This invention describes an improved casting and manufacturing method for a creep-resistant nickel-based superalloy for advanced high-temperature applications. This technology is available for licensing and/or further collaborative research from the U.S. Department of Energy’s National Energy Technology Laboratory.

Challenge
In the future, advanced ultra-supercritical (A-USC) and/or supercritical carbon dioxide (sCO₂) power plants are expected to raise efficiencies of coal-fired power plants from around 35 to greater than 50%. However, these advanced systems feature components that operate at high pressures and temperatures exceeding 760 degrees Celsius. These conditions cause gradual permanent deformation, known as creep, in components manufactured with currently used alloys like ferritic-martensitic high-strength steels and austenitic stainless steels.
Certain nickel-based super alloys such as Inconel 740H (IN740H) currently meet requirements for use in A-USC in a wrought version, but using the alloy in a cast form would be valuable in terms of the range of component size, geometries and complexities, and cost.
Previous efforts at casting IN740H have resulted in poor creep performance when compared to wrought versions. Furthermore, several compositions within the nominal specified range for IN740H have been investigated but failed to provide a material in the as-cast form that would withstand long-term, high temperature exposure in creep.
 

This invention describes a uniquely engineered 2-D amorphous carbon film and a memristor fabricated with coal-derived carbon quantum dots as the dielectric (switching) media for resistive random-access memory (RRAM). The atomic dielectric carbon layer can provide large storage density and 3-D packing ability, allowing memory and logic devices to be integrated in one chip, providing faster data processing with low energy consumption. This patent application is jointly owned by NETL and the University of Illinois-Urbana Champaign (UIUC) and it is available for licensing and/or further collaboration.

Challenge
Memory is essential to future computing with the exponential growth of data. These emerging memory technologies aim to revolutionize the existing memory hierarchy. Various emerging memory technologies are actively being investigated to meet ideal performance characteristics. RRAM has various advantages such as easy fabrication, simple metal-insulator-metal structure, excellent scalability, nanosecond speed, and long data retention. RRAM has been commercialized since 2013. Despite showing great promise over conventional RAM and its popularity in academia, RRAM has not become commercially popular. This is due to high device variability and high operation voltage.

This patent-pending technology establishes a novel system and method for the microwave-assisted dry reforming of methane. The technology is available for licensing and/or further collaborative research from the U.S. Department of Energy’s National Energy Technology Laboratory.

Challenge

Traditional steam reforming of methane to produce hydrogen (H₂), which is then reacted with carbon (CO) to produce methanol and other industrial commodity chemicals, is an extremely energy intensive process with large carbon footprint. For example, the steam reforming reaction produces 10 tons of carbon dioxide (CO₂) for every ton of H₂. Methane dry reforming uses an alternative reaction that uses CO₂ as a soft oxidant to produce CO and H₂ from methane, which can be further processed into methanol or hydrocarbons. Further, using CO₂ to produce commodity chemicals, such as H₂ and CO, can generate revenue to offset carbon capture costs, reduce the carbon footprint of fossil-fuel powered processes, and allow sustainable use of fossil fuel resources.

Traditional dry reforming techniques are extremely energy intensive and require very high temperatures (>800C) that make it unpractical economically compared with the lower-temperature, carbon-positive, methane steam reforming. Microwave-assisted catalysis has been demonstrated as an enabling technology to promote high temperature chemical processes. Unlike traditional thermal heating, microwaves can rapidly heat catalysts to extremely high temperatures without heating the entire reactor volume. This reduces heat management issues of conventional reactors and enables rapid heating/cooling cycles. Ultimately, this can allow reactors to utilize excess renewable energy on an intermittent basis (load follow) to promote traditionally challenging, thermally-driven reactions for on-demand chemical production.

Microwave absorption is a function of the electronic and magnetic properties of the material, and a properly designed catalyst may function as a both a microwave heater and a reactive surface for driving the desired reaction. Microwave absorption is extremely sensitive to the catalyst’s chemical state and electronic structure, and effective catalysts must maintain microwave activity across a wide range of temperatures in both oxidative and reductive environments.

This patent-pending technology establishes a novel system and method for laser induced breakdown spectroscopy (LIBS) applications. The technology is available for licensing and/or further collaborative research from the U.S. Department of Energy’s National Energy Technology Laboratory.

Challenge

Low-cost, efficient monitoring of remote locations has and continues to be highly sought in the industry. For example, drilling production or injection wells for oil/gas extraction or carbon dioxide (CO2) storage always has the potential for leakage into the surrounding formations and environment. The ability to measure the subsurface fluids in and around the injection/production area before and after subsurface activities becomes more important when there is a suspected leak. Current downhole monitoring systems rely on bulk parameters such as pH and conductivity. Lab based systems can provide trace element measurements of subsurface fluids but require fluids to be taken from the field and digested prior to measurement. A system that can provide trace element measurements in real time while deployed in the subsurface is potentially of great value.

Current diode pumped solid state (DPSS) laser systems used for laser induced breakdown spectroscopy applications in fluid system measurements have numerous limitations. First, the systems are susceptible to dimensional changes caused by temperature and pressure swings in fluctuating environments in downhole applications. A second issue is the size of the laser spark that is produced in the fluid for measurements affecting signal strength. The third issue is the efficient collection and transmission of the plasma emission for analysis.

This invention describes an improved method for extracting rare earth elements (REEs) from coal ash at ambient temperatures. This technology is available for licensing and/or further collaborative research from the U.S. Department of Energy’s National Energy Technology Laboratory.

