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At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

A Comparative Radiative Property Evaluation of Sintered Bauxite and AMS4003 Ceramic Particles

The radiative properties of sintered bauxite (ACCUCAST ID80) and AMS4003 particles were measured and compared to assess their performances as direct absorption and heat transfer media for particle-based concentrated solar power (CSP) plants. Reflectance measurements were performed over the spectral range 0.2–20 µm and used to calculate solar and thermal emission properties of the particles. In addition, reflectance was measured as a function of temperature up to 1000 °C for the spectral range 1–20 µm. The solar absorptance of AMS4003 was greater than that of ACCUCAST both before and after thermal cycling of the materials at 1000 °C, although thermal cycling was found to substantially decrease the solar absorptance of both materials. The thermal emittance of AMS4003 was also greater than that of ACCUCAST at all temperatures tested. Finally, the radiaitve properties measured in this study were used to estimate absorber efficiencies as a way to compare the particles in terms of their performance in a solar receiver. AMS4003 yielded greater efficiencies than ACCUCAST, suggesting its potential as a material for CSP.

14 SOLAR ENERGY↗
DOE OSTI2018

Sulfur Removal by Adding Iron During the Digestion Process of High-sulfur Bauxite

This paper proposes a novel approach to sulfur removal by adding iron during the digestion process. Iron can react with high-valence sulfur (S{sub 2}O{sub 3}{sup 2−}, SO{sub 3}{sup 2−}, SO{sub 4}{sup 2−}) to generate S{sup 2−} at digestion temperature, and then S{sup 2−} enter red mud in the form of Na{sub 3}FeS{sub 3} to be removed. As iron dosage increases, high-valence sulfur concentration decreases, but the concentration of S{sup 2−} increases; sulfur digestion rate decreases while sulfur content in red mud markedly increases; the alumina digestion rate, conversely, remains fairly stable. So sulfur can be removed completely by adding iron in digestion process, which provide a theoretical basis for the effective removal of sulfur in alumina production process.

36 MATERIALS SCIENCE↗
DOE OSTI2017

System Dynamics Analysis of Strategies to Reduce Energy Use in Aluminum-Intensive Sectors

Aluminum is one of the most widely used materials in industry, with applications in buildings, vehicles, aircraft, and consumer products. Its ubiquity is also on the rise: aluminum is beginning to supplant steel in lightweight vehicles and aircraft, and is used in many green or LEED-certified buildings. Although aluminum tends to be highly recycled, particularly by manufacturers of aluminum products, the sector as a whole is still far from a closed system. As a result, the increase in aluminum consumption also means an increase in primary aluminum production-an energy-intensive process-and an increase in consumption of the raw material bauxite, which in the U.S. is almost entirely imported. Our objectives for this study are to identify and analyze aluminum sector technologies and practices that reduce the energy required to manufacture aluminum products and reduce U.S. dependence on imported aluminum and bauxite. To accomplish these objectives, we will develop a system dynamics (SD) model of aluminum production, use and recycling in key application areas, including aerospace, ground vehicles and consumer products. The model will cover the entire aluminum supply chain as it exists in the U.S., from bauxite importing and refining, to the manufacture of products, to the product use phase and end-of-life processing steps. Aluminum flows throughout the model will be determined by the annual domestic demand for each application area as well as demand projections that extend to 2030. Energy consumption will be tracked based on the flows of aluminum through each step of the supply chain. Using the SD model, we will evaluate several technologies and practices that have the potential to reduce energy consumption and reliance on imported bauxite. These include implementation of advanced primary aluminum production technologies, increased recycling within and between application areas, increased material efficiency and increased product lifetimes. Each of these strategies results in short term reductions in energy use, and every strategy except the advance production technologies will also reduce the need for imported bauxite. This model differs from other SD models previously built to study aluminum stocks and flows in two key areas- alloy recycling and product lifetimes. Aluminum recycling is frequently complicated by the need to maintain quality of many different alloys, especially in aerospace applications. This necessitates scrap sorting and product disassembly to avoid contamination; advanced recycling processes of this type are one of the strategies to be evaluated. Product lifetime similarly complicates aluminum recycling, as products with longer lifetimes yield smaller recycling streams compared to disposable or short lifetime products, such as soda cans. When these additional complexities are accounted for in the SD model, a more realistic idea of the short term and long term impacts of the various strategies can be captured, as can any potential synergies and trade-offs between the strategies. Results of the analysis will indicate which strategy, or combination of strategies, yields the lowest cumulative energy consumption and bauxite consumption required to satisfy current and future demand for aluminum products.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2014

