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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
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

The Modeling of Synfuel Production Process: ASPEN Model of FT production with electricity demand provided at LWR scale

Synfuels, or electro-fuels (e-fuels) have the unique potential to significantly reduce greenhouse gas (GHG) emissions across the transportation sector. This is especially true for applications with substantial payloads and daily miles traveled, such as long-haul heavy-duty vehicles, rail locomotives, marine vessels and aviation aircrafts that are challenging to directly electrify via battery or fuel cell powertrain technologies. Synfuels, or electro-diesel/electro-jet fuels, have similar properties with the incumbent petroleum fuels, compatible with current infrastructure but have much lower GHG emissions relative to the petroleum counterpart, because they utilize waste carbon dioxide (CO2) streams and green hydrogen (H2) sourced from electrolysis. To achieve substantial reductions in GHG emissions, electricity sources must be zero carbon or near-zero carbon, which is the case with solar, wind, hydro and nuclear power. Compared to the intermittency of solar, wind and hydro, nuclear energy provides a steady energy source. In addition, it’s advantageous for nuclear power to produce synfuels because it provides not only near-zero carbon electricity to displace grid electricity, but also near-zero carbon steam to displace carbon-intensive natural gas combustion for steam generation. The availability of electricity and steam also enables more efficient green hydrogen production by using high-temperature electrolysis. In this work, Argonne National Laboratory (ANL) models a synfuel production process via the Fischer- Tropsch (FT) reaction by using nuclear power to provide electricity and steam. In 2021, using ASPEN Plus software, ANL established a detailed process model of a stand-alone FT production facility, assuming feedstocks of pure CO2 and H2. This stand-alone model can be expanded to integrate H2 production from nuclear power via low-temperature and high-temperature electrolysis at light-water reactor (LWR) scale. This report summarizes the stand-alone ASPEN Plus model results with a detailed mass and energy analysis. Our modeled facility produces 351 MT/day (130,000 gal/day) of FT fuel (a mixture of naphtha, jet fuel, and diesel) by converting 223 MT/day of H2 and 2,387 MT/day of CO2. The FT fuel production energy efficiency is 58% and the carbon conversion efficiency (from CO2 to FT fuel) is 46%. The production of green hydrogen requires 390–470 MWe of electricity, which is compared with the capacity of an LWR plant. For the stand-alone FT process, the detailed energy demand (electricity and heat) is summarized in the table below. Based on the energy supply source and the required temperature, potential insertion points of nuclear energy are identified. Based on the potential nuclear energy utilization, this report discusses potential modification options for expanding the system boundary to integrate nuclear power use, for example on-site hydrogen production via water electrolysis. Modeling of the integrated system is conducted by closely working with ANL and Idaho National Laboratory (INL) collaborators to harmonize design parameters of nuclear plants and the FT production process.

Zang, Guiyan↗
DOE OSTI2022

The Modeling of the Synfuel Production Process: Process models of Fischer-Tropsch production with electricity and hydrogen provided by various scales of nuclear plants

