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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 OSTI2017

Observed Changes in As-Fabricated U-10Mo Monolithic Fuel Microstructures After Irradiation in the Advanced Test Reactor

A low-enriched uranium U-10Mo monolithic nuclear fuel is being developed by the Material Management and Minimization Program, earlier known as the Reduced Enrichment for Research and Test Reactors Program, for utilization in research and test reactors around the world that currently use high-en-riched uranium fuels. As part of this program, reactor experiments are being performed in the Advanced Test Reactor. It must be demonstrated that this fuel type exhibits mechanical integrity, geometric stability, and pre-dictable behavior to high powers and high fission densities in order for it to be a viable fuel for qualification. This paper provides an overview of the microstructures observed at different regions of interest in fuel plates before and after irradiation for fuel samples that have been tested. These fuel plates were fabricated using laboratory-scale fabrication methods. Observations regarding how microstructural changes during irradiation may impact fuel performance are discussed.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2015

ZnO/perovskite core–shell nanorod array based monolithic catalysts with enhanced propane oxidation and material utilization efficiency at low temperature

Here, a hydrothermal strategy combined with colloidal deposition synthesis was successfully used to grow ZnO/perovskite (LaBO 3 , B=Mn, Co, Ni) core-shell nanorod arrays within three dimensional (3-D) honeycomb cordierite substrates. A facile sonication assisted colloidal wash coating process is able to coat a uniformly dispersed perovskite nanoparticles onto the large scale ZnO nanorod arrays rooted on the channel surfaces of the 3D cordierite substrate achieved by hydrothermal synthesis. Compared to traditional wash-coated perovskite catalysts, an enhanced catalytic performance was observed for propane oxidation with 25°C lower light-off temperature than wash-coated perovskite catalyst of similar LaMnO 3 loading (4.3mg). Temperature programmed reduction and desorption under H 2 and O 2 atmosphere, respectively, were used to study the reducibility and oxygen activity of these core-shell nanorod arrays based monolithic catalysts, revealing a catalytic activity sequence of LaCoO 3 >LaMnO 3 >La 2 NiO 4 at the initial stage of catalytic reaction. The good dispersion and size control in La-based perovskite nanoparticles and their interfaces to ZnO nanorod arrays support may contribute to the enhancement of catalytic performance. Lastly, this work may provide a new type of Pt-group metals (PGM) free catalysts with improved catalytic performance for hydrocarbon oxidations at low temperatures.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Cooperative and bifunctional Ga-Ca-Cr 2 O 3 @CaO structured monoliths as versatile platform for reactive capture of CO 2 and its subsequent conversion to ethylene

Cooperative and bifunctional materials (BFMs) that integrate adsorbents and catalysts offer a promising strategy for the reactive capture of CO 2 to produce valuable fuels and chemicals. In this study, we developed structured BFMs via 3D printing that combine CaO as an adsorbent with Ga–Ca–Cr 2 O 3 metal oxides as the catalyst for the reactive capture of CO 2 and its subsequent conversion to C 2 H 4 via the oxidative dehydrogenation of C 2 H 6 (CO 2 -ODHE). Three different Ga–Ca compositions were used to modify the catalyst surface characteristics and enhance C 2 H 4 selectivity. In these formulations, Ga ions stabilize the oxygen lattice of the BFM, while Ca ions interact strongly with Cr to form CaCrO 4 , thereby altering the oxygen species and enhancing the material’s basic properties. Under adsorption–reaction conditions at 600–650 °C, the optimal BFM achieved an excellent C 2 H 4 selectivity of 96.4 %, attributed to a balanced redox process and improved basicity that facilitate efficient C 2 H 6 conversion and rapid desorption of C 2 H 4 without excessive oxidation. Overall, this work provides new insights into the formulation of BFMs monoliths and highlights the critical role of catalytic surface modification in enhancing C 2 H 4 selectivity in the CO 2 -ODHE reactive capture process.