Invited Article: In situ comparison of passive radon-thoron discriminative monitors at subsurface workplaces in Hungary

During a one-year long measurement period, radon and thoron data obtained by two different passive radon-thoron discriminative monitors were compared at subsurface workplaces in Hungary, such as mines (bauxite and manganese ore) and caves (medical and touristic). These workplaces have special environmental conditions, such as, stable and high relative humidity (100%), relatively stable temperature (12°C–21°C), low or high wind speed (max. 2.4 m s{sup −1}) and low or elevated aerosol concentration (130–60 000 particles m{sup −3}). The measured radon and thoron concentrations fluctuated in a wide range among the different workplaces. The respective annual average radon concentrations and their standard deviations (in brackets) measured by the passive radon-thoron discriminative monitor with cellulose filter (CF) and the passive radon-thoron discriminative monitor with sponge filter (SF) were: 350(321) Bq m{sup −3} and 550(497) Bq m{sup −3} in the bauxite mine; 887(604) Bq m{sup −3} and 1258(788) Bq m{sup −3} in the manganese ore mine; 2510(2341) Bq m{sup −3} and 3403(3075) Bq m{sup −3} in the medical cave (Hospital Cave of Tapolca); and 6239(2057) Bq m{sup −3} and 8512(1955) Bq m{sup −3} in the touristic cave (Lake Cave of Tapolca). The respective average thoron concentrations and their standard deviation (in brackets) measured by CF and SF monitors were: 154(210) Bq m{sup −3} and 161(148) Bq m{sup −3} in the bauxite mine; 187(191) Bq m{sup −3} and 117(147) Bq m{sup −3} in the manganese-ore mine; 360(524) Bq m{sup −3} and 371(789) Bq m{sup −3} in the medical cave (Hospital Cave of Tapolca); and 1420(1184) Bq m{sup −3} and 1462(3655) Bq m{sup −3} in the touristic cave (Lake Cave of Tapolca). Under these circumstances, comparison of the radon data for the SF and CF monitors showed the former were consistently 51% higher in the bauxite mine, 38% higher in the manganese ore mine, and 34% higher in the caves. Consequently, correction is required on previously obtained radon data acquired by CF monitors at subsurface workplaces to gain comparable data for SF monitors. In the case of thoron, the data were unreliable and no significant tendency was seen during the comparison therefore comparison of previously obtained thoron data acquired by either CF or SF is doubtful. There was probable influence by relative humidity on the detection response; however, the effects of the high wind speed and elevated aerosol concentration could not be excluded. The results of this study call attention to the importance of calibration under extreme environmental conditions and the need for using reliable radon-thoron monitors for subsurface workplaces.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Techno-economic and life cycle assessment of aluminum electrorefining from mixed scraps using ionic liquid

Aluminum production from bauxite ore uses significantly high amount of energy and capital expenditure. Recycle and reuse of aluminum can be economical and minimize the environmental impacts. Smelter based recycle and reuse of aluminum is used in recent days, however, it also uses high amount of energy with high cost of production and yields high life cycle impacts. The University of Alabama has developed aluminum electrorefining technology from mixed scraps using ionic liquids as an alternative to traditional smelter based recycle and reuse. This study has explored the techno-economical, and life cycle viability of that technology. An excel-based techno-economic and life cycle assessment model was developed at Idaho National Laboratory for techno-economic and life cycle assessment. SimaPro was used to get the necessary database for the life cycle assessment. This study determined that a 20,000 kg/day ionic liquid-based electrorefining system can be profitable with a net yearly profit of $2.00 million. Further, in terms of net global warming potential, it emits 0.92 kg CO 2 equivalent per kg of aluminum recycled, whereas the traditional smelter-based recycle technology emits 1.57 kg CO 2 equivalent per kg of aluminum recycled, and the aluminum production from bauxite ore emits 17.8 kg CO 2 equivalent per kg of aluminum produced. In other life cycle assessment categories, electrorefining of aluminum emits >88 % less than aluminum production from bauxite ore and it is also better than traditional aluminum recycling in six out of ten categories studied. This makes ionic liquid-based electrorefining technology a very promising technology in terms of process economics and environmental sustainability.

