Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Production Based Costing”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 253 records · Page 14

Modeling Global Carbon Costs of Plant Nitrogen and Phosphorus Acquisition

Abstract Most Earth system models (ESMs) do not explicitly represent the carbon (C) costs of plant nutrient acquisition, which leads to uncertainty in predictions of the current and future constraints to the land C sink. We integrate a plant productivity‐optimizing nitrogen (N) and phosphorus (P) acquisition model (fixation & uptake of nutrients, FUN) into the energy exascale Earth system (E3SM) land model (ELM). Global plant N and P uptake are dynamically simulated by ELM‐FUN based on the C costs of nutrient acquisition from mycorrhizae, direct root uptake, retranslocation from senescing leaves, and biological N fixation. We benchmarked ELM‐FUN with three classes of products: ILAMB, a remotely sensed nutrient limitation product, and CMIP6 models; we found significant improvements in C cycle variables, although the lack of more observed nutrient data prevents a comprehensive level of benchmarking. Overall, we found N and P co‐limitation for 80% of land area, with the remaining 20% being either predominantly N or P limited. Globally, the new model predicts that plants invested 4.1 Pg C yr −1 to acquire 841.8 Tg N yr −1 and 48.1 Tg P yr −1 (1994–2005), leading to significant downregulation of global net primary production (NPP). Global NPP is reduced by 20% with C costs of N and 50% with C costs of NP. Modeled and observed nutrient limitation agreement increases when N and P are considered together ( r 2 from 0.73 to 0.83).

54 ENVIRONMENTAL SCIENCES↗

State of Innovation 2024: Paving the Way for Low-Carbon Cement and Concrete

Concrete production in the U.S. accounted for nearly 393 million cubic yards in 2023, with $38.8 billion in revenue. While cement, the key ingredient in concrete, is only 10%-15% of concrete's mixture by mass, 8% of total global emissions come from the production of cement. A significant challenge lies in the fact that roughly 51% of concrete emissions stem from the material calcination process of cement production. Stakeholders ranging from cement producers to government agencies are beginning to take measures to significantly reduce concrete emissions by 2050 and are seeking novel technologies from the startup community. Strategies to lower carbon emissions include reducing quantities of cement in concrete formulas; optimizing digital and automated production; lower temperature processing; carbon capture, utilization, and durable storage; and other cost-saving approaches to energy and material efficiencies. New materials based on carbon mineralization and novel cement chemistries hold the potential to reach net-zero or even carbon-negative concrete production; however, there is presently no readily available substitute that can replicate concrete's unique properties and versatility at the volume demanded by construction worldwide. The nature of concrete's raw materials, diverse applications, and scale of demand means that complete decarbonization will rely on a combination of innovative production methods and novel cement chemistries. Low-carbon solutions will need to compete economically with traditional concrete to become viable in a high-volume commodity market, although consumer demand and regulation will play important roles. Despite these challenges, this analysis reveals that venture capital (VC) investments in low-carbon concrete reflect a growing awareness of the decarbonized cement market opportunity. Between 2022 and 2023 emerging low-carbon technologies garnered more than $700 million in VC investments, representing a growing share of investment in the built environment. An investment gap appears after Series A for technology solutions, demonstrating the sector's potential, as well as the need for additional performance assurance and technology incubation.

cement↗

Coal gasification systems engineering and analysis, volume 2

The major design related features of each generic plant system were characterized in a catalog. Based on the catalog and requirements data, approximately 17 designs and cost estimates were developed for MBG and alternate products. A series of generic trade studies was conducted to support all of the design studies. A set of cost and programmatic analyses were conducted to supplement the designs. The cost methodology employed for the design and sensitivity studies was documented and implemented in a computer program. Plant design and construction schedules were developed for the K-T, Texaco, and B&W MBG plant designs. A generic work breakdown structure was prepared, based on the K-T design, to coincide with TVA's planned management approach. An extensive set of cost sensitivity analyses was completed for K-T, Texaco, and B&W design. Product price competitiveness was evaluated for MBG and the alternate products. A draft management policy and procedures manual was evaluated. A supporting technology development plan was developed to address high technology risk issues. The issues were identified and ranked in terms of importance and tractability, and a plan developed for obtaining data or developing technology required to mitigate the risk.

