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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 OSTI2021

The Fundamental Creep Behavior Model of Gr.91 Alloy by ICME Approach (Final Report)

The current project mainly focused on the fundamental creep cracking mechanism of the Grade 91 system during the operation conditions in the advanced technologies FE power plants and build the link among Composition-Processing Parameters-Phase Stability-Microstructure-Creep Resistance. A model based on computational thermodynamics and diffusion kinetics will be developed to provide guidance on how to improve the creep resistance of the alloy system. The PI mainly investigate the Gr.91 base alloy and weldment with the Integrated Computational Materials Engineering (ICME) approach. The long-term goal of the proposed program is to develop a model for creep and fatigue resistant alloys with different elemental systems, compositions, and processing parameters of weldment and heat-treatment. In addition, new creep and fatigue resistant alloys are to be designed based on the predictions from the model. The computational as well as experimental results include three sections: 1) The compositional optimization and secondary phases evaluation regarding the creep resistance in Grade 91 steel through the CALPHAD approach. In this section, the formation of the critical secondary phases, M23C6, MX and Z-phase were well predicted based on many conditions like the temperature as well as compositions. Meanwhile, the role of different alloying elements was also considered as they will directly affect the formation of the secondary phases mentioned above based on the compositional evolution of the alloying elements. 2) An investigation of Creep Resistance in Grade 91 Steel through Computational Thermodynamics. We systematically considered the evolution of the four critical temperatures, Ac3, Ac1, the threshold of M23C6 and Z-phase, on basis of the computational approach. Meanwhile, the equilibrium cooling as well as Scheil simulations were also considered to perform further predictions based on the different cooling rates. 3) Creep lifetime and microstructural evolution of the Grade 91 steel. In this part, mainly experimental approach was performed on the real creep test from the beginning of the commercial Gr.91 alloys. The alloys were normalized, tempered, welded (Gleeble) and PWHT and finally subjected to the creep lifetime analyses. Finally, all the samples after each process were further characterized based on the OM, XRD and SEM technique to draw final conclusions.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2020

Low-Temperature Plasma Treatment for Enhanced Recovery of Highly Valued Critical REEs from Coal (Final Technical Report)

The principle objective of this project was to develop a novel process flowsheet using low-temperature plasma treatment (LTP) integrated with conventional hydrometallurgical processes to recover rare earth elements (REEs), especially highly valued REEs (i.e. scandium and critical REEs), from coal and coal byproducts. LTP treatment was used to pretreat the solid feed material prior to leaching in an effort to improve the leaching characteristics of the REEs and potentially reduce acid consumption. Initially, a detailed experimental program was performed on a laboratory LTP furnace to identify a set of process parameter values to be used for assessing the enhanced leaching performance achieved on four specific gravity fractions of West Kentucky No. 13 and Fire Clay coarse coal refuse materials. High-temperature oxidation (HTO)) was also evaluated as a means for improving REE leachability on the same fractions of both coal sources. The lixiviants used to assess leachability improvements included i) untreated water, ii) 0.1 M ammonium sulfate solution and iii) 1.2 M sulfuric acid solution at a temperature of 75°C. The laboratory data was used to develop multiple process flow sheets using HTO only to produce a rare earth oxide mix concentrate or utilizing both LTP and HTO treatment processes to generate a high purity heavy REO mix concentrate and a light REO mix concentrate. A techno-economic analysis was performed on each circuit.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Electrochemical conversion of coal-derived CO 2 into fuels and chemicals using a modified PEM electrolyzer. Final report

Opus 12 is developing an electrochemical process to convert CO 2 into chemicals and fuels. Using only CO 2 , water, and electricity as inputs, the electrochemical reduction of CO 2 could form the basis of an artificial carbon cycle that replaces a wide range of products that are currently derived from fossil fuel resources. We have developed a prototype that demonstrates high selectivity and current density for CO 2 conversion to CO, which can be used to make high-value products including methanol, acetic acid, polymers, and pharmaceuticals.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Demonstrations of Holistic, Lower Cost/Energy Effluent Water Management Approaches for Coal-Fired Energy Plants

