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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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DOE OSTI2024

Improved Beam Loss Accounting with Fast Data Acquisition (DAQ) Chassis

Identifying the source of beam loss events in the CE-BAF accelerator can be a challenging task. However, with our new prototype system, this task becomes more effi-cient. The system, developed in the fall of 2022, utilizes a dispersive beam position monitor (BPM) and the exist-ing switched electrode electronics BPM hardware. Previ-ously a commercial off-the-shelf data acquisition (DAQ) system was employed to capture BPM wire signals at a sample rate of 20 kS/s. The fast shutdown signal triggered the system, which disables the beam at the injector. Analysis of beam position and energy variation before a beam loss event was used to determine if the beam loss event was associated with an energy transient. The proto-type system, implemented using National Instruments hardware and LabVIEW® software, relied on a software trigger. Manual post-processing was required to ascertain whether the fault was due to an un-tripped cavity with a gradient or phase transient. This work focuses on deploying a Fast DAQ Chassis to monitor BPM hardware in real time and during beam loss events. This system was originally developed and in-stalled in CEBAF to monitor the time-domain RF control signals in the legacy analog RF systems. This technology was leveraged to also monitor BPM signals. As the new system employs a hardware trigger, developing tools to automatically identify faults linked to energy transients unrelated to cavity faults will be straightforward. This paper will discuss the project's initial updates, underlin-ing the crucial role of each member of our team in this achievement

Tiskumara, J.↗
DOE OSTI2026

SRF cavity instability detection with machine learning at CEBAF

During the operation of the Continuous Electron Beam Accelerator Facility (CEBAF), one or more unstable superconducting radio-frequency (SRF) cavities often cause beam loss trips while the unstable cavities themselves do not necessarily trip off. The present RF controls for the legacy cavities report at only 1 Hz, which is too slow to detectfast transient instabilities during these trip events. These challenges make the identification of an unstable cavity out of the hundreds installed at CEBAF a difficult and time-consuming task. To tackle these issues, a fast data acquisition system (DAQ) for the legacy SRF cavities has been developed, which records the sample at 5 kHz. An unsupervised learning framework has been developed to identify anomalous SRF cavity behavior. We will discuss the present status of the DAQ system and our framework, along with recent successes in detecting anomalous cavity behavior. Overall, our method offers a practical solution for identifying unstable SRF cavities, contributing to increased beam availability and machine reliability.

Accelerator Physics↗
DOE OSTI2024

Evaluating the Effectiveness of Retrieval-Augmented Large Language Models in Scientific Document Reasoning

Despite the dramatic progress in Large Language Model (LLM) development, LLMs often provide seemingly plausible but not factual information, often referred as hallucinations. Retrieval-augmented LLMs provide a non-parametric approach to solve these issues by retrieving relevant information from external data sources and augment the training process. These models helps to trace evidence from an externally provided knowledge base allowing the model predictions to be better interpreted and verified. In this work, we critically evaluate these models in their ability to perform in scientific document reasoning tasks. To this end, we tuned multiple such model variants with science-focused instructions and evaluated them on a scientific document reasoning benchmark for the usefulness of the retrieved document passages. Our findings suggest that models justify predictions in science tasks with fabricated evidence and leveraging scientific corpus as pretraining data does not alleviate the risk of evidence fabrication.