C2H4 production↗
DOE OSTI2021

Direct ink writing of boron carbide monoliths

Direct ink writing – an extrusion-based additive manufacturing process – followed by pressureless sintering was investigated to produce boron carbide monoliths. The effects of ceramic powder loading and Pluronic binder concentration on the rheology of boron carbide pastes were studied and linked to both processing behaviour and final outcome in terms of sintered density and hardness. The effects of printing parameters, in particular orifice diameter and printing speed, were also investigated. Reducing the size of the extrusion nozzle from 584 μm to 406 μm led to significantly better shape retention, lower surface roughness, as well as higher density and hardness. A 203 μm printing orifice was also trialled but was unsuccessful due to faster drying kinetics that occurred with smaller ceramic struts resulting in rapid warping and nozzle clogging. Carbon-black – 8 wt% relative to B 4 C – acted as an effective sintering aid to increase both density and hardness. After optimisation of feedstock and printing parameters, few-layer samples (3–5 layers) had a density as high as ~ 97 % TD and a hardness of ~ 30 GPa. On the other hand, 18-layer specimens had a sintered density of ~ 87 % TD, despite a fully dense microstructure, due to the formation of a 3D array of inter-strut pores. Nevertheless, several issues that arose during manufacturing and post-processing were detrimental to the density and structural integrity of printed specimens; these issues were identified, discussed, and suggestions for future work are provided in this report.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Fabrication and testing of U–7Mo monolithic plate fuel with Zircaloy cladding

The Materials Management and Minimization program is developing fuel designs to replace highly enriched fuel with fuels of low enrichment. In the most challenging cases, U–(7–10wt%)Mo monolithic plate fuel are proposed. The chosen design includes aluminum-alloy cladding, which provides some challenges in fabrication and fuel/cladding interaction in service. We investigated zircaloy cladding, specifically Zry–4as an alternative cladding, and development of a fabrication method was performed by researchers with the Comisión Nacionalde Energia Atómica (CNEA) in Argentina, resulting in test fuel plates (Zry–4 clad U–7Mo) which were subsequently tested in the Advanced Test Reactor in Idaho. Because Zry–4 and U–(7–10)Mo have similar high-temperature mechanical properties, fabrication was simplified in that the fuel foil and cladding could be co-rolled and bonded. The challenge was to prevent a thermal-expansion mismatch which could destroy the fuel/cladding bond before complete bonding was achieved; the solution was to prevent the composites from cooling significantly between roll passes. Our final product performed very well in-reactor, showing good bonding, very little fuel/cladding interaction, either from fabrication or in-reactor testing, and little swelling, especially no detectable heterogeneous bubble formation at the fuel/cladding interface tested to a fission density of up to 2.54E+21

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

Mechanical properties examined by nanoindentation for selected phases relevant to the development of monolithic uranium-molybdenum metallic fuels

Nanomechanical properties, specifically the reduced modulus and hardness of several intermetallic and solid solution phases are reported here to assist the development of the U-10 wt% Mo (U-10Mo) monolithic fuel system for research and test reactors. Findings from this study and reported values of mechanical properties provide data critical for understanding and predicting the structural behavior of the fuel system during fabrication and irradiation. The phases examined are products of interdiffusion and reaction between (1) the AA6061 cladding and the Zr diffusion barrier, namely (Al,Si) 3 Zr and Al 3 Zr, (2) the U-10Mo fuel and the Zr diffusion barrier, namely UZr 2 , Mo 2 Zr, and a-U, and (3) the U (or U-10Mo) and Mo, namely a mixture gradient of α- and γ-phases. The UC inclusions observed within the fuel alloy were also examined. Only phases present in thick or continuous microstructure on cross-sectioned fuel plates and diffusion couples were investigated for reduced modulus and hardness. Concentration-dependence of room-temperature reduced modulus in U solid solution with 0–10 wt% Mo was semi-quantitatively modeled based on mixture of α- and γ-phases and solid solutioning within the γ-phase.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

The porosity surrounding carbides and second phase stringers in monolithic U-10Mo fuel plate after irradiation

Post-irradiation microstructure characterization plays an important role in qualifying the low-enriched uranium (LEU) monolithic U-10 wt%Mo plate-type fuel for United States high-performance research reactors (USHPRRs) program. Inhomogeneous features resulting from manufacturing and irradiation processes, including carbides, second phase stringers, and extensive void spaces caused by the combining of small porosities, may increase the risk of heat concentration in local regions of the fuel plate over the operating conditions. In this study, characteristics of carbides, stringers, and porosity after multiple levels of irradiation at varying fission densities were studied by electron microscopes to decipher the morphology of pores and the porosity evolution in U-10 wt%Mo. For carbides, the result shows that porosities start forming on UMo grain boundaries, then on UMo/carbides interfaces as the burn-up going higher. However, the porosities surrounding carbides grow larger than the ones on UMo grain boundaries. The porosities around the uranium carbides could interconnect to form larger void space. The study revealed that the void spaces larger than 5 µm were found around uranium carbides after high burnup, while no evidence was observed to support the similar voids formed near second phase stringers even though the size of the stringers (> 50 µm) was much larger than uranium carbides (< 20 µm). The evolution of porosities suggests that the formation of second phase stringers may not create more significant porosities compared to regular uranium carbides regions during fuel operating conditions.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Optimizing energy yield of monolithic perovskite/silicon tandem solar cells in real-world Conditions: The impact of luminescent coupling