The project work conducted under DOE award DE-FE0031678 was comprised of three overarching project goals: (1) evaluate the performance of Saltworks’ Flex EDR Selective process for treating wet flue gas desulfurization (FGD) wastewater, (2) conduct bench-scale testing of wastewater encapsulation as a byproduct management technology for the EDR generated brine, and (3) develop a dynamic water balance model encompassing the results of the aforementioned testing.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Inexpensive and Sustainable Anti-Corrosion Coating for Power Generation Applications

The goal of the project was to achieve lab-scale demonstration of a corrosion prevention technology, which will facilitate the capture of CO 2 from coal and natural gas fired power generation by reducing the cost of construction materials and maintenance. The project built on technology previously developed by LumiShield to address more broad-based corrosion issues and the results shown will be applicable to a wide range of markets requiring cost effective corrosion resistant coatings. That technology developed is a base layer to improve the performance and reduce the cost of organic anti-corrosion coatings. The impact of those changes on overall plant economics were demonstrated with the help of engineers at AECOM through an initial cost-benefit-analysis at the end of BP1 which will be updated at the end of BP2.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

SOFC Prototype System Test

The goal of this U.S. Department of Energy (DOE) sponsored project is to test a 200 kWe thermally self-sustaining atmospheric-pressure solid oxide fuel cell (SOFC) prototype system at a prominent site. Fuel Cell Energy Inc. (FCE) utilized the state-of-the-art SOFC technology of its wholly-owned subsidiary Versa Power Systems (VPS) to design, fabricate and test the 200 kW prototype system. The specific objectives of this project were to achieve an SOFC stack power degradation rate of ≤1.5% per 1000 hours for the 400 kW stand-alone prototype power system undergoing ≥ 5000 hours of steady state tests at thermally self-sustained normal operating conditions (NOC), and to verify the prospects for a high volume SOFC stack production cost below the DOE target of 225 dollars per kilowatt. Achieving these goals enables commercial natural gas fueled SOFC system deployment in the 2020 timeframe, which will eventually lead to SOFC technology that is viable for large scale central power generation applications.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Sustainable Coal Tar Pitch Carbon Fiber Manufacturing

Coal is a versatile resource that has historically propelled the Industrial Revolution, transportation, and energy generation, and continues to meet needs for power. The United States possesses the largest worldwide coal reserves (with a 2019 total production-to-recoverable-reserves ratio of 0.05) that are of high quality and are cost-effective to recover (i.e., $0.03/kg–$0.10/kg). However, the demand of coal for power generation has declined because of a shift to natural gas (because of lower natural gas prices) and to renewable energy sources. This decline has affected the economic viability US coal industry. Historically, domestic demand for coal was driven mostly by the electric power sector, which accounts for about 93% of the total demand, followed by industrial uses (primarily for cement and chemicals at a minimal level) and steel production (coke). The complex, dense carbon chemical structure of coal, abundant domestic supply, and stable, low price gives it great potential for use in a wide range of value-added non-fuel coal products (e.g., nanomaterials at $20,000/kg–$100,000/kg and commercial-grade carbon fiber at $22/kg–$33/kg), as well as in upgraded coal fuels.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

High Throughput In-Line Coating Metrology Development for Solid Oxide Fuel Cell Manufacturing

