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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Low Weight, High Strength Coal-Based Building Materials for Infrastructure Products (Rev.A)

Semplastics has developed, tested, and proven the viability of a new class of composite infrastructure components that use coal as the primary component. Phase I resulted in the production of brick and block components, called X-BRIX and X-BLOX, with dimensions comparable to commercially available bricks and concrete blocks, but with superior mechanical strength, lower weight, greater hardness, improved toughness, greater abrasion resistance, and greater chemical resistance than concrete. Multiple samples of full-size (16” × 8” × 8”) X-BLOX and full-size (8” × 4” × 2.5”) X-BRIX were made to demonstrate the technology, and to support the development of mortar or joining techniques. Phase I moved the coal-based composite materials technology from a current Technology Readiness Level (TRL) of 3 to TRL 5. Semplastics’ coal-based composite materials exhibit a number of high-performance characteristics, including high strength (five times the flexure strength of the best commercial brick, and more than twice the compressive strength of construction-grade concrete block), lower density (by 37 to 41%), improved mechanical durability and abrasion resistance, and resistance to chemicals, acids, salts, and chemical wastewater. These properties offer significant improvements over conventional bricks, concrete blocks, and pavers. The coal particles are completely encapsulated and bonded using a specially formulated polymer-derived ceramic (PDC) that is cured to form an “aggregate” of coal and PDC resin. This aggregate can be further processed and lightly pressed (at 10 to 50 psi) to produce a brick. After pyrolyzing (similar to the processing used to make standard clay bricks), the finished coal-based brick is significantly harder and more abrasion-resistant than regular bricks. We have produced prototype X-BRIX and X-BLOX that contain at least 55% coal by weight (71% carbon by weight, due to the controlled carbon content of the PDC) and showed their superior mechanical properties through in-house and contracted testing.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2026

Biobased Flame Retardants Towards Sustainable Building Materials with Low Embodied Carbon

Incorporation of fire retardants in different types of products is one of the essential steps in the material production process to minimize fire risk and meet fire safety requirements. A variety of commonly used flame retardants based on halogen, mineral, and other compounds has gained popularity due to their efficient flame-retardant behaviors. However, especially in the case of halides, there are numerous toxicity related issues and environmental pollution effects that have urged the building sector to deviate from their use and focus on the development of non-toxic alternatives. Therefore, to enhance the safety of flame retardants, the synthesis of flame retardants from waste feedstocks using phosphorous chemistry with a dual flame-retardant mechanism has been established. A range of waste feedstocks that include cardanol, vanillin, and gallic acids has been converted into a series of flame retardants using a one-step approach by incorporating phosphorous moieties into their structures. The established pathways allow to develop a range of flame-retardant materials by converting waste feedstocks into phosphorous-based materials with inherent flame retardancy. The introduction of abundant aromatic structures from biobased feedstocks enables high charring capabilities in materials in which these biobased flame retardants have been incorporated, increasing their char yields which significantly enhances the flame suppressing properties of the designed materials. Studies show that inclusion of phosphoric moieties into structures allows the displacement of flame enhancing radicals, by releasing non-flammable and non-toxic gases, therefore inhibiting the spread of fire in the gas phase. The resulting biobased flame retardants have been incorporated in wood substrates, foam insulation, and hemp fibers where the results show that only 1-5% of loading of biobased flame retardant suppressed the flame completely. This study represents a novel approach for the development of flame retardants with high performance while utilizing waste feedstocks as a source for their design.

