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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 1,135 records · Page 63
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

CO 2 conversion to syngas via electrification of endothermal reactors: Process design and environmental impact analysis

CO 2 utilization via reverse water gas shift (rWGS) reaction has been proposed as a path to the sustainable utilization. Here this work presents a detailed process modelling study where steam methane reforming (SMR) generated hydrogen was combined with rWGS to produce syngas (CO + H 2 ) with various hydrogen-to-carbon oxide ratios. To further decrease CO 2 emissions that may offset the benefits of CO 2 converted in rWGS, electrification of endothermal reactors, both SMR and rWGS was considered where CO 2 emitting fuel burning in the furnace was replaced by the emerging ohmic (resistive) heating. Material and energy inventory obtained from process design calculations was used to perform Life Cycle Analysis (LCA) to calculate environmental impacts of CO 2 consumption and reactor electrification. The results showed that greenhouse gas emissions, in CO 2 kg equivalent, were the lowest when both SMR and rWGS were heated using wind-generated electricity, decreasing from 25 to 10 kg CO 2 equivalent for H 2 :CO = 2:1 while the conventional electricity mix used for furnace electrical heating across the board of scenarios generated highest environmental impacts, much higher than those that used natural gas as fuel. Process economics calculations suggested that, when both SMR and rWGS were electrically heated, the process only showed product syngas cost parity with the conventional fuel heated design when electricity cost was ~$0.008/kWh. This suggests that CO 2 utilization scenarios involving process electrification need to be carefully considered from the total design perspective so they do not produce more greenhouse gases than in conventional non-electrified scenarios.

42 ENGINEERING↗
DOE OSTI2024

Vascular Carbon/Carbon composites for concentrated solar power

Due to their exceptional mechanical and thermal properties under high temperature conditions, for the first time, a novel vascular (embedded channels) Carbon/Carbon (C/C) composite was developed for use as a modular concentrated solar power (CSP) gas receiver. The fabrication process involves the combination of the vaporization of sacrificial component (VaSC) technique with conventional methods to produce C/C composites with well preserved channels. Different heat treatments were evaluated together with X-ray diffraction (XRD) analysis to determine optimal fabrication conditions that maintains the material and channel’s integrity. Mechanical testing confirms that structural integrity is maintained, with statistical analyses indicating no compromise in flexural strength or modulus. Furthermore, this research introduces an innovative pathway for efficient CSP gas receivers, which can bridge the gap towards improved energy generation efficiency in next-gen CSP plants through higher operating temperatures with the use of C/C composites.

14 SOLAR ENERGY↗
DOE OSTI2014

Plasma-produced phase-pure cuprous oxide nanowires for methane gas sensing

Phase-selective synthesis of copper oxide nanowires is warranted by several applications, yet it remains challenging because of the narrow windows of the suitable temperature and precursor gas composition in thermal processes. Here, we report on the room-temperature synthesis of small-diameter, large-area, uniform, and phase-pure Cu{sub 2}O nanowires by exposing copper films to a custom-designed low-pressure, thermally non-equilibrium, high-density (typically, the electron number density is in the range of 10{sup 11}–10{sup 13} cm{sup −3}) inductively coupled plasmas. The mechanism of the plasma-enabled phase selectivity is proposed. The gas sensors based on the synthesized Cu{sub 2}O nanowires feature fast response and recovery for the low-temperature (∼140 °C) detection of methane gas in comparison with polycrystalline Cu{sub 2}O thin film-based gas sensors. Specifically, at a methane concentration of 4%, the response and the recovery times of the Cu{sub 2}O nanowire-based gas sensors are 125 and 147 s, respectively. The Cu{sub 2}O nanowire-based gas sensors have a potential for applications in the environmental monitoring, chemical industry, mining industry, and several other emerging areas.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2018

Pilot Test of Novel Electrochemical Membrane System for Carbon Dioxide Capture and Power Generation (Final Report)

