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DOE OSTI2011

Sustainability Assessment of Coal-Fired Power Plants with Carbon Capture and Storage

Carbon capture and sequestration (CCS) has the ability to dramatically reduce carbon dioxide (CO2) emissions from power production. Most studies find the potential for 70 to 80 percent reductions in CO2 emissions on a life-cycle basis, depending on the technology. Because of this potential, utilities and policymakers are considering the wide-spread implementation of CCS technology on new and existing coal plants to dramatically curb greenhouse gas (GHG) emissions from the power generation sector. However, the implementation of CCS systems will have many other social, economic, and environmental impacts beyond curbing GHG emissions that must be considered to achieve sustainable energy generation. For example, emissions of nitrogen oxides (NOx), sulfur oxides (SOx), and particulate matter (PM) are also important environmental concerns for coal-fired power plants. For example, several studies have shown that eutrophication is expected to double and acidification would increase due to increases in NOx emissions for a coal plant with CCS provided by monoethanolamine (MEA) scrubbing. Potential for human health risks is also expected to increase due to increased heavy metals in water from increased coal mining and MEA hazardous waste, although there is currently not enough information to relate this potential to actual realized health impacts. In addition to environmental and human health impacts, supply chain impacts and other social, economic, or strategic impacts will be important to consider. A thorough review of the literature for life-cycle analyses of power generation processes using CCS technology via the MEA absorption process, and other energy generation technologies as applicable, yielded large variability in methods and core metrics. Nonetheless, a few key areas of impact for CCS were developed from the studies that we reviewed. These are: the impact of MEA generation on increased eutrophication and acidification from ammonia emissions and increased toxicity from MEA production and the impact of increased coal use including the increased generation of NOx from combustion and transportation, impacts of increased mining of coal and limestone, and the disposal of toxic fly ash and boiler ash waste streams. Overall, the implementing CCS technology could contribute to a dramatic decrease in global GHG emissions, while most other environmental and human health impact categories increase only slightly on a global scale. However, the impacts on human toxicity and ecotoxicity have not been studied as extensively and could have more severe impacts on a regional or local scale. More research is needed to draw strong conclusions with respect to the specific relative impact of different CCS technologies. Specifically, a more robust data set that disaggregates data in terms of component processes and treats a more comprehensive set of environmental impacts categories from a life-cycle perspective is needed. In addition, the current LCA framework lacks the required temporal and spatial scales to determine the risk of environmental impact from carbon sequestration. Appropriate factors to use when assessing the risk of water acidification (groundwater/oceans/aquifers depending on sequestration site), risk of increased human toxicity impact from large accidental releases from pipeline or wells, and the legal and public policy risk associated with licensing CO2 sequestration sites are also not currently addressed. In addition to identifying potential environmental, social, or risk-related issues that could impede the large-scale deployment of CCS, performing LCA-based studies on energy generation technologies can suggest places to focus our efforts to achieve technically feasible, economically viable, and environmentally conscious energy generation technologies for maximum impact.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2014

Recycling of non-metallic fractions from waste electrical and electronic equipment (WEEE): A review