Demchuk, Zoriana [ORNL] (ORCID:0000000326292235)↗
DOE OSTI2022

Biochar as a Building Material: Sequestering Carbon and Strengthening Concrete

It is possible to offset the carbon footprint of concrete by 60 kg (132 lbs) per cubic yard of ready-mix by deeply sequestering carbon with an engineered biochar additive. Our multidisciplinary team specializing in char production and cementitious materials has demonstrated that for every ton of cement, adding 100 kg of engineered biochar will not only lock in carbon, but also strengthen concrete in all key dimensions via enhancements to hydration and integration into the hardened matrix. As a non-chemical, inert additive the cement sequestration (CemSeq) char product can fully complement other powerful tools to reduce cement emissions and unlock the possibility for carbon negative concrete by 2050. The key findings of our initial research have shown that to achieve this the following are required: tailored milling of the char, using fast pyrolysis to produce the char, and modulating the cement flowability.

biochar↗
DOE OSTI2024

Electrochemically Enhanced Carbonate Precipitation into Building Materials: A Scalable Carbon Sequestration Strategy

Decarbonization goals across hard-to-abate industries have prompted an urgent need for advanced carbon capture and storage technologies. Sequestering CO2 into carbonate minerals is a scalable method of carbon management with the ability to produce value-added carbon negative materials from waste streams for the construction industry. Waste streams rich in Ca and Mg such as nickel mine tailings, iron/steel slag, and reverse osmosis brines can store 7.6 Mt CO2/year as minerals. Additionally, CO2 mineralization in acid-neutralization processes currently present in industrial waste treatment can eliminate associated CO2 emissions of lime processing by improving process circularity. The carbonate minerals formed from these waste sources are valuable as components of carbon-negative concrete, which have the potential to sequester 1.8 billion Mt of CO2/year. Electrochemical means of CO2 mineralization improves the kinetics of the thermodynamically favorable mineralization process, lessening or eliminating the high energy requirements of traditional methods. Here, we investigate benchtop scale electrochemical CO2 mineralization of alkaline mining waste, highlighting the effects of key constituents in mining waste on the mineralization process.

carbon capture↗
DOE OSTI2024

Developing a Database of Bio-based Materials for Building Envelope Applications

Oak Ridge National Laboratory (ORNL) has been funded by the Department of Energy (DOE) to help accelerate the introduction of building envelope materials that would reduce the carbon footprint of the buildings sector. The DOE’s Building Technologies Office has historically sought to resolve the knowledge gaps regarding the energy efficiency and moisture durability of building envelope systems and to develop the data, guidance, and tools needed to facilitate rapid industry adoption of high-performance, moisture-managed envelope systems. This project will help accelerate the widespread acceptance of a new generation of building materials developed specifically with the intent of reducing the carbon footprint of buildings. We have produced a database of hygrothermal transport properties on low embodied carbon building materials that can be added to energy and durability simulation tools. Properties that were measured include density, heat capacity, thermal conductivity as a function of temperature and relative humidity, moisture dependent permeance, and sorption isotherms as a function of relative humidity. These data sets were measured following consensus national standards using state-of-the-art facilities. The data has been compiled and is being made available to building designers who require these data to assess these new materials in their designs. We will publish the data and seek its addition to reference databases such as the ASHRAE Handbook of Fundamentals.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Assessing the hygrothermal performance of bio-based materials in building wall systems

Building envelope systems are crucial in regulating thermal and moisture exchange between interior and exterior environments, accounting for approximately 28 % of building energy consumption in the United States with walls being the primary contributors. Improper selection of building envelope materials can lead to moisture-related issues, reduced resilience, and compromised durability. Hygrothermal performance assessment is a key factor in efficient building design. As such, improving the energy and hygrothermal performance of opaque wall materials, through careful assessment of material choices, is essential to enhancing building resilience, lowering energy costs, and improving occupant comfort. As the building industry seeks new strategies to reduce material energy intensity, bio-based materials emerge as a promising solution. However, their long-term hygrothermal performance in building envelope systems remains underexplored. To fill this gap, this study evaluates the hygrothermal behavior of 13 bio-based materials in residential wall systems across three U.S. climate zones. Laboratory experiments were performed to measure material properties such as density, thermal conductivity, moisture transmission, and sorption isotherms. These data were integrated into the WUFI® simulation tool to assess wall hygrothermal performance in Houston, Baltimore, and Chicago. A three-phase modeling approach was used: (1) baseline residential walls with oriented strand board (OSB) and gypsum board; (2) replacing OSB with bio-based materials; and (3) replacing drywall with bio-based materials. Results showed that the evaluated bio-based materials maintained acceptable moisture thresholds of ≤ 16 % across all climates, confirming their viability as an alternative for current sheathing materials. Furthermore, this study provides a foundation for future research and innovation in material science on the use of certain bio-based materials in high-performance, low energy use residential construction. Ultimately, providing critical data, offering a database of bio-based material properties, and supplying a simulation-based approach will help designers make informed decisions for future efficient building practices.

