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

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

Modeled Performance of the Hathaway Solar Patriot house - Washington D.C

This Dataset contains field research raw data, analysis spreadsheet, photos, and final report from the Hathaway Solar Patriot House Building America Case Study project. This dataset details the monitored and modeled performance of a solar home outside of Washington, D.C. We modeled the home energy performance using DOE 2.2, performed numerous short-terms tests on the home, and monitored its occupied performance for 29 months. The home used modular construction, solar water heating, a ground-coupled heat pump, efficient appliances, and compact fluorescent lighting to reduce its energy consumption by 35% compared to the Building America research benchmark home. The addition of 6kW of photovoltaics (PV) increased the savings to 67% compared to the Building America research benchmark. A more efficient shell to reduce space conditioning loads would have brought the home closer to its zero energy goals. However, even with efficient lighting and appliances, the lights, appliance and plug loads were a significant energy consumer. About 4 kW of PV was required to meet the needs of these loads alone. To achieve the zero energy goal with no further efficiency increases, the Hathaway house would need about 2.6 kW of PV in addition to the 6.0 kW it now has. Applying advanced efficiency measures available or being developed, such as heat-recovery ventilation, superinsulation, and electrochromic windows, could reduce the heating, cooling, and domestic hot water (DHW) energy use to less than 1700 kWh per year, an 88% reduction in these loads from the Building America Benchmark. At this efficiency level, the appliance and plug loads come to dominate energy consumption and account for nearly 70% of the total energy use. This analysis points out that even with highly effective energy-savings technologies (pushed beyond levels currently practical), whole-house energy use reduction by efficiency measures is only about 60% without also reducing the energy use of appliances and plug loads largely considered outside the designers jurisdiction.

Array↗
DOE OSTI2018

Application of a Triple Bubbler Sensor for Determining the Density, Surface Tension, and Depth in Molten Salts

Electrochemical (i.e. pyroprocessing) technology is being widely studied throughout the world as a potential alternative to aqueous reprocessing of spent nuclear fuel (SNF). Central to this process is the electrorefiner (ER), in which the useful uranium in the SNF is electrochemically transported through a molten salt electrolyte to a cathode for later recovery. As part of this process, uranium, plutonium, and other actinides accumulate in the ER salt over time. Material accountancy and safeguards of these special nuclear material buildups in near real-time is a significant challenge due to the elevated processing temperatures, remote operation within a hotcell, and high radiation fields. Analytical techniques outside of the hotcell can be used to provide the SNM concentrations of salt samples from the ER. However, determining the actual mass of these materials in the ER presents a significant challenge because the density and volume within the vessel is largely unknown. The Idaho National Laboratory (INL) has developed a triple bubbler sensor capable of determining the density, surface tension, and depth of a fluid in near real-time. Previous experiments in aqueous media has shown that the sensor is capable of determining the density, surface tension and depth with accuracies on the order of 0.2%. The goal of this current work is to test the sensor in several molten salt media to calibrate and validate the triple bubbler. Experiments have been performed in LiCl-KCl eutectic salt. Calibration factors were 1.0015 and 1.26 for density and surface tension, respectively. With the above calibration factors applied, the depth of the salt in the test vessel was determined to within 0.4%. These results indicate that the triple bubbler sensor has the potential to accurately (less than 1% uncertainty) determine the density, surface, tension, and depth of the ER salt in near real-time. The triple bubbler sensor designed at INL can significantly enhance the material accountancy, safeguards, and process monitoring of the electrochemical processing of SNF.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2016

TH-EF-BRA-03: Assessment of Data-Driven Respiratory Motion-Compensation Methods for 4D-CBCT Image Registration and Reconstruction Using Clinical Datasets