Highlights: • NMFs from WEEE were treated by incineration or land filling in the past. • Environmental risks such as heavy metals and BFRs will be the major problems during the NMFs recycling processes. • Methods and technologies of recycling the two types of NMFs from WEEE, plastics, glasses are reviewed. • More environmental impact assessment should be carried out to evaluate the environmental risks of the recycling products. - Abstract: The world’s waste electrical and electronic equipment (WEEE) consumption has increased incredibly in recent decades, which have drawn much attention from the public. However, the major economic driving force for recycling of WEEE is the value of the metallic fractions (MFs). The non-metallic fractions (NMFs), which take up a large proportion of E-wastes, were treated by incineration or landfill in the past. NMFs from WEEE contain heavy metals, brominated flame retardant (BFRs) and other toxic and hazardous substances. Combustion as well as landfill may cause serious environmental problems. Therefore, research on resource reutilization and safe disposal of the NMFs from WEEE has a great significance from the viewpoint of environmental protection. Among the enormous variety of NMFs from WEEE, some of them are quite easy to recycle while others are difficult, such as plastics, glass and NMFs from waste printed circuit boards (WPCBs). In this paper, we mainly focus on the intractable NMFs from WEEE. Methods and technologies of recycling the two types of NMFs from WEEE, plastics, glass are reviewed in this paper. For WEEE plastics, the pyrolysis technology has the lowest energy consumption and the pyrolysis oil could be obtained, but the containing of BFRs makes the pyrolysis recycling process problematic. Supercritical fluids (SCF) and gasification technology have a potentially smaller environmental impact than pyrolysis process, but the energy consumption is higher. With regard to WEEE glass, lead removing is requisite before the reutilization of the cathode ray tube (CRT) funnel glass, and the recycling of liquid crystal display (LCD) glass is economically viable for the containing of precious metals (indium and tin). However, the environmental assessment of the recycling process is essential and important before the industrialized production stage. For example, noise and dust should be evaluated during the glass cutting process. This study could contribute significantly to understanding the recycling methods of NMFs from WEEE and serve as guidance for the future technology research and development.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS2026

Electromagnetic Melt Processing: A Pathway to New Additive Manufacturing Technologies for Functional High-Performance Thermoplastics

In this study, we apply the electromagnetic (EM) melt processing of thermoplastics on an innovative EM field-driven powder bed fusion additive manufacturing (AM) concept for high-performance functional parts: Selective Microwave Melting/Sintering (SMM/SMS). This technique leverages the EM susceptibility of carbon nanotube-coated polymer micro-pellets to achieve rapid, localized heating and powder fusion. Thus, selective microwave melting (SMM) was used to fabricate multilayer specimens made of recycled polyphenylene sulfide (rPPS) and carbon nanotubes (CNTs). The resulting SMM specimens exhibited very good interlayer integrity, localized fusion at pellet boundaries, and tolerable residual porosity, indicating effective fusion and acceptable consolidation. CNT-rich interphases were retained after irradiation, generating anisotropic electrically active network pathways and enabling conductivity enhancement at low filler content. At only 1.0 wt% CNT, the specimens exhibited electrical conductivity approximately three orders of magnitude higher than neat rPPS. Dynamic mechanical analysis showed improved viscoelastic response relative to neat rPPS, while tensile testing confirmed that the SMM-processed specimens retained practical mechanical integrity despite localized voids. These results demonstrate that SMM can effectively consolidate EM susceptible thermoplastic powder beds while preserving their segregated conductive networks. This may become a scalable route for producing multifunctional thermoplastic parts with low filler loadings, tunable anisotropy, and structured materials and parts. Overall, the findings suggest that EM field-based AM can help overcome key limitations of conventional thermoplastic processing by enabling scalable, energy-efficient fabrication of nanostructured composites and expanding AM to a broader range of resins, including high-performance thermoplastics with customized functional properties.

Powder bed fusion↗

NASA NTRSDate not supplied

Development and Characterization of the Integrally Stiffened Cylinder (ISC) Process for Launch Vehicles and Aircraft Fuselage Structures

Over the past decade, NASA Langley has led development of the Integrally Stiffened Cylinder (ISC) Process, a near-net shape, flow-forming technology. This innovative process is being evaluated for launch vehicle and commercial aircraft manufacturing. A thick-walled, cylindrical preform is flow-formed in a single operation into a thin-walled barrel with longitudinal stiffeners. The one-piece, stiffened barrels offer a direct replacement for conventional multi-piece welded or riveted structures. A cost-benefit analysis for launch vehicles estimated that the ISC process offers up to a 50% reduction in manufacturing costs and a 10% reduction in mass. NASA, the European Space Agency (ESA), and industry partners have teamed to manufacture 10-ft. diameter aluminum ISCs. The intent is to demonstrate the commercial viability of the process at a scale relevant to the commercial launch and aircraft industries. Development activities will be presented, including process scale-up, formability assessment, microstructural analysis, and mechanical property testing.

