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Production of regeneratively cooled rocket thrust chambers by removable tooling and subsequent hot isostatic pressing in gas autoclave
This project demonstrated the technical viability and economic promise of a modular system for converting flared natural gas into valuable carbon nanoproducts (CNPs) through catalytic chemical vapor deposition (CVD). All major project milestones were successfully completed, including reactor design and commissioning, catalyst development, process optimization, technoeconomic analysis, and application testing in concrete systems. The overarching goal was to create a scalable, field-deployable process that valorizes stranded methane by producing high-value carbon materials for use in cementitious composites. At the lab scale, the team designed and built a fluidized bed reactor optimized for use with silica fume-supported nickel catalysts synthesized via atomic layer deposition (ALD). A statistically designed sintering study enabled precise tuning of nickel nanoparticle size, identifying the influence of oxygen partial pressure, time, and temperature on catalyst morphology and performance. These insights allowed the team to target catalyst conditions that maximize carbon nanofilament growth. Subsequent CVD experiments achieved up to 31.8 wt% carbon deposition under optimized conditions, with TEM confirming the presence of nanofilament structures and sustained hydrogen evolution during reaction. Reactor upgrades and empirical fluidization studies supported the development of reliable, repeatable experimental protocols. The modular pilot-scale skid reactor was fully constructed, instrumented, and commissioned. Capable of operating at 675–800°C and pressures up to 290 psig, the system was designed for continuous operation at a carbon production rate of 1 kg/hr. Initial demonstration runs confirmed solids handling, thermal control, and system leak-tightness, although a critical reactor component (the downfeed tube) was inadvertently omitted during final assembly. This omission limited gas–solid contact and prevented meaningful carbon deposition during pilot-scale CVD runs. Nonetheless, the system operated safely under design conditions, and the root cause of performance limitations was clearly identified. Complementary work on UHPC formulations demonstrated that small additions of carbon nanoproducts, including those derived from flare gas, can significantly enhance mechanical performance while preserving workability. A comprehensive study of CNF dispersion techniques and mix design optimization led to a clear protocol for integrating these nanomaterials into concrete. Incorporation of CNPs improved flexural toughness and reduced porosity, supporting their use in high-performance infrastructure applications. A technoeconomic analysis (TEA) confirmed that this process can produce CNP-loaded catalyst material at a levelized cost below $\$$7/kg across a range of catalyst loadings and reaction yields. With estimated market values for the carbon composite product ranging from $\$$14 to over $\$$60/kg, and the ability to blend CNPs into concrete at sub-percent levels with less than 10% added cost, the system presents a compelling economic case. While additional engineering work is needed to optimize fluidization and heat transfer at scale, this project establishes a strong foundation for commercial development. The process is not only technically sound but also economically promising, representing a viable pathway for flare gas mitigation through modular carbon nanomaterial production.
In this paper, we review relevant technologies—primarily thermochemical and plasma conversion processes—that use natural gas to produce solid carbon and hydrogen, and recent research progress and commercial activities. Technical challenges include the high energetic 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 where it was concluded that the cost of pyrolytically produced CO2-free hydrogen can be potentially reduced to <$4/kg target levels with the co-production and sale of sufficiently high-value carbon products.
The effluent gas for the Paragon Ionomer Water Processor (IWP), UMPQUA Ultrasonic Brine Dewatering System (UBDS), and the NASA Brine Evaporation Bag (BEB) were analyzed using Headspace GCMS Analysis in the recent AES FY14 Brine Processing Test. The results from the analysis describe the number and general chemical species of the chemicals produced. Comparisons were also made between the different chromatograms for each system, and an explanation of the differences in the results is reported.
Significant simplifications to power processors for inert gas ion thrusters in the 1 to 5 kW range have been identified. They include elimination of all but three power supplies - one each for the neutralizer, main discharge, and beam. The neutralizer and discharge power supplies would provide both cathode heating and plasma generating functions. This dual-use power supply concept was validated via integration tests with a 30 cm diameter xenon ion thruster. The beam/accelerator power supply would have positive and negative outputs to allow a single power supply to provide both functions. The discharge and beam power supplies would incorporate full-bridge inverters similar to those proven for flight-ready arcjet propulsion systems. Operation of this simplified power processing scheme at an inverter frequency of 50 kHz results in a projected power processor design with low mass and high efficiency. A 2 kW reference point design has estimated values of specific mass of 5.4 kg/kW and an efficiency of 93 percent.