Bio-based materials↗
DOE OSTI2025

Thermal performance and energy consumption validation of an occupied local government office building outfitted with ceiling tile phase change materials

Buildings present an opportunity for energy conservation and the modulation of peak energy demand through controlled Heating, Ventilation, and Air Conditioning (HVAC) energy use. The administrative and office building stock in the United States holds potential to achieve energy and demand savings through retrofits such as insulation, weatherization, and thermal energy storage. Specifically, there is a need to validate passive phase change material (PCM) applications in full scale in aging administrative buildings in the US to evaluate the energy benefits. Aim of this study was to conduct a whole building level thermal and energy validation of an operational building and explore an alternative method for evaluating energy efficiency. To accomplish this, the study employed PCMs in the drop ceiling and carry out an energy audit and on-site measurement of HVAC systems' energy demand and consumption. A full-scale EnergyPlus energy model, modeled by the authors, served as a baseline for evaluation. The results show that calibrated model's envelope temperature measures fall within the accepted errors. HVAC energy simulation results also fall within the accepted errors for monthly and hourly pre- and post- PCM retrofit electricity and natural gas data. The novelty of this study is that it employees energy scales per Heating Degree Hour and Cooling Degree Hour, in contrast to the commonly used Heating Degree Days and Cooling Degree Days as reported in the literature to analyze energy savings. These findings underscore the pivotal role of a calibrated model in assessing the efficacy of a singular energy measure, like a PCM-retrofitted ceiling, in an occupied office building.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Methods and systems for 3D printing with powders

A method of printing a three dimensional article (201) can include forming a bottom layer of the three dimensional article (201) by spraying a dry build material powder (210) onto a build platform (230) while heating the dry build material powder (210). The dry build material powder (210) can include metal or ceramic particles mixed with a polymeric binder having a softening point temperature. The dry build material powder (210) can be heated to a temperature above the softening point temperature such that the dry build material powder (210) adheres to the build platform (230). Subsequent layers can be formed by spraying dry build material powder (210) onto a lower layer while heating the dry build material powder (210) such that the dry build material powder (210) adheres to the lower layer.

Fang, Zhigang Zak↗
DOE OSTI2021

Whole-building life-cycle analysis with a new GREET® tool: Embodied greenhouse gas emissions and payback period of a LEED-Certified library

Embodied greenhouse gas (GHG) emissions of building components and buildings operations need to be quantified to holistically address building sustainability. To evaluate embodied GHG emissions of buildings and to provide insights on building materials and building design decisions toward decarbonization, we have recently created a building life-cycle assessment (LCA) module in the widely used Greenhouse gases, Regulated Emissions, and Energy use in Technologies (GREET (R)) LCA model. We applied the GREET building LCA module to examine embodied GHG impacts and the payback period of a LEED (Leadership in Energy and Environmental Design) certified public library in Chicago, USA. We developed localized, detailed life-cycle inventories to address individual building materials used in the library. We expanded the LCA system boundary to include the mechanical, electrical, and plumbing system, as well as refrigerant impacts, which are often ignored in previous studies. Results show that the total embodied GHG emissions are approximately 817 metric tons, or approximately 538 kg/m 2 . Sensitivity analysis highlights the positive role of increasing the use of recycled materials for reducing embodied GHG emissions. Sensitivity analysis on embodied GHG emissions payback periods shows the need to benchmark the embodied and operational carbon performance of buildings for comparison to alternative building designs and sustainability practices. Furthermore, this analysis demonstrates that building LCA models, such as the GREET building LCA module, which addresses embodied and operational GHG emission impacts of whole buildings holistically, could empower building architects, technology developers, manufacturers, and general contractors to address embodied and operational impacts holistically for building sustainability.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

