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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 325 records · Page 18
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Advancing Conduction-Cooled 650 MHZ SRF Technology for Industrial Accelerators at Fermilab S IARC

The National Nuclear Security Administration (NNSA) funds the Illinois Accelerator Research Center (IARC) at Fermilab in developing a high-power, conduction-cooled Superconducting Radio Frequency (SRF) accelerator tailored for industrial applications requiring robust and efficient operation. A 650 MHz, 1.6 MeV, 20 kW SRF accelerator is currently under development, employing a conduction cooling approach to simplify cryogenic requirements and enhance accessibility for industrial use. The accelerator's control system is implemented on the Blinky Lite platform, selected for its open-source architecture, secure remote access capabilities, and operational flexibility attributes advantageous for industrial deployment and sustained operation. A dedicated beamline is designed to measure essential beam parameters and test the integrated performance of the accelerator and control systems, thereby validating their operational readiness for intended applications.

Ji, Yichen [Fermilab]↗
DOE OSTI2024

Characterization of Oscillatory Response of Light-Weight Wind Turbine Rotors under Controlled Gust Pulses

Given the industry-wide trend of continual increases in the size of utility-scale wind turbines, a point will come where reductions will need to be made in terms of the weight of the turbine’s blades to ensure they can be as long as needed without sacrificing structural stability. One such technique that may be considered is to decrease the material used for the shell and spar cap. While this will solve the weight issue, it creates a new one entirely—less material for the shell and spar cap will in turn create blades that are more flexible than what is currently used. This article aims to investigate how the oscillatory response of light-weight wind turbine rotors is affected by these flexibility changes. The object of our study is the Sandia National Lab National Rotor Testbed (SNL-NRT) wind turbine, which the authors investigated in the course of a research project supported by SNL. Using a reduced-order characterization (ROC) technique based on controlled gust pulses, introduced by the authors in a previous work, the aeroelastic dynamics of the NRT’s original baseline blade design and several of its flexible variations were studied via numerical simulations employing the CODEF multiphysics suite. Results for this characterization are presented and analyzed, including a generalization of the ROC of the SNL-NRT oscillatory dynamics to larger machines with geometrical similarity. The latter will prove to be valuable in terms of extrapolating results from the present investigation and other ongoing studies to the scale of current and future commercial machines.

Ponta, Fernando (ORCID:0000000321032864)↗
DOE OSTI2026

Machine Tool Data Analytics for Digital Twin and Machine Predictive Maintenance

The primary objective of this project is to improve machining process performance using in-process machining data from the machine tool controller and external sensors. Advances in the Industrial Internet of Things (IIoT) enable monitoring of machines using controller data. Examples of the data provided by a controller include execution status of the controller, part count, block of code being executed, door status, tool position, the spindle and axis load, etc. MTConnect and OPC-UA are the two common protocols for capturing machine information. In this collaboration, methods for retrieving the machine controller data from selected machine tool controls and making these data accessible in different subsystems (such as digital twins and machine maintenance portals, etc.) will be developed and tested. In addition, analytics to improve machining process performance (by increasing productivity and reducing downtime) will be developed.

42 ENGINEERING↗
DOE OSTI2022

Biocontainment of Genetically Engineered Algae

Algae (including eukaryotic microalgae and cyanobacteria) have been genetically engineered to convert light and carbon dioxide to many industrially and commercially relevant chemicals including biofuels, materials, and nutritional products. At industrial scale, genetically engineered algae may be cultivated outdoors in open ponds or in closed photobioreactors. In either case, industry would need to address a potential risk of the release of the engineered algae into the natural environment, resulting in potential negative impacts to the environment. Genetic biocontainment strategies are therefore under development to reduce the probability that these engineered bacteria can survive outside of the laboratory or industrial setting. These include active strategies that aim to kill the escaped cells by expression of toxic proteins, and passive strategies that use knockouts of native genes to reduce fitness outside of the controlled environment of labs and industrial cultivation systems. Several biocontainment strategies have demonstrated escape frequencies below detection limits. However, they have typically done so in carefully controlled experiments which may fail to capture mechanisms of escape that may arise in the more complex natural environment. The selection of biocontainment strategies that can effectively kill cells outside the lab, while maintaining maximum productivity inside the lab and without the need for relatively expensive chemicals will benefit from further attention.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2021

