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All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

WBS 4.1.2.31 Bioproduct Transition System Dynamics

Bioproducts are chemicals derived from a biomass feedstock; they can be produced on their own or as co-products of a biorefinery that also produces biofuels. Bioproducts have historically been difficult to scale up and bring to market, despite a broad understanding developed within BETO of the various conversion processes that can be used to produce bioproducts. Expanding the bioproducts industry by bringing more bioproducts to market would have a variety of positive impacts. Growth in the bioproducts industry would support the biofuels industry by enabling biorefinery co-products that yield additional revenue streams, allowing biofuel selling prices to be reduced and expanding the biofuels market. A larger bioproducts industry also has the potential to reduce carbon and other emissions associated with the U.S. chemical sector and contribute to increased price stability in some areas of the chemical market by shifting portions of the chemical sector away from reliance on fossil feedstocks. The key barrier to realizing these positive impacts is a lack of knowledge around the factors that prevent or enable bioproducts to reach the commercial market. To date, there has been essentially no research done on how successful bioproducts (commercially produced bioproducts that have captured market share) become successful, why failed bioproducts fail, and what the similarities and differences are between successful and failed bioproducts. The current project addresses this knowledge gap with a decision support tool that can be used by investors, technology developers and government agencies to bring more bioproducts to market, thereby simultaneously growing the bioproducts and biofuels industries. Development of the decision support tool was based on research on the technology development process and success rates in analogous industries, data gathered during previous BETO-funded projects, and a series of interviews with subject-matter experts within BETO, the bioproducts industry, and the investment community. This information formed a knowledge base around how bioproducts are developed from applied research to commercial scale was assembled, which was used to build the Bioproduct Transition Dynamics (BTD) model, a system dynamics (SD) model that tracks bioproduct development projects from applied research through the 'valley of death' of piloting and demoing to commercial scale production. The end-of-project goal is to release the BTD, along with supporting documentation, as a transparent open-source model that will inform decisions around bioproduct development and investments and enable more bioproducts to reach the market. The BTD takes as inputs techno-economic data on specific bioproducts, behavioral parameters for developers and investors, expectations around government support, and exogenous market factors. Model outputs include bioproduct technological progress over time, a cash flow statement for the development project, and market share estimates. Following initial model development, a sensitivity analysis was performed on a subset of model inputs to determine, first, if the BTD could be used to answer analysis questions of interest to BETO, and second, which of the inputs considered were most influential on bioproduct success. Results indicate that the BTD can be used to identify scenarios that enable bioproduct development, and that 'soft' or semi-quantitative factors play a large role in determining if a bioproduct will reach the market. A workshop was also held for subject-matter experts and prospective BTD users in July 2018. The workshop covered BTD model logic, input data and assumptions as well as the sensitivity analysis results and a discussion of potential use cases. Workshop feedback was used to identify additional model development tasks and was incorporated into a draft technical report completed in September 2018. BTD model development, validation and application will continue through 2019.

09 BIOMASS FUELS↗
DOE OSTI2026

High-Speed Layup and Forming of Automotive Composite Components

This Project is focused on the design and manufacture of automotive components that meet functional and environmental requirements of an existing automotive application at a cost of ≤ $\$$11.00 per kilogram weight reduction. This project fosters the development of composite material technologies suitable for high volume automotive processes and run rates as well as industry workforce development with these technologies. Current automotive manufacturing involves utilizing steel or aluminum in sheet form which is rapidly stamped into components at rates up to 3600 per hour. The metallic sheets are available in many different thicknesses, strength levels, and manufacturing rates are reasonable independent of part size. While composite materials are available for use in automotive applications, the material cost, labor to manufacture and the processing of the waste far exceed the cost compared to metallic designs. Typical composite layer by layer layup procedures don’t meet the desired 60 second layup time that current automotive processes require and are also restricted by part size. Due to these factors, composites have not yet made advances into today’s high volume automotive applications. Industry partners DURA, BASF, Ford, and IACMI core innovation partner MSU collaborated to develop a manufacturing process technology that is capable of manufacturing composite blanks at high volume and independent of part size. IACMI core innovation partner Purdue provided FEA analysis and cost modelling. The objective of this project was to demonstrate a composite sheet layup and consolidation process that can be commercialized for high volume requirements, identify potential layup equipment suppliers, and develop a process of 60 second layup, forming, and trimming of a continuous fiber automotive component for the mainstream market.