A rapid embodied carbon assessment tool for priority materials

Embodied carbon limits within building materials are a driving factor in global trade, generating new research and analysis tools in industry. These product assessments, which require utilizing life-cycle assessment (LCA) across broad supply chains, can be expensive, time and data-intensive, and subject to significant variations. Existing methods and tools, such as specific environmental product declarations, typically do not capture these variations and dynamics in supply and manufacturing. Moreover, models and tools must enable stakeholders to assess customized supply chains and future scenarios. In this study, we present the Rapid Embodied Carbon Assessment and Target-setting for Emissions-intensive Materials (REDuCE) tool for building materials. We developed a tool that allows users to select production technologies, transportation mode and distances, concrete carbonation, fuel sources, and regional electricity mixes to supply customization for cement and concrete produced and consumed in California. We generated and integrated a material demand model using residential building stock projections. We provide the user with a wide range of mitigation alternatives through low-carbon production pathways, material use efficiency, transportation modes, and projected electricity grid mixes. In a case study application through four mitigation scenarios, we find emission savings up to 80% by maximizing user mitigation alternatives, primarily driven by reductions in material use intensities. This work represents a foundation for expanding LCA and embodied carbon tools to better enable stakeholders to rapidly and accurately assess customized supply chains while meeting trade requirements.

building materials↗
DOE OSTI2025

BRE‐X Emissions Database for End‐of‐Life Scenarios of Selective Building Construction Materials to Enable Circular Economy in Construction

In the United States, construction and demolition debris predominately end up in landfills with minimal end‐of‐life Re‐X (recover, recycle, reuse, etc.) scenarios, resulting in large environmental impacts and lost opportunities for material recovery. Except for concrete and metals, which seem to have a few well‐defined end‐of‐life pathways, there seems to be a lack of well‐documented end‐of‐life scenarios for other construction materials, let alone their emissions data. Hence, there is a need for documented end‐of‐life Re‐X scenarios and end‐of‐life data of more building materials to motivate widespread use of Re‐X strategies in building design. This paper outlines the efforts of the National Renewable Energy Laboratory, Carbon Leadership Forum, Building Transparency, and Skidmore, Owings & Merrill to (a) create an open‐access BRE‐X (Building Re‐X) end‐of‐life emissions database consisting of greenhouse gas emissions data associated with various end‐of‐life scenarios for a select list of high‐impact building construction materials, and (b) integrate the BRE‐X end‐of‐life emissions database with CAD/BIM/LCA tools for evaluating various end‐of‐life scenarios. The paper also presents a few existing life cycle inventory databases that contain sparse amounts of end‐of‐life data for a few construction materials and their limitations in terms of scaling and data consolidation. Finally, a sample of how the collected data can be ingested into whole‐building LCA tools using open data formats and a public access link to the BRE‐X end‐of‐life emissions database is also included.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Greenhouse gas emissions of global construction material production

Abstract Global production of building materials is a primary contributor to greenhouse gas (GHG) emissions, but the production of these materials is necessary for modern infrastructure and society. Understanding the GHG emissions from building materials production in the context of their function is critical to decarbonizing this important sector. In this work, we present estimates of global production, approximate ranges of GHG emissions, and ranges of material properties of 12 critical building material classes to provide a unified dataset across material types. This dataset drew from industry analyses of production and emissions, ranges of emission factors within a material type, and broad reporting of thermal and mechanical properties to compare both within and between material types. Globally, in 2019, we estimate 42.8 Gt of these 12 materials were produced, with 38.6 Gt used in the building and construction industry. As a result of this production, 9.3 Gt of CO 2 was emitted, or 25% of global fossil GHG emissions, with 5.8 Gt CO 2 (16% of global GHG emissions) due to materials used in construction applications. Both construction material production and emissions are primarily driven by structural materials, such as concrete and steel. Material selection can play a key role in reducing emissions in the context of the function, with variation in emissions of structural materials per unit strength between 0.001–0.1 kg CO 2 /kg/MPa and in insulation materials per R -value/thickness of 0.018–0.14 kg CO 2 /kg/(K⋅m 2 W −1 ))). The developed dataset can play a key role in supporting decision-making in materials by providing a unified source for examining emissions, material properties, and quantity of material produced.

