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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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DOE OSTI2020

Leveraging Flexible Smart Manufacturing to Accelerate Industrial Supply Chain Recovery

Any major crisis such as the latest coronavirus disease pandemic will have a monumental effect on the worldwide economy and on the international supply chain. Much of the global supply chain relies on China, Germany, and the United States for manufacturing and distribution; this fragile system is subject to failure. Climactic changes in demand and rapid shortages in necessities are the results of the pandemic’s disruption. The recovery forecast for the ongoing pandemic is uncertain and, therefore, any recovery effort will need to be adaptable to build the supply chain resiliency. A wide adoption of flexible smart automated technologies in the manufacturing sector are helping to build robust supply chains and assisting in recovery. Here, a brief discussion of these smart manufacturing technologies is presented, along with a list of potential supply chain issues and corresponding solutions. Such smart manufacturing technologies possess the potential to empower and revolutionize the traditional manufacturing environment by enhancing its resiliency and flexibility. These smart technologies will play a crucial role in accelerating the worldwide supply chain recovery in and after a pandemic.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

Oxygen Reduction on Platinum-Nickel and Platinum-Cobalt Alloy Based Catalysts for High Temperature Proton Exchange Membrane Fuel Cells

Catalyst layers, with commercial PtNi/TKK (TECNiE52; platinum 46.5 wt%), PtCo/TKK (TEC36E52; platinum 45.8 wt%) catalysts, and an in-house catalyst PtNi-NC (platinum 38.4 wt%), synthesised using acoustic mixer and a tube furnace, are prepared using three different ionomers: 20 wt% Nafion®, 60 wt% polytetrafluoroethylene (PTFE), and an in-house 5 wt% ionomer (‘Ionomer X’). These inks are bar-coated onto carbon paper gas diffusion layers (GDLs), which are cut into 3 cm × 5 cm pieces. The coated layers are tested for oxygen reduction in a commercial gas diffusion electrode (GDE) test cell, FlexCell® (Gaskatel GmbH, Germany), using 85 wt% phosphoric acid at both room temperature and at 155°C. This study evaluates the polynorbornene (PNB)-based in-house ionomer performance as binder and in-house catalyst oxygen reduction reaction (ORR) activity in comparison to commercial products. The catalyst layers are characterised using X-ray diffraction (XRD) analysis, X-ray photoelectron spectroscopy (XPS), and high-angle annular dark-field scanning transmission electron microscopy (HAADF-STEM). Among the catalyst layers prepared with PTFE ionomer and tested at 155°C, the in-house catalyst demonstrates the highest ORR activity. Ionomer X proves to be a good candidate to be used as a per- and polyfluoroalkyl-free binder for high-temperature (HT) proton exchange membrane fuel cell (PEMFC) applications.

85 wt% phosphoric acid↗
DOE OSTI2023

The Energy Transition: Advanced Nuclear Needed but Address Climate Vulnerabilities Now

The term “Energy Transition” is an attempt to capture an elaborate set of activities related to the modernization and decarbonization of energy grids. Performed concurrently and often in an ad hoc manner across local, state, regional and national boundaries, it is bringing chaos to what should arguably be one of the most conservatively managed of all critical infrastructure sectors. What’s more, with climate change producing an increasing tempo of extreme events, confidence in the intended resilient and redundant structure of the electric grids is likely to ebb. Even without these climate induced stressors, the nation’s electric grid was built for an earlier century. In addition to a drive towards greater efficiency via digitization and a continuing price decline in distributed energy resources (DERs), one could argue that climate change concerns are the primary driver of the energy transition. Non-CO2 emitting generation sources like wind and solar have become an important part of the overall generation fleet, albeit ones that cannot be counted upon to provide dispatchable power. Current projections indicate deployment of even larger percentages of DERs in coming years. Until far better storage capabilities arrive, the variability of wind and solar, inconsistent performance of traditional thermal generation plants, and energy delivery failures associated with natural gas pipelines will reinforce mounting reliability concerns. This pertains to both electric transmission and distribution. The recent shuttering of nuclear power plants in Germany, Japan, the US and elsewhere are also putting more downward pressure on dispatchable generation. Russia’s attack on Ukraine has roiled energy markets worldwide and forced some countries to return to coal as a primary fuel. In view circumstances such as these, it is essential that significant changes be made to policies and planning criteria, and to the standards and code on which they are based. Given the accelerating pace of extreme weather events, this needs to occur as soon as possible.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

