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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 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

A Study of Intermittent Turbulence in Stable Arctic Boundary Layers

Abstract Polar boundary layers are difficult to model due to the existence of intermittent turbulence within stable layers. Here we present a case study evaluation of coherent structures in a stable boundary layer observed during a series of flights with an uncrewed aircraft system (DataHawk2) on 19 October 2016 at Oliktok Point, Alaska as part of the ERASMUS (Evaluation of Routine Atmospheric Sounding Measurements using Unmanned Systems) field campaign. During a sequence of five flights over a nine-hour period, 57 profiles of atmospheric properties (0–400 m a.g.l) were collected. Turbulence was identified using derived Richardson Number, temperature structure function parameter, and turbulence kinetic energy dissipation. Throughout all flights on this strongly stable day, intermittent turbulence was observed. These turbulent layers showed well-mixed potential temperature profiles embedded within otherwise stable potential temperature profiles; often resulting in a characteristic staircase pattern. Turbulent layers ranged from 1 to 30 m deep, with most individual layers being 1–2 m deep. Vertical propagation velocities of layers in the lower atmosphere were on the order of a few cm s −1 , typical of non-convective environments. In different regions of the profile, turbulence was driven by a different balance of buoyancy and shear forces, with turbulence in the near surface environment driven by strong shear forces overcoming strong resistance to buoyancy, while turbulence in elevated layers characterized by weaker shear forces overcoming weaker resistance to buoyancy. We discuss the potential of such datasets for improving subgrid parameterizations of small-scale turbulence embedded within stable boundary layers.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Pursuing graphite-based K-ion O 2 batteries: a lesson from Li-ion batteries

The replacement of lithium metal by lithium intercalated graphite was crucial for developing safe lithium-ion batteries. Superoxide-based potassium–oxygen batteries represent an exciting metal–oxygen battery with the highest energy efficiencies. However, using potassium metal is a more serious safety threat than lithium. Herein, we explore the possibility of graphite-intercalation anodes for potassium-ion oxygen batteries (PIOBs) with enhanced safety. This work demonstrates for the first time that establishing an artificial potassium salt-rich solid electrolyte interphase (SEI) enables a reversible graphite-intercalation anode (249.6 mA h g -1 after 600 cycles) in a potassium bis(trifluoromethanesulfonyl)imide (KTFSI)-based localized high-concentration electrolyte. Such an electrolyte is stable with the superoxide cathode. The PIOB delivers energy efficiencies above 90% at a depth of discharge (DOD) of 25% for 80 cycles. A three-electrode measurement shows that its overpotential mainly comes from the anode. The lifespan is limited to the gradual degradation of the artificial SEI caused by oxygen crossover. This work represents a step towards achieving holistic anode–electrolyte–cathode compatibility in a PIOB and its realistic evaluation under a controlled DOD.

25 ENERGY STORAGE↗
DOE OSTI2021

Synthetic accessibility and stability rules of NASICONs

In this paper we develop the stability rules for NASICON-structured materials, as an example of compounds with complex bond topology and composition. By first-principles high-throughput computation of 3881 potential NASICON phases, we have developed guiding stability rules of NASICON and validated the ab initio predictive capability through the synthesis of six attempted materials, five of which were successful. A simple two-dimensional descriptor for predicting NASICON stability was extracted with sure independence screening and machine learned ranking, which classifies NASICON phases in terms of their synthetic accessibility. This machine-learned tolerance factor is based on the Na content, elemental radii and electronegativities, and the Madelung energy and can offer reasonable accuracy for separating stable and unstable NASICONs. This work will not only provide tools to understand the synthetic accessibility of NASICON-type materials, but also demonstrates an efficient paradigm for discovering new materials with complicated composition and atomic structure.

