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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 OSTI2024

Radio Frequency Calcination of Gypsum for Sustainable Wallboard Production

This presentation details several accomplishments in the dielectric calcination of gypsum to stucco. 1) Verification that gypsum can be calcined via RF heating, 2)Characterization of heating and mass loss curve for a nucleation propagation reaction under electromagnetics 3) Full parametric studies examining effect of free moisture on heating and calcination, and 4) Finite element model of process with high predictive capability. Overall, Industrial implementation could save up to 63% energy, 50% water, and reduce carbon emissions by 63% based on batch scale studies.

Tjards, Jacob↗
DOE OSTI2024

Process for the Recovery of Actinide and Lanthanide Oxides via Thermal Decomposition and Calcination of Loaded Diglycolamide Resin

Diglycolamide (DGA) resin, a product produced by Eichrom Technologies, Inc. employs TODGA (N,N,N',N'-tetraoctyldiglycolamide) as the active extractant, which will be used by Savannah River National Laboratory to extract trivalent actinides and lanthanides from dissolved irradiated Mark-18A targets. The final form of the extracted material will be an oxide suitable for shipment. A two-step process was developed and validated for the direct recovery of actinides and lanthanides loaded on I-grade DGA resin as nitrates by thermally drying and decomposing resin loaded with Nd(III), a surrogate for trivalent actinides and lanthanides, under inert conditions followed by calcining the resultant residue in air to provide an oxide product. Further, a stepwise heating profile up to 385°C under argon gas flow resulted in 85% to 89% mass loss during the resin drying and decomposition step, and calcination of the resultant Nd-loaded resin residue provided an overall material mass loss of ≥ 98%. Recoveries from resin saturated with Nd(III) from 7 M and 0.35 M nitric acid subjected to this process were 30.7 mg and 27.6 mg Nd/g dry resin, respectively, representing an average of 96.1% of Nd retained in the resin bed.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2022

Process design for calcination of nickel-based cathode materials by in situ characterization and multiscale modeling

Developing battery materials towards commercial use, from the early discovery through synthesis, processing, scaling up, and eventually to industrial production, may take decades. A notable example is Ni-based layered oxides, which were discovered as early as 1950s and intensively pursued as cathode active materials (CAMs) since the early 90s but have yet to realize their full commercial potential. Significant efforts have been devoted to materials development aiming at improving performance, far less to process development for large-scale synthesis and processing of CAMs. In this paper, we present a rational design of calcination for scalable production of Ni-based CAMs. We start with an overview of the current understanding and knowledge gaps hindering rational process design and scaling-up of the calcination process. Then with specific examples, we demonstrate how to tackle those fundamental challenges through in situ characterization and multiscale modeling. Finally, we conclude by providing perspectives on the remaining challenges and emerging opportunities in commercial development of Ni-based cathodes, calling for more endeavors in this field.

25 ENERGY STORAGE↗
DOE OSTI2024

Precision Calcination Mechanism of CaCO 3 to High-Porosity Nanoscale CaO CO 2 Sorbent Revealed by Direct In Situ Observations

Deploying energy storage and carbon capture at scale is hindered by the substantial endothermic penalty of decomposing CaCO 3 to CaO and CO 2 , and the rapid loss of CO 2 absorption capacity by CaO sorbent particles due to sintering at the high requisite decomposition temperatures. The decomposition reaction mechanism underlying sorbent deactivation remains unclear at the atomic level and nanoscale due to past reliance on postmortem characterization methods with insufficient spatial and temporal resolution. Thus, elucidating the important CaCO 3 decomposition reaction pathway requires direct observation by time-resolved (sub-)nanoscale methods. Here, chemical and structural dynamics during the decomposition of CaCO 3 nanoparticles to nanoporous CaO particles comprising high-surface-area CaO nanocrystallites are examined. Comparing in situ transmission electron microscopy (TEM) and synchrotron X-ray diffraction experiments gives key insights into the dynamics of nanoparticle calcination, involving anisotropic CaCO 3 thermal distortion before conversion to thermally dilated energetically stable CaO crystallites. Time-resolved TEM uncovered a novel CaO formation mechanism involving heterogeneous nucleation at extended CaCO 3 defects followed by sweeping reaction front motion across the initial CaCO 3 particle. These observations clarify longstanding, yet incomplete, reaction mechanisms and kinetic models lacking accurate information about (sub-)nanoscale dynamics, while also demonstrating calcination of CaCO 3 without sintering through rapid heating and precise temperature control.

