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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 OSTI2025

Effects of Particle Mixing and Gravitational Settling on Charge Transport in Carbon Flow-Electrode Cells

Flowable carbon slurries are actively studied and under development for charge transport in various electrochemical systems including flow capacitors, capacitive deionization cells, semi-solid flow batteries, and lithium extraction. However, much less is known about in operando slurry flow dynamics and their corresponding effect on charge transport. We performed an experimental study of mixing and settling dynamics of slurry electrodes within an electrochemical flow cell during continuous operations. The electrochemical cell consisted of two horizontal co-flowing channels, separated by a cation-exchange membrane (CEM). Here we used high-speed optical imaging of planes parallel to gravity and simultaneous electrochemical measurements. At low flow rates, dense yet dynamic particle beds formed on the bottom electrode in each channel, which unexpectedly yielded the highest currents. This approach enables the operation of the flow cell at low system-average particle concentrations while leveraging gravity-driven particle settling to locally enhance carbon concentrations precisely at the current collector sites. Conversely, high flow rates were characterized by thin particle beds and well-mixed particle flows. In the latter case, the electrodes in closest proximity (located on either side of the CEM) achieved a current higher than the other electrode pairs. The observations have implications for slurry control and electrode designs in electrochemical systems.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Motion of Air Bubbles in a Cement Slurry

The dynamics of air (gas) bubbles in a column of cement slurry is examined numerically. The air injected at the bottom of a laboratory-scale column through a porous distributor plate spatially distributes and migrates as a swarm of bubbles throughout the slurry toward the freeboard. The two-phase system of the cement slurry and the air bubbles is modeled using the conservation equations of mass and linear momentum in the framework of the volume-of-fluid (VOF) approach. The cement slurry is modeled using the Herschel–Bulkley and Bingham fluid models. Results show that the mean Sauter diameter and the mean rise velocity of the bubbles decrease with the gas flow rate. Meanwhile, it is found that the rising of the bubbles is controlled by breakup events, along with relatively weak path instabilities of the bubbles resulting in relatively straight trajectories, independent of the gas flow rate. The extent of the yielded region appears larger for the Herschel–Bulkley model compared to the Bingham fluid model (by approximately 10%).

36 MATERIALS SCIENCE↗
DOE OSTI2021

Role of Low Molecular Weight Polymers on the Dynamics of Silicon Anodes During Casting

This work probes the slurry architecture of a high silicon content electrode slurry with and without low molecular weight polymeric dispersants as a function of shear rate to mimic electrode casting conditions for poly(acrylic acid) (PAA) and lithium neutralized poly(acrylic acid) (LiPAA) based electrodes. Rheology coupled ultra-small angle neutron scattering (rheo-USANS) was used to examine the aggregation and agglomeration behavior of each slurry as well as the overall shape of the aggregates. The addition of dispersant has opposing effects on slurries made with PAA or LiPAA binder. With a dispersant, there are fewer aggregates and agglomerates in the PAA based silicon slurries, while LiPAA based silicon slurries become orders of magnitude more aggregated and agglomerated at all shear rates. The reorganization of the PAA and LiPAA binder in the presence of dispersant leads to a more homogeneous slurry and a more heterogeneous slurry, respectively. This reorganization ripples through to the cast electrode architecture and is reflected in the electrochemical cycling of these electrodes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Probing Clustering Dynamics between Silicon and PAA or LiPAA Slurries under Processing Conditions

This work explores the complex interplay between slurry aggregation, agglomeration, and conformation (i.e., shape) of poly(acrylic acid) (PAA)- and lithiated PAA-based silicon slurries as a function of the shear rate and the resulting slurry homogeneity. These values were measured by small-angle neutron scattering (SANS) and rheology-coupled ultra-SANS at conditions relevant to battery electrode casting. Different binder solution preparation methods, either a ball milling (BM) process or a planetary centrifugal mixing (PCM) process, dramatically modify the resulting polymer dynamics and organization around a silicon material. This is due to the different energy profiles of mixing where the more violent and higher energy PCM causes extensive breakdown and reformation of the binder, which is now likely in a branched conformation, while the lower energy BM results in simply lower-molecular weight linear polymers. In conclusion, the breakdown and reorganization of the polymer structure affect silicon slurry homogeneity, which affects subsequent electrode architecture.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Avoiding surface instability and slurry jamming in simultaneous multilayer coating of structured particulate films