ISC, flow forming, near net shape↗

NASA NTRSDate not supplied

Development and Characterization of the Integrally Stiffened Cylinder (ISC) Process for Launch Vehicles and Aircraft Fuselage Structures

Over the past decade, NASA Langley has led development of the Integrally Stiffened Cylinder (ISC) Process, a near-net-shape, flow-forming technology. This innovative process is being evaluated for launch vehicle and commercial aircraft manufacturing. A thick-walled, cylindrical preform is flow-formed using a single operation into a thin-walled barrel with integral longitudinal stiffeners. The one-piece, stiffened barrels offer a direct replacement for conventional multi-piece, welded or riveted structures. A cost-benefit analysis for launch vehicle cryogenic propellant tanks estimated that the ISC process offers up to a 50% reduction in manufacturing costs and a 10% reduction in mass. NASA, the European Space Agency (ESA), and industry partners have teamed to manufacture 3-m(10-ft.) diameter aluminum ISCs. The intent is to demonstrate the commercial viability of the process at a scale relevant to the commercial launch and aircraft industries. Development activities will be presented, including process scale-up, formability assessment, and mechanical property testing.

ISC, flow forming, near net shape↗

DOE OSTI2014

A Novel Absorption Cycle for Combined Water Heating, Dehumidification, and Evaporative Cooling

In this study, development of a novel system for combined water heating, dehumidification, and space evaporative cooling is discussed. Ambient water vapor is used as a working fluid in an open system. First, water vapor is absorbed from an air stream into an absorbent solution. The latent heat of absorption is transferred into the process water that cools the absorber. The solution is then regenerated in the desorber, where it is heated by a heating fluid. The water vapor generated in the desorber is condensed and its heat of phase change is transferred to the process water in the condenser. The condensed water can then be used in an evaporative cooling process to cool the dehumidified air exiting the absorber, or it can be drained if primarily dehumidification is desired. Essentially, this open absorption cycle collects space heat and transfers it to process water. This technology is enabled by a membrane-based absorption/desorption process in which the absorbent is constrained by hydrophobic vapor-permeable membranes. Constraining the absorbent film has enabled fabrication of the absorber and desorber in a plate-and-frame configuration. An air stream can flow against the membrane at high speed without entraining the absorbent, which is a challenge in conventional dehumidifiers. Furthermore, the absorption and desorption rates of an absorbent constrained by a membrane are greatly enhanced. Isfahani and Moghaddam (Int. J. Heat Mass Transfer, 2013) demonstrated absorption rates of up to 0.008 kg/m2s in a membrane-based absorber and Isfahani et al. (Int. J. Multiphase Flow, 2013) have reported a desorption rate of 0.01 kg/m2s in a membrane-based desorber. The membrane-based architecture also enables economical small-scale systems, novel cycle configurations, and high efficiencies. The absorber, solution heat exchanger, and desorber are fabricated on a single metal sheet. In addition to the open arrangement and membrane-based architecture, another novel feature of the cycle is recovery of the solution heat energy exiting the desorber by process water (a process-solution heat exchanger ) rather than the absorber exiting solution (the conventional solution heat exchanger ). This approach has enabled heating the process water from an inlet temperature of 15 C to 57 C (conforming to the DOE water heater test standard) and interfacing the process water with absorbent on the opposite side of a single metal sheet encompassing the absorber, process-solution heat exchanger, and desorber. The system under development has a 3.2 kW water heating capacity and a target thermal coefficient of performance (COP) of 1.6.

Absorption Heat Pump↗

NASA NTRS1991

Controls for agility research in the NASA High-Alpha Technology Program

The research process being used to develop control law design methodologies and guidelines in the NASA High-Alpha Technology Program are discussed. This step-by-step process consists of four basic elements: (1) control law architecture definition and linear synthesis, (2) nonlinear batch simulation, (3) piloted simulation evaluation, and (4) flight test validation. This paper discusses the research tools being used in this effort and provides a status report on design methodologies and guidelines being developed for each of these elements.

