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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 19 records

Supercritical/Solid Catalyst (SSC)

INL's patented, continuous-flow Supercritical/Solid Catalyst (SSC) produces the highest ASTM-quality B-100 biodiesel from waste fats, oils, and greases at the site of waste generation. SSC delivers low-cost transportation fuel, avoids significant landfill costs for municipalities, and reduces potent methane and other emissions produced in landfills from these wastes. You can learn more about INL's energy research programs at http://www.facebook.com/idahonationallaboratory.

09 BIOMASS FUELS↗

Lifecycle assessment of microalgae to biofuel: Comparison of thermochemical processing pathways

Microalgae are currently being investigated as a renewable transportation fuel feedstock based on various advantages that include high annual yields, utilization of poor quality land, does not compete with food, and can be integrated with various waste streams. This study focuses on directly assessing the impact of two different thermochemical conversion technologies on the microalgae to biofuel process through life cycle assessment. A system boundary of a “well to pump” (WTP) is defined and includes sub-process models of the growth, dewatering, thermochemical bio-oil recovery, bio-oil stabilization, conversion to renewable diesel, and transport to the pump. Models were validated with experimental and literature data and are representative of an industrial-scale microalgae to biofuel process. Two different thermochemical bio-oil conversion systems are modeled and compared on a systems level, hydrothermal liquefaction (HTL) and pyrolysis. The environmental impact of the two pathways were quantified on the metrics of net energy ratio (NER), defined here as energy consumed over energy produced, and greenhouse gas (GHG) emissions. Results for WTP biofuel production through the HTL pathway were determined to be 1.23 for the NER and GHG emissions of -11.4 g CO 2-eq (MJ renewable diesel) -1 . WTP biofuel production through the pyrolysis pathway results in a NER of 2.27 and GHG emissions of 210 g CO2 eq (MJ renewable diesel)-1. The large environmental impact associated with the pyrolysis pathway is attributed to feedstock drying requirements and combustion of co-products to improve system energetics. Discussion focuses on a detailed breakdown of the overall process energetics and GHGs, impact of modeling at laboratory- scale compared to industrial-scale, environmental impact sensitivity to engineering systems input parameters for future focused research and development and a comparison of results to literature.

09 BIOMASS FUELS↗

Commercial Activated Carbon for the Catalytic Production of Hydrogen via the Sulfur-Iodine Thermochemical Water Splitting Cycle

Eight activated carbon catalysts were examined for their catalytic activity to decompose hydroiodic acid (HI) to produce hydrogen; a key reaction in the sulfur-iodine (S-I) thermochemical water splitting cycle. Activity was examined under a temperature ramp from 473 to 773 K. No statistically significant correlation was found between catalyst sample properties and catalytic activity. Four of the eight samples were examined for one week of continuous operation at 723 K. All samples appeared to be stable over the period of examination.

08 HYDROGEN↗

Are grid cells used for navigation? On local metrics, subjective spaces, and black holes

The symmetric, lattice-like spatial pattern of grid-cell activity is thought to provide a neuronal global metric for space. This view is compatible with grid cells recorded in empty boxes but inconsistent with data from more naturalistic settings. Here, we review evidence arguing against the global-metric notion, including the distortion and disintegration of the grid pattern in complex and three-dimensional environments. We argue that deviations from lattice symmetry are key for understanding grid-cell function. We propose three possible functions for grid cells, which treat real-world grid distortions as a feature rather than a bug. First, grid cells may constitute a local metric for proximal space rather than a global metric for all space. Second, grid cells could form a metric for subjective action-relevant space rather than physical space. Third, distortions may represent salient locations. Finally, we discuss mechanisms that can underlie these functions. These ideas may transform our thinking about grid cells.

