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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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At least 847 records · Page 47
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Macrophage infiltration regulates the adipose ECM reconstruction and the fibrosis process after fat grafting

Background: Fat grafting experiences a regeneration process from free lipoaspirate to intact adipose tissue. The adipose extracellular matrixes (ECM) provide the structure and biochemical support for surrounding cells; inflammatory cells, like macrophages, regulate the process. Our hypothesis states that transferred fat undergoes ECM remodeling after fat grafting and this process is regulated by macrophage infiltration. Methods: Lipoaspirate was injected subcutaneously into the back of nude mice. The micro-structure of the fat grafts was observed and evaluated using scanning electron microscope (SEM) and collagen I immunohistostaining. The gene transcription level of collagen proteins and the matrix metalloproteinases (MMPs) were assessed by qRT-PCR. Local injection of clodronate-encapsulated liposome was used to evaluate the role of macrophages of fat grafts at different stages in ECM remodeling, depletion of macrophages, at different time points (Week 1 and Week 4). Results: Results from the SEM analysis showed that liposuction caused severe damage to the ECM structure in freshly aspirated adipose tissue. On Day 1 post-transplantation, the surface of adipocytes was covered with platelets and this secreted fibrin network on the fat grafts. An integral adipose structure was already established with an intact ECM at the end of Week 1. The early depletion of macrophages remarkably hindered ECM reconstruction process by down-regulating the expression of collagen proteins and MMPs. Expression of Collagen I was significantly decreased after depletion of macrophages in both gene and protein levels. Results also showed that the depletion of macrophages at the later stage of fat grafting resulted in less fibrosis and capsule formation. Conclusion: Free fat aspirates undergo a prompt ECM reconstruction process and completed in the first week; this process can be initiated with platelets and mainly modulated by inflammatory cells such as macrophages. It was also observed that prolonged macrophage infiltration contributes to fibrosis and capsule formation in fat grafts. - Highlights: • Free fat aspirates undergo a prompt ECM reconstruction process in the first week. • The ECM reconstruction process is initiated with platelets and modulated by macrophages. • Depletion of macrophage in transferred fat resulted in delayed ECM reconstruction.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2026

Membrane-based solvent extraction for the recovery of rare earths from phosphate mining process streams

This study reports on the capture of rare earth elements (REEs) from phosphate industry process streams, including phosphoric acid (PA) sludge and phosphogypsum (PG), using a membrane solvent extraction (MSX) process. While MSX has been proven effective for a relatively concentrated feed, its effectiveness for dilute REEs solutions remains unexplored. Investigated PA-sludge and PG particles contain total REEs concentrations of ∼1100 and ∼320 ppm, respectively. Acid leaching, implemented to dissolve the REEs, significantly dilutes the REEs concentration to ∼210 ppm for PA-sludge leachate and ∼60 ppm for PG leachate. These low concentrations, compounded by the higher levels of non-REE ions and radioactive species, uranium (U) and thorium (Th), poses challenges to the MSX process. Here, we demonstrated that N,N,N′,N′-tetraoctyl-diglycolamide (TODGA) selectively binds REEs from a >3 M nitric-acid leachate while effectively rejecting U and Th. Concentrations of light REEs in strip solution were doubled compared to the feed, while heavy REEs were preferentially extracted. Furthermore, >99% purity gypsum, free of U and Th, was precipitated during the acid leaching process, aiding separation by removing significant amounts of non-REEs species (e.g., calcium) prior to the MSX process. Molecular simulations support the experimental data, suggesting preferential separation of heavy over light REEs. Based on these results, a cost-effective integrated process including pretreatment, acid leaching, MSX, and wastewater treatment is proposed for the co-recovery of REEs, phosphoric acid, gypsum, and U. This study shows MSX as a technically and economically feasible process for the recovery of REEs from low-concentration process streams, offering advantages over conventional solvent extraction.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Genesis of a novel high-rate composite manufacturing process using large-scale additive manufacturing – compression molding (AM-CM) system: Possibilities and limitations

