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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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11 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Automated Laboratory Kilogram-Scale Graphene Production from Coal

The flash Joule heating (FJH) method converts many carbon feedstocks into graphene in milliseconds to seconds using an electrical pulse. This opens an opportunity for processing low or negative value resources, such as coal and plastic waste, into high value graphene. Here, in this work, a lab-scale automation FJH system that allows the synthesis of 1.1 kg of turbostratic flash graphene from coal-based metallurgical coke (MC) in 1.5 h is demonstrated. The process is based on the automated conversion of 5.7 g of MC per batch using an electrical pulse width modulation system to conduct the bottom-up upcycle of MC into flash graphene. This study then compare this method to two other scalable graphene synthesis techniques by both a life cycle assessment and a technoeconomic assessment.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

The physics potential of a reactor neutrino experiment with Skipper CCDs: Measuring the weak mixing angle

We analyze in detail the physics potential of an experiment like the one recently proposed by the vIOLETA collaboration: a kilogram-scale Skipper CCD detector deployed 12 meters away from a commercial nuclear reactor core. This experiment would be able to detect coherent elastic neutrino nucleus scattering from reactor neutrinos, capitalizing on the exceptionally low ionization energy threshold of Skipper CCDs. To estimate the physics reach, we elect the measurement of the weak mixing angle as a case study. We choose a realistic benchmark experimental setup and perform variations on this benchmark to understand the role of quenching factor and its systematic uncertainties, background rate and spectral shape, total exposure, and reactor antineutrino flux uncertainty. We take full advantage of the reactor flux measurement of the Daya Bay collaboration to perform a data driven analysis which is, up to a certain extent, independent of the theoretical un- certainties on the reactor antineutrino flux. We show that, under reasonable assumptions, this experimental setup may provide a competitive measurement of the weak mixing angle at few MeV scale with neutrino-nucleus scattering.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2023

Synthesis and processing of lithium-loaded plastic scintillators on the kilogram scale

Plastic scintillators that can discriminate between gamma rays, fast neutrons, and thermal neutrons were synthesized and characterized while considering the performance at the kilogram scale. The synthesis and processing of these plastic scintillators on the kilogram scale required examination of several factors. The examination of these factors was necessitated by the inclusion of 0.1 wt.% lithium-6 to enable detection of thermal neutrons. First, methacrylic acid was used as an additive to solubilize salts of lithium-6, which allow for a thermal-neutron capture reaction that produces scintillation light following energy transfer. Second, a trade-off between scintillation performance and processability was considered because the increasing content of the methacrylic acid that aided processability resulted in a sharp decrease in the light output. The use of small amounts of methacrylic acid (≤3 wt.%) resulted in better performance but required high processing temperatures. At large scales, these high temperatures could initiate exothermic polymerization that results in premature curing and/or defects. Additionally, the deleterious effects of the methacrylic acid may be mitigated by using m-terphenyl as a primary dye rather than 2,5-diphenyloxazole (PPO), which has been traditionally used in organic scintillators. Finally, the curing environment was controlled to avoid defects like cracking and discolouration​ while maintaining solubility of dopants during curing. For scintillators that were produced from kilogram-scale batches of precursors, the effective attenuation of scintillation light was characterized.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Performance of large-scale 6 Li-doped pulse-shape discriminating plastic scintillators

A 6 Li-doped plastic scintillator with pulse-shape discrimination capabilities, commercially identified as EJ -299-50, has been developed and produced at the kilogram-scale. A total of 44 bars of dimensions 5.5 cm x 5.5 cm x 50 cm of this material have been characterized. Optical properties like light output and effective attenuation length have been found to be comparable to 6 Li-doped liquid scintillators. Further, the scintillator EJ -299-50 shows good neutron detection capabilities with an effective efficiency for capture on 6 Li of approximately 85%. Stability tests performed on two formulation variations showed no intrinsic degradation in the material or optical properties during several months of observations.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

Improved Solid-State Reaction Method for Scaled-Up Synthesis of Ceramic Proton-Conducting Electrolyte Materials

Protonic ceramic electrochemical cells (PCECs) represent promising technologies in the production of clean electricity, decarbonized hydrogen, chemicals, and fuels at intermediate temperatures. One of the challenges in commercializing PCECs is to produce the electrolyte materials on a large scale. The conventional solid-state reaction (SSR) method suffers from tedious synthesis procedures and low phase purity of the products due to the formation of unwanted secondary phases. Herein, we report an improved SSR (i-SSR) method for kilogram-scale production of high phase-purity electrolyte material BaZr 0.4 Ce 0.4 Y 0.1 Yb 0.1 O 3–δ (BZCYYb4411). In this method, the ball-milled precursor powders are pelletized prior to calcination, which effectively reduces the length of the diffusion paths between the components during perovskite phase formation. In this study, the synthesis procedure and calcination temperature are carefully optimized for efficient and repeatable production based on the powder crystallization behavior. A combined technoeconomic analysis and life cycle assessment modeling suggest that the i-SSR method could reduce the total production cost and greenhouse gas emissions by up to 19% and 39%, respectively, compared to the conventional SSR method. The high quality of the synthesized electrolyte material is corroborated by the excellent electrical conductivity and electrochemical performance of the fabricated PCEC cells.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Industrializable interlayer with catalytic conversion of dead lithium for Ah–level Nickel–rich lithium metal batteries