25 ENERGY STORAGE↗
DOE OSTI2025

Techno-Economic Analysis of Compressed Air Energy Storage and Hydrogen Production from Variable Renewable Energy

This study presents the techno-economic analysis (TEA) results of integrating electrolysis hydrogen (H 2 ) production, compressed air energy storage (CAES), and H 2 -fired combustion turbines in a high variable renewable energy (VRE) market environment. The inconsistent nature of VRE creates challenges for power producers in maintaining a stable electrical grid as it is increasingly utilized. The mission of the National Energy Technology Laboratory (NETL) is driving innovation and delivering energy solutions, and a multiangle approach involving H 2 production, energy storage, and next-level H 2 -fired combustion turbine generator (CTG) technologies could provide one solution for the nation’s growing electrical grid issues with increasing VRE sources. The H 2 production and CAES concept were investigated due to its ability to provide utility-scale H 2 -fueled power generation with large-scale energy storage capabilities. Two facilities with CAES and natural gas-fired CTGs (in McIntosh, Alabama, and Huntorf, Germany) have been operating for decades. In contrast, this study investigates the potential to replace the natural gas fuel with H 2 fuel. This concept has been publicly presented by both Siemens Energy and Bechtel Global Engineering, Construction & Project Management (Bechtel) at two different power generating levels. The CAES and air expansion/combustion turbine power generation in this study are primarily based on the Siemens Energy system (Bailie, Aug. 10-11, 2021) (Scheller, Feb. 21, 2023). The inclusion of a H 2 turboexpander generator is from Bechtel (Gülen, Sep. 6, 2022). A block flow diagram of the proposed process is illustrated in Exhibit ES-1.

08 HYDROGEN↗
DOE OSTI2026

EXERGETIC: De-Risking Next-Generation Resilient Geothermal Hybrids via At-Scale Evaluation Using Virtual Emulation Digital Twin Environment for Efficient Operation

The DOE-GTO-funded project, award number 5.1.2.12, entitled "EXERGETIC - De-risking Next Generation Resilient Geothermal Hybrids via at-Scale Evaluation Using a Virtual Emulation Digital Twin Environment for Efficient Operation," advances the solution to these challenges by developing and validating a geothermal co-emulation environment implemented at the National Laboratory of the Rockies (NLR)'s Advanced Research on Integrated Energy Systems (ARIES) platform. This framework enables the de-risking of next-generation geothermal and geothermal hybrid systems through high-fidelity modeling, real-time digital emulation, advanced control strategies, and techno-economic assessment. The project focused on geothermal hybrid configurations that integrate geothermal power plants with concentrated solar power and underground thermal energy storage, enabling enhanced efficiency, flexibility, and grid support capabilities. The main goal of this project was the development of a geothermal digital co-emulation environment to demonstrate the technical and economic value of geothermal hybrid systems and their contribution to grid stability and flexibility. The EXERGETIC framework combined physics-based models, controls, and real assets at ARIES, including digital real-time simulators (DRTS), a 20-MW-scale controllable grid interface (CGI), and a 2-MW conventional generator. Detailed transient models were developed for the key subsystems of a hybrid geothermal plant, including parabolic trough solar collectors, reservoir thermal energy storage (RTES), and a binary Organic Rankine Cycle (ORC) power plant. The ORC model explicitly captured thermal inertia and off-design operation and integrated control strategies to dynamically respond to electric load profiles. The models were validated against published experimental and numerical studies, demonstrating strong agreement and confirming the accuracy and robustness of the modeling approach. The resulting digital twin represents geothermal-solar-storage systems at multiple scales (1 MW to 100 MW) and enables realistic emulation of grid-connected operation. The control architecture allows the geothermal resource to provide stable baseload generation, while solar and stored thermal energy supply flexible, dispatchable support during periods of high demand or variable grid conditions. A key contribution of the EXERGETIC project is the demonstration that geothermal hybrid systems can be designed to be active grid assets rather than passive baseload generators. Using the ARIES platform, the digital twin was evaluated under multiple grid scenarios, including load following, voltage support at the distribution level, and frequency response at the transmission level. Results show that hybrid geothermal systems can respond effectively to dynamic grid conditions, providing inertia-like behavior, primary frequency support, and voltage regulation through coordinated control. In addition to the performance and grid services capability analysis of geothermal and hybrid geothermal systems, the EXERGETIC project also focused on scalability and techno-economic analysis of geothermal hybrid plants. In particular, for the scalability analysis, machine-learning (ML)-based surrogate models were trained using data generated from the geothermal digital twin under different grid-connected scenarios and plant capacities. These ML models demonstrated strong interpolation and extrapolation capabilities across plant sizes, accurately reproducing both steady-state and transient responses with very low errors. Regarding the techno-economic analysis, plant performance results were integrated with cost models for hybrid geothermal systems, and the levelized cost of electricity (LCOE) was used as the main economic metric to evaluate system performance across a range of system capacities, solar shares, solar multiples, and storage durations. Results indicate that economies of scale significantly reduce geothermal LCOE as plant capacity increases, with large-scale systems (25-100 MW) achieving substantially lower costs than small plants. Hybridization with solar thermal energy and storage further improves economic performance by increasing capacity utilization and enabling flexible dispatch. In addition, thermal storage plays a critical role in reducing LCOE by maximizing geothermal, solar, and stored energy resources. In summary, the results from this project demonstrate that geothermal hybrid systems represent a promising alternative for increasing the energy conversion efficiency of geothermal technologies, contributing to the preservation of geothermal resources, and supporting the transition of geothermal plants from traditional baseload resources into flexible, resilient, and cost-competitive energy conversion technologies.

