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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 307 records · Page 17

Machine learning for surrogate process models of bioproduction pathways

Technoeconomic analysis and life-cycle assessment are critical to guiding and prioritizing bench-scale experiments and to evaluating economic and environmental performance of biofuel or biochemical production processes at scale. Traditionally, commercial process simulation tools have been used to develop detailed models for these purposes. However, developing and running such models can be costly and computationally intensive, which limits the degree to which they can be shared and reproduced in the broader research community. This study evaluates the potential of an automated machine learning approach to develop surrogate models based on conventional process simulation models. The analysis focuses on several high-value biofuels and bioproducts for which pathways of production from biomass feedstocks have been well-established. The results demonstrate that surrogate models can be an accurate and effective tool for approximating the cost, mass and energy balance outputs of more complex process simulations at a fraction of the computational expense.

09 BIOMASS FUELS↗

Process Intensification for the Biological Production of the Fuel Precursor Butyric Acid from Biomass

The production of fuels from lignocellulosic biomass is key to reduce our reliance on petroleum and to promote a sustainable bioeconomy. Butyric acid (BA) is a promising chemical precursor for the production of renewable diesel and jet fuels. BA can be biologically produced from lignocellulosic sugars. However, challenges associated with product selectivity and recovery must be overcome to achieve industrially relevant metrics. Here, we evaluate various fermentation configurations and demonstrate near-homo-butyrate production by using the biocatalyst Clostridium tyrobutyricum. We also develop an advanced in situ product recovery process based on hybrid extraction-distillation (HED-ISPR) and conduct techno-economic analyses and life cycle assessments. We demonstrate that the HED-ISPR process lowers the overall capital and operating expenses and environmental impact compared to other traditional fermentation processes. Overall, BA minimum product selling price from biomass is 55% of the current BA selling price from petroleum, a significant decrease toward viable renewable fuel production.

09 BIOMASS FUELS↗

Low cost silicon solar array project silicon materials task

A program was established to develop a high temperature silicon production process using existing electric arc heater technology. Silicon tetrachloride and a reductant will be injected into an arc heated mixture of hydrogen and argon. Under these high temperature conditions, a very rapid reaction is expected to occur and proceed essentially to completion, yielding silicon and gaseous sodium chloride. Techniques for high temperature separation and collection of the molten silicon will be developed using standard engineering approaches, and the salt vapor will later be electrolytically separated into its elemental constituents for recycle. Preliminary technical evaluations and economic projections indicate not only that this process appears to be feasible, but that it also has the advantages of rapid, high capacity production of good quality molten silicon at a nominal cost.

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Tribocharging Lunar Soil for Electrostatic Beneficiation

Future human lunar habitation requires using in situ materials for both structural components and oxygen production. Lunar bases must be constructed from thermal-and radiation-shielding materials that will provide significant protection from the harmful cosmic energy which normally bombards the lunar surface. In addition, shipping oxygen from Earth is weight-prohibitive, and therefore investigating the production of breathable oxygen from oxidized mineral components is a major ongoing NASA research initiative. Lunar regolith may meet the needs for both structural protection and oxygen production. Already a number of oxygen production technologies are being tested, and full-scale bricks made of lunar simulant have been sintered. The beneficiation, or separation, of lunar minerals into a refined industrial feedstock could make production processes more efficient, requiring less energy to operate and maintain and producing higher-performance end products. The method of electrostatic beneficiation used in this research charges mineral powders (lunar simulant) by contact with materials of a different composition. The simulant acquires either a positive or negative charge depending upon its composition relative to the charging material.

