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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 OSTI2023

Process-based cost estimation framework for assessing economic viability of environmentally and socially sustainable rare earth element feedstocks

Rare Earth Elements (REEs) are critical raw material inputs that are required to enable the energy transition. Constraints on the U.S. supply of conventional REE feedstocks and the desire to diversify U.S. reliance on foreign supply chains have motivated the pursuit of REE recovery from unconventional feedstocks including waste products. Recovery of REEs from unconventional sources is also motivated by environmental and social considerations, including the potential to offset new mining activity and subsidize the remediation of REE-containing wastes from coal, natural gas, and other mineral extraction activities. Sourcing REEs from unconventional feedstocks would reduce supply chain constraints and minimize the environmental impacts of REE extraction, but current processes to exploit these feedstocks have uncertain technical and economic performance and the processes have not been demonstrated at scale. This work aims to reduce uncertainty in evaluating the performance of new REE production pathways. A database of operating and capital expenses for REE recovery and establish consistent process unit costs for common stages in the conventional supply chain are developed. Market prices are used to develop well-defined methods for determining product values for a diverse set of products that can be generated (e.g. oxalates, alloys, end-use products such as magnets) but are not typically considered in technoeconomic analyses. Finally, to provide insight on the effects of economies of scale and feedstock purity on capital and operating costs, process unit level cost functions relating total costs per kilogram of REE produced are reported. These tools can be applied to assess and facilitate scale-up of REE production from diverse sources of REEs.

Fritz, Alison↗
DOE OSTI2024

The Feedstock-Conversion Interface Consortium - Understanding and Mitigating the Impacts of Feedstock Variability in Bioconversion Processes

The Feedstock-Conversion Interface Consortium is led by DOE as a collaborative effort among researchers from 9 National Laboratories. The FCIC was formed because biomass feedstock properties are variable and different from other commodities, and empirical approaches to address these issues have been unsuccessful. The FCIC uses first-principles-based science to de-risk biorefinery scale-up and deployment by understanding and mitigating the impacts of feedstock variability on bioenergy conversion processes. In this presentation, we present a brief overview of key FCIC prinicples and recent results.

biomass↗
DOE OSTI2024

Computational Analysis of Different Sparging Systems and their Influence in the Fluid-Dynamic Behavior of Bubble Column Reactors

Bubble column bioreactors are being actively considered for gas fermentation applications, specifically for CO2 utilization, and sugars to fuels conversion. Their main advantages include good mass transfer without any moving parts and low-cost of operation and maintenance. However, the design and scale-up of such reactors is challenging specifically for carbon capture applications where a mixture of gases (e.g. CO2/CO/H2) with variable solubilities is used. The overall performance of scaled-up bioreactors (e.g., mass transfer rate) is largely affected by gas holdup, bubble size distribution (BSD), and multiphase hydrodynamics. We investigate the effect of gas sparger designs on the performance of these large-scale bioreactors using computational fluid dynamics simulations in this work, so as to improve CO2 conversion at scale. The gas distribution systems in bubble column reactors not only determines operational regime, but also affects the evolution of the BSD, which in turn influences interfacial mass transfer and ultimately the efficiency of the gas-liquid exchange process. In addition to the BSD, uniformity in gas sparging affects gas holdup and bubble residence time which constitute important metrics of performance in gas-liquid systems. In this work, we use computational models to simulate high fidelity representations of different sparger designs and their effect on the operation of a bubble column reactor. Four different types of spargers have been selected for the computational study (Fig. 1): ladder, multi-ring, single-ring and toroidal. Their effect on superficial velocity, gas holdup mixing efficiency, and BSD will be evaluated in this work. The model uses a multiphase Eulerian framework similar to [1] and include a composition of mixtures of H2/CO/CO2 gases, common in fermentation applications.

BIOMASS FUELS,MATHEMATICS AND COMPUTING↗
DOE OSTI2023

The Production of Low Ash Coals Using the Hydrophobic-Hydrophilic Separation Process with Novel Developments

Froth flotation is a common mineral processing method in coal preparation. This process becomes less efficient, however, as particle size is reduced, and ultrafine particles are often discarded prior to froth flotation, contributing to a substantial amount of coal waste in impoundments. Because of the land-use and risk of an impoundment failure, these impoundments pose an environmental liability. To address ultrafine coal rejection, researchers at Virginia Tech developed the hydrophobic-hydrophilic separation (HHS) process. Unlike in froth flotation, HHS uses an organic solvent to separate and dewater hydrophobic particles from hydrophilic minerals. Past work on the HHS process yielded promising results. In particular, the HHS process has produced a low-ash (<2%) and low moisture (<8%) product, which is a viable feed stock for carbon products. In this work, an investigation of the effects of auxiliary processes on the HHS process was conducted. The auxiliary processes included grinding, pre-concentration, and reagent conditioning. This work also contains an investigation on the interaction between two primary unit operations in the HHS process: oil agglomeration and de-emulsification. Lastly, to make the HHS process more viable for commercial scale-up, a novel unit operation was developed and tested that performs comparably to the current HHS process.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

