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At least 73 records · Page 4

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DOE OSTI2025

Evaluation of Pozzolan-substituted Cast Stone for Pretreated Hanford Tank Waste

Portland cement. The future availability of quality Class F fly ash has come into question as coal-fired power plants are being converted to gas or taken offline. Consequently, alternative pozzolanic reagents are being evaluated for fly ash replacement in cementitious matrices for treating radioactive waste and debris. In 2023 and 2024, Savannah River National Laboratory (SRNL) was funded to evaluate natural pozzolans for the replacement of Class F fly in the Savannah River Site (SRS) Saltstone formulation. Based on the promising results and uncertain availability of Class F fly ash in the northwestern US, Hanford Tank Waste Operations & Closure, LLC (H2C) requested SRNL to evaluate the potential for substituting natural pozzolans in the Hanford West Area Pretreated Low Activity Tank Waste (PTW/LAW) Cast Stone formulation1 . Task 1 in this request was to determine the change in Cast Stone volume resulting from stabilization/solidification of 1 L of PTW/LAW tank waste. The densities of three (Hess Pumice, tephra pumice, and clinoptilolite zeolite) pozzolan-substituted Baseline Cast Stone mixes were determined, and volume changes relative to the fly ash-Baseline Mix with a water-to-dry mix = 0.40 were calculated.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2022

Textured ceramic membranes for desilting and deoiling of produced water in the Permian Basin

Oil production in the Permian Basin gives rise to large volumes of produced water contaminated by silt, emulsified oil, and additives used for enhanced oil recovery. There is intense interest in the design of membrane modules as sustainable alternatives for produced water treatment to enable the reuse of produced water for agricultural applications, injection into aquifers, and redeployment in oil recovery. Here, we report a hierarchically textured cement-based membrane exhibiting orthogonal wettability, specifically, superhydrophilic and underwater superoleophobic characteristics. The in situ formation of ettringite needles accompanied by embedding of glass spheres imbues multiscale texturation to stainless-steel mesh membranes, enabling the separation of silt and oil from produced water at high flux rates (1600 L h -1 ∙m -2 , at ca. 2.7 bar). Oil concentration is reduced as low as 1 ppb with an overall separation efficiency of 99.7% in singlepass filtration. The membranes show outstanding mechanical resilience and retention of performance across multiple cycles.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Integrated Design of Ultradurable, Low CO 2 Alternative Binder Systems via Machine Learning

This ARPA-E project developed a machine learning tool to use in formulation design of cementitious binders for concrete having 50% less embodied CO 2 and possessing twice the durability compared to concrete based on ordinary portland cement (OPC) binders. The technical focus was on limestone/calcined clay cement (LC3), the leading replacement for OPC. Here, hierarchical machine learning (HML) was used to model the flowability, set time, strength, and durability of LC3 concrete. This methodology identifies latent variables derived from domain knowledge and empirical models that develop an accurate model for a response surface from small datasets. For the flowability metric, particle packing was a dominant factor, while strength and durability were both strongly determined by the fraction of metakaolin and the water:solids ratio. Under constraints of water:binder ratio, material performance metrics, embodied CO 2 , and cost per tonne of OPC, multi-objective optimization was used to design binders parameterized by the mineral composition replacing OPC, particle size distributions, and water:solids ratio. The trained algorithm was able to predict multiple mixes met these performance criteria, and experimental testing validated the predictions. The model demonstrated here is relevant for North America, where pure kaolin deposits are found broadly. The approach is being taken forward into commercial application by Ansatz AI, a materials informatics company founded by PI Washburn and co-PI Poczos. Through collaborations with the cement and concrete industry, and funding from SBIR programs, a commercial software will be developed in future research.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Evaluating the carbon capture potential of industrial waste as a feedstock for enhanced weathering

