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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Elastic-wave sensitivity-guided adaptive seismic survey design for cost-effective monitoring of geological carbon storage

Effective seismic monitoring is essential for verifying CO₂ containment, detecting potential leakage, and optimizing operational decisions in geologic carbon storage. Here, this study presents a time-adaptive, elastic-wave sensitivity-guided framework for designing cost-effective seismic monitoring layouts for tracking CO₂ plume migration. The method is based on elastic-wave sensitivity analysis, which quantifies how variations in subsurface properties impact seismic wavefields. Two complementary design strategies are developed: one based on selecting a fixed number of seismic sources (Method A), and the other based on selecting source–receiver pairs contributing to a fixed fraction of cumulative elastic-wave sensitivity energy (Method B). The optimization workflow to identify source–receiver configurations with the highest detection potential is demonstrated using a hypothetical GCS scenario at the Kimberlina site in California using simulations of elastic-wave sensitivity data at multiple post-injection timesteps. Results show that both strategies adapt to evolving plume geometries and wavefield sensitivities, with Method B offering broader spatial coverage and Method A ensuring simpler deployment. This framework enables site-specific, cost-effective, and risk-informed seismic survey designs, enhancing the ability to monitor CO₂ migration over time in evolving geological environments

58 GEOSCIENCES↗
DOE OSTI2022

An algorithmic approach to predicting mechanical draft cooling tower fan speeds from infrasound signals

Mechanical draft cooling towers (MDCTs) serve a critical heat management role in a variety of industries. For nuclear reactors in particular, the consistent, predictable operation of MDCTs is required to avoid damage to infrastructure and reduce the potential for catastrophic failure. Accurate, reliable measurement of MDCT fan speed is therefore an important maintenance and safety requirement. To that end, we have developed an algorithm for automatically predicting the rotational speeds of multiple, simultaneously operating fan rotors using contactless, infrasound measurements. The algorithm is based on identifying the blade passing frequencies (BPFs), their harmonics, as well as the motor frequencies (MFs) for each fan in operation. Using the algorithm, these frequencies can be automatically identified in the acoustic waveform’s short-time Fourier transform spectrogram. Attribution is aided by a set of filters that rely on the unique spectral and temporal characteristics of fan operation, as well as the intrinsic frequency ratios of the BPF harmonics and the BPF/MF signals. The algorithm was tested against infrasound data acquired from infrasound sensors deployed at two research reactors: the Advanced Test Reactor (ATR) located at Idaho National Laboratory (INL) and the High Flux Isotope Reactor (HFIR) located at Oak Ridge National Laboratory (ORNL). After manually identifying the MDCT gearbox ratio, the algorithm was able to quickly yield fan speeds at both reactors in good agreement with ground truth. Ultimately, this work demonstrates the ease by which MDCT fans may be monitored in order to optimize operational conditions and avoid infrastructure damage.

42 ENGINEERING↗
DOE OSTI2021

Transactive HVAC Agent - Design and Performance Evaluation

Transactive energy systems are playing an increasingly important role in the efficient and reliable marketbased operation of the power grid. Since a significant portion of the residential building energy consumption is from heating ventilation and air conditioning (HVAC) systems, HVAC is one of the most promising resources to provide load flexibility. However, utilizing HVAC flexibility to provide various grid services while simultaneously maintaining consumer comfort and cost-reductions is challenging. This paper presents a design of a transactive HVAC agent (T-HVAC) to be used as a supervisory control for the HVAC system that can simultaneously ensure comfort and cost-reduction. In particular, the T-HVAC a) estimates HVAC thermal dynamics, b) ensures optimal operations of the HVAC system, and c) participates into markets, and d) implements a market-based control via controlling the thermostat temperature set-point. The T-HVAC performance is demonstrated through multiple scenarios and illustrations.

