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DOE OSTI2019

Life cycle assessment of biochar produced from forest residues using portable systems

Forest fires are getting extreme and more frequent because of increased fuel loads in the forest and extended dry conditions. Fuel treatment (i.e., thinning) methods to mitigate forest fires will generate large volumes of forest residues together with available logging residues that can be used to produce biochar. It has been proposed that portable biochar systems are economical means to utilize forest residues as an alternative to slash burning. In this study, the environmental impacts of biochar produced from forest residues using three portable systems [1. Biochar Solutions Incorporated (BSI), 2. Oregon Kiln, and 3. Air-curtain Burner] were evaluated using a cradle-to-gate life-cycle assessment approach. Environmental impacts were analyzed considering the various quality of feedstock, biomass collection methods, different production sites, and various sources of power used in the production of biochar. The results illustrate that the global warming potential (GWP) of biochar production from forest residues through BSI, Oregon Kiln, and Air-Curtain Burner were 0.25–0.31, 0.11, and 0.16 tonne CO 2 eq./tonne of fixed carbon in biochar respectively. Compared to pile burn, biochar production from forest residues with a portable system at the landing, reduced global warming potential (GWP) by 1.92–2.83, 2.7, and 1.9 tonnes CO 2 eq./tonne of biochar through BSI, Oregon Kiln, and Air-Curtain Burner respectively. The Air-Curtain Burner and Oregon Kiln have minimal feedstock preparation, thus have lower environmental impacts than the BSI system. The BSI system requires feedstock preparation and power to operate the system. The use of the biomass-gasifier generator improved the environmental performance substantially (16–280%) compared with a diesel generator in biochar production. Overall, the net GWP in biochar produced (0.10–1.63 tonne CO 2 eq./tonne of residues) from forest residues can reduce environmental impacts (2–40 times lower net CO 2 eq. emissions) compared to slash burning.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2018

Modifying High-Voltage Olivine-Type LiMnPO 4 Cathode via Mg Substitution in High-Orientation Crystal

The LiMnPO4 material with Mg2+ ion substitution in transition metal site is successfully obtained by a facile solvothermal method combining with the subsequent spray drying and pyrolysis. The TEM image shows the controlled crystalline orientation of the primary Mg-doped LiMnPO4 particle, and the three-dimensional (3D) hierarchical micronano structure and the electronic structure of the Mg-doped material are investigated by the reconstructed nanotomography and X-ray absorption spectroscopy, respectively. The uniformity of Mg2+ ions substitution at the secondary particle level is confirmed by the transmission X-ray microscopy combined with X-ray absorption near edge structure. The prepared material exhibits an excellent electrochemical performance with the capacity of 156 mAh/g at the rate of 0.1 C, and good capacity retention of 100% after 400 cycles at the rate of 1 C. The in operando synchrotron X-ray diffraction data indicate that the performance improvement of the Mg-doped materials is attributed to the changed electrochemical reaction mechanism from the typical two-phase reaction for pristine LiMnPO4 material to the two-phase reaction combined with the single-phase (solid-solution) reaction process. These findings provide a new approach and understanding on developing high-energy cathode materials for lithium-ion batteries.

high orientation↗

DOE OSTI2025

Cold-Sprayed NMC622 Composite as a Cathode for Lithium-Ion Batteries

The growing demand for high-energy, low-cost lithium-ion batteries (LIBs) to power electric vehicles (EVs) necessitates advances in both materials and manufacturing processes. Conventional cathode fabrication methods, such as slurry casting and drying, are energy-intensive and pose challenges for scalability and environmental compliance. In this study, we propose cold-spray (CS) deposition as a solvent-free approach for fabricating LiNi 0.6 Mn 0.2 Co 0.2 O 2 (NMC622) composite cathodes. Powder blends of NMC622, poly(vinylidene fluoride) (PVDF), and carbon black (CB) are directly deposited onto stainless steel and Inconel substrates under varied gas temperatures, pressures (and thus velocities), and standoff distances. The effects of temperature on the deposit morphology, coating density, and volume are systematically investigated. Computational fluid dynamics simulations reveal that increasing the gas temperature enhances the particle velocity, narrows the spray angle, and reduces the mass concentration radially at the nozzle outlet. CS deposition results in a dense cathode microstructure, accompanied by fracture in polycrystalline NMC622 particles. X-ray diffraction analysis further verifies that there are no phase changes during the deposition process. The electrochemical performance of the cold-sprayed cathodes reveals an initial capacity of approximately 96 mAh g –1 for single-crystal NMC622 and 167 mAh g –1 for polycrystalline NMC622. While these values are modest compared to state-of-the-art slurry-cast cathodes, which typically exhibit 180–200 mAh g –1 under optimized conditions. The results demonstrate a competitive performance given the solvent-free nature of the CS process and compare favorably with tape-cast samples made from identical feedstock. In conclusion, he CS process enables the formation of dense, binder-integrated cathode coatings without the need for solvent processing, offering a promising pathway for scalable, energy-efficient dry electrode manufacturing of next-generation LIBs.

