Project Selections for DE-FOA-0002620: Carbon Ore Processing

Development Of Coal-Based Supercapacitor Materials for Energy Storage – The Board of Trustees of the University of Illinois (Urbana, Illinois) plans to develop high-value supercapacitor materials from domestic coal in a cost-effective manner. The team plans to convert coal samples to high-performance supercapacitor materials at a laboratory scale and quantify the performance of the developed materials in comparison with a baseline commercial material. The team will also perform a techno-economic analysis and technology gap assessment for the proposed technology. After further development, the proposed technology could provide low-cost coal-based supercapacitor materials for energy storage and other industrial or electronic applications, generating a new market for domestic coal.

DOE Funding: $ 1,000,000
Non-DOE Funding: $ 250,000
Total Value: $ 1,250,000

Electrochemical Coal to Two-Dimensional Materials Process to Enable Renewable Energy Storage – Ohio University (Athens, Ohio) intends to develop an electrochemical coal to two-dimensional materials process targeting generation of graphene and carbon quantum dots derived from coal and coal waste at a price point lower than currently sold materials. The team intends to further the development of energy storage devices utilizing the nanoscale carbon materials, create a performance comparison to commercial supercapacitor devices with generation of a product datasheet, update techno-economic analyses for the process and products, and identify market applications best suited for the materials. Project success could create jobs in the Appalachian region and have a positive impact on climate change by facilitating more widespread adoption of renewable energy and electric vehicles.

DOE Funding: $ 999,995
Non-DOE Funding: $ 250,005
Total Value: $ 1,250,000

Ultra-Conductive Carbon Metal Composite Wire for Electric Motors – Ohio University (Athens, Ohio) plans to develop cost-effective carbon metal composites (CMCs) with enhanced bulk electrical properties for use in electric motors to increase energy efficiency and reduce greenhouse gas emissions. The CMC materials will be made using primary conductor materials (including copper and aluminum) with coal-derived nano-graphite and/or graphene. CMC wire formulations will be synthesized using unique methodologies that will overcome key challenges associated with existing CMC processing techniques. Ultra-conductive CMC wire offers a host of performance, economic, and environmental advantages. If successful, the CMC wire technology will create a new high-value application for coal-derived graphitic carbons by significantly improving the efficiency of electric motors.

DOE Funding: $ 1,000,000
Non-DOE Funding: $ 250,000
Total Value: $ 1,250,000

Spray Deposition of Coal-Derived Graphene-Copper Nanocomposites for Advanced Conductors – Tennessee Technological University (Cookeville, Tennessee) plans to focus on the optimization of the spray deposition parameters for the synthesis of high-performance copper-matrix nanocomposite with uniformly distributed graphene particulates. The team will conduct a techno-economic analysis to demonstrate the viability and cost-effectiveness of the proposed nanocomposite manufacturing process. The spray-deposited nanocomposites are expected to offer enhanced electrical/thermal conductivities, strength, and temperature capability over copper wires and cables currently used in clean energy applications. This project will also provide workforce training and opportunities for underrepresented students to participate in clean energy research. In addition, this project will enhance the research capability of a minority-serving university and help disadvantaged rural communities through technology innovation to promote economic inclusion.

DOE Funding: $ 1,000,000
Non-DOE Funding: $ 255,742
Total Value: $ 1,255,742

Lab-scale Additive Manufacturing of Coal-derived Carbon-Metal Composites for High-Performance Heat Sink –The University of Delaware (Newark, Delaware) intends to develop a lab-scale additive manufacturing process to fabricate carbon-copper composites with a high heat dissipation rate and low thermal stress and demonstrate its robust use for on-demand fabrication of high-performance thermal management devices (e.g., heat sinks) for electrical applications. This project seeks to create a transformational change in high-value carbon-metal composite manufacturing. The proposed technology has the potential to advance both 3D printing and composite manufacturing, train a new generation workforce in coal-derived product manufacturing, and strengthen the United States as the world-leading additive manufacturing research and development and manufacturing nation.

DOE Funding: $ 1,000,000
Non-DOE Funding: $ 250,000
Total Value: $ 1,250,000

Coal-Derived Graphene Materials for Industrial Applications – The University of Wyoming (Laramie, Wyoming) plans to utilize inexpensive sources of Wyoming Powder River Basin (PRB) sub-bituminous coal by processing them with strong oxidation reagents to produce graphene oxide that can be further processed to produce reduced graphene oxide and graphene nanosheets. These graphene materials have many applications, including performance improvement of sodium ion battery anodes and strengthening additives for concrete—both of which are included in this project. Developing the conversion of low-priced PRB coal to these graphitic products can reduce the economic barriers to researching and using these materials and open new markets that will continue to use abundant coal resources.

DOE Funding: $ 1,000,000
Non-DOE Funding: $ 250,000
Total Value: $ 1,250,000