Controlled Pyrolysis: A Robust Scalable Composite Recycling Technology

The reinforced composites industry is facing significant challenges in handling the scrap composite material from automobile manufacturing, the wind turbine industry, and others. The fibers in the material, whether they be carbon, glass, or other materials have commercial value if they can be recovered successfully. Successfully means the fibers are clean with no sizing or other binders and have adequate strength and physical properties that would allow them to be economically reprocessed into valuable product. The composites recycling project was an industry-collaborative effort to develop a composite recycling technology using controlled pyrolysis. Through the recycling of scrap and end-of-life (EOL) cured composite materials, this pilot study was intended to create a business case by realizing a cost-effective means for recycling EOL and production scrap composite materials, ultimately reducing the volume of composite materials destined for landfill. The project was led by the Institute for Advanced Composites Manufacturing Innovation (IACMI), the American Composites Manufacturers Association (ACMA), Oak Ridge National Laboratory (ORNL), Continental Structural Plastics (CSP) a Teijin Group Company, CHZ Technologies, and A. Schulman with support from Owens Corning, John Deere, General Electric (GE), Ashland LLC, and Plastics Europe (CEFIC). The team studied and tested CHZ Technologies’ controlled pyrolysis system, known as the Thermolyzer TM , which operates on a scalable basis to convert organic polymer materials into a clean synthesis gas and char containing the recoverable carbon and glass fiber reinforcement. The recoverable energy contained in the input polymers creates the synthesis gas that can be used to provide heat to the Thermolyzer TM primary reactor in a sustainable manner. That is, once the Thermolyzer TM is started with a small amount of external natural gas, the synthesis gas that is created from the polymers will continue to operate the burners so long as feedstock is supplied. The reinforcing fiber materials remaining in the solid phase char were separated and cleaned for re-use in other polymer systems based on the retained properties of the fibers. The study created reports (attached in the appendix) on the Mass and Energy Balances, syngas analytics, VOC assessment, yield analysis and other analytics necessary for a Techno-Economic Analysis (TEA) to quantify the economic impact of the recovery and sustainable re-use of the carbon and glass fibers. The process consisted of 4 steps: Selection of 4 samples of cured composite waste materials from project partners interested in materials recycling and recovering the reinforcing fibers for best case re-use. The materials included glass fiber (GF) polyester/vinyl ester automotive SMC from CSP, GF epoxy balsa/PVC foam wind blades from GE, carbon fiber (CF) epoxy wind blade laminated spar caps from GE, and GF/CF epoxy hybrid assembly from John Deere. Processing the waste composite samples into 1-2” shreds. Packaging the shredded composites into bulk sacks on international shipping pallets for shipment to KUG in Forst (Lausitz), Germany. Pyrolysis of the shredded composites under controlled conditions designed for each polymer system. Collecting samples of the gas and char for analysis. Shipping the char containing the CF/GF back to the US for the next steps of testing the fibers and developing protocols for sustainable re-use of the fibers in composite applications.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Control of zeolite pore interior for chemoselective alkyne/olefin separations

The efficient removal of alkyne impurities for the production of polymer-grade lower olefins remains an important and challenging goal for many industries. We report a strategy to control the pore interior of faujasite (FAU) zeolites by the confinement of isolated open nickel(II) sites in their six-membered rings. Under ambient conditions, Ni@FAU showed remarkable adsorption of alkynes and efficient separations of acetylene/ethylene, propyne/propylene, and butyne/1,3-butadiene mixtures, with unprecedented dynamic separation selectivities of 100, 92, and 83, respectively. Additionally, in situ neutron diffraction and inelastic neutron scattering revealed that confined nickel(II) sites enabled chemoselective and reversible binding to acetylene through the formation of metastable [Ni(II)(C 2 H 2 ) 3 ] complexes. Control of the chemistry of pore interiors of easily scalable zeolites has unlocked their potential in challenging industrial separations.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Demonstration of the Human and Technology Integration Guidance for the Design of Plant-Specific Advanced Automation and Data Visualization Techniques

Nuclear power continues to be a safe, reliable, and carbon-free electricity generating source for the United States, though the cost of operating and maintaining the current United States nuclear power plant fleet has become uncompetitive with other sources. This gap is attributed to the advent of new digital instrumentation and control technologies that other electricity generating industries are currently leveraging to streamline work and greatly reduce operating, maintenance, and support costs. Digital instrumentation and control systems and control room modernization offers significant opportunities to reduce operating and maintenance costs to ensure the continued operation of the existing United States light-water reactors.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Cyber Secure Sensor Network for Fossil Fuel Power Generation Assets Monitoring

