Publications

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Materials in the La_xSr_1–xCo_yMn_1–yO_3–δ (LSCM) and La_xSr_1–xCo_yFe_1–yO_3–δ (LSCF) families are candidates for high-temperature thermochemical energy storage due to their facility for cyclic endothermic reduction and exothermic oxidation. A set of 16 LSCM and 21 LSCF compositions were synthesized by a modified Pechini method and characterized by powder X-ray diffraction and thermogravimetric analysis. All materials were found to be various symmetries of the perovskite phase. LSCM was indexed as tetragonal, cubic, rhombohedral, or orthorhombic as a function of increased lanthanum content. For LSCF, compositions containing low lanthanum content were indexed as cubic while materials with high lanthanum content were indexed as rhombohedral. An initial screening of redox activity was completed by thermogravimetric analysis for each composition. The top three compositions with the greatest recoverable redox capacity for each family were further characterized in equilibrium thermogravimetric experiments over a range of temperatures and oxygen partial pressures. As a result, these equilibrium experiments allowed the extraction of thermodynamic parameters for LSCM and LSCF compositions operated in thermochemical energy storage conditions.

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Concentrating solar power systems coupled to energy storage schemes, e.g. storage of sensible energy in a heat transfer fluid, are attractive options to reduce the transient effects of clouding on solar power output and to provide power after sunset and before sunrise. Common heat transfer fluids used to capture heat in a solar receiver include steam, oil, molten salt, and air. These high temperature fluids can be stored so that electric power can be produced on demand, limited primarily by the size of the capacity and the energy density of the storage mechanism. Phase changing fluids can increase the amount of stored energy relative to non-phase changing fluids due to the heat of vaporization or the heat of fusion. Reversible chemical reactions can also store heat; an endothermic reaction captures the heat, the chemical products are stored, and an exothermic reaction later releases the heat and returns the chemical compound to its initial state. Ongoing research is investigating the scientific and commercial potential of such reaction cycles with, for example, reduction (endothermic) and re-oxidation (exothermic) of metal oxide particles. This study includes thermodynamic analyses and considerations for component sizing of concentrating solar power towers with redox active metal oxide based thermochemical storage to reach target electrical output capacities of 0.1 MW to 100 MW. System-wide analyses here use one-dimensional energy and mass balances for the solar field, solar receiver reduction reactor, hot reduced particle storage, re-oxidizer reactor, power block, cold particle storage, and other components pertinent to the design. This work is part of a US Department of Energy (DOE) SunShot project entitled High Performance Reduction Oxidation of Metal Oxides for Thermochemical Energy Storage (PROMOTES).

Certain details of the additive manufacturing process known as selective laser melting (SLM) affect the performance of the final metal part. To unleash the full potential of SLM it is crucial that the process engineer in the field receives guidance about how to select values for a multitude of process variables employed in the building process. These include, for example, the type of powder (e.g., size distribution, shape, type of alloy), orientation of the build axis, the beam scan rate, the beam power density, the scan pattern and scan rate. The science-based selection of these settings con- stitutes an intrinsically challenging multi-physics problem involving heating and melting a metal alloy, reactive, dynamic wetting followed by re-solidification. In addition, inherent to the process is its considerable variability that stems from the powder packing. Each time a limited number of powder particles are placed, the stacking is intrinsically different from the previous, possessing a different geometry, and having a different set of contact areas with the surrounding particles. As a result, even if all other process parameters (scan rate, etc) are exactly the same, the shape and contact geometry and area of the final melt pool will be unique to that particular configuration. This report identifies the most important issues facing SLM, discusses the fundamental physics associated with it and points out how modeling can support the additive manufacturing efforts.

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Recent advances in the production of photovoltaic panels have driven down the cost of solar power. Estimates for the levelized cost of electricity from PV range from 10 to 30 cents per kWh. And though this is still higher than the cost of generation from a newly built coal-fired thermal power station, solar power could be the cheapest electricity available in some areas within a few years, according to data from the Energy Information Agency.

