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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Advanced Engine and Fuel Technologies 2021 Annual Progress Report

This report highlights progress achieved by the Advanced Engine and Fuel Technologies Program during fiscal year 2021. The nature, current focus, and recent progress of the Program are described together with summaries of National Laboratory, industry, and university projects that provide an overview of the exciting work being conducted to address critical technical barriers and challenges to commercializing higher-efficiency engine, emissions control, and fuel technologies for passenger and commercial vehicles.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Process Control Plan to Monitor Acceptable Levels of Flux and other residues

IPC J-STD –001G, Amendment 1 requires that the assembler have a sampling plan to assure that the process remains in control once qualified and validated. It is well documented that electrochemical failures occur at component sites where flux residues are not fully activated. It is also well known that specific components have a higher risk of electrochemical failure. Selecting a control plan that monitors the process and its performance on challenging components provides assurance that the process maintains control once established during process qualification. The test board used to qualify the process establishes an upper and lower spec limit for each of the component types on the test board. Surface Insulation Resistance upper and lower control limits, using challenging components that are representative of production hardware, represent a golden process condition. The golden image is a measure of process deviations that represents the performance of a resistance curve within a specific period. The objective is to judge whether the process in or out of control.

42 ENGINEERING↗
DOE OSTI2020

Engineering Biomolecular Self–Assembly at Solid–Liquid Interfaces

Biomolecular self–assembly is a key process used by life to build functional materials from the “bottom up.” In the last few decades, bioengineering and bionanotechnology have borrowed this strategy to design and synthesize numerous biomolecular and hybrid materials with diverse architectures and properties. However, engineering biomolecular self–assembly at solid–liquid interfaces into predesigned architectures lags the progress made in bulk solution both in practice and theory. Here, recent achievements in programming self–assembly of peptides, proteins, and peptoids at solid–liquid interfaces are summarized and corresponding applications are described. Recent advances in the physical understandings of self–assembly pathways obtained using in situ atomic force microscopy are also discussed. Furthermore, these advances will lead to novel strategies for designing biomaterials organized at and interfaced with inorganic surfaces.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Integration of plant and microbial oil processing at oilcane biorefineries for more sustainable biofuel production

Oilcane—an oil-accumulating crop engineered from sugarcane—and microbial oil have the potential to improve renewable oil production and help meet the expected demand for bioderived oleochemicals and fuels. To assess the potential synergies of processing both plant and microbial oils, the economic and environmental implications of integrating microbial oil production at oilcane and sugarcane biorefineries were characterized. Due to decreased crop yields that lead to higher simulated feedstock prices and lower biorefinery capacities, current oilcane prototypes result in higher costs and carbon intensities than microbial oil from sugarcane. To inform oilcane feedstock development, we calculated the required biomass yields (as a function of oil content) for oilcane to achieve financial parity with sugarcane. At 10 dw% oil, oilcane can sustain up to 30% less yield than sugarcane and still be more profitable in all simulated scenarios. Assuming continued improvements in microbial oil production from cane juice, achieving this target results in a minimum biodiesel selling price of 1.34 [0.90, 1.85] USD∙L –1 (presented as median [5th, 95th] percentiles), a carbon intensity of 0.51 [0.47, 0.55] kg CO 2 e L –1 , and a total biodiesel yield of 2140 [1870, 2410] L ha –1 year –1 . Compared to biofuel production from soybean, this outcome is equivalent to 3.0–3.9 as much biofuel per hectare of land and a 57%–63% reduction in carbon intensity. While only 20% of simulated scenarios fell within the market price range of biodiesel (0.45–1.11 USD∙L –1 ), if the oilcane biomass yield would improve to 25.6 DMT∙ha –1 ∙y –1 (an equivalent yield to sugarcane) 87% of evaluated scenarios would have a minimum biodiesel selling price within or below the market price range.