Abstract Limiting anthropogenic global climate warming since the start of the industrial period to less than 2 °C will very likely require both deep and rapid reductions in anthropogenic greenhouse gas emissions and a range of approaches toward carbon dioxide removal (CDR). One prominent CDR approach is enhanced weathering (EW), in which crushed silicate rock is applied on land or in the open ocean to accelerate natural weathering processes that absorb carbon dioxide from Earth’s ocean–atmosphere system. However, in addition to a range of potential environmental, socioeconomic, and ethical issues associated with this pathway, bottlenecks in feedstock sourcing represent a key barrier for deployment of EW at scale. Here, we evaluate the potential of silicate wastes produced from industrial processes—such as steel slag and cement waste—as feedstocks for the EW process. An empirical model that links industrial alkaline waste production to gross domestic product at purchase power parity is developed to forecast waste production in the alternative futures described by the shared socioeconomic pathway (SSP) framework. By incorporating these results into an intermediate-complexity Earth system model, we also explore the impacts of EW using industrial waste on changes to global temperature, ocean pH, and ocean aragonite saturation state, while also quantifying overall CDR efficiency through the end of the century. We estimate a maximum cumulative end-of-century capture potential of ∼400 GtCO 2 for industrial waste, which could represent a significant fraction of the projected CDR requirement of many mitigation scenarios in the SSP framework. However, feedstock-dependent environmental impacts and the technoeconomics of feedstock redistribution may ultimately limit deployment scope.

Xu, Pengxiao (ORCID:0009000633724293)↗

DOE OSTI2025

Feasibility of Algal Biochar, a Byproduct of Biofuel Production, as a Supplemental Cementitious Material

Algal biochar, as the solid residue of biofuel production from algal biomass, is reported to explore disposition options, aiming to lessen the liability or obstacles to biofuel production processes. However, landfills and open combustion lead to adverse environmental impacts. One way to add value to such wastes is to use them as admixtures in cementitious construction materials. This study aims to investigate the feasibility of algae-derived biochar as supplementary cementitious materials (SCM) at different water contents and mixture ratios. Algal biochar-cement composites were prepared with different algal biochar content as well as different water-to-cement (w/c) ratios, and the surface area, morphology, elemental, and mineralogical composition were characterized. To compensate for the high-water absorption of algal biochar, a small concentration of a superplasticizer was used since higher w/c ratios negatively impact strength. The mechanical performance of algal biochar-cement composites is compared with control composites using commercial silica fume as a typical commercial SCM. The findings suggest that algal biochar is a promising candidate to replace commercial SCM, like silica fume, since algal biochar-cement composites can reach comparable compressive strength and Young’s modulus to commercial pozzolan-cement materials with the same w/c ratio, though at later curing times, 33 days. Although the tensile strength of algal biochar-cement composites is statistically similar at 7 days, it is significantly lower at later curing times, and further investigation is required to improve this property. Algal biochar-based cement binders showed comparable embodied carbon to silica fume-based cement binders based on a cradle-to-gate lifecycle analysis. However, the ability of algal biochar to absorb large volumes of CO 2 over short periods of time, as measured in this study, makes this novel SCM an excellent alternative to reduce the embodied carbon of concrete structures cradle-to-grave at 1/10 of the cost. In conclusion, valorization of algae-derived solid waste provides great potential to reduce embodied carbon and brings credit to biofuel production and concrete-based construction.

algae-derived↗

DOE OSTI2021

The crystal structure of a new calcium aluminate phase containing formate

A new calcium aluminate phase containing formate ions was synthesized and its crystal structure determined. This new phase is indicated as M-phase and was firstly observed in Portland cement pastes hydrated in presence of Ca-formate and in excess of water. The crystal structure of the M-phase was successfully solved in the R-3 space group of the trigonal system on the basis of synchrotron X-ray single crystal diffraction data. The structural model was confirmed by Rietveld refinement of the powder diffraction data acquired on the synthesized pure sample. The crystal structure of the M-phase is similar to that of ettringite, being characterized by columns of AlO{sub 6} octahedra alternating with groups of three edge-sharing CaO{sub 7} polyhedra. The formate ions (HCOO){sup −} share two oxygens with Ca polyhedra and are located in the interspace between the columns. The crystal structure of the M-phase testifies the strong interaction occurring between small organic molecules as formate and the calcium aluminate components of Portland cement.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Monitoring accelerated alkali-silica reaction in concrete prisms with petrography and electrical conductivity measurements

