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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Chromium Tolerant, Highly Active and Stable Electrocatalytic Internal Surface Coating for Cathode of Commercial SOFCs (Final Report)

This project is aimed to develop a chromium (Cr) tolerant, highly active, and stable coating layer on the internal surfaces of the porous composite cathode from commercially available SOFCs. Such coating layer was developed using the additive manufacturing process of Atomic Layer Deposition (ALD) and has been applied on the cathode consisting of either an electronic conductor of LaxSr 1-x MnyO 3-δ (LSM) or mixed ionic and electronic conducting La x Sr 1-x Co y Fe 1-y O 3-δ (LSCF). PI's work has demonstrated that the internal surface of cathode from the commercial cells, can be further tailored using ALD coating to dramatically enhance the cell performance. For instance, ALD layer consisting heterostructured nano composite of nano-Pt and nano-(Mn 0.8 Co 0.2 ) 3 O 4 oxide on the internal surface of porous LSM/YSZ cathode from SOFCs, has resulted in the large reduction of the cell polarizations resistance by up to 53%, and enormous increase of power density over 370%. For the cells with LSCF/Sm 2 O 3 doped CeO 2 (SDC) cathode, the conformal layer of nano-composite consisting of superjacent CoOx and subjacent minimum amount of Pt nano-grains has resulted in the power density enhancement by 126% for the large scale industry tubular cells at 750°C, and both the performance enhancement and nanostructure of the ALD layer are stable over ~ 2000 h continuous operation performed at industry test station. In the meanwhile, those ALD coating layer developed by PI's work is also inherently Cr-tolerant, and could act as physical barrier for preventing Cr diffusion into the cathode backbone, so as to mitigate the Cr poisoning effect on the cathode. In this project, the impact of Cr on the performance of those ALD coated commercial cells has been evaluated. Based on evolution of the cell performance, the ALD coating layer chemistry and ALD coating layer thickness has been optimized to maximize the overall Cr tolerance, cell power density and cell longevity. Different ALD coating has been applied onto the internal surface of LSM/YSZ and LSCF/SDC backbone respectively. The architecture/scaffold structures on the internal surface of different cathode, designed by this project, was catalogued and analyzed using High Resolution Transmission Electron Microscopy (HRTEM), and cell power/durability performance are assured via comprehensive electrochemical performance testing in the industry operation relevant conditions. The impact of the electrochemical operation current density, the water humidity, the cell operation temperature, and cell operation duration on the Cr tolerance of ALD coated cells has been systematically investigated. There is completely different nanostructure degradation mechanisms between LSM and LSCF cells induced by Cr contamination. For the LSCF/SDC baseline cell, With the Cr source, there is no apparent Sr surface segregation phase even for the baseline cell operated for 3000 h at 750 °C. With the Cr source, there is significant amorphous (SrCr)Ox phase accumulated in the original pore region. For the commercial baseline cells, Cr contaminants on the LSM electrode severely impacted the entire cell's electrochemical performance and nanostructure degradation. Those degradations include (1). Peak power density loss of 64 % after 109 h of operation. The dramatic increase in Rp (2). They are cracking at LSM/SSZ interface, LSM grains. SSZ remains intact but with (CrMn)Ox. By contrast, ALD coating (MnCo)Ox/Pt dramatically improves the Cr resistance, as follows (1). ALD-coated cell with a power density is 280-380 % of the baseline cell, depending on the ALD layer thickness. (2). For a cell with a 20 nm thick ALD layer, there is a large performance enhancement (> 200 % power density) induced by ALD coating of Cr-tolerant Mn 0.8 Co 0.2 Ox. (3). For a cell with a 20 nm thick ALD layer, after 168 h at 750 °C power density of the ALD-coated cell is ~ 600% of that baseline cell upon operation with Cr contamination for 109 h. The ALD coating on the internal surface of cathode developed by this project integrated multi-functions. Those multi-functions include (1). Dramatically improving the cell power density for the commercial cells; (2). Dramatically improving contamination resistance of the cathode, for being an excellent protection coating layer sealing off Cr contamination. (3). Dramatically increasing the cell longevity by potentially preventing the microstructure evolution and grain coarsening of the cathode. Overall, this project will provide a simple solution to simultaneously enhance power density and increase the reliability, robustness, and endurance of commercial SOFCs, over the entire operating temperature range of 650-800 °C. For the inherently functional SOFC, the ALD coating of LSM based cathode mitigate the Cr-contamination. Power density of ALD-coated cell is ~ 600% of that baseline cell upon operation with Cr contamination. In addition to SOFCs, the novel on-demand design approach and creation of multifunctional heterogeneous architecture on the electrode surface presented in this work opens further research for their application in other types of fuel cells, batteries, and sensors for which electrochemical reactions on the surface are similarly critical.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Development of ion specific media to treat Sr-contaminated water at Fukushima Daiichi Nuclear Power Plant - 15486

