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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Scaling-Up and Roll-to-Roll Processing if Highly Conductive Sulfide Solid-State Electrolytes (CRADA 510)

This project aims to identify and address key technical barriers in scale-up synthesis and roll-to-roll processing of highly conductive solid-state electrolytes (SSEs) by leveraging PNNL’s patent pending SSEs, Ampcera Inc.’s environmentally friendly manufacturing capability, and UW’s rollto-roll processing. The ultimate goals are 1) development of novel sulfide SSEs with room temperature Li+ conductivity > 5 mS/cm and Li/SSE interfacial resistance <5 Ωcm2, 2) scalable production of sulfide SSEs at 1 metric ton/year, and 3) a high throughput roll-to-roll processing of highly conductive (>1 mS/cm) and ultra-thin solid film (10-100 μm). The materials and the solid film achieved in the project will be tested at practical conditions and validated in a realistic pouch cell format with achievable energy > 300 Wh/Kg.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Umida AG Fish Protection Prize, Cooperative Research and Development Agreement (CRADA) PNNL CRADA 487 (Final Report)

In FY2020, the National Renewable Energy Laboratory (NREL) initiated a Prize competition with support from Pacific Northwest National Laboratory (PNNL), and sponsored by the U.S. Department of Energy Water Power Technologies Office (DOE WPTO), to support the development of innovative methods for excluding fish from water diversions and intakes: the Fish Protection Prize. Proposed solutions can include new ideas for addressing fish exclusion or improvements to existing technologies. Solutions can be applied to river and canal diversions, unscreened diversion pipes, or intakes at dams. In FY20 PNNL provided voucher support in the form of technical reviews and support, as well as graphics and presentation support, in helping the 9 finalists prepare for the Pitch Contest at the American Fisheries Society (AFS) virtual meeting. There were no subject inventions, patent applications, copyrights, and trademarks under this CRADA. The report herein provides an abstract of the presentation that the finalist presented at the American Fisheries Society virtual meeting in September 2020.

13 HYDRO ENERGY↗
DOE OSTI2021

Shielded and Low-Damping SPM Probes For Quantitative Electrical and Electrochemical Characterization (Phase IIB)

The purpose of this DOE SBIR award was to develop new scanning probe microscopy tools for the elucidation of electrical and electrochemical properties at the nanoscale. High performance probes are important for energy materials research. In both solar cells and batteries, the essential physics and chemistry occur at the nanoscale and nanoscale characterization tools are required for their elucidation. The introduced new models are a shielded probe and an electrically insulated probe where only less than one micron of a conductive tip is exposed. In Phases I and IIa, we explored the development of cost-effective methods to insulate cantilevers from aqueous solutions and patented a technology that provides an insulated electrical contact to the tip. Also, our technology was adapted to be compatible with all popular commercial AFM systems. In Phase IIb, we improved reproducibility and batch size to drive down costs while maintaining quality control with testing. We transformed our product into a convenient turnkey solution to make electrochemical characterization approachable to a wide range of researchers. In January 2021, the technology was well received by the AFM community and Nanosurf Inc. (Woburn, MA) acquired Scuba Probe Technologies. The technology and expertise of Scuba Probe Technologies complements Nanosurf’s development of the full range of nano-electrical characterization tools.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Scalable Nano-Scaffold SOFC Anode Architecture Enabling Direct Hydrocarbon Utilization

