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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Blended conventional and high oxygen permeability ionomers as a fuel cell electrode binder

Ionomer strongly influences the performance of proton exchange membrane fuel cells (PEMFCs), affecting catalyst activity and reactant transport within the electrodes. While recent work on high oxygen permeability ionomers (HOPI) has demonstrated improved performance compared to conventional perfluorosulfonic acid (PFSA) ionomers such as Nafion™, there have also been reports of increased cracking in fabricated electrodes. We investigated the effects of blending HOPI with Nafion™ ionomer dispersions when fabricating cathode catalyst layers (CCLs). Small-angle x-ray scattering suggests that the ionomers mix well, and adsorption measurements indicate that HOPI adsorbs less strongly to the carbon-supported platinum (Pt) catalyst, and in blends, the Nafion™ ionomer exhibits a greater degree of adsorption. Imaging CCLs revealed a decrease in crack formation in blended samples as HOPI content decreased, with 14% HOPI having the lowest crack density. In a membrane electrode assembly (MEA) using a high surface area carbon support, the 14% HOPI blend exhibited similar performance to 100% HOPI. However, similar performance enhancements were not achieved with a medium surface area carbon support. These findings suggest a path for low-crack CCLs with enhanced oxygen transport, while highlighting a need for further investigation of ionomer blending towards efficient and durable PEMFCs.

25 ENERGY STORAGE↗
DOE OSTI2025

Bridging interfacial properties and cell performance: A multiscale model for proton-exchange-membrane fuel cells

Here, to elucidate the impact of local interfaces on mass-transport resistance and overall cell performance of low-loaded proton-exchange-membrane fuel cells (PEMFCs), we present a multiscale modeling framework incorporating a novel modified agglomerate model. The model considers three distinct Pt-electrolyte interfaces: Pt on the carbon surface covered by either ionomer or water film and Pt inside carbon nanopores. Detailed mass-transport voltage-loss breakdowns reveal that coupled agglomerate-interface-scale mass transport dominates the mass-transport loss. The ionomer poisons the exterior-Pt surface through suppressing O 2 adsorption and intrinsic ORR activity, leading to low current-density performance. Conversely, interior-Pt interface enhances the kinetic performance but limits high current-density performance due to its low interfacial permeability. The exterior-Pt/water interface demonstrates superior kinetic performance and mass transport, though its practical implementation requires ensuring proton transport. By coupling the multiscale CL properties with ink parameters, the model identifies an optimal I to C ratio of approximately 0.5, a moderate value where the ionomer content is sufficient to guarantee proton transport without fully covering the Pt surface and forming large agglomeration, thus allowing the utilization of the Pt-water interface and avoiding high mass-transport loss. Overall, the model helps unravel limiting phenomena across different operating regimes and provides routes for optimizing performance.

Cell diagnostic↗
DOE OSTI2025

High Flux Isotope Reactor Low-Enriched Uranium High Density Silicide Fuel Preliminary Design Update: System Transient Analysis

As a part of conversion efforts from highly enriched uranium (HEU) to low-enriched uranium (LEU) fuel under direction of the National Nuclear Security Administration of the U.S. Department of Energy, multiple proposed designs of the High Flux Isotope Reactor (HFIR) have been created and assessed regarding reactor physics performance metrics, including designs utilizing uranium silicide dispersion fuel (U3Si2-Al). This report updates the previous analyses that evaluated the nuclear safety performance of LEU fuel designs with respect to selected accident events from the HFIR Safety Analysis Report (SAR). Both the Low Density (LD) and High Density (HD) Optimized designs’ reactivity initiated accident fuel performance improved relative to the HEU fuel, attributed to greater 238 U negative Doppler feedback. However, the thermal margins for primary coolant system accidents were reduced with some acceptance criteria unable to be met. The need to resolve reduced thermal margin, open modeling items, and unresolved assumptions was identified.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Deep learning‑based metal artefact reduction in X-ray computed tomography of TRISO fuel compacts