09 BIOMASS FUELS↗
DOE OSTI2015

Process monitoring of additive manufacturing by using optical tomography

Parts fabricated by means of additive manufacturing are usually of complex shape and owing to the fabrication procedure by using selective laser melting (SLM), potential defects and inaccuracies are often very small in lateral size. Therefore, an adequate quality inspection of such parts is rather challenging, while non-destructive-techniques (NDT) are difficult to realize, but considerable efforts are necessary in order to ensure the quality of SLM-parts especially used for aerospace components. Thus, MTU Aero Engines is currently focusing on the development of an Online Process Control system which monitors and documents the complete welding process during the SLM fabrication procedure. A high-resolution camera system is used to obtain images, from which tomographic data for a 3dim analysis of SLM-parts are processed. From the analysis, structural irregularities and structural disorder resulting from any possible erroneous melting process become visible and may be allocated anywhere within the 3dim structure. Results of our optical tomography (OT) method as obtained on real defects are presented.

42 ENGINEERING↗
DOE OSTI2022

Oxidation Resistance in 1200°C Steam of a FeCrAl Alloy Fabricated by Three Metallurgical Processes

Abstract FeCrAl alloys are a leading candidate material for accident tolerant fuel cladding due to their good performance in both normal light-water reactor operating conditions as well as their resilience to high-temperature accident scenarios. For commercial-scale production, new fabrication techniques need to be investigated. In this study, the effects of fabrication methods on the high-temperature steam oxidation performance of C26M (Fe12Cr6Al2Mo in wt.%) were investigated. Three variants of C26M were manufactured: wrought (cast and forged) (WC26M), powder metallurgy hot isostatic pressing (PMC26M), and laser powder bed fusion additive manufacturing (AMC26M). All three variants were exposed to steam at 1200°C for 2 h. Results showed no significant variation in mass change between the variants after steam exposure. All three variants effectively formed stable protective alumina films with ~0.6–1.3 µ m thickness. This study suggests FeCrAl alloys have excellent resilience to high-temperature steam in nuclear reactor accident scenarios regardless of the fabrication method.

Materials Science↗
DOE OSTI2017

A UNIFAC-Based Approach to Gasoline Droplet Evaporation and the Role of Oxygenates on PM Precursor Vaporization

In some studies, a relationship has been observed between increasing ethanol content in gasoline and increased particulate matter (PM) emissions from vehicles equipped with spark ignition engines. The fundamental cause of the PM increase seen for moderate ethanol concentrations is not well understood. As a result, existing PM indices such as PMI may not be indicative of measured PM emissions for oxygenated biofuel blends. Ethanol features a greater heat of vaporization (HOV) than gasoline and also influences vaporization by altering the liquid and vapor composition throughout the vaporization process. A droplet vaporization model was developed to explore ethanol's effect on the evaporation of aromatic compounds known to be PM precursors. The evolving droplet composition is modeled as a distillation process, with non-ideal interactions between oxygenates and hydrocarbons accounted for using UNIFAC group contribution theory. Detailed hydrocarbon analysis was applied to fuel samples, and used as input for the initial droplet composition. The droplet can be modeled in terms of energy transfer, which in turn provides the transient mass transfer, droplet temperature, and droplet diameter. Model predictions suggest that non-ideal vapor-liquid equilibrium along with an increase in HOV can alter the droplet composition evolution. Results predict that the presence of ethanol causes enrichment of the higher boiling fractions (T90+) in the aromatic components as well as lengthens the droplet lifetime. A simulation of the evaporation process in a transient environment as experienced within an engine cylinder predicts a decrease in mixing time of the heaviest fractions of the fuel prior to spark initiation, possibly explaining observations linking ethanol to PM. A correlation between liquid phase PM precursors and measured PM emissions is shown.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2015

Bench Scale Thin Film Composite Hollow Fiber Membranes for Post-Combustion Carbon Dioxide Capture

