This invention describes a novel catalytic method combined with a chemical looping process to produce a hydrogen (H₂)-rich synthesis gas (syngas) stream free of the nitrogen from coal. The catalytic process uses reduced metal oxide/coal/steam to produce a H₂-rich syngas stream that is free of nitrogen (N₂) from coal while the chemical looping combustion (CLC) of fuel with the metal oxide is used for production of the heat required for the catalytic process. CLC processes also produce a concentrated stream of carbon dioxide (CO₂) that is ready for sequestration. This technology is available for licensing and/or further collaborative research from the U.S. Department of Energy’s National Energy Technology Laboratory.

Challenge

Traditional coal gasification requires an expensive air separation unit to produce N₂-free syngas. However, NETL’s novel catalytic process using reduced metal oxide/coal/steam does not require an air separation unit for production of nitrogen free syngas stream. Heat is traditionally produced via fuel combustion, which generates a CO₂ stream mixed with N_2. This stream requires expensive separation technologies for CO₂ sequestration. The novel catalytic process uses the heat from CLC of fuel, which generates a sequestration ready CO₂ stream. Integration of the processes, addressing contaminant issues and scaling up the technology for commercialization are necessary.

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.

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.
 

The U.S. Department of Energy’s National Energy Technology Laboratory (NETL) has developed a system for enhancing chemical reactions by electrostatic/microwave and/or/ radio frequency controlled resonant electron interaction. The invention performs at a much lower temperature than conventional processes. The system can reduce the cost of many important industrial processes including nitrogen and hydrogen production. Although the focus of the invention is on producing hydrogen from hydrocarbon sources, many different reactions could be activated using the same physics. This invention is available for licensing and/or further collaborative research.

Challenge

Approximately 50 percent of natural gas is used by industry. The existing chemical reaction-based processes, such as, the Haber process, are very energy intensive and costly. This invention increases the rate and extent of chemical reactions at much lower temperatures resulting in higher product yield and overall production. It also allows for reduced energy requirements and reactor size of dry and partial oxidation reformers.

The U.S. Department of Energy’s National Energy Technology Laboratory (NETL) has developed a system and method for combining polyamines, which immobilizes the dye-absorbing amine sites within low cost, porous silica particles. The innovation has the potential to remove organic-based colorants and pollutants from different water sources. This invention is available for licensing and/or further collaborative research from NETL

The U.S. Department of Energy’s National Energy Technology Laboratory (NETL) has developed a method for achieving tunable gas sensitivity of surface acoustic wave (SAW) devices. The innovation implements a class of materials with tunable absolute film conductivities called conducting metal oxides (CMOs), which enables SAW devices to be calibrated for gas sensitivity in diverse harsh-environment conditions.

The U.S. Department of Energy’s National Energy Technology Laboratory (NETL) has developed a laser induced breakdown spectroscopy (LIBS) probe featuring simplified construction that minimizes the need for optical elements from the probes data collection path, reducing potential interference with the transmission of high quality spectra. By reducing the complexity and cost of the laser head, the invention maximizes the amount and quality of light returned for analysis and increases the usefulness of LIBS research.

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.

The invention is a system and method for monitoring the interior of metallic tubular structures like pipelines, well-bores, and boiler-tubes using an integrated wireless system. The technology uses a combination of the pipe or tubular structure as a wave guide, integrated radio frequency (RF) patch antennas, integrated passive surface acoustic wave (SAW) sensors, and data analytic methodologies. The technology is available for licensing from the U.S. Department of Energy’s National Energy Technology Laboratory.

Challenge

Safety and longevity are major concerns in fossil fuel industries and other technologies that use long metallic tubular structures like gas pipelines, well-bores, and boilers. Real time monitoring of the tubular structures for multiple variables within them, including but not limited to corrosion, leaks, and mass flow, is crucial to ensure safety and cost-effective maintenance in timely manner. Conventional techniques for investigating the state-of-health and operational conditions of tubular structures use non-destructive acoustic-based techniques, which are limited by the ability to interpret the data because, as an indirect measurement, requires models to be made of the infrastructure under investigation.

The invention is a new low-cost way to form an optical sensor array that monitors multiple parameters such as temperature and hydrogen in essential components of electrical transmission and distribution networks. It uses multi-wavelength interrogation combined with multiple sensor elements using a single optical fiber. This technology is available for licensing and/or further collaborative research from the U.S. Department of Energy’s National Energy Technology Laboratory.

Challenge

Power transformers are among the most essential components of electrical transmission and distribution networks. To avoid the substantial financial and social expenses caused by catastrophic failures, there is a growing need to develop low-cost and real-time analytical techniques and instruments to detect and diagnose fundamental changes in the operating characteristics of transformers. Key parameters, such as dissolved gases content and temperature, provide valuable information for assessing the condition of transformers. For example, dissolved gas analysis (DGA) identifies electrical or thermal faults in transformers. In addition, temperature information is vital because when the temperature in transformers exceeds 90o C, the aging rate of insulation and tensile strength grows, resulting in a dramatic deterioration of transformer life expectancy. It is therefore of significant value to monitor the temperature under various ambient and loading conditions to identify failures before they result in significant damages.