Synthetic fuels (synfuels), also known as electro-fuels (E-fuels), are hydrocarbon fuels produced from waste CO2 streams and water electrolysis, with electricity as the primary source of energy. To achieve substantial reductions in greenhouse gas (GHG) emissions, electricity sources must release zero carbon or near-zero carbon, as is the case with solar, wind, hydro, and nuclear power. Nuclear power is one of the largest and steadiest domestic sources of clean energy in the United States. Moreover, nuclear power has the potential to produce hydrogen economically for less than $2/kg, reaching the DOE near-term target price. Thus, using nuclear power to produce synfuels has the unique potential to significantly reduce the GHG emissions of hydrocarbon fuels production and end-use applications. Fisher-Tropsch or FT fuel (a mixture of naphtha, jet fuel, and diesel) is of great interest because it is a drop-in fuel that can be blended with conventional petroleum counterparts and is compatible with existing infrastructure. By using the ASPEN Plus model, this report develops FT fuel production models on three scales, corresponding to nuclear plants with capacities of 1000 MWe, 437 Mwe, and 100 MWe, respectively. The FT model case with energy from a 437-MWe nuclear plant is used as a baseline case. This report summarizes the baseline ASPEN Plus model results with a detailed mass and energy analysis. Our modeled facility produces 507 MT/day (185,000 gal/day) of FT fuel by converting 255 MT/day of hydrogen and 1,580 MT/day of CO2. The FT fuel production energy efficiency from hydrogen and electricity energy inputs is 70% (lowerheating-value or LHV-based). Including the high-temperature electrolyzer in the system boundary, the FT fuel production LHV efficiency from electricity and thermal energy inputs is 51%, considering 39.8 kWh/kg of electricity and 6.86 kWh/kg of thermal energy use from a nuclear plant for hydrogen production. The FT production efficiency can potentially be increased by further integrating the heat exchange between nuclear plant and FT process, and this study is underway. The carbon conversion ratio in the baseline case is 99%, with process CO2 capture and recirculation and oxy-combustion using the oxygen by-product from water electrolysis. The hydrogen consumption is 1.38 kg/gal-FT fuel and the CO2 consumption is 8.56 kg/gal-FT fuel in the baseline case. With different FT production scales determined by the nuclear plant capacity, the FT model was scaled using the same operating parameters, which led to the same conversion efficiency regardless of scale. However, the different FT plant scales will impact the economics of FT fuel production; this impact will be examined in the next phase of this study.

Zang, Guiyan↗
DOE OSTI2023

Method and apparatus for efficient metal distillation and related primary production process

Method and apparatus are provided for efficient metal distillation, and for related primary product process. Vertically stacked and gravity-driven evaporators and condensers are employed to distill metals, such metals having different volatilities. A multiple-effect thermal system of magnesium and other volatile metals is used to efficiently distill and separate metals from multiple metal alloys.

Powell, IV, Adam Clayton↗
DOE OSTI2023

Field Scale Testing of the Thermocatalytic Ethylene Production Process Using Ethane and Actual Coal Fired Flue Gas Co 2

This report provides a summary of the work performed and results obtained from a project supported by the US DOE (DE-FE0031713). In this study, Southern Research (SR) completed field-scale demonstration of a rationally designed novel nano-engineered catalyst driven thermochemical process to produce high yield of ethylene by using CO 2 derived from actual coal-fired flue gas and ethane. This process, referred to here as “CO 2 -ODH” due to CO 2 use via oxidative dehydrogenation (ODH) mechanism, follows a modified pathway to classical steam cracking (SC) process of ethylene production thus paving the way for significantly reduced CO 2 footprint, marginally improved thermodynamics, higher product selectivity and lower reaction temperatures.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

Energy and Techno-Economic Analysis of Bio-Based and Low-Carbon Chemicals and Fuels Production Processes

This presentation will highlight that to decarbonize the fuel and chemicals industry, we must reduce energy usage and decarbonize process heating, which also extends to bio-based and low-carbon chemicals and fuel production processes. Two examples will be given. The first is to compare separation technologies to concentrate 2,3-butanediol (BDO), a biomass-derived intermediate for producing sustainable aviation fuel for commercial aviation decarbonization. The other example shows that decarbonizing methanol production offers numerous beneficial routes toward industrial decarbonization as it is a versatile compound, finding utility as both a fuel and a chemical intermediate. Techno-economic and life cycle analyses provide integrated analysis technical approaches to evaluate the R&D that enables industrial decarbonization.

BIOMASS FUELS↗
DOE OSTI2022

DBD plasma-assisted ethanol steam reforming for green H 2 production: Process optimization through response surface methodology (RSM)

Herein this work investigates ethanol steam reforming (ESR) to produce hydrogen (H 2 ) in a dielectric barrier discharge (DBD) plasma reactor. A five-level, three-factor experiment design was performed using a response surface methodology (RSM) to evaluate the combined effects of the three process parameters, including discharge power, total flow rate, and ethanol-to-water (EtOH/H 2 O) molar ratio on the plasma-assisted ESR reaction. Quadratic regression models were employed in RSM to fit the experimental results and present the correlation between process parameters and targeted responses (EtOH conversion, H 2 yield, H 2 selectivity, and specific energy requirement (SER) for H 2 production). The results suggested that the EtOH/H 2 O molar ratio is considered to have the most significant effect on the EtOH conversion and H 2 , H 2 selectivity, while the total flow rate is the most significant parameter determining SER for H 2 production. Process optimization demonstrated the optimal process conditions, including a discharge power of 55.9 W, a total flow rate of 26.7 ml/min, and an EtOH/H 2 O molar ratio equal to 0.34. A validation test was performed and confirmed the feasibility of the optimization process.

