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Results for “coal-derived material”

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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48 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Manufacture of Carbon Foam in Continuous Process at Atmospheric Pressure

CFOAM LLC has been manufacturing vitreous carbon foam from coal in panel form for several years. The process is currently set up in batch mode as two steps, where the first step is conducted at very high pressure. In order to reduce cost and increase capacity, a new process for making carbon foam is being developed that can be performed at atmospheric pressure. This advance in turn would enable the development of a continuous manufacturing process, which is also being pursued. Both carbon foam panels and light weight aggregates are being investigate. Progress on the evolution of the pilot scale manufacturing plant and initial results of processing, microstructure, properties and performance of carbon foam products made using this new process will be discussed. This project is being supported by a cooperative agreement with the Department of Energy – National Energy Technology Laboratory (DE-FOA-0002185, Area of Interest 4: Coal-Derived Carbon Foam Produced via a Continuous Process, award number DE-FE-0031992).

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Manufacture of Carbon Foam in Continuous Process at Atmospheric Pressure

CFOAM LLC has been manufacturing vitreous carbon foam from coal in panel form for several years. The process is currently set up in batch mode as two steps, where the first step is conducted at very high pressure. In order to reduce cost and increase capacity, a new process for making carbon foam is being developed that can be performed at atmospheric pressure. This advance in turn would enable the development of a continuous manufacturing process, which is also being pursued. Both carbon foam panels and light weight aggregates are being investigate. Construction of the pilot scale manufacturing plant has been completed and results of processing, microstructure, properties and performance of carbon foam products made using this new process will be discussed. This project is being supported by a cooperative agreement with the Department of Energy – National Energy Technology Laboratory (DE-FOA-0002185, Area of Interest 4: Coal-Derived Carbon Foam Produced via a Continuous Process, award number DE-FE-0031992).

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

Light, High Performance and Scalable Coal-Derived Composites for Construction: Precast and Cast-in-Place Applications

The overall objective of this project was to produce a coal-based construction material that has up to ~95 weight percent (wt. %) coal with physical, chemical, and thermal properties exceeding those of ordinary Portland cement (OPC)-based construction materials. Additionally, the project aimed to minimize external binders by implementing novel mixing techniques, while exceeding the performance/cost ratio of OPC. Finally, the project was to demonstrate production of precast products via the design and fabrication of products via a bench scale process. Consistent with some of these objectives, the project successfully fabricated samples of coal-based composite materials with >80 wt% coal with physical, chemical and thermal properties on par with cement-based concrete. Select samples demonstrated compressive strengths with >7,000 psi and flexural strength of >420 psi. The composite materials minimized external binders and also demonstrated durability, as evidenced by resistance to acidic and basic solutions. Finally, larger slab and beam type samples were produced using a process developed by the Recipient, although, the process was not semicontinuous in nature. Taken together, the results of this project suggest that domestic coal has potential to serve as a replacement for cementitious materials utilized in incumbent construction technologies, which could significantly reduce the energy and emissions of the construction industry

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

Coal and Coal Wastes to High-Quality Graphite for Lithium-Ion Battery Applications

Conference presentation for 2023 International Freiberg Conference on Circular Carbon Technologies, Rotterdam, Netherlands, September 24–29, 2023. To assist in meeting the global graphite supply limitations, this study aims to investigate efficient ways to synthesize high-quality graphite from abundant coal and coal waste resources that exist in many areas around the world. A recently developed upgraded coal-to-products (UCP) process has shown great promise in the ability to reduce coal-borne impurities and produce a graphitizable product that yields good quality graphite for LIB applications. Preliminary results show that the quality of coal-derived graphite obtained by the UCP process is similar to that of commercial flake graphite. Available results are presented and discussed as well as maturation plans and flexibility of the UCP technology.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

Upgraded Coal to High-Quality Graphite for Lithium-Ion Battery Applications

Presentation for the World Conference on Carbon 2023, Cancun, Mexico, July 16–21, 2023. To assist in meeting the global graphite supply limitations, this study aims to investigate efficient ways to synthesize high-quality graphite from abundant coal resources that exist in many areas around the world. A recently developed upgraded coal-to-products (UCP) process has shown great promise in the ability to reduce coal-borne impurities and produce a graphitizable product that yields good-quality graphite for LIB applications. Preliminary results show that the quality of coal-derived graphite obtained by the UCP process is close to that of commercial LIB-grade graphite. Results are presented and discussed as well as maturation plans and flexibility of the UCP technology.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