Cavity Qualification and Production Update for SNS-PPU Cryomodules at Jefferson Lab

The Proton Power Upgrade (PPU) project at Oak Ridge National Lab’s Spallation Neutron Source (SNS) currently being constructed will double the proton beam power capability from 1.4 to 2.8 MW by adding seven cryomodules, each containing four six-cell high-beta (β = 0.81) superconducting radio frequency cavities. Research Instruments, located in Germany, built and processed the cavities at the vendor site, including electropolishing as the final active chemistry step. Twenty-eight cavities for seven cryomodules and an additional four cavities for a spare cryomodules were delivered to Jefferson Lab and first qualification tests were completed on all cavities as received from the vendor. The performance largely exceeded the requirements on quality factor and accelerating gradient. Here we present the status of initial cavity qualification tests, rework on unqualified cavities and final cavity qualification with helium vessel prior to installation in cryomodules. In addition, an update on cryomodule production is presented.

Dhakal, P.↗
DOE OSTI2022

Cavity Production and Testing of the First C75 Cryomodule for CEBAF

The CEBAF cryomodule rework program was updated over the last few years to increase the energy gain of refurbished cryomodules to 75 MeV. The concept recycles the waveguide end-groups from original CEBAF cavities fabricated in the 1990s and replaces the five elliptical cells in each with a new optimized cell shape fabricated from large-grain, ingot Nb material. Eight cavities were fabricated at Research Instruments, Germany, and two cavities were built at Jefferson Lab. Each cavity was processed by electropolishing and tested at 2.07 K. The best eight cavities were assembled into ’cavity pairs’ and re-tested at 2.07 K, before assembly into the cryomodule. All but one cavity in the cryomodule were within 10% of the target accelerating gradient of 19 MV/m with a quality factor of 8·10⁹. The performance limitations were field emission and multipacting.

Ciovati, G.↗
DOE OSTI2020

XXVIIth International Conference on Supersymmetry and Unification of Fundamental Interactions (SUSY 2019) (Final Report)