08 HYDROGEN↗
DOE OSTI2023

Vertical Structure and Ice Production Processes of Shallow Convective Postfrontal Clouds over the Southern Ocean in MARCUS. Part II: Modeling Study

Abstract Part I of this series presented a detailed overview of postfrontal mixed-phase clouds observed during the Measurements of Aerosols, Radiation, and Clouds over the Southern Ocean (MARCUS) field campaign. In Part II, we focus on a multiday (23–26 February 2018) case with the aim of understanding ice production as well as model sensitivity to ice process parameterizations using the Weather Research and Forecasting (WRF) Model. The control simulation with the Predicted Particle Properties (P3) microphysics scheme underestimates the ice content and overestimates the supercooled liquid water content, contrary to the bias common in global climate models. The simulations targeted at ice production processes show negligible sensitivity to cloud droplet number concentrations. Further, neither increasing ice nuclei particle (INP) concentrations to an unrealistic level nor adjusting it to MARCUS field estimations alone guarantees more ice production in the model. However, the simulated clouds are found to be highly sensitive to the implementation of immersion freezing, the thresholding of condensation/deposition freezing initiation, and the rime splintering process. By increasing immersion freezing of cloud droplets, relaxing thresholds for condensation/deposition freezing, or removing rime splintering thresholds, the model significantly improves its performance in producing ice. The relaxation of the immersion freezing temperature threshold to the observed cloud-top temperature suggests an in-cloud seeder–feeder mechanism. The results of this work call for an increase in observations of INP, especially over the remote Southern Ocean and at relatively high temperatures, and measurements of ice particle size distributions to better constrain ice nucleating processes in models.

Meteorology & Atmospheric Sciences↗
DOE OSTI2023

Techno-economic and life cycle analyses for a supercritical biodiesel production process from waste cooking oil for a plant located in the Midwest United States

Existing literature lacks detailed techno-economic and environmental life cycle analyses (TEA-LCA) focused on supercritical biodiesel production pathways produced via waste products. Therefore, in this work, the TEA-LCA was conducted to generate supercritical biodiesel from waste cooking oil for plants located in the Midwest region of USA having annual production capacities of 10,600 and 128,000 t using Aspen Plus and GREET softwares. Here, two plant production capacities were chosen to capture the economies of scale impact on biodiesel manufacture cost. In the supercritical process, methanol and propane were used as a cosolvent to synthesize biodiesel from waste cooking oil (WCO) at 280 °C and 128 bar at a residence time of 8.4 min and a WCO conversion rate of 97%. Economic analysis revealed that the supercritical process was an economically attractive pathway with a 2-year payback period for the 10,600 t/year capacity along with a break-even selling price of $\$$ 2.42/gal of diesel. In case of the larger plant (128,000 t/year capacity), the payback period and the breakeven selling price were considerably lower at values of 0.4 years and $1.31/gal of diesel, respectively, due to economies of scale impact. The generated biodiesel from supercritical process for the both the plant capacities met European (EN14214) and US (ASTM D6751) fuel quality standards while the obtained commercially valuable side product, i.e., glycerol, adhered to a pharmaceutical grade of 99.7%. Cradle to gate life cycle analysis using GREET revealed that supercritical process possessed 17% lower CO2 emissions than alkali-catalyzed process and 4% lower CO2 emissions than the conventional diesel production process. Other biodiesel production pathways in the literature were also compared to the results of the TEA-LCA of supercritical biodiesel production pathway.