Purpose: To evaluate the performance of a 4D-CBCT registration and reconstruction method that corrects for respiratory motion and enhances image quality under clinically relevant conditions. Methods: Building on previous work, which tested feasibility of a motion-compensation workflow using image datasets superior to clinical acquisitions, this study assesses workflow performance under clinical conditions in terms of image quality improvement. Evaluated workflows utilized a combination of groupwise deformable image registration (DIR) and image reconstruction. Four-dimensional cone beam CT (4D-CBCT) FDK reconstructions were registered to either mean or respiratory phase reference frame images to model respiratory motion. The resulting 4D transformation was used to deform projection data during the FDK backprojection operation to create a motion-compensated reconstruction. To simulate clinically realistic conditions, superior quality projection datasets were sampled using a phase-binned striding method. Tissue interface sharpness (TIS) was defined as the slope of a sigmoid curve fit to the lung-diaphragm boundary or to the carina tissue-airway boundary when no diaphragm was discernable. Image quality improvement was assessed in 19 clinical cases by evaluating mitigation of view-aliasing artifacts, tissue interface sharpness recovery, and noise reduction. Results: For clinical datasets, evaluated average TIS recovery relative to base 4D-CBCT reconstructions was observed to be 87% using fixed-frame registration alone; 87% using fixed-frame with motion-compensated reconstruction; 92% using mean-frame registration alone; and 90% using mean-frame with motion-compensated reconstruction. Soft tissue noise was reduced on average by 43% and 44% for the fixed-frame registration and registration with motion-compensation methods, respectively, and by 40% and 42% for the corresponding mean-frame methods. Considerable reductions in view aliasing artifacts were observed for each method. Conclusion: Data-driven groupwise registration and motion-compensated reconstruction have the potential to improve the quality of 4D-CBCT images acquired under clinical conditions. For clinical image datasets, the addition of motion compensation after groupwise registration visibly reduced artifact impact. This work was supported by the National Cancer Institute of the National Institutes of Health under Award Number R01CA166119. Hugo and Weiss hold a research agreement with Philips Healthcare and license agreement with Varian Medical Systems. Weiss receives royalties from UpToDate. Christensen receives funds from Roger Koch to support research.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2017

Characterization of reactive CaCO 3 crystallization in a fluidized bed reactor as a central process of direct air capture

A laboratory-scale, fluidized-bed pellet reactor (BPR) was used to investigate a CaCO 3 crystallization process for the recovery of CO 2 in a Direct Air Capture (DAC) process. The BPR performance was validated against data from a pilot-scale unit. Subsequently, the pellet growth under process-relevant conditions was studied over a period of 144 h. The experimental results with the BPR, containing a bed of pellets sized between 0.65 and 0.84 mm, have shown that a calcium retention of 80% can be achieved at a fluidization velocity of 60 m h -1 and a calcium loading rate of 3 mol h -1 . This result is consistent with calcium retention observed at pilot scale operation and hence, results from the BPR are considered representative for the pilot scale unit. Starting with a bed of pellets sized between 0.15 and 0.5 mm, the average pellet growth rate, G, at the reactor bottom increased from 8.1E-10 to 11E–10 m s -1 at the onset and decreased to 4.9E–10 m s -1 over the course of a 144 h test. The calcium retention over the course the test showed the same trend (initial increase and final decrease) as the pellet growth rate. A theoretical bed growth model was developed and validated against data from the pilot scale and benchtop pellet reactors. The model was used to calculate the bed porosity and total pellet surface area in each control volume. Lastly, the pellet surface area growth at the bottom of the reactor reproduced the pellet growth and retention data trends.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

Study on hot deformation behavior and workability of squeeze-cast 20 vol%SiCw/6061Al composites using processing map

Highlights: • Prasad’s and Murty’s criteria were better than Gegel’s criterion in predicting the flow instability for the composites. • Partial melting and DRX at high temperature and high strain rate improved the workability of the composites. • The softening mechanism changed from DRV to DRX with the increase of deformation temperature and strain rate. • The safe deformation region of the composites was at higher temperature of 450-500°C and higher strain rate of 0.1-1s{sup -1}. • The safe deformation region predicted by processing maps was validated by uniaxial upsetting and two-directional forging. - Abstract: The hot deformation behavior and workability of squeeze-cast 20 vol%SiCw/6061Al composites were investigated by isothermal compression test and development of processing map, which was verified by uniaxial upsetting and two-directional forging of big cylindrical billets. Due to dispersed strengthening caused by SiC whiskers, the activation energy of 20 vol%SiCw/6061Al composites was much higher than the self-diffusion activation energy of pure Al. Both the DMM and MDMM were reliable in predicting the safe deformation regions. The instability regions predicted by the Prasad's and Murty's instability criterion were smaller than the actual ones, while the Gegel's instability criterion was not appropriate in predicting the instability regions of 20 vol%SiCw/6061Al composites. The optimum deformation region was at higher temperature of 450–500 °C and higher strain rate of 0.1–1 s{sup − 1}, in which the compressed samples exhibited perfect surface without cracks and microstructure with few of cavities due to the occurrence of partial melting and dynamic recrystallization. With the increase of deformation temperature and strain rate, the deformation mechanism changed from dynamic recovery to dynamic recrystallization. Squeezing casting technique with high filtration pressure may also contribute to the increase of strain rate of DRX, which was helpful for hot forging of Al matrix composites with high productivity.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Catalytic Bio-crude Production in a Novel, Short-Contact Time Reactor