The goal of this U.S. Department of Energy (DOE) sponsored project under cooperative agreement DE-FE0026580 is to verify that Fuel Cell Energy’s (FCE) Electrochemical Membrane (ECM)-based Combined Electric Power and Carbon Separation (CEPACS) system can achieve at least 90% carbon dioxide (CO 2 ) capture rate from Pulverized Coal (PC) power plant flue gas with 95% CO2 purity at a cost of electricity (COE) 30% less than baseline CO 2 capture approaches. To progress towards the DOE’s ultimate carbon capture program goals, the specific objectives of Budget Period 1 (BP1) of the project are to perform a preliminary Techno-Economic Analysis (TEA) and Environmental, Health and Safety (EH&S) Risk Assessment study, as well as to complete the detailed design of a pilot-scale ECM-based CEPACS system. This final technical report summarizes the results of the preliminary TEA and EH&S assessment of an ECM-based CEPACS system designed to capture and compress >90% of CO 2 from the flue gas of a reference 550 MW (net AC) Pulverized Coal (PC) Supercritical Steam Cycle Plant. Also included in this report is a summary of the detailed design for a pilot 3 MWe (flue gas equivalent) ECM-based CEPACS system designed to capture ≥90% of CO 2 from a PC plant flue gas slipstream and produce high-purity (≥95%) CO 2 . The pilot system is designed to process a slipstream of flue gas from the Unit 5 coal-fired boiler at the James M. Barry Electric Generating Station (Plant Barry). Plant Barry is located in Bucks, Alabama and is owned and operated by Alabama Power Company, a subsidiary of Southern Company. The TEA shows that the ECM-based CO 2 capture technology has an economic advantage over the existing CO 2 capture technology and meets the DOE’s cost target and performance goals for post-combustion CO 2 capture. The EH&S study includes the identification and quantification of the emissions from the CEPACS system. Properties of the waste including reactivity, flammability, corrosivity and toxicological effects are discussed along with the methods for minimization/elimination where applicable. The study shows that no major EH&S issues are expected to hinder commercialization of the ECM technology for large scale carbon capture applications. The detailed Front End Engineering Design (FEED) package for FCE’s MW-class ECM-based CO 2 capture pilot system is complete. It is designed in accordance with the project objectives and is now at a point where equipment/component procurement, skid final design and fabrication, and site preparation activities can begin in a follow-on project phase.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2014

Life Cycle Analysis of Natural Gas Extraction and Power Generation

Natural gas is considered a cleaner burning and more flexible alternative to other fossil fuels today. It is used in residential, commercial, industrial, and transportation applications in addition to having an expanding role in power production. However, the primary component of natural gas is methane, which is also a powerful greenhouse gas (GHG). Methane losses from natural gas extraction vary geographically and by extraction technology. This analysis inventories the GHG emissions from extraction, processing, and transmission of natural gas to large end users, and the combustion of that natural gas to produce electricity. In addition to GHG emissions, this analysis inventories other air emissions, water quality, water use, land use, and resource energy metrics.

03 NATURAL GAS↗
DOE OSTI2016

L{sub CO}{sup ′}/L{sub FIR} relations with CO rotational ladders of galaxies across the Herschel spire archive

