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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 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
NASA NTRS2015

Update on Risk Reduction Activities for a Liquid Advanced Booster for NASA's Space Launch System

The stated goals of NASA's Research Announcement for the Space Launch System (SLS) Advanced Booster Engineering Demonstration and/or Risk Reduction (ABEDRR) are to reduce risks leading to an affordable Advanced Booster that meets the evolved capabilities of SLS; and enable competition by mitigating targeted Advanced Booster risks to enhance SLS affordability. Dynetics, Inc. and Aerojet Rocketdyne (AR) formed a team to offer a wide-ranging set of risk reduction activities and full-scale, system-level demonstrations that support NASA's ABEDRR goals. For NASA's SLS ABEDRR procurement, Dynetics and AR formed a team to offer a series of full-scale risk mitigation hardware demonstrations for an affordable booster approach that meets the evolved capabilities of the SLS. To establish a basis for the risk reduction activities, the Dynetics Team developed a booster design that takes advantage of the flight-proven Apollo-Saturn F-1. Using NASA's vehicle assumptions for the SLS Block 2, a two-engine, F-1-based booster design delivers 150 mT (331 klbm) payload to LEO, 20 mT (44 klbm) above NASA's requirements. This enables a low-cost, robust approach to structural design. During the ABEDRR effort, the Dynetics Team has modified proven Apollo-Saturn components and subsystems to improve affordability and reliability (e.g., reduce parts counts, touch labor, or use lower cost manufacturing processes and materials). The team has built hardware to validate production costs and completed tests to demonstrate it can meet performance requirements. State-of-the-art manufacturing and processing techniques have been applied to the heritage F-1, resulting in a low recurring cost engine while retaining the benefits of Apollo-era experience. NASA test facilities have been used to perform low-cost risk-reduction engine testing. In early 2014, NASA and the Dynetics Team agreed to move additional large liquid oxygen/kerosene engine work under Dynetics' ABEDRR contract. Also led by AR, the objectives of this work are to demonstrate combustion stability and measure performance of a 500,000 lbf class Oxidizer-Rich Staged Combustion (ORSC) cycle main injector. A trade study was completed to investigate the feasibility, cost effectiveness, and technical maturity of a domestically produced Atlas V engine that could also potentially satisfy NASA SLS payload-to-orbit requirements via an advanced booster application. Engine physical dimensions and performance parameters resulting from this study provide the system level requirements for the ORSC risk reduction test article. The test article is scheduled to complete critical design review this fall and begin testing in 2017. Dynetics has also designed, developed, and built innovative tank and structure assemblies using friction stir welding to leverage recent NASA investments in manufacturing tools, facilities, and processes, significantly reducing development and recurring costs. The full-scale cryotank assembly was used to verify the structural design and prove affordable processes. Dynetics performed hydrostatic and cryothermal proof tests on the assembly to verify the assembly meets performance requirements. This paper will discuss the ABEDRR engine task and structures task achievements to date and the remaining effort through the end of the contract.

Crocker, Andrew M.↗
NASA NTRS2017

Update on Risk Reduction Activities for a Liquid Advanced Booster for NASA's Space Launch System