15 GEOTHERMAL ENERGY↗
DOE OSTI2021

A Stable, Low Permeable TEMPO Catholyte for Aqueous Total Organic Redox Flow Batteries

We report aqueous organic redox flow batteries (AORFBs) are highly attractive for large-scale energy storage because of their nonflammability, low cost, and sustainability. (2,2,6,6-Tetramethylpiperidin-1-yl)oxyl (TEMPO) derivatives, a class of redox active molecules bearing air-stable free nitroxyl radicals and high redox potential (>0.8 V vs NHE), has been identified as promising catholytes for AORFBs. However, reported TEMPO based molecules are either permeable through ion exchange membranes or not chemically stable enough for long-term energy storage. Herein, a new TEMPO derivative functionalized with a dual-ammonium dicationic group, N 1 , N 1 , N 1 , N 3 , N 3 , 2, 2, 6, 6-nonamethyl-N 3 -(piperidinyloxy)propane-1,3-bis(ammonium) dichloride (N 2 -TEMPO) as a stable, low permeable catholyte for AORFBs is reported. Ultraviolet–visible (UV–vis) and proton nuclear magnetic resonance ( 1 H-NMR) spectroscopic studies reveal its exceptional stability and ultra-low permeability (1.49 × 10 -12 cm 2 s -1 ). Coupled with 1,1'-bis[3-(trimethylammonio)propyl]-4,4'-bipyridinium tetrachloride ((NPr) 2 V) as an anolyte, a 1.35 V N2-TEMPO/(NPr)2V AORFB with 0.5 m electrolytes (9.05 Wh L -1 ) delivers a high power density of 114 mW cm -2 and 100% capacity retention for 400 cycles at 60 mA cm-2. At 1.0 m electrolyte concentrations, the N 2 -TEMPO/(NPr) 2 V AORFB achieves an energy density of 18.1 Wh L -1 and capacity retention of 90% for 400 cycles at 60 mA cm -2 .