36 MATERIALS SCIENCE↗
DOE OSTI2024

In situ Synchrotron X‐ray Metrology Boosted by Automated Data Analysis for Real‐time Monitoring of Cathode Calcination

Abstract Synchrotron X‐ray‐based in situ metrology is advantageous for monitoring the synthesis of battery materials, offering high throughput, high spatial and temporal resolution, and chemical sensitivity. However, the rapid generation of massive data poses a challenge to on‐site, on‐the‐fly analysis needed for real‐time process monitoring. Here, a weighted lagged cross‐correlation (WLCC) similarity approach is presented for automated data analysis, which merges with in situ synchrotron X‐ray diffraction metrology to monitor the calcination process of the archetypal nickel‐based cathode, LiNiO 2 . The WLCC approach, incorporating variables that account for peak shifts and width changes associated with structural transformations, enables rapid extraction of phase progression within 10 seconds from tens of diffraction patterns. Details are captured, from initial precursors to intermediates and the final layered LiNiO 2 , providing information for agile on‐site adjustments during experiments and complementing post hoc diffraction analysis by offering insights into early‐stage phase nucleation and growth. Expanding this data‐powered platform paves the way for real time calcination process monitoring and control, which is pivotal to quality control in battery cathode manufacturing.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Engineered Cementitious Composites (ECC) with limestone calcined clay cement (LC 3 )

Recent research have recognized that coupled use of calcined clay, limestone and cement clinker in concrete is viable to reduce environmental footprints at manufacture and to enhance material durability. In this study, a novel application of the limestone calcined clay cement (LC 3 ) is demonstrated by substituting the Ordinary Portland Cement (OPC) in Engineered Cementitious Composites (ECC). The composite mechanical properties including σ-δ and σ-ε relationships and residual crack widths were evaluated to 28 days under uniaxial tension. Matrix chemistry was characterized using thermogravimetric analysis and X-ray diffraction, while the pore structure of matrices and composites was analyzed using mercury intrusion porosimetry. The LC 3 -based ECC showed more rapid early strength development but lower 28-day strength (~32 MPa) due to a 20% higher water-to-solid ratio for attaining adequate workability and fiber dispersion. Nevertheless, the tensile strain capacity of LC 3 -based ECC achieved over 6% with an average residual crack width less than 50 μm. Additionally, the composite pore structure exhibited a decreasing volume fraction of large pores and voids (>100 nm) after substituting LC 3 for OPC. Here, the use of LC 3 marginally decreased the embodied material energy and cost, but led to about 32% and 28% reductions in CO 2 emissions compared to traditional OPC-based ECC and concrete, respectively. As a preliminary study, LC 3 -based ECC shows promise as a greener ductile concrete compared with OPC-based ECC.

36 MATERIALS SCIENCE↗
DOE OSTI2025

UR 2 : Ultra-rapid reactivity test for real-time, low-cost quality control of calcined clays

To reduce cement's carbon footprint, there is growing interest in commercial adoption of sustainable SCMs such as calcined clays. However, the existing ASTM standard (R 3 test, C1897) to test the reactivity of such clays takes up to 7 days and cannot be used for real-time quality control in an industrial setting. We address this issue by introducing a 5-min Ultra-Rapid Reactivity (UR 2 ) test. By dissolving 47 clay specimens in 4 M NaOH solutions at 90°C, we report that a dissolution index of 1.54Al + Si correlates strongly to the 7-day R 3 heat (R 2 = 0.92, RMSE = 94.1 J/g). This dissolution index also correlates to the 28-day compressive strength for 14 clay mixtures (R 2 = 0.94, RMSE = 1.7 MPa). This UR 2 test relies on colorimetry and can be conducted via off-the-shelf, low-cost cameras. Overall, our new UR 2 test opens a pathway for real-time, low-cost quality control of calcined clays.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Substitution-Mediated Calcination of Nickel-Based Cathodes: Decoupling Lithiation and Crystallization

Nickel-based layered cathodes such as LiNiO 2 offer high energy density for lithium-ion batteries, yet improvements in cycling performance and safety are required for practical use–often achieved through manganese and cobalt substitution as in LiNi 0.80 Mn 0.10 Co 0.10 O 2 (NMC811). However, how such substitution impacts calcination, the key process that governs lithiation, structural ordering, crystallization, and ultimately the resulting material properties, remains unclear. Here, in this study, we investigate substitution-mediated calcination dynamics in NMC811 compared to LiNiO 2 using multiscale-correlated in situ spectroscopy and atomistic-to-mesoscale modeling. While both systems progress through the same sequence of intermediates toward the thermodynamically favored layered phase, NMC811 exhibits an earlier onset of layering, concurrent with hydroxide decomposition followed by sluggish crystallization. Modeling reveals that Mn and Co lower the energy barrier for lithium incorporation and ordering but increase the penalty for interlayer gliding, thereby slowing crystal growth at elevated temperatures. This substitution-mediated decoupling of lithiation and crystallization explains the fine-grained microstructure observed in NMC811 versus coarsened particles in LiNiO 2 and establishes a mechanistic framework for predictive microstructure engineering of Ni-based cathodes.