Supersymmetry (SUSY) is one of most elegant extensions of the Standard Model (SM) and explains the puzzles of the SM by providing a candidate to explain the dark matter content of the universe, allowing scientists to understand the origin of the electroweak scale requiring the top mass to be around 170 GeV and leading to the unification of forces at a grand unified scale. Further the minimal supersymmetric standard model (MSSM) predicts the Higgs boson mass to be less than 135 GeV. The discovery of the Higgs Boson with mass around 125 GeV at the LHC has provided a major support to SUSY ideas. Searches for SUSY are ongoing at the Large Hadron Collider (LHC). Direct and indirect dark matter experiments are searching for a particle dark matter candidate which arises most naturally in SUSY models. Proton decay predicted by SUSY grand unified theories is being searched for at deep underground experiments. In addition, recent advances in neutrino and dark matter physics, observational astrophysics, precision cosmology and the promising new window into the cosmos opened by the direct detection of gravitational waves, have brought new ideas on the potential connections between new fundamental particles and our understanding of their impact on the early universe and its evolution. At present, the major questions include: Is SUSY still the best candidate for models beyond the SM? Do we have any well motivated alternative to SUSY? Have we exhausted all possibilities to search for new physics at high and low energy scales? XXVIIth International Conference on Supersymmetry and Unification of Fundamental Interactions (SUSY 2019), hosted by Texas A&M University – Corpus Christi during May 20-24, 2019, provided a unique venue to discus and understand the status of SUSY, connection between particle physics and cosmology, supersymmetry and its alternative, Higgs sector, neutrino sector, flavor sector, dark matter, electroweak phase transition, astroparticle physics, gravitational waves and string theory. Discussion of results from the LHC, recent neutrino experiments and observations, direct and indirect dark matter detection experiments, detection of gravitational waves, data from particle colliders, as well as measurements of the CMB and Large Scale Structure were an integral part of SUSY 2019. To ensure the younger participants will benefit from the conference the most, the conference was preceded by the 4 day long pre-SUSY summer school for graduate students and postdocs. The invited speakers were leading scientists in the fields of SUSY interest. The school took place on Texas A&M University – Corpus Christi campus during the week prior the SUSY 2019 conference (May 15 – 18, 2019). Since its inception in 1993, SUSY has become one of the most important and widely attended international meetings in high energy physics, devoted to new ideas in fundamental particle physics. SUSY 2019 brought together approximately 250 scientists, theorists, phenomenologists, experimentalists and cosmologists, (including over 60 graduate students and 70 postdocs) representing 22 nations: Australia, Belgium, Canada, Chile, China, Colombia, France, Germany, India, Italy, Japan, Mexico, Peru, Portugal, Romania, South Korea, Spain, Sweden, Switzerland, Taiwan, United Kingdom and United States. SUSY 2019 provided a stimulating venue for the exchange of scientific ideas among experts in dark matter, neutrino physics, particle physics, astrophysics and cosmology. The following scientific topics were delivered during SUSY 2019 in form of 44 plenary talks and over 200 parallel talks: Unification of Forces; Electroweak, Top and Higgs Physics; Precision Calculations and MC tools; BSM in Flavor Physics; Neutrino Masses: Models and Phenomenology; Cosmology and Gravitational Waves; Dark Matter, Astroparticle Physics; Formal Field Theory and Strings; Alternatives to Supersymmetry; Quantum Information: Machine Learning/Big Data. 28 talks were given during the pre-SUSY program related to the following topics: Neutrino Physics; Big Data; Collider Physics & SUSY; String Phenomenology; Cosmology; Dark Matter; SUSY Models and Phenomenology

43 PARTICLE ACCELERATORS↗
DOE OSTI2020

Involute Working Group – Validation of CFD Turbulence Models for Steady-State Safety Analysis

There are three research reactors in the world having fuel plates curved as circle-involute (a spiral generated around a circle): The Oak Ridge National Laboratory (ORNL) High Flux Isotope Reactor (HFIR) located in Tennessee, U.S.A. [ORNL, 2018]; The Laue-Langevin Institute (ILL) High Flux Reactor (RHF) located in Grenoble, France [ILL, 2018]; and, The Technical University of Munich (TUM) Research Neutron Source Heinz Maier-Leibnitz (FRM II) located in Garching, Germany [TUM, 2018]. All three reactors are currently using Highly Enriched Uranium (HEU, 235U/U ≥ 20 wt. %) as fuel and all three are actively engaged in activities to convert to Low Enriched Uranium (LEU, 235U/U < 20 wt. %) fuel. More information on these reactors can be found in Section two. For various reasons, these reactors have expressed interest in using Computational Fluid Dynamics (CFD) tools to perform their Steady-State Thermal-Hydraulic (SSTH) safety calculations. Using CFD tools for SSTH analysis represents generally a significant departure from traditional methods and requires thorough verification and validation (V&V) to be accepted by regulators. This is why Argonne National Laboratory (ANL) and the involute reactors formed an informal group to help each other in this endeavor. This so-called Involute Working Group (IWG) aims at supporting the qualification of CFD tools for SSTH safety calculations. Activities include benchmarking, code-to-code comparison, Verification and Validation (V&V) as well as technical support. More information on the IWG and the reasons why involute-plate reactors are interested in CFD can be found in Section three. The present study aims at testing three turbulence models commonly implemented in commercial software (namely K-Epsilon, K-Omega and Reynolds-Stress) and assessing their relevance for involute-plate reactor application. An experiment performed by Gambill and Bundy in 1961 was performed to measure heat transfer coefficients in conditions prototypic of the HFIR reactor [Gambill, 1961]. More details on this experiment are provided in Section four. Based on the information available, CFD models of this experiment have been created and the experimental results have been compared to the ones obtained with these CFD models. CFD models and the results of this comparison are provided in Section five.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Harnessing the Hydroelectric Potential of Engineered Drops (Final Technical Report)