This project is based on WVU’s pending patents, technology and aims to design and modify the internal surfaces of the Ni/YSZ anode from currently commercially viable Solid Oxide Fuel Cells (SOFCs) using the additive manufacturing process of Atomic Layer Deposition (ALD). The surface architecture/scaffold added onto the internal surface of the anode possesses an engineered nanostructure but it features only commonly-used oxide conductors and electro-catalyst materials. The surface layer possesses a minimum thickness of ~2-40 nm and is solely designed to control the surface reforming reactions and to increase catalytic activity. Three-dimensional (3D) nano scaffold architectures with the noble metal nano-catalyst, low-cost bimetallic catalytic alloys, and nano-scale ionic conducting oxide fully compatible with the state-of-the-art Ni/YSZ anode, were applied to the internal surface of the entire porous SOFC anode using ALD. In the present work, the surface scaffold architecture is essentially multi-functional at the nano-scale, facilitated by the multiple heterostructured interfaces. It will significantly enhance the power density and cell durability for direct hydrocarbon utilization by (1) increasing the number of electrochemical reaction sites to enhance the hydrogen/hydrocarbon oxidation reactions; (2) reducing carbon formation; (3) mitigating the coarsening of backbone Ni phase and the oxidation attack of Ni from oxidants (e.g., H2O, CO2); and (4) promoting the internal reforming capabilities, especially for natural gas applications. ALD is employed to generate stable anode surface architectures that are uniform, precisely controllable at the atomic scale, and accurately repeatable for processing. The engineered anode surface nano-scaffold architecture was cataloged and analyzed using High-resolution Transmission Electron Microscopy (TEM), and cell power/durability performance assessed via comprehensive electrochemical performance testing with commercial specimens and relevant environments using hydrocarbon fuels. To the best of our knowledge, this project is the First Report on ALD of Ni/YSZ. The actual achievement of this Project includes (1). Successful demonstration of 7 types of ALD layers on Ni/YSZ anode, including Co, Ni, Mn, Pt, Ru, ZrOx and multi-functional nano-composite. (1). Conformal coating and subsequently spontaneously pinning the discrete nano-catalyst, including the precious metal nano-catalyst and the Ni and Co catalysts, on the YSZ surface upon the electrochemical operation in the reduced atmosphere. Those nano-catalysts on the ionic-conducting YSZ provided excellent sites for promoting internal reforming; (2). Demonstrated ALD coating increased both catalytic activity and conductivity of Ni/YSZ. Conformal coating provided dopants and introduced additional electrical conducting pathways on the YSZ ionic conductor. The doped surface layer of YSZ with mixed conductivity thus further introduces the active triple phase boundaries adjacent to the ALD-coated nano-catalysts such as Pt, Co, and Ni that are pinned on the YSZ surface. The nano-composite ALD coating on Ni/YSZ anode has significantly increased cell durability; and (3). ALD coating of Ni/YSZ anode increased the power density of the entire cell by 300%. For a long time, the SOFC performance, such as the power density, was deemed hindered by the cathode. The sluggish oxygen reduction reaction (ORR) in the cathode was deemed as hindering the power density of the SOFCs. For the anode-supported commercial SOFCs, the cell performance is considered to be limited by the cathode's performance. For the first time in the field of SOFC, this project has demonstrated that (1). the performance of commercial SOFCs can be further increased by the ALD coating on Ni/YSZ anode backbone. (2). ALD coating on Ni/YSZ fuel electrodes results in the enhancement of power density, and increased reliability, robustness, and endurance of SOFCs, for their application using both hydrogen and hydrocarbon fuels over the entire operating temperature range of 650-800ºC for the inherently functional commercial cells. (3). ALD coating provides alternative approaches of exsolutions for introducing the stable catalyst onto the internal surface of the Ni/YSZ electrode. ALD coating could be much more versatile than exsolution in employing the catalysts with various chemistries onto the various backbones. (4). Due to the negligible amount of ALD materials coated onto the internal surface of the porous cathode of the as-fabricated cells, a peak power density increase up to 300 % induced by ALD coating was simultaneously achieved in terms of both power density and specific power. (5). The ALD coating developed through this project was applied to both the SOFC and Solid Oxide Electrolysis Cells (SOEC). SOEC’s face a similar but more demanding need to improve the fuel electrode's performance. It opens further research directions for electrocatalytic surface nanoionics with a wide range of chemistry. It will revolutionize our ability to render the formation of a nanostructured electrode that has been constantly pursued yet barely achieved for practical SOFC/SOEC applications. The research is also immediately transformative since both the preliminary data and the proposed work are on the direct implantation of nanoionics into the state-of-the-art inherently functional SOCs. It represents an immediate impact on the commercial sectors in SOC technology since the applied ALD processing is computer-controlled ALD coating using the commercial ALD systems, and it is scalable to both the single cells and SOC stacks.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Cooperative Research and Development Agreement between National Energy Technology Laboratory and Birla Carbon U.S.A., Inc. [Final Report]

NETL researchers collaborated with Birla Carbon, U.S.A., to leverage NETL's patented catalyst work on methane decomposition to develop a cost-effective process for production of hydrogen and valuable carbon from natural gas. This process is cost-effective, energy efficient and environmentally friendly with minimal CO 2 mitigation costs. The objectives of the project include evaluation of effect of feed gas composition of natural gas on the performance, lowering the catalyst production cost and to conduct cost analysis for a process.