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Despite rapid progress, solar thermochemistry remains high risk; improvements in both active materials and reactor systems are needed. This claim is supported by studies conducted both prior to and as part of this project. Materials offer a particular large opportunity space as, until recently, very little effort apart from basic thermodynamic analysis was extended towards understanding this most fundamental component of a metal oxide thermochemical cycle. Without this knowledge, system design was hampered, but more importantly, advances in these crucial materials were rare and resulted more from intuition rather than detailed insight. As a result, only two basic families of potentially viable solid materials have been widely considered, each of which has significant challenges. Recent efforts towards applying an increased level of scientific rigor to the study of thermochemical materials have provided a much needed framework and insights toward developing the next generation of highly improved thermochemically active materials. The primary goal of this project was to apply this hard-won knowledge to rapidly advance the field of thermochemistry to produce a material within 2 years that is capable of yielding CO from CO2 at a 12.5 % reactor efficiency. Three principal approaches spanning a range of risk and potential rewards were pursued: modification of known materials, structuring known materials, and identifying/developing new materials for the application. A newly developed best-of-class material produces more fuel (9x more H2, 6x more CO) under milder conditions than the previous state of the art. Analyses of thermochemical reactor and system efficiencies and economics were performed and a new hybrid concept was reported. The larger case for solar fuels was also further refined and documented.

Active brazes have been used for many years to produce bonds between metal and ceramic objects. By including a relatively small of a reactive additive to the braze one seeks to improve the wetting and spreading behavior of the braze. The additive modifies the substrate, either by a chemical surface reaction or possibly by alloying. By its nature, the joining process with active brazes is a complex nonequilibrium non-steady state process that couples chemical reaction, reactant and product diffusion to the rheology and wetting behavior of the braze. Most of the these subprocesses are taking place in the interfacial region, most are difficult to access by experiment. To improve the control over the brazing process, one requires a better understanding of the melting of the active braze, rate of the chemical reaction, reactant and product diffusion rates, nonequilibrium composition-dependent surface tension as well as the viscosity. This report identifies ways in which modeling and theory can assist in improving our understanding.

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Ferrites are promising materials for enabling solar-thermochemical cycles. Such cycles utilize solar-thermal energy to reduce the metal oxide, which is then re-oxidized by H2O or CO2, producing H2 or CO, respectively. Mixing ferrites with zirconia or yttria-stabilized zirconia (YSZ) greatly improves their cyclabilities. In order to understand this system, we have studied the behavior of iron oxide/8YSZ (8 mol-% Y2O3 in ZrO2) using in situ X-ray diffraction and thermogravimetric analyses at temperatures up to 1500 °C and under controlled atmosphere. The solubility of iron oxide in 8YSZ measured by XRD at room temperature was 9.4 mol-% Fe. The solubility increased to at least 10.4 mol-% Fe when heated between 800 and 1000 °C under inert atmosphere. Furthermore iron was found to migrate in and out of the 8YSZ phase as the temperature and oxidation state of the iron changed. In samples containing >9.4 mol-% Fe, stepwise heating to 1400 °C under helium caused reduction of Fe2O3 to Fe3O4 to FeO. Exposure of the FeO-containing material to CO2 at 1100 °C re-oxidized FeO to Fe3O4 with evolution of CO. Thermogravimetric analysis during thermochemical cycling of materials with a range of iron contents showed that samples with mostly dissolved iron utilized a greater proportion of the iron atoms present than did samples possessing a greater fraction of un-dissolved iron oxides.© 2012 JCPDS-ICDD.

This 'campus executive' project sought to advance solar thermochemical technology for producing the chemical fuels. The project advanced the common interest of Sandia National Laboratories and the University of Arizona in creating a sustainable and viable alternative to fossil fuels. The focus of this effort was in developing new methods for creating unique monolithic composite structures and characterizing their performance in thermochemical production of hydrogen from water. The development and processing of the materials was undertaken in the Materials Science and Engineering Department at the University of Arizona; Sandia National Laboratories performed the thermochemical characterization. Ferrite/yttria-stabilized zirconia composite monoliths were fabricated and shown to have exceptionally high utilization of the ferrite for splitting CO{sub 2} to obtain CO (a process analogous to splitting H{sub 2}O to obtain H{sub 2}).

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