RTI has developed a catalytic fast pyrolysis (CFP) process to produce biomass-based hydrocarbon replacement fuels. From a technology perspective, this advanced biofuels process produces liquid transportation fuels that can leverage capital expenditures in the existing petroleum distribution infrastructure. From a business perspective, this technology does not face potential market limitations caused by oxygenate blend limitations for light duty vehicle applications. A promising catalyst has been developed with excellent potential for deoxygenation to produce a hydrocarbon-rich biocrude that is more suitable for upgrading with traditional hydroprocessing technology. The role of the catalyst is to control the chemistry during biomass pyrolysis to produce a biocrude in a single step that has lower oxygen content and is more thermally stable than conventional biomass fast pyrolysis oil. Catalyst properties are optimized to minimize gas and coke production and improve catalytic deoxygenation and biocrude yields. Results from this project have demonstrated that biocrudes from catalytic fast pyrolysis contain <20 wt% oxygen, with the organic fraction as low as 12% oxygen. These oxygen numbers are > 50% lower compared to traditional fast pyrolysis oils. The biocrude produced from our CFP process can be upgraded to gasoline range hydrocarbons. A very conservative approach for upgrading included a preliminary stabilization step followed by a hydroprocessing step. The oxygen content in the upgraded product was decreased by 97% (to less than 3wt %) from the oxygen content of the biocrude sample. Additionally, the acid content was reduced by 99% from the acid content of the biocrude sample. In an optimized integrated process, the CFP step and the hydroprocessing (upgrading) step need to be carefully balanced to maximize the input biomass energy that is recovered in the finished biofuels. Hydrogen utilization and carbon recovery during both catalytic biomass pyrolysis and biocrude upgrading need to be optimized to maximize energy recovery in the finished biofuel. A nominal 1 ton per day (TPD) catalytic biomass pyrolysis system was designed based on the laboratory experimental data. The system was designed to achieve the short residence times (0.5–2 sec) and high heat transfer rates required for maximum liquid biocrude yields while optimizing process integration to maintain catalyst activity by continuous regeneration. The catalytic biomass pyrolysis reactor is a continuously circulating single-loop transport reactor design that is flexible enough to allow sensitivity studies around temperature, residence time, biomass feed rate, and catalyst-to-biomass ratio (i.e., catalyst circulation rate) for process optimization. For a nominal 100 lb/hr feed rate of dry biomass, the products include ~25 lb/hr char and coke, ~20 lb/hr permanent gases, and ~55 lb/hr condensable vapors. Pyrolysis temperatures are 350–600°C, and the system is operated close to ambient pressure. Production of the catalyst developed within the project was scaled up to provide enough material (200kg) for bench-scale testing. The 1TPD bench-scale unit was fabricated, installed and commissioned with this project. Biocrude samples from wood were produced in this unit with the CFP catalyst with material balance > 90%. The intermediate biocrude yields and chemical composition compare well with previous laboratory results and a hydroprocessing strategy for upgrading the resulting biocrude was developed. The experimental results obtained within this project were used to develop a process model for a 2000 TPD commercial facility. Detailed flow sheets were developed for all major unit operations in the process and provided a basis for an economic analysis to develop capital and operating costs. Estimates of the biofuel production costs were used to develop internal rates of return for the yields and compositions measured for the current state of technology at the end of this project and for the yields anticipated for an optimized (nth plant) scenario as additional process improvements are made.

