Extremely Durable Concrete using Methane Decarbonization Nanofiber Co-products with Hydrogen (EERE - Pipeline H2) Modular Processing of Flare Gas for Carbon Nanoproducts (NETL - Flare Gas) Alan W. Weimer, PI, University of Colorado – Boulder (CU) Mija H. Hubler, co-PI, University of Colorado – Boulder (CU) Team Members: Forge Nano (FN), National Ready Mixed Concrete Association (NRMCA) Project Vision Total Project Cost (mo) We are producing H2 and a beneficial carbon nanofiber concrete additive from natural gas by chemical vapor deposition using a low-cost sacrificial EERE: $1.25 M (36) and compatible catalyst support NETL: $3.75 M (41) The Concept and the Project Objectives 1 The Team 2 EERE (Pipeline): In-situ Ambient Pressure ALD/CCVD Reactor Design Pipeline Gas (EERE) Key Process Parameters Catalyst ALD fabrication In-situ Catalyst Support Fumed Silica Monometallic (e.g, Fe, Ni, Catalyst Metal or Co) Pressure Range Ambient Temperature Range 600 – 850°C Pipeline centralized Scale-up process High-performance CNF application concrete 3 NETL (Flare Gas): Ex-situ ALD Pressurized CCVD Reactor Design Flare Gas (NETL) Key Process Parameters Catalyst ALD Ex-situ fabrication Catalyst Support Silica fume Bimetallic (e.g, Fe/Co, Catalyst Metal Ni/Co, Fe/Ni etc…) Pressure Range 400 – 500 psig Temperature Range 600 – 850°C Scale-up Modular process Carbon Nanoproduct Ultra high- Application performance concrete 4 EERE: Mix design and mechanical tests for HPC Reproduce HPC Mix design (wt.%) with Expected Performance CNFs successfully dispersed by two stage process: 1) premixing with HRWR to change surface properties Coarse 28-day comp. w/c Cement Water Sand SF HRWR 2) Ultrasound dispersion to break Van der Waals forces aggregate strength (psi) 0.32 19.92 6.34 27.66 1.92 0.46 43.69 9732 Premixing Ultrasound Ensure Minor Change in Setting time of HPC when adding CNFs 95.0 90.0 85.0 80.0 Temperature, F Temperature, HPC with commercial CNF toughness testing 75.0 Toughness no CNFs CNF addition Toughness (N-mm) ultrasonic dispersed CNFs Increment (%) 70.0 No CNFs (general sand) 321 0 0 200 400 600 800 1000 1200 1400 1600 1800 Ultra 0.1 cwt% of CNFs 411 +28 Time, min. Ultra 0.25 cwt% of CNFs 374 +17 5 NETL: Mix design and mechanical tests for UPHC Develop Optimized UHPC mix design UHPC mix design (wt.%) Optimize Dispersion for Improved Flexure Strength of UHPC with Commercial CNFs Ground Mix w/c Cement Water Sand SF HRWR quartz Mix design 5 with 0.1 cwt% of commercial CNFs 1 0.22 31.62 6.97 44.28 7.89 1.33 7.89 Peak Load Dispersion method Peak Load (N) 2 0.23 30.05 6.91 51.92 9.75 1.37 0.00 Increment (%) 3 0.22 38.68 8.53 32.54 9.66 0.94 9.66 NoCNFs (general sand) 6440 0 4 0.21 34.45 7.43 34.93 6.90 1.30 14.99 Dumpin 6094 -5 5 0.18 35.84 6.45 49.51 6.64 1.55 0.00 Ultra 6129 -5 Averaged compressive strength of samples after 28 days curing (psi) Premix+Ultra 6815 +6 1 2 3 4 5 Achieved required UHPC Fine sand only 6427 0 17103 15412 18795 15767 18007 compressive strength. Fine Sand+CNFs+Ultra 6882 +7 Slump test results (in) Fine Sand+CNFs+Premix+Ultra 6936 +8 1 2 3 4 5 Optimized for Flexure Test 4.25 3.25 3.5 3.875 4.75 medium slump. Dispersion is critical for improved mechanical performance. 6 EERE Results: Preliminary Technoeconomic Analysis Parameters Hydrogen price: $2/kg NG cost: $3/KSCF Natural Gas CVD Heat IRR: 10% Feed Reactor with Exchanger Lifetime: 15 years 12 BSCF/yr Integrated Furnace Estimated TDC: $2B-4B Cost of Capital: 8.5% Sacrificial CNF coated Results Catalyst Silica Fume Furnace CNF coated silica, price range: 770k mt/yr Exhaust $2 - $4 per kg Pressure Pure CNF, price range: Compressor Swing $10 - $20 per kg Adsorbers Hydrogen Product Pure CNF, current technology: 43k mt/yr $300 per kg (bulk) 7 NETL Results: Preliminary Technoeconomic Analysis Parameters NG cost: Free IRR: 10% CVD Natural Gas Lifetime: 15 years Heat Reactor with Feed Estimated TDC: $1M-2M Exchanger Integrated 9.7 MMSCF/yr Cost of Capital: 8.5% Furnace Results Sacrificial CNF coated CNF coated silica, price range: Catalyst Silica Fume $2 - $4 per kg 580 mt/yr Pure CNF, price range: Hydrogen Furnace $10 - $20 per kg Exhaust Pump Pure CNF, current technology: $300 per kg (bulk) 8 Challenges and Technical Partnerships Challenges/Risks ‣ CNF/CNP Synthesis Risk - Particle ALD catalyst will be unable to grow substantial CNF/CNP quantity ‣ Cement Mixing Risks - The produced CNFs/CNPs are not easily homogenized with cement ‣ CVD Reactor Scale-up Risk ‣ Identify technology implementation of CNF/CNP additives Reducing Risk/Mitigation Strategies ‣ CNF Synthesis Risk Reduction - Metal nanoparticles will be deposited as metals in-situ using ALD with a reduction step, followed by CVD (can be sequenced if desired) ‣ Cement Mixing Risk Reduction – Methods to ensure dispersion will be investigated using detergents and anti-foam agents ‣ Skid Design, Construction, and Operation at Forge Nano ‣ NRMCA will link the research team with potential contacts or organizations and the co-PI will be engaged in committees writing standards for implementation 9 I Timeline EERE (Pipeline) 2020/2021 2021/2022 2022/2023 10 Timeline: NETL (Flare Gas) Completed Tasks 1.1 Project Mgt. Plan 1.2 Project Maturation Plan 1.3 TEA Current Tasks 2.1 Lab CVD Construction 3.1 Skid Design 4.1 Concrete Mix Design 11 Collaborations Fund-Receiving Collaborator Project Roles Reactor/process design and ForgeNano technoeconomic analysis National Ready Mixed Concrete materials, mix design, Concrete Association and consulting (NRMCA) 12 Acknowledgements 13 What questions do you have? 14.