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DOE OSTI2024

Custom-form iron trifluoride Li-batteries using material extrusion and electrolyte exchanged ionogels

Custom-form factor batteries fabricated in non-conventional shapes can maximize the overall energy density of the systems they power, particularly when used in conjunction with energy dense materials (e.g., Li metal anodes and conversion cathodes). Additive manufacturing (AM), and specifically material extrusion (ME), have been shown as effective methods for producing custom-form cell components, particularly electrodes. However, the AM of several promising energy dense materials (conversion electrodes such as iron trifluoride) have yet to be demonstrated or optimized. Furthermore, the integration of multiple AM produced cell components, such as electrodes and separators, along with a custom package remains largely unexplored. In this work, iron trifluoride (FeF 3 ) and ionogel (IG) separators are conformally printed using ME onto non-planar surfaces to enable the fabrication of custom-form Li-FeF 3 batteries. Further, to demonstrate printing on non-planar surfaces, cathodes and separators were deposited onto cylindrical rods using a 5-axis ME printer. ME printed FeF 3 was shown to have performance commensurate with FeF 3 cast using conventional means, both in coin cell and cylindrical rod formats, with capacities exceeding 700 mAh/g on the first cycle and ranging between 600 and 400 mAh/g over the next 50 cycles. Additionally, a ME process for printing polyvinylidene fluoride-co-hexafluoropropylene (PVDF-HFP) based IGs directly onto FeF 3 is developed and enabled using an electrolyte exchange process. In coin cells, this process is shown to produce cells with similar capacity to cells built with Celgard separators out to 50 cycles, with the exception that cycling instabilities are observed during cycles 8–20. When using printed and exchanged IGs in a custom cylindrical cell package, 6 stable high-capacity cycles are achieved. Overall, this work demonstrates approaches for producing high-energy-density Li-FeF 3 cells in coin and cylindrical rod formats, which are translatable to customized, arbitrary geometries compatible with ME printing and electrolyte exchange.

25 ENERGY STORAGE↗

DOE OSTI2017

A novel method for resonant inelastic soft X-ray scattering via photoelectron spectroscopy detection

A method for measuring resonant inelastic X-ray scattering based on the conversion of X-ray photons into photoelectrons is presented in this paper. The setup is compact, relies on commercially available detectors, and offers significant flexibility. Finally, this method is demonstrated at the Linac Coherent Light Source with ~0.5 eV resolution at the cobalt L 3 -edge, with signal rates comparable with traditional grating spectrometers.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2017

Final Research Performance Progress Report: Geothermal Resource Development with Zero Mass Withdrawal, Engineered Convection, and Wellbore Energy Conversion

This project is intended to demonstrate the technical and economic feasibility, and environmental and social attractiveness of a novel method of heat extraction from geothermal reservoirs. The emphasis is on assessing the potential for a heat extraction method that couples forced and free convection to maximize extraction efficiency. The heat extraction concept is enhanced by considering wellbore energy conversion, which may include only a boiler for a working fluid, or perhaps a complete boiler, turbine, and condenser cycle within the wellbore. The feasibility of this system depends on maintaining mechanical and hydraulic integrity of the wellbore, so the material properties of the casing-cement system are examined both experimentally and with well design calculations. The attractiveness depends on mitigation of seismic and subsidence risks, economic performance, environmental impact, and social impact – all of which are assessed as components of this study.

15 GEOTHERMAL ENERGY↗

DOE OSTI2017

Electrochemical device for syngas and liquid fuels production

The invention relates to methods for creating high value liquid fuels such as gasoline, diesel, jet and alcohols using carbon dioxide and water as the starting raw materials and a system for using the same. These methods combine a novel solid oxide electrolytic cell (SOEC) for the efficient and clean conversion of carbon dioxide and water to hydrogen and carbon monoxide, uniquely integrated with a gas-to-liquid fuels producing method.

02 PETROLEUM↗

DOE OSTI2019

Catalysts for conversion of 2,3-butanediol-containing fermentation mixture to hydrocarbons

A method for producing one or more hydrocarbon compounds from at least one of 2,3-butanediol, acetoin, and ethanol, the method comprising contacting said at least one of 2,3-butanediol, acetoin, and ethanol with a catalyst at a temperature of at least 100° C. and up to 500° C. to result in said 2,3-butanediol, acetoin, and/or ethanol being converted to said one or more hydrocarbon compounds, wherein said catalyst is either: (i) a catalyst comprising nanoparticles composed of (a) a first metal oxide selected from the group consisting of zirconium oxide, cerium oxide, titanium oxide, and lanthanum oxide, and (b) a main group metal oxide; or (ii) a catalyst comprising a zeolite loaded with at least one metal selected from the group consisting of copper, silver, nickel, palladium, platinum, rhodium, and ruthenium in an amount of 1-30 wt % by weight of the zeolite.

