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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2013

Mechanisms Underpinning Degradation of Protective Oxides and Thermal Barrier Coatings in High Hydrogen Content (HHC) - Fueled Turbines

The overarching goal of this research program has been to evaluate the potential impacts of coal-derived syngas and high-hydrogen content fuels on the degradation of turbine hot-section components through attack of protective oxides and thermal barrier coatings. The primary focus of this research program has been to explore mechanisms underpinning the observed degradation processes, and connections to the combustion environments and characteristic non-combustible constituents. Based on the mechanistic understanding of how these emerging fuel streams affect materials degradation, the ultimate goal of the program is to advance the goals of the Advanced Turbine Program by developing materials design protocols leading to turbine hot-section components with improved resistance to service lifetime degradation under advanced fuels exposures. This research program has been focused on studying how: (1) differing combustion environments – relative to traditional natural gas fired systems – affect both the growth rate of thermally grown oxide (TGO) layers and the stability of these oxides and of protective thermal barrier coatings (TBCs); and (2) how low levels of fuel impurities and characteristic non-combustibles interact with surface oxides, for instance through the development of molten deposits that lead to hot corrosion of protective TBC coatings. The overall program has been comprised of six inter-related themes, each comprising a research thrust over the program period, including: (i) evaluating the role of syngas and high hydrogen content (HHC) combustion environments in modifying component surface temperatures, heat transfer to the TBC coatings, and thermal gradients within these coatings; (ii) understanding the instability of TBC coatings in the syngas and high hydrogen environment with regards to decomposition, phase changes and sintering; (iii) characterizing ash deposition, molten phase development and infiltration, and associated corrosive/thermo-chemical attack mechanisms; (iv) developing a mechanics-based analysis of the driving forces for crack growth and delamination, based on molten phase infiltration, misfit upon cooling, and loss of compliance; (v) understanding changes in TGO growth mechanisms associated with these emerging combustion product streams; and (vi) identifying degradation resistant alternative materials (including new compositions or bi-layer concepts) for use in mitigating the observed degradation modes. To address the materials stability concerns, this program integrated research thrusts aimed at: (1) Conducting tests in simulated syngas and HHC environments to evaluate materials evolution and degradation mechanisms; assessing thermally grown oxide development unique to HHC environmental exposures; carrying out high-resolution imaging and microanalysis to elucidate the evolution of surface deposits (molten phase formation and infiltration); exploring thermo-chemical instabilities; assessing thermo-mechanical drivers and thermal gradient effects on degradation; and quantitatively measuring stress evolution due to enhanced sintering and thermo-chemical instabilities induced in the coating. (2) Executing experiments to study the melting and infiltration of simulated ash deposits, and identifying reaction products and evolving phases associated with molten phase corrosion mechanisms; utilizing thermal spray techniques to fabricate test coupons with controlled microstructures to study mechanisms of instability and degradation; facilitating thermal gradient testing; and developing new materials systems for laboratory testing; (3) Correlating information on the resulting combustion environments to properly assess materials exposure conditions and guide the development of lab-scale simulations of material exposures; specification of representative syngas and high-hydrogen fuels with realistic levels of impurities and contaminants, to explore differences in heat transfer, surface degradation, and deposit formation; and facilitating combustion rig testing of materials test coupons.

Mumm, Daniel↗
DOE OSTI2021

CO2 Capture Strategies via Mineralization with Industrial Waste Brines

Large coal-fired power plants (>500 MW) account for 30% of global CO2 emissions, and long-term management of this CO2 to is urgently needed mitigate global temperature increases. Sequestration of CO2 within stable mineral carbonates (e.g., CaCO3) represents an attractive emission reduction strategy because it offers a leakage-free alternative to geological storage of CO2 in an environmentally friendly form. We have previously described a mineralization process in which divalent cations are sourced from various waste streams (e.g., produced water and brackish water) and alkalinity is induced via regenerable ion-exchange materials (Bustillos et. al. Frontiers in Energy Research. 2020, 8, 352). In our process, aqueous carbonate-bearing streams with pH > 8 are produced by contacting fresh water and carbon dioxide with various ion-exchange materials (e.g., Na form zeolites or ion exchange resins). These streams are mixed with produced water containing varying concentrations (~0.01 – 1.0 M) of Ca2+ leading to the precipitation of solid calcium carbonate (PCC). This process has the advantages of using regenerable solids in a simple and continuous process to increase the pH of water by ion exchange instead of relying on the consumption of costly and unsustainable sources of alkalinity (e.g., sodium hydroxide). While once-through column experiments showed the above benefits, the same were yet to established in a steady-state process with recycle streams. In this work, we set up a process simulation to quantify the energy requirements and CO2 emissions associated with the process and seek optimal produced water compositions and CO2 concentrations (5 – 20 vol%). The process simulation was set up in ASPEN Plus using eRNTL as the thermodynamic property method and sequential modular strategy. Ion exchange alkaline solution was simulated using sodium hydroxide and validated against the experimental data obtained from once-through kinetic experiments. Nanofiltration and reverse osmosis membrane steps were also implemented for the separation of divalent cations and production of fresh water and a regeneration stream following mineralization. Sensitivity analysis was carried out using a range of produced water compositions (0.01 – 1.0 M Ca2+, 0.001 – 0.15 M Mg2+, 0.5 – 3.5 M Na+ and 0.0004 – 0.002 M Fe2+) according to the United States Geological Survey (USGS) database. Calcium carbonate yields increased with increasing CO2 concentrations and were maximized using produced water compositions with larger Ca2+ concentrations. Maximum calcium carbonate yields produced at 5 vol%, 12 vol% and 20 vol% CO2 were 2.3 mmol/L, 5.5 mmol/L, and 9.3 mmol/L, respectively, with the formation of brucite (a magnesium hydroxide phase, Mg(OH)2) and goethite (an iron hydroxide phase, FeOOH) as the primary contaminant phases (99% calcite, 0.6% brucite, 0.4% goethite), which agree with phases detected by XRD experimentally. These results indicate high purity calcium carbonate can be precipitated using industrial waste streams. Consequentially, energy consumption and net CO2 emissions were minimized where precipitated calcium carbonate was maximized for all produced water compositions and CO2 concentrations. Minimum energy consumptions were 0.21 kWh/ton CO2 processed, with 98% of the energy input required coming from the membrane filtration steps. Produced water compositions with large Na+ concentrations (> 0.5 M) were effective at reducing energy consumptions due to faster regeneration time of ion exchange materials. Additionally, calculated net CO2 emissions were negative for the process and ranged from -0.02 kg/ton CO2 to -0.15 kg/ton CO2 processed, indicating a low emission process. We will also present techno-economic assessment showing the economic benefits of the current process as an alternative to the addition of stoichiometric bases to induce alkalinity for the precipitation of CaCO3.