• Artificial intelligence (AI) / machine learning ↗
DOE OSTI2025

Estimating time in quantum chaotic systems and black holes

We characterize new universal features of the dynamics of chaotic quantum many-body systems, by considering a hypothetical task of "time estimation". Most macroscopic observables in a chaotic system equilibrate to nearly constant late-time values. Intuitively, it should become increasingly difficult to estimate the precise value of time by making measurements on the state. We use a quantity called the Fisher information from quantum metrology to quantify the minimum uncertainty in estimating time. Due to unitarity, the uncertainty in the time estimate does not grow with time if we have access to optimal measurements on the full system. Restricting the measurements to act on a small subsystem or to have low computational complexity leads to results expected from equilibration, where the time uncertainty becomes large at late times. With optimal measurements on a subsystem larger than half of the system, we regain the ability to estimate the time very precisely, even at late times. Hawking's calculation for the reduced density matrix of the black hole radiation in semiclassical gravity contradicts our general predictions for unitary quantum chaotic systems. Hawking's state always has a large uncertainty for attempts to estimate the time using the radiation, whereas our general results imply that the uncertainty should become small after the Page time. This gives a new version of the black hole information loss paradox in terms of the time estimation task. By restricting to simple measurements on the radiation, the time uncertainty becomes large. This indicates from a new perspective that the observations of computationally bounded agents are consistent with the semiclassical effective description of gravity.

Black holes↗
DOE OSTI2024

Dynamic Binary Complexes (DBC) as Super-Adjustable Viscosity Modifiers for Hydraulic Fracturing Fluids

In the preceding project year two, we refined three DBC formulations from a selection of over 50 different chemistries. The optimization study primarily encompassed testing for (i) reversibility extent, (ii) performance in the presence of chemical additives, (iii) adhesion and friction behavior during displacement in wellbores and pipelines, (iv) corrosion protection performance, and (v) injection performance with model fracture systems at the laboratory scale. Highly promising results obtained from all these tests signify the significant potential of DBCs in enhancing hydrocarbon recovery from unconventional reservoirs. The primary activities in the third project year included publishing experimental findings across multiple articles and conducting outreach initiatives. Throughout the year, we undertook tasks such as replicating experimental results, further optimizing various formulations and their associated experimental sets, and conducting additional tests to address missing components based on reviewer feedback and suggestions. We also explored the surfactant and friction-reduction aspects of selected formulations through drag reduction tests. In addition, we constructed an improved fracturing performance setup and performed flow injection tests. The specific DBC formulations focused on during this project period were A8/B1, A12/B5, and A10/B12. We also obtained results for additional DBC formulations and a select few commercial fracturing fluids for the purpose of comparison. Within the project's scope, we aim to enhance the experimental findings with the development of various models. The first two years focused on two key aspects: (i) the creation of a high-fidelity hydraulic fracturing model for non-Newtonian fluids to gain insights into the implementation of DBC fluids in fracking environments, and (ii) the development of a multiphase flow simulator for estimating total production, fluid saturation in the reservoir, and the creation of a fracture propagation model and kinetic Monte Carlo (kMC) models for diverse applications. In the third year, we delved into the fundamental nanostructural properties of DBCs, exploring aspects such as material chemistry, pH tunability, and control of DBC formation and stability. Subsequently, in the extension year, we conducted a systematic investigation of various building blocks containing primary, secondary, and tertiary amine functional groups to understand their impact on rheological and viscoelastic properties. Furthermore, we explored a Dissipative Particle Dynamics (DPD) model to simulate self-assembly processes with precision, creating a high-fidelity representation of relevant nanostructures. The tasks performed this year with the significant results obtained have been discussed in Section 2.

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

Marine Algae Industrialization Consortium (MAGIC): Combining biofuel and high-value bioproducts to meet the RFS