09 BIOMASS FUELS↗

DOE OSTI2020

Zeolitic catalytic conversion of alcohols to hydrocarbon fractions with reduced gaseous hydrocarbon content

A method for converting an alcohol to a hydrocarbon fraction reduced in gaseous hydrocarbon content, the method comprising: (i) contacting said alcohol with a metal-loaded zeolite catalyst under conditions suitable for converting said alcohol to a first hydrocarbon fraction containing liquid hydrocarbons having at least five carbon atoms along with gaseous hydrocarbons having less than five carbon atoms, wherein said metal-loaded zeolite catalyst is catalytically active for converting said alcohol to said first hydrocarbon fraction; and (ii) selectively removing said gaseous hydrocarbons from the first hydrocarbon fraction and contacting said gaseous hydrocarbons with a metal-loaded zeolite catalyst under conditions suitable for converting said gaseous hydrocarbons into liquid hydrocarbons having at least five carbon atoms to produce a second hydrocarbon fraction reduced in gaseous hydrocarbon content, wherein the metal-loaded zeolite catalyst in steps (i) and (ii) are the same or different.

09 BIOMASS FUELS↗

DOE OSTI2022

Conversion of lignin into bioplastics and lipid fuels

The present invention provides methods and compositions for increasing lignin degradation to produce a biological product. Also provided are methods for increasing expression of laccase in a bacterial species to produce increased lignin degradation. Also provided are bacterial cells and commodities or commodity produces produced from such methods.

Yuan, Shuhua↗

DOE OSTI2019

Synthesis and emerging properties of 2D layered III–VI metal chalcogenides

Atomically thin layered III–VI metal chalcogenides are an emerging class of 2D materials that have attracted increasing attention in recent years due to their remarkable physical properties and technological applications. Thanks to the recently developed theoretical and experimental methods, a number of exciting discoveries for these materials have revealed their new phases, a unique “Mexican hat”-shaped electronic band structure, and superior optical and electronic properties that distinguish them from other 2D materials such as transition metal dichalcogenides. This review summarizes the novel properties, structures, and synthesis strategies for these materials and emphasizes the most cutting-edge and seminal achievements in this rapidly growing field in order to provide input for future research works. We first present the rich crystal structure and phases that have been found in these materials, with an emphasis on the possibility of phase engineering. Then, we discuss the synthesis strategies for 2D layered III–VI metal chalcogenides from the top-down, bottom-up, and template-based chemical conversion approaches. We focus on the highly controlled synthesis methods that provide fine-tuning of the thickness, phase, edge structure, and other morphological characteristics. Third, we discuss the properties and applications of these materials, focusing on their unique electronic structure including the Mexican hat-shaped valence band, their superior nonlinear optical properties, high-performance electronic devices, promising photoelectrochemical properties, and emerging quantum properties such as quantum emission, exciton condensation, ferromagnetism, and topological quantum phase transition. To conclude, we provide our perspective on the current challenges and future directions in this field.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Biorefining compounds and organocatalytic upgrading methods

The invention provides new methods for the direct umpolung self-condensation of 5-hydroxymethylfurfural (HMF) by organocatalysis, thereby upgrading the readily available substrate into 5,5'-di(hydroxymethyl)furoin (DHMF). While many efficient catalyst systems have been developed for conversion of plant biomass resources into HMF, the invention now provides methods to convert such nonfood biomass directly into DHMF by a simple process as described herein. The invention also provides highly effective new methods for upgrading other biomass furaldehydes and related compound to liquid fuels. The methods include the organocatalytic self-condensation (umpolung) of biomass furaldehydes into (C.sub.8-C.sub.12)furoin intermediates, followed by hydrogenation, etherification or esterification into oxygenated biodiesel, or hydrodeoxygenation by metal-acid tandem catalysis into premium hydrocarbon fuels.