Source record↗

Formation of carbon and oxygen rich surface layer on high purity magnesium by atmospheric carbon dioxide plasma

Carbon and oxygen-rich corrosion barrier layer formed on Mg by a simple and scalable CO 2 atmospheric plasma (CO 2 -AP) process. The reactive CO 2 -AP interacts with the Mg surface and forms a unique layered structure with the top MgCO 3 /MgO-intermixed particulates pillars and the bottom dense layer. The surface features were simultaneously formed on the nano-/micro-structured MgO layer by carbonate molecules, plasma-active CO 2 molecules, and/or other volatile organic compounds on the nano-/micro-structured MgO particle layer. The resulting surfaces after CO 2 -AP were either hydrophobic or hydrophilic and exhibited lower anodic current or high resistance for Mg corrosion. For the hydrophobic surfaces of CO 2 -AP treated Mg, molecular dynamic simulations were performed to understand the origin of hydrophobicity and identified that the amorphous carbon layers formed on the Mg surface are the source. The environmentally benign abundant-gas-based process enables the cost reduction associated with waste treatment, generation of by-product, and supply of raw material.

36 MATERIALS SCIENCE↗

Development of Ternary Transition Metal Oxide Catalysts for Oxygen Evolution Reaction

Electrochemical water splitting, a promising method for green hydrogen production, is currently hindered by the high cost of precious-group metal (PGM)-based catalysts for the oxygen evolution reaction (OER). This study addresses this challenge by advancing the development of catalysts for OER, focusing on the development of high-performance PGM-free catalysts using nickel-iron-cobalt (NiFeCo)-based aerogels. The catalysts were synthesized via a sol-gel method and critical point drying to achieve a highly porous structure with an exceptionally high surface area. The designed catalyst structure provides an ideal platform for maximizing catalytic active sites and enhancing mass transport kinetics. Co has been systematically incorporated into the current PGM-free state-of-the-art, NiFeOx catalyst, and the metal ratios have been optimized. In addition to the experimental studies, density functional theory calculations were performed to study the material’s properties of this ternary catalyst and the effect of Co addition on enhancing OER catalysis.

Mizrahi, Michal [Bar-Ilan University, Ramat Gan, I↗

Ferromagnetic resonators synthesized by metal-organic decomposition epitaxy

Abstract Metal-organic decomposition epitaxy is an economical wet-chemical approach suitable to synthesize high-quality low-spin-damping films for resonator and oscillator applications. This work reports the temperature dependence of ferromagnetic resonances and associated structural and magnetic quantities of yttrium iron garnet nanofilms that coincide with single-crystal values. Despite imperfections originating from wet-chemical deposition and spin coating, the quality factor for out-of-plane and in-plane resonances approaches 600 and 1000, respectively, at room temperature and 40 GHz. These values increase with temperature and are 100 times larger than those offered by commercial devices based on complementary metal-oxide semiconductor voltage-controlled oscillators at comparable production costs.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

A Durable, Inexpensive and Scalable Redox Flow Battery Based on Iron Sulfate and Anthraquinone Disulfonic Acid

A new redox flow battery system based on iron sulfate and anthraquinone disulfonic acid (AQDS) is shown here to have excellent electrical performance, capacity retention, and chemical durability. While these redox couples, iron(II)/iron(III) and AQDS are well known individually, their combination in a redox flow battery is shown here for the first time to provide unique benefits for large-scale energy storage. Based on iron sulfate, a waste product of the steel industry, the active materials cost for this battery is anticipated to be $66/kWh. Cycling studies of over 500 cycles in the symmetric cell configuration show a negligibly low capacity fade rate of 7.6 × 10 −5 % per cycle. This symmetric cell also shows a notably high average coulombic efficiency of 99.63%. Using a graphite felt electrode modified with multi-walled carbon nanotubes (MWCNTs), we could achieve a peak power density of 194 mW cm −2 . The major voltage losses are ascribed to the ohmic resistance of the electrode and electrolyte. Despite the lower cell voltage of the system relative to the vanadium flow battery, the iron–AQDS flow battery system presents a good prospect for simultaneously meeting the demanding requirements of cost, durability and scalability for large-scale sustainable energy storage.