The potential for low-head hydropower in the engineered drops in both federal and private irrigation system is well known and significant. The environmental and socio/recreational impacts of harnessing this renewable energy resource in man-made conduits are much less, and often insignificant, compared with comparable hydro-electric potential in natural water features on rivers, lakes, and streams. Yet, few new plants have been commissioned in more than two decades. Over the same time period, low head hydro installations in Germany have more than doubled. The challenge is in finding economical ways to harness the hydro-electric potential in the engineered drops, and efficiently deliver the power to the grid. The objectives of Percheron Power, LLC's (Percheron Power) Project were to design, develop, permit, and operate an innovative low-head hydro-electric generation facility on an existing engineered drop of a large irrigation canal system. The hydro-electric generation facility was designed to employ a new type of turbine and technology, called an Archimedes Hydrodynamic Screw (AHS), to harness the existing potential of the engineered drop. The goal was to demonstrate the new lower cost AHS technology system to federal agencies, irrigation districts and other system owners and to support further development of new small hydropower projects at previously marginal low-head sites in the U.S. The objective of this funding opportunity of the Department of Energy Water Power Technologies Office was to reduce the Levelized Cost of Energy (LCOE) for small hydropower to less than ${$}$0.07/kWh (${$}$70/MWh) to be competitive with existing base-load power sources such as coal-powered power plants.

13 HYDRO ENERGY↗
DOE OSTI2020

An approach for the measurement of the bulk temperature of single crystal diamond using an X-ray Free Electron Laser

We present a method to determine the bulk temperature of a single crystal diamond sample at an X-Ray Free Electron Laser using inelastic X-ray scattering. The experiment was performed at the High Energy Density (HED) instrument at the European XFEL GmbH, Germany. The technique, based on inelastic X-ray scattering and the principle of detailed balance, was demonstrated to give accurate temperature measurements, within 8% for both room temperature diamond and heated diamond to 500 K. Here, the temperature was increased in a controlled way using a resistive heater to test theoretical predictions of the scaling of the signal with temperature. The method was tested by validating the energy of the phonon modes with previous measurements made at room temperature using inelastic X-ray scattering and neutron scattering techniques. This technique could be used to determine the bulk temperature in transient systems with a temporal resolution of 50 fs and for which accurate measurements of thermodynamic properties are vital to build accurate equation of state models.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2020

New Measurements on the Neutrino Mass: KATRIN and Project 8 (Final Technical Report for DE-SC0014130)

The overarching goal of the funded research is to build experiments and develop techniques towards the major goal of measuring the mass of the neutrino, particularly by the method of high-resolution spectroscopy of the endpoint of tritium. The goals of this project were to make hardware and intellectual contributions towards the KATRIN experiment, an international project under construction in Germany, and towards the "Project 8" R&D program to develop new electron spectroscopy methods and apply them to tritium. A minor goal of the project was to support simulation work and R&D on future neutrino and dark matter detectors.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2020