42 ENGINEERING↗
DOE OSTI2019

Probing the active fraction of soil microbiomes using BONCAT-FACS

The ability to link soil microbial diversity to soil processes requires technologies that differentiate active microbes from extracellular DNA and dormant cells. Here, we use BONCAT (bioorthogonal non-canonical amino acid tagging) to measure translationally active cells in soils. We compare the active population of two soil depths from Oak Ridge (Tennessee, USA) and find that a maximum of 25-70% of the extractable cells are active. Analysis of 16S rRNA sequences from BONCAT-positive cells recovered by fluorescence-activated cell sorting (FACS) reveals that the phylogenetic composition of the active fraction is distinct from the total population of extractable cells. Some members of the community are found to be active at both depths independently of their abundance rank, suggesting that the incubation conditions favor the activity of similar organisms. We conclude that BONCAT-FACS is effective for interrogating the active fraction of soil microbiomes in situ and provides a new approach for uncovering the links between soil processes and specific microbial groups.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2017

Virginia Offshore Wind Technology Advancement Project (VOWTAP) DOE EE0005985 Final Technical Report Rev 1a

The primary purpose of the VOWTAP was to advance the offshore wind industry in the United States (U.S.) by demonstrating innovative technologies and process solutions that would establish offshore wind as a cost-effective renewable energy resource. The VOWTAP Team proposed to design, construct, and operate a 12 megawatt (MW) offshore wind facility located approximately 27 statute miles (mi) (24 nautical miles [nm], 43 kilometers [km]) off the coast of Virginia. The proposed Project would consist of two Alstom Haliade™ 150-6 MW turbines mounted on inward battered guide structures (IBGS), a 34.5-kilovolt (kV) alternating current (AC) submarine cable interconnecting the WTGs (inter-array cable), a 34.5-kV AC submarine transmission cable (export cable), and a 34.5 kV underground cable (onshore interconnection cable) that would connect the Project with existing Dominion infrastructure located in Virginia Beach, Virginia (Figure 1). Interconnection with the existing Dominion infrastructure would also require an onshore switch cabinet, a fiber optic cable, and new interconnection station to be located entirely within the boundaries of the Camp Pendleton State Military Reservation (Camp Pendleton). The VOWTAP balanced technology innovation with commercial readiness such that turbine operations were anticipated to commence by 2018. Dominion, as the leaseholder of the Virginia Wind Energy Area (WEA), anticipated leveraging lessons learned through the VOWTAP, and applying them to future commercial-scale offshore wind development.

17 WIND ENERGY↗
DOE OSTI2016

LAWPS Technology Maturation Program and Scaled Testing - 16589

The Technology Maturation Program for the Low-Activity Waste Pre-Treatment System (LAWPS) had been developed utilizing the guidance of DOE-Order 413.3B for Technology Readiness and Technology Maturation. The technology maturation plan (TMP) for LAWPS established principal technology elements (TEs) for the proposed process, designated critical technology elements (CTEs), and identified the necessary activities to mature the technologies for successful deployment of the LAWPS System. The TMP is being utilized to guide the CTEs advancement to Technical Readiness Level (TRL) 6 for the combined Critical Decision 2 and 3 Milestones (CD-2/3) in the 413.3B process. The development of the TMP, the multi-scale testing program, culminating in the integrated scale testing as a predecessor to achieve TRL 6 are presented. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRSDate not supplied

Digital Prototyping Methods to Enable Product Development Analysis Cycle Compression in Aerospace Systems

