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At least 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Zero Energy Ready Out of the Box

In this conference paper for the ASHRAE Buildings XV conference, December 2022, PNNL staff share key metrics for companies who are combining off site construction with certification to the U.S. Department of Energy’s Zero Energy Ready Home program to create homes that are both cost effective to construct and high performance to live in. Key performance metrics and measures for modular, panelized, and SIP homes are compared against all homes in the DOE Zero Energy Ready Home program and against new homes built to code. These metrics show that off-site construction homes got similar or better energy performance to site-built homes, and in the case of modular and panelized, at considerably lower average cost than site-built homes. The paper also highlights the experiences of two DOE Zero Energy Ready Home builders who employ offsite construction methods. One builder constructs production homes using pre-assembled panels. The other builder designs and ships kit homes all over the United States. The paper will focus on the optimum value engineering aspects of the panelized construction processes used by each builder to identify management and production practices employed by the builders to operate profitably while meeting high energy performance goals, despite a year marked by skyrocketing materials costs and supply chain and labor shortages. Cost and labor savings methods will be discussed in the context of these two unique business models.

U.S. Department of Energy Building Technologies Pr↗
DOE OSTI2025

Modular Processing of Flare Gas for Carbon Nanoproducts

This project demonstrated the technical viability and economic promise of a modular system for converting flared natural gas into valuable carbon nanoproducts (CNPs) through catalytic chemical vapor deposition (CVD). All major project milestones were successfully completed, including reactor design and commissioning, catalyst development, process optimization, technoeconomic analysis, and application testing in concrete systems. The overarching goal was to create a scalable, field-deployable process that valorizes stranded methane by producing high-value carbon materials for use in cementitious composites. At the lab scale, the team designed and built a fluidized bed reactor optimized for use with silica fume-supported nickel catalysts synthesized via atomic layer deposition (ALD). A statistically designed sintering study enabled precise tuning of nickel nanoparticle size, identifying the influence of oxygen partial pressure, time, and temperature on catalyst morphology and performance. These insights allowed the team to target catalyst conditions that maximize carbon nanofilament growth. Subsequent CVD experiments achieved up to 31.8 wt% carbon deposition under optimized conditions, with TEM confirming the presence of nanofilament structures and sustained hydrogen evolution during reaction. Reactor upgrades and empirical fluidization studies supported the development of reliable, repeatable experimental protocols. The modular pilot-scale skid reactor was fully constructed, instrumented, and commissioned. Capable of operating at 675–800°C and pressures up to 290 psig, the system was designed for continuous operation at a carbon production rate of 1 kg/hr. Initial demonstration runs confirmed solids handling, thermal control, and system leak-tightness, although a critical reactor component (the downfeed tube) was inadvertently omitted during final assembly. This omission limited gas–solid contact and prevented meaningful carbon deposition during pilot-scale CVD runs. Nonetheless, the system operated safely under design conditions, and the root cause of performance limitations was clearly identified. Complementary work on UHPC formulations demonstrated that small additions of carbon nanoproducts, including those derived from flare gas, can significantly enhance mechanical performance while preserving workability. A comprehensive study of CNF dispersion techniques and mix design optimization led to a clear protocol for integrating these nanomaterials into concrete. Incorporation of CNPs improved flexural toughness and reduced porosity, supporting their use in high-performance infrastructure applications. A technoeconomic analysis (TEA) confirmed that this process can produce CNP-loaded catalyst material at a levelized cost below $\$$7/kg across a range of catalyst loadings and reaction yields. With estimated market values for the carbon composite product ranging from $\$$14 to over $\$$60/kg, and the ability to blend CNPs into concrete at sub-percent levels with less than 10% added cost, the system presents a compelling economic case. While additional engineering work is needed to optimize fluidization and heat transfer at scale, this project establishes a strong foundation for commercial development. The process is not only technically sound but also economically promising, representing a viable pathway for flare gas mitigation through modular carbon nanomaterial production.