Oak Ridge National Laboratory (ORNL) has developed a highly automated manufacturing process for thermoplastic composites that combines the benefits of Additive Manufacturing and Compression Molding (AM-CM) to produce high-performance functional composite structures at automotive production rates. Here, the AM-CM process creates highly precise preforms by additively placing extruded fiber-filled polymers (with controlled fiber orientations and multi-material configurations) in the desired mold location before undergoing a secondary compression molding process immediately before the preform cools down. Preforms can be in the form of short, long-chopped, or continuous fiber-filled thermoplastic polymers (e.g., CF/GF-filled ABS, PC, LM-PAEK, etc.). The AM-CM process combines the benefits of controlled fiber alignment, that is only achievable in AM-printed parts with the classical CM process, which eliminates porosity and good surface finish. A preform created using AM-CM can integrate various materials to enable additional architectural functionalities, including over-molding, selective stiffening, and the incorporation of electrically or thermally conductive channels. All these advantages come with a fast part production cycle time. The AM-CM process can manufacture multi-material, multi-functional parts in under 3 min, starting from raw material (pellets) to the final product. The novel AM-CM process offers superior microstructural control and enhanced multi-functionality previously unattainable with any other traditional high-rate thermoplastic composite manufacturing method. This work covers the manufacturing concept, system development, materials and applications of AM-CM process in detail.

Kumar, Vipin [Oak Ridge National Laboratory (ORNL)↗
DOE OSTI2020

Mineral Recovery Enhanced Desalination (MRED) process: An innovative technology for desalinating hard brackish water

Desalination of water containing high concentrations of calcium, dissolved carbon dioxide, sulfate, silica and other sparingly soluble salts is difficult because of the scaling potential. An innovative pre-treatment scheme was investigated at bench scale that selectively removes these constituents and produces a soft water to enable desalination with high feed water recovery. The process first removes dissolved carbon dioxide by air stripping at low pH. Magnesium is removed by precipitation at high pH. Calcium is removed by ion exchange (IX), and sulfate is removed by nanofiltration (NF). Cation regenerant from IX, containing calcium, and concentrate from NF, containing sulfate, is combined to precipitate gypsum. Concentrate from the desalination process consisting of a concentrated NaCl solution is used to regenerate the IX resins. The selective precipitation, IX, and NF processes were tested in laboratory experiments and produced magnesium hydroxide and gypsum at greater than 90% and 95% purity respectively. A process model was developed to calculate process performance, mass and liquid flow rates. Finally, the MRED process offers the following benefits: 1) greater recovery of brackish feedwater by a desalination process, 2) recovery of marketable commodities and 3) reduction in the volume and mass of waste products from the treatment process.

42 ENGINEERING↗
DOE OSTI2022

Development of an innovative process for post-combustion CO 2 capture to produce high-value NaHCO 3 nanomaterials

An innovative post-combustion process using aqueous sodium glycinates solutions (SGS) for CO 2 capture from a split flue gas stream emitted from the 600 MWe coal power plant, used in the Wolverine Clean Energy Venture (WCEV) project, was developed in Aspen Plus v.10. The flue gas flow rate used in the process was 12.43 kg/s (at 353.15 K and 101.33 kPa) and contained 0.0023 and 13.33 mol% of SO 2 and CO 2 , respectively. The overall process includes 5 main units designed to remove all SO 2 and capture more than 90 mol% of CO 2 in the flue gas stream, while producing high-value, salable sodium bicarbonate (NaHCO 3 ) nanomaterials to offset the total process costs. The hydraulics, mass transfer characteristics, and process performance obtained using Aspen Plus were discussed. Also, the capital expenditure (CAPEX), operating expenditure (OPEX), and Levelized cost of CO 2 capture (LCOC) were calculated to assess the feasibility of this process. Further, the hydraulics in the SO 2 washing and CO 2 capture units showed a pressure drop of 12 and 1 kPa, respectively, and the behaviors of the liquid holdup and normalized packing specific wetted surface area were similar in both units. The gas-side mass transfer coefficients were orders of magnitude greater than the liquid-side mass transfer coefficients. The process was able to capture 2.352 kg/s of CO 2 and produce 4.486 kg/s of valuable NaHCO 3 nanomaterials. Also, the calculated CAPEX, OPEX, and LCOC of the process for a 30-year plant lifetime were ($\$ $4,450,552), (233.00 $\$ $/h) and (35.49 $\$ $/ton of CO 2 captured), respectively.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Gradient process parameter optimization in additive friction stir deposition of aluminum alloys