09 BIOMASS FUELS↗

DOE OSTI2017

Biorefining compounds and organocatalytic upgrading methods

The invention provides new methods for the direct umpolung self-condensation of 5-hydroxymethylfurfural (HMF) by organocatalysis, thereby upgrading the readily available substrate into 5,5'-di(hydroxymethyl) furoin (DHMF). While many efficient catalyst systems have been developed for conversion of plant biomass resources into HMF, the invention now provides methods to convert such nonfood biomass directly into DHMF by a simple process as described herein. The invention also provides highly effective new methods for upgrading other biomass furaldehydes and related compound to liquid fuels. The methods include the organocatalytic self-condensation (umpolung) of biomass furaldehydes into (C.sub.8-C.sub.12)furoin intermediates, followed by hydrogenation, etherification or esterification into oxygenated biodiesel, or hydrodeoxygenation by metal-acid tandem catalysis into premium hydrocarbon fuels.

09 BIOMASS FUELS↗

DOE OSTI2021

Prototype and Codesign of Nascent Flexible Wave Energy Converter Concepts

Prevailing mainstream ocean wave energy converter (WEC) archetypes are often relatively large monolithic rigid bodies with singular means of power take-off (e.g., relative motion between rigid bodies) and solo prime mover mechanisms (e.g. a rotary generator, a hydraulic piston). These mainstream WEC archetypes have existed for decades with some having histories spanning more than a century of significant investments and interests. As an alternative to the domain of mainstream WEC archetypes is the domain of distributed embedded energy converter technologies (also known as DEEC-Tec). Use of DEEC-Tec to create WECs - often called flexWECs - is a nascent domain of research and development that centers itself upon the interconnection of many relatively small energy converters - very small energy transducers - that interconnect and combine to create a much larger, overall, energy converting structure. The DEEC-Tec domain enables promising possibilities such as: direct in situ ocean wave energy harvesting and conversion throughout the volume of an entire flexWEC; inherent broad-banded ocean wave energy capture and conversion arising from near semi-continuous structural degrees of freedom; an innate absence of focusing and concentrating of ocean wave energy into a single prime mover and/or transmission system; and built-in implicit redundancy. As such, the DEEC-Tec domain could revolutionize how we conceptualize ocean wave energy conversion - both in terms of ocean wave energy converter design and what we view as viable environments and circumstances for ocean wave energy conversion. The research and development opportunities for the DEEC-Tec domain, therefore, are vast compared to the prevailing mainstream ocean wave energy converter domain. Correspondingly, there are ample opportunities to invest time and money into the DEEC-Tec domain with an aim to enable a paradigm shift in how ocean waves can be utilized as a more viable form of renewable energy. To that end, two seedling efforts have been enacted providing a very cursory investigation into the DEEC-Tec domain: (1) a preliminary simple fabrication/prototyping effort and (2) a preliminary co-design effort. The prototype seedling centers upon the design of a fabrication and evaluation rig for individual DEEC-Tec transducers; e.g., dielectric elastomer generators. The co-design seedling centers upon the analysis of those methods suitable for DEEC-Tec, ocean wave energy conversion, and fluid-structure interaction co-design efforts.

50 EE - Wind and Water Power Program - Water (EE-4↗

DOE OSTI2021

One-loop matrix elements of effective superstring interactions: α' -expanding loop integrands

In the low-energy effective action of string theories, non-abelian gauge interactions and supergravity are augmented by infinite towers of higher-mass-dimension operators. We propose a new method to construct one-loop matrix elements with insertions of operators D 2k F n and D 2k R n in the tree-level effective action of type-I and type-II superstrings. Inspired by ambitwistor string theories, our method is based on forward limits of moduli-space integrals using string tree-level amplitudes with two extra points, expanded in powers of the inverse string tension α'. Similar to one-loop ambitwistor computations, intermediate steps feature non-standard linearized Feynman propagators which eventually recombine to conventional quadratic propagators. With linearized propagators the loop integrand of the matrix elements obey one-loop versions of the monodromy and KLT relations. We express a variety of four- and five-point examples in terms of quadratic propagators and formulate a criterion on the underlying genus-one correlation functions that should make this recombination possible at all orders in α'. The ultraviolet divergences of the one-loop matrix elements are crosschecked against the non-separating degeneration of genus-one integrals in string amplitudes. Conversely, our results can be used as a constructive method to determine degenerations of elliptic multiple zeta values and modular graph forms at arbitrary weight.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2017

Life-cycle analysis of greenhouse gas emissions from renewable jet fuel production