36 MATERIALS SCIENCE↗
DOE OSTI2013

In-situ subaqueous capping of mercury-contaminated sediments in a fresh-water aquatic system, Part II-evaluation of sorption materials

The function and longevity of traditional, passive, isolation caps can be augmented through the use of more chemically active capping materials which have higher sorptive capacities, ideally rendering metals non-bioavailable. In the case of Hg, active caps also mitigate the rate and extent of methylation. This research examined low cost, readily available, capping materials for their ability to sequester Hg and MeHg. Furthermore, selected capping materials were evaluated to inhibit the methylation of Hg in an incubation study as well as the capacity of a selected capping material to inhibit translocation of Hg and MeHg with respect to ebullition-facilitated contaminant transport in a column study. Results indicated that bauxite had a better capacity for mercury sorption than the other test materials. However, bauxite as well as soil capping materials did not decrease methylation to a significant extent. Materials with larger surface areas, higher organic matter and acid volatile sulfide (AVS) content displayed a larger partitioning coefficient. In the incubation experiments, the presence of a carbon source (lactate), electron acceptor (sulfate) and the appropriate strains of SRB provided the necessary conditions for Hg methylation to occur. The column study showed effectiveness in sequestering Hg and MeHg and retarding transport to the overlying water column; however, disturbances to the soil capping material resulting from gas ebullition negated its effectiveness.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Investigation of Solid Particle Reactors for Nonoxidative Dehydrogenation of Ethane: Toward Solar Thermal Ethylene Production

Concentrating solar power plants can generate renewable heat at temperatures well above those of most industrial processes. Ceramic particles irradiated with concentrated sunlight can store high-quality sensible heat and transfer this to power generation systems. These concepts and materials hold great potential to also enable thermal processes in the chemical industry, but effective strategies for transferring heat from thermal energy storage media into chemical reactors are still under development. This present work evaluated the thermal and chemical compatibility of various solid particle media (including quartz, bauxite, and alumina particles) integrated directly into tube reactors and the subsequent effects on reactor performance for the nonoxidative dehydrogenation of ethane reaction. Empty tube reactors without loaded particles (representing conventional ethane cracking coils) showed significant heat transfer limitations as the tube diameter was scaled. The incorporation of media into the reactor significantly aided heat transfer to the gaseous ethane reactant and increased its conversion by as much as 10% at similar space velocities. Despite direct contact with hydrocarbon gases, alumina and quartz media showed negligible coke formation. Even during reaction in 100% ethane feed gas at 825 °C, the average selectivity of the coke product was only 0.57% when using the quartz media. These materials further demonstrated excellent thermal stability during subsequent reoxidation in air at 800 °C, which simulated the reheating of particles in a circulating particle solar receiver. Conversely, high rates of coke formation, with a product selectivity of 27.5%, were observed on sintered bauxite particles during the reaction, likely promoted by transition metal constituents. These particles fractured upon reoxidation due to exotherms generated from coke combustion. In conclusion, while the use of cofed steam could mitigate attrition of redox-active particles, the ability of inert metal oxide particles to efficiently transfer heat to concentrated ethane reactant gas while suppressing side reactions or degradation suggests that these media could effectively couple solar thermal plants to reactors for next-generation production of ethylene and other critical chemicals.