03 NATURAL GAS↗
DOE OSTI2022

Liquid Salt Combined-Cycle Pilot Plant Design

The work described in this report is responsive to the Office of Fossil Energy program ‘Energy Storage for Fossil Power Generation.’ This Phase I report has been prepared by Pintail Power LLC, with support from Nexant ECA, Electric Power Research Institute (EPRI) and Southern Company Services as a deliverable for the U.S. Department of Energy for NETL Award DE-FE-00320016. The Liquid Salt Combined Cycle™ (LSCC™) technology provides large-scale energy storage integrated with Fossil Electric Generating Units (FEGUs) to meet critical needs in the energy transition by providing: • the lowest cost large-scale storage for time-shifting of renewable energy, • superior fuel efficiency to reduce GHGs from dispatchable resources, • flexible capacity and ramping to balance variability of wind and solar resources, • essential grid stability services to assure reliability of a low-carbon grid. The LSCC approach: • employs equipment that has already been proven in utility service, • uses safe, non-toxic, non-degrading, perpetual-life storage medium, • leverages and repurposes existing FEGU assets, • expands the value stack of energy storage to reduce market, financing, and commodity risks. Pintail Power has developed the LSCC technology to meet the need for reliable, efficient, and cost-effective integration of Variable Renewable Energy (VRE) into a low-carbon electric grid by coupling proven thermal energy storage with proven gas turbines, steam turbines, and heat transfer equipment. This novel approach is intended to address the key issues facing the grid and operators of renewable and fossil generating units including: • Overgeneration and curtailment of renewables, • Need for fast ramping dispatchable resources, • Improved efficiency and flexibility of fossil units, • Additional peaking capacity to support electrification of transportation and heating, • Provision of reliability services to support high penetration of VRE, especially synchronous inertia and fast frequency response. A Technology Readiness assessment by EPRI confirmed that LSCC technology consists of commercially proven hardware used in industrial and utility applications. Although the novel LSCC approach has not yet been demonstrated as a complete system, interfaces between major components have been conservatively specified. A Phase III pilot is planned to demonstrate equipment integration and operation. The patented innovation is removal of the evaporator section from the exhaust heat recovery system, with the evaporation performed by stored energy in a separate steam generator. This arrangement couples renewable and fossil power generation via long-duration energy storage to deliver cost, performance, and operational synergies, including superior charging and discharging flexibility, reduced fuel consumption and lower CO 2 emissions compared to conventional Combined Cycle Power Plants, and low-cost, large-scale energy storage. The LSCC technology is composed of proven equipment integrated with gas turbine exhaust heat in a novel system. During charging, electric heaters raise the salt temperature as it flows from the Cold Salt Tank to the Hot Salt Tank. During discharging, hot salt produces steam from feedwater that is heated with gas turbine exhaust, which also superheats steam to drive a steam turbine. LSCC technology can be added to any combustion-turbine to integrate renewable energy, provide needed grid services, and increase the value of fossil electric generating units based on the technology’s following attributes: • Long-duration storage enables time-shifting of VRE to avoid curtailment and impairment of renewable assets. • Long storage duration combined with fast-charging capability increases arbitrage opportunities by storing more energy when the price is low and discharging more hours when the price is high. • Long storage duration allows resource adequacy to be supplied across multiple days to increase reliability and reduce risk. • The stored energy reduces fuel heat rate and GHG emissions, and increases merit, so the LSCC dispatches earlier and longer to increase the plant’s capacity factor and asset value. • The stored energy enables pre-heating and startup of the steam cycle, without operating the gas turbine, to enable fast startup and ramping when dispatched for discharge. • The steam turbine can operate without the gas turbine so it can provide valuable synchronous inertia during charging without consuming fuel. • Fast frequency response and regulation services can be provided during charging using solid-state heater and pump controls to vary the charge power input in response to grid signals. • The LSCC system can be configured for resilience including black