Simultaneous multilayer coating techniques are widely known, but their industrial application remains limited to narrow market sectors. One barrier to adoption may be the mismatch between industries that are familiar with such processes but have no need, and industries that have need but are not familiar. Moreover, there are application-specific technical challenges to developing multilayer-coating processes. In this article, we describe our resolution of two specific issues in simultaneous multilayer coating of all aqueous highly loaded slurries for new and emerging energy applications. The first issue is particle jamming (associated with Shear-thickening) of the highly loaded slurries in the die internals, which we alleviated by adding small amounts of viscosity modifiers without reducing the solid loading. The second issue is a Marangoni-driven surface instability that resembles top layer de-wetting, which we solved by carefully selecting surfactants to tune the dynamic surface tensions of each slurry. Both issues were resolved early in a step-wise development, saving significant development cost which in our case was driven by expensive materials.

08 HYDROGEN↗
DOE OSTI2024

Solid–liquid separation of lignocellulosic sugars from biomass by rotating ceramic disc filtration

In many biomass conversion processes, the separation of cellulosic sugars from residual, lignin-rich solids is a critical step, and achieving high recovery yields of sugars by conventional tangential crossflow and vacuum filtration is challenged by the presence of biomass solids, which rapidly foul filters, resulting in decreased throughput. Considering the performance limitations of traditional filtration methods, dynamic filtration, which generates high shear at the membrane surface to decrease fouling, is emerging as a viable alternative for demanding solid–liquid separations. For high solids separations, there is little available information regarding the performance, limitations, and energy consumption of dynamic filtration. To that end, here we characterized the performance of a dynamic filtration module, specifically a rotating ceramic disc (RCD) filter, for the aseptic recovery of cellulosic sugars from biomass solids following pretreatment and enzymatic hydrolysis. We show how RCD rotational velocity and percent biomass solids impact the filter throughput. Additionally, we used computational fluid dynamics (CFD) simulations to estimate the shear rate at the membrane surface and to visualize hydrodynamic profiles within the module. With the combined CFD simulations and experimental results, we estimated the energy demand and operating expenses for a viable dynamic filtration system operating with a lignocellulosic feed slurry. Our results indicate that an RCD filter can achieve ≥95% recovery of sugars and produce a retentate slurry containing 12 wt% insoluble solids with low energy consumption (a 2.2-fold improvement over cross-flow filtration) and low operating costs ($\$$0.06 per kg sugars). These results show a viable path towards operationally reliable, energy efficient, and cost-effective separations of sterilized cellulosic sugars from biomass solids and highlight the potential of dynamic filtration systems for challenging solid–liquid separations.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Origin of rate limitations in solid-state polymer batteries from constrained segmental dynamics within the cathode

Currently, one of the key challenges preventing the wide commercialization of polymer-based solid-state batteries is achieving high-rate capabilities. This work unravels chain structure and segmental dynamics in a polymer-based composite cathode consisting of LiFePO 4 (LFP), carbon, and poly(ethylene oxide) (PEO) with lithium bis(trifluoromethanesulfonyl)imide. Small-angle neutron scattering (SANS) data reveal that PEO chains are adsorbed on the surface of LFP particles during slurry processing to make the composite electrode. The strong interaction between LFP and PEO chains leads to greatly reduced segmental dynamics of PEO, as discovered by quasi-elastic neutron scattering (QENS). The reduced segmental dynamics results in 70% decreased Li + mobility of the polymer electrolyte in the composite cathode. The combined SANS and QENS study indicates that one of the key bottlenecks that limits the rate performance of PEO-based polymer batteries originates from molecular interactions within the cathode.