Efficient light management is key to maximizing power conversion efficiency (PCE) in monolithic perovskite/silicon tandem solar cells. Achieving peak efficiency requires closely matched current generation in all junctions, especially in integrated configurations. However, real-world conditions vary significantly due to factors such as sunlight spectrum, diffuse-to-direct sunlight ratio, angular distribution of light, subcell temperature coefficients, and ground reflection. This study introduces a comprehensive optical and device simulation to optimize perovskite/silicon tandem cells, considering experimental luminescent coupling (LC) efficiency and its dependence on working conditions, alongside variations in radiative recombination, effect of temperature on absorptivity spectra, and cloud cover. Our results show potential energy yield improvements of up to 1.4 % with LC, based on current perovskite radiative recombination records, and up to 4 % with direct bandgap materials. Although radiative recombination's dependence on excitation intensity reduces output power and requires thicker absorbers, LC compensates for these losses. LC also lowers the optimized bandgap for the perovskite top cell from 1.72 eV to 1.64–1.68 eV, or even lower in regions with redshifted irradiance. Additionally, optimization revealed that thinner silicon bottom cells require a higher perovskite top cell bandgap, impacting the balance between fabrication cost and cell stability.

14 SOLAR ENERGY↗
DOE OSTI2026

Low power on-chip data transmission for wafer-scale monolithic active pixel sensors

Here, this paper details the implementation of the digital pulse shaping subsystem within the Backbone Transmission Line Encoding (BTLE) driver, a low-power, long-distance on-chip data transmission solution designed in a 65 nm CMOS process. Digital pulse shaping is critical for minimizing inter-symbol interference (ISI) caused by bandwidth limitations of on-chip interconnects, especially in wafer-scale monolithic active pixel sensors (MAPS). A duobinary encoder coupled with a parallelized polyphase finite impulse response (FIR) filter is used for efficient shaping of the transmitted signal spectrum. This reconfigurable architecture achieves reliable 160 Mb/s data transfer over a 10 cm on-chip link, as validated by simulations demonstrating low power consumption (FoM 37.3 fJ/bit/mm of transmission line length) and effective ISI mitigation.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

Switching Characteristics of a 1.2 kV, 50 mΩ SiC Monolithic Bidirectional Field Effect Transistor (BiDFET) with Integrated JBS Diodes

—The switching performance of large area (1cm x 1cm) monolithic 1.2 kV 50 mΩ 4H-SiC bidirectional field effect transistor (BiDFET) with integrated JBS diodes is reported for the first time. The devices were fabricated in a 6-inch commercial foundry and then packaged in a custom-designed four-terminal module. The switching performance of the BiDFET has been observed to be 1.4x better than that of its internal JBSFETs. Dynamic characterization was performed at 800 V with different gate resistances, current levels and case temperatures. An increase in switching losses was observed for the BiDFET with increasing gate resistance and current level as observed for SiC power MOSFETs. The BiDFET showed a 9% reduction in total switching loss from 25 °C to 150 °C with a current of 10 A.

Silicon Carbide, Monolithic, Bidirectional, FourQu↗
DOE OSTI2019

Monolithic Integration of Self-Biased C -Band Circulator on SiC Substrate for GaN MMIC Applications

We have designed and fabricated the first self-biased circulator operating in C-band and monolithically integrated it with Qorvo's GaN MMIC technology by embedding a FeNi-based magnetic nanowire composite (MNC) in a 100 $μ$m thick SiC substrate. This integrated microstrip circulator shows a circulation frequency centered at 5.7 GHz, with an insertion loss of 2.7 dB and isolation of 14 dB. Additionally, the circulator demonstrated power handling of 9.6 W with continuous wave and at least 40W under pulsed conditions. This letter points a path in integrating miniaturized circulators into full-duplex GaN T/R MMICs with stringent form factor limits.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Enhancement-Mode GaN Monolithic Bidirectional Switch With Breakdown Voltage Over 3.3 kV

