Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “industries”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 325 records · Page 18
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

University of Dayton Industrial Assessment Center

The University of Dayton Industrial Assessment Center (UD-IAC) was established in 1981. Since then, the UD-IAC has completed 1,050 industrial energy assessments for the Department of Energy. The UD-IAC is committed to an ethic of continuous improvement, building upon the enormous knowledge and commitment it has developed over the past four decades and developing strong links to educational, research, and DOE initiatives. We feel lucky to be part of this great IAC program and pledge our best and most sustained efforts toward its continued success.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Industry Scan of Non-SF6 Gas-Insulated Technologies

Sulfur Hexafluoride (SF 6 ) 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 SF 6 has a global warming potential (GWP) 23,000 times higher than Carbon Dioxide, and has the highest GWP of all gases assessed (Myhre 2013). SF 6 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 SF 6 one of the leading sources of anthropogenic climate change. Since SF 6 recognition as a significant contributor to climate change, most governments and organizations have sought ways to reduce or eliminate their use of this gas. Many utilities have initiated leak monitoring and repair programs which have significantly reduced emissions of this gas into the atmosphere. While leak reduction programs have been effective at reducing emission rates in the developed world, leak rates remain frozen at ~1% annually. However, one of the largest and fastest growing markets for this gas is in the developing world where emissions standards are often lacking (P&S Intelligence. 2023). To fully eliminate the environmental impacts of SF 6 , alternative technology is needed. The ideal replacement would be a technology that can fulfil the same role as SF 6 , 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. This report was commissioned by the United States Department of Energy’s Office of Electricity under the Transformer Resilience and Advanced Components (TRAC) program to assess the state of industry adoption and manufacturing capability for SF 6 -free alternative technologies for use at the high-voltage level, and the primary barriers to broader adoption. While this report is tailored to the United States, the findings should be relevant to all stakeholders seeking to reduce SF 6 emissions.

24 - POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2026

An Educational Program on Concentrated Solar Power and Heliostats for Power Generation and Industrial Processes

The objective of this project was to design and implement a comprehensive educational and applied research program in Concentrated Solar Thermal Power (CSTP) and heliostat technologies at Northeastern University. In alignment with the U.S. Department of Energy's Heliostat Consortium (HelioCon) goals, the project aimed to expand student and public understanding of CSTP systems while simultaneously contributing to workforce development and the broader decarbonization strategy. A particular emphasis was placed on integrating hands-on student design projects and publicly disseminating educational content relevant to CSTP systems. The project addressed a critical gap in renewable energy education: CSTP and heliostats, despite their importance in utility-scale solar energy, are rarely included in standard mechanical engineering programs. This project established new pathways for students to engage with the topic through the creation of a 4-credit graduate/senior elective course, development of five industry-facing short courses, and the inclusion of CSTP-based capstone design projects. Over two academic years, 36 students across six senior design teams developed and tested technologies such as deformable heliostats, beacon-based tracking systems, and solar-powered pyrolizers for biomass-to-biochar conversion. Concurrently, 30 undergraduate and graduate students were enrolled in the new academic course centered around CSTP principles. To ensure the relevance and accessibility of the short course content, the project team engaged with industry professionals, technical policy stakeholders, and potential course participants through structured surveys and informal consultations. Feedback from 28 respondents guided the structure, length, and delivery format of the courses - resulting in a modular design broken into five workshops. The feedback emphasized the need for flexible, asynchronous delivery and practical case studies, particularly in areas such as heliostat control, thermal storage, and solar fuel production. This engagement helped align the courses with the evolving knowledge demands of the renewable energy workforce and ensured that participants from both technical and policy backgrounds could meaningfully benefit from the material. The research and educational activities advanced the understanding of heliostat control systems, optical performance under misalignment, and thermal system integration in solar-driven pyrolysis applications. Methods and designs explored in this project proved to be both technically effective and economically feasible at the lab scale. Prototypes were constructed using commercially available components and custom-fabricated elements, demonstrating that meaningful performance improvements can be achieved with modest material and fabrication costs, supporting the feasibility of student-led research in this field. The public benefit of this project is twofold. First, it cultivates a pipeline of engineers trained to be familiar with CSTP principles, an essential workforce need identified by the Department of Energy for achieving its 2030 cost and deployment targets. Second, it contributes openly accessible educational materials, course content, and experimental frameworks to the broader community, enabling other institutions to adopt or adapt similar programming. Through outreach activities, curriculum integration, and technical exposure, this project contributes to a more informed and capable renewable energy workforce while supporting innovation in heliostat and CSTP system design. A new technical report is being prepared to document the development of the course and its outcomes, with plans to publish it in the ASME Open Access Journal of Engineering to ensure global accessibility, free of cost.