We present a catalog of all CO (J = 4−3 through J = 13−12), [C i], and [N ii] lines available from extragalactic spectra from the Herschel SPIRE Fourier Transform Spectrometer (FTS) archive combined with observations of the low-J CO lines from the literature and from the Arizona Radio Observatory. This work examines the relationships between L {sub FIR}, L{sub CO}{sup ′}, and L {sub CO}/L {sub CO,1−0}. We also present a new method for estimating probability distribution functions from marginal signal-to-noise ratio Herschel FTS spectra, which takes into account the instrumental “ringing” and the resulting highly correlated nature of the spectra. The slopes of log(L {sub FIR}) versus log(L{sub CO}{sup ′}) are linear for all mid- to high-J CO lines and slightly sublinear if restricted to (ultra)luminous infrared galaxies ((U)LIRGs). The mid- to high-J CO luminosity relative to CO J = 1−0 increases with increasing L {sub FIR}, indicating higher excitement of the molecular gas, although these ratios do not exceed ∼180. For a given bin in L {sub FIR}, the luminosities relative to CO J = 1−0 remain relatively flat from J = 6−5 through J = 13−12, across three orders of magnitude of L {sub FIR}. A single component theoretical photodissociation region (PDR) model cannot match these flat SLED shapes, although combinations of PDR models with mechanical heating added qualitatively match the shapes, indicating the need for further comprehensive modeling of the excitation processes of warm molecular gas in nearby galaxies.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2017

Thermochemistry and growth mechanism of SiC nanowires

The chemical reaction thermodynamics and a novel two-stage growth mechanism of SiC nanowires synthesized by carbothermal reduction reactions were investigated based on the Si-C-O systems over a wide temperature range (1050 ≤ T ≤ 2000 K). The carbothermal reduction reaction process involves the fast formation of gaseous SiO and CO crucial intermediates, and the further carbon reduction of SiO to SiC. The relationship between the free energy changes and temperature at different pressures was also discussed. Some fundamental data in the work can help to analyze the thermochemistry of the carbothermal reduction reaction in the Si-C-O system, which is beneficial to optimize the temperature, pressure and the input precursors for controlling the SiC nanowire growth. - Graphical abstract: The chemical reaction thermodynamics of SiC nanowires synthesized by carbothermal reduction reactions was investigated, and a novel two-stage growth mechanism was proposed. The growth mechanism involved the formation of initial SiC embryos by heterogeneous nucleation and the growth of SiC nanowires by a gas-phase reaction. The process involved the fast formation of gaseous SiO and CO crucial intermediates, and the further carbon reduction of SiO to SiC. Display Omitted - Highlights: • The chemical reaction thermodynamics of SiC nanowires are investigated. • A novel two-stage growth mechanism of SiC nanowires is proposed. • The initial SiC particles/embryos can be formed by heterogeneous nucleation. • The gas-phase reaction of SiO and CO is the crucial step for the SiC nanowire growth.

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

Post-starburst properties of post-merger galaxies

Post-starburst galaxies (PSBs) are transition galaxies showing evidence of recent rapid star formation quenching. To understand the role of galaxy mergers in triggering quenching, we investigate the incidence of PSBs and resolved PSB properties in post-merger galaxies using both SDSS single-fibre spectra and MaNGA resolved IFU spectra. We find post-mergers have a PSB excess of 10–20 times that relative to their control galaxies using single-fibre PSB diagnostics. A similar excess of ∼ 19 times is also found in the fraction of central (C)PSBs and ring-like (R)PSBs in post-mergers using the resolved PSB diagnostic. However, 60 per cent of the CPSBs + RPSBs in both post-mergers and control galaxies are missed by the single-fibre data. By visually inspecting the resolved PSB distribution, we find that the fraction of outside-in quenching is seven times higher than inside-out quenching in PSBs in post-mergers while PSBs in control galaxies do not show large differences in these quenching directions. In addition, we find a marginal deficit of HI gas in PSBs relative to non-PSBs in post-mergers using the MaNGA-HI data. The excesses of PSBs in post-mergers suggest that mergers play an important role in triggering quenching. Resolved IFU spectra are important to recover the PSBs missed by single-fibre spectra. The excess of outside-in quenching relative to inside-out quenching in post-mergers suggests that AGNs are not the dominant quenching mechanism in these galaxies, but that processes from the disc (gas inflows/consumption and stellar feedback) play a more important role.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2019