59 BASIC BIOLOGICAL SCIENCES↗

Electrification and decarbonization of spent Li-ion batteries purification by using an electrochemical membrane reactor

The expanding electric vehicle market brings with it exponential growth in the use of lithium (Li)-ion batteries (LIB) for which a wave of spent LIB is expected to come within the next 5 to 10 years. Due to the economic and strategic value imbedded within the metals contained in LIB, different recycling technologies, including hydrometallurgy, pyrometallurgy and direct recycling, are under development. Being different from previous hydrometallurgical methods, which may have high chemical consumption and negative environmental impact, an electrochemical membrane reactor is designed and validated for the first time, to electrify and decarbonize the impurity removal process. This reactor electroplates copper (Cu) and electrochemically precipitates aluminum (Al) and iron (Fe) from simulated spent LIB leachates, by consuming only air, water, and electricity, and the impurities are reduced to <1 ppm. The purified leachate maintains 99.5 % of the nickel (Ni), 95.4 % of the cobalt (Co) and 99.14 % of manganese (Mn) from the original leachate solution, and then can be directly applied for cathode precursor synthesis. Additionally, the purification process doesn’t introduce extra impurity, and the reactor restoration process generates valuable by-product hydro sulfate (H2SO4). This electrochemical process can reduce the cost, because of the much less chemical consumption and the valuable by-product generation, and mitigates the waste emissions, because of no extra impurity introduced and no greenhouse gas (GHG) produced. In conclusion, the chemical precipitation method uses significant amount of NaOH, which induced GHG emission during the manufacturing process.

25 ENERGY STORAGE↗

Electrodialysis: An effective methodology to purify the leachate of spent Li-ion batteries

The electrification of transportation and the transition of society towards low or net-zero carbon emissions has led to a skyrocketing global demand for Li-ion batteries. After a service life of three to ten years, Li-ion batteries have less than 80 % of their initial capacities and draw near to the end of their lives for practical utilization. Due to potential supply chain shortages and the value embodied in Li-ion batteries, it is imperative to recycle them, to recover the materials, and to improve the circularity and the sustinability of the industry. How to cost-effectively purify spent batteries while reducing time, energy, and waste emissions is a challenge faced by Li-ion battery recyclers. The first electrochemical membrane reactor reported in our group hasa high selectivity towards lower Cu 2+ , Al 3+ and Fe 3+ ions (<5 ppm) and retains >95% of the Ni 2+ , Co 2+ and Mn 2+ ions in the leachate. An advanced electrochemical membrane reactor was developed in this study. Further, not only does the new reactor have the same selectivity as the original reactor, but other advantages including a faster leachate processing rate (up to 10X faster). The advanced reactor can also directly generate acid at the anode side; eliminating the reactor restoration step. The prominent advantages that this electrodialysis technology has over chemical-precipitation methods include: (1) ion recovery efficiencies do not diminish after removing the impurities, Ni 2+ , Co 2+ and Mn 2+ , even at a higher initial Ni 2+ ion concentrations; in comparison, chemical precipitation has Ni 2+ , Co 2+ and Mn 2+ ion recovery efficiencies reduced significantly when the initial Ni 2+ , Co 2+ and Mn 2+ ion concentrations increase. (2) electrodialysis does not change the concentrations of Ni 2+ , Co 2+ and Mn 2+ ions significantly, but chemical precipitation could reduce Ni 2+ and Co 2+ ions to less than half of their initial values. Through electro-dialyzing the leachate, the H 2 evolution reaction mechanism was found to switch from the Volmer-acid Heyrovsky mechanism to the Volmer-alkaline Heyrovsky mechanism at a pH of around 3.7.

25 ENERGY STORAGE↗

Thermal Stability of Cyclopentane as an Organic Rankine Cycle Working Fluid

Laboratory experiments were performed to aid in determining the maximum operating temperature for cyclopentane as an Organic Rankine Cycle working fluid. The thermochemical decomposition of cyclopentane was measured in a recirculation loop at 240 C, 300 C and 350 C at 43 bar in a glass-lined heated tube. It was determined that in the absence of air at the lower two temperatures, decomposition was minor after more than twelve days of continuous operation. At 240 C, the total cyclopentane decomposition products were approximately 65 parts per million (ppm) and at 300 C, total decomposition products were on the order of 270 ppm at the end of the experiment. At 350 C, decomposition products were significantly higher and reached 1,500 ppm. When the feed was contacted with air, the decomposition rate increased dramatically. Residues found in the reactor after the decomposition experiments were examined by a number of different techniques. The mass of the residues increased with experimental temperature, but was lower at the same temperature when the feed was contacted with air. Analysis of the residues suggested that the residues were primarily heavy saturated hydrocarbons.

