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#1 Re: Not So Free Chat » Politics » 2025-09-12 00:46:15

The US will not be a Constitutional Republic if Trump continues what he is doing now. It is becoming a fascist totalitarian dictatorship. If he can, there will be no more elections.

Our leftist Democrats are now warning us about the fact that they're behaving as real communists / fascists / what's the difference typically behave, because they're tired of waiting to establish a proper dictatorship here in America.  Whatever accusations Democrats are making, you can be sure that's what they're actually doing.  Thanks for the warning, though.  My fellow Republicans have told them, repeatedly, that their dystopian dictatorship fantasy is never going to happen.  I've not seen Democrats this agitated since we took their slaves away from them.

Constitutional separation of powers has already been challenged.

Separation of powers is an ongoing issue, one which will never be fully resolved, especially since Congress continuously delegates authority to the President.  Whether it was wise for Congress to delegate their authority is another matter entirely.

If he can, there will be no more elections.

One American President you disagree with was elected for four years, so there will be no more elections in America after he's gone?  Good to know.  I'll file that one away for the next election in 2028.  I'm aware of the fact that Democrats want to remove the ability of the electorate to choose who and what to vote for, but President Trump's second election was a giant middle finger to that idea.

Courts have ordered Trump to stop deporting people nabbed by ICE. Courts have ordered individuals who have landed immigrant status, legal residents, to be returned to the US. Trump and his team have refused. Blatant refusal to comply with court orders means the Constitution no longer exists.

When President Obama deported far more illegals than President Trump has thus far, where was your outrage over the constitutionality of his decision making back then?  Either show some consistency in your condemnation or admit that you're not consistent because you're prejudiced against President Trump because he's making decisions that show deference to the American people, its own citizens, rather than people from everywhere else.

Trump claimed he has the ability to interpret law.  The Constitution says the President does no such thing, the Courts do that. Trump claimed the ability to create tariffs by executive order. The Constitution says only Congress can do that.

All law enforcement requires interpretation of the law.  If a person who is not a lawyer or judge isn't allowed to interpret what a law means, then there's no such thing as law enforcement.  Lawyers and judges aren't rolling around in squad cars, arresting murderers, thieves, and rapists.  The person enforcing the law is effectively "deciding" if/when/how a law has been broken... which sounds an awful lot like they had to make an interpretation of what the law is and how to enforce it.

The United States Congress has delegated their authority to make / adjust tariffs, to the President of the United States, pursuant to codified law, which Congress has passed and previous Presidents have duly signed into law.  More specifically, a Democrat President named John F. Kennedy signed much of the basis for the President Trump's congressionally-delegated power to levy and/or increase tariffs, into codified enforceable law.  Democrat President Jimmy Carter used this law in 1979.  Republican President Reagan used the law in 1982.  President Trump is now using that very same law in 2025.

The US Constitution is the litmus test for all laws.  It is not now and never has been the law itself.  The only thing that's meaningfully changed in 2024 is that President Trump has recognized that the US cannot run a trillion dollar trade deficit indefinitely without affecting the quality of life for the lower and middle classes here in America, so he's using the powers delegated to him, by Congress, to attempt to improve their lives through greater domestic production of all goods and services, which they can capitalize on by supplying their own labor in deference to their own countrymen.  If the United States Congress doesn't like President Trump's delegated powers to make or change tariffs, then a 2/3rds majority vote to modify or entirely rescind the Trade Expansion Act of 1962 would remove all previously delegated Executive Branch power to make and adjust tariffs, irrespective of what President Trump thinks about it, which Congress has thus far refused to do.

Until the Supreme Court either reinterprets the President's delegated powers to make or change tariffs, or the United States Congress acts to modify or rescind those powers, President Trump's ability to exercise those delegated powers carries the force of law with it.  I do so wish people lecturing Americans about our own laws would inconvenience themselves by actually learning something about the law and how it works, beyond their personal beliefs / desires about it.

About a decade ago, the mainstream left in America ran out of plausible arguments to explain away their increasingly anti-social behavior, which was a manifestation of their radicalization.  From the time of President Obama onward, the Democrat Party was hijacked by radicals, people who became the "next-wave" socialists and communists, the ones who were responsible for the majority of the political violence in America between the 1960s and 1970s.  Senator Joe McCarthy wasn't wrong about the threat these people represented, but American society was too earnest and polite to deal with them as the clear and present danger to human civilization that they've always been.  After more than a century, there hasn't been a single successful implementation of their utopian socialist / communist society, yet they persist in their dogmatic religious beliefs about the proper role of government in society.  They've always brought misery and mass death to people dumb enough to fall for their tricks.  Those same radicals, who are now of age to hold positions of significant political power, don't even pretend that they want to be Americans anymore.

The rest of us have been forced to suffer through the radical left's endless stream of fake manufactured identity crises and general depravity.  The left's indoctrination-from-birth radicalizes their cry-bullies and general purpose street thugs via the educational system, and then leads them around by the nose, from made-up problem to made-up problem.  The sky is always falling in their world.  That's the only way to unite the left's myriad of fractious opposing-interest factions, who otherwise have little to no common cause to vote for the same people.  The near-nonexistent attention span of their rank-and-file membership is all our radical left has left to work with.  Any honest classical liberal has already left the Democrat Party, the party of death and destruction, finally realizing to their horror that they don't remotely believe the same things the people around them do.  It's an endless attempt to avert attention away from how wicked they've become in their lust for power.  The left's now self-evident issue connecting with ordinary Americans is that normal people who have classical liberal tendencies don't want to live in a society based upon wickedness, intimidation, and violence.  That "control strategy" has not worked well for them, as of late.  More and more people are fed-up with the corrosive nature of the left's policies and their naked communist agenda.

Charlie Kirk was the most recent sacrifice to the violence which is both supported and imposed by the radical left.  He dared to voice his opinions in public, one which merely illustrated the results of the radical left's horror show of public policy making and culture, which makes a mockery of the ideals of democracy, so one of them murdered the man who was famous for going to college campuses around the country and debating beliefs and policies with leftists.  He exchanged words with people he disagreed with, rather than arrows.  Our leftist media and their brainwashed drones immediately posted videos gleefully celebrating his murder.  Their total lack of self-awareness is mind-numbing but predictable.  They represent the latest incarnation of a failed ideology, one devoid introspection or love or forgiveness.

Any person or political party who publicly advocates for your murder and financial destruction, or attempts to silence you until they can murder you, is not one which you can peacefully coexist with, because they won't allow it.  I'm done pretending that these people are anything but brainwashed to the point of absurdity and violence.  They no longer attempt civil discourse, because they're incapable of it.  Every action and utterance of theirs only further reinforces that point.

#2 Re: Science, Technology, and Astronomy » Google Meet Collaboration - Meetings Plus Followup Discussion » 2025-09-08 20:19:43

I'd like to point out that the landing gear on the Falcon 9 / Falcon Heavy boosters are 100% CFRP structures, with a white thermal barrier protective coating, presumably some kind of thermal spray ceramic coating.  Landing gear absolutely counts as a high stress load-bearing structure, one expected to survive a landing so hard that it permanently deforms an Aluminum crush tube contained within each hydraulic strut upon landing.  Moreover, the outer-mold-line for that gear is markedly different from the Falcon's Al-2195 propellant tank, which ensures that they also experience some brief localized shock impingement heating.

To wit, Falcon's CFRP landing gear components have repeatedly survived both the peak heating impulse caused by plunging back through the thicker lower atmosphere following their Mach 6 burnout velocity, plus some minor impingement of the engine plume upon restart for retro-propulsion.  A Merlin engine is nowhere near as powerful as a Raptor, but it's still briefly bathing the underside of the booster in a sheet of white-hot flame.

My assertion, which should not be too controversial, is that the booster cores for both Falcon and Starship rockets could be fabricated from CFRP consisting of IM7 fiber bound within a PBI matrix, with a thin thermal barrier coating applied, which should result in virtually no loss of base material tensile strength associated with peak heating.  Al-2195 Aluminum-Lithium alloy (82ksi with a T8 temper) and 304L stainless (30.5ksi according to MatWeb, possibly up to 42ksi for slightly modified alloys) or similar alloys are very weak materials compared to IM7 (800ksi for the fiber, 395ksi in a typical composite using 8552 resin, given a typical 60/40 fiber-to-resin ratio, by volume).  Said resin is weaker than PBI, so my presumption is that a 60/40 IM7-to-PBI composite would be modestly stronger.

IM7 composite is 9.4X to 13X stronger than 304L and 4.8X stronger than Al-2195-T8.  All known metal alloys, irrespective of type, are W-E-A-K compared to this "garden variety" aerospace structural CFRP, fabricated using the modern method of using automated fiber placement machines, aka "tape winding machines", laying down unidirectional fiber tow / roving / tape.  That said, we will still use metal for the thrust structure, 300M (turbofan engine mounts for airliners) or Aermet VIM/VAR steels (more exotic, but considerably better YS than 300M or Ti-6Al-4V, though more expensive than either by a wide margin) or Ti-6Al-4V (common enough here in America, where there is extensive Titanium forging experience for military aircraft and government spacecraft).  For commercial rocketry, I would bet on 300M, but government rockets frequently call for carefully designed Titanium mounts, such as that used by the Space Shuttle.  Use of the described materials has become a fairly well accepted industry standard practice in aerospace because it's so exhaustively well-proven at this point.

NCAMP / NASA Material Qualification Report for IM7 (uni-tape)/8552 composites:
Hexcel 8552 IM7 Unidirectional Prepreg 190g/m^2 & 35% RC Qualification Material Property Data Report

Unidirectional IM7 tape / tow / roving, laid down by an automated fiber placement machine, followed by hot mold curing using PBI, is what I'm proposing.  This is how high temperature / cryogenic temperature capable composite propellant tanks could be fabricated.