TEMPO↗
DOE OSTI2025

Increased Defect Resistance and Ordering in MnBi 2 (Se 1– x Te x ) 4 via Accurate Diffusion Monte Carlo

Stabilizing materials and controlling defect formation remain key challenges in materials science, particularly for theory, where small energy differences must be resolved for accurate predictions. Here, we applied state-of-the-art theoretical methods to topological materials, focusing on MnBi 2 Te 4 (MBT), which is a promising intrinsic magnetic topological insulator. Antisite defects in MBT alter its electronic structure and magnetism, degrading topological properties and causing experimental inconsistencies. Using diffusion Monte Carlo and density functional theory, we investigated the thermodynamic stability and defect formation in MBT, MnBi 2 Se 4 (MBS), and MnBi 2 (Se 1–x Te x ) 4 . We found that MnBi 2 Se 2 Te 2 can be stable at finite temperatures, with higher defect formation energies due to stronger Mn–Se bonding and reduced internal strain. Se preferentially substitutes Te near Mn instead of Te in the outer layer, encouraging long-range ordering when incorporated. For MnBi 2 (Se 1–x Te x ) 4 , cluster expansion phase diagrams revealed solid solution behavior when x <0.5 and phase separation for larger x. MBT and MBS are topological insulators; therefore, the MnBi 2 (Se 1–x Te x ) 4 family could offer tunable topological behavior and improved stability.

MnBi2Te4↗
DOE OSTI2022

Size Ranges of Magnetic Domain States in Tetrataenite

Paleomagnetic studies of meteorites provide unique constraints on the evolution of magnetic fields in the early solar system. These studies rely on the identification of magnetic minerals that can retain stable magnetizations over ≳4.5 billion years (Ga). The ferromagnetic mineral tetrataenite (γ''-Fe 0.5 Ni 0.5 ) is found in iron, stony-iron and chondrite meteorite groups. Nanoscale intergrowths of tetrataenite have been shown to carry records of paleomagnetic fields, although the effect of magnetostatic interactions on their magnetic remanence acquisition remains to be fully understood. Tetrataenite can also occur as isolated, non-interacting, nanoscale grains in many meteorite groups, although the paleomagnetic potential of these grains is particularly poorly understood. Here, we aim to improve our understanding of tetrataenite magnetization to refine our knowledge of existing paleomagnetic analyses and broaden the spectrum of meteorite groups that can be used for future paleomagnetic studies. We present the results of analytical calculations and micromagnetic modeling of isolated tetrataenite grains with various geometries. We find that tetrataenite forms a stable single domain state at grain lengths between 6 and ~160 nm dependent on its elongation. It also possesses a magnetization resistant to viscous remagnetization over the lifetime of the solar system at 293 K. At larger grain sizes, tetrataenite's lowest energy state is a lamellar two-domain state, stable at Ga-scale timescales. Unlike many other magnetic minerals, tetrataenite does not form a single-vortex domain state due to its large uniaxial anisotropy. Our results show that single domain and two-domain tetrataenite grains carry an extremely stable magnetization and therefore are promising for paleomagnetic studies.

58 GEOSCIENCES↗
DOE OSTI2024

The seventh blind test of crystal structure prediction: structure ranking methods

A seventh blind test of crystal structure prediction has been organized by the Cambridge Crystallographic Data Centre. The results are presented in two parts, with this second part focusing on methods for ranking crystal structures in order of stability. The exercise involved standardized sets of structures seeded from a range of structure generation methods. Participants from 22 groups applied several periodic DFT-D methods, machine learned potentials, force fields derived from empirical data or quantum chemical calculations, and various combinations of the above. In addition, one non-energy-based scoring function was used. Results showed that periodic DFT-D methods overall agreed with experimental data within expected error margins, while one machine learned model, applying system-specific AIMnet potentials, agreed with experiment in many cases demonstrating promise as an efficient alternative to DFT-based methods. For target XXXII, a consensus was reached across periodic DFT methods, with consistently high predicted energies of experimental forms relative to the global minimum (above 4 kJ mol −1 at both low and ambient temperatures) suggesting a more stable polymorph is likely not yet observed. The calculation of free energies at ambient temperatures offered improvement of predictions only in some cases (for targets XXVII and XXXI). Several avenues for future research have been suggested, highlighting the need for greater efficiency considering the vast amounts of resources utilized in many cases.