42 ENGINEERING↗

Solvent-driven fractional crystallization for atom-efficient separation of metal salts from permanent magnet leachates

Abstract This work reports a dimethyl ether-driven fractional crystallization process for separating rare earth elements and transition metals. The process has been successfully applied in the treatment of rare earth element-bearing permanent magnet leachates as an atom-efficient, reagent-free separation method. Using ~5 bar pressure, the solvent was dissolved into the aqueous system to displace the contained metal salts as solid precipitates. Treatments at distinct temperatures ranging from 20–31 °C enable crystallization of either lanthanide-rich or transition metal-rich products, with single-stage solute recovery of up to 95.9% and a separation factor as high as 704. Separation factors increase with solution purity, suggesting feasibility for eco-friendly solution treatments in series and parallel to purify aqueous material streams. Staged treatments are demonstrated as capable of further improving the separation factor and purity of crystallized products. Upon completion of a crystallization, the solvent can be recovered with high efficiency at ambient pressure. This separation process involves low energy and reagent requirements and does not contribute to waste generation.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Separation of isoprene from biologically-derived gas streams

Renewable organic precursors, including olefinic compounds such as isoprene, have attracted interest from the polymer and pharmaceutical industries. Biologically-derived processes can generate these target compounds; however, their gaseous product streams are complex mixtures of condensable organic vapors (COVs), water vapor, carbon dioxide (CO 2 ), and/or nitrogen (N 2 ). Because COVs, CO 2 and water vapor are known to alter polymer membranes, mixed gas separations data at ambient and elevated temperatures are limited. Here, this study focused on two classes of polymer membranes, glassy [polyetherimide (Ultem®)] and a rubbery [polydimethylsiloxane (PDMS)] with results indicating that isoprene separation is possible in humidified gas environment (2–4 vol% water). Gas permeabilities of these membranes did not noticeably change in the presence of humidity; however, the selectivity of these membranes was significantly lower compared to their performance under dry conditions. The role of water vapor in gas transport was derived from the energy of activation of permeation (E p ) for PDMS and Ultem® from 30–80°C in humidified mixed gas streams. For both polymers, E p data shows a slight decrease in selectivity with the other gases (hydrogen, N 2 , CO 2 , and methane) at elevated temperatures in the presence of water vapor. Thus, these COVs separations are feasible with polymer membranes in the presence of humidified gas streams, even in the case of glassy and rubbery membranes in series.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Comparison of Two Preparation Methods on Catalytic Activity and Selectivity of Ru-Mo/HZSM5 for Methane Dehydroaromatization

Catalytic performance of Mo/HZSM5 and Ru-Mo/HZSM5 catalysts prepared by vaporization-deposition of molybdenum trioxide and impregnation with ammonium heptamolybdate was analyzed in terms of catalyst activity and selectivity, nitrogen physisorption analyses, temperature-programmed oxidation of carbonaceous residues, and temperature-programmed reduction. Vaporization-deposition rendered the catalyst more selective to ethylene and coke than the catalyst prepared by impregnation. This result was assigned to lower interaction of molybdenum carbide with the zeolite acidic sites.

Petkovic, Lucia M.↗

Recycling rare earths: Perspectives and recent advances

Abstract Rare-earth element (REE) demand is expected to increase by a factor of up to 7 by 2040. Recycling avoids the significant hurdles associated with opening new mines, but collection and disassembly of REE-containing devices are barriers. Absolute and relative abundances of REEs and co-occurring constituents differ significantly in secondary compared to primary sources, presenting challenges and opportunities. REE concentrations are typically low, but manufactured devices include only the desired REE, avoiding the “REE balance problem” that besets natural ores. Fewer REEs need to be separated, as compared to separation of the entire lanthanide series. Co-recovery of precious (e.g., Au, Ag, Pt) or base metals (e.g., Cu, Sn, Zn) from e-wastes can offset recycling costs. Some examples of recently developed approaches for REE extraction and separation are presented here, with an emphasis on methods offering environmental benefits such as lower toxic chemical usage and reduced energy costs. Graphical abstract