TRISO (TRi-structural ISOtropic) – compact-type micro-particle fuels – are next generation nuclear fuel compacts designed with safety in mind. Structural integrity and characterisation before and after irradiation are important to determine the performance of the fuel compacts under real reactor conditions. X-ray computed tomography can be an important tool for non-destructive evaluation of these fuel compacts. The fuel particles are highly attenuating for X-rays which creates metal artefact, rendering the images unusable. Our artefact correction can mitigate these artefacts significantly. The proposed method works by first segmenting highly-attenuating structures (metal) and forward projecting to localise the source of artefacts in the projection domain, then, using a traditional or U-net-based deep learning architecture, contextually interpolating those regions to remove the artefacts. Finally the reconstruction from the modified projection is fused with the segmented metal. The proposed method shows a significant improvement in the image quality while significantly reducing the reconstruction time compared to the standard technique.

Rahman, Obaid [ORNL] (ORCID:0000000277810840)↗
DOE OSTI2026

Effects of Uranium Impurities in Downblended HEU on HTGR Performance

Many advanced reactor designs require fuel enriched between 5% and 20% 235 U. To assist in producing fuel at these enrichment levels, government-owned inventories of highly enriched uranium can be downblended. However, fuel produced from these inventories contain uranium impurities that are not often found when enriching natural uranium or accounted for when modeling reactor cores. To address this concern, this work models reactor designs like the X-energy Xe-100 and the Ultra Safe Nuclear Company’s Micro Modular Reactor, and compares their performance with fuel from enriching natural uranium to fuel from downblended highly enriched uranium. This paper evaluates the models based on the effective neutron multiplication factor, k eff , effective delayed neutron fraction, β eff , and energy- and spatially dependent neutron flux, ϕ, as well as the fuel, coolant, moderator, and total reactivity temperature feedback coefficients, α F , α C , α M , and α T . The results show that the fuel from downblended highly enriched uranium inventories leads to differences in each of the metrics, especially in the keff values. In the Xe-100–like and Micro Modular Reactor–like models, k eff changes by about 1400 pcm and up to 1200 pcm, respectively. Total reactivity feedback coefficients α T are negative with the impure fuels and the keff values remain above 1 for each core configuration and fuel composition. These results show that the impure fuel compositions do not necessarily prevent achieving key design parameters, such as cycle length, or from operating in a safe condition.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Tracing U.S. fuel life-cycle greenhouse gas emissions in a multi-sector dynamics model using LC-GCAM

Model-based analysis of fuel pathways is essential for informing energy and environmental policy. Two major model types are typically used: multi-sector dynamics models, which capture the broader energy-economy, such as GCAM (Global Change Analysis Model), and life cycle assessment models, such as GREET (Greenhouse Gases, Regulated Emissions, and Energy Use in Transportation). Each has distinct strengths and limitations, and recent studies increasingly adopt hybrid approaches to harness the advantages of both. However, such integration is often time-consuming and complicated by inconsistencies in system boundaries and technology definitions. We present LC-GCAM, a new tool that enables estimation of life-cycle greenhouse gas emissions and primary energy use for any fuel pathway represented in GCAM. We apply LC-GCAM to 300 scenarios designed to explore key uncertainties affecting the life-cycle performance of future fuel options in the U.S. freight sector. To evaluate LC-GCAM, we compare its results with those from GREET for nine fuel types in a 2030 reference scenario. When input assumptions are modestly aligned, LC-GCAM and GREET estimates typically agree within 10% (absolute sum-based mean absolute percentage error). LC-GCAM offers a flexible and efficient approach to generating life-cycle metrics within an integrated modeling framework, supporting robust policy analysis across a wide range of interacting energy system uncertainties.