Chemistry↗
DOE OSTI2024

Mild pH-decoupling aqueous flow battery with practical pH recovery

Establishing a pH difference between the two electrolytes (pH decoupling) of an aqueous redox flow battery (ARFB) enables cell voltages exceeding the 1.23 V thermodynamic water-splitting window, but acid–base crossover penalizes efficiency and lifetime. Here we employ mildly acidic and mildly alkaline electrolytes to mitigate crossover, achieving high round-trip energy efficiency with open circuit voltage >1.7 V. We implemented an acid–base regeneration system to periodically restore electrolytes to their initial pH values. The combined system exhibited capacity fade rate <0.07% per day, round-trip energy efficiency >85% and approximately 99% Coulombic efficiency during stable operation for over a week. Cost analysis shows that the tolerance of acid–base crossover could be increased if the pH-decoupling ARFB achieved a higher voltage output and lower resistance. Finally, this work demonstrates principles for improving lifespan, rate capability and energy efficiency in high-voltage pH-decoupling ARFBs and pH recovery concepts applicable for pH-decoupling systems.

25 ENERGY STORAGE↗
DOE OSTI2021

Energy catalysis needs ligands with high oxidative stability

Replacing fossil fuel-based energy by renewable sources is a transition that society needs to make to meet future energy demand and simultaneously address climate change. Coupling renewable energy sources with electrochemical catalysis provides a promising path to carbon-neutral fuels and chemicals when the necessary reducing equivalents and protons are harvested from water. Developing highly active, stable, and inexpensive electrocatalysts for the oxygen evolution reaction (OER) is accordingly a centerpiece of a renewable energy portfolio. Whereas viable OER catalysts are heterogeneous in nature, owing to their oxidative stability, the realization of stable molecular OER catalysts greatly expands the horizon of energy science with the ability to tune OER energetics and mechanisms with fidelity. In this perspective, current challenges in the field of molecular OER catalysis are addressed with promising lines of research that are directed to designing ligands that can withstand the harsh oxidizing environment of OER.

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

Evaluation of the Energy, Hygrothermal, and Thermal Capacity Performance of Cross-Laminated Timber

Cross-laminated timber (CLT) construction is gaining momentum in the US because it offers multiple advantages over traditional construction methods. Benefits that have received the most attention focus on constructability, the environment, and protection (e.g., blast resistance), although CLT construction is likely to offer other benefits, as well. Still, these have not been studied at length because such evaluations are costly, requiring long-term assessments in an actual building and specialized technical knowledge. Among the possible benefits, CLT construction likely provides a higher-performing building envelope. Using CLT panels to enclose a building means fewer joints in the opaque envelope than what is required in traditional stick-framed construction. Fewer joints mean fewer locations where the air- and water-resistive barrier (WRB) could be compromised; thus, a CLT building enclosure may require less maintenance and have a longer lifespan than a traditionally built structure because of fewer air and water leaks. In addition, CLT’s thermal mass moderates indoor temperatures, allowing the heating, ventilation, and air conditioning (HVAC) system to operate more efficiently during peak hours, reducing operational energy consumption throughout the lifetime of the CLT building (Salonvaara et al., 2022). Furthermore, more stable indoor temperatures can increase occupant comfort. The CLT’s thermal mass can also reduce energy costs by adjusting to utility time-of-use pricing without affecting occupant comfort. The ability of CLT buildings to bridge periods without HVAC operation prepares them for future grid interaction and provides a certain level of resilience against power outages. Researchers have attempted to quantify these benefits; however, their work is based on simplified simulations with numerous assumptions. To correctly understand the benefits, an actual building must be monitored. Therefore, information needs to be gathered on indoor and outdoor temperatures, HVAC energy consumption, thermostat setpoints, temperatures, and thermal transport in CLT components to comprehend how these parameters are affected by the CLT’s thermal mass. These data are needed to reduce the number of assumptions and calibrate simulation models to optimize HVAC controls to minimize overall energy consumption, reduce energy use and higher fees during peak demand, and maintain occupant comfort. Additionally, the calibrated simulation model allows the optimization exercise to be repeated in various US climates. Potential benefits can be tailored to buildings in various locations, and decisions can be made on where CLT construction could be most advantageous. Furthermore, monitoring and simulation results are needed to evaluate the durability of the CLT structures in different climates. This project’s researchers gathered information to help understand and quantify the benefits of CLT buildings concerning operational energy, moderated indoor temperatures, and comfort; the dynamic operation to provide grid services; and resilience in times of power outage. Through the corroboration of simulation models with real-world measurements, this study paves the way for extrapolating findings to other climatic zones and building typologies, thereby broadening the understanding of CLT’s multifaceted benefits and reinforcing its position as a material of choice in sustainable construction.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Battery500 Consortium: Development of High Capacity Cathodes and Robust Solid Electrolytes