Simonetti, Dante↗
DOE OSTI2021

Exploring the elevated water vapor signal associated with the free tropospheric biomass burning plume over the southeast Atlantic Ocean

In southern Africa, widespread agricultural fires produce substantial biomass burning (BB) emissions over the region. The seasonal smoke plumes associated with these emissions are then advected westward over the persistent stratocumulus cloud deck in the southeast Atlantic (SEA) Ocean, resulting in aerosol effects which vary with time and location. Much work has focused on the effects of these aerosol plumes, but previous studies have also described an elevated free tropospheric water vapor signal over the SEA. Water vapor influences climate in its own right, and it is especially important to consider atmospheric water vapor when quantifying aerosol-cloud interactions and aerosol radiative effects. Here we present airborne observations made during the NASA ORACLES (ObseRvations of Aerosols above CLouds and their intEractionS) campaign over the SEA Ocean. In observations collected from multiple independent instruments on the NASA P-3 aircraft (from near-surface to 6-7 km), we observe a strongly linear correlation between pollution indicators (carbon monoxide (CO) and aerosol loading) and atmospheric water vapor content, seen at all altitudes above the boundary layer. The focus of the current study is on the especially strong correlation observed during the ORACLES-2016 deployment (out of Walvis Bay, Namibia), but a similar relationship is also observed in the August 2017 and October 2018 ORACLES deployments. Using reanalyses from the European Centre for Medium-Range Weather Forecasts (ECMWF) and Modern-Era Retrospective analysis for Research and Applications, Version 2 (MERRA-2), and specialized WRF-Chem simulations, we trace the plume-vapor relationship to an initial humid, smoky continental source region, where it mixes with clean, dry upper tropospheric air and then is subjected to conditions of strong westward advection, namely the southern African easterly jet (AEJ-S). Our analysis indicates that air masses likely left the continent with the same relationship between water vapor and carbon monoxide as was observed by aircraft. This linear relationship developed over the continent due to daytime convection within a deep continental boundary layer (up to ~5-6 km) and mixing with higher-altitude air, which resulted in fairly consistent vertical gradients in CO and water vapor, decreasing with altitude and varying in time, but this water vapor does not originate as a product of the BB combustion itself. Due to a combination of conditions and mixing between the smoky, moist continental boundary layer and the dry and fairly clean upper-troposphere air above (~6 km), the smoky, humid air is transported by strong zonal winds and then advected over the SEA (to the ORACLES flight region) following largely isentropic trajectories. Hybrid Single-Particle Lagrangian Integrated Trajectory model (HYSPLIT) back trajectories support this interpretation. This work thus gives insights into the conditions and processes which cause water vapor to covary with plume strength. Better understanding of this relationship, including how it varies spatially and temporally, is important to accurately quantify direct, semi-direct, and indirect aerosol effects over this region.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2017

Hybrid Molten Bed Gasifier for High Hydrogen Syngas Production

The techno-economic analyses of the hybrid molten bed gasification technology and laboratory testing of the HMB process were carried out in this project by the Gas Technology Institute and partner Nexant, Inc. under contract with the US Department of Energy’s National Energy Technology Laboratory. This report includes the results of two complete IGCC and Fischer-Tropsch TEA analyses comparing HMB gasification with the Shell slagging gasification process as a base case. Also included are the results of the laboratory simulation tests of the HMB process using Illinois #6 coal fed along with natural gas, two different syngases, and steam. Work in this 18-month project was carried out in three main Tasks. Task 2 was completed first and involved modeling, mass and energy balances, and gasification process design. The results of this work were provided to Nexant as input to the TEA IGCC and FT configurations studied in detail in Task 3. The results of Task 2 were also used to guide the design of the laboratory-scale testing of the HMB concept in the submerged combustion melting test facility in GTI’s industrial combustion laboratory. All project work was completed on time and budget. A project close-out meeting reviewing project results was conducted on April 1, 2015 at GTI in Des Plaines, IL. The hybrid molten bed gasification process techno-economic analyses found that the HMB process is both technically and economically attractive compared with the Shell entrained flow gasification process. In IGCC configuration, HMB gasification provides both efficiency and cost benefits. In Fischer-Tropsch configuration, HMB shows small benefits, primarily because even at current low natural gas prices, natural gas is more expensive than coal on an energy cost basis. HMB gasification was found in the TEA to improve the overall IGCC economics as compared to the coal only Shell gasification process. Operationally, the HMB process proved to be robust and easy to operate. The burner was stable over the full oxygen to fuel firing range (0.8 to 1.05 of fuel gas stoichiometry) and with all fuel gases (natural gas and two syngas compositions), with steam, and without steam. The lower Btu content of the syngases presented no combustion difficulties. The molten bed was stable throughout testing. The molten bed was easily established as a bed of molten glass. As the composition changed from glass cullet to cullet with slag, no instabilities were encountered. The bed temperature and product syngas temperature remained stable throughout testing, demonstrating that the bed serves as a good heat sink for the gasification process. Product syngas temperature measured above the bed was stable at ~1600ºF. Testing found that syngas quality measured as H 2 /CO ratio increased with decreasing oxygen to fuel gas stoichiometric ratio, higher steam to inlet carbon ratio, higher temperature, and syngas compared with natural gas. The highest H 2 /CO ratios achieved were in the range of 0.70 to 0.78. These values are well below the targets of 1.5 to 2.0 that were expected and were predicted by modeling. The team, however, is encouraged that the HMB process can and will achieve H 2 /CO ratios up to 2.0. Changes needed include direct injection of coal into the molten bed of slag to prevent coal particle bypass into the product gas stream, elevation of the molten bed temperature to approximately 2500ºF, and further decrease of the oxygen to fuel gas ratio to well below the 0.85 minimum ratio used in the testing in this project.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2021