Fission Product Volatility and Off-Gas Systems for Molten Salt Reactors

The overall objective of the Department of Energy investigation into off-gas technology for molten salt reactors (MSR)s is to develop a list of functional requirements for an effective and reliable system. In collaboration with other elements of the Advanced Reactor Campaign ( denoted in italics ), the off-gas work package will address the following questions: 1. What is the composition of the gas stream going to the off-gas system ( chemistry and source term work package )? 2. What is the function of each off-gas treatment component, and how do they work? How efficient are they at removing or delaying fission and activation products? 3. What are the maintenance requirements of the off-gas system? 4. Is the system able to effectively detect and respond to off-normal events ( off-gas, source term, and simulation work packages )? 5. What measurement capabilities are possible now? What are the gaps? The objective of the off-gas project in fiscal year 2019 was to address the second, fourth, and fifth questions above. Thus, project has proceeded along two fronts: one focused on scrubber development at Oak Ridge National Laboratory and the other focused on spectroscopic detection of simulant fission product iodine at Pacific Northwest National Laboratory. A molten hydroxide scrubber was proposed for removal of both acidic gases, entrained mists, and particulates from a sparged molten salt off-gas. Hydroxide solutions are well known for their scrubbing ability and have been used in the off-gas systems of salt processing facilities. For the current project, a NaOH–KOH eutectic is being evaluated as a gettering medium. A laboratory-scale prototype glass scrubber was designed and built for the removal of aerosol simulants. The glass allows visualization of the scrubber operation, which is important for designing the stainless-steel housing for the NaOH–KOH eutectic. In parallel, Pacific Northwest National Laboratory has been developing optical sensors for detecting fission products and aerosol or mist species that could be entrained in the off-gas flow of an MSR. Efforts include Raman spectroscopy to identify and quantify iodine species such as I2 and ICl and laser-induced breakdown spectroscopy and laser-induced fluorescence for mists. Next year, these optical methods will be added to the hydroxide scrubber instrumentation to determine its effectiveness against airborne vapors and mists of concern.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2014

Direct Conversion of Syngas-to-Hydrocarbons over Higher Alcohols Synthesis Catalysts Mixed with HZSM-5

The synthesis of hydrocarbon fuels directly from synthesis gas (i.e. one step process) was investigated with a catalytic system comprised of HZSM-5 physically mixed with either a methanol synthesis catalyst or a higher alcohols synthesis (HAS) catalyst. The metal sites of the methanol or HAS synthesis catalyst enable the conversion of syngas to alcohols, whereas HZSM-5 provides acid sites required for methanol dehydration, and dimethyl ether-to-hydrocarbons reactions. Catalytic performance for HZSM-5 when mixed with either a 5 wt.% Pd/ZnO/Al2O3 methanol synthesis catalyst or a HAS catalyst was evaluated at 300°C, 70 bars, GHSV=700 h-1 and H2/CO=1 using a HZSM-5: alcohols synthesis catalyst weight ratio of 3:1. The major difference observed between the methanol synthesis and HAS catalyst mixtures was found in the production of durene which is an undesirable byproduct. While durene formation is negligible with any of the HAS catalysts mixed with the HZSM-5 evaluated in this study, it represents almost 50% of the C5+ fraction for the methanol synthesis catalyst (5 wt.% Pd/ZnO/Al2O3 ) mixed with HZSM-5. This presents an advantage for using HAS catalysts over the methanol synthesis catalyst to minimize the durene by-product. The yield toward the desired C5+ hydrocarbons is thus twice higher with selected HAS catalysts as compared to when HZSM-5 is mixed with 5 wt.% Pd/ZnO/Al2O3. Among all the HAS catalysts evaluated in this study, a catalyst with 0.5 wt.% Pd/FeCoCu catalyst was found the most promising due to higher production of C5+ hydrocarbons and low durene formation. The efficiency of the one-step process was thus further evaluated using the HZSM-5: 0.5 wt.% Pd/FeCoCu catalyst mixture under a number of process conditions to maximize liquid hydrocarbons product yield. At 300oC, 70 bars, GHSV = 700 h-1 and HZSM-5: 0.5 wt.% Pd/FeCoCu = 3:1 (wt.), the C5+ fraction represents 48.5% of the hydrocarbons. Unfortunately, it is more difficult to achieve higher selectivity to desired C5+ hydrocarbons as the formation of CO2, CH4, and other light hydrocarbons is challenging to suppress in the presence of mixed metal and acid sites. When the 0.5 wt.% Pd/FeCoCu and HZSM-5 are operated sequentially by way of a two-step process the C5+ hydrocarbons fraction is lower and represents 30.4% of the hydrocarbons under comparable conditions. The yield toward the C5+ hydrocarbons is twice higher for the one-step process due to an improved CO conversion and higher C5+ hydrocarbons fraction. The main advantage of the one-step process is that higher syngas conversion can be achieved as the equilibrium-driven conversion limitations for methanol and dimethyl ether are removed since they are intermediates to the final hydrocarbons product.