BioHydrogen (BioH2) Consortium to Advance Fermentative H2 Production

The overall objective of this project is to develop a carbon-neutral, microbial dark fermentation technology to convert waste lignocellulosic biomass into H2 with a production cost less than $2/kg-H2 via strain engineering, bioprocess design for scale-up, and integrating fermentation with microbial electrolysis cell (MEC).

bioH2↗
DOE OSTI2024

BioHydrogen (BioH2) Consortium to Advance Fermentative H2 Production

The overall objective of this project is to develop a carbon-neutral, microbial dark fermentation technology to convert waste lignocellulosic biomass into H2 with a production cost less than $2/kg-H2 via strain engineering, bioprocess design for scale-up, and integrating fermentation with microbial electrolysis cell (MEC).

bioH2↗
DOE OSTI2024

High-Fidelity Arc-Discharge Model for Hydrogen-Plasma-Smelting-Reduction of Iron Ore

Electrification and use of renewable hydrogen is currently a necessity for decarbonizing the iron-and-steel industry. In this regard, hydrogen plasma smelting reduction (HPSR) is a novel pathway that is being explored for reduction of iron ore. HPSR provides several decarbonization merits compared to conventional blast furnaces. Firstly, the use of renewable hydrogen drastically reduces the CO2 emissions compared to the use of coke. Secondly, renewable electricity in the form of a thermal plasma for making reactive hydrogen species (radicals, ions) are more efficient at reducing iron ore compared to neutral H2. Thirdly, a molten product compatible with downstream processes is obtained from the intense heat transfer from the plasma. However, the scale-up of this technology requires fundamental exploration of hydrogen plasma dynamics and its interaction with complex solid material that include phase changing iron-ore and slag. In this work, we present a first principles continuum scale model for thermal plasmas in Ar/H2 gas mixtures typically used for HPSR. The thermal plasma governing equations for mass, momentum and energy with Lorentz force and Joule heating source terms are solved along with electromagnetic equations for electrostatic and magnetic vector potential. Our solver will be based on Pele, a suite of reacting flow solvers designed for advanced scientific computing architectures (Henry De Frahan et al., Proceedings of SIAM Parallel Processing, 13-25, 2024), and will utilize adaptive mesh generation for enhanced resolutions at locations of intense physicochemical interactions. This study will present the impact of Ar to H2 ratios on excited/dissociated hydrogen species concentrations, plasma temperature and conductivity along with the impact of outgassed species (water, metal vapor, O, OH radicals) from ore surface on gas phase chemistry. Furthermore, the heat and species flux to the surface will be quantified as a function of applied voltages in a transferred arc configuration.

hydrogen plasma↗
DOE OSTI2024

Hydrogen and its Vital Role in a Clean Energy Future

Large-scale, low -cost hydrogen production can enable an economically competitive, secure, and environmentally beneficial future energy system across multiple sectors. Furthermore, clean hydrogen can address specific sectors that are hard to decarbonize (e.g., heavy-duty trucking, load-following electricity, iron, steel, and cement) and can help the U.S. meet the net zero carbon goal by 2050. To achieve this goal, tens of millions of metric tons of clean, reliable, and affordable hydrogen will be needed annually1. In 2021, the Hydrogen Energy Earthshot was launched, and its goal is to reduce the cost of clean hydrogen to $1 per $1 kilogram in 1 decade (1 1 1) 2. One very promising pathway for large-scale hydrogen production is water splitting. Water splitting technologies range from commercial technologies such as electrolyzers to approaches that are at a much earlier stage of development, such as photoelectrochemical (PEC) and thermochemical (TCH) processes. All these water splitting pathways offer diverse benefits in energy storage, grid services, and cross-sector emissions reductions while taking advantage of the diverse domestic resources. However, critical materials-, component- and system-level challenges must be addressed to improve efficiency and durability and reduce cost. To address these barriers and move these promising and high impact technologies forward, the HydroGEN Advanced Water Splitting Materials (AWSM) and the H2 from the Next-generation of Electrolyzers of Water (H2NEW) consortia were formed and supported by the Department of Energy (DOE) EERE Hydrogen and Fuel Cell Technologies Office (HFTO). HydroGEN (https://www.energy.gov/eere/h2awsm/) consortium, established in 2016, is an Energy Materials Network (EMN) that aims to accelerate the materials R&D of low technology readiness level (TRL) advanced water splitting (AWS) technologies. The consortium comprises five core national laboratories and focuses on four early-stage AWS pathways: alkaline exchange membrane (AEM) electrolysis, proton conducting solid oxide electrolysis (p-SOEC), photoelectrochemical, and thermochemical water splitting. Liquid alkaline and PEM electrolyzers are already commercial and significant advancements in oxygen conducting solid oxide electrolysis cells (o-SOECs) have been realized. Yet, these systems are still too expensive and not sufficiently durable for wide-scale commercialization. To enable high-volume manufacturing of affordable, durable, efficient electrolyzers, H2NEW (https://h2new.energy.gov/), another multi-lab consortium, was established in 2020. This comprehensive, concerted effort is focused on overcoming barriers related to components and materials integration and scale-up to achieve performance, durability, with an initial focus to achieve $2/kg H2 by 2026.