Pilot-Scale Testing of an Integrated Circuit for the Extraction of Rare Earth Minerals and Elements from Coal and Coal Byproducts Using Advanced Separation Technologies

The primary objective of this project was to develop and demonstrate an integrated pilot-scale circuitry for recovering high-value rare earth elements (REEs) from coal and coal byproducts. The target performance was to produce a mixed REE product with content of at least two percent by weight on a dry mass basis in a cost-effective and environmentally benign manner. During the first nine months of the project period (Phase 2 Budget Period 2), pilot plant construction was completed including all field site startup activities such as permitting, engineering design, procurement/bidding, unit fabrication, site construction, equipment installation, module assembly, safety training, and circuit shakedown. During the remaining 21 months of project period (Phase 2 Budget Period 3), detailed field-testing activities were performed including feedstock sample collection and preparation, exploratory testing, circuit modification, detailed parametric study, and performance optimization. A detailed techno-economic analysis was performed based on the pilot plant testing findings which provided various scenarios for REE production. The project successfully accomplished the proposed target performance by producing mixed rare earth oxide (REO) with greater than 90% purity by weight in a continuous pilot scale operation from two distinctly different coarse refuse materials (i.e., West Kentucky No. 13 and Fire Clay coal seams), and at least three secondary sources (i.e., heap leach process and naturally formed acid mine drainage system). Project partners included the University of Kentucky, Virginia Tech, West Virginia University, Alliance Coal, Blackhawk Mining, Mineral Refining Company, and Mineral Separation Technologies. The pilot scale test facility was constructed at a former mining complex owned by Alliance Natural Resource Partners (Alliance Coal). The site was rehabilitated to accommodate the equipment installation, construction and fabrication, electrical power requirement, water line management and containment. The process units constructed and installed included X-ray sorting unit, crushing and grinding unit, physical separation unit, acid leaching unit, solvent extraction unit, and wastewater management unit. A rare earth mineral concentration unit was constructed as a standalone unit for flexible operation. A detailed environmental assessment and control plan was carried out to identify and quantify any potential impacts of the pilot-scale processing circuitry on the human and eco-system health and well-being. Corresponding mitigation strategies and control measures were provided. A conceptual flowsheet was developed to effectively remove thorium and uranium from high purity rare earth oxide mix or any potential radionuclide enriched stream. The two distinct feedstock materials were secured from the Blackhawk Mining Complex in eastern Kentucky where the Fire Clay (Hazard No. 4) seam is processed. The West Kentucky No. 13 (Baker) coarse refuse material was collected from an active process stream at an Alliance coal preparation plant located in western Kentucky. Characterization analysis indicated that both of feed materials generated from the two sources contained >300 ppm of TREEs on a dry whole mass basis which met the requirements for a qualified feed stock. The two feedstocks were further upgraded using a dual x-ray sorter to prepare the feed material for hydrometallurgical circuit. Thermal treatment on feed material prior to leaching was found to: 1) improve the leaching recovery of REEs, 2) increase the leaching kinetics, and 3) allow the leaching reaction to occur at lower acidity. Roasting at 600°C was selected as the pre-treatment condition for both West Kentucky No. 13 and Fire Clay coarse refuse material. Over 40% of leaching recovery was achieved by roasting West Kentucky No. 13 material having a top particle size of 3 mm in the pilot scale operation using 1.2M sulfuric acid leaching at 75OC. Initial pilot scale testing involved continuous operation of the pilot plant for 94 hours. The leaching unit was operated at solid-to-liquid ratio of 1 to 10 (w/v) using 0.5M sulfuric acid solution at a temperature of 75°C. The continuous solvent extraction circuit utilized rougher and cleaner units with DEHPA and TBP as the extractants. An innovative stripping circuit was developed to accumulate the REE concentration in the stripping solution to a level above 600 ppm. A bleed stream from the recycled strip solution was treated using oxalic acid precipitation which produced a high grade rare earth oxalate. The oxalate product was roasted to remove the oxalate which produced a rare earth oxide product having a purity greater 90%. Due to high concentrations of contaminant ions in the pregnant leach solution (PLS), a modified flowsheet was developed that involved pre-concentration of the REEs using multiple stages of precipitation and redissolution. The advantage of this process was improved removal of contamination before the downstream purification process and a significant cost reduction relative to the circuit that utilized the solvent extraction process. The modified circuitry included processes involving leaching, multistage precipitation, redissolution, and oxalate precipitation followed by roasting of the oxalate product. The circuit produced a mixed REO that was 92.96% pure from the initial test. A detailed parametric test plan was carried out which involved varying key parameters including solids feed rate, acid flowrate, acid concentration, multistage precipitation pH, redissolution pH, oxalate precipitation dosage and pH. The response variables included REE recovery, contaminant recovery, REO product grade and overall chemical consumption. Test results indicated that the acid-to-solid ratio is the key parameter to leaching efficiency as performance deteriorated with an increase in solids concentration. The optimal pH determined for REE precipitation and redissolution was 6.5 and 2.5, respectively. Additional tests were conducted to further improve the flowsheet. Recirculating a portion of the PLS to the feed of the leach tanks improved the leaching performance by lowering the pH of the leaching system and reducing the contamination recovery by shortening the residence time. Moreover, the removal of Al prior to REE precipitation significantly reduced the oxalic acid consumption in the oxalate precipitation circuit. The modified circuit produced over 90% grade REO by weight from both West Kentucky No. 13 and Fire Clay coarse refuse material in pilot scale continuous test programs. A case analysis model was developed to project the REE and major contaminants concentration in each PLS stream based on the leaching condition, pH cut point, and oxalic acid dosage. A correlation was established using empirical and semi-empirical models. Using the models, chemical consumption required for each stage was predicted based on the projected performance of the hydrometallurgy circuit. After identifying the optimum conditions, validation tests were carried out for the treatment of both West Kentucky No. 13 and Fire Clay coarse refuse materials in the pilot plant. The actual circuit performance and chemical consumptions were very close to the model predictions. Other than the two coarse refuse sources, several secondary feedstocks were also tested in the pilot plant facility. A “heap leach” system was constructed using the coarse refuse material generated from cleaning the West Kentucky No. 13 seam coal. Using the two stage SX rougher and cleaner circuit, a concentrate with a grade >90% REO was produced while recovering >97% of the REEs from the heap leach PLS. Naturally generated acid mine drainage (AMD) from West Kentucky No.13 mine was processed using the multistage precipitation circuit in the pilot plant in a test conducted for a period of 32 hours. The final grade of the mix RE oxide produced from the AMD was 90.84% with an overall circuit recovery of 64%. The primary source of REE was the selective precipitation steps involving iron and aluminum rejection. The hydrophobic-hydrophilic separation (HHS) process was proven to effectively recover coal from fine waste materials. For REM recovery, the HHS process was able to produce concentrates at grades of approximately 1.8% REE on an ash basis; however, recovery values were typically low, <10%, under the optimal conditions determined in the laboratory-scale testing. Staged testing of the pilot-scale HHS process for coal recovery and semi-continuous laboratory testing for REM testing showed that a total concentration ratio of more than 15x was observed for the REM recovery process. A circuit simulation package was developed for REE extraction and purification using a spreadsheet-based platform (Microsoft Excel). The REESim circuit simulation package is configured to track the mass and volume flows of components passing through a series of unit operations specified and configured by the user. The mass rates can then be utilized by the user to determine important performance indicators such as product mass yields, concentrate purity levels, element-by-element recoveries, and so forth. The techno-economic analysis showed that the roasting and leaching operations were the most expensive capital items, each contributing approximately 30% to the total capital cost. One notable contributor to the high production costs was the low REE recovery observed in the pilot scale trials. The product basket price was shown to have a strong influence on the economic viability of the scenarios, with the scandium price being the most significant influencer. Operating cost was shown to be extremely sensitive to REE recovery, REE feed grade, and leaching acid consumption. An analysis of ten different scenarios for a 500 t/h commercial operation revealed that three were economically favorable, producing internal rates of return varying from 27.7% to 33.1% and payback periods of 4 to 5 years. The project successfully developed and demonstrated a process to recover REEs from coal and coal byproducts in a pilot-plant operation which consistently produced over 90% grade REO mix from varies types of feedstocks. Commercialization analysis showed that the technology readiness level successfully achieved TRL 6 at the end of the project and demonstrated the need and the potential for scaling the process to further advance the technologies toward the goal of providing a domestic supply of REEs at a commercial scale.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Hardness Prediction by Incorporating Heat Transfer and Molten Pool Fluid Flow in a Multi-pass, Multi-layer Weld for Onsite Repair of Grade 91 steel