03 NATURAL GAS↗
DOE OSTI2025

Orientation reversal and the Chern-Simons natural boundary

We show that the fundamental property of preservation of relations, underlying resurgent analysis, provides a new perspective on crossing a natural boundary, an important general problem in theoretical and mathematical physics. This reveals a deeper rigidity aspect of resurgence in a quantum field theory path integral. The physical context here is the non-perturbative completion of complex Chern-Simons theory that associates to a 3-manifold a collection of q-series invariants labeled by Spinc structures, for which crossing the natural boundary corresponds to orientation reversal of the 3-manifold. Our new resurgent perspective leads to a practical numerical algorithm that generates q-series which are dual to unary q-series composed of false theta functions. Until recently, these duals were only known in a limited number of cases, essentially based on Ramanujan’s mock theta functions, and the common belief was that the duals might not even exist in the general case. Resurgence analysis identifies as primary objects Mordell integrals: up to changes of variables, they are Laplace transforms of resurgent functions. Their unique Borel summed transseries decomposition on either side of the Stokes line is simply the unique decomposition into real and imaginary parts. In turn, the latter are combinations of unary q-series in terms of q and its modular counterpart $\overset{\sim }{q}$ , and are resurgent by construction. The Mordell integral is analytic across the natural boundary of the q and $\overset{\sim }{q}$ series, and uniqueness of a similar decomposition which preserves algebraic relations on the other side of the boundary defines the unique boundary crossing of the q series. We demonstrate that this continuation can be efficiently implemented numerically. In the cases where unique mock modular identities are known, they are found by this numerical procedure, but the procedure can go well beyond the known list of identities. A particularly interesting feature of the resurgent approach is that it reveals new aspects, and is very different from other known approaches based on indefinite theta series, Appell-Lerch sums, and representation theory of logarithmic vertex operator algebras.

Chern-Simons theories↗
DOE OSTI2021

A canonical purification for the entanglement wedge cross-section

In AdS/CFT we consider a class of bulk geometric quantities inside the entanglement wedge called reflected minimal surfaces. The areas of these surfaces are dual to the entanglement entropy associated to a canonical purification (the GNS state) that we dub the reflected entropy. From the bulk point of view, we show that half the area of the reflected minimal surface gives a reinterpretation of the notion of the entanglement wedge cross-section. We prove some general properties of the reflected entropy and introduce a novel replica trick in CFTs for studying it. The duality is established using a recently introduced approach to holographic modular flow. We also consider an explicit holographic construction of the canonical purification, introduced by Engelhardt and Wall; the reflected minimal surfaces are simply RT surfaces in this new spacetime. We contrast our results with the entanglement of purification conjecture, and finally comment on the continuum limit where we find a relation to the split property: the reflected entropy computes the von Neumann entropy of a canonical splitting type-I factor introduced by Doplicher and Longo.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2025

Fused Deposition Modeling Additive Manufacturing of Carbonized Structures via Waste-Enhanced Filaments

This report details the development, characterization, and use of coal-enhanced composite materials in additive manufacturing applications. High coal loading formulations—containing up to 70 wt.% coal—were successfully extruded and processed using commercially available 3D printers. Extensive experimental testing was conducted to assess the mechanical, thermal, and microstructural properties of the composites. In parallel, multi-scale computational modeling was employed to elucidate atomistic interactions and evaluate the effects of printing-induced defects on structural performance. Large-scale printability trials demonstrated the feasibility of fabricating complex components for tooling and construction applications, including wind turbine blade molds and modular wall sections. Techno-economic analyses demonstrated the cost-effectiveness and scalability of coal-enhanced composites for large-scale additive manufacturing applications such as wind turbine blade tooling.

