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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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DOE OSTI2024

Mesophase pitch-based high performance carbon fiber production using coal extracts from mild direct coal liquefaction

Mild direct coal liquefaction (autogenous pressure, no catalyst, no H2 gas) of Springfield coal in fluid catalytic cracking decant oil is shown to effectively produce coal extract precursors to spinnable mesophase pitch. Here this work demonstrates that the coal extract can be thermally treated to obtain mesophase pitch in a facile one-step process, bypassing the production of an intermediate isotropic pitch. Furthermore, the presence of 25 wt.% coal in the initial slurry can increase the yield to mesophase pitch nearly twofold and yield to carbon fiber by approximately 70%. The coal extract-derived mesophase pitch was melt-spun and heat treated to produce carbon fiber with graphitic texture, high modulus (>400 GPa) and tensile strength up to 943 MPa. Overall, this work demonstrates that coal can be effectively utilized to markedly amplify the mesophase pitch and carbon fiber yield from fluid catalytic cracking decant oil by relatively simple processing, while conserving utility as a precursor to high performance carbon fiber and potentially other high value graphitic products.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Effect of Strength of Soluble and Solid Acid Catalysts on Selectivity in Aldol Reactions

Aldol reactions can follow the classical condensation path and produce an α,β-unsaturated carbonyl compound and water, however in some cases, aldol chemistry may be steered towards a fission that gives an olefin and a carboxylic acid. This investigation examines how the strength of Brønsted acid sites—both in homogeneous and heterogeneous catalysis—controls these two pathways and their kinetics. The cross-aldol reaction between benzaldehyde and 3-pentanone served as test case. Batch reactions, conducted in toluene as solvent at a temperature of 140 °C under autogenous pressure, were analyzed by GC and in situ ATR-FTIR spectroscopy to determine product distributions and rate constants for condensation and fission pathways. A series of soluble acids including a family of sulfonic acids mostly favored the condensation pathway, with formic acid as the weakest in the series by its pKa being inactive for aldol chemistry. Significant amounts of fission products were rare except for the known selectivity of phosphoric acid, and the circumstances were difficult to delineate. For the sulfonic acid family, the logarithm of the first-order condensation rate constants scaled only roughly with pKa (water) values, whereas a good correlation was obtained with calculated deprotonation Gibbs energies in toluene. A series of H-forms of isomorphously substituted beta zeolites, HESiBEA with E = Al, Ga, Fe, or B, favored the fission pathway. Site density and site strength were characterized by calorimetric measurements of the heats of adsorption of isopropylamine, which decreased in the order Al > Ga, Fe > B. The logarithm of the site-normalized first-order fission rate constants scaled roughly with the heats of adsorption and correlated excellently with reported deprotonation energies. In conclusion, acid strength mainly affects activity and can be seen as a pre-requisite for either aldol condensation or fission chemistry, whereas additional, yet to be full clarified catalyst properties and reaction conditions are required to steer aldol chemistry towards fission selectivity.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Effects of alkali dosage and silicate modulus on autogenous shrinkage of alkali-activated slag cement paste

Autogenous shrinkage of alkali-activated slag cement (AASC) paste prepared with different levels of alkali dosage and silicate modulus (M{sub s}) is investigated. The results show that autogenous shrinkage of AASC paste increases at a decreasing rate with alkali dosage, which is attributed to enhanced capillary pore pressure and syneresis of C-A-S-H gels. Autogenous shrinkage of AASC paste with a constant alkali dosage increases as M{sub s} increases from 0.5 to 1.0, followed with a reduction as M{sub s} further increases to 2.0. Increasing M{sub s} initially enhances the capillary pore pressure due to the enhanced reaction degree, and promotes the formation of saturated capillary pores and viscoelasticity, which facilitates the autogenous shrinkage of AASC paste. However, excessive silicate in the activator retards the internal moisture consumption, and subsequently decreases the autogenous shrinkage of AASC paste. Furthermore, increasing M{sub s} can also intensify syneresis of C-A-S-H gels, contributing to the early-age autogenous shrinkage of AASC paste.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Impact of downhole pressure and fluid-access on the effectiveness of wellbore cement expansion additives

Autogenous shrinkage of wellbore cement widely impairs zonal isolation. MgO-based cement expansion additives (CEAs) can mitigate this shrinkage, or even impart net expansion, by creating porosity through displacive crystal growth-processes. However, both MgO hydration and autogenous shrinkage behaviour depend strongly on stress state. Evaluation of CEA performance in wellbore cements therefore requires testing under elevated pressures representative for subsurface environments. We report experiments addressing the chemical and bulk volume changes that occur in cement hydrating at 10 MPa confining pressure and 90 °C. Volumetric response was investigated as function of MgO concentration, external water supply, and pore pressure decrease through water consumption during reaction. Results show the bulk expansion achieved using MgO-based CEAs diminishes markedly with increasing effective confining pressure or, equivalently, upon restricting fluid supply. This reduced expansion-potential under pressure has profound implications for slurry design, notably regarding CEA-concentrations required to counteract micro-annulus formation while maintaining low cement permeability.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Investigation of Process Emissions during Thermal Cutting of Clad Metals from the Nuclear Sector - 20183

Typically, reactor pressure vessels as well as steam generators comprising low alloyed steel with a cladding of stainless steel. Recently the permissible values for Cr (VI) in the air of the working areas have been reduced in Germany from 100 μg/m{sup 3} to 1 μg/m{sup 3} air. This results in the danger that even with low-alloy steel with claddings these limit values would be exceeded when using flame cutting technologies. In order to ensure compliance with the permissible limit values, exhaust gas systems with gas cleaning measures are provided. The process emission test shall replace the assumptions required for the design of these systems with measured values. NUKEM Technologies Engineering Services GmbH (NUKEM) has chosen autogenous flame cutting as an example of a thermal cutting system for process emission testing, as there are no proven values in the literature for the Cr (VI) and NiOx emissions produced. The autogenous flame cutting can be used for a variety of cutting tasks within decommissioning projects. In order to simulate the material to be cut, mock ups were generated and cut from information about the material specification for the reactor pressure vessel from existing nuclear power plants including possible claddings. The cutting length needed for analysis in the test will be maximum 100 mm. The airborne emissions from the thermal cutting process will be captured and analyzed as follows: - Dust emission: The generated particles will be collected by a hood equipped with strong suction device and suitable filter elements. The resulting filter is gravimetrically measured before and after the tests. - Particle Size Distribution: The airborne particle size distribution measurement will result in figures for the size and number of particles arising from the thermal cutting process. - Gas Analysis: The gas analysis enables the determination of e.g. CO{sub 2}, CO, O{sub 3}, NO, NO{sub 2}. - Cr (VI) and NiOx Analysis: For the Cr (VI) and NiOx analysis, samples of the filter residue will be taken. As a result Cr (VI) in relation to total Cr as well as the Ni content will be determined by ICP-optically emission spectroscopy and put in relation to the total dust amount. The process emissions test itself as well as the necessary gas analyses and spectroscopic analyses were carried out at the Institute of Materials Science (IW) of Leibniz Universitaet Hannover (LUH). The results of the process emission tests are used to confirm the design of the gas cleaning systems. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