Introduction: In the current fleet of fossil-fired power plants, creep strength enhanced ferritic steels (CSEF) are used to sustain the harsh service conditions. Enhanced properties of Grade 91 steel result from tempered martensite with a fine distribution of MX and M23C6 carbides. Grade 91 steel is subjected to onsite welding repair to remedy their degradation due to extreme service condition. Knowledge of weld repairability of these steels, such as as-welded hardness distribution, is essential to establishing sound repair procedures. Experimental trial and error tests can consume a lot of time as many welding variables need to be studied. For numerical modelling, most of the multi-pass multi-layer models are based on finite element method, which are limited to solve the heat conduction equation and ignore convective heat transfer due to melt flow. Moreover, the mesh has to be pre-built based on a known or assumed weld cross-section geometry. These finite element based models thus have limited predictive capability as defects are not considered and nugget size are pre-assumed. This research aims at developing a thermal and microstructure evolution model incorporating molten pool dynamics in a multi-pass multi-layer material deposition to predict the as-welded hardness distribution. Technical Approach: All the thermal, physical, and metallurgical properties of Grade 91 as a function of temperature are collected from the literature and inputted into the thermo-fluid model based on Flow-3D, a computational fluid dynamics software. A multi-pass, multi-layer material deposition is simulated where the melting of filler wire into the molten pool is directly considered based on the volume of fluid (VOF) method. The flow behaviour of the molten pool is used to understand the formation of deposition geometry and defects. The temperature profiles during the multi-pass, multi-layer welding are calculated. The results computed using the new model are compared against the experimental data of fusion zone geometry and thermal cycles. Hardness prediction in the heat-affected zone (HAZ) are made using Johnson-Mehl-Avrami (JMA) equation for solid-state phase transformation kinetics. The JMA parameters are extracted from the experimental data available in the literature. For comparison, a standard finite element heat conduction model is also developed to predict the thermal cycles and hardness distribution in the multi-pass, multi-layer weld. Expected Result: Results obtained using the molten pool dynamic simulation versus the finite element heat conduction model are compared. Specifically, the effects of convective heat transfer on the accuracy of the calculated thermal history, bead shape and size, and HAZ hardness distribution are examined.