Background: The introduction of renewable jet fuel (RJF) is considered an important emission mitigation measure for the aviation industry. This study compares the well-to-wake (WtWa) greenhouse gas (GHG) emission performance of multiple RJF conversion pathways and explores the impact of different co-product allocation methods. The insights obtained in this study are of particular importance if RJF is included as an emission mitigation instrument in the global Carbon Offsetting and Reduction Scheme for International Aviation (CORSIA). Results: Fischer–Tropsch pathways yield the highest GHG emission reduction compared to fossil jet fuel (86–104%) of the pathways in scope, followed by Hydrothermal Liquefaction (77–80%) and sugarcane- (71–75%) and corn stover-based Alcohol-to-Jet (60–75%). Feedstock cultivation, hydrogen and conversion inputs were shown to be major contributors to the overall WtWa GHG emission performance. The choice of allocation method mainly affects pathways yielding high shares of co-products or producing co-products which effectively displace carbon intensive products (e.g., electricity). Conclusions: Renewable jet fuel can contribute to significant reduction of aviation-related GHG emissions, provided the right feedstock and conversion technology are used. The GHG emission performance of RJF may be further improved by using sustainable hydrogen sources or applying carbon capture and storage. Based on the character and impact of different co-product allocation methods, we recommend using energy and economic allocation (for non-energy co-products) at a global level, as it leverages the universal character of energy allocation while adequately valuing non-energy co-products.

Bioenergy↗

DOE OSTI2023

IPL-Annealed Mixed-Cation Perovskites with Robust Coating Window toward Scalable Manufacturing of Commercial Perovskite Solar Cells

Perovskite solar cells (PSCs) are a promising alternative solar technology, but the technical challenges of (1) stability/durability, (2) efficiency at scale, and (3) manufacturability must be overcome to achieve widespread PSC commercialization. The challenge of balancing solution ink formulation and scalable manufacturing is often overlooked in the literature, where focus is on adopting inks from processes that will not scale. In this study, we apply a classical roll-to-roll manufacturing perspective, utilizing both compositional engineering and intense pulsed light (IPL) annealing, to develop a mixed-cation perovskite ink with a robust coating window that simultaneously solve issues of stability and manufacturability for PSCs. Our method resulted in blade-coated, flexible, mixed-cation PSCs on ITO-PET substrates with a champion power conversion efficiency (PCE) efficiency of 16.7% using IPL annealing of the absorber layer and, to our knowledge, is one of the fastest processing methods for the perovskite layer. This overall reduction in processing time with a stable ink represents an advance toward the scaled production of perovskite solar cells on flexible substrates.

flexible perovskite solar cells↗

DOE OSTI2023

Neutron imaging the spatial progression of chemical oxidation of lithium-ion cathode material in a packed bed reactor

Emerging electrochemical systems relevant to energy applications including redox targeted flow batteries rely on chemical redox of solid electroactive materials using dissolved redox couples. One configuration to facilitate contact between the redox shuttles and solid material which is volume efficient is a packed bed reactor. While methods have been reported to assess the overall progression by analysis of the packed bed reactor effluent, herein analysis of the spatial progression of the chemical redox will be reported. Combination of neutron and x-ray tomography enabled assessing the pore and particle structure in the packed bed reactor and the spatial homogeneity of the reaction at different overall extents of conversion of the reactor bed. Finally, these characterization tools provide methods to probe the chemical redox processes occurring within the reactor environment.

25 ENERGY STORAGE↗

DOE OSTI2025

Improving cellulose attribution by selectively removing yeast glucans from grain fermentation intermediates

Abstract This article presents an industry-relevant method for quantifying cellulose in mixed substrate samples. We built upon the cellulosic glucan measurement proposed by Sluiter et al. (2021) to investigate significant cellulose loss under cold caustic conditions, which has hindered the establishment of an industrially relevant method. To overcome this issue, we used dimethyl sulfoxide (DMSO) as an alternative solvent, which avoids mercerization reactions (Budtova and Navard 2015) but may leave some resistant starch in the sample. Treatment via an enzyme mixture removed starch and conformed to US Environmental Protection Agency (EPA) guidance on cellulose measurement by establishing quantitative de-starching via nuclear magnetic resonance (EPA 2022). The selective removal of yeast beta-glucan was accomplished using a commercially available Zymolyase. Our results demonstrated excellent reproducibility, with coefficients of variance of 7.14% or less, when measuring cellulose in low cellulose content samples. The method was tested on relevant lab and plant samples, showing an average 0.9% ethanol derived from the conversion of cellulose when cellulase was added to the process and zero response when no cellulase was added. These findings indicate that a cellulose method using DMSO and pullulanase provides a complete and accurate view of cellulose content, composition, and conversion in industrial fermentation processes.