Calcination↗
DOE OSTI2022

Unusual water-assisted NO adsorption over Pd/FER calcined at high temperatures: The effect of cation migration

Moisture contained in vehicle exhaust gas normally degrades the capacity and efficiency of Pd ion-exchanged zeolites as NO x adsorbents by competitive adsorption on active sites. Here, we report a counterexample to this general proposition, in which moisture facilitates the storage of NO as a nitrosyl complex on hydrated Pd ions in high temperature calcined FER-type zeolites. The divalent Pd 2+ cations upon elevated temperature (>800 °C) calcination occupy cationic position that render them fully coordinated by oxygen ions of the zeolite framework, and become inactive for the adsorption of probe molecules such as NO or CO. These ‘hidden’ Pd ions, however, are accessible by NO when the zeolite is hydrated, but readily release NO at around 200°C as dehydration proceeds. Herein, by combining systematic in situ infra-red data with X-ray diffraction Rietveld analyses, we revealed that the high temperature-induced relocation of Pd ions to more stable cationic positions located near 6-membered ring of the ferrierite cage is responsible for this anomalous behavior. This discovery constitutes a notable advance in understanding coordination chemistry of cations in zeolites.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Mechanisms dominating thixotropy in limestone calcined clay cement (LC3)

Limestone calcined clay cement (LC3) is a green binder with great practical importance for the cement industry. Growing application has increased the need to understand the mechanisms governing its thixotropy for better control of workability. While formation of C-S-H bridges is understood to dominate the thixotropy of ordinary Portland cement, LC3 paste displayed unique thixotropy properties. In this study, focused beam reflectance measurement, zeta potential, 1H nuclear magnetic resonance relaxometry and micro X-ray computed tomography were used to track the colloidal interaction and hydration extent within LC3 paste. Results showed that flocculation due to the negative surface charge and water affinity of calcined clay appears to be the dominating factor. This leads to a reduction of water available to contribute to fluidity of the paste and, in turn, governing the development of thixotropy over time. In addition, the dilution effect due to high clinker substitution diminishes thixotropy growth with time.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Predicting the rheology of limestone calcined clay cements (LC 3 ): Linking composition and hydration kinetics to yield stress through Machine Learning

The physicochemical characteristics of calcined clay influence yield stress of limestone calcined clay cements (LC 3 ), but the independent influences the clay's physical and chemical characteristics as well as the effect of other variables on LC 3 rheology are less well-understood. Further, a relationship between LC 3 hydration kinetics and yield stress – important for informing mixture design – has not yet been established. Here, rheological properties were determined in pastes with varying water-to-solid ratio (w/s), constituent mass ratios (PC:metakaolin:limestone), limestone particle size and gypsum content. From these data, an ML model developed allowed the independent examination of the different mechanisms by which metakaolin fraction influences yield stress of LC 3 , identifying four predictors – packing index, Al 2 O 3 /SO 3 , total particle density and metakaolin fraction relative to limestone (MK/LS) – most significant for predicting LC 3 yield stress. A methodology based on kernel smoothing also identified hydration kinetics parameters best correlated with yield stress.

36 MATERIALS SCIENCE↗
DOE OSTI2023

The hydration, microstructure, and mechanical properties of vaterite calcined clay cement (VC 3 )

Limestone (calcite) calcined clay cement (LC 3 ) is a promising low-CO 2 binder, but the low activity of calcite cannot compensate the reduction in clinker factor, resulting in low one-day strength and limiting its broad applications. As recent carbon capture and utilization technologies allow scalable production of vaterite, a more reactive CaCO 3 polymorph, we overcome the challenge by introducing vaterite calcined clay cement (VC 3 ), inspired by the vaterite-calcite phase change. In the present study, VC 3 exhibits higher compressive strengths and faster hydration than LC 3 . Compared to hydrated LC 3 , hydrated VC 3 exhibits increased amount of hemi- and mono-carboaluminate formation and decreased amount of strätlingite formation. With gypsum adjustment, the 1-day strength of VC 3 is higher than that of pure cement reference. Finally, VC 3 , a low-CO 2 binder, presents great potential as a host of the metastable CaCO 3 for carbon storage and utilization and as an enabler of carbon capture at gigaton scales.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Nitrated Anion Exchange Resin Disposal Plan Calcination Studies