As the world have witnessed the tremendous development in portable electronic devices as well as electric vehicles, the current generation lithium-ion battery is unlikely to satisfy the bourgeon of market and the demand of the customers. A next generation battery, with cell energy density higher than 500 Wh kg -1 , needs to be developed to meet the growth of the industry. With its high theoretical capacity (3,860 mAh g -1 , or 2,061 mAh cm -3 ) and low electrochemical potential (–3.04 V versus the standard hydrogen electrode), lithium metal has been regarded as the ideal candidate for the next generation battery anode. In fact, Lithium metal anode is irreplaceable for Lithium-Sulfur chemistry. However, the continuous formation of inactive Li, which eventually leads the loss of reversible capacity of the cell, has prevented lithium metal to be used as anode in commercial rechargeable cells. The ultimate goal of the project is to propose a pathway to enable Li metal battery for stable cycling at 99.9% of Coulombic efficiency with energy density higher than 500 Wh kg -1 . A variety of advanced characterization tools, electrolyte systems, 3D current collectors and failure analysis methodologies have been developed throughout the project during the past 5 years. The UCSD effort is carried out by the groups of Ping Liu and Shirley Meng.

25 ENERGY STORAGE↗
DOE OSTI2024

Measurement-Based Approach for Inertia-Trend Analysis of the US Western Interconnection

Rising deployment of inverter-based resources (IBRs), characterized by a lack of rotating mass, is decreasing the total inertia of the system. This can lead to an increased Rate of Change of Frequency (RoCoF) during the disturbance and false activation of protective devices. There is a need to assess the inertia over the past decade amidst the evolving landscape of renewable energy sources to develop strategies for integrating energy storage, enhancing resilience measures, and ensuring the stable and reliable operation of the grid. Therefore, a realistic assessment of the inertia trend using a measurement-based approach that addresses the limitations of existing models is proposed. An inertia study of the Western Interconnection in the United States is performed utilizing the data from 2013 to 2022, obtained from FNET/ GridEye network. The three-second RoCoF time window is chosen for the study as it showed an optimum balance between a strong correlation with the power imbalance (ΔP) and minimum inclusion of primary response from governor. The obtained inertia trend result shows a small percentage declination of inertia over the decade. By examining the result alongside a generation mix graph, insights are gained into the dynamic interplay between shifting energy landscape and system inertia.