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A production parylene coating process for hybrid microcircuits

The real impetus for developing a production parylene coating process for internal hybrid passivation came as a result of the possibility of loose conductive particles in hybrid microelectronic circuits, causing intermittent and sometimes permanent failures. Because of the excellent mechanical properties of parylene, it is capable of securing the loose particles in place and prevent such failures. The process of coating described consists of (1) vaporizing the initial charge, which is in the form of a dimer; (2) conversion of the dimer into a reactive monomer; and (3) deposition and subsequent polymerization of the monomer in the deposition chamber which forms a uniform parylene film over all the cold surfaces in contact. Experimental results are discussed in terms of wire bond reliability, resistor drift, high-temperature storage characteristics of parylene, and coating acceptance standards. It is concluded that internal cavities of microelectronic circuits can be successfully coated with parylene provided appropriate tooling is used to protect external leads from the parylene monomer.

Kale, V. S.↗

Visualizing Progress

Reality Capture Technologies, Inc. is a spinoff company from Ames Research Center. Offering e-business solutions for optimizing management, design and production processes, RCT uses visual collaboration environments (VCEs) such as those used to prepare the Mars Pathfinder mission.The product, 4-D Reality Framework, allows multiple users from different locations to manage and share data. The insurance industry is one targeted commercial application for this technology.

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Towards low-carbon low-energy concrete alternatives: Life cycle assessment of carbonated cementitious material-based precast panels

Cement is responsible for 22 % of all global CO 2 emissions from industrial processes. Technological innovation for developing and deploying of alternative materials will be required to decarbonize the cement industry. Carbonated cementitious materials (CCMs) are building materials that rely on carbon mineralization for their strength. A process-based cradle-to-gate life cycle assessment (LCA) was conducted to evaluate the global warming potential (GWP), cumulative energy demand, and water consumption of a lab-scale CCM-based precast panel compared to a conventional precast concrete panel. Since the CCM process is currently a lab-scale early-stage process, the CCM panel showed higher environmental impacts compared to the conventional panel. However, scenario analyses include mature production process scenarios. In conclusion, a sensitivity analysis revealed that the GWP of CCM can be lowered to below that of the conventional panel using polymers, fillers, low-carbon electricity sources, and optimized carbonation parameters.

36 MATERIALS SCIENCE↗

Carbon-negative production of acetone and isopropanol by gas fermentation at industrial pilot scale

Many industrial chemicals that are produced from fossil resources could be manufactured more sustainably through fermentation. In this work, we describe the development of a carbon-negative fermentation route to producing the industrially important chemicals acetone and isopropanol from abundant, low-cost waste gas feedstocks, such as industrial emissions and syngas. Using a combinatorial pathway library approach, we first mined a historical industrial strain collection for superior enzymes that we used to engineer the autotrophic acetogen Clostridium autoethanogenum. Next, we used omics analysis, kinetic modeling and cell-free prototyping to optimize flux. Finally, we scaled-up our optimized strains for continuous production at rates of up to ~3 g/L/h and ~90% selectivity. Life cycle analysis confirmed a negative carbon footprint for the products. Unlike traditional production processes, which result in release of greenhouse gases, our process fixes carbon. These results show that engineered acetogens enable sustainable, high-efficiency, high-selectivity chemicals production. We expect that our approach can be readily adapted to a wide range of commodity chemicals.

59 BASIC BIOLOGICAL SCIENCES↗

HydroGEN Seedling: High-Temperature Reactor Catalyst Material Development for Low-Cost and Efficient Solar-Driven Sulfur-Based Processes

The HyS process, driven by solar power, has great potential to reach high-efficiency and low-cost hydrogen production without greenhouse gas emissions. The high-temperature section of the HyS cycle, which operates the catalytic decomposition of sulfuric acid into sulfur dioxide, oxygen, and water, is a fundamental part of the cycle affecting the overall plant efficiency and cost. Therefore, a high-performance catalyst (i.e., low cost, high catalytic activity, and low degradation catalyst) is of critical importance to achieve high efficiency and low hydrogen cost. Research and development has highlighted that a Pt-based monometallic catalyst had unacceptable catalytic activity and performance degradation for a high-efficiency and low-cost hydrogen production process. A high-efficiency solar receiver-reactor system, which incorporates the new catalyst, also needs to be developed to achieve the required plant efficiency and cost. Greenway Energy (GWE) and the University of South Carolina (USC), partnering with HydroGEN node laboratories Idaho National Laboratory (INL), Savannah River National Laboratory (SRNL), and National Renewable Energy Laboratory (NREL), propose the development of a new catalyst formulation, included in a novel solar receiver-reactor concept, to be tested experimentally in the last part of the project.