01 COAL, LIGNITE, AND PEAT↗
NASA NTRS2017

Design of Multifunctional Hierarchical Space Structures

We describe a system for the design of space structures with tunable structural properties based on the discrete assembly of modular lattice elements. These lattice elements can be constructed into larger beam-like elements, which can then be assembled into large scale truss structures. These discrete lattice elements are reversibly assembled with mechanical fasteners, which allows them to be arbitrarily reconfigured into various application-specific designs. In order to assess the validity of this approach, we design two space structures with similar geometry but widely different structural requirements: an aerobrake, driven by strength requirements, and a precision segmented reflector, driven by stiffness and accuracy requirements. We will show agreement between simplified numerical models based on hierarchical assembly and analytical solutions. We will also present an assessment of the error budget resulting from the assembly of discrete structures. Lastly, we will address launch vehicle packing efficiency issues for transporting these structures to lower earth orbit.

Aeronautics↗
NASA NTRS1982

A modular data system for Spacelab experiments

This overview describes a flexible system of electronic and mechanical building blocks with characteristics and capabilities suitable for construction of a flight-capable experiment data management system. The initial space application of this modular system, called the Spacelab Payload System Modular Electronics (SPSME), is the data system for the Nuclear Radiation Monitor (NRM) on Spacelab Mission 2.

Frost, W. O.↗
DOE OSTI2022

Assessing the interfacial corrosion mechanism of Inconel 617 in chloride molten salt corrosion using multi-modal advanced characterization techniques

The United States Department of Energy (DOE) has committed to expanding the domestic clean energy portfolio in response to the rising challenges of energy security in the wake of climate change. Accordingly, the construction of a series of Generation IV reactor technologies are being demonstrated, including sodium-cooled, small modular, and molten chloride fast reactors (MCFRs). To date, there are no fully qualified structural materials for constructing MCFRs. A number of commercial structural alloys have been considered for the construction of MCFRs, including alloys from the Inconel and Hastelloy series. Informed qualification of structural materials for the construction of MCFRs in the future can only be ensured by expanding the current fundamental knowledgebase of information pertaining to material performance under environmental stressors relevant to operation of the reactor, including corrosion susceptibility. The purpose of this investigation is to illustrate how a correlative multi-modal electron microscopy characterization approach, including the novel application of focused-ion beam 3D reconstruction capabilities, can elucidate the corrosion mechanism of a candidate structural material Inconel 617 for MCFR in NaCl-MgCl 2 eutectic salt at 700°C for 1,000 h. Evidence of intergranular corrosion, Ni and Fe dealloying, and Cr-O enrichment along the grain boundary, which most likely corresponds to Cr 2 O 3 , is a phenomenon that has been documented in other Ni-based superalloys exposed to chloride molten salt systems. Additional corrosion products, including the formation of insoluble MgAl 2 O 4 , within the porous network produced by the salt attack is a novel observation. In addition, Mo 3 Si 5 and τ 2 precipitates are detected in the alloy bulk and are dissolved by the salt. Furthermore, the lack of detection of design γ' precipitates in Inconel 617 after 1,000 h could indicate that the molten salt corrosion mechanism has indirectly induced a phase transformation of Al 2 TiNi (τ 2 ) and Ni 3 (Al,Ti) (γ’) phase. This investigation provides a comprehensive understanding of molten salt corrosion mechanisms in a complex material system such as a commercial structural alloy for applications in MCFRs.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Unique safety features and licensing requirements of the NuScale small modular reactor