The stated goals of NASA's Research Announcement for the Space Launch System (SLS) Advanced Booster Engineering Demonstration and/or Risk Reduction (ABEDRR) are to reduce risks leading to an affordable Advanced Booster that meets the evolved capabilities of SLS and enable competition by mitigating targeted Advanced Booster risks to enhance SLS affordability. Dynetics, Inc. and Aerojet Rocketdyne (AR) formed a team to offer a wide-ranging set of risk reduction activities and full-scale, system-level demonstrations that support NASA's ABEDRR goals. During the ABEDRR effort, the Dynetics Team has modified flight-proven Apollo-Saturn F-1 engine components and subsystems to improve affordability and reliability (e.g., reduce parts counts, touch labor, or use lower cost manufacturing processes and materials). The team has built hardware to validate production costs and completed tests to demonstrate it can meet performance requirements. State-of-the-art manufacturing and processing techniques have been applied to the heritage F-1, resulting in a low recurring cost engine while retaining the benefits of Apollo-era experience. NASA test facilities have been used to perform low-cost risk-reduction engine testing. In early 2014, NASA and the Dynetics Team agreed to move additional large liquid oxygen/kerosene engine work under Dynetics' ABEDRR contract. Also led by AR, the objectives of this work are to demonstrate combustion stability and measure performance of a 500,000 lbf class Oxidizer-Rich Staged Combustion (ORSC) cycle main injector. A trade study was completed to investigate the feasibility, cost effectiveness, and technical maturity of a domestically-produced engine that could potentially both replace the RD-180 on Atlas V and satisfy NASA SLS payload-to-orbit requirements via an advanced booster application. Engine physical dimensions and performance parameters resulting from this study provide the system level requirements for the ORSC risk reduction test article. The test article is scheduled to complete fabrication and assembly soon and continue testing through late 2019. Dynetics has also designed, developed, and built innovative tank and structure assemblies using friction stir welding to leverage recent NASA investments in manufacturing tools, facilities, and processes, significantly reducing development and recurring costs. The full-scale cryotank assembly was used to verify the structural design and prove affordable processes. Dynetics performed hydrostatic and cryothermal proof tests on the assembly to verify the assembly meets performance requirements..

Crocker, Andrew M.↗
NASA NTRS1992

Process comparison study. MSFC Center Director's Discretionary Fund (CDDF)

A process comparison study was conducted using four different advanced manufacturing techniques to fabricate a composite solid rocket booster systems tunnel cover. Costs and labor hours were tracked to provide the comparison between the processes. A relative structural comparison of the components is also included. The processes utilized included filament winding, pultrusion, automated tape laying, and thermoplastic thermoforming. The hand layup technique is also compared. Of the four advanced processes evaluated, the thermoformed thermoplastic component resulted in the least total cost. The automated tape laying and filament winding techniques closely followed the thermoplastic component in terms of total cost; and, these techniques show the most promise for high quality components and lower production costs. The pultruded component, with its expensive tooling and material requirements, was by far the most expensive process evaluated, although the results obtained would not be representative of large production runs.

Golden, T.↗
DOE OSTI2023

Potential Availability of and Supply Curves for Low-Cost, Dispatch-Constrained Electricity

Among other changes, variable renewable energy (VRE) - primarily wind and solar photovoltaics - is achieving a growing share of total generation. High VRE penetrations may result in an increased level of curtailment and thus suppress the value of additional VRE. This VRE, that either would not be built due to price suppression or would be curtailed, can be considered a resource that we define as low-cost, dispatch-constrained electricity (LDE). LDE could be used for various applications which value low-cost electricity and can operate at reduced capacity factors. Examples include electrolytic hydrogen production and carbon capture. This report provides initial estimates of the quantity and availability of the potential LDE resource in the U.S. under scenarios with high VRE penetrations. It also provides supply curves that can be used in subsequent analysis of the opportunity to use the LDE. We modeled several scenarios using capacity expansion and production cost models for LDE prices ranging from $\$ $0/MWh to $\$ $30/MWh. These LDE prices, coupled with low renewable energy cost assumptions, resulted in VRE penetrations ranging from 48-66% in 2050. The resulting LDE supplies range from 100 - 300 TWh/yr at a price of $\$ $0/MWh to 3,500 - 4,200 TWh/yr at $\$ $30/MWh. Increasing LDE prices increases wind and photovoltaics deployment; however, other generation technology capacities do not decrease equivalently in our models. Thus, additional generation is available but the capacity of traditional dispatchable generation is only reduced slightly. The available LDE is concentrated in the central and southwest U.S. regions because of their high wind and solar resources.

24 POWER TRANSMISSION AND DISTRIBUTION↗
NASA NTRS1981

The small community solar thermal power experiment. Parabolic dish technology for industrial process heat application

Aspects of incorporating a thermal energy transport system (ETS) into a field of parabolic dish collectors for industrial process heat (IPH) applications were investigated. Specific objectives are to: (1) verify the mathematical optimization of pipe diameters and insulation thicknesses calculated by a computer code; (2) verify the cost model for pipe network costs using conventional pipe network construction; (3) develop a design and the associated production costs for incorporating risers and downcomers on a low cost concentrator (LCC); (4) investigate the cost reduction of using unconventional pipe construction technology. The pipe network design and costs for a particular IPH application, specifically solar thermally enhanced oil recovery (STEOR) are analyzed. The application involves the hybrid operation of a solar powered steam generator in conjunction with a steam generator using fossil fuels to generate STEOR steam for wells. It is concluded that the STEOR application provides a baseline pipe network geometry used for optimization studies of pipe diameter and insulation thickness, and for development of comparative cost data, and operating parameters for the design of riser/downcomer modifications to the low cost concentrator.