Dulal, Saurav↗
DOE OSTI2021

Stabilizing electrode–electrolyte interfaces to realize high-voltage Li||LiCoO 2 batteries by a sulfonamide-based electrolyte

High-voltage lithium-metal batteries (LMBs) with LiCoO 2 (LCO) as the cathode have high volumetric and gravimetric energy densities. However, it remains a challenge for stable cycling of LCO >4.5 V Li . Here we demonstrate that a rationally designed sulfonamide-based electrolyte can greatly improve the cycling stability at high voltages up to 4.7 V Li by stabilizing the electrode–electrolyte interfaces (EEIs) on both the Li-metal anode (LMA) and high-voltage LCO cathode. With the sulfonamide-based electrolyte, commercial LCO cathodes retain 89% and 85% of their capacities after 200 and 100 cycles under high charging voltages of 4.55 V Li and 4.6 V Li , respectively, significantly outperforming traditional carbonate-based electrolytes. The surface degradation, impedance growth, and detrimental side reactions in terms of gas evolution and Co dissolution are well suppressed. Our work demonstrates a promising strategy for designing new electrolytes to realize high-energy Li||LCO batteries.

25 ENERGY STORAGE↗
DOE OSTI2022

Optimizing the Operational Parameters of an Electrochemical Purification Cell for Corrosion Mitigation in CSP Plants During Operation: Preprint

To make concentrating solar power (CSP) cost-competitive, the next generation of CSP plants will increase efficiency by operating at a higher temperature, which will require a new thermal energy storage material. One option for the thermal energy storage material is a ternary chloride salt that is stable at the temperatures required, but reacts easily with the atmosphere to form MgOHCl, a corrosive impurity. If left unchecked, this impurity will corrode the containment alloys, potentially leading to dangerous spills. We are working to design an electrochemical purification cell to remove MgOHCl from the molten chloride salt during CSP plant operation. In this paper, we use predictive modeling to assess the rate at which purification must occur. Additionally, we analyze possible process flow pathways for the molten chloride salts. Ultimately, we determine that implementation of a single reactor through which all chloride salts flow is the most efficient design to reduce impurity concentration below 0.1 mol % impurity.

concentrating solar power↗
DOE OSTI2024

Sustainable and Energy-Efficient Production of Rare-Earth Metals via Chloride-Based Molten Salt Electrolysis

Neodymium metal is a critical component of rare earth magnets, essential for electric vehicles and the green energy transition, but its production has severe environmental impacts across its mining, separation, purification, and metal electrowinning steps. Specifically, conventional neodymium electrowinning in oxyfluoride molten salts using a consumable graphite anode generates greenhouse gases, e.g., carbon dioxide and perfluorocarbon (PFC). We propose an alternative chloride-based molten salt electrolysis process utilizing a novel dimensionally stable anode (DSA). Our process lowers the specific electrical energy consumption compared to the state of the art, while producing reusable chlorine gas and eliminating direct CO 2 and PFC emissions. Chloride-based molten salt electrolysis of NdCl 3 (1.65 M) added to a LiCl–KCl eutectic (45:55 wt %), while using a RuO 2 -coated DSA enables high Coulombic efficiency (>80%), low specific energy consumption (2.3 kWh/kg-Nd), and excellent electrowon Nd product purity (>97 wt %). Life cycle analysis, excluding the common input feedstock (Nd 2 O 3 ), shows that the global warming potential for the proposed chloride-based electrolysis approach is 5 kg CO 2 equivalent, compared to 9–16 kg CO 2 equivalent for the conventional process, representing a 44–69% reduction in CO 2 emissions.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Optimization-based algorithms for nonlinear mechanics and frictional contact

An optimization-based strategy for solving nonlinear mechanics problems is proposed. In contrast to typical nonlinear equation solver algorithms that aim to find zeros in the residual force function, we minimize an energy (or energy-like) function to encourage solutions which are locally stable equilibria. These smooth and potentially non-convex objective functions are minimized using a preconditioned conjugate-gradient trust-region algorithm. Contact is formulated as an inequality constrained minimization problem, and is solved with an augmented Lagrangian algorithm. Friction is included in the approach via a regularized quasi-potential energy, and other dissipative behavior is included through the use of variational constitutive updates. Finally, to accelerate convergence rates for the Lagrange multipliers, we propose a novel multiplier update algorithm utilizing the Fischer-Burmeister function, and demonstrate super-linear solver convergence for some applications.

42 ENGINEERING↗