The Marine Algae Industrialization Consortium (MAGIC) was formed to address pressing challenges in the commercialization of microalgae as a source of biofuel. The “Marine Algae Industrialization Consortium (MAGIC): Combining biofuel and high-value bioproducts to meet the RFS” project formally addressed two US Department of Energy Bioenergy Technologies Office (BETO) goals: (1) Model the sustainable supply of 1 million metric tonnes ash free dry weight (AFDW) cultivated algal biomass and (2) Demonstrate valuable co-products produced along with biofuel intermediates to increase value of algal biomass by 30%. To achieve these goals, the project demonstrated and validated high-value co-products to drive down the cost of biofuel by increasing the value of algae “co-products” towards increasing the selling price of total algae biomass as one of the key drivers of economics and adoption. This was accomplished through five core, interdependent tasks including: (1) strain selection to identify and deliver strains for mass culture, (2) mass culture using a hybrid cultivation system and following key operating parameters for downstream applications to provide algae feedstock, (3) recovery and conversion to evaluate two alternative methods to separate dry algae biomass into oil and residuals for downstream testing, (4) product assessment to determine biofuel, aquafeed or poultry feed product efficacy using algae biomass fractions as well as to provide critical performance data for valuation and (5) commercialization to use technoeconomic and life cycle assessments (TEA/LCA) as iterative design and assessment tools including consideration of target markets, competitors, and distribution channels to guide product assessment, development and valuation. A total of 46 peer-review publications, many open-access, provide detail of much of the work carried out and the results of the tasks. Additional reports and presentations provide other technical and public engagement material. At a high level, using a variety of approaches, more than 1000 marine microalgae strains were evaluated to ultimately identify the seven winners that were down-selected to be grown in mass culture. Strain selection demonstrated that there were no ‘super strains’ and that each candidate had strengths and limitations for specific products, growth conditions or operational considerations. Mass culture growth of these seven strains at >5000 L / 29 m 2 scale found that four them were suitable for product assessment. More than 250 kg of biomass was produced across hundreds of pond runs along with thousands of cultivation entries on the growth and biomass characteristics as well as environmental parameters. In the process, dozens of standard operating procedures were generated as was custom software to process and analyze cultivation data. Recovery and conversion of algae biomass demonstrated that a hexane solvent based extraction protocol was most effective at recovering oil (biocrude) from algae and four strains were processed to produce oil and lipid extracted algae (residuals) for downstream testing. Membrane-based oil separation was less successful, but may still be applicable to other commercial applications in the future. Product testing demonstrated that algae biocrude is of high quality and hydrotreating generated numerous fractions of high quality composition for fuel and lubricate based applications. Aquafeed studies performed at a variety of scales showed that both whole and defatted (lipid extracted algae) microalgae were suitable as a feed ingredient, but that the specifics of the fed animal and biochemical composition of the algae are critical factors when determining formulation. Similarly, poultry studies on whole and defatted microalgae generally showed positive outcomes on animal growth and health, with some microalgae providing enhanced nutritional composition of the animal product. Economic and life cycle assessments covered a wide range of possible commercialization and sustainability scenarios. Replacement value, improved product value added, consumer values marketing added valuation and improved animal health were considered as alternatives for microalgae valuation. Using the open pond system, algae productivity was identified as the key driver of commercialization economics, but combination of co-products (e.g. animal feed) with biofuel production substantially increased the total selling price of algae. Modeled microalgae selling price exceeded $\$$1500/tonne and could generate competitive biofuel selling prices below $\$$5 gallon gas equivalents using realistic algal productivities. Short (process scale) and longer (decadal trends) sustainability assessments show that marine microalgae can enhance the sustainability of energy production and lead to other realized benefits in water, fertilizer and land use for other sectors (e.g. agriculture). This project successfully demonstrated all of the components of an end-to-end process from mass microalgae cultivation and dewatering, to recovery and conversion of algae biomass components, to final product demonstration and process valuation; the combined results provide a framework for future commercialization of algae based biofuels.

09 BIOMASS FUELS↗
DOE OSTI2024

Development of Human and Technology Integration Guidance for Work Optimization and Effective Use of Information