Historically, the product development life cycle (spanning from origination of a systems concept to initial delivery or fielding) for large-scale aerospace systems is 10-25 years. Examples of recent programs exhibiting this timeline are the Space Shuttle (13 years), , International Space Station (18 years), NASA Hubble telescope (16 years), USAF F-35 Strike Fighter (22 years), Missile Defense Agency THAAD (21 years), USAF V-22 Osprey (26 years), USAF B-2 Spirt (19 years), US Army RAH-66 Comanche (22 years, cancelled prior to fielding), James Webb Space Telescope (25 years), Space Launch System (10 years). This list illustrates the challenges of developing and fielding a modern integrated multi-disciplinary aerospace system. These development timelines are often preceded by significant research and development programs and followed by multiple increments, blocks, or spirals to reach planned operational capability. In the modern era of aerospace system acquisition, there is significant pressure to reduce system development timelines to meet system objectives and enable competitiveness in the current industry and landscape. Across the aerospace industry, a range of rapid acquisition and prototyping programs are seeking to achieve system development within timelines considerably less than 10 years. Notably, in September of 2019, NASA issued a solicitation for the development and demonstration of a Human Landing System (HLS) to deliver humans to the lunar surface by 2024 (5 years) and for the development and demonstration of a more sustainable HLS by 2026 (7 years). Lengthy product development cycle timelines are a product of multiple factors ranging from programmatic, sociological, technical, and systems engineering issues. New approaches in systems engineering provide new ways to enable these compressed development timelines. These approaches employ expanded application of advanced systems engineering methods and cross-cutting digital tools to accelerate system development, utilizing digital prototyping to connect maturing sub-system or component technologies into system or system-of-systems hardware prototypes. Approaches such as the use of system integrating physics relationships to reduce the number of design analysis cycle iterations and state analysis modeling to reduce necessary software testing (and improving coverage of system execution scenarios) represent steps forward in reducing the engineering time needed to field new systems. In addition to cost, schedule and performance benefits, expanded digital exploration and demonstration reduce risk in live system test and demonstration. This incremental demonstration approach, where digital prototyping and demonstration leads and informs full system test and demonstration, could be more important for space applications because of the increased difficulty of test and demonstration of space systems and architectures. The Advanced Concepts Office (ACO) at Marshall Space Flight Center merges traditional multi-disciplinary concept definition methods with modern, cross-cutting systems engineering concepts to enable iterative design and analysis of space architectures and systems through coordinated, strategic management of human capital, technical processes, and technology. This paper provides an overview of that approach, including recent examples and a strategic path forward to enabling continued reduction of aerospace system product development life cycles.

Michael D Watson↗
DOE OSTI2021

Identification of opportunities for integrating chemical processes for carbon (dioxide) utilization to nuclear power plants

The energy and industrial sectors are responsible for more than 75% of global carbon dioxide emissions, which are primary contributors to climate change. Decarbonization strategies to reduce overall carbon dioxide emissions are urgently needed. Among the numerous decarbonization strategies that are being defined and implemented, a particular strategy of interest for the present work is “the Re-X or zero waste” strategy, which involves recycling, reuse, repurposing, and remanufacturing of industrial emissions, by-products, and waste in general. A circular value chain or Circular Economy is embedded within this strategy. In a circular carbon economy, efficient reuse of emitted carbon dioxide is considered. However, the stability of carbon dioxide implies the requirement of significant amounts of energy for its transformation into value-added chemicals or products, which must be supplied by low carbon emitting energy sources. Nuclear power plants are low carbon energy sources that, additionally to electricity, could also supply heat and radiation for chemical transformations. This work identifies the opportunities and challenges for the development of integrated energy systems to upgrade and transform carbon dioxide, involving chemical and nuclear energy. The analysis encompasses possible use of the different forms of energy that can be obtain from nuclear reactors (i.e., radiation, electricity, and heat), by reviewing the published literature on potential routes for its conversion. Overall, our review indicates that an universal technology of the one-fits-all solution-type is an utopic dream. Instead, a suite of (contaminants tolerant) technologies for processing various concentrations CO 2 and producing a variety of products is currently needed.