The energy sector is undergoing digital transformation which is to say more and more power generation assets have become automated and connected to the internet. The connected sensors can tap into plants to monitor the health of assets and manage fleets remotely. These are just some of the benefits digitalization is bringing to the power industry. Within a power plant, control systems are no longer concerned with one system or one piece of equipment, but rather whole fleet of assets inter-connected with smart sensors which have the function of continuously monitoring and transmitting real-time operational data to operators. These connected systems will form a part of the industrial internet of things (IIoT). The big data scenarios provide benefits of performing system prognostics and optimization which is a key selling point of power plant digitalization.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

Dynamic machine learning-based optimization algorithm to improve boiler efficiency

With decreasing computational costs, improvement in algorithms, and the aggregation of large industrial and commercial datasets, machine learning is becoming a ubiquitous tool for process and business innovations. Machine learning is still lacking applications in the field of dynamic optimization for real-time control. This work presents a novel framework for performing constrained dynamic optimization using a recurrent neural network model combined with a metaheuristic optimizer. The framework is designed to augment an existing control system and is purely data-driven, like most industrial Model Predictive Control applications. Several recurrent neural network models are compared as well as several metaheuristic optimizers. Hyperparameters and optimizer parameters are tuned with parameter sweeps, and the resulting values are reported. Further, the best parameters for each optimizer and model combination are demonstrated in closed-loop control of a dynamic simulation, and several recommendations are made for generalizing this framework to other systems. Up to 0.953% improvement is realized over the non-optimized case for a simulated coal-fired boiler. While this is not a large improvement in percentage, the total economic impact is $991,000 per year, and this study builds a foundation for future machine learning with dynamic optimization.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Land-based wind turbines with flexible rail-transportable blades – Part 1: Conceptual design and aeroservoelastic performance

This work investigates the conceptual design and the aeroservoelastic performance of land-based wind turbines whose blades can be transported on rail via controlled bending. The turbines have a nameplate power of 5 MW and a rotor diameter of 206 m, and they aim to represent the next generation of land-based machines. Three upwind designs and two downwind designs are presented, combining different design goals together with conventional glass and pultruded carbon fiber laminates in the spar caps. One of the five blade designs is segmented and serves as a benchmark to the state of the art in industry. The results show that controlled flexing requires a reduction in the flapwise stiffness of the blades, but it represents a promising pathway for increasing the size of land-based wind turbine rotors. Given the required stiffness, the rotor can be designed either downwind with standard rotor preconing and nacelle uptilt angles or upwind with higher-than-usual angles. A downwind-specific controller is also presented, featuring a cut-out wind speed reduced to 19 m s –1 and a pitch-to-stall shutdown strategy to minimize blade tip deflections toward the tower. The flexible upwind and downwind rotor designs equipped with pultruded carbon fiber spar caps are found to generate the lowest levelized cost of energy, 2.9 % and 1.3 %, respectively, less than the segmented design. The paper concludes with several recommendations for future work in the area of large flexible wind turbine rotors.

17 WIND ENERGY↗
DOE OSTI2020

Well-to-wheels greenhouse gas and air pollutant emissions from battery electric vehicles in China

Electric vehicles (EVs) play a crucial role in addressing climate change and urban air quality concerns. China has emerged as the global largest EV market with 1.2 million EVs sold in 2018. This study established a novel life cycle energy use and emission inventory collecting up-to-date data including the electricity generation mix, emission controls in the power and industrial sectors, and the energy use in the fuel transport to estimate the well-to-wheels (WTW) greenhouse gas (GHG), and air pollutant emissions for battery electric vehicles (BEVs) and gasoline passenger vehicles in China. The results show that an average BEV has 35% lower WTW GHG emissions than an average gasoline car. BEVs reduce volatile organic compounds (VOCs) and nitrogen oxides (NOX) emissions by 98% and 34%, respectively, but have comparable or slightly higher primary fine particulate matter (PM2.5) and sulfur dioxide (SO2) emissions. Compact and small-size vehicles generally have lower GHG and air pollutant emissions than mid- and large-size vehicles. Class A vehicles contribute the most in the absolute amount of GHG and air pollutant emissions and therefore have the biggest potential for emission reduction. Our results suggest that global policymakers should continue to promote the transition to clean power sources, emission control, and fuel economy regulations, which are critical to enhancing emission mitigation benefits of BEVs. We also suggest EV development strategies should be formulated targeting vehicle class with the biggest emission mitigation potentials.