Since April of 2011, Kurion, Inc. contracted with the Tokyo Electric Power Company (TEPCO) to remediate cooling water using Ion Specific Media targeting cesium (Cs). The effluent of the Cs-sorption systems routed into a reverse osmosis (RO) system. While the RO permeate was recirculated into the cooling loop, the RO reject was captured in carbon-steel tanks. However, the cesium-extracted tank water at Fukushima Daiichi also has a high strontium (Sr) activity (∼4 x 10{sup 5} Bq/mL) and needs to be reduced to lower the onsite and boundary doses. To treat this highly contaminated water, Kurion developed the Kurion Mobile Processing System (KMPS). The KMPS uses a powder batch-contact addition step in concert with a series of ion exchange vessels to decontaminate the high Sr-activity water. Kurion tested and developed several ion specific media to treat the water. Several inorganic media were evaluated in the down-select for the system. Equilibrium batch tests, shortened contact time batch tests and column tests were performed to assess the media depending on water conditions. Two media were selected for KMPS: FAS-P (a powdered zeolite) to reduce Ca{sup 2+} and Sr{sup 2+} concentrations and TS-G (a synthetic titanosilicate) to polish the Sr{sup 2+} downstream. The results of these laboratory tests and their performance in the field will be discussed. The operation of the system has led to the continued reduction of dose at the Fukushima Daiichi nuclear power plant. This system and these media can be applied to other difficult wastewater solutions involving high levels of contaminants and salinity. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2012

Full-length U-xPu-10Zr (x=0, 8, 19 wt%) Fast Reactor Fuel Test in FFTF

The Integral Fast Reactor-1 (IFR-1) experiment performed in the Fast Flux Test Facility (FFTF) was the only U-Pu-10Zr (Pu-0, 8 and 19 wt%) metallic fast reactor test with commercial-length (91.4 cm active fuel column length) conducted to date. With few remaining test reactors there is little opportunity for performing another test with a long active fuel column. The assembly was irradiated to the goal burnup of 10 at.%. The beginning of life (BOL) peak cladding temperature of the hottest pin was 608?C, cooling to 522?C at end of life (EOL). Selected fuel pins were examined non destructively using neutron radiography, precision axial gamma scanning, and both laser and spiral contact cladding profilometry. Destructive exams included plenum gas pressure, volume, and gas composition determinations on a number of pins followed by optical metallography, electron probe microanalysis (EPMA), and alpha and beta gamma autoradiography on a single U-19Pu-10Zr pin. The post-irradiation examinations (PIEs) showed very few differences compared to the short-pin (34.3 cm fuel column) testing performed on fuels of similar composition in Experimental Breeder Reactor-II (EBR-II). The fuel column grew axially slightly less than observed in the short pins, but with the same pattern of decreasing growth with increasing Pu content. There was a difference in the fuel-cladding chemical interaction (FCCI) in that the maximum cladding penetration by interdiffusion with fuel/fission products did not occur at the top of the fuel column where the cladding temperature is highest, as observed in EBR-II tests. Instead, the more exaggerated fission-rate profile of the FFTF pins resulted in a peak FCCI at ~0.7 X/L axial location along the fuel column. This resulted from a lower production of rare earth fission products higher in the fuel column as well as a much smaller delta-T between fuel center and cladding, and therefore less FCCI, despite the higher cladding temperature. This behavior could actually help extend the life of a fuel pin in a “long pin” reactor design to a higher peak fuel burnup.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Dynamic Decarbonization through Autonomous Physics-Centric Deep Learning and Optimization of Building Operations (Abstract only)