09 BIOMASS FUELS↗
DOE OSTI2026

A Mobile Hot Cell for Conditioning Disused Sealed Radioactive Sources for Storage or Transportation

An innovative Mobile Hot Cell (MHC) has been developed for conditioning Disused Sealed Radioactive Sources (DSRS) category 1 and 2 for storage or transportation. The MHC is designed to provide both Radiological and Biological containment with a maximum capacity of 1000 Ci Co60 or 5000Ci Cs137 source and can be transported via standard cargo containers. This project has been supported through the National Nuclear Safety Administration (NNSA) Offsite Source Recovery Program (OSRP). The project is intended for the international community rather than domestic although domestic use is a possibility. Many countries have significant stockpiles of these devices that are often stored in less-than-optimal circumstances. This necessitates that these devices be addressed expeditiously, and the sources secured. The MHC utilizes robotics, automation, and other non-traditional methods for disassembling, characterizing, and packaging these sources that have reached end of life or are otherwise not needed. These innovative approaches are necessary to facilitate an expedited timeline to efficiently and safely secure these sources in a non-proliferation effort. Conditioning efforts include disassembling the device such as a teletherapy head used for cancer treatment, or blood/research irradiators such that the radioactive sources may be removed safely. The sources are then characterized. Leak checks are performed, dimensions are verified, and serial numbers are confirmed. Upon completion, the sources are typically placed into a Standard Forms Capsule which is seal welded closed. It is leak tested and placed into a Long-Term Storage Shield (LTSS) which can either be secured for storage directly or loaded into an appropriate cask for transportation. Further innovations include multiple deployment scenarios that include a full deployment of MHC components, deployment of the MHC automation internal components to an existing hot cell, deployment of minimally required MHC components and incorporation of sand for shielding, and integration of the MHC for Silo Storage, or Bore Hole Storage efforts. The MHC has evolved from a very specific use case to a “Swiss Army Knife” type of a tool in that it can be readily adapted to a large variety of situations. Innovative approaches such as the use of robotics, Computer Numeric Control (CNC) machining centers, automated welding equipment, HDMI Cameras, and LED lighting are some of the developed technologies incorporated into the MHC design. Shielding is accomplished with a steel walled Base Box which is surrounded by four nesting doll shield shells which when combined limits the external dose rate to 5mr/hr when a 1000 Ci Co60 source is exposed inside.

99 - GENERAL AND MISCELLANEOUS↗
DOE OSTI2019

Selective capture of radionuclides (U, Pu, Th, Am and Co) using functional nanoporous sorbents

Using our self-assembled silanol technology, we developed eight functional nanoporous silica sorbents for capturing two classes of radionuclides: the actinide uranium (U), thorium (Th), plutonium (Pu), americium (Am) and the transition metal cobalt (Co). We tested them in sea, ground, and river water that were adjusted to pH 0-8.0 and doped with competing metals (Mg, Ca, K, Se, Mn, Fe, Co, Cu, Zn, and Mo) at levels encountered in environmental or physiological samples. Sorbents having three analogs of hydroxypyridinones (HOPO) and acetamide phosphonate (Ac-Phos) were exceptional at capturing U, Th, and Pu from pH 2.0 to 8.0, and very good at capturing Am from pH 5.0 to 8.0 with the affinity ranged from 3,4-HOPO > 1,2-HOPO > 3,2-HOPO > Ac-Phos. However, the affinity is reversed at near zero pH. For capturing Co, a family of glycine derivatives on nanoporous silica has been developed and the affinity for Co ranged from IDAA ~ DE4A > ED3A between pH 5.0-8.0. Our materials significantly outperformed the commercially available cation sorbents such as Chelex-100 and activated carbon in terms of binding affinity and rate; thus demonstrating great potential to be used as decorporation agents for water treatment and recovery of valuable actinides.

uranium (U), thorium (Th), plutonium (Pu), americi↗
DOE OSTI2017

Final Report to DOE EERE – Geothermal Technologies Program Project Title: Monitoring and modeling of fluid flow in a developing enhanced geothermal system (EGS) reservoir