Wolfram, Paul↗
DOE OSTI2026

Depletion benchmark for a high-assay low-enriched uranium fuel experiment in the advanced test reactor

Reactor physics depletion benchmarks for high-assay low-enriched uranium (HALEU) fuel are limited in number. In particular, there is limited data for HALEU benchmarks for U-10Mo (uranium-10% molybdenum) plate fuel that is being developed for use in the United States’ high performance research reactors including the Advanced Test Reactor (ATR), Advanced Test Reactor Critical Facility (ATR-C), High Flux Isotope Reactor (HFIR), Massachusetts Institute of Technology Reactor (MITR), University of Missouri Research Reactor (MURR), National Bureau of Standards Reactor (NBSR). These six reactors currently operate with highly enriched uranium dispersed fuel in an aluminum matrix. In support of conversion to a HALEU fuel, qualification of U-10Mo formed into a monolithic foil is being performed. Fuel qualification involves irradiating fuel specimens in the ATR. The irradiation tests provide an opportunity to benchmark depletion capabilities of reactor physics codes in support of the ATR operation, as well as develop benchmarks that can be used by other institutions to benchmark other reactor physics codes. This paper documents the development of a benchmark model of the irradiation of the ATR Full-size plate In center flux trap Position 7 (AFIP-7) experiment using the depletion codes MC21 and Advanced Dimensional Depletion for Engineering of Reactors (ADDER).

Nielsen, Joseph W. [Idaho National Laboratory (INL↗
DOE OSTI2025

Mechanical Property Assessment of Unirradiated Cladding After Exposure to Time at Temperature

Light water reactors in the United States are operated within inherent safety limits designed to account for anticipated operational occurrences (AOOs). Unlike more severe reactor transients, these events permit the potential reuse of reactor cladding, highlighting the nuanced role of thresholds in influencing reactor efficiency compared to design-basis or beyond-design-basis transient conditions. The threshold designated for AOO peak cladding and fuel temperatures are currently grounded around thermal hydraulic limits such as surpassing the critical heat flux (CHF), rather than in fuel-cladding material performance. This CHF criterion therefore represents a conservative approach to AOO transients during the reactor lifetime. Extending this threshold to higher temperatures than CHF can result in additional operation efficiency gains. Here, a material performance-based approach is assessed to better understand the physical material limits of short time scale exposures to elevated temperatures. This approach, termed time at temperature (t@T), references fuel cladding microstructural and mechanical response to rapid temperature transients in absence of radiation damage. The results of this work are expected to help identify margin for the United States reactor fleet, which could be utilized to increase operational efficiencies through decreased reactor outages.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

A critical review of the history of fabricating monolithic U-Mo fuel plates

The fabrication of monolithic uranium-molybdenum alloy fuels, specifically those developed for high-performance research and test reactors, began in the early 2000s. The primary fuel form consists of uranium alloyed with 10-wt% molybdenum in a thin foil coated with zirconium and encapsulated in aluminum-6061 cladding. Over the years, the process has evolved with different types of casting, heat treatments, rolling schedules, and cladding applications. This review examines the history of these fabrication processes and their impact on microstructure and fuel-swelling performance. Even though various fabrication methods were used, we found little correlation between fabrication variation and fuel swelling. This insensitive relationship between fabrication variation and fuel swelling is primarily due to inhomogeneous microstructures that formed during casting and grain refinement that occurred during rolling. We conclude that the fabrication processes we examined produced similar microstructures, indicating that the fuel microstructure is somewhat insensitive to the fabrication parameters evaluated. However, the relatively small amount of historic data, such as those for grain sizes, limited this analysis. More recently fabricated materials, such as those from ongoing irradiation experiment, Mini-Plate-1 and Mini-Plate-2, were also excluded from this analysis and are intended to be reviewed separately. The findings, that fuel microstructure is somewhat insensitive to the fabrication parameters, do not imply that any fabrication method is acceptable, given the uncertainties in data and fuel-swelling observations. For example, only arc melting and vacuum induction melting casting processes were previously explored in the historic fabrication efforts. In conclusion, the findings should not be extrapolated to other casting processes.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Status Report on Design of In-situ Thermomechanical Testing at LANSCE