This project directly addresses the primary goal of Area of Interest 2 in the CRADA call: to advance optimization-based integrated energy management systems in commercial and residential buildings. Pacific Northwest National Laboratory (PNNL) and its industry partner PassiveLogic aim to accomplish this by reaching three key objectives. First, to ensure a broad impact in the building controls industry, PNNL will extend its open-source library for predictive control synthesis by augmenting its capabilities with data-driven self-learning of building models and auto-calibration of predictive controllers. The effort will focus on building use cases selected in collaboration with PassiveLogic. The team will specifically address the development of methods for data-driven adaptation of building models, investigation of model architectures that best address specific building types, and automated synthesis of differentiable predictive controllers that optimize diverse objectives. Second, PNNL will collaborate with PassiveLogic to integrate the aforementioned methods with PasiveLogic’s advanced controls platform. The collaborative integration effort will inform the developments under the first objective by providing specific data on the attainable performance of model learning on resource-constrained edge computing platforms. This software integration effort will increase the technical maturity of the developed libraries by exploring the use of software integration tools and methods. Third, PNNL and PassiveLogic will work to improve the technology readiness of the developed predictive controllers by testing their performance in relevant test environments, such as high-fidelity simulation, hardware in the loop, and actual test buildings.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2015

Progress towards developing neutron tolerant magnetostrictive and piezoelectric transducers

Current generation light water reactors (LWRs), sodium cooled fast reactors (SFRs), small modular reactors (SMRs), and next generation nuclear plants (NGNPs) produce harsh environments in and near the reactor core that can severely tax material performance and limit component operational life. To address this issue, several Department of Energy Office of Nuclear Energy (DOE-NE) research programs are evaluating the long duration irradiation performance of fuel and structural materials used in existing and new reactors. In order to maximize the amount of information obtained from Material Testing Reactor (MTR) irradiations, DOE is also funding development of enhanced instrumentation that will be able to obtain in-situ, real-time data on key material characteristics and properties, with unprecedented accuracy and resolution. Such data are required to validate new multi-scale, multi-physics modeling tools under development as part of a science-based, engineering driven approach to reactor development. It is not feasible to obtain high resolution/microscale data with the current state of instrumentation technology. However, ultrasound-based sensors offer the ability to obtain such data if it is demonstrated that these sensors and their associated transducers are resistant to high neutron flux, high gamma radiation, and high temperature. To address this need, the Advanced Test Reactor National Scientific User Facility (ATR-NSUF) is funding an irradiation, led by PSU, at the Massachusetts Institute of Technology Research Reactor to test the survivability of ultrasound transducers. As part of this effort, PSU and collaborators have designed, fabricated, and provided piezoelectric and magnetostrictive transducers that are optimized to perform in harsh, high flux, environments. Four piezoelectric transducers were fabricated with either aluminum nitride, zinc oxide, or bismuth titanate as the active element that were coupled to either Kovar or aluminum waveguides and two magnetostrictive transducers were fabricated with Remendur or Galfenol as the active elements. Pulse-echo ultrasonic measurements of these transducers are made in-situ. This paper will present an overview of the test design including selection criteria for candidate materials and optimization of test assembly parameters, data obtained from both out-of-pile and in-pile testing at elevated temperatures, and an assessment based on initial data of the expected performance of ultrasonic devices in irradiation conditions.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2014