Modeling, Grade 91 steel, Multi-pass multi-layer d↗
DOE OSTI2022

Improving the Economic Viability of Biological Utilization of Coal Power Plant CO 2 by Improved Algae Productivity and Integration with Wastewater Treatment

The overall goal of this project was to improve the cost-effectiveness of systems using algae to capture and beneficially utilize CO 2 from the flue gas of coal-fired power plants. Algal biomass cultivation is an attractive alternative for carbon capture and utilization because it can uptake more CO 2 per land area than any other photosynthetic crop. Also, the resulting biomass can be used to make valuable large-market commodity products, such as biofuels and animal feed. However, the use of algal carbon capture has been limited by several factors including: (1) high costs for growing algae (>$\$1,300$/ton), (2) large land requirements for algae cultivation, and (3) environmental concerns about the large amount of water and nutrient inputs needed for growing algae. This project has taken direct aim at resolving these key limitations and demonstrated several viable approaches to improve the economic and environmental feasibility of algal carbon capture. In particular, this project demonstrated a significant increase in average annual algal productivity from baseline values of 8 g/m 2 -day to above 20 g/m 2 -day. This supports a much lower projected cost of algae production (<$\$500$/ton) and reduces land requirements by more than 50%. Additionally, this project confirmed the ability to grow multiple algae species with wastewater nutrients, which facilitates the potential for substantial new revenue streams for algae cultivation based on tipping fees for nutrient laden wastewater. This study highlighted that there is more potential value in wastewater nutrient treatment credits than in the primary commodity products made from algae. The use of wastewater inputs also mitigates the concerns associated with the large amount of water needed for growing algae. The algal biomass grown for this project using wastewater and simulated flue gas inputs were characterized for potential use as an animal feed ingredient. The algae had a protein content in the range of 35-40%, which is between some common commodity animal feed products— distiller’s grains (~25-30% protein) and soybean meal (45-50% protein). In-vitro digestion tests using cattle rumen fluids, showed that this algae biomass was best suited for use as “bypass protein”, which is digested in the animal intestine. Based on the protein content and amino acid profile of the algae grown in this study, it was estimated to have market value in the range of $\$190$-$\$280$/ton. There is potential for higher value feed products if the algae content of omega-3 fatty acids or antioxidants is accounted for. This project also did small scale demonstration of forward osmosis algae dewatering and nanofiltration of hydrothermal liquefaction aqueous products, which were shown to improve the cost and energy balance for producing algal products. When all the improvements demonstrated in this study were included in techno-economic analysis, it showed there was a viable pathway to profitable algal CO 2 utilization with a payback period in the range of six to ten years.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

A Comprehensive Numerical and Experimental Study for the Passive Thermal Management in Battery Modules and Packs

Cooling plates in battery packs of electric vehicles play critical roles in passive thermal management systems to reduce risks of catastrophic thermal runaway. In this work, a series of numerical simulations and experiments are carried out to unveil the role of cooling plates (both between cells and a bottom plate parallel to the cell stack) on the thermal behavior of battery modules and packs under nail penetrations. First, we investigated the role of side cooling plates on the thermal runaway propagation mitigation in battery modules (1S3P) and packs (3S3P) by varying the key parameters of the side cooling plates, such as plate thicknesses, thermal contact resistances, and materials. Then, three important factors for passive thermal management systems are identified: (i) thermal mass of side cooling plates, (ii) interfacial thermal contact resistances, and (iii) the effective heat transfer coefficients at exterior surfaces. The roles of bottom cooling plates on thermal runaway propagation mitigation in 1S3P and 1S5P battery modules are numerically investigated by comparing the thermal behavior of the modules with only side cooling plates and with both side and bottom cooling plates.

25 ENERGY STORAGE↗
DOE OSTI2014

Novel Supercritical Carbon Dioxide Power Cycle Utilizing Pressured Oxy-combustion in Conjunction with Cryogenic Compression

The team of Southwest Research Institute ® (SwRI) and Thar Energy LLC (Thar) applied technology engineering and economic analysis to evaluate two advanced oxy-combustion power cycles, the Cryogenic Pressurized Oxy-combustion Cycle (CPOC), and the Supercritical Oxy-combustion Cycle. This assessment evaluated the performance and economic cost of the two proposed cycles with carbon capture and included a technology gap analysis of the proposed technologies to determine the technology readiness level of the cycle and the cycle components. The results of the engineering and economic analysis and the technology gap analysis were used to identify the next steps along the technology development roadmap for the selected cycle. The project objectives, as outlined in the FOA, were 90% CO 2 removal at no more than a 35% increase in cost of electricity (COE) as compared to a Supercritical Pulverized Coal Plant without CO 2 capture. The supercritical oxy-combustion power cycle with 99% carbon capture achieves a COE of $\$$121/MWe. This revised COE represents a 21% reduction in cost as compared to supercritical steam with 90% carbon capture ($\$$137/MWe). However, this represents a 49% increase in the COE over supercritical steam without carbon capture ($\$$80.95/MWe), exceeding the 35% target. The supercritical oxy-combustion cycle with 99% carbon capture achieved a 37.9% HHV plant efficiency (39.3% LHV plant efficiency), when coupling a supercritical oxy-combustion thermal loop to an indirect supercritical CO 2 (sCO 2 ) power block. In this configuration, the power block achieved 48% thermal efficiency for turbine inlet conditions of 650°C and 290 atm. Power block efficiencies near 60% are feasible with higher turbine inlet temperatures, however a design tradeoff to limit firing temperature to 650°C was made in order to use austenitic stainless steels for the high temperature pressure vessels and piping and to minimize the need for advanced turbomachinery features such as blade cooling. The overall technical readiness of the supercritical oxy-combustion cycle is TRL 2, Technology Concept, due to the maturity level of the supercritical oxy-combustor for solid fuels, and several critical supporting components, as identified in the Technical Gap Analysis. The supercritical oxycombustor for solid fuels operating at pressures near 100 atm is a unique component of the supercritical oxy-combustion cycle. In addition to the low TRL supercritical oxy-combustor, secondary systems were identified that would require adaptation for use with the supercritical oxycombustion cycle. These secondary systems include the high pressure pulverized coal feed, high temperature cyclone, removal of post-combustion particulates from the high pressure cyclone underflow stream, and micro-channel heat exchangers tolerant of particulate loading. Bench scale testing was utilized to measure coal combustion properties at elevated pressures in a CO 2 environment. This testing included coal slurry preparation, visualization of coal injection into a high pressure fluid, and modification of existing test equipment to facilitate the combustion properties testing. Additional bench scale testing evaluated the effectiveness of a rotary atomizer for injecting a coal-water slurry into a fluid with similar densities, as opposed to the typical application where the high density fluid is injected into a low density fluid. The swirl type supercritical oxy-combustor was developed from initial concept to an advanced design stage through numerical simulation using FLUENT and Chemkin to model the flow through the combustor and provide initial assessment of the coal combustion reactions in the flow path. This effort enabled the initial combustor mechanical layout, initial pressure vessel design, and the conceptual layout of a pilot scale test loop. A pilot scale demonstration of the supercritical oxy-combustion cycle is proposed as the next step in the technology development. This demonstration would advance the supercritical oxy-combustion cycle and the supercritical oxy-combustor from a current TRL of 2, Technology Concept, to TRL 6, Pilot Scale System Demonstrated in a Relevant Environment, and enable the evaluation and continued refinement of the supercritical oxy-combustor and critical secondary systems.