Nuclear fuel encounters severe thermomechanical environments in which its mechanical response is determined by its microstructure, temperature and stress level histories. Simulating the response of such microstructures is crucial for predicting both performance and transient fuel mechanical responses and experimental verification of such predictions is therefore of great interest. While most of the deformation in a nuclear fuel rod occurs in the cladding, deformation of the fuel itself is still of interest with deformation mechanisms at operating temperature and above including creep, swelling, cracking as well as pellet-clad interaction. Characterization of these properties and understanding of the underlying deformation phenomena at operating or excursion temperatures is therefore of great importance for development and ultimately licensing of improved and novel nuclear fuel forms. Diffraction techniques offer unique insight on the atomistic (e.g. crystal structure) and microstructure (e.g. phase transformations, texture, defects) length scales and have a long history of providing unique data to inform relevant deformation models that enable the required predictive capabilities. For example, dislocations lead to diffraction peak broadening that can be characterized to estimate the dislocation density and study the role of dislocations on the deformation while measuring lattice strains allows to studie load sharing in two phase materials. In this report the requirements for a sample environment for high temperature deformation of nuclear fuels are defined. The HIPPO neutron time-of-flight diffractometer at LANSCE will host this sample environment and is also described. This instrument covers diffraction angles from 140° to 40° and is also equipped with an event-mode neutron imaging detector system, enabling energy-resolved neutron imaging in parallel with the diffraction that could measure sample temperature from Doppler broadening of neutron absorption resonances or measure pore densities from changes in the attenuation. Designs of devices to characterize thermomechanical properties of nuclear fuel without diffraction are also considered to guide the design. While this report is focused on applications for nuclear fuels, the device can also characterize cladding, moderator or structural materials and therefore contribute to other fields of research and development for advanced reactors. The temperatures planned to be reached are above 2000℃, thus enabling characterization of LWR reactor fuels under accident scenarios but also reaching temperatures of fuels developed for nuclear thermal propulsion and providing opportunities to characterize those. In conjunction with the energy-resolved neutron imaging detector, this setup would allow to measure neutron cross-sections at high temperatures, filling a gap towards development of reactors operating at high temperatures.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Understanding the Impact of Fuel on Surfactant Microstructure of Firefighting Foam

Abstract Aqueous film-forming foam is being phased out due to the environmental impacts of fluorinated surfactants contained in the firefighting foams. To develop an environmentally friendly firefighting foam, it is important to understand the factors controlling the firefighting performance of surfactants. Fuel transport through foam has been considered as a dominant mechanism for foam collapse. Therefore, the impact of fuels (heptane, octane and trimethylbenzene (TMB)) on surfactant microstructure was studied for three different types of surfactants (Capstone, Glucopon, and siloxane) that have applications in firefighting foam. Multiple techniques were used to identify the microstructure and interfacial properties of surfactants with and without exposure to liquid fuel. The ignition time of fuel vapor through foam and solubility of fuel through liquid surfactant solution were measured as well. This work shows fuel solubility has an impact on the surfactant microstructure and interfacial properties. In addition, fuel solubility and vapor pressure affect the ignition time of fuel vapors.