HexCel HexTow IM7 Carbon Fiber Product Data Sheet

HexCel 8552 Resin Matrix Product Data Sheet

As the data sheet shows, 8552's tensile strength is 17.5ksi.

PBI exhibits a tensile strength of about 32ksi when used as the matrix in CFRP composites, or 23ksi for the neat resin.  IIRC, PAI is one of the strongest "neat" polymers, around 28ksi without any fiber reinforcement, but only rated to 500F service temps.

Any composite capable of 800F service temps without meaningful weakening is more than good enough for a booster stage.  A good thermal barrier coating means the composite can survive transient 1,000F+ aerodynamic heating associated with Mach 5 to Mach 7 burnout velocity without permanent weakening of the composite structure.

#3 Re: Science, Technology, and Astronomy » Google Meet Collaboration - Meetings Plus Followup Discussion » 2025-09-08 08:44:11

The "missing context" of my prior post, since only GW and tahanson43206 were present for our Sunday meeting, is for use as the material of choice for the booster stage's propellant tanks, which only see a peak velocity of about Mach 5 and peak heating of about 1,000F as the booster falls back through the atmosphere and lands the way the Starship booster lands.

CFRP is far stronger and lighter than any kind of metal alloy, even with temperature transients of up to 1,000F.  CFRP fabricated using special resins, such as Polybenzimidazole (PBI), used in conjunction with externally applied thermal barrier coatings, can survive the peak heating transient associated with the booster's burnout velocity, without the use of heavier and more delicate heat shielding tiles.  The combination of 800F capable PBI (without degradation or softening) and a thin (1.4mm thickness) thermal barrier coating such as Aluminum-Oxide (Al2O3), will allow a booster stage's propellant tanks to be fabricated from IM7 fiber, at perhaps 1/4 the mass of 304L stainless steel, presuming that the bulk structure is 4mm thick (the propellant tank wall thickness of the actual Starship Super Heavy Booster).  Said composite would still be drastically stronger than 304L over the entire temperature range that the booster experiences.  Said materials have already been tested by NASA, for use in the Space Shuttle Program, all the way back in 1969, which is when testing of those materials began.

PBI is expensive and hard to process because it requires greatly elevated temperatures during the molding process, relative to all other thermoplastics.  The base material itself is not egregiously expensive to purchase in bulk quantity, but on a per-mass basis, plastic parts made from or with PBI are much more expensive to use than resins which can be molded at much lower temperatures.  I think it qualifies as a "Gucci" material in that regard, but only because resin molding at elevated temperatures is relatively uncommon.  All that is to say that the molding equipment required to fabricate gigantic PBI-infused CFRP parts, such as propellant tanks, will cost a pretty penny (tens to low hundreds of millions), but buying the PBI plastic resin material itself from Celanese / "PBI Performance Products, Inc." will not be outlandishly costly.  If a corporation or Uncle Sam owns the high temperature mold and robotic tape winding equipment, that's one-time cost to them, and then very light yet highly temperature resistant CFRP parts can be robotically tape-wound / compression molded / fully cured in a matter of days, with far less touch-labor on the part itself.  A small team of semi-skilled materials handlers will be required.  Touch labor will mostly be limited to removal of mold flashing.  Application of the thermal barrier coating would be done using a robot to ensure highly uniform thickness, as is already common for ceramic coated pipeline components used in the oil and gas industry.

#4 Re: Science, Technology, and Astronomy » Google Meet Collaboration - Meetings Plus Followup Discussion » 2025-09-08 01:26:02

Thermal barrier coating for carbon fiber-reinforced composite materials

Abstract

Carbon fiber-reinforced plastic (CFRP) composites are widely employed in lightweight and high performance applications including supercars, aero-vehicles, and space components. However, although carbon fibers are thermally stable, the low thermal endurance of the matrix materials remains a critical problem in terms of the performance of the material. In this study, we proposed a new, Al2O3-based thermal barrier coating (TBC) for the CFRP composites. The TBC comprised α-phase Al2O3 particles with a mean diameter of 9.27 μm. The strong adhesion between the TBC and the CFRP substrate was evaluated using a three-point bending test. When the CFRP substrate was subjected to a 500–700°C flame, the 1.45-mm thick TBC protected the CFRP substrate remarkably by reducing the surface temperature to 188–228°C. The thermo-mechanical responses of this TBC/CFRP composite were analyzed after thermal shock tests. Surprisingly, 50% of the pristine flexural strength of the TBC/CFRP composite was preserved, whereas that of neat CFRP was reduced significantly by 95%.

Porous Thermal Barrier Coating Formation Technology for Carbon Fiber Reinforced Composites through Flame Spraying

Compared to metal or ceramic matrix composites, carbon fiber-reinforced plastics (CFRPs) are versatile but have low durability in high-temperature environments. This characteristic requires that a thermal-barrier coating be applied to protect the CFRP. Various methods have been used to apply such a coating to metal matrix composites, such as electron-beam physical vapor deposition, chemical vapor deposition, and thermal spray. Among these, thermal spray is preferred for its simplicity, short processing time, and scalability for large applications. But despite inherent utility, this technique was previously known to be unsuitable for CFRP applications. By adjusting flame spraying coating parameters, a method was discovered that not only allows a thermal coating to be applied to CFRP materials but also allows deliberate manipulation of each individual layer. Through this method, pores can be intentionally introduced in the inside layers of the coating, further decreasing thermal conductivity.

The process has proven successful, decreasing thermal conductivity to the point of protecting CFRP composites from temperatures up to 500°C. Combining lightweight, high-strength, and extreme-environment properties into one, this paves the way for improved firefighting equipment, aerospace body protection, and applications in the automotive industry.

file.php?id=38099

All those yellow areas shown are high temperature composite parts.  On the side facing the engine, they have thermal barrier coatings applied, in addition to high temperature capable resins.  Hot bleed air from the turbine flows around the nozzle, to help mask the thermal signature from the far hotter exhaust flow from that giant F-135 engine.

Here's a good shot of the nozzle:
6696f008c2742e67fda564a9-f135enginecloseuppromo.png?auto=format,compress&fit=crop&q=45&h=356&height=356&w=640&width=640

That saw-tooth pattern you see on both the nozzle itself and the composite skin does more than merely reduce the radar return.  It also aids in mixing and acoustic signature reduction.  On the composite skins you see on the jet engine nacelles of the most modern commercial airliners, it's deliberately used to reduce engine noise.

qtd2_sunrise_3024x2016_0.jpg

NASA partnered with industry many times during years of chevron testing, including these tests of nozzles on a specially-adapted GE engine mounted on a Boeing 777. Chevron nozzles will be seen on more engines in the coming years. - The Boeing Company / Bob Ferguson

NASA Helps Create a More Silent Night

Anyway...

F-35 heat management
The skin temperature near the engine is not uniform and is affected by several active and passive cooling systems.

Cooling vents: The F-35's airframe near the engine nozzle has small vent holes to circulate air over the engine, dissipating some of the heat.

Bypass air: The F-35 uses a turbofan engine that mixes hot exhaust from the engine core with cooler bypass air. This significantly lowers the overall temperature of the engine's exhaust plume, which reduces its IR signature.

Exhaust dilution: By diluting the hot exhaust, the F-35 reduces its heat output before it leaves the jet.

Thermal coatings: The aircraft uses specialized thermal barrier coatings to insulate the skin from the engine's heat.

Material limits: The aircraft's skin near the engine is made from high-temperature resistant materials, but in 2014, an F-35 experienced an engine fire due to a rub in the engine that caused a local temperature of over 1,000C (1,900F), exceeding the material limit of 540C (1,000F)

Material Data Sheet for the Cycom 5250-4 Resin System used in the high-temp BMI composites near the F-135's hot section:
CYCOM® 5250-4 PREPREG SYSTEM

Maximum continuous service temperature up to 400F (204C)
Short-term service temperature up to 450F (232C)

Max service temp is only 450F, but take careful note of how those aforementioned thermal barrier coatings can drastically reduce temperature and damage to the resin matrix.

Proof Research is a maker of CFRP over-wrap firearms barrels and they also fabricate the hot section composites for the F-35.
PROOF Research - May 18, 2016 FaceBook Posting

Our Advanced Composites Division in Dayton, Ohio makes high temp composite parts for the F-35, they also design our barrels using the same technology.

Gun barrels get really freaking hot, much like the engine casing of that gigantic F-135 engine.

All that said, I promised GW to provide a link to a 1,000F capable (intermittent service use) "resin", used in high-temp CFRP applications:

Wikipedia:
Polybenzimidazole

It was first synthesized in 1949, by the Material Laboratory of Wright Patterson Air Force Base, which is why I'm a little surprised that this keeps getting questioned.  That said, full synthesis of the material we use today was accomplished in 1961.  NASA contracted with Celanese to use PBI in the space suits used in the Apollo spacecraft, following the Apollo I fire.  Today, the company originally created to make PBI-based polymers, named "Celanese", operates as PBI Performance Products, Inc.  The Space Launch System 5-segment solid rocket motors use PBI plastic

In 2016, NASA qualifies the use of PBI in the insulating compound for the reusable and largest solid fuel rocket motor ever built for flight - the Space Launch System Five-Segment Booster.

