Low cost ablative heat shields for space shuttles Final report
Fabrication of prototype low density ablative heat shield panels for space shuttles with production cost estimates
Freeder, H.↗
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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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Modeling Flexible Generator Operating Regions via Chance- constrained Stochastic Unit Commitment
Here, we introduce a novel chance-constrained stochastic unit commitment model to address uncertainty in renewables' production uncertainty in power systems operation. For most thermal generators,underlying technical constraints that are universally treated as "hard" by deterministic unit commitment models are in fact based on engineering judgments, such that system operators can periodically request operation outside these limits in non-nominal situations, e.g., to ensure reliability. We incorporate this practical consideration into a chance-constrained stochastic unit commitment model, specifically by in-frequently allowing minor deviations from the minimum and maximum thermal generator power output levels. We demonstrate that an extensive form of our model is computationally tractable for medium-sized power systems given modest numbers of scenarios for renewables' production. We show that the model is able to potentially save significant annual production costs by allowing infrequent and controlled violation of the traditionally hard bounds imposed on thermal generator production limits. Finally, we conduct a sensitivity analysis of optimal solutions to our model under two restricted regimes and observe similar qualitative results.
42 ENGINEERING↗
Bioprocess development and scale-up for cis , cis -muconic acid production from glucose and xylose by Pseudomonas putida
Bioprocess development enhanced muconate titers and productivities from mixed sugars, leading to reduced production costs and a significant decrease in GHG emissions compared to fossil carbon-based adipic acid production. Created with BioRender.com.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Polycrystalline silicon material availability and market pricing outlook for 1980 through 1988
The results of the second JPL update to an original report to assess the availability and prices of polycrystalline Si for solar cells in the 1983-88 interval are reported. It is noted that the demand for poly-Si for solar cells competes with the demand for the same material for semiconductors, although the solar cell industry can use material rejected from the semiconductor industry. A sufficient supply is projected for the 6 yr period, rising from 3224 metric tons to 10,220 metric tons in 1988, with prices dropping from the 1980 level of $140/kg to $25/kg. The price reduction and improved production are noted to be due in large part to DOE efforts at defining lower-cost production processes.
Costogue, E. N.↗
The design-to-cost manifold
A mathematical technique which both quantifies the design-to-cost process and the mass/complexity issue is presented. A simplified approximation of the PRICE H production-production cost is used to generate a dual set of differential equations which define the directions of maximum and minimum cost change over (mass, complexity) space. The equations are solved in closed form to obtain the one-dimensional design-to-cost and design-for-cost spaces. Preliminary results indicate that cost is relatively insensitive to changes in mass and that the reduction of complexity, both in the manufacturing process and in the spacecraft itself, is dominant in reducing cost. Two major objections to the design-to-cost method are discussed.
Dean, Edwin B.↗
2022 System Optimization Awardee: XFlow Energy Company
Vertical-axis wind turbines offer several cost-saving advantages over traditional horizontal-axis wind turbines, including lower blade manufacturing costs and a simpler mechanical design. Unfortunately, until now, vertical configurations have not been able to match the power production and durability of more conventional horizontal-axis models. XFlow Energy Company (XFlow Energy) plans to improve the design and reduce the production costs of its 25-kilowatt (kW) vertical-axis wind turbine, delivering a levelized cost of energy that is competitive with that of U.S. retail electricity generated by coal-fired power plants. XFlow Energy's efficient turbine also is designed to maximize power production and longevity. Two previous Competitiveness Improvement Project (CIP) awards funded XFlow Energy's development of a 10-meter vertical-axis turbine prototype.