Towards eliminating systematic errors caused by the experimental conditions in Biochemical Methane Potential (BMP) tests

Highlights: • The evaluated factors introduce significant systematic errors (10–38%) in BMP tests. • Ambient temperature (T) has the most substantial impact (∼10%) at low altitude. • Ambient pressure (p) has the most substantial impact (∼68%) at high altitude. • Continuous monitoring of T and p is not necessary for kinetic calculations. - Abstract: The Biochemical Methane Potential (BMP) test is increasingly recognised as a tool for selecting and pricing biomass material for production of biogas. However, the results for the same substrate often differ between laboratories and much work to standardise such tests is still needed. In the current study, the effects from four environmental factors (i.e. ambient temperature and pressure, water vapour content and initial gas composition of the reactor headspace) on the degradation kinetics and the determined methane potential were evaluated with a 2{sup 4} full factorial design. Four substrates, with different biodegradation profiles, were investigated and the ambient temperature was found to be the most significant contributor to errors in the methane potential. Concerning the kinetics of the process, the environmental factors’ impact on the calculated rate constants was negligible. The impact of the environmental factors on the kinetic parameters and methane potential from performing a BMP test at different geographical locations around the world was simulated by adjusting the data according to the ambient temperature and pressure of some chosen model sites. The largest effect on the methane potential was registered from tests performed at high altitudes due to a low ambient pressure. The results from this study illustrate the importance of considering the environmental factors’ influence on volumetric gas measurement in BMP tests. This is essential to achieve trustworthy and standardised results that can be used by researchers and end users from all over the world.

09 BIOMASS FUELS↗
DOE OSTI2017

Exactly energy conserving semi-implicit particle in cell formulation

We report a new particle in cell (PIC) method based on the semi-implicit approach. The novelty of the new method is that unlike any of its semi-implicit predecessors at the same time it retains the explicit computational cycle and conserves energy exactly. Recent research has presented fully implicit methods where energy conservation is obtained as part of a non-linear iteration procedure. The new method (referred to as Energy Conserving Semi-Implicit Method, ECSIM), instead, does not require any non-linear iteration and its computational cycle is similar to that of explicit PIC. The properties of the new method are: i) it conserves energy exactly to round-off for any time step or grid spacing; ii) it is unconditionally stable in time, freeing the user from the need to resolve the electron plasma frequency and allowing the user to select any desired time step; iii) it eliminates the constraint of the finite grid instability, allowing the user to select any desired resolution without being forced to resolve the Debye length; iv) the particle mover has a computational complexity identical to that of the explicit PIC, only the field solver has an increased computational cost. The new ECSIM is tested in a number of benchmarks where accuracy and computational performance are tested. - Highlights: • We present a new fully energy conserving semi-implicit particle in cell (PIC) method based on the implicit moment method (IMM). The new method is called Energy Conserving Implicit Moment Method (ECIMM). • The novelty of the new method is that unlike any of its predecessors at the same time it retains the explicit computational cycle and conserves energy exactly. • The new method is unconditionally stable in time, freeing the user from the need to resolve the electron plasma frequency. • The new method eliminates the constraint of the finite grid instability, allowing the user to select any desired resolution without being forced to resolve the Debye length. • These features are achieved at a reduced cost compared with either previous IMM or fully implicit implementation of PIC.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2019

Analytical Model of High-Velocity Impact of a Deformable Projectile Against Textile-Based Composites