25 ENERGY STORAGE↗
DOE OSTI2022

Design and performance analysis of a Swirl Pintle injector for a 1 MW th pressurized oxy-coal combustor

Pressurized Oxy-coal combustion has the potential to achieve high thermal efficiency by recovering the latent heat of steam from flue gases and providing options for up to 95% carbon capture. Here, this study proposes a novel burner technology for pressurized oxy-coal combustion and investigates its operability. Three burner versions are designed and tested; no swirl, swirl numbers 0.9 and 1.2 to identify optimum design parameters and performance. A commercially available Dantec Dynamics software is used to conduct the shadowgraph experiments to observe burner performance. Coal water slurry is used as fuel with three different slurry ratios where the coal percentage by weights were 30, 40 and 50. Droplet size, distribution, spray angle and jet breakup lengths are measured and analyzed to quantify the performance. The study found that increasing the swirl number enhanced atomization. Implementing swirlers allowed the jet to spread through faster primary jet separation, thus improving atomization. In addition, higher slurry ratios improved the generation of smaller particles. However, it was also found that excessive increases in oxidizer momentums negatively impact the atomization process by jet shrinkage. The study concluded that operating a pintle burner at 1.2 swirl conditions with a 40/60 slurry ratio produces optimum performance.

42 ENGINEERING↗
DOE OSTI2020

Large Cemented Gibbsite Agglomerates in Alkaline Nuclear Waste at the Hanford Site and the Impacts to Remediation

Recent work with the remediation of legacy alkaline nuclear waste has focused on nanometer and micrometer particle sizes, emphasizing how these small particles can impact efforts to treat the waste. Building upon this work, we present here findings that show very large particles (several centimeters in size) also exist in these waste which likewise play an important role in the remediation process. While large cemented gibbsite nodules have been periodically reported in acid soils in the literature, this study found similar large gibbsite agglomerates (7 cm in diameter) in alkaline nuclear waste, the first time that such large agglomerates have been identified in an alkaline environment. The morphology of the gibbsite in the agglomerates that were grown over more than 40 years of storage in the waste tank were similar to the much smaller agglomerates that have been reported in previous shorter term studies. Fluid dynamics calculations indicate that these cemented particles would be difficult to mobilize with standard jet slurry technologies, which is consistent with their residence in the waste heel after jet sluicing of the tank.

agglomerates, alkaline nuclear waste↗
DOE OSTI2020

Particle Size and Density Measurement

This project has developed a miniature gravity settling classifier (flow cell) and flow system that separates slurry particles by settling rate into six different Cuts. The settling rates for particles in each Cut were determined from COMSOL computational fluid dynamics (CFD) modeling of the flow in the flow cell together with particle tracking for particles of differing settling rates. For particles collected in each Cut, the particle concentration and size distribution were measured. The effective particle densities from each Cut are calculated from their respective CFD modeled settling rates using a relationship between the unhindered settling rate, particle size distribution (PSD), and effective density. The particle size and density distribution (PSDD) of the slurry sample is then calculated by combining the size and density distributions determined for the particles collected in each of the settling rate Cuts.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

System Configuration Evaluation for Process Settling of Hanford Waste Solid Particles

