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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 OSTI2026

Measuring Loss Tangents of Substrates for Superconducting Qubits with Part-per-Billion Precision

We report precision measurements of dielectric loss tangents in substrates for superconducting qubits using an ultra-high quality factor niobium SRF cavity operating at millikelvin temperatures and low electric fields. Multiple substrate types and surface treatments are compared to assess how processing impacts microwave dissipation. The RF results are correlated with materials analysis, including ToF-SIMS and XPS, to identify dominant loss mechanisms. This combined study links microscopic surface chemistry to macroscopic performance and provides a framework for materials-driven improvements in qubit coherence and device design.

Bafia, Daniel [Fermilab]↗
DOE OSTI2025

Development of a microwave-assisted downdraft moving-bed gasifier for continuous processing of lignite and biomass chars

This research illustrates a microwave-assisted downdraft moving-bed gasifier for the first time. Such design enables continuous solid gasification process. An adjustable auger was applied to control the solid removal rate and the gas-solid interaction time. Both lignite and biomass chars were investigated to determine the capability of the current system for low-tar feedstocks with different densities. Here, the presented reactor design was able to operate continuously for 3 hours and 20 minutes under 700 ℃ and atmospheric pressure, with air as the gasifying agent. For yellow pine char, the processing rate could reach 34.1 grams per hour with decent syngas production. The downdraft moving-bed design shows better cold gas and syngas production efficiencies compared to the common fixed-bed design, due to controllable residence time and more homogeneous microwave heating. The limitations of the current design and the direction of novel microwave-assisted chemical reactor design were discussed. This novel reactor design provides a way to improve the efficiency of microwave-assisted gasification process and shows its potential to be incorporated into other established chemical reaction processes as a modular add-on.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Abstract for CRADA between NETL and West Virginia University Research Corporation

The National Energy Technology Lab (NETL) will collaborate with West Virginia University to develop and demonstrate a dynamically operated modular, microwave-enhanced catalytic process for the co-production of ammonia and olefins. Ammonia and olefins (e.g., ethylene) are the most widely produced chemicals in the U.S. by volume, but their processes are also the most carbon and energy intensive as they rely on fossil-based feedstocks and combustion of fossil fuels for heating. The project will leverage the unique ability of microwaves to intensify process heating by providing pulsed, targeted energy to active sites of a mixed catalyst bed to convert a mixture of CH 4 /N 2 into ethylene and ammonia. The collaboration will facilitate the development of microwave technology that has the potential to utilize distributed waste resources like shale gas or biogas as well as renewable electricity to produce these valuable chemicals. It is expected that the results will decarbonize chemical production by using renewable energy and waste feedstocks, improve efficiency by reducing unit operations (H 2 production), and de-risk microwave technology for chemical production by demonstrating long-term and dynamic operability. This project was funded by an award from the Department of Energy’s EERE IEDO.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Microwave-Assisted Methane Dehydroaromatization: Impact of Process Parameters

Flaring of associated natural gas is a significant challenge for oil and gas producers that often results in high amounts of lost revenue for the industry. One way to improve economics of this process is to convert natural gas into value-added chemicals using chemical conversion. Methane, which is the principal component of natural gas, can typically be converted into valuable aromatics using non-oxidative conversion routes such as dehydroaromatization. For the current work, methane dehydroaromatization was investigated in a microwave-assisted reactor and the effect of various parameters such as reaction temperature (550-750 °C) and space velocity (3-8 L/gcat/hr) were studied. Both the parameters had a very strong effect on the overall performance of the reaction. The variation in temperature had significant impact on the overall methane conversion, whereas the variation in space velocity had significant impact on the selectivity and product distribution.

methane dehydroaromatization↗
DOE OSTI2025

Microwave-Mediated Extraction of Critical Metals from LED E-Waste

This study introduces a microwave-assisted technique for extracting critical minerals from LED electronic waste. The process begins with microwave irradiation, which thermally decomposes the LED’s plastic lens into a brittle, charred residue. During this stage, the LED chip undergoes deflagration—being rapidly ejected from the reflective cavity and becoming embedded within the decomposed lens material. Consequently, the chip is encapsulated in the resulting charred residue. This composite, consisting of the charred lens and the LED chip, can be easily separated from the metallic pins (Fe, Ni, Ag), which remain almost undamaged. Subsequent calcination of the charred material in air exposes the materials making up the LED chip, which contain critical metals (e.g., Ga, As, In, Y, Au). These metals are then extracted through a two-step acid leaching process involving aqua regia followed by hot concentrated hydrochloric acid, yielding them in potentially recoverable forms. The synergistic effect of microwave irradiation and acid treatment achieves an average extraction efficiency of 96% for critical metals. Notably, this approach enables complete and loss-free recovery of the LED chip, offering a practical and efficient solution for LED e-waste recycling.

