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DOE OSTI2018

Air Pollutant Emissions and Regulatory Implications of a Biorefinery Co-Processing Bio-Oil in a Petroleum Refinery: Preprint

Pyrolysis oil, often referred to as bio-oil when derived from biomass through a fast pyrolysis process, has attracted considerable attention because of the high carbonaceous matter and high heating value compared to the original biomass. Pyrolysis oil provides a viable link between the agriculture/forestry and (petro-) chemical industry. Utilizing existing fossil fuel infrastructure by introducing bio-oil in petroleum refineries to produce renewable hydrocarbon fuels (i.e., repurposing existing assets) is appealing due to its relatively low capital requirement. Our analysis examined the air pollutant emissions for a biorefinery utilizing an ex situ catalytic fast pyrolysis process to produce raw bio-oil, with a design capacity of 2,000 dry metric tons of biomass per day. Such a biorefinery is capable of providing sufficient bio-oil to a 4,200 barrels per day capacity of fluidized catalytic cracking unit if the bio-oil is co-processed at 5% (by volume) feed rate. This research is focused on understanding the potential air pollutant regulatory and permitting implications for a refinery co-processing 5% bio-oil with 95% vacuum gas oil in a fluidized catalytic cracking unit for two scenarios: the first case assumes that an ex situ biorefinery is collocated with a petroleum refinery, and the second one assumes that a petroleum refinery will receive bio-oil from a stand-alone biorefinery. We estimated the potential-to-emit values for 4 biorefinery and FCC sizes and assessed technically feasible emission control options that could help to avoid being subject to prevention of significant deterioration requirements due to petroleum refinery modifications to co-process bio-oil. This research fills gaps and overcomes barriers related to air permitting requirements for co-processing bio-oil in existing refineries for various stakeholders. The insights gained from this analysis can facilitate decision making and help expedite permitting processes for petroleum refineries, which seek opportunities to produce lower carbon fuels in their existing infrastructure.

09 BIOMASS FUELS↗

DOE OSTI2019

Air Pollutant Emissions and Regulatory Implications of a Biorefinery Co-Processing Bio-Oil in a Petroleum Refinery

09 BIOMASS FUELS↗

DOE OSTI2018

Improved Superconducting Properties of Thick YBa{sub 2}Cu{sub 3}O{sub 7−δ} Film by Adding Amino-Rich Polyethyleneimine in Precursor Solution

Polyethyleneimine (PEI) with an amount of –NH{sub 2} groups used in precursor solution could effectively reduce Cu{sup 2+} volatilization during the pyrolysis process. Thermogravimetric analysis shows that the temperature window of low-temperature pyrolysis for precursor solution with PEI (PEI-YBCO) is widened significantly. The slower pyrolysis process can enrich Cu{sup 2+} and improve critical current density (J{sub c}) of PEI-YBCO films. The highest J{sub c} is 3.03 MA/cm{sup 2} at 77 K when the amount of PEI is 0.5 g/10 mL and the film thickness is 400 nm. Then the thickness increases from 0.4 to 2.0 μm by changing the coating times. The J{sub c} values of PEI-YBCO films decrease gradually with the thickness increase. However, the critical current (I{sub c}) can be up to 197 A/cm (at 77 K, self-field) and J{sub c} can still keep 1.68 MA/cm{sup 2} at 1.2 μm.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2019

Catalytic conversion of rubber wastes to produce aromatic hydrocarbons over USY zeolites: Effect of SiO 2 /Al 2 O 3 mole ratio

