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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.
It has been proposed to convert the National Institute of Standards and Technology (NIST) research reactor, known as the NBSR, from high-enriched uranium (HEU) fuel to low-Enriched uranium (LEU) fuel. The motivation to convert the NBSR to LEU fuel is to reduce the risk of proliferation of special nuclear material. This report is a compilation of relevant information from recent studies related to the proposed conversion using a metal alloy of LEU with 10 w/o molybdenum. The objective is to inform the design of the mini-plate and full-size-Plate irradiation experiments that are being planned. This report provides relevant dimensions of the fuel elements, and the following parameters at steady state: average and maximum fission rate density and fission density, fuel temperature distribution for the plate with maximum local temperature, and two-dimensional heat flux profiles of fuel plates with high power densities. The latter profiles are given for plates in both the inner and outer core zones and for cores with both fresh and depleted shim arms (reactivity control devices). A summary of the methodology to obtain these results is presented. Fuel element tolerance assumptions and hot channel factors used in the safety analysis are also given.
This project had two main goals. The first goal was to evaluate several high yielding tropical perennial grasses as feedstock for biofuel production, and to characterize the feedstock for compatible biofuel production systems. The second goal was to assess the integration of renewable energy systems for Hawaii. The project focused on high-yield grasses (napiergrass, energycane, sweet sorghum, and sugarcane). Field plots were established to evaluate the effects of elevation (30, 300 and 900 meters above sea level) and irrigation (50%, 75% and 100% of sugarcane plantation practice) on energy crop yields and input. The test plots were extensive monitored including: hydrologic studies to measure crop water use and losses through seepage and evapotranspiration; changes in soil carbon stock; greenhouse gas flux (CO 2 , CH 4 , and N 2 O) from the soil surface; and root morphology, biomass, and turnover. Results showed significant effects of environment on crop yields. In general, crop yields decrease as the elevation increased, being more pronounced for sweet sorghum and energycane than napiergrass. Also energy crop yields were higher with increased irrigation levels, being most pronounced with energycane and less so with sweet sorghum. Daylight length greatly affected sweet sorghum growth and yields. One of the energy crops (napiergrass) was harvested at different ages (2, 4, 6, and 8 months) to assess the changes in feedstock characteristics with age and potential to generate co-products. Although there was greater potential for co-products from younger feedstock, the increased production was not sufficient to offset the additional cost of harvesting multiple times per year. The feedstocks were also characterized to assess their compatibility with biochemical and thermochemical conversion processes. The project objectives are being continued through additional support from the Office of Naval Research, and the Biomass Research and Development Initiative. Renewable energy assessments included: biomass feedstocks currently being produced by Hawaiian Commercial & Sugar Co., and possibilities of producing methane from agricultural and livestock wastes and the potential of photovoltaic systems for irrigation pumping at HC&S. Finally, the impact of a micro-hydroelectric system on a small-farm economics and the local community was assessed.
The Renewable Energy Institute International, in collaboration with Greyrock Energy and Red Lion Bio-Energy (RLB) has successfully demonstrated operation of a 25 ton per day (tpd) nameplate capacity, pilot, pre-commercial-scale integrated biorefinery (IBR) plant for the direct production of premium, “drop-in”, synthetic fuels from agriculture and forest waste feedstocks using next-generation thermochemical and catalytic conversion technologies. The IBR plant was built and tested at the Energy Center, which is located in the University of Toledo Medical Campus in Toledo, Ohio.
The purpose of the TREAT reactor is to generate large transient neutron pulses in test samples without over-heating the core to simulate fuel assembly accident conditions. The power transients in the present HEU core are inherently self-limiting such that the core prevents itself from overheating even in the event of a reactivity insertion accident. The objective of this study was to support the assessment of the feasibility of the TREAT core conversion based on the present reactor performance metrics and the technical specifications of the HEU core. The LEU fuel assembly studied had the same overall design, materials (UO 2 particles finely dispersed in graphite) and impurities content as the HEU fuel assembly. The Monte Carlo N–Particle code (MCNP) and the point kinetics code TREKIN were used in the analyses.
The following report describes the neutronics results obtained with the MCNP model of the RHF U7Mo LEU reference design that has been established in 2010 during the feasibility analysis. This work constitutes a complete and detailed neutronics analysis of that LEU design using models that have been significantly improved since 2010 and the release of the feasibility report. When possible, the credibility of the neutronics model is tested by comparing the HEU model results with experimental data or other codes calculations results. The results obtained with the LEU model are systematically compared to the HEU model. The changes applied to the neutronics model lead to better comparisons with experimental data or improved the calculation efficiency but do not challenge the conclusion of the feasibility analysis. If the U7Mo fuel is commercially available, not cost prohibitive, a back-end solution is established and if it is possible to manufacture the proposed element, neutronics analyses show that the performance of the reactor would not be challenged by the conversion to LEU fuel.