When Skylab fell to Earth, the part that survived the re-entry was coated in PBI and thus did not burn up.
...
Imidazole derivatives are known to be stable compounds. Many of them are resistant to the most drastic treatments with acids and bases and not easily oxidized. The high decomposition temperature and high stability at over 400°C suggests a polymer with benzimidazole as the repeating unit may also show high heat stability. Polybenzimidazole and its aromatic derivatives can withstand temperatures in excess of about 500°C (932°F) without softening and degrading. The polymer synthesized from isophthalic acid and 3,3'-Diaminobenzidine is not melted by exposure to a temperature of 770°C (1,420°F) and loses only 30% of its weight after exposure to high temperature up to 900°C (1,650°F) for several hours.

This NTRS Report dates back to 1971, in which PBI composites were studied for Space Shuttle Program TPS:
STUDY AND PRODUCTION OF POLYBENZIMIDAZOLE BILLETS, LAMINATES, AND CYLINDERS - Prepared by LOCKHEED MISSILES & SPACE COMPANY

Said study describes tests performed on PBI-infused carbon cloth "laminates" (CFRP by another name) materials.

In 2025, for a thermally-protected spacecraft propellant tank structure, we'd probably use IM7 fiber as government-furnished material (no choice, because it's what NASA and our aerospace primes have on-hand, meaning no ultra-high tensile strength T1200 fiber), get a specialty PBI resin from a company that makes it, use an aerospace prime to fabricate the part (Boeing or Lockheed-Martin or Northrop-Grumman), and then we'd hire a specialty company to apply a highly uniform ceramic thermal barrier coating (expensive but necessary).

#5 Re: Human missions » Starship is Go... » 2025-09-05 20:02:22

Hypersonic Materials and Structures

All those new materials and fabrication methods under T&E 10 years ago are now fairly standard for reentry TPS.  Starship could be using any of those new TPS materials, most likely some combination of them.

#6 Re: Meta New Mars » Housekeeping » 2025-09-04 23:24:20

tahanson43206,

This weekend I should have some time to address the banned users issue.

#7 Re: Interplanetary transportation » NASA funds Direct Drive Fusion Propulsion » 2025-09-04 23:20:31

I think pure greenfield science is a worthy goal unto itself.  I agree with the notion that pursuit of knowledge, for its own sake, is a worthy and laudable goal.  However, when our stated exploration goals require better / cheaper / faster propulsion systems, and we have what's required on-offer from a competent corporation that can deliver the goods, I think that is where science must be goal-oriented.  A number of corporations have offered improved engines over many decades now.  Apart from SpaceX and Blue Origin, NASA is still using engines that were the product of 1970s development efforts.  NASA and DoD spent billions upon billions of dollars on new engine designs, but none of them ever replaced what they've either been developing or actively using over 50+ years.  That's the extent of what we have to show for all the efforts made by our various aerospace primes.  There's no world where that makes rational sense, except in a carefully constructed one that's long since been strangled by bureaucracy.  The RS-25 could've been evolved into something 3D-printed components, uncooled RCC nozzles, improved turbopump designs and materials, etc.  We spent good money and decades of development work on all of that, yet it's nowhere to be found in the engines NASA is using to send people back to the moon.  It's little wonder that their rockets cost so much and have flown so infrequently, relative to what was promised.  We can't keep running the same program while expecting different results.

There's a reasonably logical progression to in-space propulsion technology, the one mission critical technology where all of humanity is weakest.  We began with solid rockets which were more suitable for weapons than space launch vehicles.  We swiftly moved on to liquid fueled engines.  We developed ion engines around the same time the Apollo Program was in full-swing.  Around the same time development of ion engines began in earnest, we also developed nuclear thermal rockets using compact / high power density fission reactor cores.  Neither were intended to replace chemical rockets for orbital launch vehicles, but both were necessary in-space propulsion solutions to problems that chemical rockets could not address in a practical way.  Fusion rockets are the next logical progression of in-space propulsion options.  While we work on fusion rockets, we should continue to pursue propellantless "impulse" engines and warp drives.  Although teleportation and various other Star Trek level technologies will likely require another century or more of development work, if we put forth the effort now, when it matters most to near-term colonization efforts, then we'll have "real starships" by the time we work out the details of the more advanced bits of Star Trek tech.  What we cannot do, presuming the goal is real exploration and colonization, is to continue to aimlessly throw money at every potentially interesting new propulsion technology without maturing "within reach" technologies to relentlessly advance our propulsion systems.  Pulsed fusion using supersonic implosion of light alloy foils to generate thrust is well within reach.  Continuous fusion using gases would be better still, but we're probably at least a couple of decades away from that being achievable.

Why wait another several decades for "better fusion rockets", when a fully functional pulsed fusion rocket would mean on-demand access (no waiting for orbits to align) to the solar system within the next decade?  All the individual pieces work.  We need to put them together into a fully functional high-thrust / 5,000s+ Isp in-space propulsion system.  This is an engineering task, rather than a greenfield tech development task.  NASA balked at spending more money on completing development of a pulsed fusion rocket engine the moment a continuous fusion rocket looked as though it was a possibility.  It's as if they cannot maintain focus long enough to produce a fully functional product usable for their own purposes.  In their own words, they did that "because a continuous fusion rocket engine could be even better".  That sounds great, but nobody has created a fully functional stationary continuous fusion reactor, so creating a flight weight continuous fusion rocket engine seems more than a little premature, even though there are companies actively pursuing this.  We have to start somewhere, so clearing the lowest set of technological hurdles to an operational fusion rocket engine seems like the best place for NASA and JPL to start.  Argue over how the rocket could be made "even better" after you have a TRL9 pulsed fusion rocket engine.  Improving the TRL of a continuous fusion rocket engine ought to be that much easier when you already have an in-service pulsed fusion engine.

We need people and corporations to expand the edges of the performance envelope with the express purpose of using the fruits of their labor as a goal-oriented enabler for our stated exploration and colonization objectives.  NASA, the agency, stated quite clearly that human exploration of Mars was the prize, even as it continued to pursue a plethora of pure science projects.  While useful in their own right, the "result" which emerged over the course of many decades was an unfocused and unimaginative collection of distantly related science projects with no clear tieback to stated exploration objectives.  The problem, at least as I see it, is the lack of measurable progress towards the agency's stated human exploration objective.  Nobody who is in charge seems the least bit interested in true exploration, likely because it's dangerous, unpredictable, expensive, and requires unwavering determination to succeed.  We clearly had that during the Apollo Program, but lost it somehow because we changed technologies.  We looked for reasons why we couldn't succeed, rather than accepting and using what was on offer.  For example, Shuttle-C should've been pursued during the Space Shuttle era to maintain the capability to conduct exploration missions.  SLS is about 30 years late.  ISS should've been used as a prototype Interplanetary Transport Vehicle.  The means has always been there, but the will has not.

It would be fair to say that private corporations are now driving technological development aimed at specific exploration and colonization objectives, because various billionaires see space exploration and colonization as one of the few remaining, truly worthwhile, "next steps" in human development.  After you acquire tens of billions of dollars, space exploration and colonization is the only worthwhile investment commensurate with the level of investment involved.  You can build more factories to turn out new tech trinkets, gold-plate your toilets, or build an enormous yacht that might get used once per year, but eventually all of those "status symbols" will be viewed as empty idle pursuits by someone who is driven to build an empire.  Elon Musk famously lives in a studio apartment, drives an unremarkable "standard" Tesla his company built, and owns a handful of clothes, because there's no point to accumulating more "stuff" that he'll never see or use.  This is a very peculiar state of affairs, because traditionally governments have been the driving force behind exploration efforts.

The men and women who are now leading these efforts have looked upon what their governments are doing and said to themselves, "You're no longer completing the job that the people you represent expect to be done, after you sold them on the idea and spent obscene amounts of money.  We don't have many milestones we can point to whereby progress can be shown to the general public.  We're taking over where you've failed us."  That's the quiet part, not typically said out-loud, but it's present in the minds of people looking at what NASA is doing and asking pointed questions about the apparent lack of progress.  Do or do not.  There is no "try".

#8 Re: Interplanetary transportation » NASA funds Direct Drive Fusion Propulsion » 2025-09-04 14:39:41

There's a major difference between the difficulty of confining a plasma long enough to use it to generate baseload electricity vs the far lower relative difficulty of intentionally allowing said plasma to escape from its magnetic confinement chamber to generate thrust.  The technological bar to clear for generating electricity using fusion, in a manner similar to a fission reactor, is monumentally high.  The bar to clear for achieving thrust has already been cleared.  There's no question that using fusion to achieve thrust actually works.

When MSNW LLC did the initial development work on the concept, they proved that all major components worked to the degree required, but then NASA immediately pivoted to something that looked better in theory, namely continuous thrust generation from continuous fusion power, but continuous fusion requires long term plasma confinement, similar to a conventional Tokamak.  That's the part we cannot yet do in a practical manner- fusion that generates net positive electrical output to use as input for a self-sustaining reaction.

Why did they do that?

NASA is focused on science, not producing tangible usable things like a pulsed fusion drive as an enabler for their own exploration missions.

That's the best answer I can come up with.

#9 Re: Science, Technology, and Astronomy » Google Meet Collaboration - Meetings Plus Followup Discussion » 2025-08-31 19:12:12

tahanson43206,

Here's a link that shows the "belly-to-belly" MUSTARD spaceplane concept that uses 3 roughly identical spacecraft, 1 of which would ascend all the way to orbit:

MUSTARD Launch Configuration Images

#10 Re: Single Stage To Orbit » SSTO Sub Forum Policy » 2025-08-31 17:52:17

GW,

CFRP's strength can be improved and porosity reduced using a method known as "Carbon Forging", which was pioneered by Lamborghini.  The process combines extreme heat and pressure.  A French Company named Duc Helices makes propeller blades for light aircraft and helicopters using this method.  The "forging" process takes less than a minute, sometimes only seconds, and can be used with chopped fiber, fabrics laid by hand in a mold, or roving/tow which has been laid down using an automated fiber placement machine, which is how CFRP rocket propellant tanks are made by companies like Rocket Labs.  IIRC, at least one company makes high performance CFRP wheels / hubs for sports cars this way.  They use a combination of fabric, chopped fiber, and roving / tow, all in one part.