As one of the most novel additive manufacturing methods, currently selection and optimization of processing parameters in additive friction stir deposition (AFSD) have mainly relied on experiments and subsequent characterization of microstructural and mechanical properties. Such approaches are both time- and resource-consuming. Therefore, an ultrasound elastography enhanced gradient process parameter optimization method was applied in the present work to obtain a window of optimized processing parameters for AFSD processing of aluminum alloy by varying both rotational and linear deposition speeds. Further, the quality of AFSD processed layer was investigated for physical nature of surface, dynamic elastic modulus, and microstructural aspects in cross-sections of the deposited layer. The efficiency in exploring process parameters was significantly enhanced by implementing a high-throughput screening experimental design based on application of gradient process parameters and continuous ultrasound elastographs. In addition, the applied ultrasonic elastography technique assisted in evaluating the homogeneity in microstructure and mechanical properties of AFSD sample over the entire gradients of the process parameters. The techniques adopted in current work can be further extended to identify suitable parameters for AFSD fabrication of components with desired mechanical properties such as hardness, fatigue, etc.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Data-driven prediction of geometry- and toolpath sequence-dependent intra-layer process conditions variations in laser powder bed fusion

Geometrical features and toolpath sequence are two important factors that cause process condition variations, such as variations in the meltpool temperature or meltpool size, that might lead to undesired material properties in the laser powder bed fusion (LPBF) process. Due to the high dynamics and complex physics of the LPBF process, it is difficult to predict variations in process conditions with simulations alone. Advances in measurement technology and computational technologies open up new possibilities for smart manufacturing. In this paper, a data-driven method to predict intra-layer variations in the processing conditions that source from the toolpath sequence and part geometry is presented. The approach is demonstrated using two-color on-axis pyrometer measurements. Three demonstration cases are presented in which it is demonstrated (1) how the trained predictive model can be used as a filter to ease the interpretation of process variations and discover patterns related to toolpath and part geometry, and (2) how to generate predictions that can be used for feedforward control, i.e., for adjusting laser power or scanning speed along the toolpath using a meltpool temperature prediction model generated based on on-axis measurements. Results show that the developed prediction model is able to meaningfully predict process variations resulted from toolpath sequence and geometry. Predictions are aligned with the results from the related work of others and for the case of 180° laser path turnarounds in our high-speed X-ray imaging experiments. In conclusion, the potential issues related to the current maturity status of the process and measuring equipment that could in practice affect the performance of the proposed solutions are also discussed.

42 ENGINEERING↗
DOE OSTI2018

An isothermal forming process with multi-stage variable speed for magnesium component assisted by sensitivity analysis

We have developed a multi-stage variable speed (MSV) isothermal forming process based on strain rate sensitivity (SRS) analysis, and successfully produced a large size of rib-web component of magnesium alloy from a cylindrical billet. The obtained rib-web component has been processed into parts for mechanical properties examination and the examination results met the standard of being safely used in aircrafts. The process parameters of the forming technology and microstructure change were explicitly linked by the SRS coefficient. The finite element (FE) simulation and SRS distribution were implemented to identify the relationship among process parameters, shaping characteristics, and microstructure development. The MSV speed process was employed for reducing the forming load, refining grain sizes and increasing the strength of the component. With the selected process parameters the maximum forming load was reduced to be less than 20 MN, which is 55.3% lower than that used in the same process with the initial constant speed unchanged. Fine dynamic recrystallization (DRX) were observed from all parts of the forged cover plate including the convex, ribs, and web region. It was also found that higher strain resulted in more uniform distribution of fine ß-Mg17Al12 precipitates and larger DRX volume fraction. Importantly the developed isothermal forming process with severe plastic deformation can be applied for obtaining grain refinement so improving the mechanical properties of Mg products.

