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At least 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Industrialized and Robotic Construction Advances in Terrestrial Construction and Opportunities in Space Construction

Advanced Building Construction (ABC) methods such as industrialized prefabrication and robotically controlled additive deposition are becoming promising technologies to support rapid construction of buildings at volume and scale. However, apart from the structural shell of the building, optimal integration of other systems – mechanical, electrical, plumbing, thermal, power generation, storage and distribution, is key to enabling functional buildings. Leveraging ABC methods to integrate such systems in the buildings requires the building design to be optimized for constructability constraints imposed by the industrialized and robotically controlled production setups entailing such ABC methods. The Industrialized Construction Innovation (ICI) team at the National Renewable Energy Laboratory (NREL) has been focusing on research and development of such ABC technologies and processes that can lead to production of buildings which are resilient to extreme climatic conditions at reduced cost and time. There is a potential synergy between such advancements in terrestrial construction, which can be leveraged for the benefit of space (orbital and extra-terrestrial) construction. Similarly, advances in space construction can lend itself to accelerated adoption of robotic construction methods in terrestrial construction. This presentation will give an overview of selective research efforts of the ICI team at NREL, along with a vision for potential collaborations with agencies like NASA.

3D printing↗
DOE OSTI2024

To What Extent Will Decarbonization Deepen the Conversation Between Industry and the Grid?

Decarbonization - the transition away from un-mitigated fossil fuel combustion throughout the economy - requires big changes from both power and process systems. On the power system side, those changes are expected to include large increases in variable generation, e.g., from wind and solar, which has near-zero marginal costs and at large shares can produce infrequent but consequential energy droughts. On the process systems side, industries are investigating their options for direct and indirect electrification, the latter exemplified by replacing fossil fuel inputs with zero-carbon, energy-carrying chemicals like hydrogen and ammonia produced via electrochemical processes. The economic features of these changes within the larger context of power and process systems suggest that their realization could be accompanied by a paradigm shift in how industrial facilities interact with the grid. For example, the dominant type of demand participation in power markets could change from today's focus on load reductions at peak times to a new focus on shifting electricity use, enabled in part by large-scale product storage, to take advantage of renewable energy that would otherwise be curtailed and to avoid consumption during high-price energy droughts. This talk will describe these and other possible design and operational approaches from grid and industrial economic perspectives, culminating in an enumeration of open problems that lie at the interface of today and tomorrow's power and process systems.

co-design↗
DOE OSTI2024

Seismic Resilience of Large Power Transformer Bushings & Non-SF6 Industrial Base Scan Review

Large (high voltage) power transformers (LPT), and more specifically, their bushings, are known to be susceptible to seismic failure. With bushing failure, a transformer will have to be replaced, which has a considerable lead time, adding to the power outage duration. Cost-efficient, proven solutions are not currently available to mitigate this risk, which can persist for the more than 30-year life of a particular transformer. This work will focus on developing and demonstrating a hardware solution to address seismic vulnerabilities and reduce outage risks from LPT failure. Sulfur Hexafluoride (SF6) is a specialty gas with excellent electrical insulation properties which has been used extensively in the power industry. This gas is unfortunately also one of the most potent greenhouse gases known to humanity. A 2014 report by the Intergovernmental Panel on Climate Change found that SF6 has a global warming potential (GWP) 23,000 times higher than Carbon Dioxide, and has the highest GWP of all gases assessed (Myhre 2013). SF6 is almost exclusively man-made and is produced for use as an insulator in high voltage electrical equipment. This makes the production and use of SF6 one of the leading sources of anthropogenic climate change. To fully eliminate the environmental impacts of SF6, alternative technology is needed. The ideal replacement would be a technology that can fulfil the same role as SF6, at the same cost or cheaper, but without adverse environmental effects. Currently, no technology fits this description, however several promising technologies have begun to enter the market. An industry scan was performed to assess the state of industry adoption and manufacturing capability for SF6-free alternative technologies for use at the high-voltage level, and the primary barriers to broader adoption.