Existing nuclear power contributes to roughly 20% of the total electricity generation, and consistently provides the highest capacity factor of any other electricity generating resource in the United States. Despite these advantages, the existing nuclear power plant fleet in the United States has been enduring significant challenges in providing electricity in a cost-competitive manner, which has ultimately threatened the long-term economic viability of these plants. A major contributor to these increased operating and maintenance costs has been the continued reliance of a large workforce who perform their work under an operating model that has largely remained unchanged since the commissioning of these nuclear power plants. Unfortunately, while this operating model has provided safe and reliable electricity, other industries have already began transforming their workforce through the use of advanced digital technology and automation that has reduced their operating and maintenance cost significantly. In order for the United States nuclear industry to remain economically viable, a similar transformation must be considered in which digital technologies and automation capabilities are brought in to support key plant functions across all work functions across plant operation, maintenance, and support. To effectively integrate digital technology and automation in the existing nuclear power plant operating model, a multidisciplinary approach is needed that addresses technological and sociotechnical (i.e., human and technology integration) considerations. This report describes an extension to the human and technology integration methodology, herein referred to as Human Integration and Technology Task Force for Work Management Optimization (HITT), to support the safe, reliable, and efficient use of proposed innovations with the intended users in their intended environment to perform their intended tasks. By effectively incorporating human and technology integration into a plant modernization effort by using HITT, we believe that a utility can significantly improve work performance and overall workforce quality of life. For instance, if HITT is performed to optimize work management, scheduling performance and scope stability can be improved by up to 10%. HITT enables these benefits through developing a rich understanding of the work being performed, the utility’s vision, and the opportunities that provide greatest value to optimize performance through a 10-step process illustrated below as a quick guide. The quick guide contains links in the righthand side of each step that allows for navigation to the detailed section (Section 4) of HITT in this technical report.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Williston Basin CORE-CM Initiative Final Report

The University of North Dakota Energy & Environmental Research Center (EERC) is leading the Williston Basin Carbon Ore, Rare Earth, and Critical Minerals (CORE-CM) Initiative to drive the expansion and transformation of coal and coal-based resource usage within the Williston Basin to produce rare-earth elements (REEs), CMs, and nonfuel carbon-based products (CBPs). This project is the first phase in a long-term program and set the stage for future work by assessing resource, market, technology, and infrastructure knowledge; identifying knowledge gaps; developing a series of plans to be carried out in future work; and initiating stakeholder engagement. Composed of several tasks, the project sought to identify, characterize, and assess several necessary aspects vital to make this future work a reality. The project’s fundamental task was to characterize the Williston Basin CORE-CM resources. Over 2500 samples from multiple sources were utilized to begin the assessment. Several locations were identified in western North Dakota where sample analysis identified the total REE (TREE) concentration as being over 500 parts per million (ppm), which is at a concentration level that would be suitable to consider for mining and extraction. Current operating coal mines have sufficient concentrations of TREEs for consideration. However, the current data across the basin are still not adequate to fully characterize REE and CM content nor give reliable estimates of the total resource potential. Waste stream reuse was also considered, and several streams were identified which ranged from potential energy sources to chemicals to material wastes. This includes streams that result from oil and gas production. These streams are not fully characterized, and further data are needed before they can be accurately assessed. Infrastructure within the Williston Basin is suitable for expansion of a new industry to mine, extract, and concentrate REEs and CMs. The development of this industry will not only preserve many existing jobs in the coal-mining industry but produce many new jobs. The supply chain for REEs and CMs is currently controlled outside of the United States in nations such as China, but the potential to develop the supply chain within the basin is considered possible. Processing of the mined materials for REEs and CMs needs further research. The technology and knowhow exist outside of the United States, and within the country much of the knowledge has been lost and must be regained. To develop the supply chain and regain lost processing technology, the creation of technology innovation centers (TICs) is crucial. The Williston Basin contains several similar centers and entrepreneurial assistance for other industries that can be applied in the development of REE and CM innovation centers. Education to develop the new skill sets required is also needed. Outreach is important for the development of the REE and CM industry within the basin. Understanding throughout federal and state governments, state agencies, industry, and resource end users is vital for the industry to form and grow. Through this project these groups have been contacted through bulletins, presentations, webinars, and annual symposiums. The report is a summary of the work conducted and throughout refers to a series of appendixes which contain more thorough and specific information about each section.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