Yang, Bo↗

Monolithic Mesoporous Metamaterials for R-10 to R-15 Glazing (Final Scientific Technical Report)

The objective of the project was to develop and validate monolithic mesoporous metamaterials (MMMs), to which we also refer as Mesoporous Optically Clear Heat Insulators (MOCHIs) capable of serving as High-thermal-barrier Glazing (including Windows, Skylights, and Daylighting) with Transparency ≥99%, Color Rendering Index ≥99%, Haze ≤1%, Thermal Insulation per inch ≥R-15, Manufacturing Cost per Square Foot ≤$0.3; In addition, MMM-Based Frame Insulation and Glazing Products with Thermal Insulation per inch R-10 to R-15. All objectives of the project were successfully accomplished.

14 SOLAR ENERGY↗

Design and Fabrication of a Ring-Stiffened Graphite-Epoxy Corrugated Cylindrical Shell

Design and fabrication of supplement test panels that represent key portions of the cylinder are described, as are supporting tests of coupons, sample joints, and stiffening ring elements. The cylindrical shell is a ring-stiffened, open corrugation design that uses T300/5208 graphite-epoxy tape as the basic material for the shell wall and stiffening rings. The test cylinder is designed to withstand bending loads producing the relatively low maximum load intensity in the shell wall of 1,576 N/cm. The resulting shell wall weight, including stiffening rings and fasteners, is 0.0156 kg/m. The shell weight achieved in the graphite-epoxy cylinder represents a weight saving of approximately 23 percent, compared to a comparable aluminum shell. A unique fabrication approach was used in which the cylinder wall was built in three flat segments, which were then wrapped to the cylindrical shape. Such an approach, made possible by the flexibility of the thin corrugated wall in a radial direction, proved to be a simple approach to building the test cylinder. Based on tooling and fabrication methods in this program, the projected costs of a production run of 100 units are reported.

Johnson, R., Jr.↗

Robotic lunar surface operations: Engineering analysis for the design, emplacement, checkout and performance of robotic lunar surface systems

The assembly, emplacement, checkout, operation, and maintenance of equipment on planetary surfaces are all part of expanding human presence out into the solar system. A single point design, a reference scenario, is presented for lunar base operations. An initial base, barely more than an output, which starts from nothing but then quickly grows to sustain people and produce rocket propellant. The study blended three efforts: conceptual design of all required surface systems; assessments of contemporary developments in robotics; and quantitative analyses of machine and human tasks, delivery and work schedules, and equipment reliability. What emerged was a new, integrated understanding of hot to make a lunar base happen. The overall goal of the concept developed was to maximize return, while minimizing cost and risk. The base concept uses solar power. Its primary industry is the production of liquid oxygen for propellant, which it extracts from native lunar regolith. Production supports four lander flights per year, and shuts down during the lunar nighttime while maintenance is performed.

Woodcock, Gordon R.↗

The FOT tool kit concept

Flight operations and the preparation for it has become increasingly complex as mission complexities increase. Further, the mission model dictates that a significant increase in flight operations activities is upon us. Finally, there is a need for process improvement and economy in the operations arena. It is therefore time that we recognize flight operations as a complex process requiring a defined, structured, and life cycle approach vitally linked to space segment, ground segment, and science operations processes. With this recognition, an FOT Tool Kit consisting of six major components designed to provide tools to guide flight operations activities throughout the mission life cycle was developed. The major components of the FOT Tool Kit and the concepts behind the flight operations life cycle process as developed at NASA's GSFC for GSFC-based missions are addressed. The Tool Kit is therefore intended to increase productivity, quality, cost, and schedule performance of the flight operations tasks through the use of documented, structured methodologies; knowledge of past lessons learned and upcoming new technology; and through reuse and sharing of key products and special application programs made possible through the development of standardized key products and special program directories.