start, islanded/micro-grid operation, and even self-recharging of storage using either gas turbine power or gas turbine exhaust heat. The commercialization plan is to add LSCC technology to existing simple cycle gas turbine power plants with the 50MW GE LM6000 aero-derivative gas turbine as the reference design basis. A Techno-economic assessment of the reference design evaluated the benefits (Levelized Avoided Cost of Energy) and costs (Levelized Cost of Energy). The plant definition included all major systems and budgetary vendor quotes. Pintail Power and NexantECA developed the overall cost estimate for the LSCC plant up to the total plant cost level, following the DOE-NETL cost estimate guidelines at AACE Class 3 (-20%/+30%). This includes the equipment cost, bulk material, direct and indirect labor costs to arrive at the bare erected cost. Engineering costs are factored from the BEC and added to it to arrive at the EPC cost. Process and project contingencies were then factored from the EPC cost and rolled-up to yield the total plant cost of $\$$184 million for 1746 MWh of discharge electricity. • At $\$$105/kWh, the reference plant costs less than any of the Energy Storage Systems evaluated by PNNL in 2020 for the Energy Storage Grand Challenge. Operations and Maintenance cost estimates were scaled from combined cycle practice, assuming that the LSCC unit was co-located with and sharing some labor expense with other units, to arrive at $\$$2.2 million per year. Plant economics were evaluated using prices from the ERCOT Day-Ahead Market for calendar year 2019 (excluding the market disruptions from the COVID pandemic and the February 2020 deep freeze event). Assuming economic dispatch in the ERCOT Day-Ahead market, the reference plant capacity factor would have discharged for 2777 hours at 91.9 MW, a 31.66% capacity factor, with a marginal cost of $\$$25.59/MWh, and a LACE of $\$$82.41/MWh. Fixed charges were calculated according to EIA guidelines to arrive at an LCOE of $\$$83.48. The benefit-to-cost ratio of 0.99 suggests that the reference plant would have been cost-effective and competitive in the market. EPRI interviewed selected utilities to gauge the need for, applicability of and interest in the LSCC system. Several utilities are currently managing increased load growth along with the inclusion of increasing levels of renewable generation, putting pressure on conventional generation by requiring increased turndown requirements and ultimately lower capacity factors. All of the utilities interviewed have CO 2 reduction targets in the 2030-2050 timeframe that will severely limit the participation of fossil generation and require better utilization of carbon free generation. While there is limited opportunity for storage in the current markets, the utilities interviewed stated that there will be a substantial need for long duration energy storage in the future given the expected trends. Utilizing an energy storage system will generally be preferred over new gas capacity in some cases, with the capabilities of the LSCC system being a potential option for retrofit to existing simple cycle gas turbine units, allowing them to deliver greater participation in the market with lower carbon intensity. A technology gap assessment and technology maturation plan identified a pilot-scale demonstration as the final step before commercialization. Key gaps to be addressed during the Phase II FEED (Front-End Engineering Design) are component selection and design, commissioning procedures, and operational procedures and the control system for LSCC charging and discharging. The project team has been expanded to include Wood Group PLC as EPC. The proposed Phase II work leads to a pilot-scale engineering demonstration (TRL 6) to be conducted at Southern Company’s Plant Rowan, where the prototype system will perform “all the functions that will be required of the operational system.” The proposed pilot will facilitate commercialization (TRL-9) by scale-up to utility-scale systems integrated with peaking GTs or directly to facility scale systems using industrial GTs. The conceptual design for the pilot plant focuses on the novel integration aspects of LSCC technology. A slipstream of gas turbine exhaust will feed a waste heat recovery unit coupled to a molten salt steam generator heated by stored energy. The pilot is intended to demonstrate all key operating modes of the LSCC technology during charging, discharging and standby. The pilot equipment will be approximately one-seventh scale of the LM6000 commercial target and is expected to have commercial off-ramp potential for facility-scale applications.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Minimizing Fraud in the Carbon Offset Market Using Blockchain Technologies