Foster, John V.↗

DOE OSTI2024

A New Understanding of Decarbonizing Industrial Process Heat

Analysis conducted over the last few years has improved our understanding of how industrial process heat is used in the United States. These improvements are important for characterizing the possibilities for industrial decarbonization. However, this analysis has largely been conducted from technical perspective and has remained disconnected from the social processes that underlie how industrial firms may adopt and implement technologies to decarbonize their process heating operations. This presentation introduces the concept of generic and configurational technology systems, and outlines the how the incorporation of user requirements and local contexts are essential for successful implementation of configurational systems. Insights drawn from semi-structured interviews with representatives of industrial firms are used to support the hypothesis that industrial process heat technologies are configurational. The potential implications for strategies to decarbonize process heat are then discussed.

adoption↗

DOE OSTI2014

Fuel Fabrication Capability Research and Development Plan

The purpose of this document is to provide a comprehensive review of the mission of the Fuel Fabrication Capability (FFC) within the Global Threat Reduction Initiative Convert Program, along with research and development (R&D) needs that have been identified as necessary to ensuring mission success. The design and fabrication of successful nuclear fuels must be closely linked endeavors. Therefore, the overriding motivation behind the FFC R&D program described in this plan is to foster closer integration between fuel design and fabrication to reduce programmatic risk. These motivating factors are all interrelated, and progress addressing one will aid understanding of the others. The FFC R&D needs fall into two principal categories, 1) baseline process optimization, to refine the existing fabrication technologies, and 2) manufacturing process alternatives, to evaluate new fabrication technologies that could provide improvements in quality, repeatability, material utilization, or cost. The FFC R&D Plan examines efforts currently under way in regard to coupon, foil, plate, and fuel element manufacturing, and provides recommendations for a number of R&D topics that are of high priority but not currently funded (i.e., knowledge gaps). The plan ties all FFC R&D efforts into a unified vision that supports the overall Convert Program schedule in general, and the fabrication schedule leading up to the MP-1 and FSP-1 irradiation experiments specifically. The fabrication technology decision gates and down-selection logic and schedules are tied to the schedule for fabricating the MP-1 fuel plates, which will provide the necessary data to make a final fuel fabrication process down-selection. Because of the short turnaround between MP-1 and the follow-on FSP-1 and MP-2 experiments, the suite of specimen types that will be available for MP-1 will be the same as those available for FSP-1 and MP-2. Therefore, the only opportunity to explore parameter space and alternative processing is between now and 2016 when the candidate processes are down-selected in preparation for the MP-1, FSP-1, and MP-2 plate manufacturing campaigns. A number of key risks identified by the FFC are discussed in this plan, with recommended mitigating actions for those activities within FFC, and identification of risks that are impacted by activities in other areas of the Convert Program. The R&D Plan does not include discussion of FFC initiatives related to production-scale manufacturing of fuel (e.g., establishment of the Pilot Line Production Facility), rather, the goal of this plan is to document the R&D activities needed ultimately to enable high-quality and cost-effective production of the fuel by the commercial fuel fabricator. The intent is for this R&D Plan to be a living document that will be reviewed and updated on a regular basis (e.g., annually) to ensure that FFC R&D activities remain properly aligned to the needs of the Convert Program. This version of the R&D Plan represents the first annual review and revision.