Fatig, Michael↗

Evolutionary Development of the Simulation by Logical Modeling System (SIBYL)

Through the evolutionary development of the Simulation by Logical Modeling System (SIBYL) we have re-engineered the expensive and complex IBM mainframe based Long-term Hardware Projection Model (LHPM) to a robust cost-effective computer based mode that is easy to use. We achieved significant cost reductions and improved productivity in preparing long-term forecasts of Space Shuttle Main Engine (SSME) hardware. The LHPM for the SSME is a stochastic simulation model that projects the hardware requirements over 10 years. SIBYL is now the primary modeling tool for developing SSME logistics proposals and Program Operating Plan (POP) for NASA and divisional marketing studies.

Wu, Helen↗

Gaussian FLOWERS: Wind-rose-based analytical integration of Gaussian wake model for extremely fast AEP estimation

A major cost in the study of wind farm layout optimization is the repeated evaluation of the annual energy production (AEP). The current approach to estimating AEP requires a large set of flow simulations to be performed that cover each discrete wind speed and direction combination contained within the wind rose, followed by a probability-weighted sum of the power production resulting from each simulation. Even with inexpensive engineering wake models, this numerical integration scheme can lead to high computational costs. In this paper, we derive an analytical formulation for estimating farm AEP across every wind direction, based on a Gaussian wake velocity model, which reduces the number of wind farm simulations to a single function evaluation. As a result, we find that the Gaussian-FLOWERS approach reduces the time for AEP calculations by more than two orders of magnitude with a small trade-off in accuracy when compared to a conventional approach. This massive reduction in computation cost is useful to reduce overall costs in wind farm layout optimization studies.

17 WIND ENERGY↗

Air classification of forest residue for tissue and ash separation efficiency

The goal of this Case Study was to evaluate the performance of air classification of logging residues toward meeting conversion CMAs for carbon and ash contents, as compared to the static status quo Base Case system in which the residues are first dried and then ground in a hammer mill with a 6 mm screen and fines < 1.18 mm are removed. Also considered were moisture and ash impacts on throughput and Overall Operating Effectiveness (OOE), as well as delivered feedstock cost and minimum fuel selling price (MFSP). Laboratory data on the impacts of fan speed and moisture content on the separation efficiency of soil ash, needles and bark from white wood were received from FCIC Subtask 5.2. Average throughput and energy consumption data were obtained from the Bioenergy Feedstock National User Facility (BFNUF) for the same air classifier. These data were utilized to develop the necessary response surface equations to perform throughput analysis using discrete event simulation. Because the Base Case status quo system utilizes drying prior to grinding, we modeled the Case Study with drying prior to air classification and subsequent grinding of the separated white wood to isolate the individual quality and cost impacts of air classification relative to the Base Case system. Key takeaways from this Case Study are that air classification improves the quality of the final material, but increases the production cost, especially when lights are disposed; this becomes a tradeoff between increased conversion yield and the extra cost. Removing material should be done as early in the process as possible. Each operation that occurs prior to removing the material increases the cost of the disposed material and leads to wasted energy expenditures. As processes are included or modified, the impact on monetary and energy cost should be included in the decision process. Identifying alternative uses and the associated value for material that is separated from the feedstock stream will have a significant impact on the delivered cost of the material. Although there was an increase in production cost by adding air classification, there was a resulting benefit to the MFSP when meeting or exceeding all of the conversion CMAs; this was an important finding that should be explored further with FCIC Subtask 8.3 and potentially FCIC Task 6.

