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At least 163 records · Page 9

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DOE OSTI2023

Performance Testing of a Moving-Bed Gasifier Using Coal, Biomass, and Waste Plastic Blends to Generate White Hydrogen

The objective of this DOE-funded project by the Electric Power Research Institute, Inc. (EPRI), Hamilton Maurer International (HMI) and Sotacarbo S.p.A. (Sotacarbo), is to qualify coal, biomass, and plastic waste blends based on performance testing of selected pellet recipes in a pilot-scale updraft moving-bed gasifier. The testing provides relevant data to advance the commercial-scale design of the moving-bed gasifier to be able to successfully use these feedstocks to produce hydrogen. In particular, the effects of the waste plastics on feedstock development (i.e., blending and pelletizing) and the resulting products (i.e., syngas compositions, organic condensate production, and ash characteristics) are a focus. The gasifier is Hamilton Mauer International, Inc. (HMI)’s moving-bed gasifier, which has been proven capable of gasifying nearly all coal ranks. It has also shown the ability in prior testing work to gasify wood chips. However, mixtures of these fuels with plastic wastes had not yet been prepared and gasified together. The feedstocks were prepared by California Pellet Mill (CPM) under contract to HMI. The technical tasks for this research project included: • Feed Procurement and Preparation: Nine different feedstocks were prepared from varying compositions of PRB coal, corn stover biomass, and car fluff waste plastics. Fuel pellets were produced by California Pellet Mill (CPM) and shipped to Sotacarbo’s test facility in Italy. • Test Plan Development: A test plan was created to define the test runs to be performed. The test plan detailed the different tests that were run, instrumentation used, extractive samples taken, and relevant figures of merit. • Gasifier Testing: Tests were performed in the pilot-scale gasifier at Sotacarbo using nine different fuel feedstocks generated from varying mixtures of coal, biomass, and plastic wastes. The testing provides information on gasification reaction efficiency/performance, yielding relevant data for models used to scale up the gasifier design. This task will also included work to reassemble the gasifier at Sotacarbo and perform a baseline 100% coal run. • Data Analysis and Reporting: Review of the data, determination of figures of merit, and interpretation of the results was reported. The results can be used to specify the range of feedstock blends that can be successfully gasified as well as quantify gasifier outputs based on specific blends. The tri-fuel pelletizing conducted at CPM and gasification testing results from Sotacarbo’s 30mm up draft moving bed gasifier are significant. Providing data for an established gasifier to help accelerate its updated design to be able to accommodate feedstocks composed of coal, biomass, and plastic waste. This should ultimately lead to development and commercialization of a lower cost, white hydrogen generation system.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2021

Gasification of Mixed Blends of Coal, Biomass, and Plastic Waste

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2023

Sustainable production of plastic degrading enzymes

The 21st century faces the challenge of transitioning to a climate-neutral economy. This hurdle will need to be addressed in a myriad of approaches, including all societal spheres, as highlighted in several UN and EU reports, including new and accessed technologies. Among them, biotechnology can play a core role by exploiting its environmental benefits (e.g., substituting fossil-based products and expected greenhouse emission reductions). In some cases, biotech can even outperform fossil counterparts' features (e.g., the biodegradability of some bioplastics). Microalga is an attractive bioplastic feedstock in this scenario since it directly substitutes petroleum and captures CO2. However, albeit its environmental benefits, the microalgal process still needs to be tipped economically and the net-positive ecological impact improved to drive adoption. To that end, we envisioned the use of a green alga as a source of bioplastic feedstock and industrial enzymes, combining natural traits of microalgae with engineered properties in a resourceful process to petroleum-based products replacement. As proof of concept, we demonstrated that we could use C. reinhardtii, a green algae, to produce plastic-degrading enzymes. We assemble a vector to secrete PHL7, a recently described PETase, capable of degrading post-consumer PET plastic. We successfully engineered the cell line to secrete the plastic-degrading enzyme. We confirmed the secretion of the enzyme by observing halos in agar plates supplemented with plastic dispersions, enzymatic assays, zymograms, and protein sequencing of supernatant samples. This approach allows using green algae to replace petrochemical-derived plastic while producing the tool necessary to recycle existing plastics sustainably.