Biodiesel production↗
DOE OSTI2024

Technoeconomic Analysis of a Solar Thermochemical Fuel Production Process Using a Packed-Bed Redox Reactor

The production of sustainable liquid fuels is paramount in decarbonization of difficult to abate sectors such as the aviation and maritime sectors. Solar thermochemical fuel production is a promising pathway to produce such fuels using concentrated solar thermal (CST) power driving high-temperature redox reactions, coupled with a gas-to-liquid process. In this work we present a preliminary technoeconomic analysis of a solar fuels plant, utilizing a new fixed-bed countercurrent redox reactor and combining both CST and photovoltaic arrays to supply the required energy.

ENERGY STORAGE,HYDROGEN,SOLAR ENERGY↗
DOE OSTI2025

Operation of Argonne's Liquid Salt-Liquid Metal Separation Testbed for U/TRU Product Processing

Argonne National Laboratory has constructed a liquid salt-liquid metal separation testbed for use in the development and advancement of cathode processing of U/TRU co‑deposits generated by pyroprocessing of used nuclear fuel. The U/TRU product recovered from the electrorefiner contains adhered and entrained salt that must be removed prior to consolidation of the U/TRU alloy for use in advanced reactor fuel fabrication. The bottom pour operation utilizes the low melting points of U/TRU co‑deposits and higher densities of molten metals compared to molten salts to separate and consolidate the U/TRU product. Argonne’s testbed is designed to support the development and optimization of bottom-pouring configurations for batch and semi-continuous operations, integration of process monitoring and control technologies, and determination of operational requirements for implementing in an industrial setting. Scoping tests were performed to demonstrate operational aspects of the testbed, including operation using single-pour spout and dual-pour spout configurations, effectiveness of salt containment and extent of salt vaporization, and the use of sensor probes to detect the location of the interface between the metal and salt phases during pouring. Recommendations for process optimization testing for further development of bottom pour processing to separate U/TRU alloys from adhered salt were made based on the results of scoping tests. Completing the recommended activities will increase the technical readiness level (TRL) of the liquid salt-liquid metal separation operation and consolidation of U/TRU alloys to support industrialization of pyroprocessing.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Development of a Techno-Economic Analysis Framework for a Solar Thermochemical Fuel Production Process

Synthetic liquid fuels can provide a drop-in substitute for fossil-based fuels in sectors such as aviation and maritime, where electrification is not a viable option due to the need for high specific energy density. However, for these alternative fuels to be adopted at a commercial scale, their price must be competitive compared to their fossil-based counterparts. The reverse water-gas shift (RWGS) reaction offers a promising pathway, using hydrogen (sourced from electrolysis) and carbon dioxide as the feed and reacting to produce syngas - a mixture of H2 and CO at a specific ratio. Syngas is a useful precursor that can be converted into fuels and chemicals via known downstream processes, such as liquid transportation fuels via Fischer-Tropsch (FT) synthesis. The RWGS reaction is currently not applied in commercial scale, unlike the rest of the components in the process chain (electrolyzers and syngas-to-fuel synthesis units). The RWGS reaction poses several challenges due to its restrictive thermodynamics. Being an equimolar reaction, high temperatures and a large excess of H2 are needed to achieve reasonable CO2 conversion at equilibrium. This has detrimental effects on practical process implementation and the quality of syngas that can be produced, with direct effect on the energy and capital requirements, as well as the need for expensive downstream separation. In this work, we are proposing to develop a new concentrating solar thermal (CST) compatible RWGS reactor, performing the reaction in a 2-step chemical looping process using metal oxide at a temperature range of 600-800 degrees Celsius. By decoupling the reactor from the solar receiver, the Generation 3 (Gen3) CST technology could be utilized, together with its proposed thermal energy storage (TES) technology, benefitting from a good match to the required temperatures. CST technology is a viable option for supplying the heat that could be rapidly deployed in scale, thus being a good match to the gas-to-liquid (GTL) process which requires a large minimal scale to be commercially viable. The integration of TES with CST also allows operating the plant at large annual capacity factors and avoids multiple shutdown/startup cycles, thus fitting into the steady-state operation mode that most GTL processes require. The main innovation in the proposed design hinges on a countercurrent reaction design using a packed bed reactor. In 2019 Metcalfe et al. showed the benefits of countercurrent species exchange could be realized in a redox chemical-looping processes, by storing the favorable countercurrent chemical potential profiles in a packed bed of non-stoichiometric oxide. Metcalfe et al. applied this breakthrough concept to the WGS reaction, which is conventionally a co-feed catalytic process, showing a dramatic improvement. Bulfin et al. (2023) performed a similar proof-of-concept demonstration for the RWGS reaction using CeO2, achieving cumulative and peak CO2 conversions of 88% and 95%, respectively, compared to a thermodynamic limit of 58% for the co-feed catalytic process at the same conditions. In our new REGENLOOP project, we are developing a reactor prototype from the heat-exchange packed bed reactor-type, a commonly used reactor in the chemical industry. The endothermic heat of reduction will be supplied to the reactor using CST, while the same heat transfer fluid (HTF) mechanism will be used to extract the exothermic heat of oxidation. An array of multiple reactors is used to supply constant high-purity CO stream, that is then mixed with H2 from electrolysis to produce a high-purity syngas at the required composition. By removing the CO-CO2 separation after the RWGS process, significant energy and cost reduction can be achieved. A physics-based TEA framework is currently being developed, covering all the major plant processes, from the solar collection through storage, chemical looping RWGS, GTL, and auxiliary unit operations, up to the liquid hydrocarbon product. This modeling framework will utilize reduced-order models for the chemical looping RWGS and TES, CST modeling using SolarPILOT, and Aspen Plus for the GTL. By using this combined physics-based approach, the effects of design/operating parameters on the performance and cost can be elucidated. In our presentation, the modeling framework will be presented in detail, including preliminary cost predictions of using this plant configuration under a few selected relevant case studies. This study will be used to identify the major cost drivers, informing further system design and optimization needed to chart the way for a commercially viable pathway.