42 ENGINEERING↗
DOE OSTI2018

Leveraging Energy Storage in a Solar-Tower and Combined Cycle Hybrid Power Plant

A method is presented to enhance solar penetration of a hybrid solar-combined cycle power plant integrated with a packed-bed thermal energy storage system. The hybrid plant is modeled using Simulink and employs systems-level automation. Feedback control regulates net power, collector temperature, and turbine firing temperature. A base-case plant is presented, and plant design is systematically modified to improve solar energy utilization. A novel recycling configuration enables robust control of collector temperature and net power during times of high solar activity. Recycling allows for improved solar energy utilization and a yearly solar fraction over 30%, while maintaining power control. During significant solar activity, excessive collector temperature and power setpoint mismatch are still observed with the proposed recycling configuration. A storage bypass is integrated with recycling, to lower storage charging rate. This operation results in diverting only a fraction of air flow to storage, which lowers the storage charging rate and improves solar energy utilization. Recycling with a storage bypass can handle larger solar inputs and a solar fraction over 70% occurs when following a drastic peaking power load. The novel plant configuration is estimated to reduce levelized cost of the plant by over 4% compared to the base-case plant.

14 SOLAR ENERGY↗
DOE OSTI2021

Nitrogen evolution, NO X formation and reduction in pressurized oxy coal combustion

Oxy-combustion is one of the most prominent solutions for reducing CO 2 emissions from coal-fired power plants using carbon-capture-and-utilization technology. However, when compared to air combustion at atmospheric pressure, oxy-combustion is very expensive, owing to the significant efficiency penalties associated with air separation, flue gas recirculation (FGR), treatment, compression, and storage or transit of CO 2 . In comparison, pressurized oxy-combustion (POC) is more efficient as it recovers a significant amount of heat energy from the flue gas moistures. Nevertheless, CO 2 derived from pressurized oxy coal combustion has impurities, e.g., acid gases (NO X and SO X ) that can corrode the plant equipment, transport lines as well as deteriorating effect on the environment. Fortunately, in pressurized combustion systems, both NO X and SO X can be scrubbed by a single-column direct contact cooler (DCC), but this requires a minimum ratio of NO X to SO X at the inlet to be efficiently removed. Therefore, NOx is one of the important hindering parameters in commercializing the pressurized oxy-combustion. Although NOx evolution during oxy-coal combustion has been explored extensively at 1 atm, higher pressure studies are rare. Much still needs to be done to better understand the NO X mechanism and the effects of different parameters on NO X emissions under these conditions. Here, this paper reviews the published literature on nitrogen evolution, NO X formation and reduction in pressurized oxy-coal combustion. At higher pressures, the NO X from fuel-bound nitrogen is generated through volatiles, tar and char, all of which are discussed. Where literature is not available, the effect of pressure on NOx evolution in different stages of coal combustion is predicted through CHEMKIN simulation. Homogeneous and heterogeneous pathways of NO X formation and their destruction in pressurized oxy-coal combustion are evaluated. Additionally, the effect of pressure on a few mature and commercialized NOx abatement methods is explored. In the last, the future perspective and recommendation are given. This review will aid in the provision of basic knowledge about NOx evolution and control in pressurized fuel combustion, as well as the identification of new research areas to pursue.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2016

A comparison of simple global kinetic models for coal devolatilization with the CPD model

Simulations of coal combustors and gasifiers generally cannot incorporate the complexities of advanced pyrolysis models, and hence there is interest in evaluating simpler models over ranges of temperature and heating rate that are applicable to the furnace of interest. In this paper, six different simple model forms are compared to predictions made by the Chemical Percolation Devolatilization (CPD) model. The model forms included three modified one-step models, a simple two-step model, and two new modified two-step models. These simple model forms were compared over a wide range of heating rates (5 × 10 3 to 10 6 K/s) at final temperatures up to 1600 K. Comparisons were made of total volatiles yield as a function of temperature, as well as the ultimate volatiles yield. Advantages and disadvantages for each simple model form are discussed. In conclusion, a modified two-step model with distributed activation energies seems to give the best agreement with CPD model predictions (with the fewest tunable parameters).