Dutra Molino, Joao Vitor↗

DOE OSTI2022

Decontamination of Mixed Paper and Plastic Municipal Solid Waste Increases Low and High Temperature Conversion Yields

With the implementation of China’s Green Fence Policy and the following National Sword Policy, there is a need to divert previously accepted waste materials away from the landfill. Mixed plastic and paper wastes that are too contaminated to be economically recycled can be used for conversion into fuels and products. The effect of common contaminants present in waste streams must be determined to make municipal solid waste (MSW) a viable alternative to agricultural feedstocks for conversion. In this study, MSW was sourced from a dual stream materials recovery facility (MRF) in Emmet County, Michigan and characterized via mass balance. The most common contaminants in mixed paper and plastic were quantified and targeted for decontamination when mixed paper was explored for low temperature conversion pathways and plastics for high temperature conversion pathways. Ink, stickies, and plastic contamination were sorted out of the mixed paper stream and did not have an impact on sugar yields during enzymatic hydrolysis (EH). Although no improvement in yield was found, it was noted that copy paper within the mixed paper stream had an elevated pH and higher concentration of fermentation inhibitors, suggesting that intrinsic properties of some paper types may not be ideal for EH and fermentation conversion. Dilute alkaline pretreatment and mechanical refining of mixed paper increased the EH yield of mixed paper, suggesting this previously established process could be used as a decontamination method. “Dirt” and particulates were washed from mixed plastic using either an aqueous detergent or a non-aqueous chemical washing method. Liquid oil yields were increased during microwave assisted fast pyrolysis. All decontamination techniques met the cost target of less than $30/dry ton with plastic decontamination ranging from $18.16 to $24.81/dry ton. Because dilute alkaline pre-treatment and mechanical refining is considered part of the conversion process, the decontamination cost during feedstock preprocessing was considered $0/dry ton.

09 BIOMASS FUELS↗

DOE OSTI2022

Design of solvent-assisted plastics recycling: Integrated economics and environmental impacts analysis

In 2018, the United States generated over 35. 7 million tons of plastic waste, with only 8.4% being recycled and the other 91.6% incinerated or disposed of in a landfill. The continued growth of the polymer market has raised concerns over the end of life of plastics. Currently, the waste management system is faced with issues of inefficient sorting methods and low-efficiency recycling methods when it comes to plastics recycling. Mechanical recycling is the commonest recycling method but presents a lower-valued recycled material due to the material incompatibilities introduced via the inefficient sorting methods. Chemical recycling offers a promising alternative as it potentially allows for plastics to maintain their original properties. To that end, there is the need to investigate feasible chemical recycling methods to help mitigate the challenging problem posed by plastics at the end-of-life stage. This work proposes a conceptual solvent-assisted plastics recycling framework based on a superstructure optimization approach. This framework is evaluated using a representative case study to recover Polyethylene Terephthalate (PET). In this case study, it is found that polymer recovery is both economically and environmentally favorable when compared to traditional methods of disposal such as incineration.

Lehr, Austin L.↗

DOE OSTI2020

Defect-resistant plastic scintillation radiation detector compositions and fabrication methods

Scintillating plastics resistant to crazing and fogging, methods of making and using the same are disclosed. The scintillating plastics include: one or more primary polymers present in an amount ranging from about 40 wt % to about 95 wt %; one or more secondary polymers present in an amount ranging from about 1 wt % to about 60 wt %; and one or more fluors present in an amount ranging from about 0.1 wt % to about 50 wt %. Methods of making such plastics include: creating a homogenous mixture of precursor materials including primary polymer, secondary polymer, and fluor in the amounts set forth above; and polymerizing the homogenous mixture. Methods of using such plastics include: exposing the scintillating plastic to one or more extreme environmental conditions for a predetermined amount of time without generating crazing or fogging within the scintillating plastic. Various additional features and specific embodiments of these inventive concepts are also disclosed.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Polymer Deconstruction and Redesign Strategies for Plastics Recycling