Textile-based composites are used in manufacturing of ballistic shields due to their favorable combination of mechanical properties which enables weight saving and efficiency while retaining or even improving ballistic performance. Predictive models are an important tool in reducing experimental tests which are still an important step in ballistic shield design. Among those, analytical models provide less accurate results but require far less computational cost than numerical models and can be used for preliminary analyses. Many authors in the literature have developed analytical models for high-velocity impact on textile-based composites based on wave propagation theory and an energy equilibrium approach. The main limitation of these models is the assumption of rigid projectile which leads to the underestimation of the ballistic limit for soft core projectiles, which are a very common type of threat for this kind of protection. For this reason, an enhanced version of these models is reported in this paper, which releases the assumption of rigid projectile and adds erosion and deformation of the projectile to the formulation. Ballistic tests were performed on panels manufactured from layers of Kevlar 29 plain weave fabric embedded in an epoxy matrix. An insight into the different kinds of energy absorption considered by the model shows that projectile deformation plays an important role in the dissipation of the kinetic energy of the projectile in case of intermediate impact velocity. For this reason, the present model delivers more accurate results than the models present in the literature. In particular, the estimation of the ballistic limit is drastically improved which is a key step in ballistic shields optimization.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Systematics in the XENON1T data: The 15-keV anti-axion

The XENON1T collaboration Aprile et al. [2020] has found an excess of electron recoil events in their Science Run 1 data below ~7 keV with a spectral shape consistent with that expected from a solar-axion-induced signal. The claimed statistical significance of the solar-axion model over the null hypothesis is 3.5σ. In this work we provide suggestive evidence for mismodeling in the electron recoil data that may decrease the local significance of the axion model. To reach this conclusion, we search for a signal with the spectral template of the solar axion model, but shifted to higher (unphysical) energies above ~7 keV. We find that the distribution of significances found from this side-band analysis does not follow the expected chi-square distribution. For example, we find a high-significance feature in the data, with a global $p$-value $p≈0.026$, when the solar axion model is shifted upwards in energy by ~15 keV and allowed to have a negative normalization. We argue that such statistical tests, if performed a priori, provide a data-driven way to test and potentially account for systematic uncertainties on the background model in low-threshold dark matter experiments.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2014

The design and construction of a high-resolution velocity-map imaging apparatus for photoelectron spectroscopy studies of size-selected clusters

A new velocity-map imaging apparatus equipped with a laser-vaporization supersonic cluster source and a time-of-flight mass spectrometer is described for high-resolution photoelectron spectroscopy studies of size-selected cluster anions. Vibrationally cold anion clusters are produced using a laser-vaporization supersonic cluster source, size-selected by a time-of-flight mass spectrometer, and then focused co-linearly into the interaction zone of the high-resolution velocity-map imaging (VMI) system. The multilens VMI system is optimized via systematic simulations and can reach a resolution of 1.2 cm{sup −1} (FWHM) for near threshold electrons while maintaining photoelectron kinetic energy resolutions (ΔKE/KE) of ∼0.53% for higher energy electrons. The new VMI lens has superior focusing power over a large energy range, yielding highly circular images with distortions no larger than 1.0025 between the long and short radii. The detailed design, simulation, construction, testing, and performance of the high-resolution VMI apparatus are presented.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2016

Determination of ultra-short laser induced damage threshold of KH{sub 2}PO{sub 4} crystal: Numerical calculation and experimental verification

Rapid growth and ultra-precision machining of large-size KDP (KH{sub 2}PO{sub 4}) crystals with high laser damage resistance are tough challenges in the development of large laser systems. It is of high interest and practical significance to have theoretical models for scientists and manufacturers to determine the laser-induced damage threshold (LIDT) of actually prepared KDP optics. Here, we numerically and experimentally investigate the laser-induced damage on KDP crystals in ultra-short pulse laser regime. On basis of the rate equation for free electron generation, a model dedicated to predicting the LIDT is developed by considering the synergistic effect of photoionization, impact ionization and decay of electrons. Laser damage tests are performed to measure the single-pulse LIDT with several testing protocols. The testing results combined with previously reported experimental data agree well with those calculated by the model. By taking the light intensification into consideration, the model is successfully applied to quantitatively evaluate the effect of surface flaws inevitably introduced in the preparation processes on the laser damage resistance of KDP crystals. This work can not only contribute to further understanding of the laser damage mechanisms of optical materials, but also provide available models for evaluating the laser damage resistance of exquisitely prepared optical components used in high power laser systems.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2016