14 SOLAR ENERGY↗
DOE OSTI2023

Continuous multimodal technologies in industrial microbiology: potential for achieving high process performance and agility

The field of industrial microbiology has great potential to tackle the most pressing challenges facing society, but today, this entails much more than classical fermentation technology followed by product upgrading. Methods are needed to confer unit-operation-level functionality and whole-system-level robustness, as well as flexibility. As examples of this concept, we focus here on methodologies often deployed at industrial scale as discrete processes—such as biological, chemical, and electrochemical unit operations—that are also capable of substantial complementarity when combined sequentially and operated continuously. A key and relatively new type of conversion step is made possible by catalyst immobilization methods at both the enzymatic and cellular level. Cases drawn from electro-fermentation for acetoin production and syngas-mediated microbial electrosynthesis of ethanol exemplify the synergy of combined operational approaches. Because modular processes can be treated as a series of reactor elements, considerable flexibility is possible. As discussed, however, not all processes are amenable to this intensification.

09 BIOMASS FUELS↗
DOE OSTI2021

Industrial Energy Assessment Training Effectiveness Evaluation: An Eye-Tracking Study

It is essential to understand the effectiveness of any training program so it can be improved accordingly. Various studies have applied standard metrics for the evaluation of visual behavior to recognize the areas of interest that attract individuals’ attention as there is a high correlation between attentional behavior and where one is focusing on. However, through reviewing the literature, we believe that studies that applied eye-tracking technologies for training purposes are still limited, especially in the industrial energy assessment training field. In this paper, the effectiveness of industrial energy assessment training was quantitatively evaluated by measuring the attentional allocation of trainees using eye-tracking technology. Moreover, this study identifies the areas that require more focus based on evaluating the performance of subjects after receiving the training. Additionally, this research was conducted in a controlled environment to remove the distractions that may be caused by environmental factors to only concentrate on variables that influence the learning behavior of subjects. The experiment results showed that after receiving the training, the subjects’ performance in energy assessment was significantly improved in two areas: production, and recycling and waste management, and the designed training program enhanced the knowledge of participants in identifying energy-saving opportunities to the knowledge level of experienced participants.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Heliostat Sizing Methodology for Solar Heat for Industrial Processes

This study presents a method to obtain a heliostat size that minimizes the levelized cost of a heliostat-based concentrating solar thermal system for industrial process heat (IPH) applications at operating temperatures from 565 to 1550 degrees Celsius. The method extends prior work by embedding a routine for system design that obtains near-optimal subsystem sizes, increasing the fidelity of drive cost functions, and adding an optical performance model. An illustrative business case is developed for Daggett, California, targeting specified annual thermal energy outputs of 50 to 400 GWhth. Optical performance is modeled using verified estimates from the literature. A surrogate heliostat cost model, derived from commercial heliostat designs and scaled for production volume, installation, and operations and maintenance costs, is used to develop cost functions. Results show that heliostat size strongly affects the levelized cost of heat (LCOH), producing a characteristic U-shaped trend with a robust near-optimal window of 8 - 12 m2; the heliostat size producing the lowest project cost in our study grows slightly as the project size increases, and is reduced as the operating temperature increases. The findings in this study are consistent with the general trend of smaller heliostats under deployment at existing projects for high-temperature industrial process heat and reflect the significant reduction in power electronics and other per-heliostat costs. The methodology we propose is general and can be tailored to revised cost curves as the technology continues to evolve.

14 SOLAR ENERGY↗
DOE OSTI2026

Industrial Locomotive Inventory Analysis

Due to their captive and local operations, industrial locomotives present a unique potential to reduce energy consumption and associated costs through application of advanced locomotive technologies. However, until now, there has been no data source for the number, size (hp), usage, and energy consumption of these locomotives, which limits the ability to design and implement a research, development, and deployment strategy. This research addresses this gap by developing the first national inventory of locomotives in industrial use and provides a tool to explore the energy and emissions associated with this transportation segment.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2024

Security of Mobile Radiological Sources: Overview of Industry Applied Technologies