In this project, we have employed a systematic approach to develop active, selective, and stable catalyst materials for important electrochemical reactions involving energy conversion. In particular, we have focused our attention on developing active catalyst materials for the hydrogen evolution reaction (HER), oxygen evolution reaction (OER) and oxygen reduction reaction (ORR). HER: We have synthesized and investigated several highly active and acid stable non-precious metal HER catalysts, including: [Mo 3 S 13 ] 2- nanoclusters (Nature Chemistry, 2014) and molybdenum phosphosulfide (MoP|S) (Angewandte Chemie, 2014). We have also aimed to engineer these catalyst formulations in a membrane electrode assembly (MEA) for fundamental studies of water electrolysis at high current densities, approximately 1 A/cm 2 (ChemSusChem, 2015). We furthermore investigated transition metal phosphide (TMP) catalysts for HER by a combined experimental–theoretical approach (Energy & Environmental Science, 2015). By synthesizing different TMPs and comparing experimentally determined HER activities with the hydrogen adsorption free energies, ΔG H , calculated by density functional theory, we showed that the TMPs follow a volcano relationship for the HER. Using our combined experimental–theoretical model, we predicted that the mixed metal TMP, Fe 0.5 Co 0.5 P, should have a near-optimal ΔG H . We synthesized several mixtures of Co and Fe phosphides alloys and confirmed that Fe 0.5 Co 0.5 P exhibits the highest HER activity of the investigated TMPs (Energy & Environmental Science, 2015). The understanding gained as to how to improve catalytic activity for the HER, particularly for non-precious metal materials, is important to DOE targets for sustainable H 2 production. OER: We have developed a SrIrO 3 /IrO x catalyst for acidic conditions (submitted, 2016). The SrIrO 3 /IrO x catalyst significantly outperforms rutile IrO 2 and RuO 2 , the only other OER catalysts to have reasonable stability and activity in acidic electrolyte, and in fact demonstrates the best activity for any known OER catalyst measured in either acidic or in alkaline electrolyte. For alkaline conditions we have demonstrated that the combined effect of cerium as a dopant and gold as a metal support, significantly enhances the OER activity of electrodeposited NiO x films. This NiCeO x -Au catalyst delivers high OER activity in alkaline media, and is among the most active OER electrocatalysts reported to date (Nature Energy, accepted 2016). These studies of new catalysts for the OER, both in acid and in base, are fundamental to enabling new technologies of interest for the DOE, including the production of sustainable fuels and chemicals. ORR: One method to significantly reduce the Pt loading in fuel cell devices is to increase the ORR activity of Pt based systems. To this end we have synthesized a high surface area supported meso-structured Pt x Ni alloy thin film with a double gyroid morphology that both exhibits high activity and stability for the ORR (submitted, 2016). We have furthermore developed a Ru-core, Pt-shell system that improves the per Pt site activity by more than a factor of 2 (ChemElectroChem, 2014). Further refinement, optimizing Pt-shell thickness and reducing particle sintering during processing, enabled us to obtain a mass activity that is 2 times higher than commercial Pt/C from TKK. These are important contributions to the DOE goal of reducing Pt loading since an improved understanding of how to increase mass activity and stability helps enable low Pt content fuel cells.
The U.S. Department of Energy (DOE) promotes the production of a range of liquid fuels and fuel blendstocks from biomass feedstocks by funding fundamental and applied research that advances the state of technology in biomass production, conversion, and sustainability. As part of its involvement in this program, the National Renewable Energy Laboratory (NREL) investigates the conceptual production economics of these fuels. This includes fuel pathways from lignocellulosic (terrestrial) biomass, as well as from algal (aquatic) biomass systems.
This project is intended to demonstrate the technical and economic feasibility, and environmental and social attractiveness of a novel method of heat extraction from geothermal reservoirs. The emphasis is on assessing the potential for a heat extraction method that couples forced and free convection to maximize extraction efficiency. The heat extraction concept is enhanced by considering wellbore energy conversion, which may include only a boiler for a working fluid, or perhaps a complete boiler, turbine, and condenser cycle within the wellbore. The feasibility of this system depends on maintaining mechanical and hydraulic integrity of the wellbore, so the material properties of the casing-cement system are examined both experimentally and with well design calculations. The attractiveness depends on mitigation of seismic and subsidence risks, economic performance, environmental impact, and social impact – all of which are assessed as components of this study.
