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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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The idea that low soot propensity of high-energy-density (HED) liquid sooting fuels and cost reduction of a multicomponent energetic fuel can be achieved by doping a less expensive, less sooting liquid fuel with HED is tested through numerical simulations.
An approach is proposed for the structuring of a planetary mission set wherein the peak annual funding is minimized to meet the annual budget restraint. One aspect of the approach is to have a transportation capability that can launch a mission in any planetary opportunity; such capability can be provided by solar electric propulsion. Another cost reduction technique is to structure a mission test in a time sequenced fashion that could utilize essentially the same spacecraft for the implementation of several missions. A third technique would be to fulfill a scientific objective in several sequential missions rather than attempt to accomplish all of the objectives with one mission. The application of the approach is illustrated by an example involving the Solar Orbiter Dual Probe mission.
The business of building satellites and space systems has matured. Few missions require, or can afford, excellent performance at any price. The new paradigm is doing more with less, providing quality systems at lower cost--in other words, doing our job 'Faster-Better-Cheaper.' The TRW Spacecraft COst REduction (SCORE) initiative was launched in 1990 by Daniel S. Goldin, then general manager of TRW's Space & Technology Group. The SCORE mission is to apply continuous improvement (CI) techniques to effect major reductions in the cost (our primary goal) and span time (as a corollary) required for the production of spacecraft. SCORE is a multi-year initiative that is having a profound effect on both the procedural and the cultural aspects of how we do business. The objectives of this initiative are being realized. The focus of this paper is not on the results of SCORE per se, but rather on the things we have leaned about how to do continuous improvement on a massive scale, with multilevel (hierarchical) CI teams. The following sections summarize the chronology of the SCORE initiative, from team formation to development of the year-end report for 1991. Lessons learned, the core of this presentation, are discussed--with particular focus on the unique aspects of SCORE. The SCORE initiative is continuing and, as a part of our evolving culture, will never end. It has resulted in profound insights into the way we do work and (the topic at hand) how to do CI for large and complex multidisciplinary development activities.
A key contributor to high capital costs and schedule overruns for new nuclear power plants is lack of standardization, driven by site-specific customization and construction of multiple designs by competing vendors rather than commitment to a single standardized program. While advanced reactor vendors typically individually target repeat construction of standardized units, the many competing designs could exacerbate the problem. “Open Architecture”, the open specification of requirements and interfaces for structures, systems and components (SSCs), has been proposed as a means of promoting standardization, by facilitating existing non-nuclear suppliers to enter the industry and/or allowing SSCs to be configured for more than one reactor within the same technology type. Contracting mechanisms that facilitate information sharing and alignment of incentives between stakeholders may complement such an approach. A preliminary scheme is presented for selection of SSCs for which such strategies could be adopted, based on a vendor make/buy decision model and stakeholder interviews. SSCs are categorized according to number of suppliers and their contribution to the reactor’s competitive edge. SSCs with many potential suppliers and a high contribution to competitive edge may be attractive for widening the supply chain via open specification of system requirements and interfaces, e.g., SSCs in the power island. SSCs with few suppliers and low contribution to competitive edge may be potential avenues for common system specification between vendors, e.g., some of the auxiliary SSCs. Potential cost reductions from such strategies will depend upon the size of the build program and the reactor type.
Thermal storage can be implemented using Phase-Change Materials (PCM), which absorb significant latent heat with a relatively small temperature change. PCM phase-change processes are transient and are driven by thermal diffusion and natural convection – the latter, especially for melting process. Modeling and simulation of PCM heat exchangers (HX’s) is typically computationally intensive due to the relatively complex time-dependent physics. Most of the PCM modeling work in the literature uses high-order modeling tools such as Computational Fluid Dynamics (CFD) and Lattice-Boltzmann Method (LBM). For design purposes, the existing PCM modeling approaches are not practical, limiting researchers in their ability to investigate new ideas and different PCM’s with faster turnarounds. This paper presents a study investigating the reduction of computational cost of PCM embedded HX’s CFD models by evaluating the feasibility of spatial reduction without losing accuracy. The analysis consists of comparing full and partial domain under full melting conditions. The subject of this study is a single straight tube with circular transverse fins in the vertical orientation, using PCM’s with 35oC nominal melting temperature. Different tube and fin dimensions are investigated. Results indicate that the reduced domain reproduces - in half the run time - the same behavior as the full domain since the buoyancy effects are localized and patterned. The outputs from the partial domain simulation were used to build a non-general correlation for the PCM heat transfer characteristics and demonstrated how it can be implemented in a Finite Control Volume Reduced Order Model (ROM). The ROM can accurately reproduce the CFD simulations at 4 to 5 orders of magnitude faster.
