Sandia Materials Science Investment Area contributed to the SARS-CoV-2 virus and COVID-19 disease which represent the most significant pandemic threat in over 100 years. We completed a series of 7, short duration projects to provide innovative materials science research and development in analytical techniques to aid the neutralization of COVID-19 on multiple surfaces, approaches to rapidly decontaminate personal protective equipment, and pareto assessment of construction materials for manufacturing personal protective equipment. The developed capabilities and processes through this research can help US medical personnel, government installations and assets, first responders, state and local governments, and multiple federal agencies address the COVID-19 Pandemic.
A preliminary investigation of the use of supercritical carbon dioxide for treating of 3M 1860 N95 masks was undertaken to evaluate a potential route to low-cost, scalable, sterilization of personal protective equipment for multiple reuse in hospital settings. Upon entering the supercritical regime, the normally distinct liquid and gaseous phases of CO2 merge into a single homogeneous phase that has density, short-range order, and solvation capacity of a liquid, but the volume-filling and permeation properties that of a gas. This enables supercritical CO2 to function as a vehicle for delivery of biocidal agents such peracetic acid into microporous structures. The potentially adverse effect of a liquid-to-gas phase transition on mask filter media is avoided by conducting cleaning operations above 31 C, the critical temperature for carbon dioxide. A sample of fifteen 3M 1860 N95 masks was subjected to ten consecutive cycles of supercritical CO2 cleaning to determine its effect on mask performance. These 15 masks, along with 5 control samples then underwent a battery of standardized tests at the CDC NIOSH NPPTL research facility in Pittsburgh, PA. The data from these tests strongly suggest (but do not prove) that supercritical carbon dioxide do not damage 3M 1860 N95 masks. Additional tests conducted during this project confirmed the compatibility of supercritical CO2 with ventilator tubing that, like N95 masks, has been in short supply during portions of the COVID-19 pandemic and cannot be sterilized by conventional means. Finally, a control experiment was also conducted to examine the effect of supercritical CO2 on a BSL-2 surrogate virus, vesicular stomatitis virus (VSV), Indiana serotype strain. In the absence of biocidal additives, supercritical CO2 exhibited no measurable lethality against VSV. This surrogate virus experiment suggests that a biocidal additive such as peracetic acid will be necessary to achieve required sterilization metrics.
Early on in the COVID-19 pandemic, potential ventilator shortages were a critical issue identified by national health care providers. Capacity modeling at the time suggested patient demand may exceed ventilator supply. Thus, the challenge became finding an urgent interim solution to meet health care needs. Our initial hypothesis was that CPAP technology could be modified to provide similar functionality to a ventilator, relieving demand and allowing physicians to decide which patients need high end machines, ultimately saving lives. In conjunction with medical experts and pulmonologists, we were able to identify three key thrusts associated with this research problem: (1) modification of CPAP technology to allow for 02 input that would be capable of providing ventilation; (2) development of an alarming function that would provide real-time audible alarms to alert medical personnel to critical conditions, which would be used inline with CPAP technology; and (3) a method of sterilizing expiratory air from such a system in order to protect medical personnel from biohazard, since CPAPs vent to the atmosphere. We were unable to realize results for thrust 1 (CPAP modification for 02); we identified potential safety issues associated with utilizing medical grade oxygen with a common CPAP device. In order to characterize and mitigate these issues, we would need to partner closely with a device manufacturer; such a partnership could not be achieved in the timeframe needed for this rapid response work. However, we determined that some medical grade BiPAP devices do not need this modification and that the significant progress on thrusts 2 and 3 would be sufficient to buy down risk of a massive ventilator shortage. Our team built a prototype alarm system that can be utilized with any assistive respiratory device to alert on all key conditions identified by medical personnel (high pressure, low pressure, apnea, loss of power, low battery). Finally, our team made significant progress in the rapid prototyping and demonstration of an inline UV air purifier device. The device is cost efficient and can be manufactured at scale with both commercially available and additively manufactured parts. Initial tests with SARS-CoV-2 analog bacteriophage MS2 show 99% efficacy at reducing bioburden. Following a successful demonstration of the prototype device with medical personnel, we were able to obtain follow-on (non-LDRD) funding to provide additional device characterization, validation, and production in order to respond to an immediate regional need.
Sandia National Laboratories currently has 27 COVID-related Laboratory Directed Research & Development (LDRD) projects focused on helping the nation during the pandemic. These LDRD projects cross many disciplines including bioscience, computing & information sciences, engineering science, materials science, nanodevices & microsystems, and radiation effects & high energy density science.
As of 2018, renewable energy sources such as wind and solar have the lowest unsubsidized levelized cost of energy, and grid-scale storage solutions are being aggressively developed and deployed. However, for a carbon-free energy generation paradigm to be realistic, any impediments to scalability must be addressed. In the wind industry, dependence on rare-earth (RE) magnets in direct-drive generators represents a significant roadblock to widespread technology proliferation. Sandia’s Twistact technology is a fundamentally new rotary electrical contact with only rolling metal-to- metal contact that eliminates the need for RE magnets by enabling a wire-wound generator architecture with no efficiency or cost penalties. This report summarizes work funded by an LDRD in FY16—18, in which we advanced the technology readiness level (TRL) of Twistact technology to TRL 5 and proved the viability of a Twistact-based generator for utility-scale, direct-drive wind turbines. We conducted coupon-level tests of rolling metallic contacts and developed a tribological model that predicts operation in either a low-wear or high-wear regime. We also built device-level testing apparatuses and observed operation of full-scale Twistact devices, which corroborated the predictions of the tribological model and demonstrated over 50 million rotation cycles (30-year lifetime in a direct-drive generator). Indeed, the present work demonstrated that Twistact technology has potential to be an enabling technology that eliminates RE magnet dependence in the wind industry. The next logical step is commercialization of Twistact technology (currently at TRL 5) in partnership with a generator original equipment manufacturer that already has an established presence in the wind power industry.