NuGraph2: A Graph Neural Network for Neutrino Event Reconstruction

Neutrino experiments are set to probe some of the most important open questions in physics, from CP violation and the nature of dark matter. The technology of choice for many of these experiments is the liquid argon time projection chamber (LArTPC). In current LArTPC experiments, reconstruction performance often represents a limiting factor for the sensitivity. New developments are therefore needed to unlock the full potential of LArTPC experiments. NuGraph2 is a state of the art Graph Neural Network for reconstruction of data in LArTPC experiments. NuGraph2 utilizes a heterogeneous graph structure, with separate subgraphs of 2D nodes (hits in each plane) connected across planes via 3D nodes (space points). The model provides a consistent description of the neutrino interaction across all planes. NuGraph2 is a multi-purpose network, with a common message-passing attention engine connected to multiple decoders with different classification or regression tasks. These include the classification of detector hits according to the particle type that produced them (semantic segmentation) and the separation of hits from the neutrino interaction from hits due to noise or cosmic-ray background. Additional decoders are being developed, performing tasks such as the regression of the neutrino interaction vertex position. Performance results will be presented based on publicly available samples from MicroBooNE. These include both physics performance metrics, achieving 95% accuracy for semantic segmentation and 98% classification of neutrino hits, as well as computational metrics for training and for inference on CPU or GPU. The status of the NuGraph integration in the LArSoft software framework will be presented, as well as initial studies about model interpretability and injection of domain knowledge.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2024

Light Water Reactor Sustainability Program: Use of Time Distributions to Predict Operator Procedure Performance in Dynamic Human Reliability Analysis

The Human Unimodel for Nuclear Technology to Enhance Reliability (HUNTER) framework affords software capable of conducting human reliability analysis (HRA) using a dynamic approach built around operating procedures (OPs) from nuclear power plants (NPPs). Previous HUNTER reports document the development of this software tool, the coupling of HUNTER to the simulator code, the collection of operator performance data by using simulators to calibrate HUNTER models, and linking HUNTER to probabilistic risk assessment (PRA) software. The present report largely addresses two topics. The first is a new function in HUNTER called the HUNTER Procedure Performance Predictor (P3). HUNTER P3 uses HUNTER’s built in Monte Carlo tools featuring human performance variability to identify potential error traps in procedures. The second topic is time distribution analysis to generate time inputs for dynamic HRA. The current analysis was performed to investigate time distributions for task primitives, which are the minimum task unit of analysis used in dynamic HRA modeling. Using the time distribution data, the elapsed time for human actions in an extended loss of AC power (ELAP) scenario is then investigated. Time data and prediction are essential for modeling procedure performance.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2024

Artificial Intelligence and Machine Learning Support for Probabilistic Fracture Mechanics

In this research, artificial intelligence and machine learning (ML) methods are used to search an uncertain parameter space more efficiently for the most important inputs with respect to response sensitivities. These methods are applied to the Extremely Low Probability of Rupture (xLPR) probabilistic fracture mechanics code used at the U.S. Nuclear Regulatory Commission (NRC) in support of nuclear regulatory research. This report documents two separate but related sub-tasks: (1) ranking important uncertain input features with respect to target outputs, determined by convergence in confidence intervals for increasing sample sizes using simple random sampling; and (2) implementation of a reduced-order surrogate model for fast, approximate sample generation. Unoptimized readily available off-the-shelf ML models were used in both sub-tasks.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Hanford Double Shell Waste Tank Corrosion Studies (Final Report FY2023)

For fiscal year (FY) 2023, the Savannah River National Laboratory (SRNL) focused on two experimental tasks related to Hanford Double Shell Tank (DST) chemistry and integrity. The first task focused on understanding risk of corrosion due to formation of either continuous layers or discrete patches of solids on the tanks’ inner sidewalls and bottoms. Differences in the conductivity between various layers of the tank (e.g., solids, liquid, etc.) could result in differences in the electrochemical potential of the tank metal at various locations. The electrochemical potential difference may result in a corrosion current between the coupled surfaces. In FY23, SRNL investigated test configurations and protocols that could evaluate the presence of a galvanic couple between the tank bottom and the tank wall.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Tools And Methods to Analyze Plant Outage Schedule and Assist Schedulers in Improving Outage Resilience