CIP↗
Process Feasibility Analysis of Waste Biomass Valorization to Biochar and Bio-Oil via Slow and Fast Pyrolysis
The United States has abundant biomass and waste feedstock to support the nation's energy addition and affordability targets. Pyrolysis, a thermochemical conversion process, decomposes lignocellulosic feedstocks into liquid, solid, and gaseous fuels that can contribute to the domestic production of biofuels, biopower, and bioproducts. Growing private sector interest in this technology is a key motivation for this comprehensive techno-economic process modeling analysis of a respective biorefinery that includes feedstock preprocessing, slow and fast pyrolysis, and product separation to bio-oil, biochar, and syngas hydrocarbons. Results show that biochar from slow pyrolysis could achieve minimum selling prices (MSPs) of $\$$188-$\$$260/t, competitive with reported market values, while bio-oil from fast pyrolysis is estimated to yield MSPs of $\$$6.49-$\$$9.68/GGE, approximately twice conventional fuel benchmarks. Sensitivity analysis identifies feedstock cost, product yield, and scale as primary cost drivers, while scenarios involving biochar carbon credits and high value applications may substantially improve economics. Overall, these results suggest that continued innovation in feedstock logistics, process integration, and market development will be critical to achieving economically viable and scalable bioproducts.
09 BIOMASS FUELS↗
Evaluation of Production Version of the NASA Improved Inorganic-Organic Separator
The technology of an inorganic-organic (I/O) separator, which demonstrated improved flexibility, reduced cost, production feasibility and improved cycle life was developed. Substrates to replace asbestos and waterbased separator coatings to replace the solvent based coatings were investigated. An improved fuel cell grade asbestos sheet was developed and a large scale production capability for the solvent based I/O separator was demonstrated. A cellulose based substrate and a nonwoven polypropylene fiber substrate were evaluated as replacements for the asbestos. Both the cellulose and polypropylene substrates were coated with solvent based and water based coatings to produce a modified I/O separator. The solvent based coatings were modified to produce aqueous separator coatings with acceptable separator properties. A single ply fuel cell grade asbestos with a binder (BTA) was produced. It has shown to be an acceptable substrate for the solvent and water based separator coatings, an acceptable absorber for alkaline cells, and an acceptable matrix for alkaline fuel cells. The original solvent based separator (K19W1), using asbestos as a substrate, was prepared.
Sheibley, D.↗
Multifunctional landscapes for dedicated bioenergy crops lead to low-carbon market-competitive biofuels
Switchgrass is a promising feedstock for cellulosic biorefineries, due to its ability to maintain comparatively high biomass yields across a wide range of soil and climatic conditions. However, there is an incomplete understanding of the economic and environmental tradeoffs associated with cultivating switchgrass on low-productivity land for conversion to biofuels. This study surveys prior literature and demonstrates a new integrated assessment framework, including agroecosystem, ecosystem services valuation, technoeconomic, and life-cycle assessment models, to quantify and contextualize the economic and environmental impacts of switchgrass cultivation on marginal land with downstream conversion to biofuels. Monetizing and incorporating the value of ecosystem services, such as improved water quality benefits from nitrate and sediment reductions, climate change mitigation benefits from CO 2 emission reduction, and recreational and pollination benefits from increased biodiversity, the modeled multifunctional landscape reduces the ethanol production cost by 33.3–58.9 cents/$\scriptsize{L}$-gasoline-equivalent ($\$$1.3–2.2/gge). Planting switchgrass in low productivity land improves soil health, resulting in the carbon footprint reduction credit of 12.8–20.2 gCO 2e /MJ. For an improved switchgrass-to-ethanol conversion pathway with the maximum benefits from ecosystem services, the minimum ethanol selling price and carbon footprint of ethanol, respectively, could reach to 31 cents/$\scriptsize{L}$-gasoline-equivalent (47% reduction relative to average gasoline price) and 3 gCO 2e /MJ (97% reduction relative to gasoline). In conclusion, this low carbon renewable ethanol leads to substantial State and/or Federal policy incentives (~$\$$1/$\scriptsize{L}$-gasoline-equivalent) providing a large benefit to biorefinery operators, farmers, and the public as a whole.