Hydrocarbons↗
DOE OSTI2012

Recovery Act: Innovative CO 2 Sequestration from Flue Gas Using Industrial Sources and Innovative Concept for Beneficial CO 2 Use

The overall goal of this DOE Phase 2 project was to further develop and conduct pilot-scale and field testing of a biomimetic in-duct scrubbing system for the capture of gaseous CO 2 coupled with sequestration of captured carbon by carbonation of alkaline industrial wastes. The Phase 2 project, reported on here, combined efforts in enzyme development, scrubber optimization, and sequestrant evaluations to perform an economic feasibility study of technology deployment. The optimization of carbonic anhydrase (CA) enzyme reactivity and stability are critical steps in deployment of this technology. A variety of CA enzyme variants were evaluated for reactivity and stability in both bench scale and in laboratory pilot scale testing to determine current limits in enzyme performance. Optimization of scrubber design allowed for improved process economics while maintaining desired capture efficiencies. A range of configurations, materials, and operating conditions were examined at the Alcoa Technical Center on a pilot scale scrubber. This work indicated that a cross current flow utilizing a specialized gas-liquid contactor offered the lowest system operating energy. Various industrial waste materials were evaluated as sources of alkalinity for the scrubber feed solution and as sources of calcium for precipitation of carbonate. Solids were mixed with a simulated sodium bicarbonate scrubber blowdown to comparatively examine reactivity. Supernatant solutions and post-test solids were analyzed to quantify and model the sequestration reactions. The best performing solids were found to sequester between 2.3 and 2.9 moles of CO 2 per kg of dry solid in 1-4 hours of reaction time. These best performing solids were cement kiln dust, circulating dry scrubber ash, and spray dryer absorber ash. A techno-economic analysis was performed to evaluate the commercial viability of the proposed carbon capture and sequestration process in full-scale at an aluminum smelter and a refinery location. For both cases the in-duct scrubber technology was compared to traditional amine- based capture. Incorporation of the laboratory results showed that for the application at the aluminum smelter, the in-duct scrubber system is more economical than traditional methods. However, the reverse is true for the refinery case, where the bauxite residue is not effective enough as a sequestrant, combined with challenges related to contaminants in the bauxite residue accumulating in and fouling the scrubber absorbent. Sensitivity analyses showed that the critical variables by which process economics could be improved are enzyme concentration, efficiency, and half-life. At the end of the first part of the Phase 2 project, a gate review (DOE Decision Zero Gate Point) was conducted to decide on the next stages of the project. The original plan was to follow the pre-testing phase with a detailed design for the field testing. Unfavorable process economics, however, resulted in a decision to conclude the project before moving to field testing. It is noted that CO 2 Solutions proposed an initial solution to reduce process costs through more advanced enzyme management, however, DOE program requirements restricting any technology development extending beyond 2014 as commercial deployment timeline did not allow this solution to be undertaken.

Dando, Neal↗
DOE OSTI2019

Correction to: Treatment of Fat-Containing Wastewater Using Binary Flocculant Mixtures Based on Chitosan and Quaternary Salt of Poly(2-dimethylamino)ethyl Methacrylate

The original version of this article unfortunately contained an error in the article title of Ref. [22]. The correct reference is given below: Bigogno RG, Rodríguez RJS, Abreu MF (2018) Quaternized chitosan for ecological treatment of bauxite mining effluents. J Polym Environ 26:4169.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

Simultaneous Removal of Silicon and Iron-Rich Phases from Coarse Al-Si Alloys Using Manganese Under Electromagnetic Field

Coarse Al-Si alloy is produced from bauxite via carbon electro-thermal reduction method. Silicon and iron-rich phases are two main detrimental impurities in coarse Al-Si alloy, and they can be simultaneously removed by adding Mn under the electromagnetic field. We focus on the influence of different Mn additions, dropping rates, and current intensity on the simultaneous removal efficiency of Si and Fe. Experimental results show that as mole ratio of Mn/Fe reaches more than 0.8, the morphology of iron-rich phases together with silicon changed from harmful acicular-like to the contributing bulks, concentrated at the bottom of Al-Si alloy as intermetallic compounds. Furthermore, when Mn/Fe reaches 1.2 and a lower dropping rate (5 to 25 μm/s) is adopted, both Si and Fe contents in the Al-Si alloy decreased drastically after electromagnetic directional solidification process, reaching 11.42 and 0.4 pct, respectively, with a desirable Fe removal efficiency of 91 pct. Finally, the principle of simultaneously separating Si and removing iron-rich phases from Al-Si alloy is studied deeply.