Challenge
As China currently controls the supply and prices of almost all the world’s REEs, developing a domestic supply is critical for the continued manufacturing of technologies that support nearly all modern devices, including critical systems for energy and national defense. REE extraction efforts from domestic sources of coal and coal-related resources have emerged as a viable solution, but successful methods must be both cost-effective and environmentally friendly.

Current methods and technologies for REE extraction from ore and other sources can be hazardous and expensive to implement without harming the environment or workers. For example, common practices employ high temperatures and strong acids or bases. This technology seeks to overcome these and other issues with current REE extraction methods by turning to a material that is currently viewed as a waste – coal ash.

These technologies are high-performance CO₂ separation membranes made from polyphosphazene polymer blends.  NETL’s technology was originally developed to aid in separating CO₂ from flue gas emitted by fossil-fuel power plants. The NETL membrane is cross-linked chemically using low intensity UV irradiation, a facile technique that improves the membrane’s mechanical toughness compared to its uncrosslinked polyphosphazene constituents. Membranes fabricated with this technique have demonstrated permeability of up to 610 barrer, with CO₂/N₂ selectivity in excess of 30, at a practical separation temperature of 40°C. NETL’s patent-pending technology is being bundled with Idaho National Laboratory’s (INL) patented technology, with NETL handling licensing.  NETL would work with a potential licensee and INL to license the technology. 

Challenge: 
Membrane-based separation is one of the most promising solutions for CO₂ removal from post-combustion flue gases produced in power generation. Technoeconomic analyses show that membranes aimed for this application must possess high gas permeability; however, most high permeability materials suffer from poor mechanical properties or unacceptable loss in performance over time due to physical aging. This technology is a successful attempt to turn one of these high-performance materials with poor mechanical properties into one amenable for use in practical separation membranes with virtually no physical aging issues.
 

This invention describes basic immobilized amine sorbents (BIAS) with improved pelletization process and formulation for use in CO₂ capture processes. This technology is available for licensing and/or further collaborative research from the U.S. Department of Energy’s National Energy Technology Laboratory.

Challenge
BIAS sorbents demonstrate high CO₂ capture capacity and thermal stability over multiple steam regeneration cycles and represent a promising approach for CO₂ removal from a variety of source points, including coal and natural gas combustion power plants. Bench- and pilot-scale testing have demonstrated the feasibility of commercial-scale BIAS sorbents. However, full commercialization of BIAS sorbents requires pelletization. Commercially available silica typically serves as the support for amine-based particle sorbents, yet these materials are not commercially feasible due to their relatively low mechanical strength and difficult management in dynamic reactor systems. Thus, the development of an economical method of fabricating a strong silica-supported BIAS pellet is a primary concern.

Research is active on the development and refinement of a process for the extraction of lithium (Li) and rare earth elements (REEs) from natural brines. This invention is available for licensing and/or further collaborative research from the U.S. Department of Energy’s National Energy Technology Laboratory.

Challenge

Current leading technology to generate materials from natural brines requires a series of football field-sized slow evaporation ponds, as well as lengthy leaching, which takes approximately 18-24 months after leaving the well. Concentration processes of the selected materials require repeated pumping from one evaporation pond to another, followed by long-distance transportation (added expenses and carbon emissions) to a processing plant that generates the selected compounds by multiple carbonation steps by leaching. Current carbonation processes require various solid additives, including soda ash, lime, hydrochloric acid, organic solvent, sulfuric acid and alcohol. Several tons of additives may be required to produce only a ton of targeted material. Therefore, current operations are considered to be costly and environmentally harsh.

This invention describes a method of encapsulating reactive materials (i.e., catalyst, sorbent or oxygen carrier) within a porous, unreactive, strong outer layer to increase attrition resistance while retaining sufficient reactivity. This technology is available for licensing and/or further collaborative research from the U.S. Department of Energy’s National Energy Technology Laboratory.

Challenge

Processes that involve fluidized bed or transport reactors require pellets with high attrition resistance because the pellets move continuously in the reactor during operation. Loss of pellets due to attrition contributes to high replacement costs and operational difficulties. Most processes that involve catalyst, sorbents and oxygen carriers operate in fluidized beds or circulating fluidized beds and require high attrition resistance for long-term operations. In addition, loss of reactive materials with low melting points, such as CuO, due to agglomeration is an issue. Pellets with high attrition resistance are needed to combat against loss of reactive materials.

The invention is a distributed radio frequency (RF) /electromagnetic (EM) interrogation scheme that leverages distributed antennas along a coaxial cable for subsurface, pipeline, and other energy infrastructure monitoring. This technology is available for licensing and/or further collaborative research from the U.S. Department of Energy’s National Energy Technology Laboratory.

Challenge: 
In industrial and wireless sensing, the communication channel often determines the characteristics and performance of the overall sensing network. For wellbore monitoring applications, telemetry challenges are acute because of harsh environmental conditions (elevated temperature and pressure, chemical corrosives) which restrict the application of complex electronics and instrumentation. In addition, inherent absorption of electromagnetic radiation within the subsurface environment limits the potential for free space wireless power and signal delivery over distances. However, distributed wireless sensors throughout the subsurface environment could provide unprecedent visibility for monitoring and minimizing environmental impacts associated with the wellbore and ensure safe and productive operation of oil and gas recovery processes, enhanced geothermal systems and carbon storage sites.  Similar needs exist for monitoring of natural gas pipelines and other energy infrastructure for which enhanced visibility can significantly impact reliability, resiliency, and security.