Magnesium alloy, Isothermal forming, Multi-stage v↗
DOE OSTI2024

Modeling Analysis of Ball-Milling Process for Battery-Electrode Synthesis

The mechanical alloying process is a promising method for synthesizing electrode materials for batteries owing to its benefits such as the ability to produce nanostructured, high-performing electrode alloys, no adverse effects on the solid electrolyte for solid-state batteries, stable production of thick electrodes, simple processing steps, and low processing costs. It is gaining intensive attention in the battery industry as one of the best methods to replace the conventional wet-slurry-solvent method, and its application is rapidly increasing these days. However, the operation is currently conducted purely based on trial-and-error methods without fully utilizing the features of its functions. Here, this may be attributed to a lack of understanding of the effect of operating parameters on the alloying process and final products. Surprisingly, there is a scarcity of the literature conducting fundamental research to comprehend the underlying physics of the entire mechanical alloying process, resulting in a significant knowledge gap. To address this knowledge gap, extensive research was conducted. The existing literature on mechanical alloying was reviewed to comprehend the current state of understanding and to discuss the direction for future research. Mathematical expressions were developed to create physics-based models capable of capturing the entire mechanical alloying process, including milling kinetics and defect-enhanced phase evolution. These methods were then applied to investigate the impact of operating parameters such as milling frequency, initial mole ratio of the alloyed materials, density of grinding balls, and energy required for the powders to become amorphous (i.e., the amorphization energy threshold). This research aimed not only to comprehend the direct effects of these operating parameters but also to unveil the physics underlying the ball-milling process. The results of our study can serve as crucial information for the battery industry in designing or operating the ball-milling process.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

A General Framework for Process Synthesis, Integration, and Intensification

Process synthesis, integration, and intensification are the three pillars of process design. Current synthesis and integration methods are able to find optimal design targets and process configurations when all the alternatives are known beforehand. Process intensification, on the other hand, combines multiple physicochemical phenomena and exploits their interactions to create innovative designs. Often times, these designs are not known beforehand, and a phenomena-level representation of chemical processes are required to identify them. This disconnection between the three paradigms limits the ability to systematically discover optimal design pathways. We demonstrate that the building block representation, originally proposed in our earlier work on process intensification, has the potential to bridge this gap. Depending on the attributes assigned to the interior and the boundaries of these two-dimensional abstract building blocks, they can represent various intensified or isolated phenomena at the lowest level, various tasks at the equipment level, and various unit operations at the flowsheet level. Here, this common multiscale representation enables an mixed-integer nonlinear optimization-based single framework for the sequential or simultaneous synthesis, integration, and intensification of chemical processes. Such a general framework is critical to reduce the risk of eliminating potential intensification pathways and candidate flowsheets at the conceptual design stage. The framework is demonstrated using a case study on an ethylene glycol process.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Non‐Linear Dimensionality Reduction With a Variational Encoder Decoder to Understand Convective Processes in Climate Models

Abstract Deep learning can accurately represent sub‐grid‐scale convective processes in climate models, learning from high resolution simulations. However, deep learning methods usually lack interpretability due to large internal dimensionality, resulting in reduced trustworthiness in these methods. Here, we use Variational Encoder Decoder structures (VED), a non‐linear dimensionality reduction technique, to learn and understand convective processes in an aquaplanet superparameterized climate model simulation, where deep convective processes are simulated explicitly. We show that similar to previous deep learning studies based on feed‐forward neural nets, the VED is capable of learning and accurately reproducing convective processes. In contrast to past work, we show this can be achieved by compressing the original information into only five latent nodes. As a result, the VED can be used to understand convective processes and delineate modes of convection through the exploration of its latent dimensions. A close investigation of the latent space enables the identification of different convective regimes: (a) stable conditions are clearly distinguished from deep convection with low outgoing longwave radiation and strong precipitation; (b) high optically thin cirrus‐like clouds are separated from low optically thick cumulus clouds; and (c) shallow convective processes are associated with large‐scale moisture content and surface diabatic heating. Our results demonstrate that VEDs can accurately represent convective processes in climate models, while enabling interpretability and better understanding of sub‐grid‐scale physical processes, paving the way to increasingly interpretable machine learning parameterizations with promising generative properties.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Improved thermonuclear rate of 42 Ti( p , γ ) 43 V and its astrophysical implication in the rp process