Refueling outages of nuclear power plants (NPPs) are considered one of the most critical phases throughout the plant lifetime. In such instances, tens of thousands of activities (e.g., maintenance, surveillance) are performed in a short amount of time (typically 2-3 weeks unless major backfitting or modernization projects are carried out) by a large number of crews (e.g., electricians, mechanics) that are hired as contractors. As a consequence, a plant outage can be expensive not only in terms of costs (e.g., contractor labor, material), but also in terms of loss generation since the plant is taken off the grid during the full outage duration (an indicative metric is about 1.2M$/day of loss of revenue). Thus, there is a continuous need to decrease the economic impact of outages on plant finances. This can be done by: decreasing the frequency of plant outages (e.g., from 18 to 24 months), reducing the time to complete the outage, and reducing the risk of outage delays. The Optimization of Outage Activities project under the Risk Informed Systems Analysis Pathway (RISA) sponsored by Department of Energy (DOE) Light Water Reactor Sustainability (LWRS) Program focuses on developing tools and methods to support NPPs with outage schedule optimization. The developed tools and methods are designed to analyze plant outage schedule with the goal of identify critical elements in the schedule that might pose a high risk of delays. These methods and tools can be considered resource-centric in the sense that they address outage challenges as a resource optimization problem. In this context, resources are either time and crews; outage delays occurs when either (or both) resources are insufficient to complete the set of tasks assigned at a specific time instant of the outage. This report provides details on how plant resources (time and crews) can be allocated in such a way that delays are minimized. In this respect, two classes of methods have been developed: the first one focuses on the time resource and how variability of the time to complete outage tasks may impact outage delays. The second one integrates available resources to assess when dailies activities should be performed such that the risk of outage delays are minimized.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Continuum Model Development for Flow and Transport in Electrochemical Systems

Stanford University (Subcontractor) shall provide the services of qualified multiscale modelers to perform tasks that contribute to reaching the objectives of the LDRD project entitled Automated and Accelerated Continuum Model Development for Electrochemical Systems (Tracking number 24-ERD-051). These tasks relate to the development, deployment, and validation of multiscale models relevant to flow and transport in electrochemical systems.

42 ENGINEERING↗
DOE OSTI2024

Technical Information Needs and Regulatory Considerations for Front-End Transportation Activities of HALEU Fuel Feed Material

This report fulfills task order number 31310022F0033 Task 1 Assessment of technical information needs and considerations for front-end transportation activities for HALEU fuel feed material. This assessment primarily focuses on the transportation outlook and packaging requirements for transporting high-assay low-enriched uranium (HALEU) fuel feed material. The regulatory framework is described in section 3.0. In section 4.0 the specific issues associated with reviewing HALEU feed material packages are discussed. The rest of the report discusses the need for new packages and Department of Energy progress on HALEU production. Through this evaluation it is shown that the 5% enrichment barrier between low-enriched uranium and HALEU is a significant challenge to transportation packaging. However, there are licensed designs and concepts that can be used to transport HALEU feedstock. No significant issues were identified through the HALEU range up to 20% enriched.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

C.9 Scribe NMAC Layer Video Development

This task incorporates NMAC insider threat principles and good practices into video format for aiding in training activities. It was labeled as Task C.9 under the FY24 Annex 1 for NA-211 SSM A&I Pillar. For activity development, the setting of a research and test reactor, RTR, was selected as the focus of this fiscal year. More specifically, a TRIGA reactor was selected for facility and reactor inspiration. FY 23/24 developed materials Research Reactor Facility Measures against the Insider Threat, LLNL-MI-839144, was used as a reference for selecting relevant, suggested mitigation measures to incorporate into the script and subsequent videos. Throughout the initial phases of development, discipline SMEs met with Scribe SMEs from Sandia National Laboratory to create the initial story arc and assess the limits of Scribe/Odin technologies available for the project. As a result, the decision for a two-fold deliverable was developed and utilized as the basis for script development efforts over the first half of the fiscal year.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2024