Kane, Seth (ORCID:0000000269401369)↗
DOE OSTI2021

Building Life-Cycle Analysis with the GREET Building Module: Methodology, Data, and Case Studies

To holistically address building sustainability, Argonne National Laboratory has expanded its Greenhouse gases, Regulated Emissions, and Energy use in Technologies (GREET) life-cycle model with a new GREET Building Module. This report documents life-cycle analysis (LCA) methodology and foreground data that Argonne National Laboratory compiles and develops to address embodied greenhouse gas (GHG) emissions and energy impacts of a wide range of envelope and structural building materials for new construction and retrofits. The methodology and data form the backbone of the GREET Building Module. This research effort focuses on developing consistent LCA methodology that conforms to building LCA standards such as the EN 15978 to address embodied GHG emissions and energy impacts of building materials/technologies. We document detailed foreground data for selected building materials and building components that are common for building construction. To test the LCA methodology and the GREET Building Module, this report includes case studies of insulation materials and wall panels for residential building retrofit. We have developed a separate document as a User Guide for understanding and applying the GREET Building Module to conduct detailed, process-level LCA of embodied carbon and energy impacts of emerging building materials and technology solutions that of interest to the Building Technologies Office (BTO) of the US Department of Energy, researchers, and industry stakeholders.

42 ENGINEERING↗
DOE OSTI2022

Integrating Embodied Carbon Knowledge for Design Decisions: Preprint

Measuring energy consumption of buildings is well established, and techniques to evaluate the carbon associated with operating buildings are improving. Embodied carbon of buildings is more complex as it considers the release of carbon throughout the building material supply chain and building material end of life fate. Decisions made early during the design and construction of the building can influence and potentially reduce the embodied carbon of buildings. The design and construction communities are uniquely positioned to make decisions that reduce embodied carbon. The objective of this project is to understand barriers to low carbon design and delivery and to point the design and construction communities to useful resources that will result in decisions that reduce embodied carbon. The outcomes of this work include educational resources that familiarize designers and contractors with embodied carbon and life cycle assessments (LCA), case studies that focus on design changes from LCA results, an overview of LCA tools, and examples of readily available, cost-effective design and construction steps to lower embodied carbon. We present an evaluation of existing resources, organized in a decision tree guidance, and identify gaps for further resource development. Through this evaluation process we investigated ways to streamline the process of identifying barriers to implementing solutions quickly.

design professional decisions↗
DOE OSTI2024

Lifespan Impacts to Infrastructure, Renewable Energy Components and Energy Storage Components Related to Fluoropolymer Use

This report focuses on the use of fluoropolymers in infrastructure materials (building construction materials, transportation, and electrical transmission and distribution); renewable energy generation components (specifically wind and solar); and energy storage components (lithium-ion batteries and fuel cells) and product lifespan impacts if fluoropolymers were no longer available or allowed in commerce. Additionally, environmental considerations for fluoropolymer manufacture, use, and end-of-life disposal are discussed. This document is the second of two companion reports. The first report, Assessment of Fluoropolymer Production and Use With Analysis of Alternative Replacement Materials, contained an analysis of use of fluoropolymers and their potential replacement technologies in aerospace, automotive, battery, building construction, chemical processing, electronics, infrastructure, semiconductor, solar panel, and wind energy industries sectors, along with qualitative life cycle assessment (LCA) and cost-benefit analysis of replacing fluoropolymers. This report does not focus on the lifecycle aspects of use of fluoropolymer or alternatives in the designated applications. For more information on those topics, see aforementioned report.

25 ENERGY STORAGE↗