Context. Accurate 42 Ti(p,γ) 43 V reaction rates are crucial for understanding the nucleosynthesis path of the rapid capture process (rp process) that occurs in X-ray bursts. Aims. We aim to improve the thermonuclear rates of 42 Ti(p,γ) 43 V based on more complete resonance information and a more accurate direct component, together with the recently released nuclear masses data. We also explore the impact of the newly obtained rates on the rp process. Methods. We reevaluated the reaction rate of 42 Ti(p,γ) 43 V by the sum of the isolated resonance contribution instead of the Hauser-Feshbach statistical model. We used a Monte Carlo method to derive the associated uncertainties of new rates. The nucleosynthesis simulations were performed via the NuGrid post-processing code ppn. Results. The new rates differ from previous estimations due to the use of a series of updated resonance parameters and a direct S factor. Compared with the previous results from the Hauser-Feshbach statistical model, which assumes compound nucleus 43 V with a sufficiently high-level density in the energy region of astrophysical interest, large differences exist over the entire temperature region of rp-process interest, up to two orders of magnitude. We consistently calculated the photodisintegration rate using our new nuclear masses via the detailed balance principle, and found the discrepancies among the different reverse rates are much larger than those for the forward rate, up to ten orders of magnitude at the temperature of 10 8 K. Using a trajectory with a peak temperature of 1.95×10 9 K, we performed the rp-process nucleosynthesis simulations to investigate the impact of the new rates. Our calculations show that the adoption of the new forward and reverse rates result in abundance variations for Sc and Ca of 128% and 49%, respectively, compared to the variations for the statistical model rates. On the other hand, the overall abundance pattern is not significantly affected. The results of using new rates also confirm that the rp-process path does not bypass the isotope 43 V. Conclusions. Our study found that the Hauser-Feshbach statistical model is inappropriate to the reaction rate evaluation for 42 Ti(p,γ) 43 V. The adoption of the new rates confirms that the reaction path of 42 Ti(p,γ) 43 V(p,γ) 44 Cr(β + ) 44 V is a key branch of the rp process in X-ray bursts.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2018

The impact of (n, γ ) reaction rate uncertainties of unstable isotopes near N = 50 on the i-process nucleosynthesis in He-shell flash white dwarfs

The first-peak s-process elements Rb, Sr, Y and Zr in the post-AGB star Sakurai's object (V4334 Sagittarii) have been proposed to be the result of i-process nucleosynthesis in a post-AGB very-late thermal pulse event. We estimate the nuclear physics uncertainties in the i-process model predictions to determine whether the remaining discrepancies with observations are significant and point to potential issues with the underlying astrophysical model. We find that the dominant source in the nuclear physics uncertainties are predictions of neutron capture rates on unstable neutron rich nuclei, which can have uncertainties of more than a factor 20 in the band of the i-process. We use a Monte Carlo variation of 52 neutron capture rates and a 1D multi-zone post-processing model for the i-process in Sakurai's object to determine the cumulative effect of these uncertainties on the final elemental abundance predictions. We find that the nuclear physics uncertainties are large and comparable to observational errors. Within these uncertainties the model predictions are consistent with observations. A correlation analysis of the results of our MC simulations reveals that the strongest impact on the predicted abundances of Rb, Sr, Y and Zr is made by the uncertainties in the (n, γ) reaction rates of 85 Br, 86 Br, 87 Kr, 88 Kr, 89 Kr, 89 Rb, 89 Sr, and 92 Sr. This conclusion is supported by a series of multi-zone simulations in which we increased and decreased to their maximum and minimum limits one or two reaction rates per run. We also show that simple and fast one-zone simulations should not be used instead of more realistic multi-zone stellar simulations for nuclear sensitivity and uncertainty studies of convective–reactive processes. Lastly, our findings apply more generally to any i-process site with similar neutron exposure, such as rapidly accreting white dwarfs with near-solar metallicities.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2022