Demonstration of μCHP in Light Commercial Hot Water Applications

Internal combustion engine driven combined heat and power (CHP) systems produce power while the waste heat is recovered and used for another purpose. For µCHP systems (less than 50kWe output) overall efficiencies can reach over 90% for products currently on the market throughout the world. On a fuel basis this offers an advantage over using grid-based power and another fuel for heat. Additionally, the cost of natural gas on an energy unit basis is significantly less expensive than electric power. This difference can lead to substantial savings for the end user of a CHP system. In some parts of the world, particularly Germany and Japan, µCHP has become a common part of the heat and distributed generation equipment mix. Market analysis conducted in 2012 showed that in North America there is potential of a 5,300 units per year market for µCHP, resulting in an annual energy savings of approximately 13.5 TBtu and more than $84 million in annual customer savings. However, µCHP still has not seen much market penetration in North America. This study helps to identify some of the reasons why, address roadblocks that still need to be overcome and provide experience to established best practices. Nine commercial sites were initially identified (fitness club, surgical center, senior community, resort and spa, commercial laundry, two multi-family housing, restaurant and manufacturing facility). Systems from two different manufacturers were installed at five sites total, but due to unforeseen circumstances, only three of those sites were finally commissioned: test data were collected by Oak Ridge National Laboratory. While not all systems were installed as intended, the project resulted in the following key findings: Micro combined heat and power is an unfamiliar technology for building owners and plumbing and electrical contractors that serve the buildings most suited for µCHP. Manufacturers will need to be aggressive in providing training and providing broad support to successfully bring the technology to market.; The proper integration of µCHP into other building systems is the most critical part of a successful installation. Manufacturers will need to be able to provide the expertise to train, advise and support the mechanical contractors during the design and installation of the heat integration system.; Regulations governing µCHP varies across the country. There are a few UL standards (UL 2200 and UL 1741) that apply nationally. Emissions are governed by EPA except in California where the California Air Resources Board (CARB) has established their own standard. Requirements that dictate installation and interconnection are dependent on local building codes and local utility processes and requirements. Some out of date building codes do not offer clear guidance for these requirements, leading to confusion. This makes developing training and determining broadly applicable best practices difficult.; Installation costs of µCHP are a key factor in making an installation successful. It is critical that these costs and all national, state and local regulations be understood and accounted for by all parties involved in the installation before a project is undertaken.; A robust customer service organization is important to meet the needs of the customers. These systems require annual maintenance and service and local capability is needed to keep costs inline.

03 NATURAL GAS↗
DOE OSTI2020

Precipitation Trade Wind Cumuli within EUREC 4 A Field Campaign Report

The campaign Trades Cumuli Precipitation Initiation and Characterization (TCPIC) within the overarching Elucidating the Role of Clouds-Circulation Coupling in Climate EUREC 4 A campaign took place from 17 January 2020 to 20 February 2020, a total of 35 days. The campaign complemented the more extensive EUREC 4 A campaign focusing on cumulus clouds' role in the Earth's climate. TCPIC concentrated on understanding what triggers the onset and development of precipitation in trade wind cumulus clouds. The campaign requested the deployment of the U.S. Department of Energy Atmospheric Radiation Measurement (ARM) Mobile Facility (AMF) roll, pitch, and heave (RPH) stabilization platform to stabilize two radars on the Maria S. Merian research vessel (RV). The advanced remote-sensing techniques from stabilized radars characterized the entire precipitation life cycle, from the formation of larger cloud drops to precipitation evaporating on its way to the surface. Retrievals of evaporation rates, to track how rain affects the trade wind boundary layer, will be based on the zenith-pointing Doppler observations collected from the stabilized micro rain radar (MRR). Figure 1 shows the instrumentation's deployment on the RV: we installed the AMF RPH stabilization platform and the radars on the uppermost deck (peil deck) of the ship. For installing the devices, we coordinated a test phase of the equipment on the Maria S. Merian RV from 25 to 29 October 2019 in Emden harbor, Germany. In this testing phase, we set up all the connections, tested how to mount the W-band and the micro rain radars firmly on the table, and experimented with guided movements of the table to test the resistance of the whole system. Figure 1 shows the final tests conducted in Emden with the stable platform and the radars mounted.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Aeroacoustics Noise Model of OpenFAST