36 MATERIALS SCIENCE↗

Hydrogenation of Clean Carbon Monoxide (CO) and Carbon Dioxide (CO 2 ) Gas Streams to Higher Molecular Weight Alcohols

Higher alcohols including ethanol, propanols, and butanols can be used as gasoline blending stocks. These alcohols not only extend fuel supplies, but can be used as gasoline oxygenates and used to enhance gasoline octane rating. The direct synthesis of higher alcohols from synthesis gas (CO, H 2 ) is thus highly desired. In this work we developed novel alkali metal promoted catalysts for the conversion of synthesis gas to mixed alcohols

10 SYNTHETIC FUELS↗

Bio-Oil Separation and Stabilization by Supercritical Fluid Fractionation. 2014 Final Report

The objective of this project is to use supercritical fluids to separate and fractionate algal-based bio-oils into stable products that can be subsequently upgraded to produce drop-in renewable fuels. To accomplish this objective, algae was grown and thermochemically converted to bio-oils using hydrothermal liquefaction (HTL), pyrolysis, and catalytic pyrolysis. The bio-oils were separated into an extract and a raffinate using near-critical propane or carbon dioxide. The fractions were then subjected to thermal aging studies to determine if the extraction process had stabilized the products. It was found that the propane extract fraction was twice as stable as the parent catalytic pyrolysis bio-oils as measured by the change in viscosity after two weeks of accelerated aging at 80°C. Further, in-situ NMR aging studies found that the propane extract was chemically more stable than the parent bio-oil. Thus the milestone of stabilizing the product was met. A preliminary design of the extraction plant was prepared. The design was based on a depot scale plant processing 20,000,000 gallons per year of bio-oil. It was estimated that the capital costs for such a plant would be $8,700,000 with an operating cost of $3,500,000 per year. On a per gallon of product cost and a 10% annual rate of return, capital costs would represent $0.06 per gallon and operating costs would amount to $0.20 per gallon. Further, it was found that the energy required to run the process represented 6.2% of the energy available in the bio-oil, meeting the milestone of less than 20%. Life cycle analysis and greenhouse gas (GHG) emission analysis found that the energy for running the critical fluid separation process and the GHG emissions were minor compared to all the inputs to the overall well to pump system. For the well to pump system boundary, energetics in biofuel conversion are typically dominated by energy demands in the growth, dewater, and thermochemical process. Bio-oil stabilization by near critical propane extraction had minimal impact in the overall energetics of the process with NER contributions of 0.03. Based on the LCA, the overall conversion pathways were found to be energy intensive with a NER of about 2.3 and 1.2 for catalytic pyrolysis and HTL, respectively. GHG emissions for the catalytic pyrolysis process were greater than that of petroleum diesel at 210 g CO2 eq compared to 18.9 g CO2 eq. Microalgae bio-oil based diesel with thermochemical conversion through HTL meets renewable fuel standards with favorable emission reductions of -10.8 g CO2 eq. The importance of the outcomes is that the critical fluid extraction and stabilization process improved product stability and did so with minimal energy inputs and processing costs. The LCA and GHG emission calculations point toward the HTL pathway as the more favorable thermochemical route towards upgrading algae to bio-fuels. Since the quality of the HTL oil was significantly lower than that of the catalytic pyrolysis bio-oil, the next steps point toward improving the quality of the HTL oils from algae biomass and focusing the critical fluid stabilization on that bio-oil product.

09 BIOMASS FUELS↗

Materials Challenges and Opportunities for Energy Generation, Conversion, Delivery, and Storage (Applied Energy Tri-Laboratory Consortium Workshop Report)