#11 Re: Business Proposals » Maximum Use of Conductors, Distributed Electric Storage, Pyrolysis. » 2025-08-26 21:34:46

Maybe this graph can help illustrate the effect of Copper ore depletion on energy consumption:
1-s20-S0921800919310067-gr5_900.jpg

#12 Re: Not So Free Chat » Oil, Peak Oil, etc. » 2025-08-24 19:50:53

Reliable Energy Intensity Estimation
Global average steel making energy intensity is 19.76GJ/t (19.76MJ/kg).  Rather than using the absolute best figure achieved, which is what our photovoltaics / electric wind turbines / batteries enthusiasts typically do, I think using a global average energy intensity value is far more appropriate, since steel will inevitably be sourced from wherever it's available.  Steel is a staple construction material, one for which we have detailed energy intensity data publicly available because it's not considered proprietary knowledge.  At 31.4kg/m^2 of solar thermal collector array, using 2mm thick stamped sheet steel mirrors and tubing for structural support (does not include the steel rebar in the foundation), the embodied energy for the steel is 620.424MJ/m^2, or 172,351Wh/m^2.  Steel mirror support structure is identical to "tube-and-fabric" light aircraft structure.

Design with Sophistication, Operate with Simplicity
At least one company holding a contract with NREL ran an AI-enhanced computer aided engineering program for optimizing support structure geometry to minimize mass and cost.  The end result was that support mass was about equal to mirror mass, using a welded tubular steel support structure.  This was done for 5m to 10m width parabolic troughs with single-axis Sun tracking, not the gigantic perfectly flat "billboard" mirrors used by solar power towers.  My assumption is that the bulk of generated power will come from the most simplistic and user-friendly solutions.  Advanced economies can afford to invest additional material and monetary resources into solar power towers, where the overall efficiency of the solution might matter more to them, at the scale they require.  For all solar thermal component designs, multiple examples of full scale hardware are built and tested, then operated within a functional power plant, typically for at least a year, but often for multiple years to evaluate durability.  Thus, very little extrapolation of potential future performance is required.  For photovoltaics, very small sample quantities are subjected to a battery of standardized tests, which is fine and desirable, but this testing tells you very little about broader context of mass production because it's frequently singular wafer special production runs in a lab, with minor variations for test purposes (also good to have), because scale-up frequently entails building a brand new factory to efficiently fabricate at scale.  Real world performance is highly dependent upon process control and testing to minimize rejection rates, equipment in the factory which has a major effect on said rejection rates, the competence of the installation crew, and site selection.  I've had an electrical engineer, a certified electrician with over 20 years of experience who specializes in commercial photovoltaic panel installations, and run-of-the-mill rooftop panel installers all show me the results of amateur hour in plant design.  They all spoke of spending days to months of rework to salvage poor quality installation work.  The consensus is that pure mechanical assembly tends to be less error-prone than a combination of mechanical / electrical / electronic assembly, because less knowledge and experience is required.

Expect Similar Energy Intensity for Solar Thermal and Photovoltaics
You have to add more energy for a steel-reinforced concrete support structure, but this also applies to roughly equally heavy photovoltaic panels with single-axis Sun tracking.  Photovoltaics still use support tubing and reinforced foundations.  Getting back to mirror design, a polished hot-dip Aluminum coating is also required.  That adds even more energy to the final total for the mirror, because there are no free lunches here or anywhere else.  There's a real energy cost to every concession made to design efficiency.  The Aluminum coating is corrosion-resistant, which is why it's applied to factory automotive exhaust tubing and mufflers, and highly reflective after polishing.  Surface finish quality of the steel greatly affects reflectivity, hence the use of a cold-rolled product.  An electronic or mechanical sun tracking mechanism is also required for each mirror assembly.  Troughs are typically rather long, but can be assembled onsite from smaller sub-assemblies for ease of transport.  The net-net is that the total mass of materials for parabolic troughs, in a real world plant, is remarkably similar to real world commercial photovoltaic farms.  Total embodied energy will be lower, but only modestly so.  There is, however, a radical difference in the embodied energy of thermal vs electrical energy storage in electro-chemical batteries.  The major difference between mirrors and photovoltaics is service life before unacceptable degradation occurs, the kinds and abundance of materials required, the use of field repairable vs factory replaceable technology units, and ease as well as completeness of recycling.  All similarities between mirrors and photovoltaics end there.  As previously stated, the Silicon that comes out of photovoltaics recycling is not readily usable in brand new photovoltaics, because the energy intensity of photovoltaics recycling significantly exceeds that of mining and refining virgin materials.

Supply Chain Management
Types of materials required by solar thermal generation and storage tend to involve very simple manufacturing processes by way of comparison to photovoltaics / control electronics / wiring / power transformers, so the supply chain is much shorter.  Complete onshore manufacturing of stamped steel is possible for major economic powers.  Materials and components don't need to crisscross the globe multiple times.  Transport energy is lower as a result.  The steel stamping / welding / hot-dipping equipment is far less energy-intensive per kg of finished good.  All electronic devices require extensive supply chains.  A myriad of highly specialized facilities are required to fabricate Silicon wafers and power electronics equipment.  No single country contains all the materials or hosts all the facilities for photovoltaics and electronics manufacturing.  There is such a thing as a purely mechanical dual-axis Sun tracker that uses solar thermal power to deliver torque to the mirror array.  No control electronics are required until we arrive at the single electric generator and step-up power transformer.

Plant Security and Assurance of Supply
The most sophisticated hackers in the world will have a very difficult time affecting a mechanical solar thermal or mechanical wind turbine plant.  Their ability to affect operations inside a solar thermal plant itself is near-zero without direct physical access.  If the Sun is momentarily masked by clouds, all that built-up thermal inertia continues to drive the turbine and electric generator.  Solar thermal plants can also include 8 to 16 hours of onsite thermal energy storage provided by tanks of pulverized rock or molten salt, because it's cost-effective to do.  Only large storage tanks of heated material are required.  That means generation doesn't end entirely at sunset.  Strictly speaking, given sufficient onsite thermal energy storage, no complete backup power plant is required when collection ends at sunset.  In large installations, the temperature delta between start of stored energy consumption at or near sunset and resumption of collection at sunrise, varies by less than 1C.  It's similar to a nuclear power plant in that regard, but without the security requirements.  If you managed to get your hands on some molten solar salt, apart from burning yourself, what else could you do with it?  Perhaps most importantly, the entire grid can't crash the way Spain's grid did, due to the fact that purely electrical photovoltaics and wind turbines provide zero grid inertia.  Vertical power spikes and drops are only possible when the turbine, electric generator, or step-up power transformer catastrophically fails.  That greatly simplifies grid operation.  Even if you did eventually have to burn some fuel due to seasonality or catastrophic equipment failure, you have hours to perhaps days to spin-up natural gas turbines, which means they don't need to run in the background 24/7/365.  You only run them for supplemental winter power.

Solar Thermal Materials Details
Cold-rolled steel and steel-reinforced concrete are the primary materials required by solar thermal, plus a small amount of Aluminum applied using the exact same technology required to create typical factory automotive exhaust tubing and mufflers (stamped and welded cold-rolled sheet steel hot-dipped in Aluminum).  The total mass of materials required per square meter of mirror surface area is not significantly more or less than the mass of materials required for photovoltaic panels.  There are no existing materials limitations when it comes to delivering enough steel, concrete, or commercially pure Aluminum coating.  We don't need to wait additional decades to centuries to acquire enough high purity Silicon, Copper, Lithium, Aluminum, rare earths (for the control and power inverter electronics) from extraction.

Materials Recycling Processes
The recycling process for Aluminized steel involves heating the shredded sheet metal to melt-off the Aluminum coating, and then stuffing the now-uncoated shredded steel back into an electric arc furnace.  Presumably, most of the Aluminum and steel can be recovered.  I'm not entirely familiar with the process used to recover concrete.  My understanding is that ground-up / powdered concrete can be and presently is mixed into fresh batches of concrete, but like so many other composite materials, it's not 100% recyclable into brand new concrete, strictly-speaking.  The steel rebar can be recovered and recycled at near-100% rates.

Solar Thermal vs Photovoltaics Service Life
A photovoltaic array has meaningfully faster degradation over time than a much simpler polished metal mirror, thus a shorter useful service life.  Metallic mirrors can easily last for a human lifetime, possibly several lifetimes with periodic re-polishing.  Some of humanity's oldest mirrors, made from materials like obsidian, predate our discovery of metallurgy.  Metal mirrors with corrosion protection should last at least 3X longer than photovoltaics.  In a very hot and dry desert, only scratches will degrade mirrors over meaningful timeframes.

I can simplify this obviously contentious issue to a pair of YES/NO questions:

1. Is 10 years of global (at 2024 production rates) steel, commercially pure Aluminum (the only kind that comes directly from the smelter), concrete, and solar salt or crushed rock production enough to deliver the solar thermal collector surface area, or mechanical wind turbines to compress air in places that are not sunny, plus 28 days of thermal and air energy storage to account for seasonality, enough to provide 70% of humanity's Total Primary Energy Supply?

2. Is 10 years of global (at 2024 production rates) high purity polySilicon, Copper, Aluminum, Lithium, and rare earth metals production enough to produce the photovoltaics, electric wind turbines, electronic control systems, and electro-chemical batteries for fast storage, to store 28 days of electrical energy to account for seasonality, enough to provide 70% of humanity's Total Primary Energy Supply?

