The invention is a new cost-effective way to make high-quality graphene from domestic coal feedstocks.  This graphene can be used to make a wide range of consumer products such as structural composites, water purification sorbents, stain- and water- resistant textiles, battery materials, and specialty pigments for paints and coatings.  Graphene is an outstanding material made from honeycomb sheets of carbon just one atom thick. Graphene is one of the lightest, strongest, and thinnest materials ever discovered. It has a high surface area, high thermal conductivity, strong chemical durability and high electron mobility making it ideal for use in products requiring mechanical strength, corrosion resistance and thermal/electrical conductivity. This inventive new process also co-produces rare earth elements (REEs) and distilled crude oil liquid, which have their own markets. The co-production of three high value products makes this invention an opportunity to maximize the profitability of a coal-based manufacturing process.

Challenge

Despite their amazing properties, carbon nanomaterials have not been widely commercialized primarily because of their high costs and limited supplies.  Currently, graphene costs approximately $20,000,000 per metric ton and global production capacity is less than 2000 tons/year. The high cost and low supply of graphene are major factors limiting its use in new and innovative consumer products.  These issues are driven, in part, by the expensive carbon feedstocks and complicated manufacturing processes currently used to make graphene.  The invention overcomes these challenges by utilizing inexpensive & plentiful domestic coal in a simple one-reactor process.  This approach brings the total manufacturing costs in line with other specialty materials, such as carbon fiber and carbon black, making the use of graphene in consumer products commercially viable.

This invention describes a technology that can capture radioactive contaminants from wastewater. This technology is available for licensing and/or further collaborative research from the U.S. Department of Energy’s National Energy Technology Laboratory.

Challenge

Radioactive isotopes in liquid nuclear wastes are difficult to remove through conventional methods. Solvent extraction and ion exchange have proved successful for removal, but most of these materials display low selectivity and require the use of environmentally unsafe solvents.  

This new Iron-based catalyst will enable a one-step process to produce hydrogen - a promising energy source that is also environmentally benign - by directly converting methane. The catalyst will eliminate the need to first create syngas and then remove carbon dioxide. In addition to creating hydrogen, carbon, which is also a useful commodity is created as a by-product. This technology is available for licensing and/or further collaborative research from the U.S. Department of Energy’s National Energy Technology Laboratory.

Challenge
The traditional commercial methods of forming hydrogen from methane are based on steam methane reforming, coal or bio-mass gasification, electrolysis, and thermos-chemical processes. Some of these methods are cost-effective, but each requires that syngas first be created and the water gas shift reaction be used to convert syngas to hydrogen and carbon dioxide. From there, the hydrogen must be purified using pressure swing adsorption to separate the hydrogen for the carbon dioxide. Developing a method that avoids these intermediate steps would reduce the cost of producing valuable hydrogen.

This novel patent-pending methane conversion technology employees microwave-assisted catalysis for chemical conversion. This technology is available for licensing and/or further collaborative research from the U.S. Department of Energy’s National Energy Technology Laboratory.

Challenge

Natural gas, primarily composed of methane, is a cheap and abundant domestic resource that can be converted to a wide range of products including liquid transportation fuels and a wide range of chemical intermediates. However, traditional methods of converting methane to valuable chemicals first require it to be converted to synthesis gas.

A direct, one-step, method to convert the methane would have significant advantages over current indirect methods, including reduced costs and increased yields, but several technology barriers must first be overcome. Microwave-assisted catalyst reactions can provide a viable direct method for overcoming these barriers.

The U.S. Department of Energy’s National Energy Technology Laboratory (NETL) developed designs, manufacturing processes, and corrosion property validations of new high-performance corrosion-resistant high-entropy alloys that are superior to and less expensive than existing alloys and demonstrate improved resistance to corrosion, including pitting corrosion in harsh environments and sea water.

Challenge
Metals and alloys used in sea water or acidic aqueous environments are prone to various forms of corrosion, including pitting and/or crevice corrosion because of the presence of aggressive salt, such sodium chloride (NaCl). Pitting and crevice corrosion can serve as initiation sites for developing cracks that will lead to catastrophic failures of the metallic components. The current solution to this problem is to coat the metals with nickel (Ni)-based superalloys such as Hastelloy® C276. Hastelloy®, which is very expensive.

This invention describes a system and method for detecting corrosion in natural gas pipelines using an optical platform or a wireless platform. This technology is available for licensing and/or further collaborative research from the U.S. Department of Energy’s National Energy Technology Laboratory.

Challenge

The U.S. Energy Information Administration states that natural gas accounts for nearly 30 percent of energy consumption in the United States. More than 300,000 miles of natural gas transmission and gathering lines deliver this valuable energy source to consumers. Like any energy infrastructure, this network of pipelines requires significant maintenance costs. In the case of natural gas pipelines, corrosion accounts for around 25 percent of incidents over the last 30 years, 61 percent of which was caused by internal corrosion.

The corrosion-related annual cost for such incidents amounts to $6 to $10 billion in the United States each year. Therefore, a need exists to monitor corrosion inside of the gas pipelines to implement corrosion mitigation and control before any failure.

The innovation represents a BIAS particle sorbent suspended in a non-aqueous fluid carrier (slurry) that is capable of CO₂ sorption, is easy to incorporate into established power plants, and can minimize energy and infrastructure requirements.

Challenge

Carbon sequestration can reduce the emissions of CO₂ from large point sources and holds potential to provide deep reductions in greenhouse gas emissions. Amine-based solid sorbents are effective and economical agents for CO₂ capture from gaseous mixtures. However, because of the high concentration of CO₂ in many feed streams, a large quantity of the gas often reacts with the sorbent exothermically to produce excessive heat, which must be removed from the sorbent to prevent temperature instability within the reactor and to eliminate potential degradation of the sorbent. Reducing the damage to sorbents with this technology and method can increase efficiency and reduce replacement costs faced by 

The invention consists of the application of metal oxide nanowire-based sensor layers to optical sensing platforms such as optical fiber-based sensor devices. This technology is available for licensing and/or further collaborative research from the U.S. Department of Energy’s National Energy Technology Laboratory.

Challenge

Thin film and thick film metal oxide based materials are typically employed as the active layer in harsh environment chemical sensing. However, these sensing layers do not have sufficient sensitivity and chemical selectivity in many applications because of their microstructure and the lack of a sufficiently large surface area.

Challenge

Research is active on a method to convert methane into synthesis gas using mixed metal oxides. The resulting syngas could be used to manufacture more valuable chemicals. This technology is available for licensing and/or further collaborative research from the U.S. Department of Energy’s National Energy Technology Laboratory.

Challenge

Natural gas (NG), which is composed primarily of methane, is one of the most abundant, low-cost carbon-containing feedstocks available. The economically available route to produce valuable chemicals from methane is via synthesis gas followed by different chemical routes to manufacture the desired chemicals. In a large-scale industrial plant, the production of syngas accounts for a large part of the total costs. Therefore, it is important to develop more efficient and cost-effective methods for the conversion of methane to syngas.