GE Global Research, Idaho National Laboratory (INL), Georgia Institute of Technology (Georgia Tech), and Western Research Institute (WRI) proposed to develop high performance thin film polymer composite hollow fiber membranes and advanced processes for economical post-combustion carbon dioxide (CO 2 ) capture from pulverized coal flue gas at temperatures typical of existing flue gas cleanup processes. The project sought to develop and then optimize new gas separations membrane systems at the bench scale, including tuning the properties of a novel polyphosphazene polymer in a coating solution and fabricating highly engineered porous hollow fiber supports. The project also sought to define the processes needed to coat the fiber support to manufacture composite hollow fiber membranes with high performance, ultra-thin separation layers. Physical, chemical, and mechanical stability of the materials (individual and composite) towards coal flue gas components was considered via exposure and performance tests. Preliminary design, technoeconomic, and economic feasibility analyses were conducted to evaluate the overall performance and impact of the process on the cost of electricity (COE) for a coal-fired plant including capture technologies. At the onset of the project, Membranes based on coupling a novel selective material polyphosphazene with an engineered hollow fiber support was found to have the potential to capture greater than 90% of the CO 2 in flue gas with less than 35% increase in COE, which would achieve the DOE-targeted performance criteria. While lab-scale results for the polyphosphazene materials were very promising, and the material was incorporated into hollow-fiber modules, difficulties were encountered relating to the performance of these membrane systems over time. Performance, as measured by both flux of and selectivity for CO 2 over other flue gas constituents was found to deteriorate over time, suggesting a system that was more dynamic than initially hypothesized. These phenomena are believed to be associated with the physical and mechanical properties of the separation material, rather than chemical degradation by flue gas or one of its constituents. Strategies to improve the composite systems via alternate chemistries and processing techniques were only partially successful in creating a more robust system, but the research provided critical insight into the barriers to engineering sophisticated composite systems for gas separation. Promising concepts, including a re-engineering of the separation material with interpenetrating polymer networks were identified which may prove useful to future efforts in this field.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Field Soil Water Retention of the Prototype Hanford Barrier and Its Variability with Space and Time

Engineered surface barriers (or covers) are used to isolate underlying contaminants from water, plants, animals, and humans. To understand the flow processes within a barrier and the barrier's ability to store and release water, the field hydraulic properties of the barrier need to be known. A multiyear test of the evapotranspiration (ET) barrier at the US Department of Energy's Hanford Site in the southeast of the state of Washington has yielded in situ soil water content and pressure data from multiple locations for a 9‐yr period, offering the opportunity to estimate soil water retention properties at different locations and times. The upper 2‐m layer of the ET barrier is a silt loam, and the top 1 m also contains 15% (w/w) pea gravel. Within this layer, valid monitoring data from 1995 to 2003 for four depths at 12 monitoring stations were used to determine the field water retention of the silt loam, with and without gravel. The data covered a wide range of wetness, from near saturation to the permanent wilting point, and each retention curve contained 51 to 96 data points. The data were described well with the commonly used van Genuchten water retention model. It was found that the spatial variation of the saturated and residual water content and the pore size distribution parameter was relatively small, while that of the van Genuchten α was relatively large. The effects of spatial variability of the retention properties appeared to be larger than the combined effects of added pea gravel and plant roots on the properties. Neither the primary wetting process in the winter season nor the drying process in the summer season nor time had a detectable effect on the water retention of the silt loam barrier.

Zhang, Z. Fred↗
DOE OSTI2023

Integrated system to reduce emissions from natural gas-fired reciprocating engines

Natural gas-fired reciprocating engines (NGFRE), which are naturally aspirated are used in the oil and gas industry for the production, storage, processing, and transmission of natural gas extracted from wells. These stationary, lean-burn engines exhibit increased combustion instability and higher emissions of methane (CH 4 ) and Volatile Organic Compounds (VOCs) at lower loads, resulting in restrictions on the operational envelope of such engines. Here, in this paper, some of the emission reduction technologies for NGFREs are reviewed. Also, an experimental investigation of an integrated system to reduce emissions and improve the combustion performance of an NGFRE is presented. The integrated system consists of an air management package and integrated sensors including an amperometric NOx/O 2 sensor, exhaust temperature thermocouple, pressure transducers and vibration sensors. Experiments were carried out using natural gas and natural gas/propane blends at different load steps, and combustion performance, as well as emissions, were analyzed. For natural gas fuel, the results show that the standard deviation of peak pressure and indicated thermal efficiency (ITE) improved by 67.4 psi and 4.2% respectively, at 40% load. Similarly, CH 4 and Nitrogen Oxides (NOx) emissions reduced considerably by 84% and 63% respectively. However, CO emissions increased from 8 ppm to 152 ppm. At 60% load, the ITE improved by 3.8% and the CH 4 emissions were reduced by 68%. The reduction in VOCs emissions was 63% at 40% load and 69% at 60% load. The findings of this research provide evidence of the effectiveness of the integrated air management system in improving the sustainability of NGFREs. In general, this technology can be implemented on air-assisted combustion applications to improve combustion performance and, consequently, reduce emissions.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Engineering Enzymes for Environmental Sustainability