08 HYDROGEN↗
DOE OSTI2017

One Step Hydrogen Generation Through Sorption Enhanced Reforming

One-step hydrogen generation, using Sorption Enhanced Reforming (SER) technology, is an innovative means of providing critical energy and environmental improvements to US manufacturing processes. The Gas Technology Institute (GTI) is developing a Compact Hydrogen Generator (CHG) process, based on SER technology, which successfully integrates previously independent process steps, achieves superior energy efficiency by lowering reaction temperatures, and provides pathways to doubling energy productivity with less environmental pollution. GTI’s prior CHG process development efforts have culminated in an operational pilot plant. During the initial pilot testing, GTI identified two operating risks- 1) catalyst coating with calcium aluminate compounds, 2) limited solids handling of the sorbent. Under this contract GTI evaluated alternative materials (one catalyst and two sorbents) to mitigate both risks. The alternate catalyst met performance targets and did not experience coating with calcium aluminate compounds of any kind. The alternate sorbent materials demonstrated viable operation, with one material enabling a three-fold increase in sorbent flow. The testing also demonstrated operation at 90% of its rated capacity. Lastly, a carbon dioxide co-production study was performed to assess the advantage of the solid phase separation of carbon dioxide- inherent in the CHG process. Approximately 70% lower capital cost is achievable compared to SMR-based hydrogen production with CO2 capture, as well as improved operating costs.

08 HYDROGEN↗
NASA NTRS2001

Deep Space 1 Ion Engine Completed a 3-Year Journey

A xenon ion engine and power processor system, which was developed by the NASA Glenn Research Center in partnership with the Jet Propulsion Laboratory and Boeing Electron Dynamic Devices, completed nearly 3 years of operation aboard the Deep Space 1 spacecraft. The 2.3-kW ion engine, which provided primary propulsion and two-axis attitude control, thrusted for more than 16,000 hr and consumed more than 70 kg of xenon propellant. The Deep Space 1 spacecraft was launched on October 24, 1998, to validate 12 futuristic technologies, including the ion-propulsion system. After the technology validation process was successfully completed, the Deep Space 1 spacecraft flew by the small asteroid Braille on July 29, 1999. The final objective of this mission was to encounter the active comet Borrelly, which is about 6 miles long. The ion engine was on a thrusting schedule to navigate the Deep Space 1 spacecraft to within 1400 miles of the comet. Since the hydrazine used for spacecraft attitude control was in short supply, the ion engine also provided two-axis attitude control to conserve the hydrazine supply for the Borrelly encounter. The comet encounter took place on September 22, 2001. Dr. Marc Rayman, project manager of Deep Space 1 at the Jet Propulsion Laboratory said, "Deep Space 1 plunged into the heart of the comet Borrelly and has lived to tell every detail of its spinetingling adventure! The images are even better than the impressive images of comet Halley taken by Europe's Giotto spacecraft in 1986." The Deep Space 1 mission, which successfully tested the 12 high-risk, advanced technologies and captured the best images ever taken of a comet, was voluntarily terminated on December 18, 2001. The successful demonstration of the 2-kW-class ion propulsion system technology is now providing mission planners with off-the-shelf flight hardware. Higher power, next generation ion propulsion systems are being developed for large flagship missions, such as outer planet explorers and sample-return missions.

Sovey, James S.↗
DOE OSTI2023

High-bandwidth density silicon photonic resonators for energy-efficient optical interconnects

The growth of artificial intelligence applications demands ever larger and more complex deep learning models, dominating today's—and tomorrow's—data center and high-performance computing systems. While traditional electronics are failing to keep pace with application demands, silicon photonic (SiPh) interconnects have emerged as a necessary technology to support these systems. SiPh-driven wavelength-division multiplexing (WDM) offers a particularly promising path toward supporting incredibly high-aggregate link bandwidth in a compact and efficient form factor. One of the basic building blocks of these integrated WDM interconnects is the SiPh resonator. Their inherent wavelength selectivity and compact footprint allow for efficient data transmission multiplexed across dozens of carrier wavelengths. Used as add-drop (AD) filters, SiPh resonators are critical to constructing integrated tunable wavelength-selective optical circuit switches as well as for demultiplexing the different carrier wavelengths toward independent wavelength-insensitive photodiodes in a dense wavelength-division multiplexing receiver. Resonators in the all-pass (AP) configuration are widespread as well, allowing for wavelength-selective modulation to drive aggregate link bandwidths far beyond the individual channel data rate. Unlike SiPh Mach–Zehnder modulators (MZM), resonant modulators can be driven using low, complementary metal-oxide-semiconductor drive voltages, allowing for tight co-integration between photonic integrated circuits, fabricated with larger process node technologies, and electronic integrated circuits, designed to exploit the advantages of the latest node. To push toward practical peta-scale interconnects, a comprehensive review of SiPh resonators is required, addressing bottlenecks and design constraints at both the architecture and device levels. We first describe the predominant integrated link architectures and identify their limits. We then discuss the device-level design considerations that can be made for both AD and AP configuration resonators to overcome the system level limits with novel resonator device designs. Analytical models and numerical simulation of resonators are validated by experimental measurement of devices fabricated in a commercial 300-mm foundry, showing a clear path toward volume manufacturing. The demonstrated resonant modulators and filters support the feasibility of increasing the aggregate bandwidth of resonator-driven SiPh interconnects into the peta-scale regime.