Small modular reactors (SMR) offer a novel approach to the construction and operation of nuclear power plants. The NuScale VOYGR™ plant uses a simplified SMR design that is based on proven light-water reactor technology with substantial improvements in nuclear safety. It consists of a 250 MWt reactor core housed with other primary system components in an integral reactor pressure vessel surrounded by a steel containment vessel, all of which is immersed in a large pool of water that also serves as the ultimate heat sink. At the core of the NuScale safety case are three primary safety systems: the decay heat removal system, the emergency core cooling system, and the containment. The ability of the NuScale Power Module (NPM) passive safety systems to remove core decay heat for an unlimited duration is demonstrated through analysis of a beyond-design-basis extended loss of AC power with no replenishment of water to the ultimate heat sink or operator actions. The NuScale methodology to evaluate an indefinite loss of AC power uses the proprietary NRELAP5 systems analysis computer code. Analysis results show that the reactor coolant system liquid level above the core is maintained and that containment pressure remains below the vessel design pressure. Once full passive air cooling is established, containment pressure and temperature will decrease over time with decreasing core decay heat. NuScale received standard design approval in September 2020 and design certification in January 2023 for its 50 MWe NPM configured as a 12 module plant. NuScale is currently seeking standard design approval to increase its core power to 250 MWt, nominally 77 MWe per module, in a 6-module plant (VOYGR™-6) configuration. The high-level safety of NuScale’s SMR technology is foundational to a new standard of nuclear power plant resilience.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

An extensible vector toolkit and parts library for advanced engineering of plant genomes

Abstract Plant biotechnology is rife with new advances in transformation and genome engineering techniques. A common requirement for delivery and coordinated expression in plant cells, however, places the design and assembly of transformation constructs at a crucial juncture as desired reagent suites grow more complex. Modular cloning principles have simplified some aspects of vector design, yet many important components remain unavailable or poorly adapted for rapid implementation in biotechnology research. Here, we describe a universal Golden Gate cloning toolkit for vector construction. The toolkit chassis is compatible with the widely accepted Phytobrick standard for genetic parts, and supports assembly of arbitrarily complex T‐DNAs through improved capacity, positional flexibility, and extensibility in comparison to extant kits. We also provision a substantial library of newly adapted Phytobricks, including regulatory elements for monocot and dicot gene expression, and coding sequences for genes of interest such as reporters, developmental regulators, and site‐specific recombinases. Finally, we use a series of dual‐luciferase assays to measure contributions to expression from promoters, terminators, and from cross‐cassette interactions attributable to enhancer elements in certain promoters. Taken together, these publicly available cloning resources can greatly accelerate the testing and deployment of new tools for plant engineering.

42 ENGINEERING↗
DOE OSTI2025

The fixed probe storage ring magnetometer for the Muon g-2 experiment at Fermi National Accelerator Laboratory

The goal of the FNAL E989 experiment is to measure the muon magnetic anomaly to unprecedented accuracy and precision at the Fermi National Accelerator Laboratory. To meet this goal, the time and space averaged magnetic environment in the muon storage volume must be known to better than 70 ppb. A new pulsed proton nuclear magnetic resonance (NMR) magnetometer was designed and built at the University of Washington, Seattle to track the temporal stability of the 1.45 T magnetic field in the muon storage ring at this precision. It consists of an array of 378 petroleum jelly based NMR probes that are embedded in the walls of muon storage ring vacuum chambers and custom electronics built with readily available modular radio frequency (RF) components. We give NMR probe construction details and describe the functions of the custom electronic subsystems. The excellent performance metrics of the magnetometer are discussed, where after 8 years of operation the median single shot resolution of the array of probes remains at 650 ppb.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Modular Staged Pressurized Oxy-Combustion (SPOC) Power Plant for Coal and Biomass – Integration of Combustor Boiler and DCC