Bourlinos, Athanasios B.↗
DOE OSTI2024

Effects of temperature inversion on densification in chemical vapor infiltration

In a classical chemical vapor infiltration (CVI) process, the competing effects of chemical kinetics and reagent gas transport lead to non–uniform depositions such that outer layers of a preform densify faster leaving the core highly porous. Currently, CVI must be performed at a sufficiently low temperature to achieve good densification quality which leads to high processing time and cost. Volumetric heating of the preform, especially through microwaves, can create temperature inversion such that the core is hotter than the outer surface and potentially, overcome the challenges associated with isothermal CVI. Direct numerical simulations (DNS) of densification under various such temperature distributions indicate that microwave heating in CVI processing can lead to better (uniform) densification of porous preforms. Here the role of key parameters describing the temperature distributions on the densification behavior is investigated. Strategic temporal control of the temperature distribution shows that processing times can be reduced by almost half while maintaining a good densification quality similar to that of low–temperature isothermal processing. Inside–out densification due to the inverted temperature profile is a key distinguishing characteristic of microwave assisted CVI.

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

Deactivation of Mo/H-ZSM-5 in Microwave-Assisted and Thermal-Driven Methane Dehydroaromatization

A better understanding of catalyst deactivation is needed to improve catalyst design and performance in microwave-enhanced methane dehydroaromatization (MDA). Here, this study investigates the deactivation of a molybdenum supported H-ZSM-5 zeolite (Mo/H-ZSM-5) catalyst in MDA under microwave-heated conditions, comparing its performance to that of the same catalyst under conventional heating. While the microwave-assisted (MW) process achieved higher benzene yields, the catalyst experienced faster deactivation due to the selective and rapid deposition of coke within the pores of the zeolite, as confirmed through Brunauer–Emmett–Teller (BET), X-ray diffraction (XRD), ammonia-temperature programmed desorption (NH 3 -TPD), thermal gravimetric analysis (TGA), temperature programmed oxidation (TPO), and X-ray photoelectron spectroscopy (XPS) analyses. The quantification of total coke content via TGA/TPO and surface carbon (XPS) revealed that nearly twice as much coke was deposited on the catalyst under MW conditions compared to that on the conventionally heated material, and the coke exhibited a more conductive and graphitic nature. The accelerated deactivation rates were attributed to the formation of hot spots in the MW system, leading to enhanced coupling with coke formed in situ during the reaction and resulting in increased Mo reduction. Observations indicated that the CO activation used to carburize the catalyst prior to the reaction is not advantageous in the MW heating environment. The presence of large amounts of Mo oxides at elevated temperatures (through hot spots) exposed to methane leads to instability under the reaction conditions. Optimizing the activation environment and improvement of the Mo dispersion within the pores are potential strategies to improve catalyst stability.

Mo/H-ZSM-5 zeolite↗
DOE OSTI2026

How Do You Hear a Quantum Computer Whisper?

Quantum transduction is the process of upconverting microwave quantum signals into optical signals to develop quantum networks through optical fibers outside the dilution refrigerator, enabling connections between quantum technologies on the quantum internet. In this project, upconversion is achieved by directing an optical laser and the microwave quantum signal into an electro-optic bulk crystal. The crystal is housed within a Superconducting Radio Frequency (SRF) cavity designed to maximize the overlap between the microwave field and the crystal volume. In the presence of microwaves, the refractive index of the crystal changes through the Pockels effect. This change in refractive index modifies the propagation of the optical field within the crystal, allowing the quantum information carried by the microwave field to be transferred to the optical field. This study focuses on coupling laser light from suspended waveguide chips into the whispering-gallery modes (WGMs) of the crystal to enable transduction. The coupling efficiency between the optical field in the suspended waveguide and the WGM depends on the position of the laser spot on the crystal. To address this challenge, a feedback-based algorithm is being developed to fine-tune the waveguide position so that the optical signal is coupled efficiently into the crystal. After passing through the crystal, the optical signal is detected by a photodiode connected to an oscilloscope. The algorithm evaluates the coupling quality and iteratively adjusts the waveguide position to maximize coupling efficiency. The expected outcome is an automated waveguide alignment method that improves optical coupling and enables more efficient microwave-to-optical quantum transduction.