Allowable Concessions to Dreamers
I'm perfectly willing to concede that potential future advances in photovoltaic and battery tech may be able to do what has thus far proven functionally impossible, provided that you are able to supply realistic materials demands estimates for all required materials.  If you can't do that, then there's nothing to compare.  You're presenting a fever dream with no numbers to evaluate.  We don't judge merit on the basis of "nothing".  In point of fact, we would say that "nothing" is entirely without merit, therefore any argument over the future potential of nothing is without merit.  It's entirely belief-driven, much like religion.  Maybe it will work beautifully, or maybe it won't, but nobody actually knows, so why are we pursuing religion when our problems are math-based?

The arguments put forth by our photovoltaics / electric wind turbines / batteries enthusiasts are exactly like debating the merits of man-made fusion reactors.  Thus far, no self-sustaining made-made fusion reactor exists.  We don't know if it's even possible because nobody has been able to make it work.  Fusion is another future technology with potential, nothing more.  Any argumentation over what it might potentially provide is without merit.  Do the hard work to create a fully functional example of the tech first, and then we'll know what merits it does or doesn't have.  I'm not going to bet the future prosperity of my children on tech that doesn't actually exist.  No sane and rational parent would tell their child to simply "believe" that everything will work itself out, without a pointed admonishment about putting in the work to make sure it does happen.

I have materials consumption figures from actual solar thermal installs, which were helpfully compiled by US DoE and NREL, to use as sanity checks for my materials demand estimates.  I don't need to dazzle anyone with futurism "nothingness" when I can show real numbers for real machines that produce reliable power.  Opportunistic power seems to provide an irresistible temptation to people who deal in possibilities, rather than probabilities.  Business and government operates primarily on probability.  The US federal government spends some money on maintaining nuclear weapons on the basis of the rather low probability but high impact of a nuclear war.  It spends many many more dollars on conventional fighting forces, because all wars to date have involved a lot more shooting than nuking.  That's why track record and trust through reliable action are so important to business and government.  They'll give you a golden opportunity, but then they expect you'll show up to do the work.  That's what our "all-electric dreamers" have failed to do thus far.  When it comes to sourcing the wish list of materials to put their ideas into practice, they think belief or possibility or "the market will figure it out" is an acceptable substitute for demonstration.  I've seen no practical demonstration of a grid run primarily on their favored technologies.  All the examples they point to are back-stopped by hydro dams, nuclear reactors, or coal / oil / gas.

#14 Re: Not So Free Chat » Oil, Peak Oil, etc. » 2025-08-21 00:07:47

Void,

Our process purifies silicon to more than 99.999%.

Photovoltaics of the 2010s, which were about 15% efficient, used 99.99999% pure Silicon.  Photovoltaics of the 2020s, which are 25% efficient, use 99.999999999% pure Silicon.  99.999% pure Silicon may allow you to create photovoltaics with 10% conversion efficiency, which may be fine for use on the lunar surface because there is near-zero atmosphere.  40% efficient triple-junction photovoltaics do not use 99.999% pure Silicon.  Add another eight "nines" to the end of that purity value.  Greater efficiency comes from much higher purity materials, exponentially more energy input, and more exotic materials.

Blue Origin's electrolysis furnace is innovative, but much like Boston Metal's electrolysis-based steel making process, it does in fact use significantly more energy.  That is a mathematical certainty, not a guess.  We've had electrolysis cells for high purity metal production for many decades now.  All that fortified food made here in America uses extreme purity Iron created through electrolysis, but there's a massive energy cost to producing it, which is why it's more expensive than Pig Iron and steel.  The energy input into Blue Origin's electrolysis cell, per kilo of metal produced, is conspicuously absent from their fluff piece.  If they had something truly remarkable, they'd be monetizing it.  The metals smelting industry would be throwing money at them.

To their credit, Boston Metal has been completely honest and very public about the fact that their CO2-minimized steel making process uses more energy than traditional Blast (Pig Iron) and Basic Oxygen Furnaces (steel).  They're producing the same steel product at the end of the day, but it's more energy-intensive.  The principle benefit is greatly reduced CO2 emissions, which is a worthy goal, but the implication of what consuming more energy means is that more energy of ALL TYPES (which includes hydrocarbon fuels) will be consumed.  Shifting where the CO2 gets generated doesn't change the fact that it's still being generated.

The reason engineers used Carbon in so many reduction processes is pretty simple.  Carbon drastically reduces the input energy for metal ore reduction.

The reduction zone in the blast furnace, where Iron ore undergoes reduction reactions, takes place between at or under 1,000C.  The hearth zone of the furnace where molten Iron is collected, is heated to at least 1,600C.  Pure Iron melts at 1,538C.  The blast zone can be much hotter, since forced air induction is used to ignite the coking coal.

The Hall-Héroult process takes place just below 1,000C, and the use of a cryolite bath and Carbon anodes is what allows Aluminum smelting to take place at this temperature.  Even at Al2O3's boiling point, which is just shy of 3,000C, Oxygen will not thermally dissociate from Aluminum, because the bond is so incredibly strong.  There are other methods for making Aluminum, all of which consume a lot more energy.

Silicon melts at 1,414C, but quartz is heated to at least 1,500C, so the 1,600C reduction temperatures mentioned in the article seems like a plausible value to me.

If regolith is simply scooped up off the lunar surface and dumped into an electrolysis furnace, whereupon every kilo of regolith is heated to 1,600C, even though not all metals need to be heated to that temperature extreme for reduction, then by definition you're using a lot more energy to do that.  After you produce liquid metal, then you need selective high temperature separation methods to produce the various different kinds of metals you want.  That issue is created by deliberately starting the process with a hodgepodge of different oxidized metals, rather than locating deposits of high grade ores, separating them using a grinding and flotation process, and then proceeding with reduction.

All parts of the metals extraction and refining processes were deliberately optimized by engineers to reduce energy consumption.  We don't use targeting of rich ore grades / grinding / flotation, "just 'cause".  We don't extract Lithium from sea water for the very same reason.  When compared to chemical reaction methods, every electrolysis process I'm aware of consumes more energy to produce the same end product.  We do tend to use electrolysis when high purity and excellent temperature control is required.  There are real benefits to using electrolysis, but energy efficiency is not one of them.  The Hall-Héroult process is an electrolysis process, but we use it in conjunction with heating and a chemical (cryolite) bath to reduce the reduction temperatures.  This assertion of fact applies to Iron, Aluminum, and Silicon.  It may not apply to certain technology metals.

If electrolysis was energy efficient, then we'd already use it to produce most metals.  It's not, though, and that's why we don't use it to produce metals, unless required, as is the case for Aluminum smelting.  There are no "free lunches" to be had here.  Nobody here wants to hear that, but it's still true.  Once again, hope is not a valid systems engineering strategy for creating the next generation of the largest machines humanity has ever created.  If you want to use natural energy sources, then you have to stop fixating on electrical technology and start understanding how energy is actually used, and then accept that only low energy input and readily recyclable materials are suitable to task.

#15 Re: Not So Free Chat » Oil, Peak Oil, etc. » 2025-08-20 11:04:00

From the "Unpopular Truth" article:

3. Solar-grade silicon (SoG-Si) making and wafering

For solar panel manufacturing to be complete, more is required. Metallurgical grade silicon (MG-Si) from the smelter, usually of 98% purity, does not meet the purity requirements of the photovoltaic industry, it must undergo two more energy-intensive processes before it can be made into solar cells and then into panels.

Firstly, the Siemens Process converts metallurgical grade silicon (MG-Si) from the smelter into polycrystalline silicon (called polysilicon) by using an extremely energy intensive process, a high-temperature vapor deposition process (Troszak 2019). The purity requirement for solar grade silicon (SoG-Si) is currently 9-11N (99.999999999%), a factor of 10,000 to 100,000 more pure compared to the 5-6N purity required for solar PV a decade ago and likely the basis for the solar panels on your roof (if you have some).  In the Siemens process, silicon is crushed and mixed with hydrochlorous acid (HCl) to create Trichlorosilane gas (SiHCl3). This gas is heated and deposited onto very hot rods of polysilicon (1.150C) while the reaction chambers walls are cooled.

Each batch of polysilicon “rods” takes several days to grow, and a continuous, 24/7 supply of electricity to each reactor is essential to prevent a costly “run abort.” Polysilicon refineries depend on highly reliable conventional power grids, and usually have two incoming high-voltage supply feeds. (Sources Mariutti and Schernikau 2024, unpublished academic paper, Troszak 2019).

Secondly, the Czochralski Process turns the liquid silicon metal from the smelter and doping materials (gallium or phosphorous) into the silicon ingot, a large monocrystal, 20-30 cm diameter and 1-2 m in length. Next, the ingot is sawed into rectangular bricks, which are sliced into wafers using a diamond wire sawing process (Figures 3 and 4). This process requires several days, and uninterrupted 24/7 power supply. An ingot/wafer/cell plant can use more than 100 MWh additional energy per ton of incoming polysilicon, which is about 6 times as much as the original smelting of the silicon from ore.

Estimates of the energy and therefore CO2 footprint of silicon purification and wafering also diverge widely in the academic literature, mainly due to two reasons. On the one hand, there is no agreement on the estimated energy demand for these core processes. For example, solar grade silicon (SoG-Si) is the most energy-intensive step in the silicon purification process and should best be understood. Yet, SoG-Si inventories report an electricity demand ranging from 50 kWh/kg to 110 kWh/kg, which appears quite low.