Direct Feed High-Level Waste (DFHLW) is a potential flowsheet operations approach to initiating high-level waste (HLW) vitrification prior to completion of the Hanford Waste Treatment and Immobilization Plant (WTP) Pretreatment Facility. A settle/decant process has been proposed to concentrate solids prior to delivery to the WTP HLW Facility during DFHLW operations, wherein the solids in a settled layer would be remixed with the supernatant liquid remaining after decanting operations to provide the feed at required solids concentrations. Settling would be used in lieu of purpose-built filtration or other solids separation equipment. Pacific Northwest National Laboratory (PNNL) is providing baseline technical support to the Washington River Protection Solutions (WRPS) Flowsheet Integration group. To support planning for DFHLW, WRPS previously requested that PNNL evaluate the current data set available to predict the time needed for HLW solids to settle and the solids concentration and strength of that settled layer, to identify gaps in the understanding and predictive capability of HLW solids waste settling times, and to provide scoping estimates of the potential settling times. Eight technical gaps were identified for predicting settling times and characteristics of the formed sediment layers. In addition to the data gaps, an overarching observation was made that there is significant variation in behavior of settling rate and settled layer data. The settling time required to concentrate solids via a settle/decant process was determined from the limited data to have a difference of potentially more than a factor of 5,000 in the estimated settling times, varying from 0.2 to 1,060 days for example depending on process vessel depth and final sediment solids concentration. In contrast, successful processes of liquid-forward output streams resulting from in-tank settling and decanting forward liquid have been reported for operations conducted at the Hanford Site. The purpose of this current report is to further support DFHLW planning by evaluating double-shell tank (DST) and alternate vessel equipment and operational configurations to enable optimization of the settle/decant process to concentrate solids. Hanford waste processing behavior specific to liquid feed availability following a slurry transfer in a DST is summarized, including process stream characteristics and process equipment configurations. The performance of DST process equipment configurations is evaluated for possible improvements using computational fluid dynamics (CFD) and simple analytical models. Potential new vessel design(s) specific to enabling effective settle/decant processes, and cursory summary of other separate and inline solids separations processes, are also provided. The CFD results indicated that improvement in outflow solids concentration was promoted by a reduction in the slurry flow rate, angling the distributor nozzles downward, and lifting the transfer pump. The solid-liquid analysis evaluating particle trajectory confirmed that the potential for particle ingestion (in the transfer pump) was decreased with increased radial separation between the inlet and outlet (transfer pump inlet), decreased inlet flow, and decreased liquid density and viscosity for a neutrally buoyant inlet flow. An assessment was also made of the potential for inflow configuration changes to result in the discrete mounding or piling of solids within the tank. Based on the characterization of the settled waste to date, HLW sediments will be unlikely to sustain a substantial angle of repose to facilitate significant variations in the elevation of the settled solids.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Rheological Properties of Enzymatically Hydrolyzed Corn Stover Pretreated via Deacetylation and Mechanical Refining

Lignocellulosic biomass is a feedstock for fuels and chemicals that does not compete with food resources and has less contaminants than refuse-derived biomass feedstocks. To convert lignocellulosics to biofuels or value-added products, multiple processing steps are typically necessary. One method of producing biofuels from lignocellulosic biomass utilizes a deacetylation and mechanical refining pretreatment and an enzymatic hydrolysis reaction to produce fermentable sugars from cellulose and hemicellulose. The rheological properties of biomass, such as yield stress and plastic viscosity, change during enzymatic hydrolysis and alter the energy requirements for pumping and mixing, an important consideration for the design of processing equipment. The dynamic changes in rheological properties that occur in a corn stover feedstock undergoing enzymatic hydrolysis are characterized in this work, and the influence on pressure losses in piping systems is estimated. Two rheometer geometries were fabricated with stereolithography 3D printing to reduce wall slip and sample ejection. The slurries have complex rheological behaviors that include shear-thinning behavior. Shear stress ramps were performed on samples at 20 and 50 degrees C using the custom geometries, and the Herschel-Bulkley model was fit to the data. The dynamic nature of the rheological properties is correlated with changes in the average fiber length at various extents of reaction, and the influence of solids concentration on the observed rheology and piping pressure losses is discussed.