Batteries↗

DOE OSTI2020

Reforming of methane with carbon dioxide over cerium oxide promoted nickel nanoparticles deposited on 4-channel hollow fibers by atomic layer deposition

Ni nanoparticles were deposited on four-channel structured α-Al2O3 hollow fibers by atomic layer deposition (ALD). CeO 2 was loaded by a liquid phase incipient wetness method to promote Ni catalysts for dry reforming of methane. For Ni/Al 2 O 3 prepared by ALD, inactive NiAl2O4 that originated from the Ni ALD process was incompletely reduced. The introduced CeO 2 was found to weaken the NiO–Al 2 O 3 interaction, free NiO from NiO–Al 2 O 3 or NiAl 2 O 4 , and improve the reducibility of NiO. The higher reducibility of NiAl 2 O 4 , tuned by CeO 2 , further activated the catalyst during DRM, because a larger proportion of NiAl 2 O 4 was gradually reduced to metallic nickel by the reaction products. The optimal catalytic performance reached a methane reforming rate of 2410 L h -1 gNi -1 at 850 °C. The CeO 2 promoted catalyst also exhibited an excellent performance after regeneration. In addition, the inhibition effect of CeO 2 on coke formation was observed, due to the enhanced CO 2 dissociative adsorption by CeO 2 .

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Developments in algal processing

Macroalgae and microalgae, including cyanobacteria, are primarily photosynthetic organisms grown for the production of renewable biomass for foods, feedstocks, and high-value specialty chemicals. While there are differences in cultivating and harvesting macro- and microalgae due to scale, many of the same downstream techniques can be used for processing algal biomass. This chapter will outline various developments in processing technologies used for the treatment of algal biomass with discussion of scalability, cost, time, and efficacy. Topics will cover methods for harvesting and dewatering algae, drying algal biomass, biomass disruption, and nutrient recovery, including case studies with lessons learned. Here, the final section presents biomass applications and product considerations. While there is no universally-adopted approach for processing algal biomass, these studies provide the foundation for making informed decisions, considering the unique properties of the algae and the integrity of the desired end products.

09 BIOMASS FUELS↗

DOE OSTI2010

Alternative Electrochemical Salt Waste Forms, Summary of FY2010 Results

In FY2009, the Pacific Northwest National Laboratory (PNNL) performed scoping studies to down-select two candidate waste forms for spent electrochemical salt, tellurite (TeO 2 -based) glasses and high-halide minerals. Both candidates showed promise with acceptable Product Consistency Test (PCT) responses (i.e., an assessment of chemical durability) and immobilization of at least 10 mass% fission product waste stream. These candidates were investigated in FY2010. Sodalite was successfully synthesized by the sol-gel method. The vast majority of the dried sol-gel consisted of sodalite with small amounts of alumino-silicates and unreacted salt. Upon firing the powders made by sol-gel, the primary phase observed was sodalite with the addition of various amounts of nepheline, carnegieite, lithium silicate, and lanthanide oxides. The amounts of sodalite, nepheline, and carnegieite varied with firing temperature, as did the bulk density of the fired pellets, sol-gel process chemistry, and the amount of glass sintering aid added to the batch. As the firing temperature was increased from 850°C to 950°C, chloride volatility increased, the fraction of sodalite decreased, and the fractions of nepheline and carnegieite increased. This indicates that the sodalite structure is not stable and begins to convert to nepheline and carnegieite under these conditions at 950°C. Density has an inverse relationship with firing temperature. The addition of NBS-1, a borosilicate glass sintering aid, had a positive effect on bulk density and increased the stability of the sodalite structure. A summary data table for FY2010 halide mineral investigations is presented in Table S1.1.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2018

Big Area Additive Manufacturing (BAAM) Materials Development and Reinforcement with Advanced Composites