09 BIOMASS FUELS↗
Primary material supply configurations and domestic recycling for cost-effective battery material production in the US
Battery cathode active material costs hinge on regionally concentrated, price-volatile metal supply. Here. we construct a regional facility-level cost model based on over 80 global lithium, cobalt, and nickel mines, refineries, and battery-grade material plants. Our model yields aggregated lithium, nickel, manganese, and cobalt production material costs from 392 region-based supply configurations for five different cathode active materials. Focusing on the United States, all-domestic supply is 9–34% costlier than global average, increasing by cobalt content, while these shortfalls can be overcome by selective low-cost material imports. Furthermore, we analyze costs of two U.S.-based recycling facilities from primary data and techno-economic modelling and compare resulting cathode active material-level costs to primary supply. Although it is still significantly higher on cathode active material cost-level, rising end-of-life flows and lowered black-mass prices will, however, make secondary supply cost-competitive to domestic and foreign primary supply cost floors. Facility-level benchmarks reveal targeted import, scaling, and production cost optimization as levers for a resilient, cost-effective U.S. battery-material supply chain.
Energy↗
Microwave Plasma Flash Pyrolysis for Coal-to-Product Applications
Since 2010, the US coal industry has experienced a precipitous decline, with coal production volumes dropping by as much as 35% according to EIA. This decline is hardly surprising given that 90% of domestic coal use is allocated to electricity production: While coal generation supplied about 45% of the nation's power in 2010, its share is projected to fall to only 22% in 2020. Fortunately, alternative uses for coal as a feedstock rather than as energy source are available. Coal tar is an established feedstock for chemicals and high-value carbon products including carbon fiber and battery-grade graphites. At present, growth of these uses is constrained by the low availability, purity, and yields of currently available coal liquids, and high energy- and CO2-intensity of current methods of production (i.e. coking). Previously reported work conducted in a partnership with Pacific Northwest National Laboratory demonstrated technical and economic viability of flash pyrolysis of coal in a microwave plasma environment at bench scales targeting production of fuel feedstocks (synthetic oil). H Quest’s work since then indicated promise of microwave-derived coal liquids to be uniquely suited for the lower-cost production of carbon materials, including synthetic graphite, carbon fiber, and composites. Low bulk process temperatures, subsecond residence times, and ambient pressure operation enable small-scale deployment, reduce capital and operating costs, and suppress formation of impurities, including QI material, typical in conventional coal tars. With no inherent production of CO2 or water consumption, microwave plasma flash pyrolysis presents a viable route to the sustainable production of both platform chemicals and carbon-based materials. Most recently, H Quest developed a novel, ruggedized microwave plasma reactor, which departs from the proof-of-concept approach and addresses the problems typically encountered in scaling laboratory microwave plasma apparata (e.g. eliminating fragile quartz enclosures prone to coking and fouling). This reactor has been integrated with a 15kW microwave power supply, a pulverized coal injection system, and a product recovery system. A series of screening tests across a range of coals (including hv-, lv-bituminous and subbituminous PRB), entrainment gas flows and compositions and microwave energy inputs are performed to evaluate conversion rates within the novel, scaled-up system, confirm yields of liquid products, and to perform compositional (GC/MS and elemental) analyses of the products. Results of these tests will be presented and discussed.