42 ENGINEERING↗
DOE OSTI2015

Precision fabrication of large area silicon-based geometrically enhanced x-ray photocathodes using plasma etching

Geometrically enhanced photocathodes are currently being developed for use in applications that seek to improve detector efficiency in the visible to X-ray ranges. Various photocathode surface geometries are typically chosen based on the detector operational wavelength region, along with requirements such as spatial resolution, temporal resolution and dynamic range. Recently, a structure has been identified for possible use in the X-ray region. This anisotropic high aspect ratio structure has been produced in silicon using inductively coupled plasma (ICP) etching technology. The process is specifically developed with respect to the pattern density and geometry of the photocathode chip to achieve the desired sidewall profile angle. The tapered sidewall profile angle precision has been demonstrated to be within ± 2.5° for a ~ 12° wall angle, with feature sizes that range between 4-9 μm in diameter and 10-25 μm depth. Here we discuss the device applications, design and present the method used to produce a set of geometrically enhanced high yield X-ray photocathodes in silicon.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2018

Contactless steam generation and superheating under one sun illumination

Steam generation using solar energy provides the basis for many sustainable desalination, sanitization, and process heating technologies. Recently, interest has arisen for low-cost floating structures that absorb solar radiation and transfer energy to water via thermal conduction, driving evaporation. However, contact between water and the structure leads to fouling and pins the vapour temperature near the boiling point. Here we demonstrate solar-driven evaporation using a structure not in contact with water. The structure absorbs solar radiation and re-radiates infrared photons, which are directly absorbed by the water within a sub-100 μm penetration depth. Due to the physical separation from the water, fouling is entirely avoided. Due to the thermal separation, the structure is no longer pinned at the boiling point, and is used to superheat the generated steam. We generate steam with temperatures up to 133 °C, demonstrating superheated steam in a non-pressurized system under one sun illumination.

14 SOLAR ENERGY↗
DOE OSTI2024

A structural equation modeling approach to leveraging the power of extant sentiment analysis tools

Machine-derived sentiment analysis has become a pervasive and useful tool to address a wide array of issues in natural language processing. Leading technology companies such as Google now provide sentiment analysis tools (SATs) as readily accessible online products. Academic researchers develop and make available SATs to support the research enterprise. One of the major challenges with SATs is the inconsistencies in results among the various SATs. Consequently, the selection of a SAT for a specific purpose may significantly impact the application. This study addresses the foregoing problem by utilizing structural equation modeling to merge the outputs of SATs to develop a combined sentiment metric without the need for a labeled training dataset. This method is applicable to a wide range of text-based problems, is data-driven, and replicable. It was tested using three publicly available datasets and compared against seven different SATs. The results indicate that as a continous measure, the proposed method outperformed other SATs in the movie reviews and SemEval datasets, and achieved a tie for first place with IBM Watson on the Sentiment 140 dataset. Also, compared to the published major alternatives, the arithmetic mean solution, this approach performed better across these three datasets.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Harvesting electrons and holes from photodriven symmetry-breaking charge separation within a perylenediimide photosynthetic model dimer