Additive manufacturing (AM) by extrusion deposition is rapidly developing as an energy efficient process that greatly reduces development time for new products including vehicle structures. Development of reinforced thermoplastic compounds that are specifically tailored to the AM process and possess the properties necessary for engineering structures is currently underway. This project focused on developing a fundamental understanding of printability by performing a number of polymer characterization tests, initial printability screenings, and basic mechanical property determinations for a number of compounds. Structural evaluations of more complex printed articles were also performed in order to build a database of mechanical performance for validation of structural simulations planned for Phase II. Included in the structural tests were components that were reinforced using a number of methods including over-wrapping with dry fabric and resin infusing to form an advanced composite having the shape of the 3D printed structure. The results indicate a number of factors that affect printability of materials, and initial structural analysis shows that the data generated will be useful for model validation.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Liquefaction of pelleted corn cobs

Liquid slurries at high loadings (pumpable slurries) are critical to handle the streams between the unit operations in a biorefinery. Their liquefaction potential was initially tested with a small-scale method using 3FPU Ctec-2 /g dry biomass, and results were confirmed in 1L bioreactors experiments. Liquid slurries of cobs were observed in small scale tests (based on visual appearance, and reducing sugars released). Results were confirmed in 1L bioreactors under similar experimental conditions. Yield stress value in bioreactor was 34 ± 6Pa at 96 h, and glucan and xylan conversion to glucose and xylose, respectively, were 41 and 21%. In addition, work has been initiated with liquefaction of other pelleted corn stover fractions: Husk/Leaf (A),Husk (B), Stems (D) and controls (whole corn stover; F and G). Compositional analysis of the pellets showed glucan content (%) in the samples ranged from 31.9 to 36.1, xylan from 19.1 to 20.9, total lignin 13.1 to 18.8,and total ash 1.73 to 10.19. The moisture content ranged from 6.21 to 11.66%. Given these similar characteristics, we also examined liquefaction of these other samples, and they also showed that liquid slurries are possible. Work is continuing to define favourable conditions for liquid slurries formation.

Cruz, Antonio↗

DOE OSTI2022

Regularized inversion of aerosol hygroscopic growth factor probability density function: application to humidity-controlled fast integrated mobility spectrometer measurements

Abstract. Aerosol hygroscopic growth plays an important role in atmospheric particle chemistry and the effects of aerosol on radiation and hence climate. The hygroscopic growth is often characterized by a growth factor probability density function (GF-PDF), where the growth factor is defined as the ratio of the particle size at a specified relative humidity to its dry size. Parametric, least-squares methods are the most widely used algorithms for inverting the GF-PDF from measurements of the humidified tandem differential mobility analyzer (HTDMA) and have been recently applied to the GF-PDF inversion from measurements of the humidity-controlled fast integrated mobility spectrometer (HFIMS). However, these least-squares methods suffer from noise amplification due to the lack of regularization in solving the ill-posed problem, resulting in significant fluctuations in the retrieved GF-PDF and even occasional failures of convergence. In this study, we introduce nonparametric, regularized methods to invert the aerosol GF-PDF and apply them to HFIMS measurements. Based on the HFIMS kernel function, the forward convolution is transformed into a matrix-based form, which facilitates the application of the nonparametric inversion methods with regularizations, including Tikhonov regularization and Twomey's iterative regularization. Inversions of the GF-PDF using the nonparameteric methods with regularization are demonstrated using HFIMS measurements simulated from representative GF-PDFs of ambient aerosols. The characteristics of reconstructed GF-PDFs resulting from different inversion methods, including previously developed least-squares methods, are quantitatively compared. The result shows that Twomey's method generally outperforms other inversion methods. The capabilities of Twomey's method in reconstructing the pre-defined GF-PDFs and recovering the mode parameters are validated.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2017

A single-column particle-resolved model for simulating the vertical distribution of aerosol mixing state: WRF-PartMC-MOSAIC-SCM v1.0

Abstract. The PartMC-MOSAIC particle-resolved aerosol model was previously developed to predict the aerosol mixing state as it evolves in the atmosphere. However, the modeling framework was limited to a zero-dimensional box model approach without resolving spatial gradients in aerosol concentrations. This paper presents the development of stochastic particle methods to simulate turbulent diffusion and dry deposition of aerosol particles in a vertical column within the planetary boundary layer. The new model, WRF-PartMC-MOSAIC-SCM, resolves the vertical distribution of aerosol mixing state. We verified the new algorithms with analytical solutions for idealized test cases and illustrate the capabilities with results from a 2-day urban scenario that shows the evolution of black carbon mixing state in a vertical column.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1972