Convert Program↗

NASA NTRSDate not supplied

Sustaining Thermal Protection Systems Needed for Uranus Probes

Summary: Achieving Uranus in-situ science objectives through deploying probes in the atmosphere requires thermal protection systems capable of withstanding extreme entry environments. NASA’s 3-D Woven based thermal protection systems (TPS), developed specifically to meet this challenge, are mature, efficient, and capable of withstanding such entry. These science-enabling capabilities need to be sustained, otherwise mission implementation risk may increase to the point that the mission is untenable. The heatshield technology has been developed in concert with industry, and manufacturing processes have been technology transferred. Current technology readiness does not guarantee future availability. Sustainment requires maintaining expertise within NASA as well as ensuring that proven industrial expertise and capabilities will be readily available in the future. A constant awareness and risk assessment followed by risk mitigation are required. The scientific community needs to be aware of these challenges. It needs to engage NASA to ensure these capabilities will be available when needed. As was the case with the atrophy of heritage carbon phenolic that led to developing the 3-D Woven capabilities, our vigilance is again needed to sustain these enabling TPS capabilities for Uranus and for other missions. Background: NASA invested in and developed Heatshield for Extreme Entry Environment Technology (HEEET) TPS that was matured to TRL 6 in 2019 as a tiled system with seams and gap-fillers. Manufacturing readiness included development of specialized looms, molding, and infusion processes using commercial partners. In support of the Mars Sample Return mission, a single-layer, seamless, single-piece variant referred to as 3MDCP (3-D woven Mid-Density Carbon-Phenolic) was developed and is limited to a 1.3m maximum diameter scale due to weaving width limitations of 80”. Molding techniques developed to transform a flat, 2”-thick 3-D woven preform into a sphere-cone shape prior to phenolic resin infusion has been demonstrated. A team at NASA Ames is currently working with industry to demonstrate infusion at full-scale. By 2026, 3MDCP will be at a high level of maturity in technical, manufacturing, and integration readiness as well as material characterization. HEEET and 3MDCP for Uranus Entry: Several system studies have evaluated and baselined 3-D Woven TPS for Uranus entry, both HEEET as well as 3MDCP. If the aeroshell carrying the descent probe is 1.3m or less, then 3MDCP is a very capable and the most mass-efficient choice. If the aeroshell is bigger than 1.3m diameter, then HEEET can meet the mission need as it allows for an aeroshell of any diameter. HEEET and 3MDCP are capable of Saturn in-situ science missions prioritized in the New Frontiers-5 draft Announcement of Opportunity (AO) and if Saturn is the mission of choice, there is a pathway for sustaining the capability. Capability Sustainment: Given NASA’s current budgetary constraints, the postponement of the next New Frontiers AO to no earlier than 2026 and the unknown delay in starting the UOP flagship effort point to potential gap years for the HEEET and 3MDCP capabilities. The first step in capability sustainment is to understand the risks as they emerge, assess those risks, and develop plans to mitigate them. Keeping the science community, who are interested in UOP as well as the larger Giant Planet missions, informed of the emerging challenges requires continuous risk assessment/mitigation. Without these steps, atrophy is more likely within the industrial partners with which NASA has partnered. This presentation will provide more details as well as steps NASA can take to minimize the impact to the UOP mission.

Ethiraj Venkatapathy↗

DOE OSTI2019

Quantum Information Processing in the Frequency Domain

Quantum technologies promise to revolutionize information processing through dramatic computational speed-ups and ultimate security compared with classical counterparts. As matter-based qubit systems increase in size, however, counteracting decoherence becomes challenging and places limits on how large a stand-alone system can be. These limitations, coupled with the many quantum computing platforms under development, have led researchers to view modular architectures, connected by a quantum network, as a promising path to large-scale quantum computing. Our group reported in several studies this year, progress on multiple fronts in such systems, using photons as quantum information carriers in the frequency domain.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2012

Techno-Economics for Conversion of Lignocellulosic Biomass to Ethanol by Indirect Gasification and Mixed Alcohol Synthesis

This techno-economic study investigates the production of ethanol and a higher alcohols coproduct by conversion of lignocelluosic biomass to syngas via indirect gasification followed by gas-to-liquids synthesis over a precommercial heterogeneous catalyst. The design specifies a processing capacity of 2,205 dry U.S. tons (2,000 dry metric tonnes) of woody biomass per day and incorporates 2012 research targets from NREL and other sources for technologies that will facilitate the future commercial production of cost-competitive ethanol. Major processes include indirect steam gasification, syngas cleanup, and catalytic synthesis of mixed alcohols, and ancillary processes include feed handling and drying, alcohol separation, steam and power generation, cooling water, and other operations support utilities. The design and analysis is based on research at NREL, other national laboratories, and The Dow Chemical Company, and it incorporates commercial technologies, process modeling using Aspen Plus software, equipment cost estimation, and discounted cash flow analysis. The design considers the economics of ethanol production assuming successful achievement of internal research targets and nth-plant costs and financing. The design yields 83.8 gallons of ethanol and 10.1 gallons of higher-molecular-weight alcohols per U.S. ton of biomass feedstock. A rigorous sensitivity analysis captures uncertainties in costs and plant performance.