This report was prepared in response to the U.S. Department of Energy Fuel Cell Technologies Office Congressional Appropriation language to support research on carbon-free production of hydrogen using new chemical processes that utilize natural gas to produce solid carbon and hydrogen. The U.S. produces 9-10 million tons of hydrogen annually with more than 95% of the hydrogen produced by steam-methane reforming (SMR) of natural gas. SMR is attractive because of its high hydrogen yield; but it also converts the carbon to carbon dioxide. Non-oxidative thermal decomposition of methane to carbon and hydrogen is an alternative to SMR and produces CO 2 -free hydrogen. The produced carbon can be sold as a co-product, thus providing economic credit that reduces the delivered net cost of hydrogen. The combination of producing hydrogen with potentially valuable carbon byproducts has market value in that this allows greater flexibility to match the market prices of hydrogen and carbon. That is, the higher value product can subsidize the other in pricing decisions. In this report we highlight the relevant technologies reported in the literature—primarily thermochemical and plasma conversion processes—and recent research progress and commercial activities. Longstanding technical challenges include the high energetic requirements (e.g., high temperatures and/or electricity requirements) necessary for methane activation and, for some catalytic processes, the separation of solid carbon product from the spent catalyst. We assess current and new carbon product markets that could be served given technological advances, and we discuss technical barriers and potential areas of research to address these needs. We provide preliminary economic analysis for these processes and compare to other emerging (e.g., electrolysis) and conventional (e.g., SMR) processes for hydrogen production. The overarching conclusion of this study is that the cost of hydrogen can be potentially reduced to target levels of $2/kg with the co-production and sale of a sufficiently high-value carbon product. Technological advances are required to understand the reaction conditions and design reactor systems that can achieve high yields of the select carbon products and segregate or separate the high-value carbon products, and optimize the production process for both hydrogen and carbon.
This project developed an alternative design for heat exchangers for application to heating supercritical carbon dioxide (S-CO 2 ) or air for power conversion. We have identified an annular coiled tube bundle configuration–where hot sodium enters tubes from multiple vertical inlet manifold pipes, flows in a spiral pattern radially inward and downward, and then exits into an equal number of vertical outlet manifold pipes–as a potentially attractive option. The S-CO 2 gas or air flows radially outward through the tube bundle. Coiled tube gas heaters (CTGHs) are expected to have excellent thermal shock, long-term thermal creep, in-service inspection, and reparability characteristics, compared to alternative options. CTGHs have significant commonality with modern nuclear steam generators. Extensive experience exists with the design, manufacture, operation, in-service inspection and maintenance of nuclear steam generators. The U.S. Nuclear Regulatory Commission also has extensive experience with regulatory guidance documented in NUREG 0800. CTGHs leverage this experience and manufacturing capability. The most important difference between steam generators and gas-Brayton cycles such as the S-CO 2 cycle is that the heat exchangers must operate with counter flow with high effectiveness to minimize the pinch-point temperature difference between the hot liquid coolant and the heated gas. S-CO 2 -cycle gas heaters also operate at sufficiently elevated temperatures that time dependent creep is important and allowable stresses are relatively low. Designing heat exchangers to operate in this regime requires configurations that minimize stresses and stress concentrations. The cylindrical tubes and cylindrical manifold pipes used in CTGHs are particularly effective geometries. The first major goal of this research project was to develop and experimentally validate a detailed, 3-D multi-phase (gas-solid-liquid) heat transport model for CTGHs, using methods similar to earlier UCB multi-scale models for PCHEs, which will enable optimization of CTGH designs with respect to the number of manifold pipes, S-CO 2 and sodium circulating power, and other design parameters. CTGHs are relatively novel because the tubes loaded in compression as well as the manifold pipes which form the tube sheets. The second major goal of the experimental and modeling effort was to optimize the assembly and heat treatment of the tube-to-tubesheet joints, using a novel tapered joint configuration, and to develop diffusion-bonded joints with high shear strength and creep resistance, as has been done in other applications for tapered plugs. The project would also conduct creep testing of these tubesheet joints in pressurized furnaces under prototypical conditions of stress and temperature, however this was not feasible due to numerous hinderances. Detailed microstructural investigations was conducted on the diffusion bond interface, while the bond strength was evaluated by tensile testing. The mechanical testing quantified the overall strength of the bond and measured the pull out force as well as long term behavior, which complemented the microstructural analysis and gave a complete understanding of the diffusion bond.