Sluiter, Justin [National Renewable Energy Laborat↗

DOE OSTI2025

A Review of Value of Solar Studies In Theory and In Practice

This brief summarizes a collection of state- and utility-commissioned value-of-solar (VoS) studies and related literature, with a focus on who commissioned the study, which value and cost categories were discussed and/or quantified, and the methods used. Our objective is to compile information on prior VoS studies to inform state regulators and other stakeholders that may pursue related studies or integrate findings into rate design. The brief is organized into three parts: 1) an introduction to distributed solar photovoltaic (DPV) compensation; 2) a review of theoretical research on VoS; and 3) a review of VoS studies. The vast majority of VoS studies have served an informational role of quantifying the net benefits of PV. Three studies were commissioned in states or utility service territories that subsequently implemented VoS tariffs in California, New York, and Austin, Texas. When applied as a tariff, VoS aims to compensate PV output as efficiently as possible by doing so at rates that reflect the marginal benefits and costs of PV through value and cost categories that may vary temporally and/or geographically. This could lead to higher compensation in locations and times where more PV output is more valuable and consequently drive adoption in those locations to provide more societal benefits. Value and cost factors can be broadly grouped into five categories: generation, transmission, distribution, other utility, and other social categories. Those conducting VoS studies must weigh various tradeoffs when deciding which categories to include and quantify. Tradeoffs include prioritizing values based on their magnitude of value or cost impact, as well as taking into account the feasibility of data collection and accurate quantification. Values of higher magnitude and estimation feasibility are quantified in the majority of studies, including the earliest of studies conducted in the 2000s and 2010s. Additionally, some values of higher magnitude but low feasibility in the earliest of studies have become quantifiable in recent years. There are some values with low average system-wide levels but very high magnitude in specific locations or hours. The value magnitude in some cases can be tied to DPV penetration with low value in areas with little congestion and/or low penetration and vice versa. In these cases, values that are easier to quantify are often incorporated, while those that are more difficult are often addressed via a placeholder value. The placeholder value is paired with a discussion around data needs and methods to improve future estimates, as well as a conversation about when these value categories may increase in magnitude and necessitate more rigorous quantification. This brief summarizes findings from two meta-analyses of VoS studies that took place between 2005 and 2018, as well as findings from four additional studies published from 2018 to 2023. Table ES-1 summarizes the various value and cost categories included in each respective study and whether they were quantified, discussed, or omitted. Values such as avoided energy, capacity, transmission capacity, line losses, and avoided environmental costs are quantified in every study. Some categories were deemed harder to quantify and less impactful at the time of the study, so they were discussed but not quantified (e.g., ancillary services). Other categories, including many at the distribution level, were very locationally and/or temporally specific and dependent on high DPV penetration. These were sometimes quantified and at other times discussed. Notably, when it came to utility costs, integration costs were discussed in all cases, though they were deemed to have a small impact. Other utility costs were omitted for the most part; however, the utility-commissioned study (by NorthWestern Energy in Montana) included both lost utility revenue and programmatic/administrative cost categories. While there are some similarities across studies, each had fairly unique methods that are detailed in the body of this brief.

14 SOLAR ENERGY↗

DOE OSTI2017

Complete carbon analysis of sulfur-containing mixtures using postcolumn reaction and flame ionization detection

Quantitative analysis of complex mixtures containing hundreds-to-thousands of organic compounds rich in heteroatoms, including oxygen, sulfur, and nitrogen, is a major challenge in the fuel, food, and chemical industries. In this work, a two-stage (oxidation and methanation) catalytic process in a 3-D–printed metal microreactor was evaluated for its capability to convert sulfur-containing organic compounds to methane. The microreactor was inserted into a gas chromatograph between the capillary column and flame ionization detector. Catalytic conversion of all sulfur-containing analytes to methane enabled carbon quantification without calibration, by the method identified as “quantitative carbon detection” or QCD. Quantification of tetrahydrothiophene, dimethyl sulfoxide, diethyl sulfide, and thiophene indicated complete conversion to methane at 450°C. Long-term performance of a commercial microreactor was evaluated for 2000 consecutive injections of sulfur-containing organic analytes. The sulfur processing capacity of the microreactor was identified experimentally, after which reduced conversion to methane was observed.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