09 BIOMASS FUELS↗

NASA NTRSDate not supplied

Moon to Mars Planetary Autonomous Construction Technology (MMPACT) Lunar Surface Construction Activity at NASA Marshall Space Flight Center

Introduction: The goal of the Moon to Mars Planetary Autonomous Construction Technology (MMPACT) Project at NASA Marshall Space Flight Center (MSFC) is to develop, deliver, and demonstrate on-demand capabilities to protect astronauts and create infrastructure elements on the lunar surface via construction of landing pads, habitats, shelters, roadways, berms, and blast shields using lunar regolith-based materials. MSFC has strong collaborations with industry, academia, and other NASA Centers to accomplish this goal. The MMPACT project consists of three elements. The first focuses on the development of an autonomous construction system. The second focuses on construction feedstock materials development. The third element focuses on the development of a microwave sintering construction capability. The team plans to demonstrate construction on a small Commercial Lunar Payload Services (CLPS) lander in the 2025 timeframe, with a future goal of constructing a subscale landing pad in 2028-2029.The MMPACT project is funded through the Lunar Surface Innovation Initiative, which is part of the Space Technology Mission Directorate. Technology Development: The MMPACT team will evaluate multiple autonomous construction and microwave construction technologies, materials, and construction element forms. Selected technologies will be matured; processes and operations will be defined for the two flight missions. Evaluations of materials, as well as the technology itself, will be demonstrated in simulated lunar environments as part of the technology maturation process. The team is keenly aware of the properties of the lunar environment. Its temperature swings, negligible exosphere, and unprepared site foundations factor into the materials for both construction and hardware, the concept of operations, and the technology’s interdependencies. Materials: The team is looking at materials that can be produced from in-situ resources in an effort to make lunar construction cost-effective. The particular focus of the materials team is cementitious materials, metals, and sintered and melted regolith. These materials will be studied for tensile, compressive, and flexural strength. They will also be tested for their ability to handle thermal swings and vacuum. They will be fully characterized using various microscopy techniques to examine micro-structures, chemistry, and crystal formation. Interdependencies: There are many interdependencies that MMPACT has already identified. These include: •Excavation interface •Regolith feedstock beneficiation •Regolith feedstock storage and provision •Requirements for structures •Site-to-site mobility systems •Availability of lunar simulant •Lander off-loading capabilities •Navigation systems •Power •Regolith composition and mineralogy •Lander specifications •Communication protocols Technology developments in these additional areas would be beneficial to MMPACT.

Moon to Mars Planetary Autonomous Construction Tec↗

NASA NTRS2016

Silicon-Carbide Power MOSFET Performance in High Efficiency Boost Power Processing Unit for Extreme Environments

Silicon-Carbide device technology has generated much interest in recent years. With superior thermal performance, power ratings and potential switching frequencies over its Silicon counterpart, Silicon-Carbide offers a greater possibility for high powered switching applications in extreme environment. In particular, Silicon-Carbide Metal-Oxide- Semiconductor Field-Effect Transistors' (MOSFETs) maturing process technology has produced a plethora of commercially available power dense, low on-state resistance devices capable of switching at high frequencies. A novel hard-switched power processing unit (PPU) is implemented utilizing Silicon-Carbide power devices. Accelerated life data is captured and assessed in conjunction with a damage accumulation model of gate oxide and drain-source junction lifetime to evaluate potential system performance at high temperature environments.