alcohols-to-hydrocarbons↗
DOE OSTI2022

Operation and performance of a dual-phase crystalline/vapor xenon time projection chamber

We have built and operated a crystalline/vapor xenon TPC, with the goal of improving searches for dark matter. The motivation for this instrument is the fact that beta decays from the radon decay chain to the ground state presently limit the state-of-the-art liquid/vapor xenon experiments. In contrast, a crystalline xenon target has the potential to exclude, or tag and reject radon-chain backgrounds. As a preamble to demonstrating such capabilities, the present article makes a first demonstration of the operation of a crystalline/vapor xenon TPC with electroluminescence (gas gain) for the electron signal readout. It also shows that the scintillation yield in crystalline xenon appears to be identical to that in liquid xenon, in contrast to previous results.

47 OTHER INSTRUMENTATION↗
DOE OSTI2012

Diagnostic options for radiative divertor feedback control on NSTX-U

A radiative divertor technique is used in present tokamak experiments and planned for ITER to mitigate high heat loads on divertor plasma-facing components (PFCs) to prevent excessive material erosion and thermal damage. In NSTX, a large spherical tokamak with lithium-coated graphite PFCs and high divertor heat flux (q{sub peak} Less-Than-Or-Slanted-Equal-To 15 MW/m{sup 2}), radiative divertor experiments have demonstrated a significant reduction of divertor peak heat flux simultaneously with good core H-mode confinement using pre-programmed D{sub 2} or CD{sub 4} gas injections. In this work diagnostic options for a new real-time feedback control system for active radiative divertor detachment control in NSTX-U, where steady-state peak divertor heat fluxes are projected to reach 20-30 MW/m{sup 2}, are discussed. Based on the NSTX divertor detachment measurements and analysis, the control diagnostic signals available for NSTX-U include divertor radiated power, neutral pressure, spectroscopic deuterium recombination signatures, infrared thermography of PFC surfaces, and thermoelectric scrape-off layer current. In addition, spectroscopic 'security' monitoring of possible confinement or pedestal degradation is recommended. These signals would be implemented in a digital plasma control system to manage the divertor detachment process via an actuator (impurity gas seeding rate).

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2015

Imaging an aligned polyatomic molecule with laser-induced electron diffraction

Laser-induced electron diffraction is an evolving tabletop method that aims to image ultrafast structural changes in gas-phase polyatomic molecules with sub-Ångstro¨m spatial and femtosecond temporal resolutions. Here we demonstrate the retrieval of multiple bond lengths from a polyatomic molecule by simultaneously measuring the C–C and C–H bond lengths in aligned acetylene. Our approach takes the method beyond the hitherto achieved imaging of simple diatomic molecules and is based on the combination of a 160 kHz mid-infrared few-cycle laser source with full three-dimensional electron–ion coincidence detection. Our technique provides an accessible and robust route towards imaging ultrafast processes in complex gas-phase molecules with atto- to femto-second temporal resolution.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2025

