilization efficiency of 74.9 and 57.9%, respectively. Both demonstration averages were within the target range of 50 to 90% utilization efficiency. For some production runs the NCCC demo did exceeded the a CO 2 utilization efficiency of 75%. An LCA of the Reversa process compared to an industry standard product revealed a net CO 2 reduction of 39% to 42%. This exceeded the target requirement of >25% net CO 2 reduction. Collection of this data was used to determine that the project was successful as the demonstration goals were achieved: (1) achieving in excess of 75% CO 2 utilization efficiency, (2) utilizing greater than 250 kg of CO 2 per production batch/run, and (3) ensuring compliance of carbonated blocks with industry standard specifications (ASTM C90).
Anthropogenic sources of carbon dioxide are generated from a number of sources, but the key among these are ordinary Portland cement (OPC) production and combustion of fossil fuels. Cement production is the largest global CO 2 source from the mineral decomposition of carbonates. This is due to the clinkering process whereby limestone (mainly consisting of CaCO 3 ) is decomposed into CaO and CO 2 , and combined with silica rich clays at high temperatures to form clinkers (i.e. the four key minerals that comprise cement). The high temperature range of 1400 – 1550°C required for this process accounts for up to 60% of the generated CO 2 from cement production. Combination of the limestone decomposition and thermal requirements of the clinkering process causes cement production to contribute 8-9% of annual global CO 2 emissions. Combustion of fossil fuels (coal, oil and gas) was shown to contribute a much larger portion of global CO 2 emissions. As of 2018, combustion of fossil fuels accounted for 65% of global CO 2 , where 41% was derived from stationary sources for electricity and heat generation and the other 24% was related to transport. To reduce these contributions, key steps forward in CO 2 utilization technologies are required. Therefore, a CO 2 mineralization technology (CO 2 mineralization concrete) to reduce the OPC content in concrete, while utilizing flue gas emissions from fossil fuel combustion has been developed to address both areas simultaneously. This Reversa™ technology utilizes low-carbon cementation agents produced by in situ CO 2 mineralization (“mineral carbonation reactions”) to offer a promising alternative to OPC. CO 2 mineralization relies upon the reaction of dissolved CO 2 with inorganic alkaline reactants to precipitate mineral carbonates (e.g., CaCO 3 ), which bind proximate particles and achieve cementation. Herein, a concrete green body, which is composed of a mixture of binder, water, and mineral aggregates, is exposed to CO 2 borne in industrial flue gas streams. This manner of CO 2 mineralization allows the production of construction components that feature equivalent engineering attributes as their OPC-based counterparts while featuring a much smaller embodied carbon intensity (eCI). The purpose of this project is to demonstrate the feasibility of the Reversa process evolving from a TRL-3 technology at the bench-scale up to TRL-6 technology at the pilot-scale. The reliability of the Reversa technology was tested to prove the effective production of three standard industrial concrete products selected during the course of the project. The results detailed herein will demonstrate the evolution of this technology to the industrial scale. The culmination of this work resulted in 9 production runs completed at the National Carbon Capture Center (NCCC), Wilsonville, AL, using natural gas (NG) flue gas as the CO 2 source. Over the course of the production runs at NCCC, the CO 2 utilization as a function of time, 24-h CO 2 uptake, electricity usage, and 28-d net area compressive strength recorded for each run. Collection of this data will be used to determine the success of the demonstration goals: (1) achieving in excess of 0.2gCO 2 /g reactant , (2) achieving greater than 50% reduction in global warming potential compared to standard produced units, and (3) ensuring compliance of carbonated concrete with industry standard specifications.
A magnesium oxysulfate (MOS) grout formulation has been identified to solidify the liquid effluent from the Savannah River Plutonium Processing Facility (SRPPF) Aqueous Recovery System (ARS). The formulation uses reactive, light burnt MgO (28 wt%), anhydrous MgSO 4 (10 wt%), and dead burnt MgO (62 wt%), resulting in a grout with good mixability, acceptable density, acceptable setting times, and a leachate pH around 9.4, within the assumed Waste Isolation Pilot Plant (WIPP) brine pH range. A series of tests were then designed to observe how this formula reacted to variations in the liquid effluent. Liquid effluent temperature, the caustic pH level, concentration of NaNO 3 , and the presence of neutralization products, trace metals, and/or sodium sulfate (all potential residuals found in the effluent from upstream processing), were evaluated to see how each impacts the grout mixing time, peak temperature, setting time, presence of bleed water, leachate pH, and density. The standard mix has an average mixing time of 18 minutes, peak temperature of 100.5 °C, and set time of 60 minutes. Increasing the temperature of the liquid effluent increased the reaction rate of the mix and reduced mixing and setting times. Between 30 and 40°C the change was relatively small, raising no more than 6 °C compared to the standard mix maximum temperature. Increasing the pH of the liquid effluent had no significant impact on the mix. The addition of neutralization products and trace metals had an overall impact of decreasing the reactivity of the mix. The addition of more ions in the liquid effluent, such as an increase in the concentration of NaNO 3 and the addition of Na 2 SO 4 , generally decreased the reactivity of the mix. None of the variations to the liquid effluent hindered solidification as indicated by the lack of bleed water found on all the samples. The leachate pH values for all mixes tested did not significantly vary from the expected pH of 9.4 and none of the density values fell below 1.8 g/cm 3 . Overall, changes to the liquid effluent were found to have a minimal impact on the formulation suggesting the grout's ability to properly form despite increased temperatures and the presence of residuals typically found in the liquid effluent from the ARS.