Engineering↗
DOE OSTI2025

HFIR LEU High Density Silicide Dispersion Optimized Design Steady-State Heat Transfer Analyses

Steady-state heat transfer simulations of the Oak Ridge National Laboratory High Flux Isotope Reactor (HFIR) with the low-enriched uranium (LEU) high-density silicide dispersion Optimized fuel design were performed to support comprehensive performance and safety metric studies concerning this design. The LEU Optimized design operates at 95 MW to maintain HFIR’s current highly enriched uranium (HEU) core performance level at 85 MW. Full cycle Mode 1 full flow Case 1 (inlet temperature), Case 2 (flux-to-flow), and Case 3 (inlet pressure) safety limit analyses were performed to assess the margins to critical heat flux. Under the prescribed conditions, this LEU design meets the safety limit and limiting control setting requirements outlined in HFIR’s documented safety analysis; however, the safety margins are less than those for the 85 MW HEU core, and several assumptions were made where fuel fabrication and qualification data are currently lacking for the silicide fuel design. Effects of changes to pertinent fuel fabrication assumptions and uncertainty factors on thermal safety margins were also evaluated, showing that the margins are sensitive to many of these parameters. Power and pressure perturbations were also performed, indicating that significant steady-state thermal margins could be gained by increasing the coolant inlet pressure.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

A study on the impact of using a subchannel resolution for modeling of large break loss of coolant accidents

The nuclear industry is investigating the feasibility of transitioning from 18- to 24-month fuel cycles because of the positive impact it would have on the operational costs for the current fleet of light-water reactors. A challenge to making this change is the increased risk of fuel fragmentation, relocation, and dispersal (FFRD) due to the known potential for ceramic fuel to pulverize into fine particles at the higher discharge burnups. Previous work has been performed by the Nuclear Energy Advanced Modeling and Simulation program to assess FFRD risk in high-burnup cores using the BISON fuel performance code and a coarse mesh thermal hydraulics (T/H) solution for a loss-of-coolant accident (LOCA) using the TRACE system T/H code. Because of the importance of the T/H solution for FFRD assessment, this study seeks to investigate the impact of using higher-fidelity subchannel techniques for modeling of the LOCA transient. CTF was used to model a subregion of a high-burnup core that was depleted by the Virtual Environment for Reactor Applications (VERA) multiphysics core simulator. Both coarse-mesh and pin-resolved models were created in CTF, and a consistent coarse-mesh TRACE model was also developed to allow for benchmarking the code results. Further, a large-break loss-of-coolant accident (LBLOCA) reflood transient was simulated using these three models, and results were compared. Results showed some consistent differences between the CTF and TRACE coarse models, including a higher peak cladding temperature (PCT) prediction in CTF and later quenching in CTF; however, the transient clad temperature behavior was similar, and these differences are likely due to post-critical heat flux heat transfer modeling differences and minimum film boiling temperature model differences. The pin-resolved results indicate that the PCT in the lumped model is often under-predicted by as much as 70 °C and that PCT occurs at a different location than the high-power pin in the assembly. The lumped model predicts a difference of 10 °C or less between the average and hot pins in the assembly, whereas the pin-resolved model predicts a range of over 100 °C. These results indicate that higher-fidelity T/H results may have an impact on predicted core behavior during LOCA, which may be important to consider when assessing FFRD risk.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Hydrogen-Battery Hybrid Energy System on Repurposed Offshore Platforms for Efficient Clean-Energy Transition