This report documents the outcomes of the Tri-Laboratory Materials Workshop that was held July 31 and August 1, 2019 to begin addressing the needs, opportunities, and challenges associated with the development, fabrication, and testing of the needed materials and components for integrated hybrid energy systems (i.e., incorporating nuclear, fossil, and renewables for electric and thermal applications). This was accomplished by assembling the research program leads and principal investigators at Idaho National Laboratory (INL), National Energy Technology Laboratory (NETL), and National Renewable Energy Laboratory (NREL), who support the research and development of new technology and system integration. The team then identified and prioritized key materials development needs. This effort was intended to enhance communications and synergy among the Tri-Lab partners. Advanced functional and structural materials are central to transformative energy technologies for energy generation, conversion, delivery, and storage. With that in mind, the workshop focused on identifying and assessing the foundational materials research needs at both the basic and applied levels. Materials challenges include the ability to withstand harsh environments, such as high temperatures and pressures, corrosion, oxidation, or irradiation while maintaining flexible mission profiles and long service lifespans. Advanced energy system material challenges and needs range from materials for the capture, upgrading/concentration, storage, and delivery of low-grade heat to materials for high temperature environments that involve liquid metals, molten salt, and very high temperature gas heat delivery and storage systems. Material improvements are needed for hybrid energy systems due to accelerated corrosion and stress-fatigue failure of materials and equipment, which results from increased frequency and amplitude of thermal, mechanical, and electrical cycling of systems components. Multifunctional materials are needed for high temperature solid-oxide fuel cells, advanced electrochemical reactors, and in-process separation. Relative to materials manufacturing, application of advanced additive and subtractive methods need to be understood to develop both thin-layer homogenous materials and materials of graded composition. Materials modeling and machine learning will be critical to accelerate the design and production of power electronics, and nuclear reactor materials and fuel, as well as to gain an understanding of beneficial materials phenomena or deleterious microstructure evolution. There is also a need for standardized models, computational structures, data reporting protocols and modeling tools across the three laboratories. This would allow consistent results, analysis, and data sharing. Combining computational capabilities between the three laboratories (e.g., hardware, software) would greatly increase computational capabilities and throughput. The workshop identified the need for laboratories to anticipate and address problems that will occur during scale-up. Laboratory work must connect with industry to ensure that research focuses on processes that are scalable and marketable. Industry input and perspective are essential to guide laboratory research to meet these requirements and deploy new technology in industrial demonstrations. Another aspect of scale-up is the integration of multiple systems since new challenges often arise at the subsystem interfaces. Establishing a scale-up manufacturing demonstration/pilot plant, potentially as an industrial user facility, would be beneficial to the laboratories and industry. That modular scale-up manufacturing demonstration/pilot plant would allow researchers to find and resolve interface problems that cannot be identified by focusing only on individual parts. Communication exchanges among the organizers, attendees, and workshop survey responses indicate that the workshop was successful in achieving its goal to identify key technology gaps and research needs. Strong positive feedback was received on the sharing of ideas, capabilities, talent, and passion to move forward on the materials-related action items.

36 MATERIALS SCIENCE↗

Reservoir Thermal Energy Storage Benchmarking (Rev. 3)

A benchmarking analysis of RTES research funded by GTO through the Beyond Batteries projects was conducted against the ESGC to see where they fit within the identified ESGC Use Cases. The projects were found to advance knowledge in multiple ESGC use cases, either directly or in some cases, indirectly as enabling technologies. This analysis is helpful to understand where RTES and associated research fits into the larger discussion around energy storage technologies. Also, a retrospective analysis of the Beyond Batteries projects was conducted to evaluate what the projects learned and how the results can be applied to advance the value of RTES. Major results of each of the studies are summarized in Table 2. Additionally, a comparative metrics analysis for RTES was completed to understand where RTES lies within the energy storage industry. Metrics for evaluation of RTES and its comparison to other storage technologies were selected and ranges of their values compiled. The selected metrics – LCOE (levelized cost of energy), capital costs, roundtrip efficiency, energy storage capacity, and storage time – were chosen based on data availability and have a particularly strong influence on the potential deployment of a storage technology. Charts which compare the metrics are presented in section 4.3 and show ranges for each of the 10 selected technologies. However, due to a lack of domestic operational facilities, values for RTES and for portions of the remaining technologies are based on theoretical modeling and studies of best-case scenarios. LCOE estimates for RTES fall within the lower reaches of Figure 15, but nevertheless amount to 2 – 5 times the ESGC Roadmap goal for LCOE, for example in the Facilitating and Evolving Grid Use Case. Capital costs for RTES sit on the higher end (Figure 16) but are expected to decrease as new projects are developed and the technology is refined. The theoretical roundtrip efficiency reported for RTES varies from mid to high percentages (Figure 17) with efficiencies upwards of 93% in modeled scenarios in the Portland Basin (Bershaw et al.,2020). RTES is also expected to have the largest energy storage capacities and longest storage times, likely matched only by lower efficiency hydrogen storage. To better assess the role that RTES could play in energy storage we examined it’s potential in the U.S. The potential depends on many factors. Recently, many researchers have started looking at deep sedimentary basins, depleted oil and gas fields, and basalt formations as potential targets for RTES development. The United States Geological Survey (USGS) has analyzed various cities and shown substantial RTES potential in the cooling sector (Pepin et al., 2021). By modeling RTES in low-quality groundwater (e.g., brackish), it is shown to be favorable across the U.S. with particular suitability in the Illinois Basin, Coastal Plains, and Basin and Range regions. Seasonal RTES operations have also been modeled in the Portland Basin by those at the USGS and Portland State University to simulate an RTES system supplying heating loads needed for the Oregon Health and Science University. Simulations suggest that high conductive heat loss in the initial years exists but tends to decrease with increasing time and development of the resource due to self-insulating nature of the basalts (Burns et al., 2020). Other national laboratory efforts are taking a close look at many of the technical issues involved with RTES (McLing et al., 2019, McLing et al., 2022). These include difficulties in understanding geochemical, hydrogeological, mechanical, and microbiological changes at such elevated temperatures and operational scenarios. Major gaps in research are identified and suggested for future work. With this increased focus to understand how to make RTES successful in the U.S., this technology could be a potential solution to many of the nation’s energy storage problems. For the energy independence of this country, the DOE should prioritize de-risking this technology by making future investments in pilot-scale demonstrations to attract potential investors.