On the other hand, secondary and pre-smelting processes are rarely included when considering the definition of an energy footprint, applicable to the average Chinese silicon industry. Currently, reporting used by governments for decision making, tend to be based on best-in-class plants, like in Europe or North America, which is far removed from reality.

#16 Re: Not So Free Chat » Oil, Peak Oil, etc. » 2025-08-20 01:10:45

Humanity's 24/7/365 energy consumption is about 20TW, so 70% is 14TW.  Existing photovoltaics will require 311.808Mt of polysilicon to deliver a constant 14TW.  Photovoltaics are currently produced using High Purity Quartz (HPQ) sand.  Global annual production is about 1.6Mt, excluding the highest purity quartz used in microchips.  Kerf, which is primarily generated by sawing polysilicon ingots into wafers, results in a loss of about 40% to 55% of all the polysilicon produced, even though it's recyclable and is mostly recycled.  Global annual net production of polysilicon for photovoltaics is therefore around 0.96Mt (960,000t), best-case scenario.  In reality, kerf consumes 50% of total polysilicon production for 0.5mm thick wafers, so 0.8Mt/year is available.  A 1m^2 photovoltaic panel made from 0.5mm thick wafers contains about 1.16kg of polysilicon.  That means it would take almost 390 years, using 2024's polysilicon production rates, to create enough usable polysilicon to deliver that constant 14TW.  Unfortunately for us, photovoltaics only last for 25 to 30 years before significant capacity (defined as 20% or more) is lost.

If average photovoltaic panel efficiency is 25%, then 1m^2 of photovoltaics generates about 1.25kWh/day (1,000W/m^2 * 0.25 * 5hrs per day).  Humanity's daily Total Primary Energy Consumption is about 336TWh (14TW * 24hrs), which means we need 268,800,000,000m^2 (336,000,000,000,000W / 1,250W/m^2) of photovoltaics to deliver equivalent constant power using 5 peak generating hours per day.  Any extra power generated during off-peak hours will likely be devoted to polysilicon production since we don't have enough HPQ.  At 1.16kg of polysilicon per square meter of photovoltaic array, we will need 311,808,000t ((268,800,000,000m^2 * 1.16kg/m^2)/1,000) of polysilicon.  Any theoretical efficiency gains over combustion will be immediately offset by vast additional production demands using lower purity materials or sub-optimal materials.

311,808,000t / 800,000t per year (2024 polysilicon production rate, minus 50% kerf)  = 389.76 years of polysilicon production at 2024 production rates, presuming 0.5mm thick wafers

What is high purity silica quartz sand, its main mine and manufacturers

According to the statistics of the United States Geological Survey, as of the end of 2019, the global high-purity quartz raw material mineral resources are about 73 million tons, of which Brazil is the country with the largest resource volume in the world, with a resource volume of 21.11 million tons, and the ore type is mainly natural crystal. The United States is the country with the second largest resource volume, with a resource volume of 18.22 million tons, and the ore type is mainly granite pegmatite quartz. Canada ranks third in the world, with resources of 10 million tons, and the ore type is mainly vein quartz.

We do recover and re-cast almost all of the kerf generated by sawn ingots of polysilicon, so that's good news, but both production capacity and proven HPQ reserves are sorely lacking.  However, we don't have enough Copper for the fast storage batteries, nor do we have enough HPQ to come within a country mile of supplying most of humanity's Total Primary Energy Consumption, by primarily using polysilicon-based photovoltaics and Lithium-ion batteries- the only technologies in mass production at the present time.

Can we use lower grade Silicon-bearing ores?

If you don't care about the energy input, anything is possible.  We'll be forced to do that fairly soon if we significantly ramp-up production rates.  There will be an exponential rise in energy consumption to refine lower grade quartz sand to the degree required, but it could theoretically be done with considerable effort and energy expenditure.

The lack of materials abundance, as it relates to current photovoltaics, wind turbines, and batteries technologies, doesn't bode well for them becoming the dominant energy source in the foreseeable future.  We need 390 years of 2024 polysilicon production, which requires more HPQ than exists in known reserves, plus more Copper than exists in known reserves to provide 28 days of fast storage, in order to deliver the first batch of Gen III solar and battery tech at sufficient scale to mostly displace hydrocarbon fuels.  Certain rare earth metals used in electric wind turbines require thousands of years of production at current rates, making them even less practical in some ways, though much better in others.

Existing PWRs like the AP-1000 design, Gen II solar thermal, and Gen I mechanical wind turbines, are looking like the only near term realistic solutions for displacing most hydrocarbon fuel consumption.  All Gen III tech is severely materials limited at the present time.  CO2 emissions keep going up every year because current Gen III tech cannot offer sufficient capacity for significant displacement of hydrocarbon fuels.

#17 Re: Not So Free Chat » Oil, Peak Oil, etc. » 2025-08-19 11:41:26

Why are there no photovoltaics factories powered by the very product coming out the loading docks of the factory?

If photovoltaics truly are the cheapest means of generating electricity and achieve energy payback so quickly, and fabrication / assembly of electronics requires lots of electricity, doesn't that seem like an absurdly obvious place to re-invest the supposedly cheapest energy that they create?

Why is 90%+ of the world's photovoltaic cell production capacity powered by coal and assembled using the equivalent of indentured servants?

Why not re-power those giant wide-open rock pits where the input materials to make photovoltaics are mined?

Doesn't that seem like an equally obvious place to put them?

Is it not the least bit curious to people advocating for more photovoltaics to generate grid energy that the bulk of the energy used to create photovoltaics doesn't come from the supposedly cheapest form of energy?

The Unpopular Truth - Coal's importance for solar panel manufacturing, by Dr. Lars Schernikau

If people advocating for more of this nonsense cannot answer such questions with honesty, then maybe it's because they either don't have good answers or are being dishonest with themselves and others.

#18 Re: Not So Free Chat » Oil, Peak Oil, etc. » 2025-08-18 23:17:47

offtherock,

Its gotten a lot more efficient in the past 25 years.
Why shouldnt we expect that development to continue.
Same with batteries and transmission.

Development has been ongoing since the 1950s.  If photovoltaics are not a mature technology by now, then by when might that happen?  This sounds like, "hope for the best and keep spending money on something that presently cannot scale to the degree required in any practical sense".  That's a classical "sunk cost" fallacy.  The largest incremental improvements are almost always front-loaded within the development cycle.  After 75 years of development, is it more probable that only small incremental improvements can be expected in the future, or game-changing improvements?  I think we both know the answer.  Lead-acid batteries of today are indeed better than Lead-acid batteries from WWII, but there are no night-and-day improvements to be had, nor should any be expected in the near-future.  Could I be wrong about that?  Sure.  Someone might concoct a seemingly miraculous new Lead-acid battery design tomorrow.  The probability of that happening is exceptionally low, so it's not something to "bet the farm on".

Its also a very war tolerant technology.

Power transformers are not "war tolerant".  A team "armed" with wire cutters can disable the plant during the night without drawing a lot of attention to the operation by making a lot of noise with explosives.  You can have as many photovoltaic panels as you want to.  No wiring and/or no functional power transformer means the power is not going anywhere.  A hasty re-wiring job will be even more effective than physically removing bits of wiring.  Military engineers are already aware of this.  If you devote a sufficiently large contingent of armed men to protect the plant, then they're not available for other operations.  Any competently-led military already knows this.

Eventually it will become much better.
But only if we actually make it so.

More sunk cost fallacy?

That doesn't help build-out a new power plant using "right here / right now" technology, which is the only kind of tech that real power plants get built with.  All the constructive argumentation I've seen revolves around future potential, rather than existing capability, which is woefully lacking.

Solve all the fundamental problems Calliban and I have outlined first, rather than treating them as "we'll figure it out as we go".  The people we've been throwing money at have had decades to "figure it out".  I'm not impressed with their rate of progress.

It will just be like pressing a button and 15 mins later ur in orbit.

This is already true.  Armies of techs monitor consoles, but only one guy or gal presses the big red button, and then the rocket takes care of guiding itself into the intended orbital insertion after that.  Nothing about space flight has radically changed since then.  It's still expensive, still time consuming, and still requires a standing army.  It's cheaper today than it has been in the past, but the logistics of making it happen are not much more efficient because all the same infrastructure pieces are still required.

It has, absolutely insane implications for humanity.

Finding a pure Copper or Platinum Group Metals asteroid and having the tech to mine the metal and then take it anywhere in the inner solar system relatively cheaply has insane implications, but we're looking at least another generation or two of space tech (25 to 50 years) before that happens.  Nobody has mined an asteroid to date.  Could that change?  Sure.  Quickly / easily / cheaply?  Not likely.  The Space Shuttle was the first reusable space flight vehicle, with initial development to end of operations spanning some 40 years (early 1970s to mid 2010s).  Nothing about it was quick / easy / cheap.  Falcon 9 / Falcon Heavy did significantly better in terms of total tonnage delivered and launch cadence, per dollar spent.  Hopefully, Starship does better still, because it should be the baseline for a truly affordable space program capable of more than "flags and footprints".

Gen I "Renewable Energy" should have been solar thermal driving steam turbines, with comparatively low temperature thermal energy storage.  That was realistically doable 50 years ago.
Gen II is solar thermal driving supercritical CO2 turbines, with high temperature storage.  No fundamental materials availability, new materials technology, or recycling technology limitations are known to exist.  This is doable now.
Gen III is photovoltaics and fast storage with all the materials sourcing and recycling issues solved.  We don't know when this might be doable at the scale demanded.

If it were up to me, I would mass deploy Gen II technology since that's ready now, wait however long it takes for Gen III to mature (asking for substantially more money and time is a sign that it's not ready), and only deploy Gen III at scale once there are no major materials availability, recycling, or other technological readiness limitations, such as grid stability.