Small radiological sources used in industrial settings recurrently require transit between job sites. Securing these sources, while stationary, can be addressed with standard security approaches and equipment. Transport of these sources increases the risk and complexity of managing and maintaining control of these sources. Implementing methodologies to securely monitor and locate sources improves response and resolution of anomalous events during transit. The Mobile Source Transit Security (MSTS) system was developed to improve security and provide situational awareness of these mobile sources throughout their job cycle. The MSTS development effort focused on creating a set of systems that could be successfully implemented in industrial radiography and well-logging applications. The MSTS team worked to address source presence and location through use and storage. The MSTS system monitors radiological sources as they move from the base of operations to the job site and back. The system provides near-real-time monitoring of the mobile source location and status and early notification of source loss or theft by transmitting operational status and alerting anomalous conditions over telematic links worldwide. The MSTS system can trigger an armed response or initiation of search and recovery operations and will automatically alert management and responsible staff if a radioactive source is lost or stolen whether it is on-site, in transport, or in storage.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2020

2018 Industrial Energy Data Book

The 2018 Industry Energy Data Book summarizes the status of, and it identifies the key trends in energy use and its underlying economic drivers across the four industrial subsectors: agriculture, construction, manufacturing, and mining.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2020

Analyzing Next-Generation Supply Chains Using the Materials Flows through Industry Tool

The Materials Flows through Industry (MFI) tool is a supply chain modeling tool developed at the National Renewable Energy Laboratory (NREL) with funding from the Department of Energy's Advanced Manufacturing Office. MFI was created to identify and analyze opportunities to reduce the energy and carbon intensities of the U.S. industrial sector (Hanes and Carpenter 2017). In this work, we present an overview of the MFI tool's structure and capabilities, as well as the results of using MFI to analyze a novel NREL-developed process to 'upcycle' PET plastic into higher-value composite materials (Rorrer et al. 2019). This process combines recycled PET (rPET) plastic with inputs that can be derived from biomass, including muconic acid, acrylic acid, and ethylene glycol, to chemically break down the plastic back to its monomers in a process called glycolization. Then, repolymerization and the application of fiberglass yields the valuable glass fiber reinforced plastic (GFRP) composite, a performance material used in the manufacture of wind turbine blades, boat hulls, and other applications. This rPET-derived GFRP was found to have superior strength and fiberglass adhesion compared to conventional GFRP formulations. Our findings indicate that this GFRP production process, were it to be widely commercialized beyond its current lab-scale, could potentially reduce the fossil energy intensity of the GFRP supply chain by between 37% and 58% compared to the conventional method of GFRP manufacture from fossil-derived inputs. We also estimate potential supply chain greenhouse gas (GHG) emissions reductions between 30% and 40% from this process. Scaling these GHG offset estimates up to annual GFRP production in the U.S. would be roughly equivalent to removing between 150,000 and 200,000 vehicles from U.S. roads. These ranges of impact estimates represent the range of differences associated with the various economic allocation methods we have assumed for the intensity contributions from the first life of the PET plastic. Following Shen et al. (2010), we derive economic allocation factors from the current price ratios of clear- and green-colored recycled PET plastic to virgin PET resin ('waste-valuation' approach) or assume them to be zero in a more simplistic allocation ('cutoff' approach). Future work involving the MFI modeling tool will also be discussed, including preliminary results comparing the energy intensity of conventional and bio-based nylons manufacturing. Attendees will also be encouraged to conduct MFI supply chain modeling of their own by requesting a user account on the MFI web application, which is freely available to the public at the following address: https://mfitool.nrel.gov.

36 MATERIALS SCIENCE↗
DOE OSTI2022

How Can Construction Process Simulation Modeling Aid the Integration of Lean Principles in the Factory-Built Housing Industry?

New and existing factories that produce and deliver factory-built housing can benefit from construction process simulation modeling to explore the integration of Lean principles in their operations. Construction process simulation modeling provides digital or virtual recreations of the real-world factory environments to visualize, quantify, analyze, and optimize their underlying behavior, including factory productivity, material flow, labor dynamics, bottlenecks, and work scope. One of the key benefits of process simulation modeling is the ability to create and compare "what-if" scenarios, including integrating Lean principles such as reducing waste (for example, transportation, waiting), line balancing, and just-in-time concepts. In general, three process simulation methods are widely used: discrete event simulation (DES), agentbased modeling (ABM), and system dynamics (SD). Myriad process simulation software also is available, but depending on the industry, complexity of the system, and purposes of the simulation, some software might be more appropriate. Similar to how computer-aided design (CAD) software such as AutoCAD and Rhinoceros enable building design of modular or factory-built housing, process simulation modeling software such as jStrobe, ProModel, and AnyLogic can enable factory design of new and existing factories to deliver modular affordable housing at scale, as opposed to traditional site-built construction. Software with DES capabilities can help generate a process model that is a logical representation of resources and activities in a factory. Software with CAD-DES integration can leverage product-process data integration to help spatially visualize a DES model of the factory in the CAD environment. Software with multimethod simulation capabilities, widely used in the manufacturing industry, brings together DES, ABM, and SD in a single platform that allows visualization, quantification, analyses, and optimization at varying data fidelities. Near-real-time data from an existing factory can be directly plugged into multimethod simulation software so that the construction process simulation model is a near-accurate representation of the real-world factory conditions. This report provides insights into the use of simulation as an aid to integrate Lean concepts in factories, including guidelines for selecting the appropriate process simulation modeling method and software. These insights have been developed as part of ongoing process simulation modeling research, development, and demonstration projects at the U.S. Department of Housing and Urban Development, the U.S. Department of Energy, and the National Renewable Energy Laboratory focused on how process simulation models can enable better integration of resilience, energy efficiency, and low-carbon design strategies.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Increasing Industry Involvement: A Solution from a Student's Perspective