Multi-process tooling for discontinuous carbon and hybrid glass fiber thermoplastics

Expensive tooling often constraints the use of composites in the design and development of automotive parts. While there is significant confidence and knowledge in sheet and bulk metals, composite processes are less understood in mass production environment. The processes used to produce composites and resulting properties are influenced by fiber length attrition, resin to fiber ratio, process waste etc. Tool designs are determined very early in the engineering process. It is cost prohibitive to build additional tools, in the event it becomes obvious a better processing method and material would be beneficial, the original decision is not easily changed. In the present work we recognize the bottleneck of tooling costs and provide an approach of multi-process tooling. The innovation of this work is the design and demonstration of a single tool for different processes namely injection, injection-compression and extrusion-compression. The materials used in this study were long and short fiber thermoplastics (LFTs and SFTs). The resulting structure-property relationships have been reported for the materials and processing methods with a battery tray (BT) tool.

Vaidya, Uday↗
DOE OSTI2023

IN SITU PLASMA PROCESSING OF SUPERCONDUCTING CAVITIES AT JLAB, 2023 UPDATE

Jefferson Lab has an ongoing R&D program in plasma processing which just completed a round of production processing in the CEBAF accelerator. Plasma processing is a common technique for removing hydrocarbons from surfaces, which increases the work function and reduces the secondary emission coefficient. The initial focus of the effort was processing C100 cavities by injecting RF power into the higher order mode (HOM) coupler ports. Results from processing cryomodules in the CEBAF accelerator as well as vertical test results will be present-ed. The goal of in-situ processing is to improve the operational gradients and the energy margin of the linacs. This work will describe the systems and methods used at JLAB for processing cavities using an argon-oxygen gas mixture as well as a helium-oxygen gas mixture. Before and after plasma processing results will also be presented.

Powers, Thomas↗
DOE OSTI2018

Lab-scale Development of a Hybrid Capture System with Advanced Membrane, Solvent system, and Process Integration

The objective of the project is to achieve lab-scale demonstration of a transformational hybrid membrane/solvent system for the capture of CO 2 from flue gas. A novel process integration scheme was proposed to overcome the low partial pressure of CO 2 present in flue gas. This scheme takes advantage of the potential synergies inherent in the membrane and solvent capture systems. The proposed hybrid technology replaces the second-stage membrane with a solvent capture process. The combustion air is used as a sweeping gas in the solvent stripper. This overall configuration has the major advantages of requiring much less air and eliminating the problems associated with oxygen slip in the membrane-based systems. Even more importantly, because of the presence of the air sweep in the stripper, much lower temperatures are required for solvent regeneration, which enables heat integration to the point that no process steam is required. This project was to perform lab-scale demonstration of Liquid Ion Solutions (LIS) transformational hybrid membrane/solvent system for post-combustion CO 2 capture while demonstrating significant progress toward achievement of the overall fossil energy performance goals of 90% CO 2 capture rate with 95% CO 2 purity at a cost of electricity 30% less than baseline capture approaches. This report is written chronologically based on budget periods. Each budget period discusses the work performed and its results. At the end of each budget period the milestone charts are provided to show the progress. This project was not able to meet its stated goals. The performances of the power plant equipped with the hybrid process and Baseline Case B12B were compared. The simulation results showed that the power plant equipped with hybrid CO2 capture process has an improved thermal efficiency of 33.4% compared to the Baseline Case B12B, which is 32.5%. However, the COE for the hybrid process is $146.3/MWh which is higher than the $142.8/MWh for Case B12B. If this process were to be applied as a retrofit, it may make sense to use this configuration as it does not require any change in an existing plant configuration and steam cycle. However, for a new powerplant the capital cost is higher than the Case B12B. On the membrane development side, we successfully showed that interfacially-controlled envelope (ICE) membranes work. The inclusion of surface modified nano-particles results in much higher gas diffusivities. The Gen-1 ICE membrane developed under this project showed exceptional improved permeability for CO 2 . However, we ran into major problems which were associated with the scalability and reproducibility of the poly(phosphozene) polymers. The issues with scale-up are and batch to batch variability is also discussed. At the end of this report we have provided our recommendations on materials development for better membrane materials and alluded to the use of much simpler chemistry while keeping the concept of ICE membrane intact. It is also clear that vacuum and compression equipment is costly. If a process which can eliminate the use of vacuum and compression equipment would significantly decrease the overall cost of capture. Some thoughts regarding such system is also provided in the outlook portion of this report.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2019