The report describes theory and application of a newly released module of OpenFAST to simulate the aeroacoustic noise generated by the rotor of an arbitrary wind turbine. OpenFAST is a fully open-source publicly available wind turbine analysis tool actively developed at the National Renewable Energy Laboratory. The aeroacoustic module, which is also fully open-source and publicly available, is based on work performed over the past three decades. Frequency-based models for turbulent inflow, turbulent boundary layer – trailing edge, laminar boundary layer – vortex shedding, tip vortex, and trailing edge bluntness – vortex shedding noise mechanisms are included. A simple directivity model is also included. The appendices of this report describe in detail the inputs to the module and how to find them in the input files of OpenFAST. The noise models are exercised simulating the aeroacoustic noise emissions of the IEA Wind Task 37 land-based reference wind turbine. A code-to-code comparison between the implementation presented here and the implementation available at the Wind Energy Institute of the Technical University of Munich, Germany, is also presented.

17 WIND ENERGY↗
DOE OSTI2020

Preserving Manhattan Project historic sites

Beginning in 1943, Project Y – the code name for Los Alamos during World War II – transformed the isolated Pajarito Plateau. The sounds of construction equipment replaced the voices of the Los Alamos Ranch School boys and local homesteaders. Construction crews hurriedly built many structures on mesa tops and in the canyons of Los Alamos. Countless concerns flooded Manhattan Project staff, but designing structures to withstand the test of time was not one of them. The top-secret race to develop an atomic bomb before Nazi Germany was on and everyone felt the pressure. Over the next 75 years, some of the structures slumped into disrepair from exposure to the harsh northern New Mexico environment - concrete cracking and spalling, wood frames rotting. That’s where Los Alamos National Laboratory’s historic preservation team enters the Manhattan Project story.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
DOE OSTI2020

KOMPASS: Compaction of crushed salt for the safe containment

In Germany, rock salt formations are a possible host rock taken into account for the safe disposal of heat-emitting radioactive waste. With respect to crushed salt will be used in the repository for backfilling of open cavitied (using dry material). With time, the crushed salt will be compacted by the convergence of the host rock and reaches porosities comparable with the rock salts. The compaction behaviour of crushed salt has been investigated within the last 40 years, however, its behaviour at low porosities and the resulting low permeabilities becomes relevant with the introduction of the approach of the containment providing rock zone. In the current state, the database and process understanding have some important gaps in knowledge referring the material behaviour, existing laboratory and numerical models, especially for the porosity range. The objective of this project was the development of methods and strategies for the reduction of deficits in the prediction of crushed salt compaction leading to an improvement of the prognosis quality. It includes the development of experimental methods for determining crushed salt properties in the range of low porosities, the enhancement of process understanding and the investigation and development of existing numerical models.

Crushed salt compaction↗
DOE OSTI2020

Studies of surface adsorbate electronic structure and femtochemistry at the fundamental length and time scales. Final report

The electronic structure and ultrafast (10-15 s-femtosecond timescale) electron dynamics were investigated for clean and atom/molecule covered metal surfaces. The studies were performed by scanning tunneling microscopy (STM) to measure the structure of adsorbed atoms and molecules on metal surfaces, and to investigate their electronic properties. The electronic structure of the observed molecular networks was calculated by electronic structure theory in collaboration with Prof. Jin Zhao, who is a long-time collaborator, a Professor at the University of Science and Technology of China, and holds an Adjunct Professorship at the University of Pittsburgh. We also investigated the electronic properties of C60 molecules when they are templated by corrugated black phosphorous surfaces. We found unexpected charge delocalization that is enabled by the templating. This research was done in collaboration with Professor Min Feng at the Wuhan University, and who also holds an Adjunct Professorship at the University of Pittsburgh. Moreover, the electronic structure and electron dynamics in metal surfaces were investigated by time-resolved photoemission electron spectroscopy. The focus of ultrafast spectroscopy has been on the plasmonic response of silver surfaces. One direction has been to develop multidimensional (energy, momentum, and time) photoelectron spectroscopy of the coherent response of solid surfaces. This method was applied to study the collective electron excitations known generally as plasmons, which screen optical fields from penetration into metals. Although this collective response has been known for more than 60 years and is used extensively to deposit optical energy into metals, how this happens is poorly known. We investigated the plasmonic response of silver at the point where the dielectric response passes through zero and bulk plasmon is excited by light. We discovered that the plasmon excitation decays by exciting electrons from the Fermi level of a metal, which is contrary to what is believed in the plasmonic science community. This research has been performed in collaboration with Dr. Marcel Reutzel, who was a postdoctoral fellow working on this research at the University of Pittsburgh, and now has a faculty position at the University of Göttingen in Germany. Prof. Branko Gumhalter from the Institute of Physics in Zagreb contributed on the theory of plasmonic decay processes. Furthermore, we investigated the Floquet engineering of electronic bands in metals leading to multiphoton photoemission and above threshold photoemission. Finally, we demonstrated that it is possible to change the electronic structure of metals by application of optical fields. Our studies indicated that this happens on subfemtosecond time scale and could potentially be used in ultrafast information processing and quantum computation. Related document information