08 HYDROGEN↗

Improved Models of R Coronae Borealis Stars

We present an improved numerical method to model subsolar He+CO-WD merger progenitors of R Corona Borealis stars that builds on our previous work. These improvements include a smooth entropy transition from the core to the envelope of the post-merger, inclusion of single-zone nucleosynthesis to mimic the effects of burning during the merger event, and post-processing the models with a larger nuclear network for analysis of s-process nucleosynthesis. We perform a parameter study to understand the effects of the entropy transition, peak temperature, and overshooting on our models. The models that best agree with observations of R Corona Borealis stars are processed with a much larger nuclear network to investigate s-process nucleosynthesis and the dredge-up of s-process products into the outer envelope in detail. We present a model with a significant enhancement in s-process elements, which also agrees with observed surface abundances and isotopic ratios of 16 O/ 16 O and C/O between 1 and 10. Finally, we find that the neutron exposure and initial neutron densities this model requires to obtain such an enhancement are much more consistent with i-process nucleosynthesis.

79 ASTRONOMY AND ASTROPHYSICS↗

Gamma ray astrophysics

Gamma ray production processes are reviewed, including Compton scattering, synchrotron radiation, bremsstrahlung interactions, meson decay, nucleon-antinucleon annihilations, and pion production. Gamma ray absorption mechanisms through interactions with radiation and with matter are discussed, along with redshifts and gamma ray fluxes.

Stecker, F. W.↗

Towards a comprehensive framework for reuse: A reuse-enabling software evolution environment

Reuse of products, processes and knowledge will be the key to enable the software industry to achieve the dramatic improvement in productivity and quality required to satisfy the anticipated growing demand. Although experience shows that certain kinds of reuse can be successful, general success has been elusive. A software life-cycle technology which allows broad and extensive reuse could provide the means to achieving the desired order-of-magnitude improvements. The scope of a comprehensive framework for understanding, planning, evaluating and motivating reuse practices and the necessary research activities is outlined. As a first step towards such a framework, a reuse-enabling software evolution environment model is introduced which provides a basis for the effective recording of experience, the generalization and tailoring of experience, the formalization of experience, and the (re-)use of experience.

Basili, V. R.↗

Nondestructive Evaluation of Additive Manufacturing State-of-the-Discipline Report

This report summarizes the National Aeronautics and Space Administrations (NASA) state of the art of nondestructive evaluation (NDE) for additive manufacturing (AM), or "3-D printed", hardware. NASA's unique need for highly customized spacecraft and instrumentation is suited for AM, which offers a compelling alternative to traditional subtractive manufacturing approaches. The Agency has an opportunity to push the envelope on how this technology is used in zero gravity, an enable in-space manufacturing of flight spares and replacement hardware crucial for long-duration, manned missions to Mars. The Agency is leveraging AM technology developed internally and by industry, academia, and other government agencies for its unique needs. Recent technical interchange meetings and workshops attended by NASA have identified NDE as a universal need for all aspects of additive manufacturing. The impact of NDE on AM is cross cutting and spans materials, processing quality assurance, testing and modeling disciplines. Appropriate NDE methods are needed before, during, and after the AM production process.

Waller, Jess M.↗

Oxygen Production System for Refueling Human Landing System Elements

Current NASA plans for lunar exploration include a human lunar landing system, comprised of separate descent andascent modules, with the eventual goal of reusability. Different oxygen production processes were studied to evaluatethe feasibility of producing 10 tons of oxygen per year assuming a high latitude landing location. The study includesconsideration of packaging the ISRU components on the descent module, methods to transfer the regolith from theexcavators to the processing plant which may be mounted well above the lunar surface, and general concept ofoperations for excavation, oxygen production, and liquefaction and storage. A solar-based power system was alsodesigned and packaged on the lander, including the use of direct solar thermal energy where appropriate.