Many engineering employers are finding that graduates are not sufficiently equipped to begin contributing productively when they exit a 4-year institution and enter the workforce. The Intern Professional Development Center (IPDC) is a proposed business model that exposes engineering undergraduates to industry-relevant knowledge, while providing them with working experience during their degree. Using a tri-stage approach, the IPDC engages with students early in their academic careers, provides continuous training and development opportunities, and finally connects the students with potential employers. The two topics most commonly under-represented in engineering programs are: - Familiarity with drafting software - Knowledge of relevant codes and standards. The Intern Professional Development Center (IPDC): A tri-stage solution for recruiting, training, and encouraging the workforce of tomorrow. An IPDC allows students to be active members of industry during their undergraduate careers, leading to: - Improved local talent retention; - Improved graduation and academic performance statistics; - Near-guarantee for post-graduation employment. In March of 2019, the first IPDC prototype began operating in the Tri-Cities, Washington. Since then, 3 undergraduate students have entered the IPDC at Stage 2, beginning with the standard training and professional development. Of those 3 students, 2 have already moved on to Stage 3, with successful ongoing internships with local employers. At a performance review for one of the IPDC's Stage 3 students after 90 days of employment, the direct manager said: 'How soon can we get another one?'.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗
DOE OSTI2024

Distributed Wind for Industrial Loads

Industrial loads have significant energy resilience requirements, which is one reason distributed wind may be a good option to help provide generation for these facilities. This fact sheet provides an overview of industrial load energy and resilience needs, and discusses why distributed wind may be a good option to provide onsite power for these facilities.

17 WIND ENERGY↗
DOE OSTI2025

Supply Chain Energy and Greenhouse Gas Analysis Using the Materials Flows Through Industry (MFI) Tool: Examination of Alternative Technology Scenarios for the U.S. Chemical Sector

Chemical manufacturing is a large and diverse sector of the U.S. economy, with products, fuels, and a wide assortment of materials used daily by both the public and businesses. Currently, several of the largest volume chemicals produced in the United States rely on fossil fuels as a feedstock, energy source, or both. The list of chemicals includes steam cracking products such as ethylene, propylene, benzene, and xylenes as well as products such as ammonia and methanol. The focus for this work is on platform chemicals that are both produced in the largest volume and have a high potential for subsequent processing into more specialized products. In this study, we explore several new pathways that reduce the overall energy consumption and greenhouse gas (GHG) emissions for each product. These pathways include energy efficiency measures applied to existing production methods, the use of bio‐based fuels and/or feedstocks as new production methods, and electrification of high‐energy‐input stages within current production methods. Scenarios for energy demand and GHG reduction were conducted with the National Renewable Energy Laboratory's Materials Flows through Industry tool. Projections of the energy demand and GHG emissions in 2030 and 2050 are included, using grid composition projections from the NREL ReEDS model. The alternative scenarios selected showcase the effect of realistic changes the industry could make, focusing on technologies with a high level of technical readiness.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2020

Understanding the Gap between Academic Research and Industrial Requirements in Rechargeable Zinc-Ion Batteries

Rechargeable Zn-ion batteries (RZIBs) are considered to be promising energy storage systems for large-scale applications owing to their relatively high energy densities and inherently low costs, environmental benignity, as well as safety. With increasing interest and effort being devoted to this field, RZIBs are being tremendously advanced and are very likely to be commercialized in the near future. However, some challenges remain that need to be addressed. Moreover, reported results are quite often overstated through artificial exaggeration and cannot be translated to industrial applications as they were obtained under ideal testing conditions. Therefore, in this perspective, here we discuss key parameters that need to be carefully considered when translating laboratory-developed RZIBs into commercial reality. We also present a critical mini-review on RZIBs and devote effort to issues that are overlooked in academic research. We believe that this perspective provides new or seldom-discussed insight for future work and bridges the gap between academia and industry.