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2021

Controlled Pyrolysis: A Robust Scalable Composite Recycling Technology

The reinforced composites industry is facing significant challenges in handling the scrap composite material from automobile manufacturing, the wind turbine industry, and others. The fibers in the material, whether they be carbon, glass, or other materials have commercial value if they can be recovered successfully. Successfully means the fibers are clean with no sizing or other binders and have adequate strength and physical properties that would allow them to be economically reprocessed into valuable product. The composites recycling project was an industry-collaborative effort to develop a composite recycling technology using controlled pyrolysis. Through the recycling of scrap and end-of-life (EOL) cured composite materials, this pilot study was intended to create a business case by realizing a cost-effective means for recycling EOL and production scrap composite materials, ultimately reducing the volume of composite materials destined for landfill. The project was led by the Institute for Advanced Composites Manufacturing Innovation (IACMI), the American Composites Manufacturers Association (ACMA), Oak Ridge National Laboratory (ORNL), Continental Structural Plastics (CSP) a Teijin Group Company, CHZ Technologies, and A. Schulman with support from Owens Corning, John Deere, General Electric (GE), Ashland LLC, and Plastics Europe (CEFIC). The team studied and tested CHZ Technologies’ controlled pyrolysis system, known as the Thermolyzer TM , which operates on a scalable basis to convert organic polymer materials into a clean synthesis gas and char containing the recoverable carbon and glass fiber reinforcement. The recoverable energy contained in the input polymers creates the synthesis gas that can be used to provide heat to the Thermolyzer TM primary reactor in a sustainable manner. That is, once the Thermolyzer TM is started with a small amount of external natural gas, the synthesis gas that is created from the polymers will continue to operate the burners so long as feedstock is supplied. The reinforcing fiber materials remaining in the solid phase char were separated and cleaned for re-use in other polymer systems based on the retained properties of the fibers. The study created reports (attached in the appendix) on the Mass and Energy Balances, syngas analytics, VOC assessment, yield analysis and other analytics necessary for a Techno-Economic Analysis (TEA) to quantify the economic impact of the recovery and sustainable re-use of the carbon and glass fibers. The process consisted of 4 steps: Selection of 4 samples of cured composite waste materials from project partners interested in materials recycling and recovering the reinforcing fibers for best case re-use. The materials included glass fiber (GF) polyester/vinyl ester automotive SMC from CSP, GF epoxy balsa/PVC foam wind blades from GE, carbon fiber (CF) epoxy wind blade laminated spar caps from GE, and GF/CF epoxy hybrid assembly from John Deere. Processing the waste composite samples into 1-2” shreds. Packaging the shredded composites into bulk sacks on international shipping pallets for shipment to KUG in Forst (Lausitz), Germany. Pyrolysis of the shredded composites under controlled conditions designed for each polymer system. Collecting samples of the gas and char for analysis. Shipping the char containing the CF/GF back to the US for the next steps of testing the fibers and developing protocols for sustainable re-use of the fibers in composite applications.

36 MATERIALS SCIENCE↗