Fraud in the Environmental Benefit Credit (EBC) markets is pervasive. To make matters worse, the cost of creating EBCs is often higher than the market price. Consequently, a method to create, validate, and verify EBCs and their relevance is needed to mitigate fraud. The EBC market has focused on geologic (fossil fuel) CO 2 sequestration projects that are often over budget and behind schedule and has failed to capture the "lowest hanging fruit" EBCs - terrestrial sequestration via the agricultural industry. This project reviews a methodology to attain possibly the least costly EBCs by tracking the reduction of inputs required to grow crops. The use of bio- stimulant products, such as humate, allows a farmer to use less nitrogen without adversely affecting crop yield. Using less nitrogen qualifies for EBCs by reducing nitrous oxide emissions and nitrate runoff from a farmer's field. A blockchain that tracks the bio-stimulant material from source to application provides a link between a tangible (bio-stimulant commodity) and the associated intangible (EBCs) assets. Covert insertion of taggants in the bio-stimulant products creates a unique barcode that allows a product to be digitally tracked from beginning to end. This process (blockchain technology) is so robust, logical, and transparent that it will enhance the value of the associated EBCs by mitigating fraud. It provides a real time method for monetizing the benefits of the material. Substantial amounts of energy are required to produce, transport, and distribute agricultural inputs including fertilizer and water. Intelligent optimization of the use of agricultural inputs can drive meaningful cost savings. Tagging and verification of product application provides a valuable understanding of the dynamics in the water/food energy nexus, a major food security and sustainability issue. As technology in agriculture evolves so to must methods to verify the Enterprise Resource Planning (ERP) potential of innovative solutions. The technology reviewed provides the ability to combine blockchain and taggants ("taggant blockchains") as the engine by which to (1) mitigate fraudulent carbon credits; (2) improve food chain security, and (3) monitor and manage sustainability. The verification of product quality and application is a requirement to validate benefits. Recent upgrades to humic and fulvic quality protocols known as ISO CD 19822 TC134 offers an analytical procedure. This work has been assisted by the Humic Products Trade Association and International Humic Substance Society. In addition, providing proof of application of these products and verification of the correct application of prescriptive humic and bio-stimulant products is required. Individual sources of humate have unique and verifiable characteristics. Additionally, methods for prescription of site- specific agricultural inputs in agricultural fields are available. (See US Patents 734867B2, US 90658633B2.) Finally, a method to assure application rate is required through the use of taggants. Sensors using organic solid to liquid phase change nanoparticles of various types and melting temperatures added to the naturally occurring materials provide a barcode. Over 100 types of nanoparticles exist ensuring numerous possible barcodes to reduce industry fraud. Taggant materials can be collected from soil samples of plant material to validate a blockchain of humic, fulvic and other soil amendment products. Other non-organic materials are also available as taggants; however, the organic tags are biodegradable and safe in the environment allowing for use during differing application timeliness.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Take an unclassified peek inside the Lab’s classified library

Just think of these sample relics: A step-by-step manual on how to assemble a Fat Man atomic bomb. A patent application for the world’s first nuclear weapons. Laboratory notebooks of Nobel laureates. And much more. The collections at the National Security Research Center (NSRC) contain millions of historical materials and traces its origin to the Technical Library started by J. Robert Oppenheimer in 1943 as part of the Manhattan Project, which was the U.S. government’s top-secret effort to create the first atomic bombs. Since then, these collections have grown and are relied upon by today’s scientists, engineers, and researchers who support our national security mission. The NSRC is the Lab’s classified library that also houses unclassified legacy materials. In recognition of National Library Week (April 3 - 9), staff from the NSRC picked some of their favorite pieces of preserved Laboratory history.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2020

Grid-Scale, Long-Term Energy Storage: Repurposing Hydrocarbon Reservoirs, Resources, and Infrastructure to Store CO 2 and Heat (Mid-Project Progress Report)

The purpose of this project is to create a viable business case for CO 2 capture, use, and storage (CCUS) by enabling grid-scale, long-term energy storage in mature hydrocarbon reservoirs and saline aquifers. Our CCUS approach, called the Earth Battery, is based on patents issued to Lawrence Livermore National Laboratory on Multi-Fluid Geo-Energy and Earth Battery Systems and to the University of Minnesota and TerraCOH, Inc. on CO 2 Plume Geothermal (CPG). Excess energy can be used to compress and store CO 2 and hot brine underground in permeable formations, including: (1) saline aquifers suitable for geologic CO 2 storage (GCS) and (2) hydrocarbon reservoirs, the focus of this project featuring a pilot test in a mature oil and natural gas (NG) field. Excess energy can come in the form of excess electricity from the grid or excess NG that does not have a market. It can also come in the form of excess heat from other sources, such as from the heat of air or CO 2 compression or from a nearby base-load power plant or solar thermal energy (STE) facility, when heat is not needed to generate electricity from those sources.