36 MATERIALS SCIENCE↗
DOE OSTI2011

Red mud characterization using nuclear analytical techniques

Red mud is a toxic waste left as a byproduct in aluminum production Bayer process. Since it contains significant concentrations of other chemical elements interesting for industry, including REE, it is also potential secondary ore source. Recent events in some countries have shown that red mud presents a serious environmental hazard if not properly stored. The subject of our study is the red mud from an ex-aluminum plant in Obrovac, Croatia, left from processing of bauxite mined during late 70's and early 80's at the eastern Adriatic coast and since than stored in open concrete basins for more than 30 years. We have used energy dispersive x-ray fluorescence analysis (both tube and radioactive source excitation), fast neutron activation analysis and passive gamma spectrometry to identify a number of elements present in the red mud, their concentration levels and radioactivity in the red mud. The high concentrations of Al, Si, Ca, Ti and Fe have been measured. Chemical elements Sc, Cr, Mn, Co, Ni, Cu, Zn, Ga, As, Se, Br, Y, La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Pb, Th and U were found in lower concentrations. No significant levels of radioactivity have been measured. (authors)

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

Rare earth elements from waste

Rare earth elements (REEs) are critical materials in electronics and clean technologies. With the diminishing of easily accessible minerals for mining, the REE recovery from waste is an alternative toward a circular economy. Present methods for REE recovery suffer from lengthy purifications, low extractability, and high wastewater streams. Here, we report an ultrafast electrothermal process (~3000°C, ~1 s) based on flash Joule heating (FJH) for activating wastes to improve REE extractability. FJH thermally degrades or reduces the hard-to-dissolve REE species to components with high thermodynamic solubility, leading to ~2× increase in leachability and high recovery yields using diluted acid (e.g., 0.1 M HCl). The activation strategy is feasible for various wastes including coal fly ash, bauxite residue, and electronic waste. The rapid FJH process is energy-efficient with a low electrical energy consumption of 600 kWh ton –1 . The potential for this route to be rapidly scaled is outlined.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2019

Feasibility and Concurrent Remediation of Red Mud as an in situ Pyrolysis Catalyst

Catalytic pyrolysis may serve as an alternative production strategy to petroleum-derived fuels and chemicals. Furthermore, red mud, a toxic industrial bauxite byproduct, could serve as a sustainable catalyst and overcome the need for more robust catalysts. To test this, in situ catalytic pyrolysis was run on a semi-pilot scale reactor with various ratios of red mud and switchgrass (Panicum virgatum). Authors hypothesized that the coking process would render red mud environmentally friendly, improve soil quality, and yield for bioenergy crop production, like biochar. Therefore, this work investigated red mud’s capability to enhance bio-oil quality, as well as, how the modified biochar produced from in situ pyrolysis affected switchgrass seedling vigor, and root/shoot mass. The results indicated that red mud was effective at increasing soil pH and biochar and bio-oil yields, while reducing the total acid number in bio-oil. While a high loading of reacted red mud had a negative impact on plant yield, the addition of uncatalyzed biochar to pure red mud considerably improved the seedling yield in marginal soils. These results suggest that this technology has potential for valorizing a waste stream and creating a soil amendment from red mud that closes nutrient and bioenergy production cycles while potentially reducing soil pollution.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2011

Combined Application of QEM-SEM and Hard X-ray Microscopy to Determine Mineralogical Associations and Chemcial Speciation of Trace Metals