The development and implementation of more efficient and sustainable technologies is key to delivering our net–zero targets. Here we review how engineered enzymes, with a focus on those developed using directed evolution, can be deployed to improve the sustainability of numerous processes and help to conserve our environment. Efficient and robust biocatalysts have been engineered to capture carbon dioxide (CO2) and have been embedded into new efficient metabolic CO2 fixation pathways. Enzymes have been refined for bioremediation, enhancing their ability to degrade toxic and harmful pollutants. Biocatalytic recycling is gaining momentum, with engineered cutinases and PETases developed for the depolymerization of the abundant plastic, PET. Finally, biocatalytic approaches for accessing petroleum–based feedstocks and chemicals are expanding, using optimized enzymes to convert plant biomass into biofuels or other high value products. Finally, through these examples, we hope to illustrate how enzyme engineering and biocatalysis can contribute to the development of more environmentally sustainable approaches, in order to protect our planet.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2015

Inertial Fusion Power Plant Concept of Operations and Maintenance

Parsons and LLNL scientists and engineers performed design and engineering work for power plant pre-conceptual designs based on the anticipated laser fusion demonstrations at the National Ignition Facility (NIF). Work included identifying concepts of operations and maintenance (O&M) and associated requirements relevant to fusion power plant systems analysis. A laser fusion power plant would incorporate a large process and power conversion facility with a laser system and fusion engine serving as the heat source, based in part on some of the systems and technologies advanced at NIF. Process operations would be similar in scope to those used in chemical, oil refinery, and nuclear waste processing facilities, while power conversion operations would be similar to those used in commercial thermal power plants. While some aspects of the tritium fuel cycle can be based on existing technologies, many aspects of a laser fusion power plant presents several important and unique O&M requirements that demand new solutions. For example, onsite recovery of tritium; unique remote material handling systems for use in areas with high radiation, radioactive materials, or high temperatures; a five-year fusion engine target chamber replacement cycle with other annual and multi-year cycles anticipated for major maintenance of other systems, structures, and components (SSC); and unique SSC for fusion target waste recycling streams. This paper describes fusion power plant O&M concepts and requirements, how O&M requirements could be met in design, and how basic organizational and planning issues can be addressed for a safe, reliable, economic, and feasible fusion power plant.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2015

Image reconstruction of single photon emission computed tomography (SPECT) on a pebble bed reactor (PBR) using expectation maximization and exact inversion algorithms: Comparison study by means of numerical phantom

Single Photon Emission Computed Tomography (SPECT) is a well-known imaging technique used in medical application, and it is part of medical imaging modalities that made the diagnosis and treatment of disease possible. However, SPECT technique is not only limited to the medical sector. Many works are carried out to adapt the same concept by using high-energy photon emission to diagnose process malfunctions in critical industrial systems such as in chemical reaction engineering research laboratories, as well as in oil and gas, petrochemical and petrochemical refining industries. Motivated by vast applications of SPECT technique, this work attempts to study the application of SPECT on a Pebble Bed Reactor (PBR) using numerical phantom of pebbles inside the PBR core. From the cross-sectional images obtained from SPECT, the behavior of pebbles inside the core can be analyzed for further improvement of the PBR design. As the quality of the reconstructed image is largely dependent on the algorithm used, this work aims to compare two image reconstruction algorithms for SPECT, namely the Expectation Maximization Algorithm and the Exact Inversion Formula. The results obtained from the Exact Inversion Formula showed better image contrast and sharpness, and shorter computational time compared to the Expectation Maximization Algorithm.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2012

RADIOACTIVE DEMONSTRATIONS OF FLUIDIZED BED STEAM REFORMING WITH ACUTAL HANFORD LOW ACTIVITY WASTES VERIFYING FBSR AS A SUPPLEMENTARY TREATMENT