Advancing plastics recycling requires both the selective deconstruction of existing polymers and the design of new materials that enable efficient reuse without loss of performance. This perspective highlights an integrated approach that is rooted in polymer chemistry, catalysis, and process engineering which can enable a circular plastics economy. Here, we outline recent advances in catalytic, solvolytic, and enzymatic pathways for plastic deconstruction, and examine the molecular design principles driving next-generation recyclable-by-design and bio-based polymers. Despite these advances, major knowledge gaps remain in understanding the evolution of polymer morphology and catalyst structure during deconstruction, assessing deconstruction processes with realistic polymers, and offering redesigned polymers with competitive cost and environmental advantage over conventional plastics. United States Department of Energy (U.S. DOE) national laboratories offer unique capabilities to address these challenges through in situ and operando characterization, high-throughput experimentation, environmental studies, technoeconomic and life cycle assessment, scale-up support, and collaboration networks. Advances made in understanding plastic deconstruction mechanisms and structure-property correlations of redesigned polymers inform emerging research directions including autonomous experimentation, real-time feedback-enabled process optimization, and protein engineering for enzymatic depolymerization.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Co-depolymerization of lignin and plastic waste using hydrothermal liquefaction process

Sustainable valorization of underutilized lignin and plastic waste beyond incineration is critical for producing renewable fuels. Hydrothermal liquefaction (HTL) provides a promising approach to convert wet lignin and plastics into high-quality oils without the need for prior drying of wet lignin. Here, this study examines the effects of temperature (300–400 °C), residence time, and polymer molecular weight on product yield and composition during HTL of polyethylene (PE), polypropylene (PP), and lignin under subcritical and supercritical water conditions. For PE, oil yields increased with temperature, with low molecular weight (LMW) PE achieving a maximum of ∼93 % at 400 °C for 30 min, while high molecular weight (HMW) PE reached ∼86 % at 400 °C for 1 h. Lignin and PP exhibited optimal oil yields at intermediate temperatures, decreasing at higher temperatures due to secondary reactions and char formation. Lignin yielded a maximum of ∼22 % oil at 300 °C for 30 min, LMW PP ∼88 % at 375 °C for 1 h, and HMW PP ∼83 % at 400 °C for 1 h. GC–MS analysis revealed that lignin oils were rich in phenols and alkylphenols, while PE and PP oils were dominated by paraffins and olefins. Oxygenated compounds in PE decreased at higher temperatures, improving oil quality. Co-liquefaction of lignin with plastics enhanced oil yields and energy content under specific conditions, demonstrating synergistic effects dependent on plastic type, molecular weight, and HTL conditions. These findings highlight the potential of HTL to produce high-energy, value-added fuels from lignin–plastic mixtures.

09 - BIOMASS FUELS↗

DOE OSTI2022

Quantification and evaluation of plastic waste in the United States

To develop viable solutions for reducing plastic waste, spatially explicit data on the management of these materials are critical. Here we employ statistical and geospatial methods to present a comprehensive assessment of plastic waste in the United States by resin type at the state, county, and local levels. Of the estimated 44 Mt of plastic waste managed in 2019 domestically, approximately 86% was landfilled, 9% was combusted, and 5% was recycled. Landfilled plastics represented significant losses to the country's economy in 2019: an average of US$7.2 billion in market value, about 3.4 EJ as embodied energy (equivalent to 12% of energy consumption by the industrial sector), and 1.5 EJ as an energy source (equivalent to 5.5% and 5% of energy consumption by the industrial and transportation sectors, respectively). Lastly, we posit that substantial amount of landfilled plastic waste could be recovered through advanced sorting, existing, and emerging recycling processes.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2024