The growth of lithium (Li) dendrites and the accumulation of dead Li (i.e., Li metal regions which are electronically disconnected from the current collector) significantly undermine the safety and performance of Li metal batteries. This study employs kilogram-scale atomic layer deposition technology to construct zinc oxide with a preferential (002) crystal orientation, which homogeneously forms on commercial carbon nanotube papers. Our approach emphasizes the importance of achieving a moderate Li adsorption energy and low Li migration energy barriers to suppress Li dendrite growth. In this work, we introduce the concept of "catalytic" effect for dead Li reconversion, as validated through time-of-flight secondary ion mass spectrometry, leading to a Li plating/stripping efficiency of 99.89%. The Ah-level Li metal pouch cells with high-nickel positive electrodes achieve a specific energy of 380 Wh kg -1 (based on the mass of the whole pouch cell) and demonstrate stable cycling under demanding conditions. Analysis of the cycled pouch cells confirms the structural integrity and provides insights into the mechanism of the dead Li "catalytic" conversion.

Shen, Huasen [Jianghan University, Wuhan (China)]↗
DOE OSTI2020

Demonstration of Integrated PostIrradiation Process Steps forMultikilogram Amounts of Low- and High-Burnup Used Nuclear Fuels

sponsored research and development (R&D) on the advanced, closed nuclear fuel cycle, including post-irradiation processing of used fuels, recovery of separated components, and preparation of recycle nuclear fuels. During the period 2007–2010, kilogram-scale demonstrations of the integrated processing steps were performed for actual light water reactor (LWR) used nuclear fuels (UNF). These integrated processing demonstrations were called “the Coupled-End-to-End” (CETE) campaigns and were associated with the Global Nuclear Energy Partnership program, which ran concurrently. The demonstrations were carried out in the shielded hot cells and associated gloveboxes located in the Irradiated Fuels Examination Laboratory (IFEL) and the Radiochemical Engineering Development Center (REDC) at the Oak Ridge National Laboratory (ORNL). Limited circulation program reports and a few technical papers were issued. The subject document provides a comprehensive summary of results, technical comparisons, and conclusions obtained from the demonstration campaigns and subsequent associated R&D.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Advanced Manufacturing of Cathode Materials for Lithium-ion Batteries

Original objectives (per the Statement of Project Objectives) centered on developing and translating a continuous pilot process for cathode materials production while targeting (i) a 29% manufacturing cost reduction, (ii) an 82% energy consumption reduction for cathode production, and (iii) a doubling of manufacturing productivity. Planned validation included characterization at appropriate analytical facilities and electrochemical performance evaluation progressing from half-cells to pouch-cell formats, with a pathway to kilogram-scale production of finished cathode materials for representative testing. Scope evolution: During execution, the project team identified that the surfactant-enabled chemistry offered high selectivity for lithium precipitation from brine sources. A formal scope revision shifted the final project year from cathode manufacturing development to direct lithium extraction/lithium recovery, while maintaining the overarching intent of cost reduction and process simplification relevant to the battery supply chain.

25 ENERGY STORAGE↗
DOE OSTI2026

Development of Post-Consumer Textile Waste Degradation Protocol and Related Downstream Transformations: Cooperative Research and Development (Final Report)

Tereform, Inc. (Tereform) is developing molecular deconstruction processes to transform waste materials into chemical building blocks. During the CRADA, Tereform deconstructed real-world post-consumer substrates into chemical monomers, validated their performance on laboratory scales, demonstrated feasibility of the degradation products in downstream transformations, and successfully scaled the reaction to kilogram-scale. These results were used to develop and refine technoeconomic analysis and lifecycle assessments to evaluate the economic feasibility and environmental impacts of the process.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Multi-channel, multi-template event reconstruction for SuperCDMS data using machine learning

SuperCDMS SNOLAB uses kilogram-scale germanium and silicon detectors to search for dark matter. Each detector has Transition Edge Sensors (TESs) patterned on the top and bottom faces of a large crystal substrate, with the TESs electrically grouped into six phonon readout channels per face. Noise correlations are expected among a detector's readout channels, in part because the channels and their readout electronics are located in close proximity to one another. Moreover, owing to the large size of the detectors, energy deposits can produce vastly different phonon propagation patterns depending on their location in the substrate, resulting in a strong position dependence in the readout-channel pulse shapes. Both of these effects can degrade the energy resolution and consequently diminish the dark matter search sensitivity of the experiment if not accounted for properly. We present a new algorithm for pulse reconstruction, mathematically formulated to take into account correlated noise and pulse shape variations. This new algorithm fits N readout channels with a superposition of M pulse templates simultaneously - hence termed the N$\times$M filter. We describe a method to derive the pulse templates using principal component analysis (PCA) and to extract energy and position information using a gradient boosted decision tree (GBDT). We show that these new N$\times$M and GBDT analysis tools can reduce the impact from correlated noise sources while improving the reconstructed energy resolution for simulated mono-energetic events by more than a factor of three and for the 71Ge K-shell electron-capture peak recoils measured in a previous version of SuperCDMS called CDMSlite to $<$ 50 eV from the previously published value of $\sim$100 eV. These results lay the groundwork for position reconstruction in SuperCDMS with the N$\times$M outputs.

Albakry, M. F. [British Columbia U.; TRIUMF]↗