We report deterioration of concrete due to alkali-silica reaction (ASR) involves a reaction between alkaline ions in the cement pore solution and non-crystalline silica found in many aggregates. Diagnosing and quantifying deterioration due to ASR in concrete currently requires destructive testing for microscopy examinations. In this paper, electrical conductivity is investigated qualitatively as an alternative non-destructive evaluation (NDE) method of ASR in hardened concrete. The study was performed using an unrestrained set of small concrete prism specimens made with highly reactive small aggregates, and kept in an environmental chamber according to ASTM C1293 standard. In a companion study, destructive petrography and damage rating index (DRI) assessment, and pore solution extraction and analysis were performed on the same set of accelerated ASR specimens. The results show that temporal evolution of nondestructive bulk resistivity is linearly correlated with destructive DRI score.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Development of 250 kW Ammonia and Hydrogen Industrial Burner Test Facility at the National Energy Technology Laboratory

In an effort to investigate the viability of ammonia and hydrogen as fuels in the industrial heating sector, the Department of Energy’s National Energy Technology Laboratory is developing a 250 kW burner test facility. The pursuit of a decarbonized industrial heating sector requires innovative approaches to convert existing assets to alternative fuels while maintaining adequate radiative heat transfer and limiting NOx. This new capability will leverage NETL’s experience and prior investments in ammonia and hydrogen combustion, to advance atmospheric pressure industrial combustion systems for industries such as cement kilns and glass factories. The intention in coming years is to collaborate with burner manufacturers and heavy industry partners to study, develop, and validate strategies for converting existing hardware from carbon-based fuels to next-generation clean ammonia and hydrogen technologies.

May, Kristyn Johnson↗

DOE OSTI2021

Pozzolanic reactivity of natural pozzolans, ground glasses and coal bottom ashes and implication of their incorporation on the chloride permeability of concrete

It is well understood that the partial replacement of portland cement with pozzolans in sufficient proportions results in improved long-term performance of concrete. However, dwindling availability of the most widely used pozzolan in the construction industry, fly ash, is forecast due to the termination of coal-fired electricity power stations around the world, necessitating the exploration of alternative pozzolans. Experimental investigations are conducted to study the performance of traditional pozzolans such as fly ash, silica fume and natural pozzolans (metakaolin, pumice, perlite and lassenite) together with novel pozzolans, including ground glasses (high-alkali and low-alkali), and ground bottom ash. Twenty-one concrete mixtures are examined for compressive strength, electrical conductivity, electrical resistivity, chloride permeability, and chloride migration coefficient. The reactivity of pozzolans studied is also determined in terms of compressive strength in lime-pozzolan mortar using a modified lime-reactivity test method. Many of the materials tested demonstrate the potential to be used in place of fly ash. However, a wide variation in the performance of these materials is evident which highlights the need for a reliable test to determine the level of reactivity of a pozzolan. The results indicate that the 7-day strength in the modified lime-reactivity test provides a good indication of the pozzolanic reactivity of the material and of how the material can be expected to contribute to the strength and permeability of concrete. The use of electrical resistivity as an indicator of the performance of pozzolans in terms of strength development and chloride penetration resistance when used to partially replace portland cement in concrete is also discussed.

36 MATERIALS SCIENCE↗

DOE OSTI2025

LDR Inorganic Spiked Simulants in Pozzolan-Substituted Cast Stone for Hanford Pretreated Low-Activity Tank Waste

Pretreated Low Activity Waste (PTW/LAW) at the Hanford Site, is currently projected for disposition through a cementitious waste form. The current standard formulation, Cast Stone, uses Class F fly ash, blast furnace slag, and Portland cement. However, the future availability of Class F fly ash is uncertain, as many coal-fired power plants—the source of this byproduct—are being decommissioned or converted to natural gas. This issue has prompted research into identifying and evaluating suitable alternative materials to replace fly ash in the cementitious waste forms used by the Department of Energy (DOE). The Savannah River National Laboratory (SRNL) successfully identified four natural pozzolans for the replacement of Class F fly ash in the current Savannah River Site (SRS) low-level waste (LLW) form, Saltstone.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2025