Developing Microalgae-Based Non-Isocyanate Polyurethane Foam Materials

Polyurethane is a versatile material with a wide range of applications in the production of foam products such as car seats, mattresses, footwear, insulation foam, and more. The traditional process for producing polyurethane foam involves the fast reaction of isocyanate with water, which generates CO2 as a blowing agent. However, the use of isocyanate has raised concerns due to its potential for causing allergic reactions and aspiration symptoms. This has led to increased regulation of isocyanate, leading to a growing interest in developing alternatives. Non-isocyanate polyurethane (NIPU) has emerged as a promising alternative to traditional toxic PU production. The most promising approach for producing NIPU is the aminolysis of cyclic carbonate with diamine. The NIPU produced through this process has a polyhydroxyurethane structure, which is similar to traditional PU chemistry. We have demonstrated that microalgal oil is a favored feedstock, as it can provide high reactivity for industrial applications. However, the NIPU production process does not generate gas, and a blowing agent is required to achieve the desired foam structure. One of the challenges in producing NIPU foam is to match the bubble formation and curing rates. We have developed a novel approach to producing NIPU foam that utilizes carbamate as a bifunctional blowing and crosslinking agent. We have used vegetable oil and microalgal oil as feedstocks to produce various NIPU for characterization. The development of microalgal NIPU provides an exciting opportunity for reducing the environmental impact of foam production and improving the safety of the materials used in the production process. The production of value-added NIPU foam can also drive down the cost of microalgal biorefinery, advancing the commercialization of microalgal biofuel.

algae↗
DOE OSTI2022

Assessment of oil and gas fields in California as potential CO 2 storage sites

California's total annual greenhouse gas (GHG) emissions (425.3 MtCO 2 e) in 2018 were about 6.4% of the US total (6,677 MtCO 2 e) and around 1% of global emissions. About 39% of 2018 GHG emissions in California were from the industrial and electrical sectors. Many of these emissions were from large stationary point sources and were suitable for carbon capture retrofit with subsequent storage of the captured carbon dioxide (CO 2 ) in geological formations. Previous studies of California found suitable geology and CO 2 storage resource. This study refines and furthers prior work using a three-stage screening process of oil fields, gas fields, and underground natural gas storage (UGS) sites by combining criteria from previous studies while excluding sites that pose technical risk or are located in regions with surface restrictions including sensitive habitats and dense populations. In the first stage, 129 CO 2 storage sites in California were identified using qualification criteria based upon formation properties including geological conditions and pore pressure. The second stage identified sensitive sites by applying conservative screens including seismic activity, faulting, population density, restricted lands, and sensitive habitats. During the third stage, 61 CO 2 potential storage sites were identified by subtraction of stage 2 areas from stage 1. The potential storage volume in the third stage ranged from 1.0 to 2.0 GtCO 2 . Finally, we applied a scoring system with seven parameters to rank the 61 potential sites based on subsurface technical criteria. The scored sites are classified as high priority, medium priority, and sites for future study. Prospective CO 2 storage sites with high and moderate priority were selected and linked to CO 2 sources. There are 14 prospective sites (above 20 MtCO 2 storage resource per site) with a total storage resource of 1024 MtCO 2 distributed in Northern and Southern California. Of these sites, there are 9 potential CO 2 -EOR sites and 1 depleted oil field with a total estimated CO 2 storage volume of ~800 MtCO 2 in the Southern San Joaquin and Ventura Basin. These 10 prospective sites with a storage resource greater than 20 MtCO 2 could potentially deliver more than 20 years of storage with an average injection rate of 40 MtCO 2 /year. The remaining 4 highly prospective sites are in Northern California. Additionally, study results suggest that saline formations should be re-evaluated in concert with storage in oil, gas, and natural gas storage reservoirs.