14 SOLAR ENERGY↗
DOE OSTI2024

Sustainable Aviation Fuel (SAF) State-of-Industry Report: State of SAF Production Process

GHG emissions related to commercial air travel were already significant, at 10% of the domestic transportation emissions and 3% of the global greenhouse gas emissions prior to the pandemic, and are expected to double by 2050, even with modest projected growth in air travel. Since Sustainable Aviation Fuel (SAF) is the only way that medium to long haul commercial aviation can be decarbonized, a US government wide "SAF Grand Challenge" was issued to encourage industry to develop capabilities to produce SAF, to reduce cost, improve sustainability, build value chains, and to scale production capabilities (1). The targets are to expand current domestic SAF 2022 production by 200X to 3 billion gallons per year by 2030, and then further by 12X to 35 billion gallons by 2050, while achieving life cycle GHG reduction of 50% relative to fossil Jet A. Following the SAF Grand Challenge, the DOE, USDA, EPA and FAA collaboratively developed a comprehensive strategy, outlined in the "SAF Grand Challenge Roadmap" (2), to inform stakeholders of the actions necessary to achieve the above volumetric targets. The purpose of this study is to provide an assessment of the current state of the SAF production industry and identify challenges and hurdles that industry may face in delivering the 2030 goals. This assessment is for the potential feedstocks and conversion pathways expected to contribute to 2030 goals and will generally follow action areas in the SAF Grand Challenge: feedstocks, conversion technology, supply chain, and policy & valuation.

09 BIOMASS FUELS↗
DOE OSTI2023

Jet-veto resummation at N 3 LL p + NNLO in boson production processes

Vetoing energetic jet activity is a crucial tool for suppressing backgrounds and enabling new physics searches at the LHC, but the introduction of a veto scale can introduce large logarithms that may need to be resummed. We present an implementation of jet-veto resummation for color-singlet processes at the level of N 3 LL p matched to fixed-order NNLO predictions. Our public code MCFM allows for predictions of a single boson, such as Z/γ*, W ± or H, or with a pair of vector bosons, such as W + W – , W ± Z or ZZ. The implementation relies on recent calculations of the soft and beam functions in the presence of a jet veto over all rapidities, with jets defined using a sequential recombination algorithm with jet radius R. However one of the ingredients that is required to reach full N 3 LL accuracy is only known approximately, hence N 3 LL p . We describe in detail our formalism and compare with previous public codes that operate at the level of NNLL. Our higher-order predictions improve significantly upon NNLL calculations by reducing theoretical uncertainties. We demonstrate this by comparing our predictions with ATLAS and CMS results.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2024