Here, this work demonstrates a GaN enhancement-mode monolithic bidirectional switch (MBDS) with breakdown voltage (BV) higher than 3.3 kV in both polarities. This MBDS is realized on a dual p-GaN gate high electron mobility transistor (HEMT) platform on sapphire substrate. It features a novel dual junction termination extension design for electric field management, which is built on the p-GaN layer in the gate stack and does not require epitaxial regrowth. The GaN MBDS exhibits symmetric on-state characteristics in both directions with a threshold voltage (V th ) of 0.6 V and a low specific on-resistance (R on,sp ) of 5.6 m Ω · cm2. This device presents the highest BV, as well as one of the best BV and R on,sp trade-offs, in all the reported MBDS devices. The R on,sp is lower than the performance limit of conventional BDS realized by two discrete devices. This 3.3 kV GaN MBDS opens the door for developing new circuit topologies and advancing system performance in medium-voltage power electronics.

42 ENGINEERING↗
DOE OSTI2015

Effects of the foil flatness on irradiation performance of U10Mo monolithic mini-plates

Monolithic plate-type fuels comprise of a high density, low enrichment, U10Mo fuel foil encapsulated in a cladding material. This concept generates several fabrication challenges such as flatness, centering or thickness variation. There are concerns, if these parameters have implications on overall performance. To investigate these inquiries, the effects of the foil flatness were studied. For this, a representative plate was simulated for an ideal case. The simulations were repeated for additional cases with various foil curvatures to evaluate the effects on the irradiation performance. The results revealed that the stresses and strains induced by fabrication process are not affected by the flatness of the foil. Furthermore, fabrication stresses in the foil are relieved relatively fast in the reactor. The effects of the foil flatness on peak irradiation stressstrains are minimal. There is a slight increase in temperature for the case with maximum curvature. The major impact is on the displacement characteristics. Furthermore, while the case with a flat foil produces a symmetrical swelling, if the foil is curved, more swelling occurs on the thin-cladding side and the plate bows during irradiation.

42 ENGINEERING↗
DOE OSTI2015

Effects of the shape of the foil corners on the irradiation performance of U10Mo alloy based monolithic mini-plates

Monolithic plate-type fuel is a fuel form being developed for high performance research and test reactors to minimize the use of enriched material. These fuel elements are comprised of a high density, low enrichment, U-Mo alloy based fuel foil, sandwiched between Zirconium liners and encapsulated in Aluminum cladding. The use of a high density fuel in a foil form presents a number of fabrication and operational concerns, such as: foil centering, flatness of the foil, fuel thickness variation, geometrical tilting, foil corner shape etc. To benchmark this new design, effects of various geometrical and operational variables on irradiation performance have been evaluated. As a part of these series of sensitivity studies, the shape of the foil corners were studied. To understand the effects of the corner shapes of the foil on thermo-mechanical performance of the plates, a behavioral model was developed for a selected plate from RERTR-12 experiments (Plate L1P785). Both fabrication and irradiation processes were simulated. Once the thermo-mechanical behavior the plate is understood for the nominal case, the simulations were repeated for two additional corner shapes to observe the changes in temperature, displacement and stress-strain fields. The results from the fabrication simulations indicated that the foil corners do not alter the post-fabrication stress-strain magnitudes. Furthermore, the irradiation simulations revealed that post-fabrication stresses of the foil would be relieved very quickly in operation. While, foils with chamfered and filleted corners yielded stresses with comparable magnitudes, they are slightly lower in magnitudes, and provided a more favorable mechanical response compared with the foil with sharp corners.