Portable spectrometer using photosensitive readouts, monitors the amount of oxygen and hydrogen in the inert gas shield of a tungsten-inert gas welding process. A fiber optic bundle transmits the light from the welding arc to the spectrometer.
Carnot Compression is a startup company developing an innovative technology for air and gas compression. This technology is inherently oil-free and isothermal due to the use of water to simultaneously compress and cool the gas throughout the process. Isothermal gas compression eliminates the need to cool the compressed gas so it may lead to significant energy savings. The development of Carnot’s isothermal compressor is limited by the lack of insight into the flow and detailed behavior of the fluids (water and air/gas) inside the air end. Previous and current attempts at Computational Fluid Dynamics (CFD) simulations by Carnot have been unable to provide the level of accuracy required to use simulations for technology development. In this Cooperative Research and Development Agreement (CRADA) project, Oak Ridge National Laboratory (ORNL) used the CFD package Star-CCM+ to successfully develop a CFD simulation, providing the much-needed insight required to speed up the development. The work is intended to enable Carnot Compression to unlock its technology potential to a level sufficient for commercialization of the intended first product. The work will also prepare Carnot to scale the technology to much larger and more energy intensive applications, positioning it to broaden the product applications. Successful development of the technology has the potential to result in 20% or more efficiency gains for compression processes, or about $3 billion in annual energy savings potential for the U.S. alone.
Abstract not provided.
Abstract not provided.
This work provides a guide for candidate mercury (Hg) and iodine-129 (129I) abatement material identification, screening, evaluation, technical gap identification, and bench-scale testing prioritization while also conceptualizing a materials deployment roadmap for implementation of new materials in the Hanford Waste Treatment and Immobilization Plant (WTP) Low-Activity Waste (LAW) Facility at Hanford in Richland, Washington, and elsewhere in the U.S. Department of Energy (DOE) complex for similar applications. The study was prompted by the need to replace the Kombisorb BAT-37 due to uncertainties in Hg and 129I capture performance and future availability for use in the WTP LAW Facility secondary off-gas system, specifically the Carbon Adsorber units. However, replacement of this material could also mitigate two other issues with Kombisorb BAT-37 (and its successor BAT II 37): (1) fire safety risk due to exothermic heat generated by adsorption reactions between the carbon material and Hg and (2) the risk of low retention of 129I in glass and subsequent downstream impacts on secondary liquid waste treatment at the Effluent Treatment Facility.
Kinetic theory of bimolecular chemical reaction and diffusive drag in gas mixtures
The 100 meter drop tube at NASA's Marshall Space Flight Center has been used for a series of experiments with niobium-germanium alloys. These experiments were conducted with electromagnetic levitation melting in a 200 torr helium environment. Liquid alloys experienced large degrees of undercooling prior to solidification in the drop tube. Several interesting metastable structures were observed. However, the recalescence event prevented extended solid solubility of germanium in the A-15 beta phase. Liquids of eutectic composition were found to undercool in the presence of solid alpha and solid Nb5Ge3.
An existing Computational Fluid Dynamics code for simulating complex turbulent flows inside a liquid rocket combustion chamber was validated and further developed. The Advanced Rocket Injector/Combustor Code (ARICC) is simplified and validated against benchmark flow situations for laminar and turbulent flows. The numerical method used in ARICC Code is re-examined for incompressible flow calculations. For turbulent flows, both the subgrid and the two equation k-epsilon turbulence models are studied. Cases tested include idealized Burger's equation in complex geometries and boundaries, a laminar pipe flow, a high Reynolds number turbulent flow, and a confined coaxial jet with recirculations. The accuracy of the algorithm is examined by comparing the numerical results with the analytical solutions as well as experimented data with different grid sizes.