Process Intensification for Electrochemical Utilization of CO 2

The conversion of CO 2 to value-added products is an attractive approach for reducing the cost of CO 2 capture. Formic acid (FA) is a multipurpose industrial chemical feedstock for formic acid fuel cells, additives in the textile and agricultural sectors, cleaning products, and corrosion inhibitors. FA can be produced directly from CO 2 via a two-electron process facilitated with DC electricity supplied via renewable/intermittent power sources [1]. The state-of-the-art method for industrial FA production is the Kemira process, which uses methanol, sodium methoxide, and CO to produce methyl formate that is subsequently hydrolyzed to formic acid. Conversely, an electrochemical approach reduces the number of chemical input for FA production, but conventional electrochemical processes for CO 2 reduction to FA continue to suffer from selectivity issues where the electrocatalyst produces a wide range of products. These competing products include FA, hydrogen, carbon monoxide, methanol, and methane that reduce faradaic efficiency by up to 50% [2]. The CAER-Andora process features an enzymatic catalyst with high selectivity for FA production with turn-over-frequency >85 s-1. The CAER-Andora process combines an electrochemical cell that features graphite electrodes and an electrochemically facile charge mediator, combined with an immobilized proprietary catalyst inside a FA production cell. These processes work together to 1) reduce faradaic inefficiencies by producing only FA, 2) protect the valuable catalyst from deactivation by overpotentials, and 3) provide a modular system configuration that facilitates independent optimization of the electrochemical and production cells. Operating at <3 V, the CAER-Andora process currently produces ~1 mM FA/hour with >90% CO2 to FA conversion in the production cell, and progress towards the intensification of the CO 2 utilization process will be discussed.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2020

Thermomechanical Processing of Uranium Alloys with 10 and 50 Weight Percent Zirconium

This work focuses on casting and thermomechanical processing for moderate sized (500-1000g) 10% by weight and 50% by weight uranium-zirconium alloys. Three castings of uranium – 10wt% zirconium and a fourth casting of uranium – 50wt% zirconium were completed using different castings processes. The first casting process relied on only induction mixing within the VIM system thereby eliminating the need for an arc-melting feedstock preparation step. The second casting process used the arc-melting process prior for feedstock to the same VIM system. In this study, the induction mixing process alone with a graphite crucible appears insufficient for the fabrication of UZr alloys. Graphite is suitable with the use of master alloy UZr feedstock produced by arc-melting. There was a moderate increase of approximately 100 ppm of carbon within the U10Zr alloys. However, there was a near 1000 ppm increase of carbon in the U50Zr alloy. This carbon content is considered too high for forming processes, and therefore, warrants the use of a ceramic crucible for UZr castings near 50wt% zirconium. Zirconia does not appear suitable for UZr castings near 50wt% zirconium. The use of Beryllia or Thoria may be a more suitable option. However, due to the significantly lower liquidus and lower zirconium content, Zirconia crucibles do appear viable for carbon reduction in the U10Zr system. Two thermomechanical processes are also studied in this work - hot extrusion of the U50Zr system and heat treatment in an argon atmosphere. This work demonstrated that extrusion of the U50Zr alloy near 680°C is a viable choice even with +1000 ppm carbon. Extrusion of the U50Zr system near 630°C was unsuccessful and does not appear viable unless significant force and tooling strength is available. There appears to be a moderate increase in extrudate hardness when compared to as-cast. Heat-treatment reduced the hardness of as-cast alloys in the U10Zr castings as well as resolve some variance in the microstructures. However, for the U50Zr billet that did not successfully extrude at 630°C, heat treatment at 900°C for 96 hours did not have a significant impact on hardness or microstructure.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