10 SYNTHETIC FUELS↗
DOE OSTI2022

Grid‐responsive smart manufacturing: A perspective for an interconnected energy future in the industrial sector

Abstract With the growing amount of renewable energy sources, the grid has become responsible for accounting for intermittency and the flexibility needed to utilize dynamic sources. Expensive peaking plants and energy storage systems have been proposed as ways to mitigate those problems. There is a large group of energy consumers that can respond to grid conditions. Historically, these consumers have been residential and commercial users, but with modern innovations and practices, industrial consumers have the potential to become a major player in this space. Grid‐responsive smart manufacturing can be used to utilize modern tools in manufacturing innovation as enablers for grid response. These modern tools already exist but are not widely used for industrial grid‐side energy management. This article defines grid‐responsive smart manufacturing, identifies five major barriers to its widespread implementation, and portrays the path to getting industrial users to be key players in grid stability and flexibility.

Billings, Blake W.↗
DOE OSTI2020

Groundwater characterization and monitoring at a complex industrial waste site using electrical resistivity imaging

A contaminated industrial waste site in Washington State (USA) containing buried, metallic-waste storage tanks, pipes, and wells, was evaluated to determine the feasibility of monitoring groundwater remediation activities associated with an underlying perched aquifer system using electrical resistivity tomography. The perched aquifer, located ~65 m below ground surface and ~10 m above the regional water table, contains high concentrations of nitrate, uranium, and other contaminants of concern from past tank leaks and intentional releases of wastes to surface disposal sites. The extent of the perched water aquifer is not well known, and the effectiveness of groundwater extraction for contaminant removal is uncertain, so supplemental characterization and monitoring technologies are being evaluated. Numerical simulations of subsurface flow and contaminant transport were performed with a highly resolved model of the hydrogeologic system and waste site infrastructure, and these simulations were used as the physical basis for electrical resistivity tomography modeling. The modeling explicitly accounted for metallic infrastructure at the site. The effectiveness of using surface electrodes versus surface and horizontal subsurface electrodes, for imaging groundwater extraction from the perched water aquifer, was investigated. Although directional drilling is a mature technology, its use for electrode emplacement in the deep subsurface under a complex industrial waste site via horizontal wells has not yet been demonstrated. Results from this study indicate that using horizontal subsurface electrode arrays could significantly improve the ability of electrical resistivity tomography to image deep subsurface features and monitor remediation activities under complex industrial waste sites.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Capacity optimization of nuclear power integration to meet dynamic industrial demand

To decarbonize their industrial facilities, The Dow Chemical Company has collaborated with Idaho National Laboratory (INL) to study the integration of nuclear power with an industrial chemical facility. Using Holistic Energy and Resource Optimization Network developed at INL for optimizing and analyzing integrated energy systems, a nuclear microreactor system was sized and evaluated for dynamic dispatch to Dow Silicones Corporation’s Carrollton, KY (USA) site for iloxane production. It was found that a 180 MW th system (12 × 15MW th ) with 75.1 MWh th of thermal energy storage could provide heat and power to the chemical facilities. In the process, this would reduce electricity imports by 99.9 % and reduce the Scope 1 and 2 emissions of the site by 292,100 tonnes CO 2 /yr (98.8 %). The primary novelty of this work is a first of a kind design and optimization of a microreactor powered integrated energy system to provide heat and power to a chemical plant using real plant data. This analysis will pave the way for future studies using dispatchable clean energy sources to reduce carbon emissions and commodity industries’ reliance on fossil fuels.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

