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All sources NASA NTRS DOE OSTI

NASA NTRS2002

Launch Vehicle/Carrier Interaction, Improving the Analytical Integration Process

A goal of the aerospace industry is to reduce the cost of space transportation by a significant within the next decade. The present cost of launching a space transportation system which includes propulsion system, vehicle, carrier, and payload integrated together to form a system, encompasses much more than the design of the propulsion system and vehicle. The total cost includes the recurring cost of the process of integrating carriers, and payloads into the vehicle for each flight. The recurring cost of the integration of carrier/payloads systems is driven by the interaction of the vehicle. If the interaction can be well characterized and made to be very predictable for a range of payloads, or if it can be minimized then the cost of integrating a payload can be reduced significantly from today's levels. The Space Shuttle is very interactive with the payload. The interaction has been well characterized through finite element modeling and is reasonably predictable for a specific payload. Experience has shown, however, that the interaction is very manifest dependent, and small changes in one portion of a payload complement can change the interaction significantly in another portion. That is the affects of one on the other are such that if one or the other is changed slightly the environment at the interfaces can change significantly. To date the Shuttle has made in excess of one hundred flights. For each of these flights several iterations of dynamic analyses have been required in the development of each vehicle/carrier/payload system. The iterative analyses are needed because of the sensitivity of the interaction of the launch vehicle to the attached carrier/payload. The Multi Purpose Logistics Module (MPLM) is a carrier designed for flight in the Space Shuttle carrying a wide variation of cargo, supplies, and experiments to and from Space Station. Its integration process provides a unique area for improvement in the template in use today for transporting items to space. Discussion of the present MPLM integration analysis requirements and possible areas for improvement of the process are provided in the subject paper. Special emphasis is placed on reduction of requirements based on similarity of items being transported, and the use of carrier hardware for protection of the Shuttle Orbiter.

Shariett, Charles A.↗

DOE OSTI2023

Method and integrated process for the carboxylation of furan derived carboxylic acids to 2,5-furandicarboxylic acid

A process for carboxylation of a furoate slurry to produce FDCA, especially 2,5-FDCA, includes the steps of: feeding a slurry containing a suspension fluid, furoate, a surfactant and an alkali metal carbonate to a carboxylation reactor; and feeding a flow of CO 2 to the carboxylation reactor at flow conditions sufficient to suspend the slurry in the reactor and react the furoate with CO 2 to form 2,5-FDCA. A fully integrated process is also disclosed.

Kittrell, James R.↗

NASA NTRS1990

Integrated Process For Insertion And Beatup Of Fill Yarns

Integrated apparatus and process devised for insertion and beatup of fill yarns during weaving of fabrics containing bias-oriented yarns. New technology supplants old shuttle method and modern water-jet method of insertion and conventional reed method of beatup. Intended for use in angle-ply or bias-direction weaving process.

Farley, Gary L.↗

NASA NTRS2011

Integration Process for the Habitat Demonstration Unit

The Habitat Demonstration Unit (HDU) is an experimental exploration habitat technology and architecture test platform designed for analog demonstration activities. The HDU previously served as a test bed for testing technologies and sub-systems in a terrestrial surface environment. in 2010 in the Pressurized Excursion Module (PEM) configuration. Due to the amount of work involved to make the HDU project successful, the HDU project has required a team to integrate a variety of contributions from NASA centers and outside collaborators The size of the team and number of systems involved With the HDU makes Integration a complicated process. However, because the HDU shell manufacturing is complete, the team has a head start on FY--11 integration activities and can focus on integrating upgrades to existing systems as well as integrating new additions. To complete the development of the FY-11 HDU from conception to rollout for operations in July 2011, a cohesive integration strategy has been developed to integrate the various systems of HDU and the payloads. The highlighted HDU work for FY-11 will focus on performing upgrades to the PEM configuration, adding the X-Hab as a second level, adding a new porch providing the astronauts a larger work area outside the HDU for EVA preparations, and adding a Hygiene module. Together these upgrades result in a prototype configuration of the Deep Space Habitat (DSH), an element under evaluation by NASA's Human Exploration Framework Team (HEFT) Scheduled activates include early fit-checks and the utilization of a Habitat avionics test bed prior to installation into HDU. A coordinated effort to utilize modeling and simulation systems has aided in design and integration concept development. Modeling tools have been effective in hardware systems layout, cable routing, sub-system interface length estimation and human factors analysis. Decision processes on integration and use of all new subsystems will be defined early in the project to maximize the efficiency of both integration and field operations. In addition a series of tailored design reviews are utilized to quickly define the systems and their integration into the DSH configuration. These processes are necessary to ensure activities, such as partially reversing integration of the X-Hab second story of the HDU and deploying and stowing the new work porch for transportation to the JSC Rock Yard and to the Arizona Black Point Lava Flow Site are performed with minimal or no complications. In addition, incremental test operations leading up to an Integrated systems test allows for an orderly systems test program. For FY-11 activities, the HDU DSH will act as a laboratory utilizing a new X-Hab inflatable second floor with crew habitation features. In addition to the day to day operations involving maintenance of the HDU and exploring the surrounding terrain, testing and optimizing the use of the new X-Hab, work porch, Hygiene Module, and other sub-system enhancements will be the focus of the FY-11 test objectives. The HDU team requires a successful integration strategy using a variety of tools and approaches to prepare the DSH for these test objectives. In a challenging environment where the prototyping influences the system design, as well as Vice versa, results of the HDU DSH field tests will influence future designs of habitat systems.