Demand flexibility, distribution system, HVAC, Tra↗
DOE OSTI2021

Highly efficient terahertz photoconductive metasurface detectors operating at microwatt-level gate powers

Despite their wide use in terahertz (THz) research and technology, the application spectra of photoconductive antenna (PCA) THz detectors are severely limited due to the relatively high optical gating power requirement. This originates from poor conversion efficiency of optical gate beam photons to photocurrent in materials with sub-picosecond carrier lifetimes. Here we show that using an ultra-thin (160 nm), perfectly absorbing low-temperature grown GaAs metasurface as the photoconductive channel drastically improves the efficiency of THz PCA detectors. This is achieved through perfect absorption of the gate beam in a significantly reduced photoconductive volume, enabled by the metasurface. This Letter demonstrates that sensitive THz PCA detection is possible using optical gate powers as low as 5 µW—three orders of magnitude lower than gating powers used for conventional PCA detectors. We show that significantly higher optical gate powers are not necessary for optimal operation, as they do not improve the sensitivity to the THz field. This class of efficient PCA THz detectors opens doors for THz applications with low gate power requirements.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

Integrated protonic ceramic electrochemical cell for sustainable energy economy using water-energy nexus framework

Reliance on fossil fuels will continue for the next decades even though there are global pushes away from it to mitigate the overarching climate challenge, most especially by its highest consumers and availability. While there is a hastening global shift away from fossil fuel, integrating its assets into this technology helps limit the risk and future losses of stranded assets and reduce the cost of investment in the new technologies. Moreover, the generation of electricity from intermittent renewable sources like solar and wind has witnessed a significant surge in recent years, leading to a pressing demand for practical energy storage systems. Electrical energy storage is anticipated to play a pivotal role in the future global energy system, facilitating load-leveling operations to support the greater integration of renewable and distributed generation. Reversible electrochemical cells (RECs) offer a promising option for addressing the fossil fuel assets integration and energy storage challenges through the interconversion between electrical and chemical energy and concurrent utilizing carbon emission. In their electrolysis mode, the RECs convert electricity into durable, storable, and portable valuable chemical fuels such as syngas and methane. Conversely, the produced chemical fuels can be used as reactants in the fuel cell mode to generate electricity on demand with minimal (hydrocarbons) or zero when H2 or NH3 is used emissions. However, a challenging goal for this type of technology remains to achieve optimal operation and high roundtrip efficiencies, which has hindered the deployment of previous electrochemical cells. This dissertation demonstrates how reversible protonic ceramic electrochemical cells (RePCECs) can be integrated with fossil fuel power plants and renewable energy sources as a potential energy storage system. In this work, integrated RePCEC systems are designed and examined using computational modeling at scales to determine appropriate system configurations and operating conditions that achieve high roundtrip efficiencies. Cell level design of the PCEC is the first approach, several cells are assembled for the stack level model that is integrated into combined cycle powerplant and solar photovoltaic for the system level model. After critical literature review, this answered the operational and integration research questions proposed to address these challenges. The designed systems perform two functions, utilizing captured CO2 and storing renewable energy through co-electrolysis of steam and CO2. The co-electrolysis reaction involves endothermic water electrolysis and exothermic methanation reaction. To enhance high roundtrip efficiency, there is a need for thermal balance and management in the electrolysis mode. This involves operating the RePCEC stack under conditions that favor methane production to balance out heat needed by water electrolysis, it crucial for the RePCEC system operation. Methanation is enhanced by low temperatures. Leveraging on fabricated BCZYYb-electrolyte RePCEC, the cell model designed revealed that the optimum temperature for methane production is 450℃ at atmospheric pressure. Thus, to achieve optimum system performance, operating in the temperature range 450-525℃ is recommended at the given configuration, combining between the optimum temperature for methane production and temperature for the optimum stack roundtrip efficiency. Configuration with carbon capture system and purge stream is the optimum configuration from the seven conceptualized and evaluated. The modeling outcomes include a thermodynamic examination of integrated RePCEC systems, calibration of cell and stack level models, and steady-state simulation and integration into a 600MW combined cycle power plant retrofitted with two two-stage membrane-based carbon capture system and a wastewater treatment and recovery unit. At 100% powerplant loading, the stack and system roundtrip efficiencies are 72% and 51.37% respectively. Adding a purge stream for produced hydrogen at the system downstream improves the efficiencies to 74 and 55.48% respectively. At atmospheric pressure and 525℃, the system model suggests that a stack roundtrip of 82% is achievable, and overall system efficiency increases by reducing the energy consumption by the balance of plant components for steam generation and storage. Economic analysis of the process gives levelized cost of methane as $2.24/MMBtu lower than the conventional production route that range between $3.46/MMBtu and $9.85/MMBtu. The lifecycle analysis shows that the global warming potential for the production of methane and hydrogen from the RePCEC system is 3.83 kg CO2 eq which is lower than 9.35 kg CO2 eq emission during steam methane reforming for hydrogen production. This answered both the environmental and economic concerns in the raised research question. The proposed RePCEC configuration and analysis carried out in this dissertation to address the surge in renewable energy and challenges with PCEC technology hold significant potential in achieving large-scale energy storage while simultaneously reducing carbon emissions. These advancements, coupled with suitable governmental policies and incentive programs, have the potential to economically disrupt the natural gas industries by using RePCEC systems for methane production, thereby making them more favorable for eventual implementation and commercialization.