This report summarizes the work carried out in furtherance of the NETL/DOE award, OTM-Enhanced Coal Syngas for Carbon Capture Power Systems and Fuel Synthesis Applications. The overall objective of the project was to further develop Oxygen Transport Membrane (OTM) technology and assess the potential for integration in coal power generation. OTM technology has the potential to enhance the quality of syngas produced by coal gasifiers, reduce the amount of cryogenic-derived oxygen required in Integrated Gasification Combined Cycle (IGCC) power plants, and allow for coal and natural gas integration. Process simulations and techno-economic analyses were carried out to estimate the cost and performance of OTM enhanced IGCC plants, IG-NGCC plants, and OTM enhanced Fischer Tropsch (FT) Liquids from coal and natural gas plants. The OTM enhanced power plants achieved higher carbon capture rates, higher efficiencies, and lower cost of electricity compared to the base cases. The most significant benefits were achieved for cases which used low rank coal as the feed. Fischer-Tropsch coal to liquids plants with iron-based catalysts and natural gas integration utilizing OTM technology showed improved carbon conversion, improved thermal efficiency and lower cost of production. With respect to OTM core technology development, significant advances have been made in several areas. The development and implementation of a third-generation membrane materials and manufacturing process has resulted in the availability of robust and reliable, high performance membranes, that can be manufactured at high yield. Progress towards the goal of higher pressure operation has been demonstrated with the development of improved metal-ceramic seals and components of the panel array module that integrate membrane-seal assemblies with primary and secondary reforming catalysts have been further developed and demonstrated. Work concluded with the successful start-up and operation of a multi-panel pilot-scale system which is the final step in technology development ahead of demonstration.
OxEon Energy evaluated a catalytic process to directly convert methane to ethylene at high conversion and selectivity. The process uses a dual catalyst reactor where the first catalyst activates methane to produce active radicals which are combined over the second catalyst to form ethylene.
The stoichiometric hydrogen deficiency of carbohydrate feedstock implies that all conversion processes must remove oxygen and concurrently increase hydrogen content to form liquid hydrocarbon products. With support from the DOE Early Career program (DE-SC0008418) we have investigated the use of transition metal carbides for hydrodeoxygenation (HDO) chemistries using CH 4 and H 2 as co-reactants. We report that concurrently processing CH 4 and C 1 -C 3 oxygenates (oxygenate/CH 4 = 0.01-0.1) at 950 K on molybdenum carbide clusters encapsulated in zeolite micropores results in a staged bed with upstream CH 4 reforming and downstream CH 4 dehydroaromatization. Forward rates of CH 4 pyrolysis limited by CH 4 activation are unperturbed by the introduction of oxygenates with a (C/H) eff <0.25 after rigorously accounting for the thermodynamic reversibility caused by the H 2 produced in oxygenate reforming reactions and the fraction of the active catalyst bed deemed unavailable for CH 4 dehydroaromatization. A binomial distribution of 12 C/ 13 C isotopologues of CO is observed upon introduction of CH 3 13 COOH/CH 4 reactants suggesting that the introduction of oxygenates with a (C/H) eff <0.25 results in complete fragmentation of the oxygenate at these temperatures which in turn results in the invariance of forward rates of CH 4 pyrolysis when using CO 2 , HCOOH, or CH 3 COOH co-feeds. The stoichiometric loss of oxygen as CO when co-processing C 1 -C 3 oxygenates and CH 4 at these temperatures demonstrates that (C/H) eff =(C-O)/H is a single valued descriptor for oxygen removal on Mo/HZSM-5 catalysts. Separately, we have demonstrated the utility of transition metal carbides for vapor phase catalytic hydrodeoxygenation using molecular hydrogen with high selectivity for C-O cleavage and near absence of sequential hydrogenation reactions at atmospheric hydrogen pressure and illustrated that the faculty of transition metal carbides for selective hydrodeoxygenation arises due to oxygen-modification of the catalyst in situ. The oxophilic characteristics of these materials engender both the observed acid-metal catalytic bifunctionality and selectivity for hydrodeoxygenation. The evolution of catalyst surface composition and catalytic function under oxidative reaction environments proffers unique challenges in structural characterization of these materials and in this context, we developed and demonstrated the use of chemical titration and chemical transient studies to assess catalytic site identity and densities.