JTAG-based PLC memory acquisition framework for industrial control systems

In industrial control systems (ICS), programmable logic controllers (PLC) are the embedded devices that directly control and monitor critical industrial infrastructure processes such as nuclear plants and power grid stations. Cyberattacks often target PLCs to sabotage a physical process. A memory forensic analysis of a suspect PLC can answer questions about an attack, including compromised firmware and manipulation of PLC control logic code and I/O devices. Given physical access to a PLC, collecting forensic information from the PLC memory at the hardware-level is risky and challenging. It may cause the PLC to crash or hang since PLCs have proprietary, legacy hardware with heterogeneous architecture. This paper addresses this research problem and proposes a novel JTAG (Joint Test Action Group)-based framework, Kyros, for reliable PLC memory acquisition. Kyros systematically creates a JTAG profile of a PLC through hardware assessment, JTAG pins identification, memory map creation, and optimizing acquisition parameters. It also facilitates the community of interest (such as ICS owners, operators, and vendors) to develop the JTAG profiles of PLCs. Further, we present a case study of Kyros implementation over Allen-Bradley 1756-A10/B to help understand the framework's application on a real-world PLC used in industry settings. The sample PLC memory dumps are shared with the research community to facilitate further research.

Rais, Muhammad Haris↗
DOE OSTI2022

CTF: A modernized, production-level, thermal hydraulic solver for the solution of industry-relevant challenge problems in pressurized water reactors

CTF is a thermal hydraulic (T/H) subchannel tool that has been extensively developed over the past ten years as part of the Consortium for Advanced Simulation of Light Water Reactors (CASL) program. The code was selected early in the CASL program for support of high-impact challenge problems that were found to be relevant to the nuclear industry and its currently operating fleet of pressurized water reactors (PWRs), including issues such as departure from nucleate boiling (DNB), crud-induced power shifts (CIPSs), and reactivity-insertion accidents (RIAs). By incorporating CTF into the multiphysics Virtual Environment for Reactor Application (VERA) core simulator software developed by CASL, CTF has become the primary means of providing fluid and fuel thermal feedback, as well as T/H figure-of-merits (FOMs) in large-scale reactor simulations. With the goal of solving industry challenge problems, CASL placed great emphasis on developing high-quality, high-performance, validated software tools that offer higher fidelity than what is currently possible with current industry methods. In support of this effort, CTF was developed from a research tool into an nuclear quality assurance (NQA-1)–compliant, production-level software tool that is capable of addressing the stated challenge problems and goals of CASL. This work presents a review of the major technological achievements that were realized in developing CTF over the past decade of the CASL program and presents an overview of the code solution approach and closure models.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Regeneration of anion-exchange resins for cyclic selenium removal from industrial wastewaters

Application of ion exchange for the removal of selenium (Se) oxyanions from industrial wastewaters is often limited by ineffective regeneration of the ion-exchange resins, particularly in complex systems containing competing ions, such as coal-ash leachate containing high-sulfate concentrations and heavy metal ions. Here, in this study, it was first demonstrated that while conventional regeneration with sodium chloride (NaCl) is effective for simulated wastewater, with ∼80% efficiency, NaCl fails to regenerate resin loaded with real industrial wastewater, achieving less than 20% efficiency. To overcome this challenge, a two-step regeneration process was investigated using a sodium carbonate (Na 2 CO 3 ) solution for elution, followed by a NaCl solution for restoration. Compared to the one-step NaCl regeneration, this integrated process restored more than 80% of the resin's capacity with real industrial wastewaters. Beyond demonstrating regeneration performance, this research emphasizes fundamental mechanistic interpretations of the observed regeneration behavior across different water matrices and experimental conditions. Particularly, accounting for pH-dependent carbonate speciation, it is proposed that the elution step exploits the resin's strong affinity for divalent carbonate ions to displace strongly bound contaminants, while the subsequent restoration step relies mainly on the mass action effects of chloride ions to regenerate the resin sites. The protocol was optimized to achieve rapid regeneration (<10 min) using moderate chemical concentrations (0.5 M) in treating real leachate. In batch cyclic experiments, Se regeneration reached nearly complete recovery after five consecutive sorption and desorption cycles, while in the fixed-bed system, the regeneration efficiency remained at approximately 80% after five cycles.