Catalytic conversion of rubber wastes to produce an alternative fuel resource is a promising approach to dispose of solid wastes and address environmental issues. In this study, catalytic fast pyrolysis (CFP) of rubber wastes over acidic zeolites was conducted, and the effect of SiO 2 /Al 2 O 3 mole ratio of USY zeolites on the formation of aromatic hydrocarbons was explored. Experimental results indicated that alkenes and aromatic hydrocarbons were the main pyrolytic products obtained from fast pyrolysis of rubber wastes, and the pyrolysis temperature played a vital role in the formation of aromatics with the highest concentration achieved at 750 °C. Furthermore, catalyst types also affected the catalytic degradation of rubber wastes since limonene was completely decomposed in the presence of zeolites. Compared to SAPO-34, zeolites with higher external surface area, stronger Brønsted acid sites, and larger pore size, including USY, HY, and Hβ, were more effective in the production of aromatic hydrocarbons with the highest content obtained from USY catalyzed run. Given the observed effect of SiO 2 /Al 2 O 3 mole ratio of USY zeolites on the formation of aromatic hydrocarbons during the CFP of rubber wastes, USY with low SiO 2 /Al 2 O 3 ratio of 5.3 was more beneficial to the generation of aromatic hydrocarbons, while that with higher SiO 2 /Al 2 O 3 mole ratio (11.5) facilitated the formation of alkenes. Simultaneously, the product distribution of aromatic hydrocarbons obtained from CFP of rubber wastes over USY zeolites was dominated by xylenes, alkylbenzenes, and toluene, and USY with SiO 2 /Al 2 O 3 mole ratio of 5.3 was more active in the production of toluene and xylenes.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2021

Catalytic degradation of waste rubbers and plastics over zeolites to produce aromatic hydrocarbons

Catalytic conversion of waste rubbers and plastics into aromatic hydrocarbons is a promising approach to waste management and energy recovery. In the present study, acidic HY zeolites were supported by cobalt, iron, and zirconium, and the catalysts were characterized by powder X-ray diffraction, nitrogen adsorption-desorption, ammonia temperature programmed desorption, X-ray photoelectron spectroscopy, and pyridine-Fourier transform infrared spectroscopy. Here, the catalytic degradation of waste polybutadiene rubbers (BR) was conducted to investigate the degradation mechanism and evaluate the catalytic activity of supported zeolites. Experimental results indicated that HY loaded by zirconium and iron led to a higher content of Lewis acid sites as opposed to cobalt supported one. Compared with the non-catalytic pyrolysis of BR, the zirconium supported HY (Zr/HY) led to a 10-fold increase in aromatic hydrocarbons production with a distinctively high selectivity of 97.9%. A series of waste polymers including waste tires (WT), polyethylene (PE), polycarbonate (PC), and BR, were subjected to catalytic pyrolysis to explore the effects of polymer type on aromatic hydrocarbons generation, and BR was the most effective substrate, with yield enhancement reaching 2.4 over Zr/HY. Catalytic co-pyrolysis of waste rubbers and plastics was conducted to probe the effect of polymer structure on aromatic hydrocarbons formation, where a significant synergistic effect was observed in the PE co-fed with PC run.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Insights into Mechanisms of Screw Feeder Plugging by Heated Pine Forestry Residues Using in-situ and Correlative Microscopy

Increasing concerns about global carbon emissions due to fossil fuel use has created interest in renewable fuel alternatives, such as lignocellulosic biomass. With an estimated global biomass production probability ten-fold higher than projected need, functionalizing and scaling biomass conversion processes, like pyrolysis, is a promising component of a diverse sustainable energy program (Kan, Strezov, & Evans, 2016). Pyrolysis reactors employed in biomass conversion often encounter the known problem of screw feeder plugging, halting work and reducing efficiency of biorefineries. Although the screw feeder is not heated directly, conductive heat transfer from the fluidized bed pyrolysis reactor creates a temperature gradient, where particles experience temperatures between 22°C and 500°C from the time they enter the feeder to being emptied into the reactor (Digman, Joo, & Kim, 2009; Nieminen & Folke, 1982). The impact of unintentional heating on this highly variable feedstock may result in particle morphology modification, surface texture transformation, and the evolution of viscous compounds and may contribute to screw feeder plugging (Haas, Nimlos, & Donohoe, 2009; Ingram et al., 2008). We hypothesized that particles of various anatomical fractions (including needles, branches, bark, cambium, and whitewood) will experience dramatic changes during this heating regime, which will be characterized by decreased particle size, increased surface roughness, degradation of key structural macromolecules, and generation of viscous compounds that would result in increased particle friction and cohesion, contributing to screw feeder plugging.

biofuels↗

DOE OSTI2018

Tuning the Performance of Single-Atom Electrocatalysts: Support-Induced Structural Reconstruction