Finite Element Analysis↗
DOE OSTI2015

EFFECTS OF THE FOIL CENTERING ON THE IRRADIATION PERFORMANCE OF U10MO ALLOY BASED MONOLITHIC MINI-PLATES

Monolithic plate-type fuel is a fuel form being developed for high performance research and test reactors to minimize the use of enriched material. These plate-type fuels consist of a high Uranium density, LEU foil contained within diffusion barriers and encapsulated within a cladding material. To benchmark this new design, effects of various geometrical and operational variables on irradiation performance have been evaluated. For this work, the effects of fuel foil centering on the thermo-mechanical performance of the mini-plates were studied. To evaluate these effects, a selected plate from RERTR-12 experiments, the Plate L1P756, was considered. The fuel foil was moved within the fuel plate to study the effects of the fuel centering on stress, strain and overall shape of the fuel elements. The thickness of the fuel foil, thickness of the Zr-liners and total thickness of the plate were held constant, except the centerline alignment of the fuel foil. For this, the position of the fuel foil was varied from the center position to a maximum offset corresponding to the minimum allowable aluminum cladding thickness of 0.1524 mm. Results were then compared with each other and with the ideal case to make a comparative assessment. Fabrication simulations indicated that the thermal expansion mismatch results in warping of the fuel plate during fabrication as the fuel plate is cooled from the HIP temperature when the fuel is not centered. Even if the model is constrained during cooling to simulate the rigid HIP can surrounding the fuel plate during cooling, warping is observed when the constraint is removed. Similarly, irradiation simulations revealed that the fuel offset causes virtually all irradiation-induced swelling to occur on the thin-cladding side of the plate. This is observed even for the smallest offset that was considered. The total magnitude of the swelling is approximately same for all offsets values.

42 ENGINEERING↗
DOE OSTI2017

High Temperature Monolithic Biochar Supercapacitor Using Ionic Liquid Electrolyte

A supercapacitor comprising of two binder-free biochar monolith electrodes and 1-butyl-3-methylimidazolium tetrafluoroborate based ionic liquid electrolyte was studied at room temperature and 140°C by cyclic voltammetry, constant-current charge-discharge, and electrochemical impedance spectroscopy. The supercapacitor exhibits an operating voltage window of approximately 6 V. It is found that increasing temperature from room temperature to 140°C considerably increases its specific mass capacity and its charge-discharge rate by a factor of approximately 10. The specific capacity of the supercapacitor calculated from the voltammetric measurements depended on scan rates. At 140°C, a capacity of 21 F g -1 was obtained at 5 mV s -1 and this value decreases to around 10 F g -1 at 100 mV s -1 ; the constant-current charge-discharge profiles exhibit pseudo-linear voltage-time responses during the discharges. The supercapacitor shows good stability characteristics of no obvious performance decay after 1000 cycles within a voltage window of 6 V. Electrochemical impedance spectra of the supercapacitor display a wide linear region corresponding to diffusion control. The energy densities of the supercapacitor that are normalized to the total active electrode materials are higher than 20 Wh kg -1 when its power density is lower than 2000 W kg -1 . In conclusion, these facts suggest that the high-temperature biochar supercapacitor would be a promising energy-storage device with high energy and power density.

25 ENERGY STORAGE↗
DOE OSTI2011

Evaluation of THOR TM Mineralized Waste Forms (Granular and Monolith) for the DOE Advanced Remediation Technologies (ART) Phase 2 Project