Utilities and grid operators worldwide are under significant pressure to incorporate intermittent renewable sources while strategizing on how to maintain the necessary stability and reliability of the grid. The development of a power plant which will be capable of flexible operation to meet the needs of the grid as more intermittent sources like wind and solar energy are incorporated is key to maintain the reliability of the grid. Through the use of innovative and cutting-edge technologies that improve efficiency and reduce carbon emissions, and being small compared to today's conventional utility-scale power plants, the modular Staged, Pressurized Oxy-Combustion (SPOC) process envisioned by and under development at Washington University in St. Louis (WUSTL) has the potential to achieve these goals. Specifically, the process offers: 1) a modular plant design that allows for better operational flexibility; 2) the utilization of fuel-staging and pressurized oxy-combustion, resulting in smaller plant size, improved plant efficiency, and reduced costs for pollutant and CO2 removal compared to traditional power plants with post-combustion capture technology; and 3) the use of small modular boilers and pollutant removal units that can be constructed off-site leading to reduced capital costs for the plant. WUSTL is advancing the development of the critical components for the SPOC power plant, including the integrated combustor-boiler system and the direct contact cooler. To demonstrate the boiler convective section and to obtain critical data for commercial-scale pressurized boiler design, a simulated convective heat transfer boiler test section was designed and integrated with the combustor (radiant section). A direct contact cooler (DCC) was integrated with the combustor-boiler to demonstrate the dynamic operation of the integrated system and the performance of the DCC, including the efficiency for simultaneous removal of NOx and SOx. This talk will present an update on the evaluation of the critical components for system integration, including heat transfer data from the simulated boiler, scrubbing efficiency for the DCC under different operating conditions, and CFD modeling and validation for burner and boiler development.

Magalhaes, Duarte↗
NASA NTRS1986

Constructing a working taxonomy of functional Ada software components for real-time embedded system applications

A major impediment to a systematic attack on Ada software reusability is the lack of an effective taxonomy for software component functions. The scope of all possible applications of Ada software is considered too great to allow the practical development of a working taxonomy. Instead, for the purposes herein, the scope of Ada software application is limited to device and subsystem control in real-time embedded systems. A functional approach is taken in constructing the taxonomy tree for identified Ada domain. The use of modular software functions as a starting point fits well with the object oriented programming philosophy of Ada. Examples of the types of functions represented within the working taxonomy are real time kernels, interrupt service routines, synchronization and message passing, data conversion, digital filtering and signal conditioning, and device control. The constructed taxonomy is proposed as a framework from which a need analysis can be performed to reveal voids in current Ada real-time embedded programming efforts for Space Station.

Wallace, Robert↗
DOE OSTI2021

Identifying Limitations of ASME Section III Division 5 For Advanced SMR Designs

This report provides an overview of the ASME Boiler & Pressure Vessel Section III, Division 5 rules for the design and construction of high temperature nuclear reactor components. The overview focuses on the application of the rules to the design of Small Modular Reactors (SMRs). The discussion covers the general ASME Code rules for base metal design and construction, the rules for designing weldments, and provides an overview of environmental degradation mechanisms affecting reactor structural materials. The analysis includes historical context on the development of the ASME design approach and a description of what actions could be taken to mitigate the gaps identified in the report. The report concludes with a summary of the key gaps identified in the rules, as they apply to SMR, and a list of recommendations on how those gaps might be addressed.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

Making Coal Relevant for Small Scale Applications: Modular Gasification for Syngas/Engine CHP Applications in Challenging Environments

The proposed project includes construction and operation of a power plant consisting of coal gasification facilities and engine generators which would produce electrical power and heat. The recovered heat and a portion of the carbon dioxide emissions from the engines would support an onsite greenhouse and other heat and power customers. The proposed project site is located on the Marathon North Pole Terminal property in North Pole, Alaska. Two gasifiers would convert the coal into syngas, which would be fed through a gas cleanup train and then combusted in six reciprocating engines driving electric generators. Heat recovery on the engine cooling loops and exhaust trains would provide heat to a glycol/water circulation system for use in the greenhouse, in the Marathon facilities and for other customers. Natural gas would fuel two additional engine generators and would also be available to supplement the syngas-fired engines.