We present observations of the neutral hydrogen, ionized hydrogen, and starlight of galaxies chosen from the 'Toomre Sequence' of merging galaxies. This sequence is meant to represent the progressive stages of the merger of two disk galaxies into a single elliptical-like remnant. The galaxies in this study span the full range of this sequence. The stars and atomic gas are very differently distributed, with the stars more widely distributed at early stages, and the gas much more widely distributed at later stages. Large quantities of neutral gas are sent to large radii (greater than or approximately equal to 100 h(exp -1) kpc), and still persist even after the central remnant has relaxed to an r(sup 1/4) light profile. There are a few times 10(exp 9) solar masses h(exp -2) of both molecular and atomic gas in each of these systems. Throughout the different stages, about half of the total gas mass lies within the galaxies' optical bodies. The fraction of this mass that is in neutral hydrogen drops rapidly in the later stage mergers, suggesting that atomic gas is processed into molecular gas, stars, and hot gas during the merger and resulting starburst. Star formation occurs at all stages of the interaction, both within the tails and in the central bodies. In the early stages, the H(alpha) shows many arcs and plumes. In the late stages, there are large H 2 regions in the tails which are associated with large quantities of neutral hydrogen. There is always a very good correlation between optical, H(alpha), and H1 peaks, with N(sub H1) greater than or approximately equal 3 x 10(exp 20) cm(exp -2) at the location of the H2 regions in the tails.
The objective of this project is to conduct measurements of elementary reaction rate constants and photochemistry parameters for processes of importance in the atmosphere. These measurements are being carried out under temperature and pressure conditions covering those applicable to the stratosphere and upper troposphere, using the chemical ionization mass spectrometry turbulent flow technique developed in our laboratory.
The objective of this project is to conduct measurements of elementary reaction rate constants and photochemical parameters for processes of importance in the atmosphere. These measurements are being carried out under temperature and pressure conditions covering those applicable to the stratosphere and upper troposphere, using the chemical ionization mass spectrometry turbulent flow technique developed in our laboratory. The next section summarizes our research activities during the first year of the project, and the section that follows consists of the statement of work for the third year. Additional details concerning the projects listed in the statement of work were described in our original proposal.
The atmospheric processing of (E)- and (Z)-1,2-dichlorohexafluorocyclobutane (1,2-c-C4F6Cl2, R-316c) was examined in this work as the ozone depleting (ODP) and global warming (GWP) potentials of this proposed replacement compound are presently unknown. The predominant atmospheric loss processes and infrared absorption spectra of the R-316c isomers were measured to provide a basis to evaluate their atmospheric lifetimes and, thus, ODPs and GWPs. UV absorption spectra were measured between 184.95 to 230 nm at temperatures between 214 and 296 K and a parametrization for use in atmospheric modeling is presented. The Cl atom quantum yield in the 193 nm photolysis of R- 316c was measured to be 1.90 +/- 0.27. Hexafluorocyclobutene (c-C4F6) was determined to be a photolysis co-product with molar yields of 0.7 and 1.0 (+/-10%) for (E)- and (Z)-R-316c, respectively. The 296 K total rate coefficient for the O(1D) + R-316c reaction, i.e., O(1D) loss, was measured to be (1.56 +/- 0.11) × 10(exp −10)cu cm/ molecule/s and the reactive rate coefficient, i.e., R-316c loss, was measured to be (1.36 +/- 0.20) × 10(exp −10)cu cm/molecule/s corresponding to a approx. 88% reactive yield. Rate coefficient upper-limits for the OH and O3 reaction with R-316c were determined to be <2.3 × 10(exp −17) and <2.0 × 10(exp −22)cu cm/molecule/s, respectively, at 296 K. The quoted uncertainty limits are 2(sigma) and include estimated systematic errors. Local and global annually averaged lifetimes for the (E)- and (Z)-R-316c isomers were calculated using a 2-D atmospheric model to be 74.6 +/- 3 and 114.1 +/-10 years, respectively, where the estimated uncertainties are due solely to the uncertainty in the UV absorption spectra. Stratospheric photolysis is the predominant atmospheric loss process for both isomers with the O(1D) reaction making a minor, approx. 2% for the (E) isomer and 7% for the (Z) isomer, contribution to the total atmospheric loss. Ozone depletion potentials for (E)- and (Z)-R-316c were calculated using the 2-D model to be 0.46 and 0.54, respectively. Infrared absorption spectra for (E)- and (Z)-R-316c were measured at 296 K and used to estimate their radiative efficiencies (REs) and GWPs; 100-year time-horizon GWPs of 4160 and 5400 were obtained for (E)- and (Z)-R-316c, respectively. Both isomers of R-316c are shown in this work to be long-lived ozone depleting substances and potent greenhouse gases.