Casing Annulus Monitoring of CO 2 Injection Using Wireless Autonomous Distributed Sensor Networks

Effective and secure carbon subsurface storage, involving the deep underground injection of CO 2 into geological formations where it is permanently trapped, is paramount to mitigating CO 2 emissions (Figure I). Ensuring the integrity of these storage sites and detecting potential leakage through the casing annulus necessitates robust monitoring. This work provides the first integrated demonstration of a wireless casing-annulus monitoring architecture that can operate in highly attenuating cement-brine environments relevant to CO 2 storage. This project focused on developing and validating a novel sensor system for integration with autonomous monitoring near the cement reservoir interface. The goal was a fully integrated Technology Readiness Level (TRL) 4/5 field validation of a distributed wireless intelligent sensor system providing real-time, direct subsurface formation measurements to enhance fluid movement monitoring in the cemented casing annulus. Achieving this objective required the development and integration of 1) wireless autonomous microsensor technology by California Institute of Technology (Caltech); 2) sensor packaging and emplacement technology by Research Triangle Institute (RTI); and 3) smart well completions using wireless active casing collars and NOV pipe by the Sandia National Lab (SNL). The collaboration with the Caltech team in this project aimed to develop millimeter-scale radio frequency identification (RFID) sensors capable of detecting CO 2 , pH, and/or methane levels. These sensors are engineered to be impervious to fluids, allowing them to be mixed with cement and installed within the casing annulus. They operate using RFID protocols at frequencies of 902–928 MHz for both power and communication. A Sandia National Laboratories’ team engaged their expertise in the development of a Smart Collar system designed for the wireless data collection from these RFID sensors embedded in the cement annulus and transmission of this information to the ground surface via IntelliPipe/IntelliServ NOV drill pipe. This is accomplished through inductive coupling at the collar, which facilitates data transfer through each segment of the pipe. Because the system cannot transmit a direct current signal to power the Smart Collar, both power and communication were implemented using alternating current and electromagnetic signals at varying frequencies. Furthermore, the developed microsensor technology had to be demonstrated and validated in comparison with reference transducer measurements in a field test site at The University of Texas at Austin (UT-Austin). Although the full sensor suite did not reach field-deployment readiness, the system-level integration achieved in this project establishes a validated pathway for future incorporation of advanced microsensors.

47 OTHER INSTRUMENTATION↗

DOE OSTI2023

Development of wind turbine blade recycling baselines in the United States

Over the past several years, the wind energy industry has received scrutiny regarding wind turbine blade (WTB) recycling due to the landfilling of WTBs caused by a lack of industrially viable recycling solutions. The amount of WTBs that will need to be recycled is set to increase in the United States as the deployment of wind energy is expected to rapidly grow to meet the nation's energy goals by 2035. While significant progress has been made worldwide, it is still unclear which WTB recycling solutions would be the most cost and energy effective within the United States for the existing fleet of wind turbines. To guide researchers and industry with a clear path forward, a range of options for WTB recycling in the United States are modeled through development of baseline scenarios and the use of formal life cycle assessment (LCA). Model data have been collected through literature review, industry engagement, and expert opinion regarding current end of life practices and considerations surrounding equipment, labor, and logistics. A detailed baseline for WTB decommissioning processes has been developed and used to assess alternative approaches, such as on-site shredding to compare the impacts on greenhouse gas (GHG) emissions. The developed LCA model and baseline scenarios for WTB recycling is used to assess the current WTB decommissioning practices in the United States along with emerging recycling pathways, including cement kiln co-processing and pyrolysis. Initial findings indicate that there are different approaches to decommissioning WTBs in the United States, each of which has unique implications for recycling. In light of this finding, additional results from the modeling will be used to better understand decommissioning practices and assist in making educated decisions on recycling pathways for the future. Throughout the analysis, focus was given to where international efforts might differ from the United States. WTB recycling is occurring worldwide, and different countries have different drivers for creating markets for recycled WTB materials. The contrasts and similarities between the United States and other countries offer insight to areas of opportunity that the United States could investigate and areas that can be readily transferred from existing solutions. By modeling and characterizing the current decommissioning practices and potential recycling solutions for the United States, a clearer vision will be created for pathways forward as to how to handle end of life WTBs to enable more efficient and cost-effective opportunities for material recovery from end-of-life WTBs.