Core-Shell Oxidative Aromatization Catalysts for Single Step Liquefaction of Distributed Shale Gas (Final Technical Report)

The objective of this project was to design and demonstrate a core-shell structured multifunctional catalyst to convert the light (dry) components of shale gas into liquid aromatic compounds (primarily benzene and toluene) in a single step. Operated in a modular oxidative aromatization system (OAS) under a cyclic redox scheme, the novel catalyst and process can significantly improve the value and transportability of distributed shale gas. Since the project started, each quarter addressed a different set of tasks related to the completion of the milestone detailed in the project award. The yearly summaries of these tasks are summarized below: Q1-Q4: • Conducted project planning and literature search. • Investigated a number of SHC redox catalysts using thermogravimetric analysis and fixed-bed reactor experiments. • Initiated process modeling towards generating two process models for the methane DHA base case and OAS process. • Developed DHA catalysts capable of producing >500 g/kg-cat-hr aromatics at 80% or greater aromatics selectivity at 700°C. Q5-Q8: • Developed alternative approaches with sequential bed configurations to enhance the aromatic yields based on OCM+DHA • Improved the zeolite synthesis efficiency by using the microwave-assisted technique and investigated the synthesis conditions on the zeolite yield, crystalline structure and morphology • Constructed a set of Aspen Plus process models with significant energy savings for OAS as compared to the base case non-oxidative DHA. • Adapted conventional hydrothermal method to be applicable to the microwave synthesizer unit for more efficient catalyst synthesis. • Studied the structure of the OCM catalyst and the dispersion of the carbonate in the redox reactions and in methane flow with Raman Spectroscopy. Q9-Q12: • Scaled up the catalyst synthesis with the microwave synthesis method. Based on its performance, procedural characterizations and catalytic performance testing were further conducted for the new microwave synthesized catalysts with the newly-developed product analysis procedure. • Developed the reaction system setup for the C2-DHA or OCM+DHA reaction product and achieved a better product collection-analysis method for the aromatic products with an improved carbon balance. The product from the OCM reaction exhibited complicated effects on the DHA catalyst. • Conducted additional OCM catalyst characterization using Near Ambient Pressure X-ray Photoelectron Spectroscopy and in situ Raman characterization • Validated the significant energy savings for OAS as compared to the base case non-oxidative DHA. Successfully set up the simulation model for the OCM+DHA+SHC reaction system based on the updated experimental results from NCSU. Q13-End of project: • Synthesized new zeolite catalysts by the microwave method, conducted characterizations (XRD, SEM, and TEM) and catalytic behavior testing. • Explored the “wet” C 2 H 6 and C 2 H 4 DHA reactions with using steam co-feed. A subsequent reduction as the regeneration step can regenerate the DHA catalyst and recover 99% activity of the fresh performance. • Achieved a 15.3% single-pass aromatic yield from methane by rationally combining the OCM and DHA at different temperatures. • Conducted a 105-hour stability test with an improved regeneration procedure, with an average aromatic yield of 13.8%. • Developed new catalyst and achieved a record-high 23.2% yield.

03 NATURAL GAS↗
DOE OSTI2024

Performance Testing of a Moving-Bed Gasifier Using Coal, Biomass, and Waste Plastic Blends with Washed and Unwashed Legacy Coals and Other Waste Fuels to Generate White Hydrogen

