Project Selections for FOA 3105: Critical Material Innovation, Efficiency, and Alternatives (Set 1)
Area of Interest 4: Alternative Materials
4A: Phase I: Bench scale development of critical minerals and materials alternatives or substitutes (excluding magnets and battery technologies) to increase robustness of domestic supply chains
Novel Carbon Reduction Pathway to Produce High Quality Graphite from Captured Atmospheric CO2 and/or Industrial Waste Streams. Idaho National Laboratory Battelle Energy Alliance LLC (Idaho Falls, Idaho), with Seerstone Development LLC and Boise State University, aims to develop a novel and fully domestic decarbonized pathway to manufacture high-purity synthetic graphite, along with other durable carbon-based materials, from carbon dioxide (CO2)-based feedstocks with a dramatically reduced carbon footprint and reduced energy consumption. The project will produce high quality carbon powder using CO2 feedstock through a thermal catalytic conversion process. The carbon powder will be upgraded through conversion from mesophase powder to dense synthetic graphite billets using the advanced manufacturing technique of electric field assisted sintering (EFAS). EFAS has the potential to sinter and graphitize this CO2-sourced mesophase carbon into synthetic graphite with a dramatic reduction in processing time, carbon intensity, and energy consumption. The project will include a techno-economic assessment and life cycle assessment to quantify the combined process’s reduction in carbon intensity, energy consumption, and scalability. The project will also collaborate with the newly formed Intermountain-west Nuclear Energy Corridor, whose focus is empowering rural, regional industry/employers, local, and Tribal governments, educational entities, economic development consortia, and industry associations.
DOE Funding: $1,000,000
Non-DOE Funding: $499,508
Total Value: $1,499,508
Critical-element-free High-Entropy-Alloy Catalysts for Hydrogen Production from Waste Feedstock. Iowa State University of Science and Technology (Ames, Iowa) plans to synergistically integrate two processes, clean electrochemical hydrogen production and the conversion of copper (Cu)-metal waste into copper sulfate. In traditional water electrolysis, a large amount of energy is used to produce by-product, oxygen, which has no commercial value, from water. In the project’s proposed Cu waste oxidation process, the anodic reaction will produce a value-added product and reduce the total energy cost for hydrogen production. For the cathode process, the project will design high-entropy catalysts with critical platinum-group metals (PGM) content reduced by at least 40 atomic percent. The PGM-reduced high-entropy catalysts are instrumental for production of hydrogen from the process of converting Cu waste generated upon recycling of permanent magnets into value-added Cu sulfate. Thus, the conversion of recycling process waste will be coupled with highly energy-efficient chemical processes for hydrogen production. The environmental benefits may improve operational energy efficiency of chemical reactions while remaining cost-neutral, or even less expensive, to manufacture compared to existing PGM-group technologies.
DOE Funding: $988,860
Non-DOE Funding: $0
Total Value: $988,860
Hexagonal Boron Nitride: A Sustainable Alternative to Gallium Nitride for Power Electronics. The Pennsylvania State University (University Park, Pennsylvania) plans to contribute to the development of a physical understanding of the materials science and engineering of boron nitride and the potential application of hexagonal boron nitride in power electronics. This research project is motivated by the recent decision by the government of China to restrict the export of gallium; much of the current world’s supply of gallium comes from China. Gallium nitride is a material of substantial importance in power electronics devices, but almost none of the gallium used in semiconductor device manufacturing in the United States is domestically produced. The project partner QuantCAD will take the lead on providing a comprehensive summer internship program that will enable both graduate and undergraduate students from underrepresented communities to learn how an idea can become a viable commercial commodity.
DOE Funding: $956,598
Non-DOE Funding: $0
Total Value: $956,598
4B: Phase II: Pilot scale development of critical minerals and materials alternatives or substitutes to reduce reliance on foreign supply chains.
Fast Charging LFP Aerogel Cathode Materials to Eliminate Nickel/Cobalt Reliance. Aspen Aerogels, Inc. (Northborough, Massachusetts) plans to scale up their lithium iron phosphate (LFP)-based battery technology from bench‐scale to pilot‐scale for use in electric vehicles (EVs). Lithium‐ion batteries (LIBs) are the current industry standard for powering EVs, but the use of LIBs is challenged by supply of key critical materials, such as nickel and cobalt, that are largely sourced outside of the United States. Furthermore, a full charge for these vehicles can take from 30 minutes up to 60 hours. LFP cathodes provide a safer and lower cost solution to LIBs, but LFP inherently has a lower specific energy and energy density, and LFP‐based batteries typically need about 60 minutes for a complete charge from an initial discharged state. Aspen Aerogels has developed an LFP cathode material based on their carbon aerogel technology that may eliminate U.S. reliance on nickel and cobalt, while simultaneously reducing battery charging time to only 5 to 10 minutes. This project will culminate with prototype battery build and performance test validation with teaming partner Oak Ridge National Laboratory.
DOE Funding: $7,304,446
Non-DOE Funding: $7,304,566
Total Value: $14,609,012