Skoptsov, George↗
Study of Mechanical Properties, Microstructure, and Residual Stresses of AISI 304/304L Stainless Steel Submerged Arc Weld for Spent Fuel Dry Storage Systems
The confinement boundaries of spent nuclear fuel (SNF) canisters are typically fusion welded. Welded microstructures, strain hardening, and residual stresses combined with a chemically aggressive, chloride-rich environment led to concerns that the welded canister may be susceptible to chloride-induced stress corrosion cracking (CISCC). A comprehensive understanding of the modification of stainless steel (SS) metallurgical and mechanical properties by fusion welding could accelerate the predictive analysis of CISCC susceptibility. This paper describes a submerged arc welding (SAW) procedure that was developed and qualified on 12.7 mm (0.5 in.) thick AISI 304/304L SS to produce joints in a way similar to actual SNF canister manufacturing. This procedure has the potential to reduce the production cost and weld CISCC susceptibility by using fewer welding passes and lower heat input than current industrial applications. Global and local mechanical behaviors and properties, as well as residual stress distributions on the welded joint, were studied. The results indicate that hardness values in the fusion zone (FZ) and heat-affected zone (HAZ) are slightly higher than that of the base metal. Strain localization was presented in the HAZ before the tensile stress reached its maximum value, and then it shifted to the FZ. The specimen finally broke in the FZ. High tensile residual stresses exhibited in the FZ and the nearby HAZ suggest the highest CISCC-susceptible spots. The maximum tensile residual stresses were along the welding direction, indicating that if cracks occur, they would be perpendicular to the welding direction. This study involved developing and qualifying a SAW procedure for SNF canister production. The new procedure yielded cost savings (SAW working efficiency increased by about 80%), improved mechanical properties, and presented moderate residual stresses. Analysis revealed that the welded joint’s low-stress and high-stress damage assessments may be affected by shifts in the strain localization spot under loading.
12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
2022 Standard Scenarios Report: A U.S. Electricity Sector Outlook
This report documents the eighth edition of the annual Standard Scenarios. It summarizes 70 forward-looking scenarios of the U.S. electricity sector that have been designed to capture a wide range of possible futures. In August 2022, the United States Congress passed the Inflation Reduction Act (IRA), a law aimed at accelerating U.S. decarbonization, clean energy manufacturing, and deployment of new power and end-use technologies. This year’s scenarios include representations of the main electricity-sector provisions from IRA and the potential impact on electricity demand. The Standard Scenarios are simulated using the Regional Energy Deployment System (ReEDS) model, which projects utility-scale electricity sector evolution for the contiguous United States using a system-wide, least-cost approach subject to policy and operational constraints. A subset of the scenarios are simulated in the PLEXOS production cost model to obtain a broader suite of metrics at the hourly resolution, which are made available through the National Renewable Energy Laboratory’s (NREL’s) annual Cambium data sets. The scenarios can be viewed and downloaded from NREL’s Scenario Viewer. Annual results are available for the full suite of scenarios in the Standard Scenarios projects in the viewer, whereas the Cambium projects contain hourly data for a subset of scenarios. The Standard Scenarios includes a scenario called the Mid-case, which has central or median values for core inputs such as technology costs and fuel prices, moderately paced demand growth averaging 1.3% per year, and electricity sector policies as they existed in September 2022 (including IRA). The remaining 69 scenarios are created by varying inputs such as technology and fuel prices, resource availability, demand growth, whether nascent generation technologies are allowed, and by introducing national decarbonization constraints.
29 ENERGY PLANNING, POLICY, AND ECONOMY↗
Micro Navigator
Miniature high-performance low-mass space avionics systems are desired for planned future outer planetary exploration missions (i.e. Europa Orbiter/Lander, Pluto-Kuiper Express). The spacecraft fuel and mass requirements enabling orbit insertion is the driving requirement. The Micro Navigator is an integrated autonomous Guidance, Navigation & Control (GN&C)micro-system that would provide the critical avionics function for navigation, pointing, and precision landing. The Micro Navigator hardware and software allow fusion of data from multiple sensors to provide a single integrated vehicle state vector necessary for six degrees of freedom GN&C. The benefits of this MicroNavigator include: 1) The Micro Navigator employs MEMS devices that promise orders of magnitude reductions in mass power and volume of inertial sensors (accelerometers and gyroscopes), celestial sensing devices (startracker, sun sensor), and computing element; 2) The highly integrated nature of the unit will reduce the cost of flight missions. a) The advanced miniaturization technologies employed by the Micro Navigator lend themselves to mass production, and therefore will reduce production cost of spacecraft. b) The integral approach simplifies interface issues associated with discrete components and reduces cost associated with integration and test of multiple components; and 3) The integration of sensors and processing elements into a single unit will allow the Micro Navigator to encapsulate attitude information and determination functions into a single object. This is particularly beneficial for object-oriented software architectures that are used in advanced spacecraft. Additional information is contained in the original extended abstract.