58 GEOSCIENCES↗
DOE OSTI2021

Modelling the complex evaporated gas flow and its impact on particle spattering during laser powder bed fusion

The additive manufacturing (AM) of metals is becoming an increasingly important production process with the potential to replace traditional techniques such as casting. Laser Powder Bed Fusion (LPBF) is used in many applications to print metal parts from powder. The metal powder is heated locally with sufficient laser radiation that the liquid melt easily reaches its boiling temperature, which leads to a metallic vapour jet that can entrain both powder bed particles and molten droplets. The small size of laser-matter interaction site makes a detailed experimental analysis of the process challenging. Synchrotron X-ray imaging experiments are one of the few methods which can capture the dynamic melting and solidification processes. Comparing such experiments with computer simulations of the process is an important approach in order to better understand the manufacturing process and to analyse the influence of process parameters on the evaporated gas jet and the subsequent impact on particle ejection, leading to potentially reduced AM component quality. The melting and solidification of the metal powder is simulated using an Eulerian multiphase approach based on a control volume discretization of powder bed and substrate and a volume of liquid separation from melt and gas phase. The gas phase modelled as an ideal gas reaches velocities up to 100 m/s. Lagrangian particle tracking in the simulation demonstrates that the velocity fields calculated by the Eulerian multi-phase approach in combination with a standard drag-force model lead to particle accelerations in good agreement with those measured experimentally. In order to avoid numerical laborious Lagrangian calculations, a direct method to compare an Eulerian multiphase simulation with synchrotron X-ray experiments was introduced and validated. This approach is used to analyse the influence of process parameters including laser power and laser speed on the maximal acceleration of particles from the melt pool area. While the particle acceleration increases linearly with line energy in the conduction mode, a linear decrease of the acceleration with increasing line energy can be found in the transition mode before the accel-eration increases again with line energy in the keyhole mode.

36 MATERIALS SCIENCE↗
DOE OSTI2022

An Innovative Zero-Liquid Discharge Intermediate-Cold-Liquid Eutectic-Freeze Desalination System

A novel freeze desalination technology is presented for purification of water produced from various industrial processes, including oil and gas extraction. The main innovative idea is introducing a water-immiscible intermediate-cold-liquid (ICL) medium which absorbs the cold from a refrigeration cycle and transfers it to a freezing chamber where it is mixed with brine. The cold ICL enters the freezing chamber at temperatures between -10°C to -30°C. Precooled brine in injected into the freezing chamber and pure water freezes out of the brine upon mixing with the ICL. The rate of freezing inside the chamber is controlled by adjusting the flow rate of the cold ICL relative to the inlet brine. Both eutectic freeze and non-eutectic freezing are possible by controlling the temperature of the freezing chamber. The solid-liquid slurry created in the freezing chamber flows to a filter separation unit after passing through a separation column. The ice crystals are separated from the liquid by a rotary filter device. The collected ice is rinsed by a centrifugal unit. The rinsed ice is melted to produce fresh water. The developed technology resolves the issues common to current freeze-desalination systems while offering superior heat transfer performance ascribed to direct-contact between the cooling medium and the brine in addition to producing solid salt and pure water. The system operates under atmospheric pressure. The low operation temperature minimizes the corrosion issues common in systems exposed to brine. Also, due to the low operating temperature, there are no concerns about evaporation of volatile organics from the produced water during the treatment. The developed technology effectively eliminates the use of chemicals for pretreatment of brine. The system can be constructed from commercially available components. Extensive testing using a lab-scale prototype by using synthetic brine and actual produced water with TDS values from 50,000 ppm to 300,000 ppm showed that freshwater could be achieved with relatively small dependency on the quality of the input brine. The quality of the treated water was found to be mainly a function of the duration of the centrifugal process. Treated water with TDS as low as 200 ppm could be achieved in the tests. Thermo-economic modeling coupled with system level thermochemical process model were developed for prediction of the LCOW. The LCOW was predicted to be $\$$0.50 to $\$$0.90 per barrel of produced water. The potential markets for deployment of the technology are the oil and gas, in-land thermoelectric powerplants, RO desalination plants, and mining industry.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