Karanastasis, Mihael [Fermilab]↗
DOE OSTI2025

Microwave-Assisted Dehydroaromatization of Flare Gas: Reactor Modeling, Plant-Wide Simulation and Economic Feasibility Analysis

Flaring is widely practiced in the oil, gas, and petrochemical sectors to ensure safety during upsets and maintenance but emits large amounts of GHGs, causing energy and economic losses. In the U.S., about one-third of Bakken gas (~250 MMSCFD) and ~100 MMSCFD from Eagle Ford are flared. Recovering this gas is essential for sustainability. Existing recovery methods—compression and reinjection (EOR), conversion to NGL, LNG/CNG, GTL, and GTW—are often limited by flowrate, composition, and variability, especially in unconventional wells. This study develops a microwave-assisted dehydroaromatization (DHA) process to convert flare gas into benzene, toluene, ethylene, and naphthalene. A laboratory reactor model is scaled up into a modular plant-wide system. Techno-economic (TEA) and life-cycle (LCA) analyses evaluate performance and sustainability, with sensitivity studies on plant capacity, electricity cost, and catalyst price confirming strong economic potential.

dehydroaromatization↗
DOE OSTI2025

Microwave-driven synthesis and modification of nanocarbons and hybrids in liquid and solid phases

Over the past 20 years, nanocarbons have become more significant as nanostructured fillers in composites and, more recently, as functional elements in a brand-new class of hybrid materials. Microwave-assisted synthesis and processing is a burgeoning subject matter in materials research with significant strides in the realm of nanocarbon during the last decade. Here, the review examines recent approaches to producing various nanocarbons using microwaves as energy sources, the characterization of such materials for various applications, and their results. The underlying factors supporting the increased performance of such materials or their composites are analyzed and reaction mechanisms are presented wherever necessary. In particular, the recently developed and verified approaches to produce porous carbon materials, CNTs and fibers, carbon nanospheres, carbon dots, CQDs, reduced graphene oxide, nanocarbon hybrid materials, and the purification and modification of CNTs are discussed. The reduction of graphene oxide and the preparation of graphene derivative hybrids using solid-state and liquid-state routes such as polyopl, mixed solvents, ionic liquids, and microwave-assisted hydrothermal/solvothermal methods are analyzed in detail. In addition, the principles of microwave heating in liquid and solid states, the use of metals particles as arcing agents or catalysts, and carbonaceous materials as internal or external susceptors during synthesis and modifications are presented in detail.

25 ENERGY STORAGE↗
DOE OSTI2024

Microwave-assisted ammonia decomposition over metal nitride catalysts at low temperatures

The negative environmental impact of fossil fuel-based energy systems has unveiled the need to develop a CO x -free sustainable hydrogen (H 2 ) economy. Employing a microwave-assisted route, a ternary metal nitride catalyst (i.e., Co 2 Mo 3 N), and a low-temperature-pressure NH 3 decomposition process, this study investigated the possibility of developing a distributed H 2 production process. Here, this study not only explored lower cost-based catalyst systems but also the use of a microwave reactor to increase the energy efficiency of the process. Results from catalytic NH 3 decomposition experiments, performed in microwave reactors on Co 2 Mo 3 N catalyst, demonstrated the peak energy efficiency (of ~0.006 kgH 2 /kWh) at 400 °C in ambient pressure (with an NH 3 conversion >90%) which was around ninety times (~90 x) more efficient than a conventional system. Activation energy calculation also displayed a 20% less energy requirement for the microwave-based process (~31 kJ mol -1 ) than the conventional system (~37 kJ mol -1 ), indicating the advantage of the microwave-based process. Further microwave-assisted catalytic measurements and characterization of the Co 2 Mo 3 N catalyst, using x-ray diffraction (XRD) technique and scanning electron microscopic (SEM) images, revealed the excellent stability of this material at its peak performance (at 400 °C) and illustrated the potential of using this catalyst for a sustainable, economic, and energy-efficient approach for producing CO x -free H 2 .