25 ENERGY STORAGE↗
DOE OSTI2022

Well–based monitoring of CO 2 geological sequestration operations in saline aquifers: Critical insights into key questions

Geological carbon sequestration in saline aquifers is one of the most promising strategies to help mitigate emissions of CO 2 to the atmosphere. Significant challenges in ensuring the security of the sequestration process rest in the evolution and expansion of the CO 2 plume in the subsurface. The ability to track the movement of the injected CO 2 poses another challenge. Critical questions related to the integrity of the sequestration operations in saline aquifers relate to plume characteristics that can we monitor using well-based variables. We addressed this and related questions using an integrated modeling framework through a numerical investigation of carbon sequestration in saline aquifers during long-term and post-injection periods. This modeling paradigm incorporates the effect of structural, geological, and petrophysical characteristics. That way, we can account for critical physicochemical processes, rock-fluid interactions, and lithology dependencies. The well fluid variables investigated include fluid composition, pH, fluid density, and ion activity. We learned that fluid property analytics and diagnostics can be powerful tools to estimate the movement of CO 2 and its storage in different trapping mechanisms. These analytics can help optimize operational aspects and simplify reservoir-scale models while still reflecting the complex nature of the CO 2 interactions underground and offering insights into plume evolution.

58 GEOSCIENCES↗
DOE OSTI2024

Partially cracked ammonia mixture combustion in gas turbine combustors

Ammonia is gaining popularity for single fuel use in existing gas turbines, as it is carbonless, has higher hydrogen content per unit volume than liquid hydrogen, and facilitates easy storage and handling. However, the low flame speed of ammonia makes it prone to flame blow off and remains the chief concern for its use in power generation. Following previous studies that have shown improved combustion performance by partially cracking the fuel, in this computational study, efficacy of partially cracked ammonia as a replacement fuel for natural gas is evaluated. A high-pressure optically accessible combustor operated at ~10 bar pressure with non-vitiated heated air was used as the test platform. This combustor was equipped with a novel multifuel multi-tube micromixing injector (M3 injector). High resolution simulations of the flow fields both in the injector as well as the combustor were performed to understand the fuel mixing in the injector and in the inlet region of the combustor. These modeling results showed that the injector was highly effective for achieving mixture homogeneity at the entrance of the combustor for ammonia and natural gas injection, whereas, for hydrogen an earlier injection facilitating longer residence time would be beneficial. Also, these simulations show that while harnessing waste heat the ideal fuel dissociation fraction is between 0.4 and 0.55 for optimal operation.