15 GEOTHERMAL ENERGY↗
DOE OSTI2021

Robust Large-Scale Dynamic Windows using Reversible Metal Electrodeposition

This project funded the study and development of dynamic windows based on reversible metal electrodeposition (RME). Dynamic windows allow user control over light and heat flow into and out of buildings, which offer both advantages in building aesthetics (with worker productivity improvement of 2%) and energy efficiency (up to 20% savings) compared to static controls such as low emissivity coatings and blinds/shades. Despite these advantages, dynamic windows, which traditionally rely on electrochromic metal oxides or conductive organic molecules for light modulation have failed to significantly impact the market due to issues related to cost, color, and optical dynamic range. Dynamic windows based on reversible metal electrodeposition (RME) are an exciting alternative approach and have the potential to overcome the issues associated with traditional technologies. A RME dynamic window is an electrochemical cell that modulates light using the reversible electrodeposition of metal on and off a transparent conducting oxide (TCO), which serves as the working electrode. The electrolyte has nearly colorless metal salts dissolved, and application of a cathodic potential on the TCO reduces the metal cations across the TCO surface to their metallic form, making a thin film that is efficient at blocking out light. A reverse in polarity oxidizes the metal, where it dissolves into solution, returning the window back to transparent. The counter electrode typically employed is a metal mesh, which is used to balance the electrochemical reactions happening on the TCO working electrode. These RME dynamic windows have the largest dynamic range (capable of reaching <<0.1% transmission) with color neutral tinting of any existing technology using solution processed techniques, which positions the technology as a promising candidate to penetrate the residential market. We have successfully scaled up the windows from 25 cm2 to 929 cm 2 , and we have demonstrated significant improvements to both the cycle life (10,000 cycles in a 3-electrode half-cell) and shelf life (>1 month) of our windows. We have published our work in high impact journals (6 published and 2 manuscripts in prep), filed 5 patents, and have incorporated TYNT Technologies to commercialize the technology.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

A Novel Process for Converting Coal to High-Value Polyurethane Products

Battelle has demonstrated a patented process for making high-value, polyurethane (PU) foam from coal, based on preparing liquefied coal via direct liquefaction, converting it to polyols as an intermediate via ozonation, and then making PU foams from these polyols. This process represents a breakthrough in innovative utilization of U.S. coals, and is applicable to bituminous as well as sub-bituminous coals. The resulting PU foam products are projected to have an extremely high value (i.e., over $\$5,000$ /ton), with nearly 100% of carbon utilization from coalderived liquid feedstock, and 31.5% to 43.5% of the carbon in the PU foam polyol product being bio-based. The targeted products represent an extremely large (i.e., over $80 billion/year), existing PU foam market, which could expand into making coatings and adhesives. The process can further help reduce petroleum imports, while improving the economics of PU foam production. This work was completed with funding from the National Energy Technology Laboratory (NETL), with cost share from the State of Ohio’s Ohio Development Services Agency (ODSA) and others, and has advanced the process to 10 kg/day continuous scale and thus to Technology Readiness Level (TRL) 5. A total of 48 coal-based polyols were prepared and evaluated. The initial 28 polyols focused on range finding for ideal conditions. The later 20 polyols were produced as part of process optimizations. These optimizations were targeted around a continuous ozonolysis process to evaluate extended time reactions and to create the necessary intermediate for production of 1-gallon samples of polyol. The most unique attribute of Battelle’s polyol is in the utilization of coal’s aromaticity to gain final foam rigidity. Typically, polyols depend on the isocyanate fraction and cross-linking to gain rigidity. By utilizing coal, we were able to maintain rigidity while reducing the overall hydroxyl value of the polyol. This is important as lower hydroxyl value leads to greater percent weight of the coal-based polyol because less isocyanate is required for foaming. This leads to greater foam cost savings. This report provides the details, process, and process cost models of the conversion of coal to polyols and further to PU foams. Battelle’s process begins with coal liquids. These liquids can be obtained by two processes: coal coking or pyrolysis to produce coal tar, and Battelle’s biobased coal-to-liquids (CTL) process to produce heavy syncrude after liquifying >85% coal. After liquification, Battelle utilizes ozonolysis to create functionalization on the polyaromatic coal structure. The functionalization is then converted to the final polyester polyol through transesterification, or to hydroxyamide polyol through amidification. Equivalent or better standard properties have been obtained for 2 lb/ft 3 density rigid, water and freon-alternative blown foams, including compressive strength, density, R-value, and dimensional stability. Target applications for these foams are insulation, packaging, and energy-absorbing foams. Some exploratory testing also showed promise for adhesives applications. A detailed economic analysis showed that Battelle’s polyol process is economical, at a 140 metric tons per day (MTD) polyol production scale. An attractive return on investment (ROI) at competitive pricing validates the process is ready for a pilot-plant demonstration. A scale-up plan is provided.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Aluminization Coatings and Glass Seals for High Temperature System: CRADA 536 [Abstract Only]