Anion-exchange resin↗
DOE OSTI2025

Evaluating the industrial potential of emerging biomass pretreatment technologies in bioethanol production and lipid recovery from transgenic sugarcane

The selection of pretreatment methods is critical to achieving high product yields during bioconversion of lignocellulosic biomass. Hydrothermal, soaking-in-aqueous ammonia, and ionic liquid pretreatment methods are viable candidates for minimizing sugar decomposition, permitting the effective hydrolysis of structural carbohydrates, and producing a fermentable substrate suitable for achieving industrial ethanol titers and yields. In this study, the effect of these three pretreatment methods on non-modified sugarcane cultivar CP88-1762 and two transgenic lipid-accumulating sugarcane lines, oilcane 1565 and oilcane 1566, were investigated and compared in terms of lipid recovery, sugar yield, and ethanol yields within the lignocellulosic biomass conversion pipeline. Fed-batch enzymatic hydrolysis at high solid loading yielded hydrolysates capable of supporting industrial bioethanol titers across all conditions. The highest sugar yields were obtained on ammonia-pretreated biomass hydrolysate (253.73 g L −1 ), followed by hydrothermally pretreated hydrolysate (213.10 g L −1 ) and ionic liquid-pretreated hydrolysate (154.20 g L −1 ). Commercially viable ethanol titers of 100.62 g L −1 , 64.47 g L −1 , and 52.95 g L −1 were achieved from ammonia, hydrothermal, and ionic liquid pretreated hydrolysate with the corresponding ethanol productivities of 2.08 g L −1 h −1 , 0.53 g L −1 h −1 , and 0.36 g L −1 h −1 . The lower acetic acid concentration in ammonia-pretreated hydrolysate may have enhanced its fermentability relative to the hydrothermal pretreatment condition, as indicated by the differences in ethanol titer and productivity. Lower sugar yields and ethanol productivities under the ionic liquid conditions likely resulted from the inhibitory effect of cholinium lysinate. Oilcane 1565 and oilcane 1566 bagasse accumulated over 16- and 3 times higher lipids than the non-modified sugarcane CP88-1762. The total fatty acid content in the oilcane samples was reduced in ammonia and ionic liquid-pretreated bagasse relative to the hydrothermal pretreatment condition. While all pretreatment techniques tested are industrially viable, the observed differences in titer, productivity, and lipid content indicate that careful selection and validation of upstream processing methods can contribute to improved economic and environmental outcomes.

09 BIOMASS FUELS↗
DOE OSTI2022

Forward-Looking State-of-the-Art Review on Earned Value Management Systems: The Disconnect between Academia and Industry

Earned value management (EVM) is a project management approach that can enhance the probability of project success. It is applied widely across different industry sectors (e.g., energy, aerospace, construction, defense, and manufacturing), generally through the use of an earned value management system (EVMS). A holistic and up-to-date literature review on EVM and EVMS does not exist. A literature review can provide a comprehensive perspective on the topic, identifying and summarizing the existing body of knowledge, as a foundation to advance the state of practice of EVM/EVMS. Therefore, the objective of this paper is to investigate the EVM/EVMS state of the art by critically reviewing academic and industry publications, with a specific focus on the maturity of EVMS and the environment surrounding its implementation. By performing a systematic literature review, the authors identified 600 publications since the inception of the EVM concept in 1962, and then narrowed down this list to 160 relevant publications from the last decade for closer review. The findings include the discovery of eight emergent themes. Of these themes, “forecasting/prediction” constitutes the largest portion of the recent literature, followed by “application of EVMS.” One interesting finding is that EVMS maturity, although being a critical topic, is only discussed in one publication. Publications focused on EVM/EVMS have increased in the last decade and significant differences were found between academia and industry literature in terms of the limitations and extensions of EVM/EVMS, EVMS environment, and compliance. A key finding is that designing a reliable EVMS should combine both technical and social aspects of implementation. This forward-looking paper provides a state-of-the-art review while highlighting gaps in the existing EVM/EVMS body of knowledge and introducing new perspectives to support EVMS research and application.