The bottom line is that we have quite a bit more work to do before making sensible prognostications about what may or may not be attainable in the mid (5-10 years) to far (10+ years) future.  We don't know.  Betting the farm on "I don't know" is not a winning strategy.

#20 Re: Not So Free Chat » Oil, Peak Oil, etc. » 2025-08-14 21:37:34

Suppose a farmer expends an average of 3,000 calories of energy per day to plant, tend to, and harvest the crops from his land.  From all that he harvests from his land, he only receives an average of 2,500 calories per day.  The farmer will either improve his "Calories Returned On Calories Invested" or his corpse will be the the next thing planted on his land.  His brain might tell him that energy math doesn't matter and he'll make do, but his body knows better.

#21 Re: Not So Free Chat » Oil, Peak Oil, etc. » 2025-08-12 23:51:38

I think it's very telling that sufficient raw materials to build this proposed new energy generating and storage system do not as yet exist.  The total global inventory of required materials is insufficient to proceed with a build-out of any of the proposed systems.  Fast storage (super capacitors or electro-chemical batteries) to deal with the grid instability caused by intermittent energy is the most deficient category of all when it comes to materials availability.  Following the total grid collapse in Spain, that much should be obvious.

1 hour of fast storage is likely to be the absolute bare minimum to avoid a total grid collapse as has already happened in Spain, or any grid which attempts to generate 70% of its power using photovoltaics and wind turbines.  Globally, 2TWh to 3TWh of batteries will be required to provide that hour, presuming most industrialized nations attempt to use photovoltaics and/or wind turbines.  Globally, somewhere between 200GWh and 300GWh of grid storage batteries presently exist.  That means battery production will have to increase by 10X at some point in the next 10 to 25 years.

At current prices, 1 hour of fast storage is about $400B USD, enough money to purchase 80 to 160 1GWe fission reactors, which corresponds to 630.72TWh to 1,261.44TWh.  1,261TWh is about 1/20th of all the world's electricity generation.  All storage, regardless of type (coal, gas, batteries, even Uranium), is a money sink.  Batteries don't generate any revenue from electric power generation, they consume it, and then give it back when required to prevent grid crashes.

For dusk-to-dawn power on a grid that's 70% powered by photovoltaics and batteries, you need at least 12 hours of storage.  If that storage is not provided by batteries, then it involves burning something.  The total amount of money sunk into 12 hours of battery storage would pay for enough 1GWe PWRs to generate about 60% of all electric power consumption.

If the battery is made from Lithium, Aluminum, Cobalt, and/or Nickel, then cost is not likely to fall dramatically.

Lead-acid is $200K to $400K/MWh.
Lithium-ion is $150K to $300K/MWh, with installed cost ranging from $180K to $580K/MWh.
Nobody knows what an Aluminum battery will cost because as-yet there are no commercialized models in mass production.

This is what's being proposed for Aluminum redox batteries for seasonal energy storage:
Rechargeable aluminum: The cheap solution to seasonal energy storage?

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This solution requires:
1. Industrial Aluminum Smelter
2. Grid Electricity to the Smelter
3. Photovoltaics
4. Household Batteries
5. Hydrogen PEMFCs
6. Heat Pumps
7. Thermal Energy Storage
8 Smart Grid Control to Direct Electricity

The company is claiming this Rube Goldberg machine can deliver stored energy for $0.09/kWh of storage.  They're going to physically ship the Aluminum oxide pebbles back to an industrial Aluminum smelter after the battery is depleted each year, re-smelt the Aluminum oxide without generating CO2, re-mill the resultant Aluminum back into 1mm diameter balls, ship the Aluminum balls back to the grid storage battery site, and then reassemble the redox battery.  They're asserting that all of that is going to cost less than a dime per kWh.

Frankly, it sounds like a great way to make electricity cost $1/kWh.

1kg of commercially pure Aluminum costs $1.60 to $2.70 before it's milled into 1mm diameter balls and combusting 1kg of pure Aluminum powder with pure O2 releases 8.6kWh of heat energy.  This "charge / discharge process" is supposed to be 65% efficient, so 5,590Wh/kg.

$1.60 / 5,590Wh = $0.286/kWh

To that cost we must add transportation back-and-forth between the smelter and grid storage battery site, the capital cost of purchasing and maintaining all that other equipment, labor costs for fabrication / installation / transport / maintenance, and the fact that countries like Spain already pay $0.20 to $0.30/kWh.  We get to use this battery once or twice per year, yet we must, because we need something.  Smelting the Aluminum requires 12kWh/kg to 17kWh/kg of energy input, roughly double what the battery can actually discharge each year / season (winter).  I would estimate 28 days of storage is the bare minimum, but 3 months is more akin to seasonal reality.  In the summer when generating is good for photovoltaics, an extra 2 to 6 months of the EU's monthly electric generating capacity, above and beyond current electricity demand, must be captured in the form of smelted and milled Aluminum balls, plus whatever energy transportation requires.

EU's monthly electricity demand is about 224.75TWh using 2023 figures, so 40,205,724,508kg, at 5,590Wh/kg using this redox battery.  That means every year the EU is going to re-smelt approximately 57% of the world's annual primary Aluminum production tonnage to deliver seasonal storage without burning something.

40,205,724,508kg * 12,000Wh/kg = 482,468,694,096,000Wh

482TWh of additional summer seasonal electric generating capacity is required from wind and solar to maintain winter grid reliability, absent hydrocarbon fuels or fission reactors.

At $0.25/kWh, that's $120,617,173,524 worth of electricity

That seems more than a little outlandish to me.  It's easy to understand why Germany has gone right back to burning lignite.  They're bankrupting themselves trying to implement this foolishness.

#22 Re: Not So Free Chat » Oil, Peak Oil, etc. » 2025-08-11 21:14:04

The underlying theme to the entire line of argumentation regarding renewable energy is, "We'll figure this out as we go."  That's not a proven successful management strategy for a complex project with such an expansive scope and scale as a complete transformation of how the majority of energy is generated and stored, how it's utilized, and which solutions work to the degree and scale necessary to achieve the desired end goal of a dramatic reduction of hydrocarbon fuel energy consumption.

We don't have enough of the required materials at the present time to build this Rube Goldberg techno-fantasy nonsense.  That's why it hasn't already been built.  If we had the materials and manufacturing capacity, then we would've built it already.

We produce 130X more Iron and 210X more concrete than Copper every single year.  I know which materials I'm going to choose to build the world's largest machine (our energy grids) based upon that fact alone.  I don't need to invoke the potential output of any new mines.  I don't need to engage in an academic debate about the potential merits of future technology improvements.  Business runs on labor, materials, and capital availability, not interesting options and debates.

Laying out a dozen different options doesn't dazzle someone like Calliban, or myself, with all the endless possibilities.  It's a tacit admission that we don't have a currently actionable materials sourcing and manufacturing plan.  If this idea requires so many different options to potentially work, then it's not a plan we can focus all available resources on implementing.  Rank order ideas in terms of technological readiness level, materials or manufacturing capacity constraints, and capital costs.  Which one come out on top?

How many trillions of dollars and how much irreplaceable time needs to be spent before "you need to spend more time and money" is no longer a valid response?

I happen to think that 10 trillion dollars spent over 25 years is more than enough "try harder".  It's not a question of how hard we've tried.  We're obviously "doing it wrong".

10 trillion (the amount of money we spent from 2000 to 2025 developing and deploying photovoltaics, wind turbines, batteries) was enough money to purchase 2,000 1GWe PWRs, at $5B USD per reactor, so 15,768TWh per year at 90% capacity factor.  That's about 65% of all the world's electricity.  China manages to build 1GWe PWRs for about $2.5B USD, so up to 4,000 reactors, possibly enough electricity to power all these BEVs and AI data centers that everyone wants to build.  PWRs get replaced every 75 years, instead of every 25 years, and are not materials constrained.

Since we instead pursued all those potentially interesting options, we're now burning more coal and natural gas than ever and will continue to do so for the foreseeable future because the money which could've been spent much more effectively to halt the rise in CO2 emissions, using existing and thoroughly proven technology, was instead devoted to development of photovoltaics, wind turbines, and batteries.  That was the true "missed opportunity cost".

After another 10 years and 10 trillion dollars have been squandered, our renewable energy evangelists will be ready with another round of excuses for the apparent lack of progress.  Meanwhile, existing problems will get worse because that is the nature of real but unsolved problems.  Until non-working ideas are abandoned in favor of pragmatism and proven solutions, humanity will continue to win stupid prizes.

#23 Re: Not So Free Chat » Oil, Peak Oil, etc. » 2025-08-11 00:06:27

We don't need an elaborate menu of energy and materials inputs, manufacturing steps, and recycling steps.  Cold-rolled steel and concrete are a lot easier to source than Copper and Lithium.

Bt = Billion metric tons

Humanity acquires / processes / transports 2Bt of lumber, 2.6Bt of steel, and 4.2Bt of concrete per year.  Only fresh water, food, and hydrocarbon fuels are consumed in greater tonnages per year.  Everything else is "noise" by way of comparison.  If we're going to harness sunlight and wind energy at a human civilization scale, then it's going to be done by using those materials because nothing else we produce is available in the required tonnages.  This is ultimately a numbers game.  Only big numbers truly matter.  Small incremental changes are completely overwhelmed by the sheer scale of the problem, to the point that we cannot show measurable improvements.

Most of the energy consumed by industry, as well as commercial and residential buildings, is heat energy or mechanical energy.  I've never read a truly compelling argument for why we need to go through multiple energy conversion steps, which are intrinsically inefficient and complex in operation.  Complexity is where all of these grand plans for transformational energy technology applications go to die.