The primary objective of this project was to improve our ability to predict performance of an Enhanced Geothermal System (EGS) reservoir over time by relating, in a quantitative manner, microseismic imaging with fluid and temperature changes within the reservoir. Historically, microseismic data have been used qualitatively to place bounds on the growth of EGS reservoirs created by large hydraulic fracturing experiments. Previous investigators used an experimentally based fracture opening relationship (fracture aperture as a function of pressure), the spatial extent of microseismic events, and some assumptions about fracture frequency to determine the size of an EGS reservoir created during large pumping tests. We addressed a number of issues (1) locating microearthquakes that occur during hydraulic fracturing, (2) obtaining more information about a reservoir than the microearthquake locations from the microearthquake data, for example, information about the seismic velocity structure of the reservoir or the scattering of seismic waves within the reservoir, (3) developing an improved methodology for estimating properties of fractures that intersect wellbores in a reservoir, and (4) developing a conceptual model for explaining the downward growth of observed seismicity that accompanies some hydraulic injections into geothermal reservoirs. We used two primary microseismic datasets for our work. The work was motivated by a dataset from the Salak Geothermal Field in Indonesia where seismicity accompanying a hydraulic injection was observed to migrate downward. We also used data from the Soultz EGS site in France. We also used Vertical Seismic Profiling data from a well in the United States. The work conducted is of benefit for characterizing reservoirs that are created by hydraulic fracturing for both EGS and for petroleum recovery.

15 GEOTHERMAL ENERGY↗
DOE OSTI2026

Flexible Natural Gas/Hydrogen CHP System

This project included design, development, and demonstration of a cost-effective and scalable, unique-to-the-industry 2.0 MWe fuel-flexible Caterpillar G3516 CHP genset that can run on 100% hydrogen, 100% natural gas, and up to 25% blends of hydrogen in natural gas (volume basis). This was accomplished based on over two years of extensive R&D work done on a single-cylinder engine for developing innovative hydrogen fueling, combustion, air, and electronic control systems design and strategies. Findings from the single-cylinder engine work were scaled up and applied for modifications of and lab testing and development of a 2.0 MWe 16-cylinder G3516 fuel-flexible engine-genset and electronic controls systems. During this testing and development in the engine lab, the genset was run on 100% hydrogen, 100% natural gas, and up to 25% blends of hydrogen in natural gas (volume basis) and its steady-state and transient performance and emission were documented.

03 NATURAL GAS↗
DOE OSTI2025

A Parameter-masked Mock Data Challenge for Beyond-two-point Galaxy Clustering Statistics

The past few years have seen the emergence of a wide array of novel techniques for analyzing high-precision data from upcoming galaxy surveys, which aim to extend the statistical analysis of galaxy clustering data beyond the linear regime and the canonical two-point (2pt) statistics. We test and benchmark some of these new techniques in a community data challenge named “Beyond-2pt,” initiated during the Aspen 2022 Summer Program “Large-Scale Structure Cosmology beyond 2-Point Statistics,” whose first round of results we present here. The challenge data set consists of high-precision mock galaxy catalogs for clustering in real space, in redshift space, and on a light cone. Participants in the challenge have developed end-to-end pipelines to analyze mock catalogs and extract unknown (“masked”) cosmological parameters of the underlying ΛCDM models with their methods. The methods represented are density-split clustering, nearest neighbor statistics, BACCO power spectrum emulator, void statistics, LEFTfield field-level inference using effective field theory (EFT), and joint power spectrum and bispectrum analyses using both EFT and simulation-based inference. In this work, we review the results of the challenge, focusing on problems solved, lessons learned, and future research needed to perfect the emerging beyond-2pt approaches. The unbiased parameter recovery demonstrated in this challenge by multiple statistics and the associated modeling and inference frameworks supports the credibility of cosmology constraints from these methods. The challenge data set is publicly available, and we welcome future submissions from methods that are not yet represented.