This report describes the development of Radical-Ion Flow Battery (RIFB) technology for electrochemical grid storage, and solar thermochemical cycles for conversion of concentrated solar energy to stored chemical energy. The Radical-Ion Flow Battery stores energy via electrolysis of a molten salt electrolyte such as NaNO2 into an alkali metal and nitrogen dioxide, both of which can be stored as liquids in non-pressurized tanks. The use of extremely facile ion-radical single electron transfer reactions at both electrodes that entail no breaking of covalent bonds is directed towards minimizing thermodynamic irreversibility in the charge/discharge cycle, and eliminating the need for catalytically active electrode materials. Both kinetics and mass transport are also facilitated by the absence of diluent species; the battery electrolyte and active chemical ingredient are one and the same. Our underlying strategy for low-cost scalability is the use of only earth abundant starting materials (NaCl, N2, O2, and steel). The underlying strategy for avoiding the problem of capacity fade over 10,000 charge/discharge cycles is the use of extremely simple chemistry. It is argued that operation at elevated temperature is highly advantageous for very large-scale batteries from the standpoint of battery heat-sinking, access to ultrahigh conductivity electrolytes, and increased electrochemical kinetic rate constants. Numerous practical considerations, such as seals, insulators, and electrical feedthroughs are examined in detail, as are questions related to low-cost mass production and battery techno-economic analysis.
While there are several heat pump technologies such thermoelectric, adsorption and magnetocaloric cycles, the oldest and most widely used is the vapor compression cycle (VCC). Currently, thermoelectric cycles have not yet achieved efficiencies nor cooling capacities comparable to VCCs. Adsorption cycles offer the benefit of using low-quality heat as the energy input, but are significantly more complex and expensive and are therefore limited to certain niche applications. Magnetocaloric cycles are still in the research phase. Consequently, improvements made for VCCs will likely have the most immediate and encompassing impact. The objective of this work is to develop an alternative VCC topology to reduce the above inefficiencies.
This report is the final deliverable for a techno-economic analysis of the Sandia National Laboratories-developed Twistact rotary electrical conductor. The U.S. Department of Energy Wind Energy Technologies Office supported a team of researchers at Sandia National Laboratories and the National Renewable Energy Laboratory to evaluate the potential of the Twistact technology to serve as a viable replacement to rare-earth materials used in permanent-magnet direct-drive wind turbine generators. This report compares three detailed generator models, two as baseline technologies and a third incorporating the Twistact technology. These models are then used to calculate the levelized cost of energy (LCOE) for three comparable offshore wind plants using the three generator topologies. The National Renewable Energy Laboratorys techno-economic analysis indicates that Twistact technology can be used to design low-maintenance, brush-free, and wire-wound (instead of rare-earth-element (REE) permanent-magnet), direct-drive wind turbine generators without a significant change in LCOE and generation efficiency. Twistact technology acts as a hedge against sources of uncertain costs for direct-drive generators. On the one hand, for permanent-magnet direct-drive (PMDD) generators, the long-term price of REEs may increase due to increases in future demand, from electric vehicles and other technologies, whereas the supply remains limited and geographically concentrated. The potential higher prices in the future adversely affect the cost competitiveness of PMDD generators and may thwart industry investment in the development of the technology for wind turbine applications. Twistact technology can eliminate industry risk around the uncertainty of REE price and availability. Traditional wire-wound direct-drive generators experience reliability issues and higher maintenance costs because of the wear on the contact brushes necessary for field excitation. The brushes experience significant wear and require regular replacement over the lifetime of operation (on the order of a year or potentially less time). For offshore wind applications, the focus of this study, maintenance costs are higher than typical land-based systems due to the added time it often requires to access the site for repairs. Thus, eliminating the need for regular brush replacements reduces the uncertain costs and energy production losses associated with maintenance and replacement of contact brushes. Further, Twistact has a relatively negligible impact on LCOE but hedges risks associated with the current dominant designs for direct-drive generators for PMDD REE price volatility and wire-wound generator contact brush reliability. A final section looks at the overall supply chain of REEs considering the supply-side and demand-side drivers that encourage the risk of depending on these materials to support future deployment of not only wind energy but other industries as well.
This report describes an FY13 effort to develop the latest version of the Sandia Cooler, a breakthrough technology for air-cooled heat exchangers that was developed at Sandia National Laboratories. The project was focused on fabrication, assembly and demonstration of ten prototype systems for the cooling of high power density electronics, specifically high performance desktop computers (CPUs). In addition, computational simulation and experimentation was carried out to fully understand the performance characteristics of each of the key design aspects. This work culminated in a parameter and scaling study that now provides a design framework, including a number of design and analysis tools, for Sandia Cooler development for applications beyond CPU cooling.