The electrochemical reduction of water to form hydrogen is an emerging alternative for energy storage, where hydrogen can be used as a transportation fuel, combusted to generate electricity, utilized in a fuel cell, or used as a feedstock for chemical synthesis. Techno-economic analysis (TEA) is a valuable tool for understanding how to inform research directions that could make hydrogen from electrolysis cost competitive with that produced by conventional means like steam methane reforming. The current state of knowledge on TEA of electrolysis systems suggests cost reductions are likely to result from advances in system design and materials, scale-up of manufacturing processes, and learning by doing effects as electrolysis deployment increases. Future directions and opportunities for TEA of electrolysis systems include dispatchable operation in wholesale power markets, optimization of capital cost and system durability, and analysis of pathways for hydrogen to support economy-wide decarbonization.
sCO2 turbomachinery that operates above 650°C requires the use of γ' strengthened Ni-based superalloys, leading to high cost and barrier of market adoption. Near-net-shape (NNS) HIP manufacturing with 282® alloy powder is being developed for sCO2 turbine components, with a significant estimated cost reduction. Tensile, creep, low cycle fatigue properties of argon gas atomized and plasma atomized powders were evaluated and compared to sand cast HAYNES® 282®. While tensile strength and fatigue life outperformed sand cast material, a 10~25% debit in the creep stress capability was observed due to the fine grain size and presence of prior particle boundaries (PPBs). Finite element model calibrated by powder rheological properties accurately predicted the nonuniform shrinkage during HIP, providing HIP tooling design to achieve the target dimension. A 20 lbs. turbine nozzle ring was successfully demonstrated within 0.01 inch dimensional tolerance at the vanes. A 1700lbs. turbine casing with complex internal struts and manifolds was also demonstrated being close to the target dimension.
Through radically improving the value equation for airline customers, Ryanair has served to shake-up established norms and practices in European aviation. Underpinning its price leadership and market success is a vigorous and relentless cost reduction ethos and resultant low break-even load factor. Ryanair has lowered European airline cost structures considerably, shattering existing cost floors. Few competitors are able to follow, either because they do not know how or they are unable due to social settlement obligations or service commitments. At the same time, the company has maintained high average load factors on its flights. Taken in conjunction with its low break-even load factor, this results in consistently high overall profit margins. On this basis, Ryanair is likely to remain a significant competitor and increase its market presence and success across Europe.
In 2007 the Johnson Space Center s Mission Operations Directorate (MOD) management team challenged their organizations to find ways to reduce the cost of operations for supporting the International Space Station (ISS) in the Mission Control Center (MCC). Each MOD organization was asked to define and execute projects that would help them attain cost reductions by 2012. The MOD Operations Division Flight Planning Branch responded to this challenge by launching several software automation projects that would allow them to greatly improve console operations and reduce ISS console staffing and intern reduce operating costs. These tasks ranged from improving the management and integration mission plan changes, to automating the uploading and downloading of information to and from the ISS and the associated ground complex tasks that required multiple decision points. The software solutions leveraged several different technologies including customized web applications and implementation of industry standard web services architecture; as well as engaging a previously TRL 4-5 technology developed by Ames Research Center (ARC) that utilized an intelligent agent-based system to manage and automate file traffic flow, archive data, and generate console logs. These projects to date have allowed the MOD Operations organization to remove one full time (7 x 24 x 365) ISS console position in 2010; with the goal of eliminating a second full time ISS console support position by 2012. The team will also reduce one long range planning console position by 2014. When complete, these Flight Planning Branch projects will account for the elimination of 3 console positions and a reduction in staffing of 11 engineering personnel (EP) for ISS.
In 2013, California implemented a mandate directing the state’s investor-owned utilities to procure 1325 MW of energy storage, to help integrate nondispatchable renewable sources of energy and assist the state in meeting its environmental goals. This paper evaluates this policy’s impact of both battery deployment, and cost, finding that as of 2019, the state was effective in spurring nearly 500 MWh of battery storage deployment over what would have been installed in absence of the policy. This additive deployment would have the effect of reducing global battery cell costs by roughly $1.00/ kWh, based on learning by doing. To support these findings, we utilize both a difference in differences estimation, and a synthetic control analysis, both of which allow us to compare battery deployment in California, to deployment in other states. To pair deployment to cost reduction, we use a learning curve analysis, which links battery shipments to cell and storage block costs. For policymakers, these results provide evidence to the effectiveness of mandates in promoting storage deployment and help explain how these policies can induce downstream effects.