Ammonia↗
DOE OSTI2020

American WAKE experimeNt (AWAKEN)

The American WAKE experimeNt (AWAKEN) is an international multi-institutional wind energy field campaign to better understand wake losses within operational wind farms. Wake interactions are among the least understood physical interactions in wind plants today, leading to unexpected power and profit losses. For example, Ørsted, the world’s largest offshore wind farm developer, recently announced a downward revision in energy estimates across their energy generation portfolio, primarily caused by underprediction of energy losses from wind farm blockage and wakes. In their announcement, they noted that the standard industry models used for their original energy estimates were inaccurate, and this was likely an industry-wide issue. To help further improve and validate wind plant models across scales from individual turbines as well as interfarm interactions between plants, new observations, such as those planned for AWAKEN, are critical. These model improvements will enable both improved layout and more optimal operation of wind farms with greater power production and improved reliability, ultimately leading to lower wind energy costs.

17 WIND ENERGY↗
DOE OSTI2026

Strategies for Enhancing Battery Life Under Fast Charging: Insights from NMC-Based Cell Cycling

Fast charging improves the usability of consumer electronics and electric vehicles (EVs) by reducing range anxiety and downtime but accelerates battery degradation and raises safety concerns. Optimizing operational conditions during fast-charging is critical to mitigating aging and ensuring safety. This study evaluated multilayer Gr/NMC811 cells under various conditions, including depths of discharge (DODs of 68%, 84%, and 100%), upper charge cutoff voltages (4.1–4.2 V), and post-charge rest periods (2–30 min), using a 20 min fast charging protocol for up to 500 cycles (up to 150,000 miles of EV use assuming 3.3 mi/kWh vehicle level energy efficiency). Surprisingly, higher DODs under fast charging improved battery life and performance compared to lower DODs. Reducing the upper charge cut-off voltage helped mitigate degradation. A brief 2 min rest period after charging further reduced aging effects. The primary aging modes were loss of lithium inventory and cathode active material. Although minor lithium plating was observed within 500 cycles, it did not affect performance significantly. These findings suggest that, with optimized conditions, cells can sustain hundreds of fast charge cycles—equivalent to over 100,000 miles of EV use—without significant adverse effects on performance or longevity.

25 - ENERGY STORAGE↗
DOE OSTI2024

Grid-connected heat pump water heater benefits for low-income households in the Southeastern United States

Energy efficient heat pump water heaters (HPWHs) reduce customer energy costs; grid-connected controls further increase HPWH value by enabling energy storage and shifting demand to cheaper, off-peak periods. However, a HPWH’s first cost premium can put it out of reach for low-income customers. This paper will present results of an ongoing study exploring the benefits of load shifting HPWHs for 24 low-income households, aiming to support increased product deployment in this demographic. The study uses EcoPort modules to shift HPWH load for a study sample consisting primarily of low-income adults and seniors in North Carolina. Building upon prior studies, the study’s HPWH operating schedules are designed to maximize shifted energy and minimize participant electricity costs based on local time-of-use rates. The study documents load profiles of grid-connected HPWHs in a less-studied demographic group and explores how certain groups may have particularly flexible loads due to their unique usage profiles. The results are relevant for HPWH product performance in the Southeast. The study will quantify HPWH load shifting performance during North Carolina’s hot summer, temperate shoulder, and occasionally sub-freezing winter seasons, and the study includes installations in conditioned, semi-conditioned, and unconditioned spaces. Finally, study results will also explore how controlled HPWHs can provide value to the regional grid by reducing seasonal peaks via demand response. Lessons learned include HPWH acceptance for low-income and senior users, best practices for maintaining HPWH connectivity among users without prior product experience, and strategies to leverage remote monitoring to ensure optimal operation and enhance HPWH reliability.