25 ENERGY STORAGE↗
DOE OSTI2022

Thermal conductivity of salvaged fused cast alumina used in the glass industry

Fused cast alumina (FCA) has been and continues to be used as a refractory material in energy intensive industries such as glass melting and chemical processing. In-service degradation due to high temperature exposure in harsh environment affects the designed furnace thermal profiles and energy consumption. Phase transformation may occur at the refractory hot face during glass melting altering the properties. Three FCA blocks recovered from industrial furnaces were investigated in this study. The as-received FCA consists primarily of a mixture of alpha (α) and beta (β) alumina that has a thermal conductivity value of 5–6 W/mK. The Hot Disk method was used to obtain thermal conductivity directly on the refractory blocks. At the hot face, a transformation from β to α alumina occurred and was confirmed by an X-ray diffraction study. Thermal conductivity measurements as a function of position also showed a clear transition from β to α alumina at both ends of a complete block with no voids. Thermal conductivity of the α alumina tripled compared to β alumina. This study provides important information of heat transfer and thermal conductivity evolution to refractory manufacturers and users.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Active and Stable PtPd Diesel Oxidation Catalysts under Industry‐Defined Test Protocols

Nanoparticle-supported Pt and Pd catalysts are employed industrially to convert CO and hydrocarbon residue from incomplete diesel fuel combustion into more environmentally-benign products. However, these catalysts deactivate over time due to sintering, especially for Pt nanoparticles which readily generate volatile species under high operating temperatures. Here, we turned the detrimental vapor-mediated sintering of Pt into an advantage by using a physical mixture of Pt and Pd catalysts prepared using a raspberry-colloid-templating (RCT) method. The RCT method produced Pt/Al 2 O 3 and Pd/Al 2 O 3 catalysts with partially embedded NPs to inhibit surface-mediated sintering pathways. As validated using an industry-defined emission control test protocol, aging a physical mixture of Pt/Al 2 O 3 and Pd/Al 2 O 3 at high temperature produced an alloyed PtPd/Al 2 O 3 catalyst that outperformed the fresh catalyst mixture and both individual catalysts for hydrocarbon conversion, while exhibiting high catalytic stability and resistance to sintering and to SO 2 poisoning. X-ray photoelectron spectroscopy revealed that in the aged catalyst mixture, half of the Pd content existed in the more active metallic state, compared to the less active oxide forms in the fresh mixture and both individual catalysts, explaining the unusual activity enhancement. Our results represent a practical approach to producing active and stable PtPd/Al 2 O 3 diesel oxidation catalysts for emission control applications.

Lim, Kang Rui Garrick [Harvard University, Cambrid↗
DOE OSTI2022

Effect of oxidation on the release of multiple metals from industrially polluted sediments and synchrotron-based evidence of Cu–S dynamic association

Disposal operations for industrially polluted sediments are usually accompanied by disturbance and resuspension, which can induce metal remobilization and secondary pollution. Evaluating the risk of metal release under various redox conditions is fundamental for predicting contaminant mobilization and guiding remediation measures. An abandoned oxidation pond, Yanjia Lake, China, was selected as a typical industrially polluted site. Re-suspension experiments were carried out by mixing polluted sediments with lake water under oxic or anoxic conditions, then investigating the effect of oxidation conditions on the release of multiple metals. Metal concentrations and aqueous chemistry in the overlying water were monitored. Synchrotron-based methods, including X-ray absorption near-edge structure (XANES) and extended X-ray absorption fine structure (EXAFS), were used to characterize oxidation states and coordination conditions of metals in sediments. The release of metals, including Cr, Co, Ni, Cu, Zn, Se, Mo, Sn, Cd, and Pb, was enhanced under oxic vs. anoxic conditions. The XANES analysis revealed that elevated Cr and Zn concentrations under oxic conditions likely resulted from the oxidation of Cr(III) and oxidizing dissolution of ZnS, respectively. K-edge Cu XANES, S XANES, and Cu EXAFS analyses reconstructed the Cu–S association, indicating that S-related oxidation promoted Cu release and Cu–O partly replaced Cu–S in the sediment after a 7-day oxic treatment. The release of most metals was promoted under oxic conditions, resulting from the oxidation of sulfides and metals as indicated by aqueous and synchrotron-based evidence. The risk of secondary pollution is greatly enhanced under oxic conditions, which suggests that measures should be taken to minimize the redox disturbance during sediment remediation. This information can guide the management of sediments in Yanjia Lake and other contaminated sites with similar properties.

54 ENVIRONMENTAL SCIENCES↗