The proposed work will demonstrate the suitability of PNNL Reactive Air Aluminization (RAA) coatings (US Patent Numbers 10,577,694, 10,378,094, and 9,481,923) for use in high-temperature systems. In particular, the Participant and Contractor will explore applicability of these coatings in Participant’s high-temperature hydrogen reactors where they would be used to prepare the sealing surfaces of the reactor technology. Utility Global will also instruct PNNL regarding their needs relating to the further development of glass seal technologies that are suitable for use in their systems. This effort will entail alkaline earth-based silicate glass development and characterization; evaluation and characterization of reliability and compatibility of the coatings with glass seals, working environments, and substrates; performance demonstrations of representative cells and intermediate cells sealed using the glass seals and/or coatings of interest; and incorporation of the aluminization coatings and glass seals into the reactor for full-scale testing.

08 HYDROGEN↗
DOE OSTI2022

Cooperative Research and Development Agreement between National Energy Technology Laboratory and OxEon Energy LLC (Abstract)

The National Energy Technology Laboratory (NETL) will collaborate with OxEon Energy LLC (OxEon) to apply NETL’s patented single step electrode infiltration technique on OxEon solid oxide fuel cells (SOFC) for Electric Vertical Takeoff and Landing (eVTOL) aircraft applications below one megawatt. The expanded application of the OxEon solid oxide cell technology on eVTOL aircraft seeks to demonstrate a high performance, durable SOFC system that will produce more electricity per weight based on possible operation on ammonia as fuel. NETL’s single-step electrode infiltration technique addresses these challenges by introducing a highly active nanocatalyst material into the SOFC electrode microstructure to improving cell performance, longevity, and fuel flexibility. Specifically for this project, OxEon will incorporate NETL’s technology to generate a small stack of cells (1 kW output) to demonstrate a fuel flexible system at a relevant scale. NETL will apply its infiltration technology to cells supplied by OxEon, test the effectiveness of the infiltration internally at NETL based on performance in hydrogen, and then supply infiltrated cells to OxEon and Pacific Northwest National Laboratory for independent confirmation and for the 1 kW stack test.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2022

Remote Area Modular Monitoring of Critical Facilities

The scope and pricipal objectives of the CRADA project is to (1) improve the design of patented Remote Area Modular Monitoring (RAMM) system, and (2) construct prototypes for testing and demonstration in nuclear facilities at Argonne National Laboratory and other DOE labs/sites.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