Krause, Elisabeth [Univ. of Arizona, Tucson, AZ (U↗
DOE OSTI2019

First Ever Polymer Flood Field Pilot to Enhance the Recovery of Heavy Oils on Alaska’s North Slope – Polymer Injection Performance

Alaska North Slope (ANS) holds an estimated 20-30+ billion barrel heavy oil resources, yet the development pace has been very slow due to high development costs and low oil recovery using conventional waterflood and EOR methods. The objective of this pilot is to perform a field experiment to validate the use of an advanced polymer flooding technology to unlock the vast heavy oil resources on ANS. The advanced polymer flooding technology combines polymer flooding, low salinity water flooding, horizontal wells, and if necessary, injection conformance control treatments into one integrated process to significantly improve oil recovery from heavy oil reservoirs. Two pairs of horizontal injection and production wells have been deployed in an isolated fault block of the Schrader Bluff heavy oil reservoir at the Milne Point Field to conduct a polymer flood pilot. The pilot will acquire scientific knowledge and field performance data to optimize polymer flood design in the Schrader Bluff heavy oil reservoirs on ANS. Polymer injection started on August 28, 2018 using a custom made polymer blending and pumping unit. This paper focuses on the facility setup and polymer injection performance into the horizontal injectors drilled and completed in the Schrader Bluff heavy oil reservoir. Partially hydrolyzed polyacrylamide (HPAM) polymer was selected and the initial target viscosity was set at 45 centipoise. Polymer injection rate was set at 2200 bbl/day for one injector (J-23A) and 1200 bbl/day for the other (J-24A) based on production voidage. Injection pressure was controlled at below fracture pressure to prevent fracturing the reservoir and causing fast breakthroughs. Step rate and pressure falloff tests indicate that short term polymer injectivity is similar to water injectivity, which means that injectivity is mostly controlled by fluid mobility deep in the reservoir rather than that in the vicinity of the injection wellbore. Long term injection data indicate that polymer injectivity has been decreasing in both injectors as the reservoir is filled by polymer. No polymer has been observed in the production stream 7 months after the start of polymer injection compared with a 3-month breakthrough time with waterflood. This indicates that polymer significantly delays breakthrough time which will lead to increased sweep efficiency.

Ning, Samson↗
DOE OSTI2018

Development Of Nutrient And Water Recycling Capabilities In Algae Biofuels Production Systems. Final Summary Report