Polzien, R. E.↗
DOE OSTI2021

Techno-economic analysis of hydroprocessed renewable jet fuel production from pennycress oilseed

Commercial production of jet fuel from biobased feedstocks is still encumbering, mainly due to their high production cost and competition with food resources. Pennycress oilseed is a potential jet fuel feedstock which can be supplied at a lower price compared to similar oilseeds, such as soybean and canola. However, the technoeconomics of pennycress-based jet fuel production needs to be evaluated. The objective of this study was to assess the technical feasibility and costs of hydroprocessed renewable jet fuel (HRJ) production from pennycress. The production capacity was considered to be 18.9 million L/yr (5 million gal/yr). The analysis considered pennycress grain handling and conditioning, oil extraction and conversion to HRJ and byproducts, i.e., LPG, naphtha and green diesel, through hydroprocessing technology, as well as pennycress meal processing as boiler fuel and wastewater treatment. Total investment for establishing the HRJ biorefinery at the selected capacity was estimated to be 90.8 million USD. Minimum selling price (MSP) of HRJ was estimated to be 1.2 USD/L, which was comparable to the MSP of HRJ from similar oilseeds, including soybean and canola. It could also be further reduced by supplying pennycress grain at a lower price, increasing the oil content and increasing the production capacity of the biorefinery. Furthermore, the outcomes of this research would help establish the performance targets needed to reach the economic viability of HRJ production from pennycress at the commercial scale.

09 BIOMASS FUELS↗
DOE OSTI2022

Analysis of Multi-Output Hybrid Energy Systems Interacting with the Grid: Application of Improved Price-Taker and Price-Maker Approaches to Nuclear-Hydrogen Systems

The growing recognition of the value of hydrogen as an energy intermediate in supporting future power systems with high shares of variable renewable energy has prompted many studies to quantify the economic potential of multi-output hybrid systems, which are one type of integrated energy systems (IES). Because of the complexity of modeling multiple sectors, these studies typically use simplified modeling approaches to capture the interactions between sectors. In this study, we explore the implications of alternative modeling approaches for nuclear-hydrogen IES focusing on a power system in the Midwest United States. We combine highly resolved capacity expansion and production cost modeling tools of the power system with a detailed hydrogen system optimization tool to determine the optimal electrolyzer and storage sizing and optimal operations of the nuclear-hydrogen hybrid resource across three future study years. We compare economic and operational outcomes across a spectrum of modeling approaches, including a non-hybridized base approach; a traditional price-taker approach that does not include the impact of hydrogen production on the electricity system; a power-system-focused price-maker approach that does not account for temporal hydrogen constraints; and two improved price-taker and price-maker approaches that each address the impact of revenue-optimal levels of electricity production on the resulting power system and temporal hydrogen constraints on the overall feasible solution. Results show how a traditional price-taker approach can overestimate the economic benefits of multi-output nuclear-hydrogen IES compared to our two improved approaches that estimate both hydrogen system constraints and power system interaction. We find that hydrogen output requirements and storage size limits are key drivers to overall operations and some economic outcomes. Under our assumed constant hydrogen output requirement, storage costs, test system, and modeling approaches, our results indicate that hybridization can provide a net benefit, but results are sensitive to the treatment of hydrogen revenues and electricity prices as impacted by the power system evolution.

capacity expansion modeling↗
DOE OSTI2023

Customization for Current Market Applications of the Carbon Nanotubes Produced by PNNL’s Regenerable Catalytic Pyrolysis (ReCaP) for Scaled Hydrogen Production

Here, we demonstrated the Regenerative Catalytic Pyrolysis (ReCaP) process that generates carbon dioxide-free hydrogen (CO 2 -free H 2 ) from inexpensive and domestically abundant natural gas (NG), while simultaneously producing H 2 at net production cost of $1.0/kg through the sale of valuable carbon nanotube (CNT) co-product. The specific goal of this project is to 1) scale up the production of CNT, 2) correlate the properties of the CNT with the reaction conditions, 3) perform a techno-economic analysis to obtain minimum selling price of H 2 and CNT, and 4) identify industrial partners interested in the CNT co-product.