While strategies to achieve net-zero emissions at an individual site are well understood, new analysis methods are required for organizations seeking to achieve net-zero across multiple facilities, each with concurrent priority goals. At a portfolio level, distinct locations present varied challenges that cannot be addressed through singular solutions, and competing goals can take precedence with the assumption that net-zero emissions strategies deter from energy resilience and cost savings, therefore negatively impacting nearby communities. This study tests these assumptions by analyzing 16 diverse sites (varying in size, climate, and energy use) to identify strategies that reduce emissions and assess the impact these strategies have on life cycle costs, resilience, and communities with environmental justice concerns. Methods were developed to approximate missing information essential to net-zero evaluation. Established methods were augmented to evaluate life cycle costs, resilience, and environmental justice impacts across a set of strategies and accommodate the multi-criteria analyses. Potential benefits from identified strategies were quantified using site characteristics and a set of corresponding metrics. The net-zero analysis found that 11 sites could use on-site strategies to eliminate all but 2% of emissions generated. The remaining emissions can be offset, for instance through sequestration, executed at the portfolio scale. On-site carbon-free energy was found to reduce 51% of emissions across all sites; efficiency reduced 19% of emissions; sequestration 16%; procured carbon-free energy 15%; fuel switching 1.6%; and fleet electrification 1.3%. Building electrification, however, increased emissions by 4.4%. Different strategies also provide cost, resilience, and/or environmental justice benefits—the degree to which varies with individual site conditions. The findings indicate an advantage to considering the strategies as a comprehensive set, which leads to co-benefits, both in the ability to achieve net-zero goals and in advancing other goals. The results present the case for comprehensive advanced planning at the portfolio level to prioritize investments that will balance the minimization of emissions and life cycle cost with the maximization of resilience and environmental justice benefits. The novel methods for evaluation and integration, valuation of benefits, and consideration at the portfolio scale allow organizations to select investments that simultaneously address multiple key priorities.
The completion of Vogtle Units 3 and 4, despite significant cost and schedule overruns, a major bankruptcy, and a pandemic, demonstrates that the U.S. nuclear industry can still develop new supply chains, train a highly skilled workforce, and build large nuclear power plants. Vogtle, being a first-of-a-kind (FOAK) plant, faced overruns, but FOAK overruns can decrease with more deployments through a combination of design standardization and modularization, transferring and implementing lessons learned between consecutive projects, and innovation. This report quantifies the potential cost and schedule reductions in future AP1000 plants in the US and identifies the barriers in achieving those reductions. It starts with a summary and analysis of the cost and construction timeline data for AP1000 plants that started construction in the United States (Vogtle) and China. Motivated by the steep schedule reductions from the first to second series of AP1000 plants in China, a cost reduction model was developed to quantify potential reductions for future AP1000 builds in the US. Results show that within about 3 more builds, AP1000s can become economically attractive in large markets in the U.S., without leveraging the Investment Tax Credit (ITC) or Production Tax Credit (PTC), and much sooner if these tax credits are available. Importantly the financial risks for future AP1000 builds in the US might be much smaller than observed in the FOAK plants. The study also identifies various barriers for future builds including the availability of a supply chain and a skilled workforce, and emphasizes the importance of making investments to gather and implement lessons learned between consecutive projects.
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Data from detailed studies on the possible economic impact of the use of remote sensing technology in industry and agriculture are presented and analyzed. The utility of satellite surveillance in reduction of crop production forecast error, recognition and monitoring of crop diseases and insect infestations, and range management is evaluated. Application of satellite maps to facilitate land resource decisions, mineral exploration, geological studies, and water resource inventories is considered, as is the usefulness of early storm warning in the reduction of property damage. The cost of remote sensing is compared to that of conventional methods whenever possible.
The cost of the DSN data base can be reduced by computerizing and unifying the current multiplicity of separate manual, computer, and hybrid data bases. Savings would accrue from eliminating all manual system costs, increasing efficiency in data base implementation and maintenance-and-operation, and increasing data accuracy. By applying a simple mathematical savings model to current data base costs, this study estimates the probable range of net ten-year savings. The minimum net savings, under the assumptions of the study, are calculated as $7.5 million.
Through this DOE funded 3.5-year research project, feasibility of fabricating supercritical carbon dioxide (sCO2) turbine components by powder metallurgy (PM) based near-net-shape (NNS) hot isostatic pressing (HIP) was demonstrated in a turbine nozzle ring, a turbine casing with Haynes 282 powder, and a bimetallic pipe with Haynes 282 and SS415 powder. As-HIP microstructure of various powders and HIP processing conditions was studied to downselect a condition for the prototype components. Tensile strength and low cycle fatigue (LCF) capability of PM HIP 282 was found to be superior to cast 282, despite a debit in creep stress capability that could be mitigated by component design modification. Near-Net-shape with minimal post machining was achieved by modeling the non-uniform shrinkage during HIP cycle and designing the HIP tooling to meet dimensional targets. The prototypes of turbine nozzle ring and bimetallic pipe were successful in achieving overall dimension, microstructure, and properties, despite dimensional tolerance affected by chemical milling rate. The prototype of a 1700lbs turbine casing was partially successful in achieving dimension, microstructure in as-HIP state, and providing consistent mechanical properties, however, cracking issue during post heat treatment required further investigation. The estimated manufacturing cost using NNS HIP was a ~50% reduction compared to forging with extensive machining, which translated into ~$100/kWe CAPEX cost reduction for concentrated solar power (CSP) power block.