Air pollutant emissions↗
DOE OSTI2023

Linker Vacancy Engineering of a Robust ftw–type Zr–MOF for Hexane Isomers Separation

Discrimination of physically similar molecules by porous solids represents an important yet challenging task in industrially relevant chemical separations. Precisely controlled pore dimension and/or tailored pore surface functionality are crucial to achieve high-efficiency separation. Metal-organic frameworks (MOFs) are promising candidates for these challenging separations in light of their structural diversity as well as highly adjustable pore dimension/functionality. We report here a microporous, ftw-type Zr-based MOF structure, HIAM-410 (HIAM=Hoffmann Institute of Advanced Materials), built on hexanuclear Zr 6 cluster and pyrene-1,3,6,8-tetracarboxylate (ptc 4– ). Its crystallographic structure has been determined using continuous rotation electron diffraction (cRED) technique combined with Rietveld refinement against powder X-ray diffraction data, aided by low-dose high-resolution transmission electron microscopy (HRTEM) imaging. The compound features exceptional framework stability that is comparable to the prototype MOF UiO-66. Interestingly, the linker vacancies in the pristine MOF structure could be partially restored by post-synthetic linker insertion. Its separation capability of hexane isomers is enhanced substantially upon the linker vacancy engineering. As a result, the restored structure exhibits efficient splitting of monobranched and dibranched hexane isomers at both room temperature and industrially relevant temperature.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Cyber-Informed Engineering Case Study of an Integrated Hydrogen Generation Plant

Strategies for securing digital instrumentation and control (I&C) systems within the nuclear industry are provided by multiple standards and guidance documents. However, since selection and use of security controls outlined in these documents are frequently only considered during or after installation, there are often limitations on their use, such as technological constraints related to design or operation. Furthermore, alternative controls intended to provide the same or similar security countermeasure as the primary control may also be infeasible at these stages, leaving the I&C system vulnerable to cyber-attacks. The limitations associated with ‘bolting on’ security controls late in the systems engineering lifecycle can be reduced by integrating Cyber-Informed Engineering (CIE) into the process. This paper evaluates the use of CIE during the high-level design stage of a hydrogen generation project where heat and electricity are provided by a nuclear power plant. Applying CIE to this project highlighted potential cyber vulnerabilities of the initial design, leading to recommendations for process flow and I&C system design modifications to reduce, and at times eliminate, the risk from both deliberate and unintentional cyber incidents.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

High Efficiency, Low Cost RF Sources for Accelerators and Colliders

Calabazas Creek Research, Inc. (CCR) and its collaborators are developing high efficiency, low cost RF sources. Phase and Amplitude Controlled Magnetrons: CCR, Fermilab, and Communications & Power Industries, LLC (CPI) recently developed a 100 kW, 1.3 GHz magnetron system with amplitude and phase control. The system operated at more than 80% efficiency and demonstrated rapid control of amplitude and phase. Multiple Beam Triodes: CCR, in collaboration with CPI and JP Accelerator Works, Inc., is developing 200 kW, pulsed and CW RF sources from 350 to 700 MHz with projected efficiencies exceeding 80% and cost of $0.50/Watt. Prototype tubes are scheduled for tests in spring 2021. High Efficiency Klystrons:CCR, CPI, and Leidos, Inc. are building a 1.3 GHz, 100 kW klystron operating at 80% efficiency. High power testing is scheduled for summer 2021. Multiple Beam IOTs: CCR and Georgia Tech Research Institute are developing MBIOTs with simplified input coupling and high efficiency. Simulations indicate that 3rd harmonic drive power can increase the efficiency 8-10 %. The program is developing a prototype tube to produce 200 kW peak, 100 kW average power at 704 MHz.

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

Liquid Containing Clouds at the North Slope of Alaska Demonstrate Sensitivity to Local Industrial Aerosol Emissions

Abstract Cloud condensation nucleus control alter cloud solar albedo through cloud droplet size. Here, we leverage anthropogenic emissions at the North Slope of Alaska as a natural laboratory to study relationships between aerosols and Arctic liquid‐containing clouds. Averaging 14 years of MODIS observations, we found a reduction in temporally averaged cloud effective radius ( ) of up to 1.0 μm related to localized pollution. Pronounced regional gradients in cloud frequency of occurrence and liquid water path prohibit the detection of potential changes of these variables. Observed changes of alter radiative fluxes and increase cloud‐reflected shortwave radiation by up to 0.8 W m − 2 in the Prudhoe Bay area for the period covered by observations (April–September). Due to the frequent occurrence of liquid‐containing clouds, this implies that enhanced local emissions in Arctic regions can impact climate processes.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Practical implications of SFQ-based two-qubit gates