Ikpe, Stanley A.↗

DOE OSTI2014

Nonequilibrium thermodynamics of dilute polymer solutions in flow

Modern materials processing applications and technologies often occur far from equilibrium. To this end, the processing of complex materials such as polymer melts and nanocomposites generally occurs under strong deformations and flows, conditions under which equilibrium thermodynamics does not apply. As a result, the ability to determine the nonequilibrium thermodynamic properties of polymeric materials from measurable quantities such as heat and work is a major challenge in the field. Here, we use work relations to show that nonequilibrium thermodynamic quantities such as free energy and entropy can be determined for dilute polymer solutions in flow. In this way, we determine the thermodynamic properties of DNA molecules in strong flows using a combination of simulations, kinetic theory, and single molecule experiments. We show that it is possible to calculate polymer relaxation timescales purely from polymer stretching dynamics in flow. We further observe a thermodynamic equivalence between nonequilibrium and equilibrium steady-states for polymeric systems. In this way, our results provide an improved understanding of the energetics of flowing polymer solutions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1984

Spinoff, 1984

A pictorial resume that underlines the challenging nature of NASA programs and their extraordinary demands for technological input, is presented. Also, NASA's current mainline programs, which require development of new technology, are given. A representative sampling of spinoff products and processes resulting from technology utiliization, or secondary application, and the mechanisms NASA employs to stimulate technology utilization are provided. Contact sources for further information are presented.

Haggerty, J. J.↗

DOE OSTI2013

Advanced Membrane Separation Technologies for Energy Recovery from Industrial Process Streams

Recovery of energy from relatively low-temperature waste streams is a goal that has not been achieved on any large scale. Heat exchangers do not operate efficiently with low-temperature streams and thus require such large heat exchanger surface areas that they are not practical. Condensing economizers offer one option for heat recovery from such streams, but they have not been widely implemented by industry. A promising alternative to these heat exchangers and economizers is a prototype ceramic membrane system using transport membrane technology for separation of water vapor and recovery of heat. This system was successfully tested by the Gas Technology Institute (GTI) on a natural gas fired boiler where the flue gas is relatively clean and free of contaminants. However, since the tubes of the prototype system were constructed of aluminum oxide, the brittle nature of the tubes limited the robustness of the system and even limited the length of tubes that could be used. In order to improve the robustness of the membrane tubes and make the system more suitable for industrial applications, this project was initiated with the objective of developing a system with materials that would permit the system to function successfully on a larger scale and in contaminated and potentially corrosive industrial environments. This required identifying likely industrial environments and the hazards associated with those environments. Based on the hazardous components in these environments, candidate metallic materials were identified that are expected to have sufficient strength, thermal conductivity and corrosion resistance to permit production of longer tubes that could function in the industrial environments identified. Tests were conducted to determine the corrosion resistance of these candidate alloys, and the feasibility of forming these materials into porous substrates was assessed. Once the most promising metallic materials were identified, the ability to form an alumina membrane layer on the surface of the metallic tubes was evaluated. Evaluation of this new style of membrane tube involved exposure to SO 2 containing gases as well as to materials with a potential for fouling. Once the choice of substrate and membrane materials and design were confirmed, about 150 tubes were fabricated and assembled into three modules. These modules were mounted on an industrial size boiler and their performance carefully monitored during a limited testing period. The positive results of this performance test confirm the feasibility of utilizing such a system for recovery of heat and water from industrial waste streams. The improved module design along with use of long metallic substrate tubes with a ceramic membrane on the outer surface resulted in the successful, limited scale demonstration of the Transport Membrane Condenser (TMC) technology in the GTI test facility. This test showed this technology can successfully recover a significant amount of heat and water from gaseous waste streams. However, before industry will make the investment to install a full scale TMC, a full scale system will need to be constructed, installed and successfully operated at a few industrial sites. Companies were identified that had an interest in serving as a host site for a demonstration system.

Keiser, James R.↗

DOE OSTI2013

Advanced Membrane Separation Technologies for Energy Recovery from Industrial Process Streams

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