Non-equilibrium plasma co-upcycling of waste plastics and CO 2 for carbon-negative oleochemicals

Mechanical recycling and chemical upcycling by thermochemical reactions have been the major approaches for recycling end-of-life plastics. Herein, we report an electrified approach to upcycle waste plastics into carbon-negative commodity chemicals using greenhouse gas CO 2 as the oxidant and additional carbon source. In this non-equilibrium plasma process, waste polyolefins were oxidatively depolymerized by plasma-activated CO 2 to produce oleochemicals and hydrocarbon chemicals in a single-step process at high reaction rates. In addition, a mixture of CO 2 and a small amount of O 2 was employed as plasma gases to selectively produce fatty alcohols from polyolefins. Based on this atmospheric pressure, non-solvent, and non-catalyst process, up to 97.6% of fatty alcohols could be produced within minutes. In this article, the co-conversion approach was demonstrated using common polyolefins and real-world mixed waste plastics to obtain comparable results. The techno-economic analysis estimates the internal rate of return to be 42.2% and 43.5% for the plasma-based conversion of waste plastics, depending on the plasma gas composition. Lifecycle assessment indicates the global warming potential is between −3.33 and −3.07 kg CO 2e per kg of plastic.

42 ENGINEERING↗

DOE OSTI2020

Combining Reclaimed PET with Bio-Based Monomers Enables Plastics Upcycling

Less than 30% of PET plastic is recycled in the United States. The low reclamation rate may be due to mechanical recycling accounting for the majority of commercial PET recycling. Mechanical recycling yields a lower-quality recycled plastic than the process of chemically recycling back to the monomer phase, which can be energetically and economically expensive. In this work, recently published in Joule, reclaimed PET bottles are chemically recycled and converted into higher-value fiberglass-reinforced plastics (FRPs).This presentation will focus on the supply-chain level energy and greenhouse gas emissions intensities associated with this novel upcycling route. The Materials Flows through Industry supply chain analysis tool, developed at NREL, is used to estimate these impacts. Depending on the extent and speed of adoption, this strategy for plastic upcycling could lead to significant energy usage and emissions reductions over the traditional FRP supply chain. Overall, this approach may provide an economic incentive for plastics recycling and renewable feedstock use through the creation of higher-value FRPs.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2020

Plastic scintillators stable for operating in wide ranges of humidity and temperature variations

To provide efficient and reproducible response to nuclear radiation, scintillating plastics should be prepared as materials of high optical transparency and homogeneity that should remain intact during the lifetime of their operation. A problem with traditionally used polyvinyltoluene (PVT) or polystyrene (PS) plastic scintillators arises from their exposure to repeated large temperature swings that cause surface and volume defects, resulting in decreased sensitivity of the detection properties. We find that the problem can be avoided by composition modifications that enable preparation of plastics with properties that are resistant to the continuous variations in environmental conditions. This paper describes improvements in physical properties that can be achieved by the addition of crosslinkers (such as divinylbenzene, DVB) and oxygen-containing compounds or copolymers (e.g. polymethylamethacrylate, PMMA) to the traditional PVT or PS polymer matrices. Results of characterization show that the new materials can be prepared with the scintillation performance equal to that of commercial plastic scintillators, such as EJ-200.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Bio‐Inspired Cascade Photocatalysis on Fe Single‐Atom Carbon Nitride Upcycles Plastic Wastes for Effective Acetic Acid Production