Understanding how to utilize symmetry-breaking charge separation (SB-CS) offers a path toward increasingly efficient light-harvesting technologies. This process plays a central role in the first step of photosynthesis, in which the dimeric “special pair” of the photosynthetic reaction center enters a coherent SB-CS state after photoexcitation. Previous research on SB-CS in both biological and synthetic chromophore dimers has focused on increasing the efficiency of light-driven processes. In a chromophore dimer undergoing SB-CS, the energy of the radical ion pair product is nearly isoenergetic with that of the lowest excited singlet (S 1 ) state of the dimer. This means that very little energy is lost from the absorbed photon. In principle, the relatively high energy electron and hole generated by SB-CS within the chromophore dimer can each be transferred to adjacent charge acceptors to extend the lifetime of the electron–hole pair, which can increase the efficiency of solar energy conversion. To investigate this possibility, we have designed a bis-perylenediimide cyclophane (mPDI 2 ) covalently linked to a secondary electron donor, peri-xanthenoxanthene (PXX) and a secondary electron acceptor, partially fluorinated naphthalenediimide (FNDI). Upon selective photoexcitation of mPDI 2 , transient absorption spectroscopy shows that mPDI 2 undergoes SB-CS, followed by two secondary charge transfer reactions to generate a PXX •+ -mPDI 2 -FNDI •– radical ion pair having a nearly 3 µs lifetime. In conclusion, this strategy has the potential to increase the efficiency of molecular systems for artificial photosynthesis and photovoltaics.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2011

Exploring the limits of cooperative phenomena using complex plasmas

With the advancing miniaturization of technological applications, processes on the mesoscale become increasingly important. This is the scale where the individual movement of particles transforms into cooperative behavior-behavior that cannot be explained by investigating the motion of individual particles alone.Complex plasmas are ideally suited to study the limits of cooperative behavior. The time scales of the dynamics of the microparticles embedded in the plasma are such that their movement can be fully resolved, and an investigation on the atomistic (kinetic) level is possible. In addition, complex plasmas can be considered a model system for ordinary fluids: The internal microparticle dynamics is basically undamped and is characterized by the similarity parameters matching those of other fluids. This similarity does not break down even at small scales: For instance, in [2], microparticle droplets comprised of only a few 1000-10000 particles were examined. In these experiments, the Weber number (the ratio of inertia to surface tension forces) matches that of falling water drops. As another example, the onset of a Rayleigh-Taylor instability in a complex plasma can be described by the ordinary dispersion relation, even at scales of only few particle layers. This allows investigating the 'nanoscale' of fluid flows, and, hence, the limits of cooperative behavior.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2018

Study of Oak Ridge soils using BONCAT-FACS-Seq reveals that a large fraction of the soil microbiome is active

The ability to link soil microbial diversity to soil processes requires technologies that differentiate active subpopulations of microbes from so-called relic DNA and dormant cells. Measures of microbial activity based on various techniques including DNA labelling have suggested that most cells in soils are inactive, a fact that has been difficult to reconcile with observed high levels of bulk soil activities. We hypothesized that measures of in situ DNA synthesis may be missing the soil microbes that are metabolically active but not replicating, and we therefore applied BONCAT (Bioorthogonal Non Canonical Amino Acid Tagging) i.e. a proxy for activity that does not rely on cell division, to measure translationally active cells in soils. We compared the active population of two soil depths from Oak Ridge (TN) incubated under the same conditions for up to seven days. Depending on the soil, a maximum of 25 – 70% of the cells were active, accounting for 3-4 million cells per gram of soil type, which is an order of magnitude higher than previous estimates. The BONCAT positive cell fraction was recovered by fluorescence activated cell sorting (FACS) and identified by 16S rDNA amplicon sequencing. The diversity of the active fraction was a selected subset of the bulk soil community. Excitingly, some of the same members of the community were recruited at both depths independently from their abundance rank. On average, 86% of sequence reads recovered from the active community shared >97% sequence similarity with cultured isolates from the field site. Our observations are in line with a recent report that, of the few taxa that are both abundant and ubiquitous in soil, 45% are also cultured – and indeed some of these ubiquitous microorganisms were found to be translationally active. The use of BONCAT on soil microbiomes provides evidence that a large portion of the soil microbes can be active simultaneously. We conclude that BONCAT coupled to FACS and sequencing is effective for interrogating the active fraction of soil microbiomes in situ and provides new perspectives to link metabolic capacity to overall soil ecological traits and processes.