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2016

A spectroscopically confirmed double source plane lens system in the Hyper Suprime-Cam Subaru Strategic Program

We report the serendipitous discovery of HSC J142449−005322, a double source plane lens system in the Hyper Suprime-Cam Subaru Strategic Program. We dub the system Eye of Horus. The lens galaxy is a very massive early-type galaxy with stellar mass of ∼7×10{sup 11} M{sub ⊙} located at z{sub L}=0.795. The system exhibits two arcs/rings with clearly different colors, including several knots. We have performed spectroscopic follow-up observations of the system with FIRE on Magellan. The outer ring is confirmed at z{sub S2}=1.988 with multiple emission lines, while the inner arc and counterimage is confirmed at z{sub S1}=1.302. This makes it the first double source plane system with spectroscopic redshifts of both sources. Interestingly, redshifts of two of the knots embedded in the outer ring are found to be offset by Δz=0.002 from the other knots, suggesting that the outer ring consists of at least two distinct components in the source plane. We perform lens modeling with two independent codes and successfully reproduce the main features of the system. However, two of the lensed sources separated by ∼0.7 arcsec cannot be reproduced by a smooth potential, and the addition of substructure to the lens potential is required to reproduce them. Higher-resolution imaging of the system will help decipher the origin of this lensing feature and potentially detect the substructure.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2018

Assessing the Geomechanical Response of CO 2 Disposal in Flood Basalt Reservoirs

In this work, we complete a multi-scale investigation of the physical processes governing geologic CO 2 sequestration in basalt reservoirs. This work integrates (i) laboratory measurements of relative permeability in a basalt fracture, (ii) theoretical modeling to understand how relative permeability uncertainty affects geomechanical performance attributes of basalt reservoirs, (iii) outcrop-scale simulation to identify the characteristics of vertical CO 2 flow in a basalt fracture network, and (iv) regional-scale assessment of permeability architecture in the Columbia River Basalt Group (CRBG). These individual studies are combined into a site-scale stochastic model of geologic CO 2 sequestration in the Columbia River Plateau, which shows how bulk and relative permeability variability affects geomechanical reservoir integrity and storage capacity of flood basalt reservoirs. This project resulted in a novel laboratory technique that combines X-ray CT and micro-PET scanning to calculate the relative permeability curves for a horizontal fracture in basalt. We also discovered that permeability on the Columbia River Plateau exhibits directionally-dependent spatial correlation, which our analysis suggests is a result of loading-induced subsidence. This analysis further discovered that permeability in the CRBG may increase at depth due to bending moment stresses. In the context of CO 2 sequestration, this result implies that storage capacity and injectivity may actually increase at depths beyond ~1 km. Our outcrop-scale investigation found that buoyant, free-phase CO 2 tends to accumulate at fracture intersections, which inhibits vertical flow over 10+ year timescales and may facilitate both physical and chemical trapping as fluid mobility decreases. At the site-scale, we find that in flood basalt reservoirs the spatial configuration of reservoir permeability exhibits substantial control on CO 2 injectivity. We utilized known borehole geology from the Wallula Basalt Sequestration Pilot Project to develop 50 equally probable permeability configurations and found that a single injection well operating at 95% of the borehole breakout pressure can deliver 0.12 to 2.0 million metric tons of CO 2 per year (MMT CO 2 per year). This maximum injection rate can support a 1,000 MW gas-fired power plant with a single injection well.

58 GEOSCIENCES↗
DOE OSTI2019

Abradable Sealing Materials for Emerging IGCC-Based Turbine Systems (Final Report)

Reducing the gap between rotating and stationary parts in gas turbine engines, and mitigating gas leakage via these paths, can significantly increase the performance and attendant efficiency. One approach to reducing such gaps is to deploy abradable coatings on the stationary shroud components as seals, to reduce the blade-tip clearances under operational conditions. Abradable coatings must be able to withstand high temperature oxidation, thermal cycling, and erosion, while providing optimal controlled abrasion and associated shape retention. Existing abradable seals utilized in power generation turbines have generally been optimized for use with natural gas-fired systems; however, preliminary testing of syngas and high-hydrogen-content (HHC) fired turbines has shown that the stability of hot-section materials (and presumably abradable sealing materials) may be substantially altered due to characteristic changes in the combustion by-products (partial pressures of water vapor, etc.) as well as characteristic impurities and particulate matter entrained in the fuel. The primary focus of this research program has been to develop a mechanistic understanding of how the altered combustion environments modify the thermo-mechanical stability and performance of the sealing materials, including the requisite abradable sealing behavior. A key component of the research program carried out has been an exploration of mechanisms underpinning observed degradation processes, and an assessment of connections to the combustion environments and characteristic non-combustible constituents. The ultimate goal of the project has been to advance the goals of the Advanced Turbine Program by developing materials design protocols leading to turbine hot-section components with improved resistance to service lifetime degradation under advanced fuels exposures. This research program has evaluated the performance and degradation of ceramic abradable seals used in the high-temperature turbine sections of gas turbine engines. The focus has been two-fold: (1) to understand performance of such materials in relation to the turbines operating on coal-derived syngas and high hydrogen content (HHC) fuels, ultimately seeking an improved understanding of factors that control performance and durability of abradable seal materials for these combustion environments (and play into materials design protocols); and (2) to evaluate the potential of alternative materials as abradable seals for the higher temperatures expected with IGCC and HHC fueled turbine systems. In particular, we carried out an initial assessment of multi-layered systems of existing abradable seal materials (YSZ) and other ceramics. The research program also investigated several classes of abradable coatings under simulated exposures to syngas-based combustion environments, evaluating the relevant wear behavior, hardness, stability under cyclic oxidation, and general thermo-mechanical behavior. The research also attempted to develop alternatives to carrying out full-scale combustion-based abradability test rig exposures to evaluate materials system performance. The research has been focused on correlating the measured thermo-mechanical behavior, and controlled abrasive wear, with the intrinsic properties of the multilayer coatings and processing-controlled microstructural features that have shown attractive machinability characteristics based on weak interfacial bonding between the constituent phases at elevate temperatures (while maintaining thermochemical stability). This program has resulted in an improved mechanistic understanding of factors governing performance of high temperature abradable seals, and degradation mechanisms unique to IGCC-based power generation turbine systems and the realization of coal-derived syngas and HHC-based combustion environments – ultimately with the goal of developing a knowledge base upon which the design of coatings that retain optimal sealing characteristics and are more resistant to the observed wear/attack mechanisms, important aspects of advancing the goals of the DOE Advanced Turbine Program.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Intelligent Experiments through Real-Time AI: Fast Data Processing and Autonomous Detector Control for High-Energy Nuclear Experiments