AEM↗
DOE OSTI2025

A Note to Reviewers Suggesting Post-reaction Catalyst Characterization: Know What You’re Asking For

Here, we highlight examples of post-reaction characterization in thermo- and electrocatalysis to present the challenges in obtaining reliable data to answer specific questions about the true identity of the active site and/or catalyst deactivation/degradation. We use this editorial to suggest to reviewers that, when formulating comments to authors that involve materials characterization after reaction testing, they should consider what specific, meaningful information can be attained or what targeted question can be answered that adds value to the individual paper and to the field in general, and how to reasonably obtain that data. In contrast, reviewers should avoid vague, open-ended comments that suggest unguided post-reaction characterization that would not add significant value to the report and, similarly, avoid comments that are substantial enough that they could form the basis of an entirely separate report.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Alkylidene functionalization produces highly recyclable and scalable polyhydroxyalkanoates

Recyclable polymers that can be produced at scale and readily tuned within the same polymer framework for specific properties are important to achieving a circular materials economy. To this end, synthetic poly(3-hydroxyalkanoate)s (PHAs) have emerged as high-performance, chemically recyclable variants of biological PHAs, but their difficult monomer syntheses and suboptimal recycling efficiencies pose challenges for large-scale deployment. In this study, we investigated a β-isopropylidene PHA, i-PHA, for which the lactone monomer can be synthesized by existing industrial methods from biomass-derived isobutyric acid. The alkylidene substituent prevents decarboxylative degradation typically observed during PHA depolymerization, enabling near-quantitative chemical recycling to monomer. Controlled hydrogenation of the β-isopropylidene side group produces PHAs with diverse performance metrics that are competitive with a range of commodity polymers, spanning strong fibers to ductile thermoplastics to superglue epoxy resins.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Operational and scaling-up barriers of SOEC and mitigation strategies to boost H 2 production- a comprehensive review

Solid oxide electrolysis cells (SOECs) proffer a flexible and environmentally friendly solution to reduce CO 2 emissions and/or produce H 2 fuel for various applications. Here, the integration of this technology with renewable energy systems makes them even more promising in realizing a near-perpetual green energy infrastructure in the near future. SOEC technology has achieved stupendous improvement in recent years, and some of the limiting factors to the commercialization of this technology have been explored. It is, therefore, necessary to have a succinct outlook of the different factors that contribute to the recent developments in SOEC technology. The current work presents a comprehensive review of the state-of-the-art SOEC component materials and their degradation mechanisms, SOEC modeling essentials and efficiencies, and the scalability of SOECs. Although SOEC is considered a highly promising technology and sufficient multifaceted research has been done, yet not been widely commercialized. Despite the improvement to mitigate degradation of the SOEC materials, a large share of the degradation concerns sprang from charge transfer reaction at the triple-phase boundaries of the H 2 -electrode. Part of which can be improved by microkinetic modeling of these materials supported by their characterization to give insight into their development. Some other directions for the future in advancing this technology toward the commercialization stage are thoroughly addressed.

08 HYDROGEN↗
DOE OSTI2025

Upcycling of post-consumer mixed polyolefin feedstock: An economic and technical evaluation

Here, this study reports techno-economic and life cycle analyses to evaluate the economic and environmental impacts of mechanically recycled PE/PP blends in the presence of rheology modifiers. Additionally, fiber-reinforced composites derived from the compatibilized blends were prepared and evaluated for their performance compared with virgin plastics. Results suggest that compatibilized PE/PP blends exhibit a 70% lower selling price compared to virgin PE. Furthermore, these blends achieved a 74% reduction in greenhouse gas emissions or climate change impact compared to the virgin counterpart. Fiber-reinforced composites from compatibilized PE/PP blends demonstrated improved or comparable mechanical properties relative to composites made from virgin PE/PP blends. Based on their favorable cost and environmental impact, along with performance comparable to virgin composites, compatibilized PP/PE composites made from post-consumer plastics can find applications in large-scale composite manufacturing.