42 ENGINEERING↗
DOE OSTI2023

Insights from high-fidelity modeling of industrial rotary bell atomization

The global automotive industry sprayed over 2.6 billion liters of paint in 2018, much of which through electrostatic rotary bell atomization, a highly complex process involving the fluid mechanics of rapidly rotating thin films tearing apart into micrometer-thin filaments and droplets. Coating operations account for 65% of the energy usage in a typical automotive assembly plant, representing 10,000s of gigawatt-hours each year in the United States alone. Optimization of these processes would allow for improved robustness, reduced material waste, increased throughput, and significantly reduced energy usage. Here, we introduce a high-fidelity mathematical and algorithmic framework to analyze rotary bell atomization dynamics at industrially relevant conditions. Our approach couples laboratory experiment with the development of robust non-Newtonian fluid models; devises high-order accurate numerical methods to compute the coupled bell, paint, and gas dynamics; and efficiently exploits high-performance supercomputing architectures. These advances have yielded insight into key dynamics, including i) parametric trends in film, sheeting, and filament characteristics as a function of fluid rheology, delivery rates, and bell speed; ii) the impact of nonuniform film thicknesses on atomization performance; and iii) an understanding of spray composition via primary and secondary atomization. These findings result in coating design principles that are poised to improve energy- and cost-efficiency in a wide array of industrial and manufacturing settings.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Utility and Industry Perceptions of Control Room Modernization Over the Last 10 Years

Within the current United States (U.S.) nuclear power fleet, main control room modernization (CRM) is an important step towards cost savings. In recent decades, plants have been engaged in upgrades to varying degrees. This process requires a nuanced, balanced, and timely approach that ensures continued safety and long-term sustainability. In 2012 a survey was issued to individuals from the nuclear industry to learn their perspectives on a range of CRM issues. The survey targeted the benefits and challenges for utilities undertaking this process, including the main drivers and barriers to technology upgrades, regulatory compliance, and the effects these factors have on concepts of operations, strategic approaches, and staffing. In 2022, the survey was issued again to understand whether CRM perceptions had changed in the last 10 years. Our findings identify changes in industry thinking from a decade ago. Here we reveal perspective shifts that represent increased optimism and, in some instances, increased doubt regarding the opportunities and challenges inherent in CRM and implementation. We also report nuanced differences in CRM perspectives between utility and surrounding nuclear industry respondents.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2025

Future Industrial Demand: Large, Elastic, and Concentrated [Guest Editorial]

Here, the future industrial demand on the grid is expected to be large, price sensitive, and concentrated. Grid industrial demand increasingly encompasses a new customer type defined as a large flexible load (LFL). This LFL type defines customers with consumption that responds quickly to price or other incentives without interrupting their core business process, such cryptocurrency mining. This customer type can often ramp up and down quickly, which across an entire industry can mean gigawatts of power within a few minutes. In addition to these price-sensitive loads, significant growth is also anticipated in sectors like manufacturing, data centers, and electrification of transportation and buildings.

Mukherjee, Srijib [Oak Ridge National Laboratory (↗
DOE OSTI2021

The Value of Diversity in the Renewable Energy Industry and Research Community

Part of creating a successful solar industry is developing a capable workforce. It has been repeatedly shown that organizations and companies are more productive when they have diverse and inclusive cultures. The solar industry in the U.S. performs well in some aspects (non-white workforce, positive work environment) but drastically under-performs in many others. We discuss these metrics and how this impacts the renewable energy industry and the solar research community. We highlight some initial actions which are necessary to begin to remediate these deficiencies, such as demographic tracking, recruiting strategies, and mentoring. We also present the historical and ongoing efforts to improve the diversity and inclusion of the Photovoltaic Specialists Conference, particularly through the work of this year’s Diversity and Inclusion (D&I) oversight committee. This year’s D&I committee is implementing diversity tracking, a women’s lunch, a diversity lunch, childcare resources, pronouns on badges, gender-neutral restrooms, addressing accessibility issues, and publishing a diversity statement and code of conduct to the PVSC website.