Urigwe, Daniela↗
DOE OSTI2021

Bandwidth extension and conversion efficiency improvements beyond phase matching limitations using cavity-enhanced OPCPA

The conversion efficiency and phase matching bandwidth of ultrafast optical parametric amplification (OPA) are constrained by the dispersion and nonlinear coefficient of the employed crystal as well as pulse shaping effects. In our work we show that an enhancement cavity resonant with the pump seeded at the full repetition rate of the pump laser can automatically reshape the small-signal gain in optical parametric chirped-pulse amplification (OPCPA) to achieve close-to-optimal operation. This new method termed cavity-enhanced OPCPA or C-OPCPA significantly increases both the gain bandwidth and the conversion efficiency, in addition to boosting gain for high-repetition-rate amplification. The goal in C-OPCPA is to arrive at a condition of impedance matching at all temporal coordinates, such that, in the absence of linear losses, all the incident pump power is dissipated in the nonlinear loss element, i.e., converted to signal and idler. The use of a low finesse enhancement cavity resonant with a low average power (<1W) and a high repetition rate (78MHz) pump source is shown to achieve more than 50% conversion efficiency into signal and idler from the coupled pump in an optical parametric process, whereas an equivalent amount of pump power in a single-pass configuration leads to negligible conversion. Additionally, the gain bandwidth is extended by a factor of 3-4 beyond the phase-matching limit. Our empirical observations are corroborated by a numerical analysis of depletion optimizing the single-pass case, which assesses the underlying impedance matching that is responsible for the observed performance improvements.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

Final Report on Aerosol Pretreatment Technology Performance and Benchmarking

Solvent-based post-combustion CO 2 capture (PCC) technology remains one of the leading methods to combat global CO 2 emissions produced from large-scale coal-fired power production. Advanced solventbased PCC technology has made significant improvements in design and performance that reduce capital and operating costs to enable its commercial use. Key to low cost, manageable logistics, and environmentally safe operation of solvent-based PCC technology are minimal solvent losses from the process through the treated gas stream exiting PCC plant absorbers. High flue gas aerosol particle concentrations (>10 5 particles/cm 3 ) for particles in the range of 70-200 nm have been shown to cause significant amine solvent losses for solvent-based PCC processes through several mechanisms including absorption of solvent and water into growing aerosol particles. Flue gas aerosol pretreatment technology is the only realistic and economically attractive method to reduce very high aerosol particle concentrations (>10 7 particles/cm 3 ) to enable solvent-based PCC for existing power plants lacking sufficient particle removal systems, such as baghouses. The overall goal of this project was to design, construct, independently test, and evaluate three flue gas aerosol pretreatment technologies identified to significantly reduce high aerosol particle concentrations (>10 7 particles/cm 3 ) in the 70-200 nm particle size range: (1) a novel, high-velocity water injection spray concept developed by RWE and tested by Linde, (2) an innovative electrostatic precipitator (ESP) device with optimized operating conditions developed by Washington University in St. Louis (WUSTL), and (3) a non-regenerative sorbent-based filter technology developed by InnoSepra for SO x and NO x removal from coal-fired power plant flue gas. Each technology has been validated with tests on 500-1000 scfm of actual coal-fired flue gas and evaluated in terms of particle removal efficiency (%), cost competitiveness, and environmental impact. Aerosol measurements were performed upstream and downstream of each aerosol reduction unit during independent testing of each technology using advanced instrumentation and analytical methods provided by WUSTL. To perform aerosol measurements, isokinetic probes were inserted into flanged pipes attached to the flue gas piping, and a small suction pump was used to sample gas containing aerosol particles. Aerosol particle number concentrations (# particles/cm 3 ) and size distributions were then measured using a scanning mobility particle sizer (SMPS, TSI Inc.) for very fine particles (<1,000 nm) and a particle counter manufactured by GRIMM for particles larger than 1,000 nm. This report summarizes the aerosol removal performance results from pilot scale testing of each technology. Performance results have been benchmarked against pre-defined targets and other flue gas aerosol pretreatment technologies with documented performance. Linde Gas North America LLC has been the prime contractor to DOE responsible for overall project management and provided the design for the high-velocity water spray-based aerosol removal technology based on a design concept developed by the German utility company RWE.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

The Role of Regional Connections in Planning for Future Power System Operations Under Climate Extremes