Whenever I look upon a photovoltaic electric wind turbine farm with battery banks, complete with thousands of sensors and electronics boxes, plus millions of lines of software, intended to deliver power to an even more absurdly complex EV, all I see a Rube Goldberg machine on a grand scale.  It technically works, but nobody who wanted a maintainable and sustainable energy generating machine above all other considerations would ever design such a ridiculous thing.  It smacks of "design by committee", rather than "design by imperative".  All that pointless complexity couldn't provide grid stability to Spain under ideal generating conditions for their photovoltaics and wind turbines.

My assertion is that if your energy generating system, regardless of what that is, cannot be manufactured, operated, and maintained by people with 6th grade education levels, then it's probably a very brittle and overly-complex system that's unlikely to ever be stable enough to entrust with providing energy to large swaths of humanity.  For a new system to have any hope of being implemented almost everywhere, it's going to adhere to that guiding design principle, or it won't work.

#24 Re: Not So Free Chat » Oil, Peak Oil, etc. » 2025-08-10 09:32:45

offtherock and Void,

Both of you do a really great job of ignoring the simple fact that if this was purely about finding a viable solution in response to a genuine emergency, then solar thermal provided that technology in the 1970s without ever running into any materials scarcity problems.  All I see from the both of you is if this / that / the other happens then "X", "in the future X/Y/Z might happen", etc.  That sounds great, and I sincerely hope you're proven correct, but various statements you've both made tell me you're ignoring present reality in favor of some ill-defined future end state using a slew of new technologies and possibilities which haven't materialized over the past 25 years, but according to somebody may be available in the future.

None of your beliefs in "futurism" addresses my fundamental and underlying point that if CO2 emissions were truly a major global threat, then we'd never monkey around with any of your future possibilities, we'd build-out the new "viable under current materials / technology limitations" energy generating plant, then address what could've been done better using new technology in future iterative technical developments.  That is how real engineering is done.  We did not send the Saturn V moon rocket to the moon after waiting for CAD and Al-2195 lightweight Aluminum alloy to become available.  We used the materials and fabrication technology we had available in the 1960s to build it.

offtherock,

We are presently limited to resources on Earth, like it or not.  Unless we level the entire Andes Mountain Range, lots of that "we know the Copper is there" is simply "not there", and we're already grinding the ore particles to below 10 microns in size.  As you grind the ore finer so that you can use the flotation process to scrape off the desired ore particles, exponentially more energy is required to extract it.  That means a lot less Copper is readily available.  There are no new major investments into opening new Copper mines which are planned over the next 25 years, and it takes 15 to 20 years to open a new mine at the present time.

Void,

Yes, I've spoke of using CNT wiring quite often.  It's something I'm aware of because I've posted about it here.  Aluminum requires 2X to 3X more energy than present Copper mining.  CNT wiring is more like 4,500X more embodied energy per kg of material, relative to Aluminum.  It's more energy-intensive than CFRP by a lot and that means something has to deliver that energy.  The good news is that we won't run out of Carbon.  The bad news is that ampacity is on-par with Copper when it's mixed with Copper, per kg of CNT.  Does a conductor material 9,000X more energy intensive than mining Copper make sense as a bulk conductor material?

The reason you're not likely to see CNT used in wind turbine motor-generators or bulk conductor wiring is the energy and therefore monetary cost of the material per kilogram.  It's the same problem as Aluminum has, but 900X worse than Aluminum.  It would make economic sense in an aviation application, but not as a mass substitute for Copper.  If production methods improve, then sure, things could change.  Once again, you and offtherock keep falling back on future possibilities, rather than current technological realities.

Should we pursue it?  Yes, absolutely.  Is it going to solve any metal shortages in the near future?  Not likely.

#25 Re: Not So Free Chat » Oil, Peak Oil, etc. » 2025-08-10 00:13:38

The energy and material intensity of the solar thermal and hydrocarbon fuel synthesis energy system I proposed is still extravagant, an inelegant brute force solution if ever there was one, but a pragmatic solution nonetheless.  It works from a basic energy math / materials availability / technology standpoint.  Any solution requiring quantities of metal that don't exist, battery technologies that don't yet exist or cannot be produced due to materials shortages, or levels of metals purity that isn't achievable by consuming any reasonable amount of energy input, is no solution at all.

Microelectronics, photovoltaics, electric wind turbines, and electro-chemical batteries, collectively, are what I call "entropy machines".  Electric wind turbine blades now consume more composite materials than the entire aircraft manufacturing industry.  Microelectronics, photovoltaics, and electro-chemical batteries, especially, go from highly disordered natural resources to the most highly ordered microscopically thin layer cakes of combined materials imaginable.  The "jelly roll" inside a Lithium-ion battery is thinner than a human hair.  These are all warning signs that the current techno-fantasy solution is impractical, and likely infeasible.  The apparent lack of progress is the other indicator that something's wrong.

Top 5 Metals by Total Tonnage for 2019
Iron (3,040,000,000t): 93.5% of all metal we produce.
Aluminum (62,900,000t): 1.937%
Manganese (56,600,000t): 1.742%
Chromium (38,600,000t): 1.188%
Copper (20,700,000t): 0.637%

Almost 50% of all the energy devoted to metals mining is expended on Copper alone.
Apart from being the best common conductor metal, we continue to mine for Copper ore because the energy input to make Aluminum wiring with ampacity equivalent to Copper wiring is still 2X to 3X greater than the energy expended mining virgin Copper ore.  In other words, mining Copper is saving energy and CO2 emissions that would otherwise be created by increasing Aluminum metal production.

If we devoted 1,000,000,000t of sheet steel production to 2mm thick stamped cold-rolled steel mirror stock (15.7kg/m^2), then we can make a mirror surface area of 63,694,267,516m^2.  Let's assert that energy efficiency is no better or worse than "average" 20% efficient photvoltaics, even though solar thermal mirrors / concentrators are typically more performant than that, and we average about 5hrs of sunlight per day, so 400kWh per square meter per year.

63,694,267,516m^2 * 400,000Wh/m^2/year = 25,477,707,006,400,000Wh/year

In 2023, global primary energy consumption was 172,222,222,222,222,360Wh (620 exajoules).

1 exajoule = 277,777,777,777,778Wh (rounded to the nearest Watt)

172,222,222,222,222,360Wh / 25,477,707,006,400,000Wh = 6.75972

When you're unconcerned with ideology or techno-fantasies, and merely want to solve a problem so we can proceed to solving the next problem, you come up with pragmatic solutions that don't involve quantities of metals or miraculous new technologies that don't exist and are unlikely to ever exist if the resource base is limited to Earth.  Over the past 25 years, we could've already built more than 100% of the global primary energy supply, in terms of solar thermal generating capacity, without ever running into any unsolvable materials or energy math problems in the process.  This should've and would've been an academic debate at this point, had we optimized for practicality over possibilities.  We could've and should've done the same thing with nuclear power between the 1970s to 1980s, and then we'd still be having an academic debate about which solution was "best".  Our techno-enthusiasts could continue to endlessly tinker with their electronics silliness while all of us have affordable emission-free energy.  If magic happens and energy and materials availability becomes functionally unlimited, then we could pursue their eccentricities at our leisure.

Instead, people who are supposed to be educated, though clearly not educated to do anything useful, have already spent 10 trillion dollars on a variety of "throw crap at the wall and hope it sticks" solutions that as-yet don't provide a significant fraction of the global primary energy supply.

Cold-rolled steel is about ~$1,000USD/t, or $1T per 1,000,000,000t, so $10T would've purchased enough steel to deliver more than 100% of the global primary energy supply.

If we devoted 50,000,000t of annual Aluminum production to 500Wh/kg Aluminum-air batteries, then 1 year of production represents 25TWh of fast storage for grid stability within a grid dominated by photovoltaics and electric wind turbines.  Total electric power generation per year is just shy of 25,000TWh (~68.5TWh per day), so producing enough batteries to store 28 days of electric power to begin to deal with seasonality would represent 76.7 years of Aluminum production at 2019 production rates.  Realistically, at least 90 days of storage is necessary, so 246.6 years of Aluminum production at 2019 production rates.  If those batteries lasted for several decades or longer and we totally ignore CO2 emissions associated with Aluminum production, then maybe that's still acceptable.  Unfortunately, no 500Wh/kg battery will last for 25+ years before it short-circuits internally, because it's a layer cake of materials thinner than a human hair.  Dendrite formation can be suppressed but not entirely eliminated.  Aluminum may not combust as spectacularly as Lithium, but an internally short-circuited battery is still useless for storing electric power.  Aluminum production generates about 2% of global annual CO2 emissions, so increasing the production rate to 10X the current annual production rate would make it 20% of the global annual total, meaning on-par with transportation.  Red mud would rapidly become the largest man-made environmental toxin.  All that ridiculous mess would be required for something that doesn't even generate any power, merely stores it so that we don't have daily and seasonal grid crashes.

Those two tidbits of information only begin to illustrate how utterly ridiculous the proposed photovoltaics / electric wind turbines / Lithium-ion / Aluminum-ion batteries solution is.  Certain kinds of metals presently used in the permanent magnets and power electronics would consume tens of thousands of years of production at 2019 production rates.

If global warming was a genuine showstopper problem, then our academics and captains of industry would've identified the most realistic and immediately attainable solutions, built-out the required infrastructure without delay, and moved on to solving the next global problem.  When you're only concerned with results and don't care about anyone's fantasies or personal preferences, this is the only correct approach to solving major over-arching problems.  Solve the immediate problem using what you have and what you know, then debate how it could've been done better after a workable solution has been implemented.  Incidentally, this is also how you solve problems in the military.

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