Fiber reinforced plastics (FRP)↗
DOE OSTI2023

Treasuring trash: Pt/SrTiO 3 catalysts process plastic waste into high-value materials

Single-use plastics are ubiquitous throughout modern society because they have properties that make them desirable in a wide variety of applications, including low cost of production, high thermal and chemical stability, and tunable mechanical properties. Several of the recycling methods currently used to process single-use plastic waste, such as mechanical recycling and pyrolysis, do not selectively process plastic materials into uniform products, as would be advantageous for repurposing these materials in pursuit of a circular economy. Catalytic hydrogenolysis, whereby C–C bonds in polymers are broken over a supported catalyst in the presence of H 2 , is a promising approach to converting plastics into value-added products that can be sold commercially without further purification. Here, in this account, we present some recent advances in polyolefin hydrogenolysis, with a focus on Pt nanoparticles on SrTiO 3 nanocuboid supports (Pt/STO). Current developments in this field, general challenges, and future directions are discussed.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Confinement of Lewis Acid–Base Sites by Microporous Silica Layers on Titania for Enhanced Alkanol Dehydration Reactivity

Alkanol dehydration offers a pathway to upgrade biomass-derived short-chain oxygenates into alkenes, essential chemical building blocks widely used in industrial applications. Transition metal oxides with Lewis acid-base site pairs are attractive catalysts due to their high reactivity and cost-effectiveness. This work demonstrates a synthetic pathway to manipulate local environments around active Lewis acid-base pairs in anatase TiO 2 to enhance their reactivity in alkanol dehydration. Microporous SiO 2 layers with an average pore diameter of ~0.6 nm and a controlled thickness of 0.8-33 nm are deposited on anatase TiO 2 powders by using a molecular templated SiO 2 deposition method. The Lewis acid-base strength of accessible Ti-O pairs remains unchanged, as shown by temperature-programmed surface reactions of surface-bound formic acid-derived species and temperature-programmed desorption of pyridine. However, measured alkanol dehydration rates on confined Ti-O pairs are much higher (by up to 7-fold) than those on TiO 2 . The extent of rate enhancements depends on the reactant size and functional group positioning, suggesting that the rate enhancements reflect the interactions between the guest molecules (reactants and transition states) and the surrounding SiO 2 micropore environments. By providing a detailed synthetic procedure to tailor the local environments around active sites in bulk oxides, this approach offers an additional avenue for enhancing catalytic performance.

09 BIOMASS FUELS↗
DOE OSTI2026

High-Capacity Enzymatic Degradation of Postconsumer Poly(ethylene terephthalate): Modeling and Experimental Investigations

Enzymatic degradation is considered as one of the key steps for biorecycling of polyethylene terephthalate (PET), a widely used plastic. Recently, we have developed an optimized leaf-branch compost cutinase PelB-LCC ICCG and demonstrated ∼80% degradation of 200 g L −1 recycled PET (RPET) within two days in bioreactors. In this study, continued research efforts were made to achieve a complete degradation of up to 300 g L −1 RPET in bioreactors. First, low-capacity reaction conditions with ≤5 g L −1 PET were examined to identify the key variables for PET degradation with PelB-LCC ICCG , including temperature, enzyme loading, and product inhibition. To better understand and further optimize the enzymatic degradation process, a mechanism-based model was established to describe the kinetics of PET degradation and formation of the main product terephthalic acid (TPA) and byproducts MHET and BHET in high-capacity bioreactors. Model simulation suggested that a minimal enzyme loading of ∼1.4 mg PelB-LCC ICCG g −1 RPET is required to achieve a nearly complete degradation of RPET within 48 h, which was used to guide more high-capacity experiments with 100−300 g L −1 RPET in fully controlled 1 L bioreactors. A higher temperature (≥65 °C) was found not only to enable rapid degradation in the beginning but also to induce a gradual increase in RPET’s crystallinity and significantly slow down the degradation after 48 h. A high loading of RPET solids and the accumulation of the produced insoluble TPA pose a big challenge on mixing and mass transfer in the stirred bioreactor, which can be addressed by increasing the stirring speed. The results pave the way toward biorecycling of PET at a large scale.

enzymatic degradation↗