Identifying the sensitivity of future power systems to climate extremes must consider the concurrent effects of changing climate and evolving power systems. We investigated the sensitivity of a Western U.S. power system to isolated and combined heat and drought when it has low (5%) and moderate (31%) variable renewable energy shares, representing historic and future systems. We used an electricity operational model combined with a model of historically extreme drought (for hydropower and freshwater-reliant thermoelectric generators) over the Western U.S. and a synthetic, regionally extreme heat event in Southern California (for thermoelectric generators and electricity load). We found that the drought has the highest impact on summertime production cost (+10% to +12%), while temperature-based deratings have minimal effect (at most +1%). The Southern California heat wave scenario impacting load increases summertime regional net imports to Southern California by 10-14%, while the drought decreases them by 6-12%. Combined heat and drought conditions have a moderate effect on imports to Southern California (-2%) in the historic system and a stronger effect (+8%) in the future system. Southern California dependence on other regions decreases in the summertime with the moderate increase in variable renewable energy (-34% imports), but hourly peak regional imports are maintained under those infrastructure changes. By combining synthetic and historically driven conditions to test two infrastructures, we consolidate the importance of considering compounded heat wave and drought in planning studies and suggest that region-to-region energy transfers during peak periods are key to optimal operations under climate extremes.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2020

Impact of installation faults in air conditioners and heat pumps in single-family homes on U.S. energy usage

To ensure that new residential air conditioners and heat pumps operate optimally, care must be taken during the initial system design and installation to avoid missteps that immediately degrade a system’s performance. Laboratory and simulation studies have quantified the impact that faults can have on capacity and efficiency. Field studies have demonstrated that installation-related faults are commonplace. However, the national impact of installation-related faults cannot be accurately estimated by only simulating a limited number of homes at several fault levels because of the variety of home characteristics and climates involved. In our analysis, we use an improved residential building stock simulation tool to predict the annual energy increase and additional utility costs resulting from two common installation faults: indoor airflow rate and refrigerant charge level. Our method considers the wide range of building characteristics and climate zones of the U.S. housing stock. We use existing field data to develop fault intensity probability distributions to inform our analysis. The study shows that these two faults result in approximately 20.7 TWh/y of additional energy use for central air conditioners and air-source heat pumps in U.S. single-family detached homes, which is a 9% increase over baseline (no-fault) usage, costing homeowners approximately $2.5 billion annually on utility bills. Air-source heat pumps are responsible for a disproportionate fraction of this energy use increase because of the larger number of operating hours compared to central air conditioners and the sensitivity of heating mode performance to the faults analyzed compared to cooling mode.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Development of a Technical, Economic, and Risk Assessment Tool for the Evaluation of Work Reduction Opportunities