08 HYDROGEN↗
DOE OSTI2025

Faceted NiO(111) nanosheets: morphological and catalytic evolution for the oxygen evolution reaction

The renaissance of the energy system through the use of green hydrogen by water electrolysis lies behind the development of abundant, active, and scalable catalysts for the oxygen evolution reaction (OER). A fundumental understanding of the surface properties for these materials is of vital importance in producing viable heterogenous catalysts. In this feature article, we summarize several years of collaborative work on a uniquely faceted NiO(111) nanosheet possessing hexagonal holes with a focus on understanding how the evolution of the catalyst surface and bulk composition effects OER performance. The importance of surface faceting, morphological evolution, and metal combination by different doping strategies are all analyzed and summarized to further improve the material's performance. Furthermore, microwave and supercritical synthesis processes are utilized to understand how varying wet-chemical techniques effect the formation of the NiO(111) nanosheet and activity of the material. We discuss our chosen strategies and the difficulties encountered with optimizing a catalyst surface for the OER.

08 HYDROGEN↗
DOE OSTI2026

Recent advances in chemical recycling and upcycling of plastic waste into valuable materials, chemicals, and energy: a comprehensive review

The global plastic waste crisis has increased in severity in recent years: annual plastic production is projected to reach 500 million metric tons by 2025, and plastic waste accumulation is expected to surpass 12 billion metric tons. Despite these growing volumes, only ∼9% of plastic waste is currently recycled; the majority is either landfilled, incinerated, or mismanaged, contributing to escalating greenhouse gas emissions—from 1.7 Gt carbon dioxide equivalent (CO 2 -eq.) in 2015 to an estimated 6.5 Gt CO 2 -eq. by 2050—and physical environmental pollution. This review provides a comprehensive overview of advanced plastic upcycling strategies to address this issue and recover value from diverse plastic waste streams. Recent developments in solvent-based dissolution, chemical depolymerization, and thermochemical conversions are examined for major plastic types, including polyolefins, polycondensation polymers, and PVC. Underlying reaction pathways, catalyst designs, and processing parameters that govern product selectivity, efficiency, and conversion yields are discussed in depth. Emerging techniques such as microwave-assisted depolymerization, tandem catalysis, and co-processing approaches are highlighted for their potential to enhance efficiency under milder conditions. Emphasis is also placed on the production of high-value products such as monomers, naphtha-range hydrocarbons, and syngas, and discussion is provided on catalyst stability, contaminant removal, scalability, life cycle effects on the environment, and technoeconomic viability. Finally, the review outlines future research directions focused on catalyst innovation, integrated process design, supportive policy frameworks, and interdisciplinary collaboration. All recommendations are aimed at accelerating large-scale implementation of plastic upcycling technologies and advancing the global circular plastics economy.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Microwave Absorbing Perovskite Catalysts for Efficient Electrification of Syngas Production from CO2 and Methane

Microwave absorbing catalysts have the potential to make thermal reactions such as methane reforming (CH4 + CO2 + H2O → H2 + CO) into carbon negative processes when coupled with decarbonized electricity. Due to microwaves directly heating the catalyst rather than heating the reactor and gases, even high temperature reactions such as dry reforming methane (DRM, CH4 + CO2 → H2 + CO) can be achieved rapidly, efficiently, and on-demand, ideal for coupling with intermittent renewable electricity. However, microwave catalysts present unique design challenges due to the same material needing to both efficiently absorb microwaves in oxidative and reductive reaction conditions and be an efficient and stable catalyst in inherently non-isothermal reactors. We screened from over 28 catalysts in the La0.8Sr0.2(Co-Ni-Mn)O3 perovskite solid-solution family to determine promising microwave reforming catalysts and identify design principles for effective materials. The best performing catalyst candidate was able to produce syngas ratios (H2:CO) from 1-3, and scale up testing showed CO and H2 production efficiencies rivaling conventional carbon intensive steam reforming efficiencies at the liters per minute level of production.