Thin epitaxial silicon PIN detectors for thermal neutron detection with improved gamma (γ) discrimination

In order to improve the gamma discrimination capability for thermal neutron measurements using silicon PIN detectors, a novel approach of use of thin epitaxial silicon PIN detectors was investigated. Thin epitaxial silicon detectors with thickness of 15 µm were developed and their performance was tested with thermal neutrons using {sup 10}B converter. The performance of this detector was compared with the performance of a 300 µm silicon detector. The results of experiments presented in this paper indicate that thin epitaxial silicon detectors can significantly improve γ discrimination for thermal neutron measurements.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2017

High voltage performance of a dc photoemission electron gun with centrifugal barrel-polished electrodes

The design and fabrication of electrodes for direct current (dc) high voltage photoemission electron guns can significantly influence their performance, most notably in terms of maximum achievable bias voltage. Proper electrostatic design of the triple-point junction shield electrode minimizes the risk of electrical breakdown (arcing) along the insulator-cable plug interface, while the electrode shape is designed to maintain <10 MV/m at the desired operating voltage aiming at little or no field emission once conditioned. Typical electrode surface preparation involves diamond-paste polishing by skilled personnel, requiring several weeks of effort per electrode. In this work, we describe a centrifugal barrel-polishing technique commonly used for polishing the interior surface of superconducting radio frequency cavities but implemented here for the first time to polish electrodes for dc high voltage photoguns. The technique reduced polishing time from weeks to hours while providing surface roughness comparable to that obtained with diamond-paste polishing and with unprecedented consistency between different electrode samples. We present electrode design considerations and high voltage conditioning results to 360 kV (~11 MV/m), comparing barrel-polished electrode performance to that of diamond-paste polished electrodes. Here, tests were performed using a dc high voltage photogun with an inverted-geometry ceramic insulator design.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2016

Dispersed SiC nanoparticles in Ni observed by ultra-small-angle X-ray scattering

In this paper, a metal-ceramic composite, nickel reinforced with SiC nanoparticles, was synthesized and characterized for its potential application in next-generation molten salt nuclear reactors. Synchrotron ultra-small-angle X-ray scattering (USAXS) measurements were conducted on the composite. The size distribution and number density of the SiC nanoparticles in the material were obtained through data modelling. Scanning and transmission electron microscopy characterization were performed to substantiate the results of the USAXS measurements. Tensile tests were performed on the samples to measure the change in their yield strength after doping with the nanoparticles. Finally, the average interparticle distance was calculated from the USAXS results and is related to the increased yield strength of the composite.

36 MATERIALS SCIENCE↗
DOE OSTI2016

SU-F-J-37: Commissioning a Six Degree of Freedom Couch

Purpose: The proper operation of a six degree of freedom couch (6DOFC) to position a patient for treatment requires that a number systems on the treatment unit work together correctly. Commissioning a 6DOFC requires not only the commissioning of each separate system but also commissioning the interactions between the systems. Methods: To commission a 6DOFC, we tested the resolvers that readout the linear and angular positions; the orthogonality of the axes of the laser positioning system, the imaging system, the gantry and the couch as well as their relationship to each other. An automated Winston-Lutz test was used verify the coincidence of the origins of the laser system, imaging system and treatment unit. The IsoCal phantom was used to verify the consistency of axes orientations between systems. The operation of the couch and imaging system was verified under simulated load conditions and an end to end test was performed to verify correct operation of the system. Results: The tests on the couch resolvers, orthogonality and coincidence of the axes of each system were successfully completed and showed excellent agreement. The automated Winston-Lutz test showed that the maximum displacement of the center of the radiation field with respect to the isocenter was <0.6 mm (radius) at isocenter. The analysis of the IsoCal phantom showed that the maximum variation of the radiation field with respect to known locations in the phantom was ∼0.9 mm for all the BBs in the phantom. Load tests showed maximum errors of 1 mm. Conclusion: We tested all system associated with the 6DOFC and found the uncertainty due to imaging was <.9mm and the uncertainty due to loading ∼1 mm, resulting in a total error of ∼1.4 mm.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2017