Efficient and cost-effective operation of a nuclear power plant (NPP) is essential to ensuring long-term economical and safe operation. Multiple cost saving opportunities exist, referred to here as work reduction opportunities (WRO). These WROs reduce plant operating costs by employing various cost-effective strategies (e.g., implementation of modern technologies). Identifying and objectively screening WROs is an essential task to help reduce overall costs. However, there is no comprehensive framework for assessing WROs in the nuclear industry and evaluating their impact on plant operations. This report presents a novel framework for systematically evaluating WROs from a technical, economic, and risk perspective. As NPPs continue to add new technology and implement modernization strategies into their current processes, potential WROs are commonly identified. Although most WROs have the potential to reduce costs, not all opportunities will result in significant cost savings due to unforeseen risks, large implementation costs, or benefits that fall short of expectations. Examples of this can be the result of a technology that is not fully developed, uncertainty in the amount of cost reduction, or difficulties introducing a new process into an organization. These uncertainties can manifest several ways and can result in a WRO with limited cost savings or even a loss of investment. The framework developed emphasizes the importance of effectively screening the WROs from a holistic perspective to objectively identify inefficiencies and ensure a positive impact to the organization. This report presents the Technical, Economic, and Risk Assessment (TERA) as a key methodology for the screening and evaluation of potential WROs. The TERA framework begins with a screening phase where the process is examined through a hybrid combination of Lean Six Sigma and Integrated Operations for Nuclear (ION) guiding principles. This framework examines the current processes using the Lean Six Sigma SIPOC (Suppliers, Inputs, Process, Outputs, Consumers) methodology but retains the ION key elements of People, Technology, Process, and Governance as important factors to the nuclear decision-making process. By combining the principles of Lean Six Sigma and ION, the developed screening process is specific to the nuclear industry in that it systematically evaluates WROs in order to implement new technology that is comprehensively evaluated. The TERA begins by mapping current processes as they relate to WROs and examining the inefficiencies. Furthermore, the created process map can be used to identify and evaluate potential solutions. Using key performance indicators (KPIs), the TERA evaluates each area—technology, economics, and risk—for uncertainties and to perform cost-benefit analysis. The results of the TERA are important KPIs that allow for an evaluation of different processes and technology implementations. This assessment enables decision-makers to compare various WROs based on metrics and then make informed decisions for which opportunity to implement first. This research includes not only the creation of the TERA framework, but also the evaluation of its performance. A case study for screening potential WROs at Southern Nuclear Company is presented that utilizes the TERA methodology. Through the use of TERA, various WROs were screened, and the solutions evaluated for cost-benefit expectations. The report concludes by summarizing the overall effort and implications for utility modernization. The performance of the screening and TERA are discussed as well as the impact on the nuclear industry. The TERA process enables utilities to evaluate and inform investment decisions for WROs and mitigate any potential risks. Through this research, we provide utilities with a valuable framework to optimize operations, reduce costs, and drive continuous process improvement.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Circular Reprocessing of Thermoset Polyurethane Foams

Thermoset polyurethane (PU) foams are widely used in industrial applications, but they cannot be recycled by conventional melt reprocessing because of their cross-linked structures. The introduction of carbamate exchange catalysts converts thermoset PU into covalent adaptable networks (CANs), which are amenable to reprocessing at elevated temperatures. However, this approach has produced solid PU films, which have fewer uses and lower commercial demand. In this work, simultaneous reprocessing and refoaming of thermoset PU foams is demonstrated by leveraging the melt-processability of PU CANs and allowing cell growth by gas generation in a twin-screw extruder. The optimal operating temperature of the refoaming process is determined through chemical, thermal, and structural analysis of PU foam extrudates. The foam-to-foam extrusion process produces controllable, continuous, and uniform foam structures, as characterized by cell diameter and cell number density. Low-density PU foams are obtained through a process simulating injection molding. The compression properties of reprocessed PU foam are compared with as-synthesized PU foam to demonstrate efficacy of the refoaming processes. These results demonstrate that PU foams can be prepared through recycling while maintaining microstructural and chemical integrity. In the future, this strategy may be applied to thermoset PU foams of various chemical compositions and shows promise for scalability.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Moving from residual lignocellulosic biomass into high–value products: Outcomes from a long–term international cooperation

Major progress in the bioprocessing of lignocellulose to fuels and value-added chemicals has created the possibility of a low carbon-footprint economy. However, the current complexity and associated costs of lignocellulose conversion result in a higher price for ethanol than for fossil fuels. The cost of cellulosic ethanol production will be lowered by further progress in development of biorefinery technology that produces both ethanol and high-value chemicals with bio-based products that are beginning to penetrate consumer markets in the USA, Brazil, and worldwide. The cost-effectiveness of low carbon-footprint bioproducts will benefit from advances in supplying large amounts of biomass solids to the biorefinery. We describe here outcomes from a successful long-term international cooperation between the Laboratory of Renewable Resources Engineering (LORRE) at Purdue University in the United States and Brazil's Agricultural Research Corporation (EMBRAPA) and Federal University of Sâo Carlos (UFSCar), which has contributed practical pathways to enhance the biorefinery concept. Furthermore, this paper gives an overview of developments that address fundamental knowledge of lignocellulosic biomass pretreatment hydrolysis under optimized operational conditions and bioreactor configurations, and the science and engineering that contributes to the effective production of fuel and ethanol and value-added products from biomass.

09 BIOMASS FUELS↗