09 BIOMASS FUELS↗

Experimental Operation of a Prototype 750C Advanced Chloride Molten Salt Bellows Valve

To achieve DOE 2030 SunShot targets that reduce the cost of liquid-based solar by an additional 40% to 70% beyond 2018 costs, a more reliable, highly manufacturable flow valve, capable of achieving operational temperatures of >700°C is required [1]. This paper investigates the development of an innovative high-temperature chloride molten salt valve, with operation up to 750°C. This valve is intended to be employed within Gen 3 CSP liquid-based thermal energy storage (TES) systems as well as Gen 4 modular salt reactor (MSR) technologies. This work details the general design and flow testing of a bellows-seal flow control valve (FCV). This design includes an integrated closed-loop thermal control system to ensure robust design for freeze-thaw cycles. The self-contained thermal management STM system, is unique in the salt valve industry since it is an integrated solution to provide a consistent, repeatable alternative to typical heat tracing. Additionally, the design includes the employment of a novel heat pipe valve stem to facilitate enhanced passive thermal management into the valve assembly. This valve stem heat pipe is designed to facilitate natural circulation within the bonnet to ensure robust operation, during both nominal and transient thermal operation. The valve body and trim will be designed using SS316H, consistent with Flowserve Corporation’s existing product base and is code qualified but will utilize clad material for materials corrosion, manufacturing cost reduction and compatibility to ensure design flexibility. A test campaign was performed in this investigation utilizing a novel 750°C ternary chloride (20%NaCl/40%MgCl2/40%KCl by mol. wt. %) molten salt flow loop. A discussion about the design and installation of the valves within this test bed is provided for this investigation. Valve test results from this study assessed Cv curves as well as multiple actuator cycles, under varying thermodynamic and operational mode conditions, which would be characteristic within a commercial molten salt facility. The results indicate nominal operation for the baseline design, though improved performance and reliability is expected with the full designed FCV.

Armijo, Kenneth (ORCID:0000000346832147)↗

Design and proof of concept for targeted phage-based COVID-19 vaccination strategies with a streamlined cold-free supply chain

Significance The COVID-19 pandemic has had an unprecedented impact. Although several vaccines have received emergency use authorization, demand has created enormous logistical challenges—including supply, access, and distribution—that justify research for alternative strategies. Phage are viruses that only infect bacteria and can be safely administered to humans. Here, as a proof-of-concept study, we demonstrate that aerosol vaccination with lung-targeted phage particles displaying short SARS-CoV-2 S protein epitopes and subcutaneous vaccination with targeted AAVP particles carrying the entire S protein gene both elicit systemic and specific immune responses in immunocompetent mice. Given their unique attributes, including sturdiness, simple-to-engineer platform, cost-effectiveness for rapid large-scale production, and stability at room temperature, these phage-based approaches may become attractive tools for COVID-19 vaccine development.

59 BASIC BIOLOGICAL SCIENCES↗

Space Biology Initiative. Trade Studies, volume 1

The six studies which are addressed are entitled: Design Modularity and Commonality; Modification of Existing Hardware (COTS) vs. New Hardware Build Cost Analysis; Automation Cost vs. Crew Utilization; Hardware Miniaturization versus Cost; Space Station Freedom/Spacelab Modules Compatibility vs. Cost; and Prototype Utilization in the Development of Space Hardware. The product of these six studies was intended to provide a knowledge base and methodology that enables equipment produced for the Space Biology Initiative program to meet specific design and functional requirements in the most efficient and cost effective form consistent with overall mission integration parameters. Each study promulgates rules of thumb, formulas, and matrices that serves has a handbook for the use and guidance of designers and engineers in design, development, and procurement of Space Biology Initiative (SBI) hardware and software.

Source record↗

Space Biology Initiative. Trade Studies, volume 2

The six studies which are the subjects of this report are entitled: Design Modularity and Commonality; Modification of Existing Hardware (COTS) vs. New Hardware Build Cost Analysis; Automation Cost vs. Crew Utilization; Hardware Miniaturization versus Cost; Space Station Freedom/Spacelab Modules Compatibility vs. Cost; and Prototype Utilization in the Development of Space Hardware. The product of these six studies was intended to provide a knowledge base and methodology that enables equipment produced for the Space Biology Initiative program to meet specific design and functional requirements in the most efficient and cost effective form consistent with overall mission integration parameters. Each study promulgates rules of thumb, formulas, and matrices that serves as a handbook for the use and guidance of designers and engineers in design, development, and procurement of Space Biology Initiative (SBI) hardware and software.

Source record↗