01 COAL, LIGNITE, AND PEAT↗
NASA NTRS2001

A Small Aircraft Transportation System (SATS) Demand Model

The Small Aircraft Transportation System (SATS) demand modeling is a tool that will be useful for decision-makers to analyze SATS demands in both airport and airspace. We constructed a series of models following the general top-down, modular principles in systems engineering. There are three principal models, SATS Airport Demand Model (SATS-ADM), SATS Flight Demand Model (SATS-FDM), and LMINET-SATS. SATS-ADM models SATS operations, by aircraft type, from the forecasts in fleet, configuration and performance, utilization, and traffic mixture. Given the SATS airport operations such as the ones generated by SATS-ADM, SATS-FDM constructs the SATS origin and destination (O&D) traffic flow based on the solution of the gravity model, from which it then generates SATS flights using the Monte Carlo simulation based on the departure time-of-day profile. LMINET-SATS, an extension of LMINET, models SATS demands at airspace and airport by all aircraft operations in US The models use parameters to provide the user with flexibility and ease of use to generate SATS demand for different scenarios. Several case studies are included to illustrate the use of the models, which are useful to identify the need for a new air traffic management system to cope with SATS.

Long, Dou↗
DOE OSTI2024

Integrated Thermal Energy Storage and Brayton Cycle Equipment Demonstration (Integrated TESTBED) Project Design Basis

The Integrated Thermal Energy Storage and Brayton cycle Equipment Demonstration (Integrated TESTBED) project seeks to retire commercial-scale risks associated with the design, integration,and operation of a supercritical carbon dioxide (sCO2) power cycle and concentrating solar power (CSP) thermal energy storage (TES) system. This requires an understanding of commercial-scale collector system transient impacts on the TES system, the dynamics of heat exchange from theTES to the power cycle, and the control and operation of the power cycle to accommodate various dispatch strategies. In order to retire these risks, Heliogen has proposed to construct a 5 MWe CSP demonstration facility based on directly heated particle and sCO2 technology. The receivers, primary heat exchanger, and power cycle will be deployed at a full commercial scale based on Heliogen’s modular plant architecture to ensure actual system integration risks are validated during design, construction, and operation. This work summarizes the design basis for the Integrated TESTBED project demonstration facility including a design target for capacity factor to support test operations, hours of storage, particle silo arrangement, centrifugal article receivers, a diffusion bonded particle-sCO2 heat exchanger, and a 5 MWe (net) integrally geared sCO2 recompression Brayton cycle.

14 SOLAR ENERGY↗
NASA NTRS1987

Design of a reconfigurable modular manipulator system

Using manipulators with a fixed configuration for specific tasks is appropriate when the task requirements are known beforehand. However, in less predictable situations, such as an outdoor construction site or aboard a space station, a manipulator system requires a wide range of capabilities, probably beyond the limitations of a single, fixed-configuration manipulator. To fulfill this need, researchers have been working on a Reconfigurable Modular Manipulator System (RMMS). Researchers have designed and are constructing a prototype RMMS. The prototype currently consists of two joint modules and four link modules. The joints utilize a conventional harmonic drive and torque motor actuator, with a small servo amplifier included in the assembly. A brushless resolver is used to sense the joint position and velocity. For coupling the modules together, a standard electrical connector and V-band clamps for mechanical connection are used, although more sophisticated designs are under way for future versions. The joint design yields an output torque to 50 ft-lbf at joint speeds up to 1 radian/second. The resolver and associated electronics have resolutions of 0.0001 radians, and absolute accuracies of plus or minus 0.001 radians. Manipulators configured from these prototype modules will have maximum reaches in the 0.5 to 2 meter range. The real-time RMMS controller consists of a Motorola 68020 single-board computer which will perform real time servo control and path planning of the manipulator. This single board computer communicates via shared memory with a SUN3 workstation, which serves as a software development system and robot programming environment. Researchers have designed a bus communication network to provide multiplexed communication between the joint modules and the computer controller. The bus supports identification of modules, sensing of joint states, and commands to the joint actuator. This network has sufficient bandwidth to allow servo sampling rates in excess of 500 Hz.

Schmitz, D.↗