Coatings play key roles in solid oxide fuel cell (SOFC) stack durability. For example, diffusion barrier coatings on Cr-containing interconnect and balance of plant (BOP) components protect electrodes from Cr poisoning over the long operational lifetimes (>10,000 hours) of the fuel cell stack. Common defects in coatings, such as cracks, pinholes, and porosity, result in a failure to protect the electrodes, resulting in shorter operational lifetime and thus higher cost. It is very unlikely, even in the best coating process, that all these defects can be mitigated, hence identifying critical defects in parts, and removing defective parts from production before they can damage the stack, becomes paramount. Furthermore, these quality control techniques must be operational in the production/assembly line (in-line), i.e., high throughput and non-destructive, and cost effective. Redox Power Systems, LLC (Redox) together with the National Renewable Energy Laboratory (NREL) developed much needed high throughput, in-line metrology techniques for protective coatings. The overall goal of the project is to lower cost while increasing robustness, reliability, and endurance of SOFC stacks. To accomplish this, we had several objectives, including: to identify key coating and substrate defects that lead to coating failure through the use of detailed characterization methods (e.g., microscopy, XRD, EDS, electrochemistry); to assess capabilities of in-line metrology techniques, e.g., optical profilometry (Redox) and thermography (NREL), to probe these defects, or evidence thereof; demonstrate long-term performance of “defect-free” protective coatings, as identified by in-line metrology, in solid oxide fuel cell (SOFC) stack operation. In the first part of this project, the ability to identify key defects expected to lead to coating and SOFC degradation using in-line metrology tools were evaluated. Coated interconnect samples with controlled defect types and populations were tested under conditions similar to SOFC operation, followed by detailed post-test analysis to reveal the defects responsible for observed degradation. In the second part of the project, the optimal in-line metrology techniques and methodologies were used to map the defect distribution in full-size interconnects with critical defects intentionally allowed to exist in some cases. These interconnects underwent SOFC testing for extended periods (up to ~3,000 hours) followed by post-test analysis to evaluate the effectiveness of in-line metrology techniques in mitigating MCO coating related degradation. Key accomplishments in this project included the following: Demonstrated ASR of < 0.05 ohm-cm 2 at 650 °C for 1,000 hours with low defect (determined by in-line metrology) interconnect samples (average ASR=37 milliohms-cm 2 after over 1,000 hours). Demonstrated that low defect coatings on interconnects (as screened using in-line metrology) have low volatilization of chromium at ~650 °C for 1,000 hours as detected using Cr-getter material (< 5 at% increase above baseline); 1022 hour duration tests under humidified, elevated temperature (750 °C rather than 650 °C) compared a base case against different coating thicknesses. Demonstrated capability to identify initial key defects of interest with in-line metrology techniques using up to 8 cm by 10 cm having coatings with and without intentional defects of interest using thermal imaging and optical profilometry. Correlated key defects identified using metrology techniques with observed coating performance (e.g., ASR and Cr volatility). Conducted several 4 cm by 4 cm cell tests using MCO-interconnects that were pre-screened using some of the metrology techniques developed in the project (e.g., optical profilometry). An analysis of ASR measurements were able to show that defect-free coatings resulted in the anticipated performance in the cell tests.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Co-Generation Wastewater Treatment at Coal-Fired Energy Plants (Final Report)

Steam electric energy generation typically results in the discharge of one or more effluent streams. Coal-fired energy plant air quality regulations have had the effect of transferring pollutants previously in the flue gas to water by means of the flue gas desulfurization (FGD) system. Combined physical-chemical and biological treatment solutions are currently the most economical approach for treating FGD wastewater. Multi-effect evaporators are significantly higher cost but can meet potential upcoming regulations that are more stringent.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Operating Stresses and their Effects on Degradation of LSM-Based SOFC Cathodes

The overall goals of the program were: To understand how selected operational parameters affect the performance of solid oxide fuel cells (SOFCs), with a focus on parameters affecting cathodes (air electrodes) comprised of lanthanum strontium manganite (LSM, (La 1-x Sr x ) 1-y MnO 3±δ ) and yttria-stabilized zirconia (YSZ, (Zr 1–z Y z )O 2±δ ). To relate the observed relationships between operational parameters and cell performance to the microstructural changes that can be observed in the cells after operation.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Investigation of Cycling Coal-Fired Power Plants Using High-Fidelity Models

The project delivers a well-integrated and validated simulation platform for cycling operation analysis in coal-fired power plant. Two critical mechanical components of the boiler island were analyzed through mechanical integrity assessment and economic benefit analysis. The current phase of the project focuses on the development of the integrated simulation infrastructure and prove its feasibility and effectiveness using two typical use cases. This integrated platform can help save a lot of engineering efforts for model development and simulation analysis. Through the real simulation scenarios in this document, it was demonstrated that using this platform, an analysis can be completed in approximately 2 days, while it could cost several weeks before using this platform. Going forward, the platform built in this project can be used for more boiler service applications, and it can be further enhanced with more functions/features to maximize its usage and benefits. 1) Extend component-level analysis with more use cases to cover all the major critical components of boiler island under cycling operations. A library of critical components can be developed and validated for typical pulverized coal-fired subcritical boiler units. 2) Develop predictive maintenance features based on the integrated models (Digital Twins) and engineering analysis procedures. Predictive maintenance enables each asset to be serviced based on forecast on life consumption and cost profile for replacing/welding the critical mechanical parts of the boiler. This minimizes the chance of unscheduled shutdowns and emergency services at much higher costs and prevent the fatal accidents in unit operations. 3) Develop and maintain a standard library for critical component analysis under flexible plant operations, which will include libraries of: process models, MI models for typical pressure parts, and economic models with typical plant operating data and ISO power trade data.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Upcycled "CO 2 -Negative" Concrete for Construction Functions