The objective of this project was to develop and demonstrate methods of recycling of water and nutrients for algal biofuels production. Recycling was accomplished both internal to the system and, in a broader sense, through import and reuse of municipal wastewater. Such an integrated system with wastewater input had not been demonstrated previously, and the performance was unknown, particularly in terms of influence of recycling on algal productivity and the practical extent of nutrient recovery from biomass residuals. Through long-term laboratory and pilot research, the project resulted in the following: 1. Bench-scale pretreatment of algal biomass did not sufficiently increase methane yield of nutrient solubilization during anaerobic digestion to warrant incorporation of pre-treatment into the pilot plant. The trial pretreatments were high-pressure orifice homogenization, sonication, and two types of heat treatment. 2. Solubilization of biomass particulate nutrients by lab anaerobic digesters ranged from 20% to nearly 60% for N and 40-65% for P. Subsequent aerobic degradation of the anaerobically digested biomass simulated raceways receiving whole digestate and resulted in an additional 20-55% N solubilization and additional 20% P solubilization. 3. Comparisons of laboratory and pilot digesters showed that laboratory units were reasonable proxies for pilot-scale. 4. Pilot-scale anaerobic digesters were designed, installed, and operated to digest algal biomass. Nutrient re-solubilization by the digesters was monitored and whole digestate was successfully used as a fertilizer in pilot algae raceways. 5. Unheated, unmixed digesters achieved greater methane yield and nutrient solubilization than heated, mixed digesters, presumably due to longer the solids residence times in unmixed digesters. The unmixed, unheated pilot digesters yielded 0.16 L CH4 /g volatile solids (VS) introduced with 0.15 g VS/L-d organic loading and 16oC average temperature. A conventional heated mixed lab digester yielded 0.22 L CH4 /g VS with 0.25 g VS/L-d and 30oC. The highest yield (0.30 L CH4 /g VS) was achieved by the unmixed lab digesters operated at a constant 20oC. All digesters were operated with a 40-d hydraulic residence time. 6. In general, 50-75% of initial particulate N and P could be solubilized during anaerobic digestion and available for subsequent rounds of algae cultivation. 7. Bench-scale experiments showed the recovery from hydrothermal liquefaction (HTL) wastewater of carbon via anaerobic digestion and of nutrients to grow algae. To satisfy the nitrogen demand of algae cultivation, HTL wastewater would be diluted 400-fold, which was found to eliminate inhibition of algae growth by HTL wastewater. 8. Anaerobic digestion methane yield was lower for algal biomass containing coagulants such as would be used to aid harvesting or dewatering. Depending on doses, starch-based coagulant decreased yield by 10-14% and aluminum chlorohydrate decreased it by 14-26%. The lowest yield was 0.28 L CH 4 /g volatile solids introduced to the digesters. 9. Algae harvested from raceways operated on recycled water had methane yields 13% higher than algae from raceways operated on both recycled water and nutrients provided by algae digestate. The slightly lower yield was expected due to the presence of previously digested biomass from the digestate fertilizer. 10. Defined media was replenished with nutrients and recycled repeatedly in sequential batch growth of Chlorella sorokiniana (DOE 1412). This laboratory study tested for inhibition and accumulation of inhibiting compounds (allelopathic or auto-inhibitory substances), information that would help estimate the blowdown ratio needed for an integrated system. In laboratory experiments in which water was recycled a total of five times, each successive round of reuse resulted in an average 4±3% reduction in log-phase specific growth rates. However, linear-phase growth inhibition was only observed in the final fifth round of reuse. 11. No decline in productivity was detected after 15 rounds of water recycling with nutrients provided by whole digestate in lab cultivation. Lab tests allowed for steady light and temperature, increasing the ability to detect inhibition. 12. In initial pilot inhibition studies, wastewater growth media was reused once while productivity was monitored. Media reuse was accomplished with triplicate sets of 33-m2 raceways operated in series. First-round gross productivity (based on effluent biomass flow) averaged 23 g/m 2 -day annually while second-round gross productivity averaged 19 g/m 2 -day annually. In terms of net productivity (based on raceway effluent biomass minus influent biomass), the first-round productivity averaged 15 g/m2-d and second round averaged 13 g/m 2 -d during June-September operation. The higher productivity in the first-round ponds was likely due to heterotrophic/mixotrophic growth on the wastewater organic matter. 13. In a culminating pilot experiment, coagulant was used to decrease the carry-over of unsettled algae into subsequent rounds of growth. Over nearly 8 months, 93% of the media (the equivalent of 14 rounds of water reuse) was recycled without significant productivity loss compared to controls. Ponds receiving both recycled water and nutrients had net productivities of 14-24 g/m 2 -d during fall and mid-summer, respectively. 14. Techno-economic analysis of the proposed facility found minimum fuel selling price to range from $7.01/gallon gasoline equivalent without revenue other than fuel to $3.85/GGE with revenue from wastewater treatment fees and LCFS and RIN (Low Carbon Fuel Standard and Renewable Identification Numbers) credits. 15. Life cycle assessment indicated GHG emissions of 40.7 g CO 2 /MJ fuel and a net energy ratio (energy required/energy produced) of 0.37.

09 BIOMASS FUELS↗
DOE OSTI2019

Recycling of Commercial E-glass Reinforced Thermoset Composites via Two Temperature Step Pyrolysis to Improve Recovered Fiber Tensile Strength and Failure Strain

Economic and regulatory pressures on the global composites industry have encouraged the research and development of technology for the recycling of fiber reinforced polymer composites. Although significant advancements have been made in the recycling of carbon fiber composites, more progress is needed in the recovery of glass fibers, which make up the overwhelming volume of the composites market. In this study, wind turbine blades and automotive sheet moulding compound (SMC) were subjected to a two temperature step pyrolysis. This multistep process yielded improvements in the recovered E-glass fiber’s tensile strength, by as much as 19%, and strain to failure, by as much as 43%, over a single high temperature step pyrolysis. Despite these gains, pre-pyrolysis fiber measurements indicate that pre-existing damage may inherently limit the quality of glass fiber recoverable from pyrolysis without any post processing.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Numerical investigation of multiphase flow through self-affine rough fractures

Multiphase flow through fractures has great significance in subsurface energy recovery and gas storage applications. Different fracture and flow properties affect flow through a fracture which is difficult to control in laboratory experiments. Here, we perform lattice Boltzmann simulations in an ensemble of synthetically generated fractures. Drainage simulations are performed at different capillary numbers, wettability, and viscosity ratios. We track the invading front and quantify breakthrough saturations and show that roughness and wettability have a strong effect on fluid invasion through a complex fracture. Invading a more viscous fluid results in more stable displacement regardless of the capillary number while at very low capillary numbers, fluid migration is dependent on the inherent structure of the fracture. We develop a fluid displacement phase diagram in a single rough fracture and compare our results from that in the literature. Finally, we extend the phase diagrams across multiple fractures and demonstrate the importance of natural fracture features of roughness and wettability in identifying stable versus unstable displacement regimes during multiphase flow through rough fractures. Our work presents an end-to-end numerical pathway for testing on experimental data and expanding numerical data sets for testing combinations of different physical phenomenon and make valuable predictions on fluid flow through rough fractures.