Upgraded Coal and Coal Waste to Graphite for Lithium-Ion Battery Applications

Presentation to the Fortieth Annual International Pittsburgh Coal Conference, Istanbul, Turkiye, October 4–6, 2023. To assist in meeting the global graphite supply limitations, this study aims to investigate efficient ways to synthesize high-quality graphite from abundant coal and coal waste resources that exist in many areas around the world. A recently developed upgraded coal-to-products (UCP) process has shown great promise in the ability to reduce coal-borne impurities and produce a graphitizable product that yields good quality graphite for LIB applications. Preliminary results show that the quality of coal-derived graphite obtained by the UCP process is similar to that of commercial LIB-grade graphite. Available results are presented and discussed as well as maturation plans and flexibility of the UCP technology.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

Upgrading of Raw Coal and Coal Waste for Coal-Derived Graphene Process

Conference presentation at 47th International Technical Conference on Clean Energy (Clearwater Clean Energy Conference), Clearwater, Florida, July 23–27, 2023. The University of North Dakota Energy & Environmental Research Center (EERC) conducted a laboratory-scale coal-derived graphene (CDG) project focused on developing a technological process for making graphite from four U.S. domestic coals and coal wastes. Coal and coal waste preprocessing methods were developed and applied to clean and upgrade the coal precursors prior to graphitization and subsequent conversion to graphene products. Carbonization and graphitization of these preprocessed coals and coal wastes has produced graphite, which was used to make graphene oxide (GO) and reduced graphene oxide (rGO). Graphene quantum dots (GQDs) were also made from the raw and upgraded coal precursors.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

Manufacturing Valuable Coal-Derived Products in Southern Appalachia

This project’s objective is to develop and deploy new technologies for manufacturing rare earth elements (REE), critical minerals (CM), and valuable non-fuel, carbon-based products (CBP) from coal and/or coal waste in the SoApp Basin, thus revitalizing distressed SoApp coal communities and reducing reliance on foreign imports of REE and CM. Resource availability and technological advances alone will not ensure this objective is met. The right mix of business climate, market forces, and policy will also be needed. This report identifies the critical technologies, infrastructure, supply chains, human capital, and policy gaps that must be addressed to manufacture REE, CM, and CBP from coal resources and wastes in SoApp The primary goal of the project is to characterize the resource base in the SoApp Basin.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Facile Synthesis of Micrometer-sized Hierarchical Porous Si@C Anodes for High-Performance Lithium-Ion Batteries

Extensive studies have been conducted to determine if replacing graphite anodes with silicon is feasible since silicon possesses a high capacity and is an abundant resource; however, Si anodes suffer significant volume changes during cycling, which pulverizes its structure and subsequently causes rapid capacity fading. We used SiO2 nanoparticles (nSiO2) and low-cost coal-derived humic acid as a feedstock to synthesize high performance Si-C anodes for Li-ion Batteries through spray drying, calcination, and magnesiothermic reductions. Our Si-C anodes features micrometer-sized porous Si coated with a graphitized carbon shell (mpSi@C). The hierarchical graphitized carbon shell and porous silicon structure relieve the mechanical stress of the Si phase upon cycling, which stabilizes the structure. This mpSi@C composite design allows for a high initial discharge capacity of 2199.9 mAh g-1 at 0.1 A g-1 and a cycling performance of 68% capacity retention after 100 cycles at 1.0 A g-1. The multipoint contact between the Si anode and C structure allows for a remarkable performance rate of 566.3 mAh g-1 at 5.0 A g-1.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

Process Optimization of Carbon Electrode Materials Manufacturing by Experimental Study and Machine Learning Techniques

Electrospun carbon fibers from coal have been investigated as electrodes for batteries and supercapacitors. Despite the excellent properties of coal-derived carbon fibers (CCNF) for energy storage devices, there still lacks systematic understanding on how various process parameters affect final electrode performances, which poses challenges to scale from pilot to high volume manufacturing. The goals of this project are twofold. First, we focuse on process optimization for converting a new precursor from powder river basin (PRB) coal, referred to as coal-based polyurethane (CPU) to CCNF using electrospinning. Second, different machine learning techniques will be examined using experimental data from this work and open literature. Specifically, for CPU the following process parameters need to be characterized and optimized in order to produce CCNFs with desirable mechanical integrity and physiochemical properties: precursor composition and viscosity, operating voltage and distance, oxidation and carbonization temperature and duration. Consequently, physiochemical properties of the fibers were characterized to correlate these process parameters with desirable electrochemical performance. Given the complex nature of the fiber production process, ML models are assessed for their ability to capture the nonlinear relationship between process parameters and the electrochemical properties in applications including supercapacitors. As such, we applied various machine learning techniques, to determine which technique produces a model that best predicts device function.

Cincotta, Robert E.F.↗