Electricity generation from coal-fired power plants represents 25% of total carbon dioxide (CO 2 ) emissions from the United States (1.4 billion tons of CO 2 emitted in 2015). In view of upcoming legislation that seeks to limit CO 2 emissions, in support of climate change goals, it is anticipated that such emissions will be (financially) penalized. This is of great consequence to emissions intensive sectors such as coalfired power generation which are expected to be substantially burdened by such penalties.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

CO 2 Mineralization Using Porous Carbon and Industrial Wastes to Make Multifunctional Concrete

Along with substantial benefits and promises of carbon capture and storage (CCS) technologies, significant challenges exist in developing scalable materials and methods for capture and of CO 2 . The overarching objective of this project is to provide a system approach for developing a new CO 2 capture and utilization technology using porous carbon and industrial wastes to make a low-cost, scalable and multifunctional concrete product. The objective of Phase I of this project is to develop and fine-tune activated carbons from different wastes such as plastic wastes to offer a cheap, abundant and scalable feedstock for CO 2 uptake. The objective of Phase 2 is creating a facile protocol to develop a concrete prototype comprising CO 2 adsorbed activated carbon (e.g. from plastic wastes), followed by product validation, life-cycle analysis, and bench-scale testing. The project objectives are designed to specifically obtain a final product and technology that directly addresses the main goals of the DOE’s CCS programs.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

A combined biological and chemical flue gas utilization system towards carbon dioxide capture from coal-fired power plants (Final Report)

Photosynthetic algal cultivation has been intensively studied for CO 2 capture and utilization for several decades. The footprint for using algae to capture CO 2 emitted from carbon-intensive industrial processes (power plants, cement plants, and fermentation processes) is extremely large, which creates serious technical and economic hurdles that must be cleared if algal technologies are to be commercially implemented. Fortunately, algal biomass is rich in proteins, carbohydrates, and lipids, providing a good chemical source for organic absorbents and other value-added chemical feedstocks. In particular, amino acids from algal protein can be used to generate amino acid salt solutions that have been proven to be effective for capturing CO 2 . In order to take advantage of both algal cultivation and biomass utilization, the goal of the proposed project is to develop a combined biological and chemical system for coal-fired power plants for sequestering CO 2 in biological absorbents and generating value-added products. This approach significantly reduces the land and energy footprint of CO 2 capture, and minimizes capital and operational expenses. Three specific objectives are targeted: 1) optimizing the growth of the selected algal strain to maximize biomass accumulation from the coal-fired flue gas; 2) developing a cascade biomass utilization to produce amino acid absorbents, polyurethanes, biodiesel, and methane; and 3) conducting techno-economic analysis (TEA) and life cycle assessment (LCA) of the proposed process. Three key technical outcomes were achieved: (1) With the selected robust algal strain and unique photobioreactor design, long-term culture stability can be extended, and algal biomass productivity reached 0.5 g dry biomass/L/day year-round at a biomass concentration of 1.2 g/L in the pilot photobioreactor; (2) The biomass utilization process led to complete utilization of the algal biomass to produce amino acid salt absorbent, polyurethanes, and methane; and (3) The combined biological and chemical flue gas utilization process concluded a technically and economically feasible commercial-scale system that completely captures CO 2 in coal-fired flue gas with greatly reduced energy consumption.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Towards A Geo-Data Science Method for Assessing Rare Earth Element and Critical Mineral Occurrences in Coal and Other Sedimentary Systems