Korey, Matt↗

DOE OSTI2022

Thermal Process Intensification: Transforming the Way Industry Uses Thermal Process Energy (Workshop Report)

The US Department of Energy’s (DOE’s) Advanced Manufacturing Office held the virtual workshop entitled “Thermal Process Intensification: Transforming the Way Industry Uses Thermal Process Energy” in November and December 2020. The workshop brought together participants from universities/laboratories, industries, equipment manufacturers, technology vendors, nongovernmental organizations, and subject-matter experts to discuss transformative technologies and strategies to substantially improve the performance (e.g., energy productivity, thermal efficiency, reduced greenhouse gas [GHG] emissions, reduced number of process steps) of thermal processing systems in the industrial sector. The US industrial sector accounts for 32% of the nation’s primary energy use (including feedstocks), and refining, chemicals, pulp and paper, iron and steel, and food products represent the top energy-consuming sectors. Thermal processing or process heating represents the largest energy use category; it accounts for 63% of all energy use in manufacturing. Additionally, thermal processing is the largest contributor of carbon dioxide (CO2) generation, resulting from combustion of fuels and process related chemical reactions, such as in the case of cement and lime production. The challenge of achieving net-zero industrial GHG emissions is colossal considering the established industrial base that depends mainly on carbon-based processes and energy sources; the time frame and cost to replace carbon-based energy sources and feedstocks; and the long-term outlook for development with large-scale adaptation of alternative non carbon–based technologies. The goals of the DOE Advanced Manufacturing Office Thermal Process Intensification Workshop were as follows: (1) Identify R&D gaps and opportunities to facilitate transformative improvement in industrial thermal processes beyond current technologies and allow for entirely new methods for processing materials; (2) Gain insight into new and innovative approaches to thermally intensify processes, reduce heat demand, harness waste heat, and use fuels and hydrocarbon feedstocks more efficiently; (3) Identify the R&D pathways to thermal process intensification (TPI) with the highest potential for impact and adoption by the industrial sector; (4) Define areas of research, development, and demonstration (RD&D) activities to accelerate development and application of emerging and transformative technologies to intensify thermal processes in industry. The scope and focus of the workshop were defined to meet these goals. Based on the available data for energy use and GHG emissions, the industries that collectively use more than 80% of the total process heating energy consumption were selected as primary focus areas. The chosen industries were combined into the following four groups based on similarities in their thermal processes: high-temperature metal processing (iron and steel industry, alumina-aluminum industry); high-temperature nonmetal and mineral processing (cement and glass industry); medium- to low-temperature thermal processing (food processing and pulp and paper industry as part of forest products sector); and hydrocarbon processing (petroleum refining and chemical industry). Furthermore, all potential TPI technologies associated with the processes defined were considered as part of the workshop. Different types of TPI technologies possible in industrial in the document.

42 ENGINEERING↗

DOE OSTI2024

Improved digital construction binder solution utilizing calcium aluminate additive for Infrastructure Scale Additive Manufacturing

Oak Ridge National Laboratory (ORNL) worked with Kerneos Inc., a Division of Imerys USA, Inc. to develop an improved digital construction binder using calcium aluminate additives produced by Kerneos along with locally available concrete materials. When the two-stage (2K) binder formulation was added to commercially available Portland Limestone Cement and sand to form a digital construction mortar, its strength exceeded a number of commercially available digital construction binders both at early and later ages. At the same time, the developed formulation showed precise control of setting time after addition and showed very low shrinkage making it a strong, reliable, and easily customizable alternative to fixed proprietary digital construction binders.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Improved digital construction binder solution utilizing calcium aluminate additive for Infrastructure Scale Additive Manufacturing