15 GEOTHERMAL ENERGY↗

Direct production of hydrogen and aromatics from methane or natural gas: Review of recent U.S. patents

Since the year 2000, the United States Patent and Trademark Office (USPTO) has granted a dozen patents for inventions related to methane dehydroaromatization processes. One of them was granted to UOP LLC (Des Plaines). It relates to a catalyst composition and preparation method. Two patents were granted to Conoco Phillips Company (Houston, TX). One was aimed at securing a process and operating conditions for methane aromatization. The other was aimed at securing a process that may be integrated with separation of wellhead fluids and blending of the aromatics produced from the gas with the crude. Nine patents were granted to ExxonMobil Chemical Patents Inc. (Houston, TX). Most of these were aimed at securing a dehydroaromatization process where methane-containing feedstock moves counter currently to a particulate catalyst. The coked catalyst is heated or regenerated either in the reactor, by cyclic operation, or in annex equipment, and returned to the reactor. The reactor effluent stream may be separated in its main components and used or recycled as needed. A brief summary of those inventions is presented in this review.

03 NATURAL GAS↗

Synthesis of Isobutene and Isobutane from Synthesis Gas. A Literature Review Since 1992

The isosynthesis reaction is commonly referred as the reaction that converts selectively synthesis gas to isobutene and isobutane. The main feature of this reaction is the production of branched hydrocarbons in higher proportion with respect to linear hydrocarbons than expected from thermodynamic equilibrium and with a molecular weight distribution favoring iso-C4 hydrocarbons. This article reviews and summarizes isosynthesis research results reported in the open scientific literature with emphasis on the articles published in the last two decades.

10 SYNTHETIC FUELS↗

Enhancement of alkylation catalysts for improved supercritical fluid regeneration

A method of modifying an alkylation catalyst to reduce the formation of condensed hydrocarbon species thereon. The method comprises providing an alkylation catalyst comprising a plurality of active sites. The plurality of active sites on the alkylation catalyst may include a plurality of weakly acidic active sites, intermediate acidity active sites, and strongly acidic active sites. A base is adsorbed to a portion of the plurality of active sites, such as the strongly acidic active sites, selectively poisoning the strongly acidic active sites. A method of modifying the alkylation catalyst by providing an alkylation catalyst comprising a pore size distribution that sterically constrains formation of the condensed hydrocarbon species on the alkylation catalyst or by synthesizing the alkylation catalyst to comprise a decreased number of strongly acidic active sites is also disclosed, as is a method of improving a regeneration efficiency of the alkylation catalyst.

Ginosar, Daniel M↗