While preliminary analyses of data from open-source resources (Ekmann, 2012) show promising concentrations of REE in individual coal samples from a number of sites and basins in the U.S., other sparse data for REE in domestic coal-related strata suggest that many occurrences are low, “subeconomic” concentrations. At present, there is no method for systematically assessing potential sedimentary occurrences of REE. However, the geologic processes responsible for REE occurrences in coal-related strata are systematic; the unpredictability of REE resources in coal-related strata is due to poorly quantified spatial resource trends and the lack of an exploration method tailored to these resources. Thus, there exists a need for a systematic assessment approach that incorporates knowledge of geological variation in the mechanisms of REE enrichment within coal basins to help minimize geologic uncertainty and reduce commercial exploration risk.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Nano-Engineered Catalyst Supported on Ceramic Hollow Fibers for the Utilization of CO 2 in Dry Reforming to Produce Syngas

The objective of this project was to develop a novel catalytic reactor containing nano-engineered catalysts for the utilization of CO 2 (captured from coal-fired power plants and other CO 2 emitting sources) in dry methane reforming (DMR) (CO 2 + CH 4 → 2 H 2 + 2 CO) to produce synthesis gas (syngas). The technology aims to reduce CO2 emissions by developing beneficial uses for CO 2 from coal-fired power plants. It also offers an alternative to mitigate CO 2 emissions in areas where geologic storage may not be an optimal solution and/or utilization could significantly offset the costs of carbon capture and sequestration. The nano-engineered Ni-based catalyst was prepared by atomic layer deposition (ALD). The Ni particles were as small as ~2-4 nm. The nano-engineered catalyst showed CH 4 conversion >95%, H 2 /CO ratio in the range of 0.7-1.0, and CH 4 reforming rate as high as 2,500 L/h/gNi at 850 ºC and pressure of 15-25 psia. The Ni-based ALD catalyst also showed good stability in DMR reaction during a 200-h continuous operation at 850 °C. This is due to strong bonding between the nanoparticles and substrates since the Ni nanoparticles were chemically bonded to the substrate during the ALD process. The high thermal stability maintains the high dispersion of Ni nanoparticles, which can inhibit coke formation because their step edges are small enough to limit carbon nucleation and growth. Technoeconomic analysis (TEA) indicates the levelized cost of syngas (LCOS) is $172/ton with our technology, which is lower than the equivalent (molar) cost of hydrogen produced by steam methane reforming (SMR) or autothermal reforming (ATR). The major operating cost is natural gas feed and fuel, and the levelized cost is highly sensitive to the price of natural gas and relatively insensitive to the CAPEX. Revenues from syngas could have a significant impact on the net cost of electricity (COE), depending on the cost of natural gas and the selling price of syngas, estimated at $36 per MWh if the syngas were sold at $195 per ton. Following DOE NETL’s guidance, a lifecycle analysis (LCA) was conducted to compare with SMR. The functional unit for the basis of comparison was defined as 1kg carbon monoxide in the product stream. The global warming potential (GWP) of our process was found to be 40% lower than the state-of-the-art SMR process. The sensitivity analysis confirms the emissions are most sensitive to the natural gas fuel requirements to deliver heat to the process.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Advanced Ultra-Supercritical Component Test (ComTest) Project for 760*C Steam Conditions

ComTest is a $27M Department of Energy-funded project. Phase I, which began in November 2015, served to identify the technology gaps, as well as the scope and cost of required testing. Phase II, which was awarded in December 2018, includes an advanced manufacturing effort to complete U.S. based supply chain development for full commercial scale (800-850 MWe) AUSC components made of nickel-based alloys, components operating at up to 760°C. Completion of Phase II scheduled for September 30, 2021. Strategic Objectives of U.S. AUSC Project include: Power Plant Efficiency Improvements –Develop cost-effective, reliable technologies to improve the efficiency of new and existing high-temperature advanced generation power plants. Close gaps to achieve readiness for commercial scale demonstration of Advanced Ultra-Supercritical (AUSC) technology. Fabricate full-scale versions of key nickel-based alloy components. Validate capabilities of US supply chain for cost certainty. Support cross-cutting high-temperature generation technologies. Obtain ASME Code approval for new materials, components and processes. Increase power plant steam temperatures for higher cycle efficiency (Note: Average efficiency of US coal-fired fleet = 33% HHV; A-USC plant efficiency over 47% HHV at 1,400°F (760°C) steam temperature).

fireside corrosion↗