We present that creating active and stable electrocatalysts remains a highly desirable and critical goal in the fields of catalysis and clean energy conversion. Single-atom catalyst (SAC), as a new research frontier in heterogeneous catalysis, has demonstrated emerging prospects for many electrocatalytic reactions. Support assisted pyrolysis approaches are widely used in the synthesis of single-atom electrocatalysts. While extensive efforts have been devoted to increase the loading of the atomically dispersed metal sites, the role of the support in creating these active metal sites remains largely unexplored. Herein, we compare catalysts created by support-free and support-assisted pyrolysis of vitamin B12 and cobalt tetramethoxyphenylporphyrin, respectively, and demonstrate an important effect of support-induced structural reconstruction that directly controls the activation of SAC. Electrochemical studies show support-free catalysts are inactive for oxygen reduction reaction whereas the support-assisted pyrolysis yields highly active catalysts using the same molecular precursors. X-ray absorption spectroscopy experiments reveal that both the metal-nitrogen coordination and the type of nitrogen species are different in these two types of samples, which leads to a difference in the d-band of the cobalt metal center and ultimately controls the catalytic activity and stability. In conclusion, this new insight provides a unique perspective on how to tune the electrocatalytic performances of SAC at the molecular level.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2020

Results of the International Energy Agency Bioenergy Round Robin on the Analysis of Heteroatoms in Biomass Liquefaction Oils

A round robin study evaluating the analysis of biomass liquefaction oils (BLOs) from fast pyrolysis and hydrothermal liquefaction (HTL) was performed, involving fifteen laboratories in seven countries in order to assess the current status of analytical techniques for the determination of nitrogen, sulfur, and chlorine content in BLOs and evaluate potential differences in origin (i.e. fast pyrolysis vs HTL). The BLOs were produced from a range of feedstocks including pine, mixed softwoods, forest residues, micro-algae, miscanthus, and wheat straw to cover a variety in nitrogen, sulfur, and chlorine content and speciation. Nine samples were distributed, comprised of eight separate BLOs and one blind duplicate produced by five producers. The samples were analyzed for water, carbon, hydrogen, nitrogen, sulfur, and chlorine content. No analytical test method was mandated; laboratories were encouraged to utilize whichever method they determined would be most applicable, relying on the existing body of BLO literature as a guide. The results of this round robin study are presented in this paper. The results of the carbon, hydrogen, and water measurements as reference analyses had relative standard deviations (2.9%, 3.5, and 5.6%, respectively) that were comparable to those found in past round robin studies on fast pyrolysis bio-oil. The analysis of nitrogen, sulfur, and chlorine showed higher levels of variability. Laboratories mostly chose the same method for water, carbon, hydrogen and nitrogen determination whereas there were a variety of methods chosen for sulfur and chlorine determination. The results suggest that specific analytical methods for the determination of nitrogen, sulfur, and chlorine should be further refined to ensure reproducible and accurate results for BLO analysis due to their importance on emissions, material selection, and catalyst activity.

Biomass, IEA Bioenergy, pyrolysis, hydrothermal li↗

DOE OSTI2023

Elucidation of Structure and Physical Properties of Pyrolytic Sugar Oligomers Derived from Cellulose Depolymerization/Dehydration Reactions: A Density Functional Theory Study

Fast pyrolysis of lignocellulosic materials is a promising research area to produce renewable fuels and chemicals. Dehydration is known to be among the most important reaction families during cellulose pyrolysis; water is the most important product. Together with water, dehydration reactions also form a range of poorly known oligomer species of varying molecular sizes, often collected as part of bio-oil water-soluble (WS) fraction. In this work, we used electronic structure calculations to evaluate the relative thermodynamic stabilities of several oligomer species resulting from up to three consecutive dehydration events from cellulose depolymerization intermediates. A library of the thermodynamically favored candidate molecular structures was compiled. Results revealed that most of the water molecules are eliminated from the non-reducing end, forming thermodynamically more stable conjugated compounds. This is consistent with results reported by other researchers in literature where dehydration reactions occur preferably at the non-reducing ends of oligomers. The physical-chemical properties of the proposed structures were estimated using quantitative structure-property relationships (QSPRs) and quantitative property-property relationships (QPPRs). The anhydro-sugars derived from cellulose are often blamed for coke formation during bio-oil hydrotreatment. Understanding their chemical structure could help to develop rational strategies to mitigate coke formation. Furthermore, the thermo-physical properties reported (boiling point, melting point, Gibb’s free energy of formation, enthalpy of formation, and solubility parameters among others) are also fundamental to conducting first principle engineering calculations to design and analyze new pyrolysis reactors and bio-oil up-grading units.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2019