Scalability of today’s superconducting quantum computers is limited due to the huge costs of generating/routing microwave control pulses per qubit from room temperature. One active research area in both industry and academia is to push the classical controllers to the dilution refrigerator in order to increase the scalability of quantum computers. Superconducting Single Flux Quantum (SFQ) is a classical logic technology with low power consumption and ultra-high speed, and thus is a promising candidate for in-fridge classical controllers with maximized scalability. Prior work has demonstrated high-fidelity SFQ-based single-qubit gates. However, little research has been done on SFQ-based multi-qubit gates, which are necessary to realize SFQ-based universal quantum computing.In this paper, we present the first thorough analysis of SFQ-based two-qubit gates. Our observations show that SFQ-based two-qubit gates tend to have high leakage to qubit non-computational subspace, which presents severe design challenges. We show that despite these challenges, we can realize gates with high fidelity by carefully designing optimal control methods and qubit architectures. We develop optimal control methods that suppress leakage, and also investigate various qubit architectures that reduce the leakage. After carefully engineering our SFQ-friendly quantum system, we show that it can achieve similar gate fidelity and gate time to microwave-based quantum systems. Furthermore, the promising results of this paper show that (1) SFQ-based universal quantum computation is both feasible and effective; and (2) SFQ is a promising approach in designing classical controller for quantum machines because it can increase the scalability while preserving gate fidelity and performance.

42 ENGINEERING↗
DOE OSTI2022

Effects of trunk injection with emamectin benzoate on arthropod diversity

Abstract BACKGROUND Pine wood nematode is a major plant quarantine object in the world. Trunk injection is an effective method for controlling pests that cause disease. To evaluate the ecological safety of trunk injection with emamectin benzoates in forests of Pinus massoniana , the community diversity and community composition of soil arthropods and flying insects (Hymenoptera) were studied at different stages of trunk injection. RESULTS The dominant taxonomic groups of soil arthropods were Collembola (30.80%), Insecta (26.42%), and Arachnida (23.84%). The taxonomic groups of flying insects (Hymenoptera) were Ichneumonidae (48.94%), Formicidae (14.10%), and Braconidae (8.44%). Trunk injection with emamectin benzoate has no significant effect on the community diversity indices of total soil arthropods and flying insects (Hymenoptera). However, it has a significant effect on the community diversity indices of detritivores for soil arthropods. It changed the community composition of soil arthropods but did not impact the community composition of flying insects (Hymenoptera). Redundancy analysis of arthropod community structure and environmental variables showed that total potassium, residual of green leaf, and residual of litter leaf have a significant impact on the community structure of soil arthropods, and total phosphorus, total nitrogen, water content, organic matter, and total potassium have a significant impact on the community structure of flying insects (Hymenoptera). CONCLUSION Trunk injection with emamectin benzoate is safe for the ecological environment. This study provides a new insight into the field for the prevention and control of pine wood nematode disease, which is of great significance to forest management and pest control. © 2022 Society of Chemical Industry.

Ouyang, Xianheng↗
DOE OSTI2023

Electrochemical Degradation of Pt 3 Co Nanoparticles Investigated by Off-Lattice Kinetic Monte Carlo Simulations with Machine-Learned Potentials

In fuel cell applications, the durability of catalysts is critical for large-scale industrial implementation. However, limited synthesis controllability and spectroscopic resolution impede a comprehensive understanding of degradation mechanisms at the atomic level. In this study, we develop a machine-learned potential (MLP) to simulate the degradation processes for Pt3Co nanoparticles. The precision of MLP is determined to be comparable to that of density functional theory calculations. Using off-lattice kinetic Monte Carlo simulations with MLP, we successfully replicate established experimental trends and offer a logical resolution to ongoing debates regarding atomic orderings. Based on the simulation results, we suggest design principles for Pt3Co nanoparticles that combine high activity and durability. Finally, we validate the wide applicability of our method by successfully applying it to Pt3Ni and Pt3Co0.5Ni0.5 nanoparticles. The research serves as a guideline for developing MLPs for alloy electrochemical catalysts and lays the foundation for designing more durable and active fuel-cell catalysts.

36 MATERIALS SCIENCE↗