A MEMS Gyroscope for Reliable Long Duration Measurement While Drilling at 300°C

The 300°C Microelectromechanical system (MEMS) gyroscope project aims to contribute to DOE’s goal of increased geothermal drilling efficiency by 2025 through the development of a 300°C MEMS gyroscope for Measurement While Drilling (MWD). At the conclusion of the 2-year project, the team will develop a 300°C capable MEMS gyroscope containing GE’s patented Multi-Ring Gyroscope Transducer (MRGT) design, custom Silicon-On-Insulator (SOI) based frontend and feedback control electronics, and with demonstrated functionality and lifetime beyond 1000 hours. The project is divided into two budget periods with Go/No-Go decision at the end of the first budget period. The goal for the first budget period is to establish the feasibility of the MRGT and electronics design for meeting the 300°C performance requirements. The goal for the second budget period is to integrate the MRGT with the SOI-based application specific integrated circuit (ASIC) and demonstrate capability to operate at 300°C for 1000 hours. In Budget Period 1 we met the phase 1 goal. We successfully validated the combined MRG, electronics and packaging capability entitlement to achieving 0.5 degrees azimuth uncertainty while enabling operation at significantly higher temperatures than the state-of-the-art. In Budget Period 2, we successfully completed the integration of the MRGT and ASIC with associated high temperature, high reliability packaging to demonstrate the performance and functionality of the integrated gyroscope across the temperature range from room temperature to at 300°C. Furthermore, the team demonstrated operating life of >1,000 hours at 300°C, thus providing a validation of application-relevant lifetime capability.

15 GEOTHERMAL ENERGY↗
DOE OSTI2021

Amine-Appended Metal–Organic Frameworks as Switch-Like Adsorbents for Energy-Efficient Carbon Capture

The goal of this final project report is to comprehensively summarize the work conducted on project FP-00006194. In accordance with the Project Management Plan (PMP) revised May 2019, and Statement of Project Objectives (SOPO) within, Lawrence Berkeley National Laboratory (LBNL), with industrial partners such as Mosaic Materials, Svante, and Electricore, as well as CCSI 2 , has developed a cost-effective post-combustion CO 2 capture system using diamineappended metal–organic frameworks (MOFs). This project involved (i) synthesis and characterization of framework materials that exhibit a switch-like CO 2 adsorption behavior, (ii) scaling-up of MOF production, development of production cost models, and fabrication of materials, and (iii) deployment of materials in a patented VeloxoTherm process and characterization to optimize the material’s performance in the context of real process streams and conditions. During each of the four project budget periods, the project team met Success Criteria for Year 1 to 3; however, because of the decision to halt the project in Q1 2021, Success Criteria for Year 4 were not achieved.

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

Large Area Projection Sintering Technology Development (CRADA Final Report)

This CRADA was formed through support of the Innovation Crossroads program, which has been an invaluable experience for Ascend Manufacturing and our additive manufacturing technology. Without Innovation Crossroads, the research, capital and operational requirements to develop our company would have been too high and Ascend Manufacturing simply would not exist. Our patented and federally funded technology would have gone to waste. Through this CRADA, Ascend has been able to collaborate with the worlds experts in additive manufacturing to assist in developing our state of the art technology. This project assisted in developing a fully scalable 3D printing process, developed an industrial and pilot system design, assisted in the fabrication of a pilot system, allowing us to print components with materials impossible by any other 3D printing process. This work has allowed us to achieve significant follow-on funding to fully commercialize this highly capable manufacturing technology.

36 MATERIALS SCIENCE↗
DOE OSTI2022

CRADA Number NFE-19-07845 with American Nanotechnologies, Inc. (CRADA Final Report)

Cooperative Research and Development Agreement (CRADA) NFE-19-07845 between Oak Ridge National Laboratory (ORNL) and American Nanotechnologies, Inc. (ANI) focused on studying the use of dielectrophoresis as a mechanism to purify nanoparticles, particularly semiconducting carbon nanotubes (CNTs). The successful development of low-cost purification processes is a significant bottleneck in the adoption of semiconducting CNTs in commercial semiconducting devices. ANI is a startup company developing scalable systems for performing nanoparticle dielectrophoresis, which has previously been used only in microfluidic devices. The work done under this CRADA is exploring the use of ANI’s patent resonant dielectrophoresis (rDEP) technology and its ability to purify semiconducting CNTs at large scale. While continued work is on-going, r-DEP has proven to be a viable way to control nanoparticles in bulk dispersions. Optimization of the process is now underway to reach minimum viable product and begin material sales. Additionally, ANI and ORNL continue to collaborate on leveraging this technology to reach down the value chain and create new commercial devices.

77 NANOSCIENCE AND NANOTECHNOLOGY↗