Challenges and Opportunities for Bio-oil Refining: A Review

Bio-oil derived from fast pyrolysis of lignocellulosic materials is among the most complex and inexpensive raw oils that can be produced today. Although commercial or demonstration scale fast pyrolysis units can readily produce this oil, this industry has not grown to significant commercial impact due to the lack of bio-oil market pull. This paper is a review of the challenges and opportunities for bio-oil upgrading and refining. Pyrolysis oil consists of six major fractions. (water 15-30 wt.%, light oxygenates, 8-26 wt.%. mono-phenols, 2-7 wt.%, water insoluble oligomers derived from lignin 15-25wt.%, and water soluble havey molecules 10-30 wt.%). The composition of water-soluble oligomers is relatively poorly studied. In the 1880s, bio-oil refining (formally known as wood distillation) targeted the separation and commercialization of C1-C4 light oxygenated compounds to produce methanol, acetic acid and acetone with the commercialization of the lignin derived water insoluble fraction for preserving wooden sailing vessels against rot. More recently the company Ensyn extracted and commercialized condensed natural smoke as a food additive. Most research efforts in the last twenty years have focused on the two-step hydrotreatment concept for the production of transportation fuels. In spite of major progress this concept remains at the demonstration. In this review, the opportunities and progress to separate bio-oil fractions and chemicals, mainly acetic acid (HAc), hydroxyacetaldehyde (HHA) and acetol, and convert them into value added co-products are thoroughly discussed. In spite of the large number of separation schemes and products tested, very few of them have been studied as part of fully integrated bio-oil refinery concepts. Furthermore, the synthesis, techno-economic and environmental evaluation of novel integrated bio-oil refinery concepts is likely to become a subject of intense research activity in the coming years.

09 BIOMASS FUELS↗

DOE OSTI2019

110th Anniversary: Microkinetic Modeling of the Vapor Phase Upgrading of Biomass-Derived Oxygenates

Bio-oil produced from fast pyrolysis of biomass is a complex mixture of more than 200 compounds, including oxygenates and acids. As these species are highly undesirable in fuels, catalytic upgrading of biomass pyrolysis product vapors, also known as catalytic fast pyrolysis, is performed to upgrade the vapors to valuable fuels and chemicals. This work presents a detailed microkinetic model, composed of elementary steps, of the catalytic upgrading of acetic acid and acetone, two common oxygenates present in bio-oil. An automated network generator was utilized to construct a reaction network composed of 580 unique species and 2160 unique reactions. The kinetic parameters for each reaction in the network were estimated using transition state theory, the Evans-Polanyi relationship, and thermodynamic data. The resulting mechanistic model is able to describe experimental data presented in the literature for the transformation of acetic acid and acetone on HZSM-5 in a fixed-bed reactor, which is modeled as a plug-flow reactor. Additionally, the model solutions reveal vital information regarding the mechanism by which acetic acid and acetone are upgraded to valuable fuels and chemicals. In the first phase of the mechanism, acetic acid is converted to acetone via acylium ion addition to acetic acid; this is followed by decarboxylation of acetoacetic acid. The second phase is dominated by the self-aldol condensation of acetone, which is shown to occur predominantly through the keto form of acetone rather than the enol form, and subsequent deoxygenation reactions leading to olefins and aromatics. Finally, net rate analysis shows that aromatics are primarily formed via a pathway including aldol condensation of mesityl oxide, whereas olefins are produced from the addition of isobutene and subsequent cracking.