02 PETROLEUM↗
DOE OSTI2018

Liberation and release of rare earth minerals from Middle Kittanning, Fire Clay, and West Kentucky No. 13 coal sources

Here, a laboratory REE release test procedure was designed to better understand the association and liberation characteristics of rare earth elements (REEs) from coal-based material, such as coal middlings and refuse. For this particular study, three samples of mixed-phase, middling material was collected from three coal preparation plants operating in three different coal basins and coal seams, namely Fire Clay, Middle Kittanning, and West Kentucky #13. In these release tests, the mixed-phase material was first ground in a laboratory ball mill for a designated amount of time and subsequently decarbonized using staged flotation. The REE content of the high ash tailings and low ash concentrate was determined, and the process was repeated for various target grind sizes down to the micron range. The results indicate that smaller grind sizes produce increased REE concentrations in the high ash tailings, and this result is predominantly driven by the increased ash content in the decarbonized tailings. The grinding characteristics of the Fire Clay coal source showed that more energy is needed to achieve the desired particle size reduction; however further size reduction of this sample resulted in a significantly higher ash and REE content in the tailings material due to improved liberation. For the Middle Kittanning and West Kentucky #13 sources, the grinding and release data indicates that the mineral matter is liberated at a coarser particle size, and micronizing the coals only produces marginal improvements in rare earth mineral liberation and recovery.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

Solidification of SRPPF Aqueous Recovery Liquid: Process Disruptions

Savannah River National Laboratory has identified a magnesium oxysulfate grout formulation to solidify the liquid effluent from the Savannah River Plutonium Processing Facility (SRPPF) Aqueous Recovery System (ARS). The formulation uses reactive, light burnt MgO, anhydrous MgSO 4 , and dead burnt MgO and provides good mixability, similar density to the original Portland Cement-based mix, and a leachate pH of 9.39, within the assumed Waste Isolation Pilot Plant (WIPP) brine pH range. The formulation will solidify the effluent using a solid first, lost paddle design, within a 55-gallon drum. A series of seven different process disruptions, or irregular processing during the expected ARS liquid effluent solidification process, were completed to assess the severity of the impact of the process disruption and how the formulation behaves under these conditions. Seven process disruptions were investigated including: No Mixing, Partial Mixing, Compacted/Stratified, Sealed, Overfilled, Underfilled, and Undermixed. The impact on solidification, leachate pH, Er (a Pu/Am surrogate) distribution, and density of the resulting grout were established. Overall, four of the process disruptions, No Mixing, Partial Mixing, Compacted/Stratified, and Overfilled, resulted in basic, unabsorbed liquid that would require additional solidification to be acceptable for WIPP. Most solids generated in this testing met the expected WIPP leachate pH requirements. Solids from the Compacted/Stratified process disruption test, however, produced a leachate pH slightly above the assumed range in the WIPP performance assessment. The distribution of Er for most of the tests was relatively consistent. The No Mixing process disruption test, however, resulted in non-homogeneous Er distribution, indicating that radioactive material would not be evenly distributed throughout this solid’s matrix. The Overfilled test is the only mix with a density slightly below the acceptable value. The Sealed and Overmixed tests produced a solid closest to the standard mix with no unabsorbed liquid, expected leachate pH levels, consistent Er concentrations, and expected density, indicating these process disruptions do not have a negative impact on the final grout form. Based on the other process disruptions, it is critical to have premixed dry materials and a well-defined mixing process to produce a solid, homogeneous magnesium oxysulfate cement, with no unabsorbed liquid. These process disruption tests show that the lack of adequate mixing is fundamental to creating an improperly solidified material that may require remediation.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