The aim of this project is to develop software and hardware for fast real-time data processing and autonomous detector control and calibration for the sPHENIX and the future EIC experiments. Below summarizes Georgia Tech team efforts in the past year: 1. We developed a real-time clustering algorithm and FPGA-based pipeline architecture for processing fired pixel data from ALPIDE sensors in sPHENIX experiments. Our Columnar Clustering Co-Design introduces a hardware-aware, stream-friendly approach that segments pixel data by column pairs using a Column Pair Clustering (CPC) strategy, followed by Cluster Stitching to merge adjacent subclusters. Implemented in Vitis HLS, the pipeline comprises five stages—read-in, subclustering, stitching, analysis, and write-out—connected by tagged HLS streams with custom end-of-event signaling for robust synchronization. We designed a pipelined dataflow model optimized for throughput, low latency, and minimal buffering, enabling scalable clustering across events of arbitrary size. Our system maintains spatial precision via center-of-mass and shape key extraction and efficiently handles edge cases such as fragmented or nested clusters. Compared against DBSCAN in both software and hardware, our approach demonstrates competitive performance under FPGA constraints. 2. We also conducted a comprehensive algorithm-to-hardware co-design of connected component analysis tailored for sPHENIX experiments, focusing on real-time, low-latency processing using FPGAs and High-Level Synthesis (HLS). Starting from a Python-based particle tracking pipeline, the team translated the core logic—graph traversal via DFS and Union-Find—into an HLS-compatible C++ model, replacing dynamic memory and recursion with static arrays and pipelined control flow. The final design includes a fully streamed and dataflow-compatible Union-Find kernel optimized across five iterations, incorporating loop pipelining, array partitioning, AXI/FIFO interface tuning, and function flattening. Experimental results show up to 14.8× speedup over the CPU baseline, reducing per-graph latency to 1.58 μs and demonstrating strong resource efficiency with only ~7k LUTs and zero BRAM usage. The design maintains functional correctness against the Python reference using a Python-based C-simulation framework and Mean Squared Error metrics. This work validates the potential of HLS-driven FPGA designs for edge-level HEP data acquisition, laying a scalable foundation for future integration with real-time detector pipelines and multi-graph processing systems.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2022

Sorbent Based Post-Combustion CO 2 Slipstream Testing

TDA Research, Inc. has developed a low-cost sorbent (alkalized alumina) based technology for post-combustion CO 2 capture. The sorbent runs in an isothermal process for adsorption and regeneration. Neither temperature swing nor pressure swing is needed. TDA designed a system which operated 10 fixed beds to simulate a moving bed process. The flow pattern was optimized to minimize the steam usage for regeneration. An excellent sorbent (Batch 1) was also developed with collaboration with our partner. The sorbent degraded after long term operation. We developed a reprocessing procedure, which can be conducted in situ, to restore the sorbent capture capacity as the fresh sorbent after running for about 1250 hours. The reprocessing extended the sorbent longevity significantly. TDA designed a pilot unit (40’ x 32’ x 11.5’), processing flue gas equivalent to 0.5 MW of power generation. It had 10 beds and each bed could hold 1.75 m 3 of sorbent. We worked with Springs Fabrication, Inc. to complete the construction of the pilot unit. It was then shipped and installed at NCCC. The pilot unit was kept running in 24-hour mode when the flue gas and steam were available. It could run automatically without operator on site. Parametric and long-term (2 months) tests were carried out successfully. The results showed that TDA’s process can achieve 90% capture and 95% CO 2 purity for both coal and NG flue gases. For coal flue gas, the system reached performance target when processing up to 0.62 MW flue gas, 24% higher than the design capacity. Thus, capital cost could be saved on the reactors and sorbent. The strip air flow was designed to be 0.25 of that of the flue gas. The test data showed the strip/flue ratio can be reduced to as little as 0.18, which saves the power consumption for the strip air blower. The pressure drop was found to be lower than what the empirical equation calculated. The sorbent still had 91.7% of original capacity after 3-month test. With the data from the pilot test, we updated the TEA. For a 550-MW e supercritical coal fired power plant with CO 2 capture, the capture cost for TDA’s process is $34.9/tonne CO 2 captured, which meets DOE’s goal of $40/tonne and is 17.1% less than the DOE baseline Case 12. Therefore, TDA’s process has a good potential for commercialization.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2013

Theory and experiments characterizing hypervelocity impact plasmas on biased spacecraft materials

Space weather including solar activity and background plasma sets up spacecraft conditions that can magnify the threat from hypervelocity impacts. Hypervelocity impactors include both meteoroids, traveling between 11 and 72 km/s, and orbital debris, with typical impact speeds of 10 km/s. When an impactor encounters a spacecraft, its kinetic energy is converted over a very short timescale into energy of vaporization and ionization, resulting in a small, dense plasma. This plasma can produce radio frequency (RF) emission, causing electrical anomalies within the spacecraft. In order to study this phenomenon, we conducted ground-based experiments to study hypervelocity impact plasmas using a Van de Graaff dust accelerator. Iron projectiles ranging from 10{sup -16} g to 10{sup -11} g were fired at speeds of up to 70 km/s into a variety of target materials under a range of surface charging conditions representative of space weather effects. Impact plasmas associated with bare metal targets as well as spacecraft materials were studied. Plasma expansion models were developed to determine the composition and temperature of the impact plasma, shedding light on the plasma dynamics that can lead to spacecraft electrical anomalies. The dependence of these plasma properties on target material, impact speed, and surface charge was analyzed. Our work includes three major results. First, the initial temperature of the impact plasma is at least an order of magnitude lower than previously reported, providing conditions more favorable for sustained RF emission. Second, the composition of impact plasmas from glass targets, unlike that of impact plasmas from tungsten, has low dependence on impact speed, indicating a charge production mechanism that is significant down to orbital debris speeds. Finally, negative ion formation has a strong dependence on target material. These new results can inform the design and operation of spacecraft in order to mitigate future impact-related space weather anomalies and failures.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