The objective of this effort, primarily funded by the United States Department of Energy (DOE), and led by the Electric Power Research Institute, Inc. (EPRI), with support by Hamilton Maurer International (HMI) and Sotacarbo S.p.A. (Sotacarbo), has been to qualify coal, biomass, and plastic waste blends based on performance testing of selected fuel pellet compositions in a pilot-scale updraft moving-bed (UDMB) gasifier. The testing provided relevant data to advance the commercial-scale design of the moving-bed gasifier to be able to successfully use these feedstocks to produce hydrogen. In particular, the effects of waste plastics on feedstock development (i.e., blending and pelletizing) and the resulting products (i.e., syngas compositions, organic condensate production, and ash characteristics) are the focus. The gasifier used for testing is HMI’s moving-bed gasifier, which has been proven capable of gasifying nearly all coal ranks. It has also shown the ability in prior testing work to gasify wood chips (biomass). However, mixtures of these fuels with plastic wastes have not been prepared and gasified together. The three feedstocks were densified and pelletized by California Pellet Mill (CPM) to meet the feedstock size required by Sotacarbo’s 30mm ID UDMB gasifier, under contract to HMI. The technical tasks and results from this two-year research project included: (1) Feed Procurement and Preparation: Nine different tri-fuel pellets were prepared from varying compositions of fresh mined PRB coal, corn stover biomass, and car fluff waste plastics. Tri-fuel pellets were produced by CPM and shipped to Sotacarbo’s test facility in Carbonia, Sardinia, Italy. (2) Test Plan Development: A test plan was created to define the test runs to be performed. The test plan detailed the different UDMB gasification tests to be performed in Sotacarbo’s 12-inch ID pilot scale gasifier, the process monitoring instrumentation used, and the extractive samples recovered for analysis of the total gasification process mass and energy balance. (3) Gasifier Testing: Nine different gasification runs were performed in the pilot-scale gasifier at Sotacarbo using nine different fuel feedstock compositions generated from varying mixtures of PRB coal, biomass, and plastic wastes. The testing generated performance data on gasification reaction efficiency and performance, yielding relevant data for models used to scale up the gasifier design. This task also included work to refurbish and reassemble the pilot gasifier at Sotacarbo and perform a baseline 100% PRB coal run. (4) Data Analysis and Reporting: Review of the data, determination of figures of merit, and interpretation of the results are reported in the project’s final report, published in March 2024. The results show that all tri-fuel pellets gasified well and maintained structural integrity throughout the gasification process. The syngas generated can be shifted to hydrogen by using commercial syngas shifting technologies. (5) High Fidelity computational fluid dynamics (CFD) Simulation: The National Energy Technology Laboratory (NETL) team performed CFD simulations of the UDMB gasifier for two of the tri-fuel pellets gasified in Sotacarbo’s pilot scale gasifier. The kinetic mechanisms for the pyrolysis of each constituent, PRB coal, corn stover biomass, and waste plastics are based on thermogravimetric analysis performed by Sotacarbo. The gasification model was validated by comparing the predicted syngas composition at the exit of the gasifier with the measured syngas composition. In addition, the reactor’s measured internal temperature profile agreed well with the predicted internal reactor temperature profile. These results validate that the model can be used to predict the performance of the updraft moving bed gasifier for different feedstocks and operating conditions. This paper summarizes the results of the completed work in which the pelletizing procedure was validated to ensure the viability of the tri-fuel pellets for the gasification runs performed at Sotacarbo’s 30 mm UDMB gasifier. The gasification performance data from this series of nine runs will enable modeling of a full-scale HMI industrial scale gasifier supporting both combined heat and power, and Hydrogen production from coal (both fresh mined and legacy) combined with various biomass and waste plastics. Additionally, plans and progress on a follow-up project, being executed by the same project team, will be presented. In this project, a total of twenty (20) different feedstocks are being prepared from varying compositions of biomass (both woody biomass and corn stover) with a mixture of legacy coal waste, plastic waste, and refuse-derived fuel (RDF). The testing will provide information on gasification reaction efficiency/performance, yielding relevant data for models used to scale up the gasifier design to 50 megawatt electric (MWe) (equivalent hydrogen production). Tests will also be performed on a bench-scale fluidized-bed gasifier for comparison purposes. The results of this testing will be used to specify the range of feedstock blends that can be successfully gasified as well as quantify gasifier outputs based on specific blends.

08 HYDROGEN↗