Development of ITM Oxygen Technology for Low-cost and Low-emission Gasification and Other Industrial Applications

Air Products carried out a scope of work under DOE Award No. DE-FE0012065 “Development of ITM Oxygen Technology for Low-cost and Low-emission Gasification and Other Industrial Applications” with subcontractors Ceramatec, Penn State, and WorleyParsons. The scope of work under this award was aimed at furthering the development of the Ion Transport Membrane (ITM) Oxygen production process toward a demonstration-scale facility known as the Oxygen Development Facility (ODF). Specific activities will help to enable design and construction of the ODF through advancement of a number of challenging technical elements that are required to manage risk in the initial deployment of ITM technology. Major objectives of the work included developing ITM Oxygen ceramic membrane materials with improved performance and reliability, optimizing ceramic module geometry and fabrication methods, testing module performance, trialing the improved fabrication process at commercial scale in the Ceramic Membrane Module Fabrication Facility (CerFab), and advancing engineering development of the ITM oxygen production process, including vessel design and contaminant control measures to prepare for deployment of the ODF. The comprehensive report that follows details the team’s work, which includes several notable accomplishments: 1) compressive creep, a likely limiter of ceramic module lifetime in service, was demonstrated to be retarded by an order of magnitude by changes in material formulation, module joining dimensions, and internal wafer geometry; 2) two promising new materials were shown to be superior to the incumbent ITM material in a key material parameter related to oxygen flux; 3) module degradation mechanisms were identified following operation in large pilot-scale equipment; 4) options for utilizing ITM in a coal-to-liquids (CTL) facility to enable liquids production with carbon capture were identified and studied; and 5) the benefits of potential improvements to the technology were assessed for their cost impact on ITM Oxygen applications to clean power, fuels, and other applications.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2015

Development of ITM Oxygen Technology for Low-cost and Low-emission Gasification and Other Industrial Applications

Air Products carried out a scope of work under DOE Award No. DE-FE0012065 “Development of ITM Oxygen Technology for Low-cost and Low-emission Gasification and Other Industrial Applications” with subcontractors Ceramatec, Penn State, and WorleyParsons. The scope of work under this award was aimed at furthering the development of the Ion Transport Membrane (ITM) Oxygen production process toward a demonstration-scale facility known as the Oxygen Development Facility (ODF). Specific activities will help to enable design and construction of the ODF through advancement of a number of challenging technical elements that are required to manage risk in the initial deployment of ITM technology. Major objectives of the work included developing ITM Oxygen ceramic membrane materials with improved performance and reliability, optimizing ceramic module geometry and fabrication methods, testing module performance, trialing the improved fabrication process at commercial scale in the Ceramic Membrane Module Fabrication Facility (CerFab), and advancing engineering development of the ITM oxygen production process, including vessel design and contaminant control measures to prepare for deployment of the ODF. The comprehensive report that follows details the team’s work, which includes several notable accomplishments: 1) compressive creep, a likely limiter of ceramic module lifetime in service, was demonstrated to be retarded by an order of magnitude by changes in material formulation, module joining dimensions, and internal wafer geometry; 2) two promising new materials were shown to be superior to the incumbent ITM material in a key material parameter related to oxygen flux; 3) module degradation mechanisms were identified following operation in large pilot-scale equipment; 4) options for utilizing ITM in a coal-to-liquids (CTL) facility to enable liquids production with carbon capture were identified and studied; and 5) the benefits of potential improvements to the technology were assessed for their cost impact on ITM Oxygen applications to clean power, fuels, and other applications.

42 ENGINEERING↗