58 GEOSCIENCES↗
DOE OSTI2015

Hydrogen Selective Exfoliated Zeolite Membranes

The objective of this project was to develop and evaluate an innovative membrane technology at process conditions that would be representative of Integrated Gasification Combined Cycle (IGCC) advanced power generation with pre-combustion capture of carbon dioxide (CO 2 ). This research focused on hydrogen (H 2 )-selective zeolite membranes that could be utilized to separate conditioned syngas into H 2 -rich and CO 2 -rich components. Both experiments and process design and optimization calculations were performed to evaluate the concept of ultra-thin membranes made from zeolites nanosheets. In this work, efforts in the laboratory were made to tackle two fundamental challenges in application of zeolite membranes in harsh industrial environments, namely, membrane thickness and membrane stability. Conventional zeolite membranes have thicknesses in the micron range, limiting their performance. In this research, we developed a method for fabrication of ultimately thin zeolite membranes based on zeolite nanosheets. A range of layered zeolites (MWW, RWR, NSI structure types) suitable for hydrogen separation was successfully exfoliated to their constituent nanosheets. Further, membranes were made from one of these zeolites, MWW, to demonstrate the potential of this group of materials. Moreover, long-term steam stability of these zeolites (up to 6 months) was investigated in high concentrations of steam (35 mol% and 95 mole%), high pressure (10 barg), and high temperatures (350 °C and 600 °C) relevant to conditions of water-gas-shift and steam methane reforming reactions. It was found that certain nanosheets are stable, and that stability depends on the concentration of structural defects. Additionally, models that represent a water-gas-shift (WGS) membrane reactor equipped with the zeolite membrane were developed for systems studies. These studies had the aim of analyzing the effect of the membrane reactor integration into IGCC plants in terms of performance and economic aspects of the plants. Specifically, simulation and design optimization studies were performed using the developed stand-alone membrane reactor models to identify the membrane selectivity and permeance characteristics necessary to achieve desired targets of CO 2 capture and H 2 recovery, as well as guide the selection of the optimal reactor design that minimizes the membrane cost as a function of its surface area required. The isothermal membrane reactor model was also integrated into IGCC system models using both the MATLAB and Aspen software platforms and techno-economic analyses of the integrated plants have been carried out to evaluate the feasibility of replacing current technologies for pre-combustion capture by the proposed novel approach in terms of satisfying stream constraints and achieving the DOE target goal of 90% CO 2 capture. The results of the performed analyses based on present value of annuity calculations showed break even costs for the membrane reactor within the feasible range for membrane fabrication. However, the predicted membrane performance used in these simulations exceeded the performance achieved experimentally. Therefore, further work is required to improve membrane performance.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2013

Development of ITM Oxygen Technology for Integration in IGCC and Other Advanced Power Generation DECISION POINT 1 UNDER PHASE 3

Air Products and the DOE have partnered over a number of years in the development of ITM Oxygen technology in support of gasification technology. Throughout this process, studies of application of the technology to IGCC and oxy-coal combustion have shown significant reduction in capital and operating costs compared to similar systems using conventional cryogenic air separation. Phase 3, the current phase of the program, focuses on the design, construction and operation of a 30- to 100-TPD pilot facility, the Intermediate Scale Test Unit (ISTU). Execution of this phase to date has resulted in significant advances in a number of areas including ceramic membrane material development, module design and production, ceramic-to-metal seal design, process control strategies, and engineering development of process cycles. Phase 3 will be complete upon successful operation of the ISTU in a series of tests making oxygen from ceramic membrane modules and producing power from a hot gas expander. Phase 3 work has extended beyond the planned schedule due to a delay in delivery of equipment from vendors. Air Products is currently managing the equipment delay by close involvement with the vendor to redesign the problematic equipment and oversee its fabrication. The result of these unforeseen challenges is that the ISTU project completion date has been delayed. Tight cost controls have been implemented both by DOE program management and APCI to meet budget constraints despite increased costs due to budget delays. Total project costs have increased in several areas. Increased costs in the ISTU project include purchased equipment, instruments, construction, and contractor engineering. Increased costs for other tasks include additional work in support of module production by Ceramatec, Inc, and increased Air Products labor for component testing. Air Products plans to complete testing as outlined in the SOPO and successfully complete all project objectives by the end of FY14.

Anderson, Lori↗