Marin, Christopher↗
DOE OSTI2025

High-power test of a C-band linear accelerating structure with an RFSoC-based LLRF system

Normal conducting linear particle accelerators consist of multiple rf stations with accelerating structure cavities. Low-level rf (LLRF) systems are employed to set the phase and amplitude of the field in the accelerating structure and to compensate for the pulse-to-pulse fluctuation of the rf field in the accelerating structures with a feedback loop. The LLRF systems are typically implemented with analog rf mixers, heterodyne-based architectures, and discrete data converters. There are multiple rf signals from each of the rf stations, so the number of rf channels required increases rapidly with multiple rf stations. With a large number of rf channels, the footprint, component cost, and system complexity of the LLRF hardware will increase significantly. To meet the design goals of being compact and affordable for future accelerators, we have designed the next-generation LLRF (NG-LLRF) with a higher integration level based on RFSoC technology. The NG-LLRF system samples rf signals directly and performs rf mixing digitally. Further, the NG-LLRF has been characterized in loopback mode to evaluate the performance of the system and has also been tested with a standing-wave accelerating structure, a prototype for the Cool Copper Collider (C 3 ) with a peak rf power level up to 16.45 MW. The loopback test demonstrated amplitude fluctuation below 0.15% and phase fluctuation below 0.15°, which are considerably better than the requirements of C 3 . The rf signals from the different stages of the accelerating structure at different power levels are measured by the NG-LLRF, which will be critical references for the control algorithm designs. The NG-LLRF also offers flexibility in waveform modulation, so we have used rf pulses with various modulation schemes, which could be useful for controlling some of the rf stations in accelerators. In this paper, the high-power test results at different stages of the test setup will be summarized, analyzed, and discussed.

47 OTHER INSTRUMENTATION↗
DOE OSTI2025

Interface-sensitive microwave loss in superconducting tantalum films sputtered on c-plane sapphire

Quantum coherence in superconducting circuits has increased steadily over the last decades because of a growing understanding of the various loss mechanisms. Recently, tantalum (Ta) emerged as a promising material to address microscopic sources of loss found on niobium (Nb) or aluminum (Al) surfaces. However, the effects of film and interface microstructure on low-temperature microwave loss are still not well understood. Here, in this study, we present a systematic study of the structural and electrical properties of Ta and Nb films sputtered on c-plane sapphire at varying growth temperatures. As growth temperature was increased, our results show that the onset of epitaxial growth of α -phase Ta correlates with lower Ta surface roughness, higher critical temperature, and higher residual resistivity ratio, but surprisingly also correlates with a significant increase in loss at microwave frequency. Notably, this high level of loss is not observed in Nb films prepared in the same way and having very similar structure. By experimentally controlling the surface on which the Ta film is nucleated, we determine that the source of loss was only present in samples having an epitaxial Ta/sapphire interface and show that it was apparently mitigated by either growing a thin, epitaxial Nb interlayer between the Ta film and the substrate or by intentionally treating, and effectively damaging, the sapphire surface with an in situ argon plasma before Ta growth. In addition to elucidating this interfacial microwave loss, this work provides adequate process details to aid reproducible growth of low-loss Ta films across fabrication facilities.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2024

Development of electro-optical quantum transducers based on three-dimensional superconducting cavities

Quantum transducers enable the conversion of quantum information and signals between different physical platforms. Based on the pioneering works in three-dimensional superconducting cavity technology developed at Fermilab, we are advancing the development of three-dimensional microwave-optical transducers and exploring their applications in quantum information processing and sensing. We present our progress in the design, fabrication, and characterization of three-dimensional microwave cavities integrated with bulk lithium niobate resonators. The material characterization using three-dimensional cavities based on a resonant-type method allows for understanding of complex permittivity and loss mechanism of electro-optic materials at cryogenic temperatures. We also evaluate the potential of the high-efficiency quantum transducers in enhancing the performance of quantum sensors for applications such as dark matter detection, compared to conventional homodyne detection approaches. This manuscript has been authored by Fermi Research Alliance, LLC under Contract No. DE-AC0207CH11359 with the U.S. Department of Energy, Office of Science, Office of High Energy Physics. This work is funded by the DOE's Early Career Research Program. This research used resources of the U.S. Department of Energy, Office of Science, National Quantum Information Science Research Centers, Superconducting Quantum Materials and Systems Center (SQMS) under Contract No. DE-AC02-07CH11359.

Zorzetti, Silvia↗