Due to the rising global energy demand and enhanced awareness of the environmental impact of fossil fuels, the Gulf of Mexico, traditionally known for oil extraction, offers a distinct chance to repurpose the existing offshore infrastructure. With the depletion of oil reserves, it is feasible to adapt previously utilized floating platforms for extraction to generate renewable energy, specifically through wind-generated power and hydrogen production. This adaptation seeks to promote a transport system that is more ecologically friendly in the future. Offshore wind turbines serve as the main energy source, with help from battery storage and hydrogen production to enhance the overall system performance, hydrogen creation, fuel, and electricity delivery for sustainable energy production. The system is divided into two distinct cases, each evaluated for cost, performance, and feasibility, with a focus on minimizing both the Levelized Cost of Energy (LCOE) and the Levelized Cost of Hydrogen (LCOH). The first case examines the integration of offshore wind turbines with hydrogen production. Excess electricity generated by wind turbines is directed toward hydrogen production via electrolysis. The hydrogen produced can be used as fuel for vehicles or transported to the shore via pipelines. The second case investigates a technology that combines wind turbines with battery storage. The batteries possess an ability to supply electricity for a continuous duration of 4 hours maximum each day. The main objective is to reduce the LCOE by considering the battery's charging and discharging cycles, together with the uncertain attributes of wind power and battery deterioration. The produced energy can be distributed for onshore applications or utilized for the purpose of offsetting offshore loads such as subsea oil and gas production, transportation, etc. The offshore hydrogen-battery hybrid system is improved via three advanced algorithms, Particle Swarm Optimization (PSO), and Grey Wolf Optimizer (GWO). In Case 1, PSO improves hydrogen production by efficiently managing the electrolyzer’s power consumption, decreasing production costs significantly. Particle Swarm Optimization (PSO) is applied to improve the efficiency of the electrolyzer, reducing production costs and achieving an optimized CAPEX of $240.00 million (from an initial $300.00 million) and OPEX of $9.60 million per year. This system produces 4,720,000 kg of hydrogen annually, with a Levelized Cost of Hydrogen (LCOH) of $6.40/kg and an annual profit of $9.27 million. In Case 2, GWO effectively reduces the overall energy cost by improving the charge-discharge management of batteries, which extends battery life and optimizes their use. The second case focuses on integrating battery storage, optimized using the Grey Wolf Optimizer (GWO), which enhances battery charge-discharge cycles, extending battery life and lowering costs. This system achieves an optimized CAPEX of $204.80 million (from an initial $256.00 million) and OPEX of $9.29 million per year, producing 310883.39 MWh of electricity annually at a Levelized Cost of Energy (LCOE) of $86.13/MWh, with an annual profit of $6.25 million. The implementation of a comprehensive strategy results in a substantial reduction in costs, improved energy efficiency, and a dependable supply of both electric power and hydrogen, emphasizing the benefits of converting offshore oil platforms for clean energy transition. This study explores a clean strategy to enable cost-effective repurposing of offshore O&G platforms. Both cases highlight the economic and technical feasibility of transitioning offshore oil platforms to clean energy systems, demonstrating substantial cost reductions and reliable energy and hydrogen supplies for sustainable energy production.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Performance-Limiting Factors of Hydrocarbon Ionomeric Binders for Fuel Cells and Electrolyzers

Here, the move toward nonfluorinated hydrocarbon ionomers for fuel cells and electrolyzers is driven by potential restrictions on polyfluoroalkyl substances such as Nafion. This study examines the key limitations of hydrocarbon ionomers through half- and single-cell experiments with model hydrocarbon ionomers. Half-cell tests reveal three major performance barriers: undesirable adsorption, electrochemical oxidation, and low gas permeability. Competitive sulfate adsorption helps counteract ionomer adsorption and oxidation. These findings align with single-cell performance data, which further reveal additional oxygen mass transport limitations likely caused by localized electrode flooding. Together, these findings offer valuable insights to guide the development of high-performance, fluorine-free hydrocarbon ionomers for next-generation fuel cells and electrolyzers.

Choi, Jong-Ho [Los Alamos National Laboratory (LAN↗
DOE OSTI2024

Cycloalkane-rich sustainable aviation fuel production via hydrotreating lignocellulosic biomass-derived catalytic fast pyrolysis oils