Plastic imposes a critical threat to the environment, ecosystems, and human health because of the low utilization efficiency of plastics. Here, we demonstrate a sustainable, highly efficient cascade photocatalysis for upcycle plastics to value-added acetic acid using Fe single-atom catalysts (Fe@C 3 N 4 SAC) at ambient conditions. Inspired by Phanerochaete chrysosporium microbial, the defective Fe@C 3 N 4 SAC acts as a bifunctional cascade photocatalyst for both Fenton-like and CO 2 reduction reactions. During the reaction, hydroxyl radicals (*OH) form and subsequently oxidize plastics into CO 2 intermediates. These CO 2 intermediates are then photo-reduced to CH 3 COOH on the same catalyst via cascade photocatalysis. The mechanism is confirmed by in situ multimodal microscopy and spectroscopies, with density functional theory calculations. A state-of-art CH 3 COOH yield of 63.8 mg h −1 gcat −1 from PVC, 12.7 mg h −1 gcat −1 from PE, 5.4 mg h −1 gcat −1 from PET, and 5.3 mg h −1 gcat −1 from PP are directly obtained under AM1.5G solar irradiation and further validated under real sunlight (≈0.6 sun), achieving 5.6 mg h −1 gcat −1 from PET, using low-cost Fe@C 3 N 4 SAC in a sealed reactor by enhancing the photon transport and utilization efficiency. The techno-economic analysis shows it is promising to practically mitigate plastic based on broader social welfare assessments.

cascade photocatalysis↗

DOE OSTI2021

Crystal plasticity model of residual stress in additive manufacturing using the element elimination and reactivation method

Selective laser melting is receiving increasing interest as an additive manufacturing technique. Residual stresses induced by the large temperature gradients and inhomogeneous cooling process can favour the generation of cracks. In this work, a crystal plasticity finite element model is developed to simulate the formation of residual stresses and to understand the correlation between plastic deformation, grain orientation and residual stresses in the additive manufacturing process. The temperature profile and grain structure from thermal-fluid flow and grain growth simulations are implemented into the crystal plasticity model. An element elimination and reactivation method is proposed to model the melting and solidification and to reinitialize state variables, such as the plastic deformation, in the reactivated elements. The accuracy of this method is judged against previous method based on the stiffness degradation of liquid regions by comparing the plastic deformation as a function of time induced by thermal stresses. The method is used to investigate residual stresses parallel and perpendicular to the laser scan direction, and the correlation with the maximum Schmid factor of the grains along those directions. The magnitude of the residual stress can be predicted as a function of the depth, grain orientation and position with respect to the molten pool. The simulation results are directly comparable to X-ray diffraction experiments and stress–strain curves.

316 stainless steel↗

DOE OSTI2020

A phase-field model for non-isothermal phase transformation and plasticity in polycrystalline yttria-stabilized tetragonal zirconia

Here we propose an elastoplastic phase-field (PF) model to investigate the mechanics of tetragonal-to-monoclinic phase transformation (TMPT) and elastoplastic deformation of polycrystalline yttria-stabilized tetragonal zirconia (YSTZ). A Landau polynomial with non-vanishing chemical energy at the equilibrium temperature is introduced to account for the actual formation energies of the phases. The effects of different grain orientations, latent heat, and temperature on TMPT and deformation mechanisms are considered. The suppressive transformation effects of the grain boundaries (GBs) is modeled using an inhomogeneous kinetic coefficient in the bulk and GBs. The simulation results for single crystals demonstrate the capability of the model to reproduce the orientation-dependent compressive deformation of YSTZ similar to atomistic simulations and micropillar experiments. The single crystal with [100] crystallographic orientation along the loading direction (SC[100]) displays both TMPT and plasticity, SC[101] experiences only phase transformation, while SC[001] undergoes only plastic yielding. The TMPT induced by compressive loading exhibits shape memory effect (SME) below the equilibrium transformation temperature and pseudoelasticity above it, while the critical transformation stress increases with increasing loading temperature. The irrecoverable plastic strain is found to trap a part of the monoclinic phase, which prevents a complete reverse transformation. The polycrystalline cases also display SME and PE at low and high temperatures, respectively. Due to the orientation differences between grains and the stress concentrations at geometric nonlinearities, plastic deformation occurs in polycrystalline YSTZ for an applied load less than the yield stress. The results suggest a possible limitation of plasticity and an improvement of the shape recovery of YSTZ if one can control the orientation of the grains and/or increase the density of stacking faults at the GBs during material processing.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Simulation of dynamic crystal plasticity with a Lagrangian discontinuous Galerkin hydrodynamic method