Reillex HPQ resin was nitrated in a manner matching procedures in use by the Aqueous Nitrate Recovery Facility. The resin was kept wet and then calcined to determine if nitrate was present in the residue. The potential for dispersion during heating and generation of soot or ash was evaluated. A series of experiments were performed by calcining the resin to 650 °C, and both residual solids and liquids were collected and measured for nitrates by Raman spectroscopy and test strip measurements.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS1971

Induction plasma calcining of pigment particles for thermal control coatings

Induction plasma heating techniques were studied for calcining zinc orthotitanate particles for use in thermal control coatings. Previous studies indicated that the optimum calcining temperature is between 1400 and 1750 C. An intermediate temperature (1670 C) was chosen as a reference point for running a temperature series at the reference point and 220 C on both sides. The effect of varying chamber temperature on the reflectance spectra, before and after vacuum UV irradiation, is presented. The correlation between Zn2Ti04 paramagnetic resonance activity and its susceptibility to vacuum UV damage is discussed.

Farley, E. P.↗
DOE OSTI2022

The Importance of Surface Oxygen for Lithiation and Morphology Evolution during Calcination of High-Nickel NMC Cathodes

Nanoscale morphology has a direct impact on the performance of materials for electrochemical energy storage. Despite this importance, little is known about the evolution of primary particle morphology nor its effect on chemical pathways during synthesis. In this work, operando characterization is combined with atomic-scale and continuum simulations to clarify the relationship between morphology of cathode primary particles and their lithiation during calcination of LiNi 0.8 Mn 0.1 Co 0.1 O 2 (NMC-811). This combined approach reveals a key role for surface oxygen adsorption in facilitating the lithiation reaction by promoting metal diffusion and oxidation, and simultaneously providing surface sites for lithium insertion. Furthermore, oxygen surface termination is shown to increase the activation energy for sintering, leading to smaller primary particle sizes at intermediate temperatures. Smaller particles provide both shorter diffusion lengths for lithium incorporation and increased surface site density for lithium insertion. These insights provide a foundation for more tailored syntheses of cathode materials with optimized performance characteristics.

25 ENERGY STORAGE↗
DOE OSTI2021

On the use of limestone calcined clay cement (LC3) in high-strength strain-hardening cement-based composites (HS-SHCC)

Highlights: • Use of LC{sup 3} slightly reduces flowability and shortens the setting time of fresh matrices. • Highly polymerized C-A-S-H gel and abundant ettringite benefit flexural strength of LC{sup 3}-matrices. • Use of LC{sup 3} enhances the bond strength between fiber and high-strength matrix. • LC{sup 3}-based HS-SHCC yields similar flexural performance as the composite with Portland cement. High-strength strain-hardening cement-based composites (HS-SHCC) demonstrate excellent mechanical and durability properties. However, high cement content typical to HS-SHCC results not only in high carbon footprint, but also in excessive hydration heat and severe autogenous shrinkage. In this investigation, Limestone Calcined Clay Cement (LC{sup 3}) was used to produce sustainable HS-SHCC. The LC{sup 3} substitution resulted in higher energy consumption during mixing and in shorter setting times of the fresh, plain matrices. Although the LC{sup 3} substitution slightly reduced the compressive strength, the formation of highly polymerized C-A-S-H gel and abundant ettringite benefited the flexural strength of the plain matrices. Additionally, single-fiber pullout experiments showed that the use of LC{sup 3} led to increased fiber-matrix bond strength and pullout energy. Finally, the replacement of Portland cement by LC{sup 3} resulted in HS-SHCC with similar mechanical performance to the reference composite, indicating a high potential for using LC{sup 3} in high-performance cement-based composites.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Strength-promoting mechanism of alkanolamines on limestone-calcined clay cement and the role of sulfate

This paper reports the strength-promoting mechanism of alkanolamines on limestone-calcined clay cement (LC{sup 3}). The hydration kinetics, phase formation and microstructure of LC{sup 3} with triethanolamine (TEA) or triisopropanolamine (TIPA) were investigated. TEA enhanced the strength of LC{sup 3}, while TIPA was effective at 28 days, and a correct sulfate addition promoted their effects. Alkanolamines accelerated the aluminate reaction of LC{sup 3} during early hydration, increased sulfate slowed this reaction by producing more ettringite. TIPA favoured the hydration of ferrite in clinker, not only accelerated the silicate reaction of metakaolin, but also resulted in a rapid limestone reaction. Alkanolamines altered the morphology and chemical composition of the aluminate hydrates and C-A-S-H. Alkanolamines enabled the reduction of porosity of hardened pastes and the increased sulfate further refined them. It was the large pores being induced by TIPA at early ages that were considered to have an adverse impact on the early strength of LC{sup 3}.

36 MATERIALS SCIENCE↗