09 BIOMASS FUELS↗

DOE OSTI2019

A Review on Lignin Liquefaction: Advanced Characterization of Structure and Microkinetic Modeling

Lignin liquefaction microkinetics is a move toward a more first principles (i.e., ab initio) based understanding at the molecular level in reaction engineering. While the microkinetic modelling of reactions to obtain kinetic rate parameters of chemical reactions have been widely used in the field of gas phase combustion and heterogeneous catalysis, this approach has not been as thoroughly developed in the area of biomass thermochemical reactions (e.g., lignin pyrolysis, hydrothermal liquefaction). The difficulties in establishing the structure of complex heterogeneous materials, like lignin, is perhaps the main challenge in developing rational microkinetic descriptions of biomass thermochemical reactions. In this manuscript we review the current state of the art and the challenges to develop microkinetic models for lignin liquefaction technologies (e.g., pyrolysis, hydrothermal liquefaction, solvolysis). A general strategy for the development of microkinetic models for lignin liquefaction technologies is discussed. Here, the first hurdle is to obtain sufficiently rich experimental data of lignin underlying polymeric structure and methodologies to use this data to build realistic lignin structural representations. Some analytical techniques for lignin structural characterization and their associated data, as well as a correlation for calculating the degree of macromolecular lignin branching are discussed. The presence of small lignin oligomeric structures and the role of these structures in lignin pyrolysis is also addressed. The ways in which elementary deconstruction and repolymerization reactions occur within this structure to form a liquid intermediate, and how these deconstruction products continue to interact with each other until they are removed from the liquid intermediate is thoroughly discussed. Further, experimental work with model compounds and the effect of reaction parameters (e.g., temperature, pressure, vapor residence time) are reviewed.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Experimental and Theoretical Study of Oxolan-3-one Thermal Decomposition

The thermal decomposition of oxolan-3-one, a common component of the bio-oil formed during biomass pyrolysis, has been studied using ab initio calculations and experiments employing pulsed gas-phase pyrolysis with matrix isolation FTIR product detection. Four pathways for unimolecular decomposition were predicted using computational methods. The dominant reaction channel led to carbon monoxide, formaldehyde, and ethylene, all of which were observed experimentally. Here, the other channels led to an assortment of products including ketene, water, propyne, and acetylene, which were all confirmed in the matrix-isolation FTIR spectra. There is also evidence for the production of substituted ketenes in pyrolysis, most likely hydroxyketene and methylketene.

09 BIOMASS FUELS↗

DOE OSTI2018

MOF-Derived Iron Catalysts for Nonoxidative Propane Dehydrogenation

The dehydrogenation of light alkanes, sourced from cracking of traditional petrochemical feedstocks and from emerging shale gas, represents an attractive route to alkenes (ethene, propene, and butenes), which are the building blocks for valuable polymers and chemicals. Carbon-supported iron catalysts formed from pyrolysis of Fe-containing metal–organic frameworks (MOFs; Fe-BTC) are investigated here for propane dehydrogenation. The temperature of pyrolysis is found to influence the iron phase (oxide, metal, and carbide) and surface area of the material, but the high-temperature reduction and reaction conditions needed for propane dehydrogenation (500–600 °C) result in a metallic iron phase that is shown to be active and selective for propene formation, though differential isoconversion data indicate that the pyrolysis temperature affects the selectivity to propene. X-ray absorption spectroscopy and X-ray diffraction are utilized to investigate the catalyst state both pre- and post-reduction and reaction. Here, this work demonstrates how using MOFs as precursors may allow the synthesis of useful and perhaps unique catalyst structures that can be designed to obtain desired rates and product selectivities of hydrocarbon processes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Surface Chemistry and Particle Morphology Changes in Pine Biomass under Indirect Thermal Gradients: Implications for Feed Screw Design

The conversion of biomass feedstocks into fuels and chemicals using fast pyrolysis is a promising approach to renewable energy. Feed screws that convey biomass to pyrolysis reactors, however, often encounter plugging. Indirect heating of the feed screw occurs due to contact with the pyrolysis chamber, resulting in a heating gradient ranging from ambient temperature (22 °C) to reactor temperature (500 °C). Given that major cell wall macromolecules, such as lignin, cellulose, and hemicellulose, begin to produce bio-oils and volatile resin acid compounds within this temperature gradient, we hypothesized that indirect heating during feed screw conveyance is sufficient to cause premature degradation of biomass. We characterized this degradation by observing increases in surface roughness, changes in overall particle morphology, and the production and deposition of bio-oils on biomass particle surfaces. Correlative analysis between optical in situ hot-stage microscopy, confocal Raman spectroscopy, and SEM analysis revealed that heating at temperatures as low as 375 °C caused significant increases in surface roughness, with large fissures forming between and within cell walls. Additionally, droplets of bio-oil were observed on particles, especially in the bark and cambium samples. This work suggests that these phenomena contribute to particle agglomeration, leading to feed screw plugging, and that engineering a solution to cool the feed screw could prevent particle agglomeration and reduce plugging incidents, thereby increasing biomass processing efficiency.