Here we present a new Lagrangian modal discontinuous Galerkin (DG) hydrodynamic method that supports a dynamic dislocation based crystal plasticity model for simulating the mechanical behavior of crystallographic materials, both single crystal and polycrystalline, under dynamic conditions. A modal DG approach is used to evolve fields relevant to conservation laws. These fields are approximated by Taylor series polynomials of varying degree. These polynomials describe macro-scale hydrodynamic behavior while their evolution is determined by evaluating the dynamic crystal plasticity model at material points within the element. The dynamic crystal plasticity model is sensitive to the time increment size, with too large of time increments leading to instability in the model. To mitigate this, the temporal evolution of the dynamic crystal plasticity model is achieved with the combination of a sub-incrementing scheme with Heun’s third-order time integration scheme, which is also used to temporally evolve the governing equations. The implementation of the dynamic crystal plasticity model within the DG framework is tested using a 2D approximation of the Taylor impact test with a single crystal material, using quadratic elements that have faces that can bend. In addition to the standard continuous material modeling, we propose a new simulation method that would represent the heterogeneous behavior of polycrystalline microstructures within an element by varying the position and material properties of the material points within the element. This method is demonstrated using random orientation distributions on materials points that are arranged in both structured and random configurations.

42 ENGINEERING↗

DOE OSTI2020

Intrinsic size dependent plasticity in BCC micro-pillars under uniaxial tension and pure torsion

The mechanical behavior of submicron body-centered cubic (BCC) micro-pillars is investigated by three-dimensional dislocation dynamics (DD) simulations to better understand the governing mechanisms for size dependent plasticity under uniaxial tension and pure torsion. A formula is developed to compute the incremental plastic twist due to dislocation motion in DD simulations. The DD simulations show that different dislocation microstructures are created depending on the loading conditions, which leads to different size dependent mechanical behavior. While in tension plasticity is mainly governed by the kinetics of dislocation motion controlled partly by the surface dislocation sources, plastic flow in torsion is controlled by dislocation pile-ups associated with strain gradients. The simulation results also reveal a Bauschinger effect and plastic recovery under cyclic twist, which have been observed in recent experiments.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Synergistic torrefaction of plastic polymers and biomass

This study explores the synergistic torrefaction of biomass and plastics, aimed at enhancing bioenergy production and promoting a circular economy. By leveraging the unique properties of both materials, we investigated the thermochemical transformations occurring during the torrefaction process, from material preparation to the final characteristics of the torrefied product. The biomass used included corn stover (CS) and loblolly pine (LP), while various plastics were categorized from #1 to #7. Torrefaction was conducted at temperatures of 200, 225, and 250 °C, with subsequent extrusion of the torrefied materials and raw materials to produce composite filaments. The results show a consistent decrease in mass yield with increased torrefaction temperature, with notable variations among different biomass-plastic combinations. Co-torrefaction of biomass with polyvinyl chloride and polypropylene resulted in accelerated reaction kinetics, with an observed mass loss rate increase of 15 % at 250 °C compared to the expected rates for individual components. This synergy was quantified, indicating a 20.3 % increase in mass loss for the loblolly pine-polypropylene combination and 23.9 % for corn stover-polypropylene. In contrast, other plastics, including polyethylene terephthalate, high-density polyethylene, low-density polyethylene, polystyrene, and polycarbonate, did not exhibit significant synergistic effects. Mechanical testing indicated that the torrefaction process alters the strength and brittleness of the resulting materials, with implications for their application in bioenergy production and bio-renewable materials. Overall, this research highlights the potential of synergistic torrefaction as a viable strategy for co-processing biomass and plastics, paving the way for innovative solutions in waste management and renewable energy resource development.

09 - BIOMASS FUELS↗