Sustainable aviation fuel (SAF) produced from lignocellulosic biomass is emerging as an ideal alternative to conventional jet fuel for aviation sector decarbonization. Catalytic fast pyrolysis (CFP) can convert lignocellulosic biomass into relatively stable bio-oil that can be selectively transformed to various transportation fuels through hydroprocessing under conditions of different severities. In this contribution, two CFP oils produced from pine-based feedstocks over different types of catalysts (i.e., ZSM-5 and Pt/TiO 2 catalysts) were hydrotreated at 125 bar in a non-isothermal process with a maximum temperature of 385 °C over a sulfided NiMo/Al 2 O 3 catalyst to produce SAF with high cycloalkane concentrations of 89–92 wt%. Cycloalkanes are an important component of jet fuel with advantageous fuel properties, such as high energy density, low sooting, and potential for replacing aromatic hydrocarbons to provide good seal swelling properties. The hydrotreating process successfully converted 91–92% of the biogenic carbon in the CFP oil intermediates to liquid-phase hydrotreated products. Through distillation, 39–40 wt% of the hydrotreated oils were collected in the jet-fuel range as SAF fractions. The rest of the hydrotreated product could be valorized as fuels (e.g., diesel) or chemicals. The SAF fractions with oxygen contents below the detection limit (<0.01 wt%) met ASTM D7566 finished fuel blend and D4054 Tier 1 specifications with respect to density, lower heating value (LHV), volatility, flash point, and freeze point. These results indicate hydrotreating lignocellulosic biomass-derived CFP oil as a promising pathway to produce high-quality SAF rich in cycloalkanes. Continued research is required to increase the SAF yield by process improvements, such as increased CFP oil yields, and an enhanced production of SAF-range molecules via e.g., cracking of high-molecular weight compounds either during CFP or hydrotreating, as well as evaluation of a broader range of jet fuel properties and performance requirements.

09 BIOMASS FUELS↗
DOE OSTI2024

Development and Characterization of Densified Biomass-plastic Blend for Entrained Flow Gasification (Final Technical Report)

Supported by the U.S. DOE NETL Award DE-FE0032043, this project was a collaborative effort. Project participants included the University of Kentucky Institute for Decarbonization and Energy Advancement (UK IDEA), Biosystems and Agricultural Engineering department (UK BAE), and Wabash Valley Resources, LLC. The goal of this final technical project report is to comprehensively summarize the work conducted on project DE-FE0032043. In accordance with the Statement of Project Objectives (SOPO), the University of Kentucky (UK) (Project Prime Recipient) has developed and studied a biomass/plastic fuel with a hydrophobic surface area less than 10 m 2 /m 3 that is suitable for oxygen-blown entrained flow gasification with slurry feed. The project involved the utilization of an existing thermogravimetric analysis (TGA)-mass spectrometer (MS), 1.5” drop tube furnace, 1 ton per day (TPD) coal gasifier, and high-pressure extruder operated at UK. The pilot-scale production of blended material was done at the Polymers Technology Center in Charlotte, North Carolina. Parametric testing and solid fuel blend slurry performance validation was completed using the UK entrained flow gasifier with multiple opposed burners to narrow the major near-term technical gaps that impede gasification of biomass and carbonaceous mixed wastes such as plastics in order to achieve net-negative CO 2 emissions. Project results validated the UK approach to address the major technical challenges on the biomass/plastic pretreatment and gasification. Previously, this has been limited in application to fluidized-type or moving bed-type gasifiers due to the high-water uptake of porous biomass containing hydroxyl groups during the conventional slurry preparation, resulting in a highly viscous, un-pumpable slurry. The biomass pretreatment with plastic developed for this project demonstrates advantages in cost and flexibility, which include: 1) the development of a blended solid fuel slurry with 55-60 wt% solids and comparable heating value to 100% coal-based water slurry; 2) the collection of gasification kinetic data and identification of preliminary operating conditions by performing thermogravimetric analysis, gasification experiments by using a 1.5” drop tube furnace; and finally 3) the demonstrated gasification of the blended solid fuel in the UK entrained flow gasifier with a long-lasting stable solid fuel blend slurry, dataset detailing operating conditions, and characterization of slag phase formation and solidification. The lab-scale data and experience obtained during this project encourages the development of technologies and commercial approaches to enable a hydrogen-based energy economy while achieving net-negative CO 2 emissions through gasification of coal, biomass, and carbonaceous mixed wastes such as plastics.

01 COAL, LIGNITE, AND PEAT↗