We describe the application of quantitative evaluation of mineralogy by scanning electron microscopy in combination with techniques commonly available at hard X-ray microprobes to define the mineralogical environment of a bauxite residue core segment with the more specific aim of determining the speciation of trace metals (e.g., Ti, V, Cr, and Mn) within the mineral matrix. Successful trace metal speciation in heterogeneous matrices, such as those encountered in soils or mineral residues, relies on a combination of techniques including spectroscopy, microscopy, diffraction, and wet chemical and physical experiments. Of substantial interest is the ability to define the mineralogy of a sample to infer redox behavior, pH buffering, and mineral-water interfaces that are likely to interact with trace metals through adsorption, coprecipitation, dissolution, or electron transfer reactions. Quantitative evaluation of mineralogy by scanning electron microscopy coupled with micro-focused X-ray diffraction, micro-X-ray fluorescence, and micro-X-ray absorption near edge structure (mXANES) spectroscopy provided detailed insights into the composition of mineral assemblages and their effect on trace metal speciation during this investigation. In the sample investigated, titanium occurs as poorly ordered ilmenite, as rutile, and is substituted in iron oxides. Manganese's spatial correlation to Ti is closely linked to ilmenite, where it appears to substitute for Fe and Ti in the ilmenite structure based on its mXANES signature. Vanadium is associated with ilmenite and goethite but always assumes the +4 oxidation state, whereas chromium is predominantly in the +3 oxidation state and solely associated with iron oxides (goethite and hematite) and appears to substitute for Fe in the goethite structure.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

The Beneficial Effect of Iron in Aluminum-Cerium-Based Cast Alloys

Iron (Fe) has been considered a major impurity since it is detrimental to the mechanical properties of many cast aluminum alloys due to the formation of Fe-containing brittle intermetallic phases. Fe is found naturally as an impurity in bauxite ore, resulting in Fe contamination of aluminum alloys with increasing contamination from current recycling practices. The Al–Ce–Fe system was investigated using CALPHAD (CALculation of PHAse Diagrams) modeling and experimental casting techniques. It was found that additions of Fe to the Al–Ce system are beneficial to the strength (slightly) and ductility (significantly) of the ternary alloys, which is attributed to the formation of fine metastable Al 8 CeFe 2 phase with aggregate morphology and equilibrium Al 10 CeFe 2 phase, suppressing coarse proeutectic Al 11 Ce 3 phase in near-eutectic Al–Ce alloys. Heat treatment study showed that the metastable Al 8 CeFe 2 phase transforms to predicted equilibrium Al 10 CeFe 2 phase at 500 °C, with essentially no intermetallic or grain coarsening; thus, the alloy displayed excellent property retention. The Al–Ce–Fe alloy system offers opportunities for sustainable, recyclable alloy development using low-cost Fe and low-cost cerium (a byproduct of rare-earth extraction).

42 ENGINEERING↗
DOE OSTI2020

Measurement of flow properties coupled to experimental and numerical analyses of dense, granular flows for solar thermal energy storage

Granular flows of sintered bauxite proppants were researched along an inclined plane for solar thermal energy storage applications. Granular flow properties needed to drive numeric granular models were measured for improved numerical model predictions for Carbobead CP 50/140, 40/100, and 30/60 particles. Particle shape and size distributions were determined by coupling optical microscopy to an in-house image processing algorithm. The impulse excitation technique was used to measure elastic and shear moduli, and compute Poisson’s ratio. The coefficient of static sliding friction was measured using the slip-stick method, and the static rolling friction was determined from measured shear on particles positioned between two hot-pressed plates. The coefficient of restitution was measured by dropping particles on a surface and determining the kinetic energy before and after impact with the surface using high resolution particle tracking velocimetry. Particle size did not significantly impact the coefficients of restitution and static rolling friction, however, particle shape distribution resulted in a large variation in measurements. An inclined flow experiment was performed to characterize granular flows of Carbobead CP 30/60 particles using particle image velocimetry. Numerical models of the experiment using discrete element method were generated with the measured mechanical properties as inputs for comparison with experimental results. A constant directional torque rolling friction model best predicted bulk granular flow behavior. Furthermore, good agreement between the model and experiment was achieved at ambient, steady state conditions, with average velocity differences <10%.

14 SOLAR ENERGY↗