Linne, Diane↗

The contribution of dissociative processes to the production of atomic lines in hydrogen plasmas

The contribution of molecular dissociative processes to the production of atomic lines is considered for a steady-state hydrogen plasma. If the contribution of dissociative processes is dominant, a substantial simplification in plasma diagnostics can be achieved. Numerical calculations have been performed for the production of Balmer alpha, beta, and gamma lines in hydrogen plasmas with medium and large degrees of ionization (x greater than about 0.0001) and for electron temperatures of 5000-45,000 K and electron densities of 10 to the 10th to 10 to the 16th/cu cm.

Kunc, J. A.↗

DFO Computational Modeling Project - Catalytic Upgrading of Bio-based Furfural to 1,5-Pentanediol: A New Renewable Monomer for the Coatings Industry (Final Report)

This report summarizes the results of a collaborative effort between Oak Ridge National Laboratory (ORNL) and Pyran™ Inc. to utilize modeling capabilities developed by the CCPC (Consortium for Computational Physics and Chemistry) to assist Pyran in scaling up its proprietary process for thermocatalytic conversion of furfural to 1,5 pentanediol (PDO). Pyran’s bio-based PDO is a direct replacement for petroleum-based PDO and 1,6 hexanediol (HDO) currently used in polymers, additives, coatings, adhesives and sealants. The current market is in excess of $\$$1B/yr. According to Pyran, their production process results in 95+% reduction in fossil CO 2 at lower production costs compared to the existing petroleum-based routes for PDO & HDO. Other chemicals based on intermediates from this process have current markets in excess of $\$$10B/yr.

36 MATERIALS SCIENCE↗

Catalytic Upgrading of Bio-based Furfural to 1,5-Pentanediol: A New Renewable Monomer for the Coatings Industry

This report summarizes the results of a collaborative effort between Oak Ridge National Laboratory (ORNL) and Pyran™ Inc. to utilize modeling capabilities developed by the CCPC (Consortium for Computational Physics and Chemistry) to assist Pyran in scaling up its proprietary process for thermocatalytic conversion of furfural to 1,5 pentanediol (PDO). Pyran’s bio-based PDO is a direct replacement for petroleum-based PDO and 1,6 hexanediol (HDO) currently used in polymers, additives, coatings, adhesives and sealants. The current market is in excess of $1B/yr. According to Pyran, their production process results in 95+% reduction in fossil CO 2 at lower production costs compared to the existing petroleum-based routes for PDO & HDO. Other chemicals based on intermediates from this process have current markets in excess of $10B/yr.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Quantifying the environmental benefits of a solvent-based separation process for multilayer plastic films

Food packaging often appears in the form of multilayer (ML) plastic films, which leverage the functional properties of different polymers to achieve specific food protection goals (e.g., oxygen, water, and temperature barriers). These properties are essential to enable long shelf lives, reduce refrigeration usage, mitigate food waste, and increase food accessibility. However, ML film production processes generate large amounts of plastic waste that cannot be mechanically recycled. Recently, we have proposed a process, called solvent-targeted recovery and precipitation (STRAP), that enables the separation and recycling of the constituent polymers of ML films. This technology uses a series of solvent washes that selectively dissolve and precipitate target polymers. Quantifying the environmental benefits of STRAP over virgin resin production is essential for the commercial deployment of this technology. Further, this work uses life cycle assessment (LCA) methods to evaluate these impacts in terms of carbon footprint, energy use, water use, and toxicity. We analyze three STRAP process variants that use antisolvent and temperature-driven precipitation to treat different ML films. Our analysis reveals that the STRAP-A and STRAP-B process variants can provide environmental benefits over virgin film production. Furthermore, it gives valuable insight into the critical components of ML films (specific polymers) and of the STRAP processes (equipment) that are responsible for the highest impacts. Ultimately, we believe that the proposed analysis framework can lead to the design of more environmentally-friendly ML films and recycling processes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