This CRADA will facilitate technology maturation for NREL-developed ALD-coated catalyst materials that are tailored for durability during harsh biomass conversion chemistries. This project will address optimizing process parameters for scale-up of Al2O3 ALD-coated catalysts, demonstrating ALD-coated catalyst performance for muconic acid hydrogenation, and validating economic models that project significant cost benefits for ALD-enhanced catalytic processes. This work will strengthen private-public partnerships in the area of advanced catalyst manufacturing for energy-related technology. Critical information will be collected to elevate the Technology Readiness Level and increase our competitiveness for cooperative R&D agreements and licensing. Success of this work will be crosscutting as it can facilitate advanced catalyst development for both renewable and conventional processes.
The Microreactor Agile Non-nuclear Experimental Testbed (MAGNET) facility is being constructed at Idaho National Laboratory’s (INL’s) Energy Systems Laboratory to assist with the development, demonstration, and validation of microreactor components and systems. MAGNET will accommodate various types of test articles representative of different microreactor designs. A power conversion unit (PCU) simulator loop was proposed to use the rejected heat from the test article and mimic the thermal hydraulic conditions (e.g., temperature, pressure and flow rate) that would be experienced if an actual Brayton cycle PCU was attached. However, due to the high-estimated cost of the PCU simulator and the availability of a turbogenerator used for previous testing at Sandia National Laboratories, the PCU simulator design was abandoned in favor of integrating an actual PCU into MAGNET. A commercial Capstone C30 was modified by Sandia to use external electrical heating, rather than combustion heating, to provide a power output from 1 to ~30 kWe. The C30 has a single-stage centrifugal combustor, a static radial heat exchanger, and a radial inflow turbine arranged on a single shaft with a high-speed alternator. Since the operating temperature and energy transfer per unit working fluid mass are comparable, the MAGNET PCU will provide researchers with the ability to evaluate the test article heat transfer under representative operating conditions with the transient system behavior associated with a closed Brayton cycle PCU. This report examines the integration of a modified commercial Capstone C30 turbogenerator into MAGNET, outlines a proposed set of tests, and describes future work.
The utilization of CO2 produced from power generation plants as a feedstock for creating new valuable products offers a strategy to reduce GHG emissions, offset carbon capture costs, and facilitate the rebalancing of the carbon cycle. After considering the thermodynamic requirement of potential products from CO2 utilization and their market size, formic acid is a desirable target that offers widespread utility in industrial chemical production and chemical energy storage as a liquid fuel. To effectively utilize CO2 from power generation plants, UK proposes an enhanced bimetallic oxide carbon utilization process (EBOCU) that enables electrochemical CO2 conversion to formic acid. The UK intensified electrocatalytic process combines three main components: 1) a novel bimetallic oxide electrocatalyst; 2) a stable electrochemical reactor using robust electrodes; and 3) a pressurized electrochemical reactor. The output from this project showed the economic viability of producing high-value formic acid from CO2 to both offset the cost associated with post-combustion CCS and reduce GHG emissions. This project developed and screened a series engineered catalysts to selectively reduce CO2 directly to formic acid. The best performing catalyst based on formic acid production, stability, and Faradaic efficiency, was immobilized on carbon electrodes, and tested inside a flow through reactor. After lab-scale testing was completed, the experimental data was used to perform a Life-Cycle Analysis (LCA) and conduct an Initial Technical and Economic Feasibility Study. The LCA showed a pathway to a net negative CO2 utilization process with the incorporation of renewable energy, while the TEA showed the potential to produce formic acid below the current commercial price. The UK EBOCU process was successfully demonstrated at the TRL3 level and has a clear pathway to further development and contribution to the nation’s ambitious decarbonization goals.
One promising candidate for manufacturing of the bismuth Telluride thermoelectric legs is laser powder bed fusion (LPBF) additive Manufacturing (AM). AM processing parameters highly influence the material properties, however current processing parameter development methods in AM are costly and time consuming. In-situ sensors allow for the capture of physically relevant process information on a layer-by-layer basis and will be used to aide process development. To optimize the AM process for the best thermoelectric performance, process variables, in-situ process sensor data and ex-situ material characterization data are collected. Several different interpretable machine learning (ML) approaches are used, and the performance of each method are assessed. Significant input process variables include laser focus, hatch spacing and laser power. The best performing models are used to determine the manufacturing parameters that maximize the power factor. AM of bismuth telluride material provides the ability to create complex geometries enabling more efficient energy conversion.