Blaes, B. R.↗
Coal gasification systems engineering and analysis. Appendix D: Cost and economic studies
The detailed cost estimate documentation for the designs prepared in this study are presented. The include: (1) Koppers-Totzek, (2) Texaco (3) Babcock and Wilcox, (4) BGC-Lurgi, and (5) Lurgi. The alternate product cost estimates include: (1) Koppers-Totzek and Texaco single product facilities (methane, methanol, gasoline, hydrogen), (2) Kopers-Totzek SNG and MBG, (3) Kopers-Totzek and Texaco SNG and MBG, and (4) Lurgi-methane and Lurgi-methane and methanol.
Source record↗
Precursor Processing Development for Low Cost, High Strength Carbon Fiber for Composite Overwrapped Pressure Vessel Applications
Carbon fiber (CF) is central to produce lightweight, high pressure, composite overwrapped pressure vessels (COPVs), which are used for on-board storage of hydrogen for fuel cell vehicles. In 2015, carbon fiber cost accounted for 62% of the cost of a hydrogen storage system, as COPVs were manufactured with T700S CF at $\$ $29.40/kg CF. The high cost of hydrogen storage, largely attributed to the carbon fiber cost, limits the application of fuel cells in vehicles. Therefore, our team endeavored to develop fiber processing to demonstrate carbon fiber tensile properties similar to T700S with a production cost potential of $\$ $12.60/kg or less. Here, the overarching goal of the project was the development of low cost, high strength carbon fiber for composite overwrapped pressure vessels. Within the project, our team investigated a new low-cost, high-volume, high quality polyacrylonitrile (PAN)-based precursor terpolymer for the production of carbon fiber precursors, methods for increasing water and energy use efficiency in wash-water/solvent separation, and ultimately developed a multifilament spinning and conversion process for the production of hollow carbon fibers from a segmented arc spinneret utilizing a solution spinning method.
08 HYDROGEN↗
Fabrication of polycrystalline solar cells on low-cost substrates
A new method of producing p-n junction semiconductors for solar cells was described; the principal objective of this investigation is to reduce production costs significantly by depositing polycrystalline silicon on a relatively cheap substrate such as metallurgical-grade silicon, graphite, or steel. The silicon layer contains appropriate dopants, and the substrates are coated with a diffusion barrier of silica, borosilicate, phosphosilicate, or mixtures of these compounds.
Chu, T. L.↗
Technoeconomic and Life Cycle Analysis of an Integrated Fermentation and Microbial Electrochemical Process for Volatile Fatty Acid Production from Food Waste
Techno-economic analysis (TEA) and life cycle assessment (LCA) were conducted for an integrated system designed for the production of volatile fatty acid (VFA) from food waste. The TEA estimated a production cost of $\$$3.12/kg VFA, and the LCA predicted negative greenhouse gas (GHG) emissions of -0.4 kg CO 2 e/kg VFA, driven primarily by diverting organic waste from landfills and avoiding methane emissions while producing valuable chemical products. Hotspot analysis showed arrested methanogenesis (AM) fermentation as the largest contributor to costs (37%) and environmental burden (47%), driven by high sodium hydroxide (NaOH) consumption. Distillation and microbial electrosynthesis (MES) units were the next-largest environmental contributors (28% and 18%). Major cost drivers also included residuals management (biosolids and wastewater) and the equipment and operating costs for AM, MES, and sonication pretreatment units. Although the new integrated system is environmentally benign, its costs and environmental impacts can be further reduced by integrating alternative energy sources, minimizing chemical and energy inputs through process optimization, and improving efficiency. In conclusion, this work highlighted the viability of waste-derived VFA production and provided a clear, data-driven strategy to accelerate the commercialization of waste valorization technology.
Carboxylic Acid Production↗