03 NATURAL GAS↗
DOE OSTI2024

Methane Pyrolysis for CO2-free H2 and Carbon Nanomaterials - CRADA 576 (Final Report)

In this CRADA project we continued to develop the Pacific Northwest National Laboratory (PNNL) patent-pending Regenerable Catalytic Pyrolysis (ReCaP) process technology for producing CO 2 -free hydrogen (H 2 ) from inexpensive and domestically-abundant natural gas (NG), while simultaneously reducing H 2 ’s net production cost to $\$$1.0/kg through the sale of valuable crystalline solid carbon co-product. Producing clean hydrogen at this price is a DOE Hydrogen Energy Earthshot goal. This effort builds on our prior catalyst and processing advances made thermocatalytic decomposition of methane (TCD). The additional scope performed here accelerated the commercial deployment of TCD for CO 2 -free H 2 and valuable solid carbon nanotubes (CNT) co-product, by i) scaling up the production of CNT co-product using a fluidized bed reactor (25 g catalyst scale versus the 1 g catalyst scale demonstrated prior), ii) producing approximately 1 kg of CNT byproduct, produced via multiple cycles of TCD, carbon-catalyst separation, and catalyst re-synthesis, to enable the production of sufficient quantities of solid carbon so as to explore its market potential, iii) understanding the quality of the co-product CNTs, produced at larger scale, using advanced characterization, and iv) beginning to explore multiple promising high volume carbon product applications (e.g., aluminum and polymer composites, steel additive, and cement reinforcement applications). We are in discussions with Department of Energy and potential commercial partners to continue funding of this effort with the goal to facilitate eventual commercial deployment.

08 HYDROGEN↗
NASA NTRS1973

Conclusions and recommendations

Conclusions and recommendations are presented for an analysis of the total energy situation; the effect of the energy problem on air transportation; and hydrogen fuel for aircraft. Properties and production costs of fuels, future prediction for energy and transportation, and economic aspects of hydrogen production are appended.

Source record↗
NASA NTRS1997

Technology Needs for Reduced Design and Manufacturing Cost of Commercial Transport Engines

The objective of the study was to assess the needs in the design and manufacturing processes and identify areas where technology could impact in cost and cycle-time reduction. At the highest level, the team first identified the goals that were in line with long-range needs of the aeropropulsion industry, and to which technology and process improvements would be required to contribute. These goals are to reduce the time and costs in the development cycle of aircraft engines by a factor of two, reduce production cycle time by a factor of four, and to reduce production costs by 25%. Also, it was the intent of the team to identify the highest impact technologies that could be developed and demonstrated in five years.

Rohn, Douglas A.↗
DOE OSTI2024

Representative Period Selection for Robust Capacity Expansion Planning in Low-carbon Grids

With the increasing urgency to decarbonize power systems, while mitigating extreme events, capacity expansion models can play a vital role in reliably planning the expansion of power systems and facilitating the integration of renewable energy sources. Optimizing capacity expansion generally involves selecting surrogate representative days from forecasts of load and the generation profiles of variable renewable energy resources. To properly select those representative days, we propose a novel input-based approach in combination with the k-means clustering algorithm that utilize three unique operational inputs: load shedding, renewable curtailment, and transmission congestion. The proposed method allows for more robust and cost-effective capacity planning. The method is validated using a capacity expansion model and a production cost model based on California Independent System Operator (CAISO)'s decarbonization goals, and results in reduced costs and drastically lower load shedding.