Optical vibrational spectroscopic signatures related to U 3 O 8 production processes

Uranium ore concentrates are materials found early within the nuclear fuel cycle and contain high concentrations of uranium in an easily transported form, making the concentrates a likely target for illegal diversion. These concentrates are typically converted to U 3 O 8 for further processing and, therefore, may lose specific physicochemical characteristics in determining the materials’ source and processing history. In this work, we explore the Raman spectra of eight oxide samples produced from various uranium ore concentrates and processing pathways to examine the presence of spectroscopic signatures relating to each sample's process history. Samples produced from amine extraction and dialkylphosphoric acid extraction processes show unique characteristics due to high concentrations of α-UO 3 , whereas samples calcinated from metallic diuranates do not form pure α-U 3 O 8 because of metallic ion inclusions. Pure α-U 3 O 8 oxide samples are obtained through calcination of ammonium diuranate, ammonium uranyl carbonate, and metastudtite intermediates. The Raman spectra of these oxide samples show close agreement with pristine α-U 3 O 8 spectra. However, deviations from the pristine spectra are observed in the 300–460 cm -1 spectral range. In conclusion, these deviations are unique identifying signatures that were likely created by lasting effects from the process history. Spectral center of mass calculations indicate grouping of samples based on processing history.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Vertical Structure and Ice Production Processes of Shallow Convective Postfrontal Clouds over the Southern Ocean in MARCUS. Part I: Observational Study

A study of the vertical structure of postfrontal shallow clouds in the marine boundary layer over the Southern Ocean is presented here. The central question of this two-part study regards cloud phase (liquid/ice) of precipitation, and the associated growth mechanisms. In this first part, data from the Measurements of Aerosols, Radiation, and Clouds over the Southern Ocean (MARCUS) field campaign are analyzed, starting with a 75-h case with continuous sea surface-based thermal instability, modest surface heat fluxes, an open-cellular mesoscale organization, and very few ice nucleating particles (INPs). The clouds are mostly precipitating and shallow (tops mostly around 2 km above sea level), with weak up- and downdrafts, and with cloud-top temperatures generally around –18° to –10°C. Further, the case study is extended to three other periods of postfrontal shallow clouds in MARCUS. While abundant supercooled liquid water is commonly present, an experimental cloud-phase algorithm classifies nearly two-thirds of clouds in the 0° to –5°C layer as containing ice (cloud ice, snow, or mixed phase), implying that much of the precipitation grows through cold-cloud processes. The best predictors of ice presence are cloud-top temperature, cloud depth, and INP concentration. Measures of convective activity and turbulence are found to be poor indicators of ice presence in the studied environment. The water-phase distribution in this cloud regime is explored through numerical simulations in Part II. Significance Statement: Climate models generally predict a lower albedo than observed over the Southern Ocean, and this is largely attributed to a lack of cloudiness, especially in the postfrontal cold sector of midlatitude cyclones. This in turn may be due to an excess of ice in these simulated clouds, resulting in rapid precipitation fallout and an overly brief cloud lifespan. The objective of this study is to examine whether shallow postfrontal clouds over the Southern Ocean are dominated by supercooled drops, or by snow and ice, using data collected by a U.S. Department of Energy Atmospheric Radiation Measurement Mobile Facility deployed aboard an Australian Antarctic supply vessel. We find that these clouds contain much supercooled liquid, even though cloud-top temperatures generally are around –18° to –8°C, and that about two-thirds of the clouds just above the freezing level contain ice. Much of the precipitation appears to grow through cold-cloud processes above the freezing level, rather than drizzle/rain. Updrafts and/or turbulence in convection or in cloud-top generating cells do not initiate much ice, compared to observations elsewhere in a similar temperature range. This may be attributable to the extremely low concentration of ice nucleating particles in this environment. Ultimately, the deepest clouds with the coldest cloud tops are most likely to be ice dominated.

54 ENVIRONMENTAL SCIENCES↗