diversity↗
DOE OSTI2021

Energy, Exergy, and Emission Analysis on Industrial Air Compressors

Abstract Air compressors, a key fluid power technology, play an essential role in industrial plants and office buildings, hospitals, and other types of facilities. The efficient use of the air compressor is crucial. By controlling unnecessary inefficiencies, high energy consumption can be reduced. This study aims to provide energy and exergy analysis on air compressors for different industries. Detailed case studies were also analyzed. The case study focuses on the energy and exergy analyses of the compressed air system of foundry industries. The results indicate that applying the six improvement recommendations yields significant amounts of energy and cost savings and significant improvements in the system's overall performance. The payback periods for different recommendations are economically feasible and worthwhile to use. The suggested improvement methods can provide cost savings with a low payback period.

Energy & Fuels↗
DOE OSTI2021

Techno-Economic Impact Assessments of Energy Efficiency Improvements in the Industrial Combustion Systems

Industrial energy efficiency assessments not only provide benefits to manufacturers but also generate significant economic and environmental benefits to localities, states, and the nation through indirect and induced benefits. Quantifying these benefits requires a systematic economic framework for capturing these interactions. This article employs methodologies for improving the energy efficiency of small- and medium-sized industry through their combustion systems. Combustion systems offer large opportunities to enhance energy efficiency through adopting advanced technologies and better-informed operations. The case studies presented illuminate the potential savings and impacts from implementing energy-efficient combustion recommendations and the importance of energy audits and energy efficiency in the fight against climate change. This study describes and quantifies the cascading economic and environmental impacts of implementing the industrial energy efficiency recommendations offered by an energy auditing program by participating facilities over a 10-year period. Results showed that it is expected that a total of $185 M would be saved in energy costs, and 2.3 million metric tons of carbon dioxide emissions would be avoided annually, and about 972 jobs could be created in the studied region if all the combustion recommendations would be implemented. Furthermore, the broader view afforded by the proposed study can be used to support better energy-efficient practices in manufacturing facilities, communities, and states.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Pinned Clouds over Industrial Sources of Heat during TRACER

An analysis of stereo-camera data from the Tracking Aerosol Convection Interactions Experiment (TRACER) campaign in Houston, Texas, reveals the existence of pinned clouds sitting atop industrial heat sources. These are not plumes of vapor and condensate emanating from stacks: The pinned shallow cumuli have cloud bases at about the lifting condensation of near-surface air. On many mornings, the pinned clouds are the only shallow cumuli in the field of view of the stereo cameras, persisting by themselves for at least an hour. On those mornings, the lower atmosphere straddles the boundary between stable and unstable, and the waste heat from industrial facilities is able to pin moist convection overhead. When solar heating of the surface becomes sufficient later in the morning, those mornings transition to having widespread shallow moist convection. Occurring within the field of view of the stereo cameras and other TRACER instruments, these pinned clouds represent steady plume-like moist convection triggered by known heat sources in a well-characterized atmosphere, making them a rich target for further study. Significance Statement This article introduces steady-state cumulus clouds observed during the Tracking Aerosol Convection Interactions Experiment (TRACER) campaign that were pinned to industrial heat sources. These pinned clouds were present in the early morning only when conditions were primed for moist convection, but for which there was not yet enough solar heating to trigger widespread convection. They persist in a statistical steady state and therefore provide a natural setting to explore the mechanisms controlling convective dynamics, which play a central role in Earth’s atmospheric circulation and radiative balance.

Atmosphere↗