Anderson, Osten P.↗
DOE OSTI2022

Market Analysis: Upcycling Natural Gas Into Solid Carbon Products

The purpose of this report is to execute a market analysis to determine the potential market opportunities for natural gas-derived high-value carbon products and their associated applications. Currently, associated gas is released through the process of either venting or flaring. Vented or flared natural gas is presently lost to the atmosphere, despite the fact that it represents a significant resource of both carbon and hydrogen—two products that could have significant value. Transforming some of this underutilized supply into high-cost products could contribute to realizing the full value of United States (U.S.) natural gas resources. The products analyzed in this report are carbon fiber, carbon nanotubes, synthetic graphite, and carbon black. The report also touches on the market opportunities for hydrogen, a by-product of the pyrolysis process.

03 NATURAL GAS↗
DOE OSTI2022

Multiplication of freestanding III-V semiconductor membranes from a single wafer by alternating growth with amorphous graphene interlayer

Freestanding single-crystalline III-V compound semiconductors are important building blocks for functional devices due to their high electron mobilities, a wide range of bandgaps, and excellent optoelectronic properties. Despite efforts to produce such membranes by detaching epitaxial layers from donor wafers, current methods suffer from either slow processes or poor material quality. Here, we demonstrate a technique to grow and harvest multiple epitaxial membranes with extremely high throughput at the wafer scale. For this, a process to directly grow amorphous graphene on III-V substrates in metal-organic chemical vapor deposition reactors is developed, which enables an advanced remote epitaxy scheme comprised of multiple alternating layers of amorphous graphene and III-V epitaxial layers that can be formed by a single epitaxy run. Each epilayer in the multi-stack structure is then harvested by layer-by-layer peeling, producing multiple freestanding membranes with unprecedented throughput from a single wafer. Because amorphous graphene provides a weak van der Waals interface that allows peeling at the interface without damaging the epilayer or the substrate, wafers can be reused for subsequent membrane production. Therefore, this work represents a meaningful step toward high-throughput and low-cost production of single-crystal membranes that can be heterointegrated.

Han, Ne Myo↗
NASA NTRS2019

Blind Validation Study of Parametric Cost Estimation Tool SEER-H for NASA Space Missions

One of the primary parametric cost modeling tools used by NASA and the aerospace industry to estimate the development and production cost of future spacecraft hardware is SEER-H by Galorath. To date, no independent validation of this tool for cost estimation of space missions has been reported in the literature. In the present validation study, cost estimators used SEER-H to estimate the cost of twelve different past NASA science missions. The estimators were prevented from knowing the actual cost of the missions in an effort to minimize cognitive biases. The point estimates of SEER-H had an average error of 23%, median error of -0.3%, and a standard deviation of 43%. Nine of the twelve mission's actual costs fell within the 80% confidence interval of SEER's probabilistic estimates. Several factors independent of SEER that may have affected the accuracy of the results have been identified and are discussed; these include: uncertainty in the technical data used for the estimates, the methods used to estimate uncertainty in spacecraft component mass and numbers of prototypes, and the experience of the estimators.

SEER-H↗
DOE OSTI2022

Multiplication of freestanding III-V semiconductor membranes from a single wafer by alternating growth with amorphous graphene interlayer

Freestanding single-crystalline III-V compound semiconductors are important building blocks for functional devices due to their high electron mobilities, a wide range of bandgaps, and excellent optoelectronic properties. Despite efforts to produce such membranes by detaching epitaxial layers from donor wafers, current methods suffer from either slow processes or poor material quality. Here, we demonstrate a technique to grow and harvest multiple epitaxial membranes with extremely high throughput at the wafer scale. For this, a process to directly grow amorphous graphene on III-V substrates in metal-organic chemical vapor deposition reactors is developed, which enables an advanced remote epitaxy scheme comprised of multiple alternating layers of amorphous graphene and III-V epitaxial layers that can be formed by a single epitaxy run. Each epilayer in the multi-stack structure is then harvested by layer-by-layer peeling, producing multiple freestanding membranes with unprecedented throughput from a single wafer. Because amorphous graphene provides a weak van der Waals interface that allows peeling at the interface without damaging the epilayer or the substrate, wafers can be reused for subsequent membrane production. Therefore, this work represents a meaningful step toward high-throughput and low-cost production of single-crystal membranes that can be heterointegrated.

Han, Ne Myo↗