Environmental microbiology as related to planetary quarantine

The experimental design of a study to evaluate the effect of different cleaning methods and storage conditions on the dry heat resistance of Bacillus subtilis var. niger spores is described and the results for the first evaluation are reported. Specifically, the synergistic effect which occurs when spores are subjected simultaneously to dry heat and gamma radiation so as to be able to specify thermoradiation sterilization cycles was investigated. Attempts were made to understand the underlying mechanism(s) that lead to spore death from this combination of stresses. Data cover: (1) the survival of spores on surfaces at various temperatures in a precisely controlled environmental system, (2) the rate of destruction of these spores at ambient temperature when subjected to gamma radiation, and (3) the rate of destruction of spores when they are subjected to combined gamma radiation and thermal stresses.

Pflug, I. J.↗

NASA NTRS1974

Mechanisms of deterioration of nutrients

Methods are reported by which freeze dried foods of improved quality will be produced. The applicability of theories of flavor retention has been demonstrated for a number of food polymers, both proteins and polysacchardies. Studies on the formation of structures during freeze drying have been continued for emulsified systems. Deterioration of organoleptic quality of freeze dried foods due to high temperature heating has been evaluated and improved procedures developed. The influence of water activity and high temperature on retention of model flavor materials and browning deterioration has been evaluated for model systems and food materials.

Karel, M.↗

NASA NTRS1980

Simplified installation of thrust bearings

Special handling sleeve, key to method of installing thrust bearings, was developed for assembling bearings on shaft of low-pressure oxygen turbo-pump. Method eliminates cooling and vacuum-drying steps which saves time, while also eliminating possibility of corrosion formation. Procedure saves energy because it requires no liquid nitrogen for cooling shaft and no natural gas or electric power for operating vacuum oven.

Sensenbaugh, N. D.↗

NASA NTRS1992

Polymer infiltration studies

Significant progress has been made during the past three months on the preparation of carbon fiber composites using advanced polymer resins. The results are set forth in recent reports and publications, and will be presented at forthcoming national and international meetings. Current and ongoing research activities reported herein include: powdered tow ribbonizing; unitape from powdered tow; customized towpreg for textiles and ATP; and textile composite research. During the period ahead research will be directed toward further development of the new powder curtain prepregging method and on ways to customize dry powder towpreg for textile and robotic applications in aircraft part fabrication. Studies of multi-tow powder prepregging and ribbon preparation will be initiated in conjunction with continued development of prepregging technology and the various aspects of composite part fabrication using customized towpreg. Also, a major effort during the coming months will be participating in the analysis of the performance of the new solution prepregger.

Marchello, Joseph M.↗

NASA NTRS1993

Polymer infiltration studies

During the past three months, significant progress has been made on the preparation of carbon fiber composites using advanced polymer resins. The results are set forth in recent reports and publications, and will be presented at forthcoming national and international meetings. Current and ongoing research activities reported herein include: textile composites from powder-coated towpreg; role of surface coating in braiding; prepregger hot sled operation; ribbonizing powder-impregenated towpreg; textile composites from powder-coated towpreg; role of bulk factor powder curtain prepreg process advanced tow placement (ATP) open-section part warpage control. During the coming months research will be directed toward further development of the new powder curtain prepregging method and on ways to customize dry powder towpreg for textile and robotic applications in aircraft part fabrication. Studies of multi-tow powder prepregging and ribbon preparation will be conducted in conjunction with continued development of prepregging technology and the various aspects of composite part fabrication using customized towpreg. Also, during the period ahead work will continue on the analysis of the performance of the new solution prepregger.

Marchello, Joseph M.↗

NASA NTRS1993

Polymer Infiltration Studies

Significant progress has been made on the preparation of carbon fiber composites using advanced polymer resins during the past three months. Current and ongoing research activities reported herein include: (1) Prepregger Hot Sled Operation; (2) Ribbonizing Powder-Impregnated Towpreg; (3) Textile Composites from Powder-Coated Towpreg: Role of Bulk Factor; and (4) Powder Curtain Prepreg Process. During the coming months research will be directed toward further development of the new powder curtain prepregging method and on ways to customize dry powder towpreg for textile and robotic applications in aircraft part fabrication. Studies of multi-tow powder prepregging and ribbon preparation will be conducted in conjunction with continued development of prepegging technology and the various aspects of composite part fabrication using customized towpreg. Also, work will continue on the analysis of the new solution prepegger.