A pilot aid -- a kinesthetic-tactual compensatory display -- for assisting novice pilots in various inflight situations has undergone preliminary inflight testing. The efficacy of this display, as compared with two types of visual displays, was evaluated in both a highly structured approach-and-landing task and a less structured test involving tight turns about a point. In both situations, the displayed quantity was the deviation (alpha sub 0 - alpha) in angle at attack from a desired value alpha sub 0. In the former, the performance with the tactual display was comparable with that obtained using a visual display of (alpha sub 0 - alpha), while in the later, substantial improvements (reduced tracking error (55%), decreased maximum altitude variations (67%), and decreased speed variations (43%)), were obtained using the tactual display. It appears that such a display offers considerable potential for inflight use.
Airline pilot selection proceedures are discussed including psychogical and personality tests, psychomotor performance requirements, and flight skills evaluation. Necessary attitude and personality traits are described and an outline of computer selection, testing, and training techniques is given.
The QSRA, when equipped with programmable color cathode ray tube displays, a head up display, a general purpose digital computer and a microwave landing system receiver, will provide a capability to do handling qualities studies and terminal area operating systems experiments as well as to enhance an experimenter's ability to obtain repeatable aircraft performance data. The operating systems experiments include the capability to generate minimum fuel approach and departure paths and to conduct precision approaches to a STOLport runway. The mode select panel is designed to provide both the flexibility needed for a variety of flight test experiments and the minimum workload operation required by pilots flying into congested terminal traffic areas.
Design parameters for two large area, low cost solar cells are presented, and electron irradiation testing, thermal alpha testing, and cell processing are discussed. The devices are a 2 ohm-cm base resistivity silicon cell with an evaporated aluminum reflector produced in a dielectric wraparound cell, and a 10 ohm-cm silicon cell with the BSF/BSR combination and a conventional contact system. Both cells are 5.9 x 5.9 cm and require 200 micron thick silicon material due to mission weight constraints. Normalized values for open circuit voltage, short circuit current, and maximum power calculations derived from electron radiation testing are given. In addition, thermal alpha testing values of absorptivity and emittance are included. A pilot cell processing run produced cells averaging 14.4% efficiencies at AMO 28 C. Manufacturing for such cells will be on a mechanized process line, and the area of coverslide application technology must be considered in order to achieve cost effective production.
A flight test maneuver autopilot (FTMAP) is currently being flown to increase the quality and quantity of the data obtained in the flight testing of the highly maneuverable aircraft technology (HiMAT) remotely piloted research vehicle (RPRV). The FTMAP resides in a ground-based digital computer and was designed to perform certain prescribed maneuvers precisely, while maintaining critical flight parameters within close tolerances. The FTMAP operates as a non-flight-critical outer loop controller and augments the vehicle primary flight control system. The inputs to the FTMAP consist of telemetry-downlinked aircraft sensor data. During FTMAP operation, the FTMAP computer replaces normal pilot inputs to the aircraft stick and throttle positions. The FTMAP maneuvers include straight-and-level flight, level accelerations and decelerations, pushover pullups, and windup turns. The pushover pullups can be executed holding throttle or Mach number fixed. The windup turns can be commanded by either normal acceleration or angle of attack. The operational procedures, control mode configuration, and initial simulation results are discussed.
The primary goal of the AFTI/F-16 program is to develop a reliable triplex digital multimode flight control system; this system is to be tailored to optimize fighter performance and capable of six-degree-of-freedom decoupled aircraft control. The multiple digital control law configurations arrived at through flight testing are presented. The changes in these designs from the results of flight tests establish that flight testing is an integral part of the development process. The flight test results are analyzed here from the standpoint of pilot comments and resulting control law design modifications.
The Inventory Technology Development (ITD) project of the Agriculture and Resources Inventory Surveys Through Aerospace Remote Sensing (AgRISTARS) program has developed an accurate, automated technology for early season estimation of spring small grains areal proportion from Landsat MSS data. The design criteria for an early season procedure included estimates available within the first 30 days of the growing season, low data processing/preprocessing requirements and no need for scene-to-scene registration. The prototype estimator which meets the design goals is based on a constrained linear model in which the observed spectral response of an entire scene is modeled as a linear combination of the major constituent elements in the scene. The procedure was evaluated over 100 sample segments collected for crop years 1976 through 1979 in the U.S. Northern Great Plains. Analysis of the test results indicated accuracy that compare favorably with both the automated at-harvest technologies tested during the FY81-82 AgRISTARS Spring Small Grains Pilot experiments and earlier analyst-intensive at-harvest technologies.
The development of an electronic primary flight display format aligned with the aircraft velocity vector, a simulation evaluation comparing this format with an electronic attitude-aligned primary flight display format, and a flight evaluation of the velocity-vector-aligned display format are described. Earlier tests in turbulent conditions with the electronic attitude-aligned display format had exhibited unsteadiness. A primary objective of aligning the display format with the velocity vector was to take advantage of a velocity-vector control-wheel steering system to provide steadiness of display during turbulent conditions. Better situational awareness under crosswind conditions was also achieved. The evaluation task was a curved, descending approach with turbulent and crosswind conditions. Primary flight display formats contained computer-drawn perspective runway images and flight-path angle information. The flight tests were conducted aboard the NASA Transport Systems Research Vehicle (TSRV). Comparative results of the simulation and flight tests were principally obtained from subjective commentary. Overall, the pilots preferred the display format aligned with the velocity vector.
This paper focuses on the work load aspects of the pilot vehicle interface in regard to the new technologies tested during AMAS Phase II. Subjects discussed in this paper include: a wide field-of-view head-up display; automated maneuvering attack system/sensor tracker system; master modes that configure flight controls and mission avionics; a modified helmet mounted sight; improved multifunction display capability; a voice interactive command system; ride qualities during automated weapon delivery; a color moving map; an advanced digital map display; and a g-induced loss-of-consciousness and spatial disorientation autorecovery system.