09 BIOMASS FUELS↗

DOE OSTI2018

Isolation and Purification of Monofunctional Methoxyphenols from Loblolly Pine Biocrude

Methoxyphenols (MPs) are valuable chemicals in liquid intermediates from pyrolysis of lignocellulosic biomass. The use of a single technique to recover a high-purity bioproduct of MPs from pyrolysis liquid is challenging. The purpose of this study is to combine distillation and chromatography techniques in sequence to recover exclusively eugenols and guaiacols as monofunctional MPs in biocrude produced from pyrolysis of loblolly pine with a nonzeolite alumina catalyst. A biocrude containing 11.0 wt% of the targeted monofunctional MPs was first distilled in two stages to recover an MP-rich fraction with 49.3 wt% concentration of MPs at a recovery efficiency of 86.9%. A flash chromatography separation using silica gel adsorbent was then used to purify the MP-enriched distillate. A final MP bioproduct with average purity of 87.3-93.1 wt% was achieved. Here, the average efficiency of the chromatography separation step varied between 73.9-82.5% depending on the silica particle size used.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Conversion of cellulose to high-yield glucose in water over sulfonated mesoporous carbon fibers with optimized acidity

The hydrolysis of cellulose to high-yield glucose in water remains challenging owing to the limited acidity and substrate contact of sulfonated carbons. In this study, we report a unique sulfonated mesoporous carbon fiber with optimized acidity prepared by the pyrolysis of FeCl 3 -impregnated wipe fibers followed by acid treatment. The Bronsted acidity (especially for SO 3 H) was produced by sulfonation of the magnetic carbon fiber intermediate, while Lewis acidity originated from small Fe 3 O 4 nanoparticles and the remaining defects. The balanced Bronsted and Lewis acidity combined with hydrophilic functionalities was simultaneously tailored by varying the Fe/wipe fiber (WF) feed ratio and pyrolysis temperature to change the porous structure of the final catalysts. The elaborately fabricated MCF-SO 3 H-20-500 (20% Fe/WF feed ratio and pyrolysis at 500 degrees C) delivered 66.0% glucose yield as cellulose was completely converted. This is the highest glucose yield achieved by the hydrolysis of untreated cellulose in water over a sulfonated carbon catalyst. The optimized Bronsted and Lewis acidity was mainly responsible for the controlled conversion of cellulose to glucose, while the rich hydrophilic functionalities and superior mesoporous structure of the catalyst facilitated contact to cellulose and mass transfer. This investigation will open new avenues to design high-performance carbon sulfoacid catalysts toward cellulose hydrolysis.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Properties of SiC-Si made via binder jet 3D printing of SiC powder, carbon addition, and silicon melt infiltration

In this work, we report the physical and mechanical properties of ceramic composite materials fabricated by binder jet 3D printing (BJ3DP) with silicon carbide (SiC) powders, followed by phenolic resin infiltration and pyrolysis (IP) to generate carbon, and a final reactive silicon melt infiltration step. After two phenolic resin infiltration and pyrolysis cycles; porosity was less than 2%, Young's modulus was close to 300 GPa, and the flexural strength was 517.6 ± 24.8 MPa. However, diminishing returns were obtained after more than two phenolic resin infiltration and pyrolysis cycles as surface pores in carbon were closed upon the formation of SiC, resulting in reaction choking and residual-free carbon and porosity. The instantaneous coefficient of thermal expansion of the composite was found to be independent of the number of phenolic IP cycles and had values of between 4.2 and 5.0 ppm/°C between 300 and 100°C, whereas the thermal conductivity was found to have a weak dependence on the number of phenolic IP cycles. While the manufacturing procedures described here yielded highly dense, gas impermeable, siliconized SiC composites with properties comparable to those of bulk siliconized silicon carbide processed according to conventional techniques, BJ3DP enables the manufacture of objects with complex shape, unlike conventional techniques.

36 MATERIALS SCIENCE↗