36 MATERIALS SCIENCE↗

DOE OSTI2023

Life Cycle Assessment of Innovative Carbon Dioxide Selective Membranes from Low Carbon Emission Sources: A Comparative Study

Carbon capture has been an important topic of the twenty-first century because of the elevating carbon dioxide (CO2) levels in the atmosphere. CO2 in the atmosphere is above 420 parts per million (ppm) as of 2022, 70 ppm higher than 50 years ago. Carbon capture research and development has mostly been centered around higher concentration flue gas streams. For example, flue gas streams from steel and cement industries have been largely ignored due to lower associated CO2 concentrations and higher capture and processing costs. Capture technologies such as solvent-based, adsorption-based, cryogenic distillation, and pressure-swing adsorption are under research, but many suffer from higher costs and life cycle impacts. Membrane-based capture processes are considered cost-effective and environmentally friendly alternatives. Over the past three decades, our research group at Idaho National Laboratory has led the development of several polyphosphazene polymer chemistries and has demonstrated their selectivity for CO2 over nitrogen (N2). Poly[bis((2-methoxyethoxy)ethoxy)phosphazene] (MEEP) has shown the highest selectivity. A comprehensive life cycle assessment (LCA) was performed to determine the life cycle feasibility of the MEEP polymer material compared to other CO2-selective membranes and separation processes. The MEEP-based membrane processes emit at least 42% less equivalent CO2 than Pebax-based membrane processes. Similarly, MEEP-based membrane processes produce 34–72% less CO2 than conventional separation processes. In all studied categories, MEEP-based membranes report lower emissions than Pebax-based membranes and conventional separation processes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Reactive binder and aggregate interfacial zones in the mortar of Tomb of Caecilia Metella concrete, 1C BCE, Rome

Integrated spectroscopic analyses and synchrotron X-ray microdiffraction investigations provide insights into the long-term reactivity of volcanic aggregate components and calcium-aluminum-silicate-hydrate (C-A-S-H) binder in mortar samples from the robust concrete of the sepulchral corridor of the Tomb of Caecilia Metella, 1st C BCE, Rome. The results of innovative micrometer-scale analytical maps indicate that Pozzolane Rosse tephra components–scoria groundmass, clinopyroxene, and leucite crystals–contributed to pozzolanic production of C-A-S-H binder and then remained reactive long after hydrated lime (Ca(OH) 2 ) was fully consumed. The C-A-S-H binding phase is reorganized into wispy halos and tendril-like strands, some with nanocrystalline preferred orientation or, alternatively, split into elongate features with short silicate chain lengths. These microstructures apparently record chemical and structural destabilization of C-A-S-H during excessive incorporation of Al 3+ and K + released through leucite dissolution. Resistance to failure may result from the intermittent toughening of interfacial zones of scoriae and clinopyroxene crystals with post-pozzolanic strätlingite and Al-tobermorite mineral cements and from long-term remodeling of the pozzolanic C-A-S-H binding phase. Roman builders’ selection of a leucite-rich facies of Pozzolane Rosse tephra as aggregate and construction of the tomb in an environment with high surface and ground water exposure apparently increased beneficial hydrologic activity and reactivity in the concrete.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Cold Sintered Ceramics and Cements for Part Encapsulation

In this project, ceramic encapsulation materials were studied for high temperature (>~°500 C) applications where typical polymer encapsulants are unstable. A new low temperature (<~°200 C) method of processing ceramics, the cold sintering process was examined. Additionally, commercially available high temperature ceramic cements were investigated. In both cases, the mechanical strengths of available materials are less than desired (i.e., desired strengths similar to Si 3 N 4 ), limiting applicability. Composite designs to increase mechanical strength are suggested. Additionally, non-uniformities in stresses and densification while embedding alumina sheets in encapsulants via cold sintering using uni-axial pressing led to fracture of sheets, and an alternative iso-static based approach is recommended for future studies.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