09 BIOMASS FUELS↗
DOE OSTI2020

Connecting particle interactions to agglomerate morphology and rheology of boehmite nanocrystal suspensions

Rheology imposes significant challenges on processing of complex suspensions such as nuclear waste slurries at the Hanford and Savannah River sites. Understanding rheology connecting to microstructures and underlying particle interactions in complex slurries is therefore important for both fundamental knowledge and practical applications. Here, we use suspensions of aluminum oxyhydroxide minerals in the form of boehmite as an analog of the radioactive waste slurry to gain physical insights on the correlation between particle interactions, microstructures, and slurry rheology. Specifically, we use a combination of Couette rheometry and small-angle scattering techniques (independently and simultaneously) to understand how the slurry microstructure changes under flow and how these structural changes manifest themselves in the bulk rheology of the suspensions. Our experiments show that the boehmite slurries are thixotropic, with the rheology and structure of the suspensions changing with increasing exposure to flow. In the slurries, particle aggregates begin as loose, system-spanning clusters, but exposure to moderate shear rates causes the aggregates to irreversibly consolidate into denser clusters of finite size. The microstructural changes directly influence the rheological properties of the slurries such as viscosity and viscoelasticity. More importantly, our study shows that solution pH affects the amount of structural rearrangement and the kinetics of the rearrangement process, with an increase in pH leading to faster and more dramatic changes in the bulk rheology. Such dynamic microstructural changes and resultant rheology are understood via correlations between particle interactions and strength of particle network, coupled with surface chemistry and anisotropic nature of particle interactions. Nearly identical structural changes are also observed in Poiseuille flow geometries, implying that the observed changes are relevant in the pipe flow conditions present during waste processing.

Weston, Javen S.↗
DOE OSTI2021

Structure and dynamics of small polyimide oligomers with silicon as a function of aging

The effect of UV curing and shearing on the structure and behavior of a polyimide (PI) binder as it disperses silicon particles in a battery electrode slurry was investigated. PI dispersant effectiveness increases with UV curing time, which controls the overall binder molecular weight. Here, the shear force during electrode casting causes higher molecular weight PI to agglomerate, resulting in battery anodes with poorly dispersed Si particles that do not cycle well. It is hypothesized that when PI binder is added above a critical amount, it conformally coats the silicon particles and greatly impedes Li ion transport. There is an “interzonal region” for binder loading where it disperses silicon well and provides a coverage that facilitates Li transport through the anode material and into the silicon particles. These results have implications in ensuring reproducible electrode manufacturing and increasing cell performance by optimizing the PI structure and coordination with the silicon precursor.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Numerical study of proppant transport and settling processes in fractures

Reservoir stimulation by creating hydraulically conductive fractures is the key step for enabling enhanced geothermal systems (EGS). The effectiveness of stimulation is significantly influenced by the deposition of proppant inside induced fractures. The transportation and settling of proppant in a propagating fracture is controlled by a multitude of operational and physical parameters, including the fracturing fluid rheology, injection rate, proppant concentration, fracture length/aperture evolution, proppant size/density/shape, etc. A numerical tool that robustly and efficiently accounts for all important attributes can facilitate the design and optimization of reservoir stimulation. This study presents the novel computational tool ELK (ELectrical fracKing) developed for the numerical simulation of proppant-fluid mixture circulation in a fractured geothermal reservoir. We enriched the MOOSE-based PorousFlow module with a suite of equations to consider the fluid-proppant mixture with particle-particle/fluid interactions, which include gravitational settling, particle convection, particle hampering, and strong density and viscosity contrasts. The computational tool is validated by comparing the predicted proppant bed evolution against two different laboratory scale experiments of proppant transport in a fixed aperture channel. Further parameter studies were performed, and the modeling results show that the proppant deposition is determined by the mixing characteristics and settling of the particles from the slurry. Concentration-dependent density and viscosity lead to an inhomogeneous distribution of the proppant, particle collision, and enhanced settling at the bottom of the fractures. Preliminary coupling with dynamic fracture propagation shows promising results and will be further developed to simulate hydraulic stimulation at high fidelity.

15 GEOTHERMAL ENERGY↗