The U.S. Department of Energy's (DOE) Office of River Protection (ORP) is responsible for the retrieval, treatment, immobilization, and disposal of Hanford's tank waste. Currently there are approximately 56 million gallons of highly radioactive mixed wastes awaiting treatment. A key aspect of the River Protection Project (RPP) cleanup mission is to construct and operate the Waste Treatment and Immobilization Plant (WTP). The WTP will separate the tank waste into high-level and low-activity waste (LAW) fractions, both of which will subsequently be vitrified. The projected throughput capacity of the WTP LAW Vitrification Facility is insufficient to complete the RPP mission in the time frame required by the Hanford Federal Facility Agreement and Consent Order, also known as the Tri-Party Agreement (TPA), i.e. December 31, 2047. Therefore, Supplemental Treatment is required both to meet the TPA treatment requirements as well as to more cost effectively complete the tank waste treatment mission. The Supplemental Treatment chosen will immobilize that portion of the retrieved LAW that is not sent to the WTP's LAW Vitrification facility into a solidified waste form. The solidified waste will then be disposed on the Hanford site in the Integrated Disposal Facility (IDF). In addition, the WTP LAW Vitrification facility off-gas condensate known as WTP Secondary Waste (WTP-SW) will be generated and enriched in volatile components such as Cs-137, I-129, Tc-99, Cl, F, and SO 4 that volatilize at the vitrification temperature of 1150°C in the absence of a continuous cold cap. The current waste disposal path for the WTP-SW is to recycle it to the supplemental LAW treatment to avoid a large steady state accumulation in the pretreatment-vitrification loop. Fluidized Bed Steam Reforming (FBSR) offers a moderate temperature (700-750°C) continuous method by which LAW and/or WTP-SW wastes can be processed irrespective of whether they contain organics, nitrates, sulfates/sulfides, chlorides, fluorides, volatile radionuclides or other aqueous components. The FBSR technology can process these wastes into a crystalline ceramic (mineral) waste form. The mineral waste form that is produced by co-processing waste with kaolin clay in an FBSR process has been shown to be as durable as LAW glass. Monolithing of the granular FBSR product, which is one of the objectives of this current study, is being investigated to prevent dispersion during transport or burial/storage but is not necessary for performance. FBSR testing of a Hanford LAW simulant and a WTP-SW simulant at the pilot scale was performed by THOR Treatment Technologies, LLC at Hazen Research Inc. in April/May 2008. The Hanford LAW simulant was the Rassat 68 tank blend and the target concentrations for the LAW was increased by a factor of 10 for Sb, As, Ag, Cd, and Tl; 100 for Ba and Re (Tc surrogate); 1,000 for I; and 254,902 for Cs based on discussions with the DOE field office and the environmental regulators and an evaluation of the Hanford Tank Waste Envelopes A, B, and C. It was determined through the evaluation of the actual tank waste metals concentrations that some metal levels were not sufficient to achieve reliable detection in the off-gas sampling. Therefore, the identified metals concentrations were increased in the Rassat simulant processed by TTT at HRI to ensure detection and enable calculation of system removal efficiencies, product retention efficiencies, and mass balance closure without regard to potential results of those determinations or impacts on product durability response such as Toxicity Characteristic Leach Procedure (TCLP). A WTP-SW simulant based on melter off-gas analyses from Vitreous State Laboratory (VSL) was also tested at HRI in the 15-inch diameter Engineering Scale Test Demonstration (ESTD) dual reformer at HRI in 2008. The target concentrations for the Resource Conservation and Recovery Act (RCRA) metals were increased by 16X for Se, 29X for Tl, 42X for Ba, 48X for Sb, by 100X for Pb and Ni, 1000X for Ag, and 1297X for Cd to ensure detection by the analytic laboratory used for the demonstration and, as with the LAW simulant, without regard to potential impacts on product durability response such as TCLP. Details of the ESTD testing that was performed in April and May of 2008 are shown in Table 1 as the Operational Summary. The first eight tests were performed on LAW using a Denitration and Mineralization Reformer (DMR) temperature of 725°C and different ratios of clay:simulant of 675 g or 640 g of OptiKast clay per liter of simulant. The last four tests were performed on WTP-SW (originally referred to as LAW-Recycle) using a DMR temperature in the range of 680°C to 700°C with a mixture of 45/55 Sagger/OptiKast clay with 307 g clay/L simulant. The coal feed rates used in the FBSR processing are also shown as noted at the bottom of Table 1. It should be noted that the carbon feed rates are averaged over those periods.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2012

Dual Layer Monolith ATR of Pyrolysis Oil for Distributed Synthesis Gas Production

We have successfully demonstrated a novel reactor technology, based on BASF dual layer monolith catalyst, for miniaturizing the autothermal reforming of pyrolysis oil to syngas, the second and most critical of the three steps for thermochemically converting biomass waste to liquid transportation fuel. The technology was applied to aged as well as fresh samples of pyrolysis oil derived from five different biomass feedstocks, namely switch-grass, sawdust, hardwood/softwood, golden rod and maple. Optimization of process conditions in conjunction with innovative reactor system design enabled the minimization of carbon deposit and control of the H2/CO ratio of the product gas. A comprehensive techno-economic analysis of the integrated process using in part, experimental data from the project, indicates (1) net energy recovery of 49% accounting for all losses and external energy input, (2) weight of diesel oil produced as a percent of the biomass to be ~14%, and (3) for a demonstration size biomass to Fischer-Tropsch liquid plant of ~ 2000 daily barrels of diesel, the price of the diesel produced is ~$\$$3.30 per gallon, ex. tax. However, the extension of catalyst life is critical to the realization of the projected economics. Catalyst deactivation was observed and the modes of deactivation, both reversible and irreversible were identified. An effective catalyst regeneration strategy was successfully demonstrated for reversible catalyst deactivation while a catalyst preservation strategy was proposed for preventing irreversible catalyst deactivation. Future work should therefore be focused on extending the catalyst life, and a successful demonstration of an extended (> 500 on-stream hours) catalyst life would affirm the commercial viability of the process.

09 BIOMASS FUELS↗