Marchello, Joseph M.↗

NASA NTRS2005

Influence of Hydroponically Grown Hoyt Soybeans and Radiation Encountered on Mars Missions on the Yield and Quality of Soymilk and Tofu

Soybeans were chosen for hmar and planetary missions due to their nutritive value and ability to produce oil and protein for further food applications. However, soybeans must be processed into foods prior to crew consumption. Wilson et al. (2003) raised questions about (1) the influence of radiation (on germination and functional properties) that the soybeans would be exposed to during bulk storage for a Mars mission, and (2) the impact of using hydroponically grown versus field grown soybeans on the yield and quality of soyfoods. The influence of radiation can be broken down into two components: (A) affect of surface pasteurization to ensure the astronauts safety from food-borne illnesses (a Hazard Analysis Critical Control Point), and (B) affect of the amount of radiation the soybeans receive during a Mars mission. Decreases in the amount of natural antioxidants and free radical formation and oxidation induced changes in the soybean (lipid, protein, etc.) will influence the nutritional value, texture, quality, and safety of soyfoods made from them. The objectives of this project are to (1) evaluate the influence of gamma and electron beam radiation on bulk soybeans (HACCP, CCP) on the microbial load, germination, ease of processing, and quality of soymilk and tofu; (2) provide scale up and mass balance data for Advanced Life Support subsystems including Biomass, Solid Waste Processing, and Water Recovery Systems; and (3) to compare Hoyt field grown to hydroponically grown Hoyt soybeans for soymilk and tofu production. The soybean cultivar Hoyt, a small standing, high protein cultivar that could grow hydroponically in the AIMS facility on Mars) was evaluated for the production of soymilk and tofu. The quality and yield of the soymilk and tofu from hydroponic Hoyt, was compared to Vinton 81 (a soyfood industry standard), field Hoyt, IA 2032LS (lipoxygenase-free), and Proto (high protein and antioxidant potential). Soymilk and tofu were produced using the Japanese method. The soymilk was coagulated with calcium sulfate dihydrate. Soybeans and tofu were evaluated using chemical, microbial, and instrumental sensory methods. The surface radiation of whole dry soybeans using electron beam or gamma rays at 10 or 30 kGy did provide microbial safety for the astronauts. However, these doses caused oxidative changes that resulted in tofu with rancid aroma, darkening of the tofu, lower tofu yields, more solid waste, and loss of the ability of the seeds to germinate. While lower doses may reduce these problems, we lose the ability to insure microbial safety (cross-contamination) of bulk soybeans for the astronauts. Counter measures could include vacuum packaging, radiating under freezing conditions. A No Effect Dose for food quality, below 10 kGy needs to be determined. Better estimates of the radiation that the food will be exposed to need to determined and shared. Appropriate shielding for the food as well as the astronauts needs to be developed. The Hoyt soybean did not provide a high yielding, high quality tofu. A new small scale system for evaluating soybeans was developed using 50 g quantities of soybeans.

Wilson, Lester A.↗

NASA NTRS2011

High Energy Failure Containment for Spacecraft

Objective: The objective of this paper will be to investigate advancements and any commonality between spacecraft debris containment and the improvements being made in ballistic protection. Scope: This paper will focus on cross application of protection devices and methods, and how they relate to protecting humans from failures in spacecraft. The potential gain is to reduce the risk associated with hardware failure, while decreasing the weight and size of energy containment methods currently being used by the government and commercial industry. Method of Approach: This paper will examine testing that has already been accomplished in regards to the failure of high energy rotating hardware and compare it to advancements in ballistic protection. Examples are: DOT research and testing of turbine containment as documented in DOT/FAA/AR-96/110, DOT/FAA/AR-97/82, DOT/FAA/AR-98/22. It will also look at work accomplished by companies such as ApNano and IBD Deisenroth in the development of nano ceramics and nanometric steels. Other forms of energy absorbent materials and composites will also be considered and discussed. New Advances in State of the Art: There have been numerous advances in technology in regards to high energy debris containment and in the similar field of ballistic protection. This paper will discuss methods such as using impregnated or dry Kevlar, ceramic, and nano-technology which have been successfully tested but are yet to be utilized in spacecraft. Reports on tungsten disulfide nanotubes claim that they are 4-5 times stronger than steel and reports vary about the magnitude increase over Kevlar, but it appears to be somewhere in the range of 2-6 times stronger. This technology could also have applications in the protection of pressure vessels, motor housings, and hydraulic component failures.

Pektas, Pete↗