The U.S. Department of Energy's Office of River Protection is responsible for the retrieval, treatment, immobilization, and disposal of Hanford's tank waste. Currently there are approximately 56 million gallons of highly radioactive mixed wastes awaiting treatment. A key aspect of the River Protection Project cleanup mission is to construct and operate the Waste Treatment and Immobilization Plant (WTP). The WTP will separate the tank waste into high-level waste (HLW) and low-activity waste (LAW) fractions, both of which will subsequently be vitrified. The projected throughput capacity of the WTP LAW Vitrification Facility is insufficient to complete the cleanup mission in the time frame required by the Hanford Federal Facility Agreement and Consent Order, also known as the Tri-Party Agreement (TPA). Therefore, Supplemental Treatment is required both to meet the TPA treatment requirements as well as to more cost effectively complete the tank waste treatment mission. Fluidized Bed Steam Reforming (FBSR) is one of the supplementary treatments being considered. FBSR offers a moderate temperature (700-750 C) continuous method by which LAW and other secondary wastes can be processed irrespective of whether they contain organics, nitrates/nitrites, sulfates/sulfides, chlorides, fluorides, and/or radio-nuclides like I-129 and Tc-99. Radioactive testing of Savannah River LAW (Tank 50) shimmed to resemble Hanford LAW and actual Hanford LAW (SX-105 and AN-103) have produced a ceramic (mineral) waste form which is the same as the non-radioactive waste simulants tested at the engineering scale. The radioactive testing demonstrated that the FBSR process can retain the volatile radioactive components that cannot be contained at vitrification temperatures. The radioactive and nonradioactive mineral waste forms that were produced by co-processing waste with kaolin clay in an FBSR process are shown to be as durable as LAW glass.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Low-Temperature Architected Cementation Agents (LAMINAE)

The cement industry contributes 5-9% of all anthropogenic CO 2 . At the same time, current concrete curing processes are passive, with little-to-no control over microstructure. The LAMINAE process offers the potential for a low-temperature pathway for producing cementitious aluminosilicate hydrate (zeolite) structures which: (a) reduces the energy burden of cement production by 30%, (b) reduces CO 2 emissions by 60%, and (c) offers microstructure control as was implicitly ensured in Roman concrete. This project generated data and engineering correlations to support further scale up and design of initial commercial processes.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Relaxation dynamics of nanosecond laser superheated material in dielectrics

Intense laser pulses can cause superheating of the near-surface volume of materials. This mechanism is widely used in applications such as laser micromachining, laser ablation, or laser assisted thin film deposition. The relaxation of the near solid density superheated material is not well understood, however. In this work, we investigate the relaxation dynamics of the superheated material formed in several dielectrics with widely differing physical properties. The results suggest that the relaxation process involves a number of distinct phases, which include the delayed explosive ejection of microscale particles starting after the pressure of the superheated material is reduced to about 4 GPa and for a time duration on the order of 1 μs. The appearance of a subset of collected ejected particles in fused silica is similar to that of micro-tektites and provides information about the state of the superheated material at the time of ejection. Lastly, these results advance our understanding of a key aspect of the laser–material interaction pathway and can lead to optimization of associated applications ranging from material processing to laser surgery.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Method and apparatus for reconstructing in-cylinder pressure and correcting for signal decay

A method comprises steps for reconstructing in-cylinder pressure data from a vibration signal collected from a vibration sensor mounted on an engine component where it can generate a signal with a high signal-to-noise ratio, and correcting the vibration signal for errors introduced by vibration signal charge decay and sensor sensitivity. The correction factors are determined as a function of estimated motoring pressure and the measured vibration signal itself with each of these being associated with the same engine cycle. Accordingly, the method corrects for charge decay and changes in sensor sensitivity responsive to different engine conditions to allow greater accuracy in the reconstructed in-cylinder pressure data. An apparatus is also disclosed for practicing the disclosed method, comprising a vibration sensor, a data acquisition unit for receiving the vibration signal, a computer processing unit for processing the acquired signal and a controller for controlling the engine operation based on the reconstructed in-cylinder pressure.

47 OTHER INSTRUMENTATION↗

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