Gill, Tracy↗

DOE OSTI2026

Solar Heat for Industrial Processes: Integration with Chemical Reactors

The integration of solar thermal systems with chemical reactors has been proposed as part of a larger effort to develop and deploy solar heat for industrial processes (SHIP) technologies. A strong motivation for SHIP processes and technologies is the potential for high thermal efficiency coupled with low-cost thermal energy storage (TES) which can enable commercial deployment of such systems. While there are different ways to categorize SHIP technologies, one important such distinction is between directly irradiated systems and indirect off-sun process driven by a SHIP system. While directly irradiated systems can provide high thermal efficiencies and high fluxes, they usually require complex engineering solutions due to the need for redesigning the established processes and unit operations. In most cases, it is also more challenging to couple such a process to a TES system, losing some of the benefits of SHIP. On the other hand, using a SHIP system to drive an industrial process off-sun can allow better integration with existing process chains, easier TES capabilities, and potential for more applications fitting a specific SHIP technology. However, the integration of SHIP systems with the industrial processes is not fully explored in detail, especially in the case of high-temperature processes such as reforming, cracking, cement manufacturing, and iron/steelmaking. Many of these systems require heating fluxes of >50 kW/m^2, supplied via combustion of hydrocarbons in a fire box and benefitting from radiative heat transfer between the flue gases and the reaction zones. As such, using SHIP systems for such processes is more complex than providing the same thermal input in the form of a heat transfer medium (HTM) entering the reactor, kiln, or furnace. Moreover, in case convective heat transfer using SHIP is envisioned, for example using supercritical CO2 as the HTM from a particle receiver, the thermal integration might be more challenging than initially envisioned: lower heat transfer coefficients and limited approach temperature might require large flow rates, causing a mismatch between the process thermal requirements and the thermal capacity of the SHIP system. In addition, even if the heat exchange between SHIP and reactor is effective, there is still a cold leg HTM at the reaction temperature or slightly below it. Chemical plants usually include a set of heat exchangers, heat recovery steam generators, and even power generation units - in a tightly integrated design - to recover the flue gases which are eventually vented. With SHIP systems mostly operating on a closed HTM loop, bottoming the cold leg is crucial. In this talk, we will present different modeling results for a variety of syngas production reactions, using catalytic and chemical looping processes, and discuss some of the challenges and design considerations for off-sun chemical reactors using SHIP systems.

14 SOLAR ENERGY↗

DOE OSTI2022

U-gas +Cool GTL™ - A New Integrated Process for Direct Biomass Conversion to Liquid Fuels

The U-Gas gasification technology, marketed by Sungas, is a proven fluid bed gasification technology for biomass conversion. U-Gas has been tested on a wide variety of biomass feeds including wood and waste streams. The U-Gas Technology has successfully converted wood for more than 20 years in a gasification plant in Skive Denmark at the 150t/d size. GTI has also recently developed the Cool GTL process for converting biogas to high quality gasoline, jet, and diesel fuels. The technoeconomics and LCA for the combination of the two technologies results an integrated optimized process, which will be discussed. The Cool GTL process is still in development and the development should be complete by 2023. Cool GTL converts high CO2 content feeds to synthesis gas with a 2-2.4/1 H2/CO ratio suitable for fuels synthesis. The process is based on a novel, highly stabile CO2/steam reforming catalyst. The 2.0-2.4/1 H2/CO synthesis gas ratio is always achieved, independently of feed CO2 content, by adjusting the amount of water added according to the amount of CO2 in the feed. The reformer catalyst has been tested for 500 hours and shows no measurable deactivation. The product from the reformer then goes directly to a low temperature slurry bed Fischer Tropsch reactor with an integrated finishing hydroisomerization reactor which makes hydrocarbon liquids from the synthesis gas. With this configuration no wax is produced. The technoeconomics and carbon intensity for the integration of UGas and the Cool GTL processes will be compared to other biomass conversion approaches. The use of electrolysis to boost H2 in the feed and increase liquid production will also be analyzed as a potential process improvement with sensitivities to the cost of electricity and the use of renewable electricity.

09 BIOMASS FUELS↗

NASA NTRSDate not supplied

Optimizing Urban Air Mobility Research Through Bi-Directional Integration Processes for Effective Verification and Validation

Urban Air Mobility (UAM), a subset of Advanced Air Mobility (AAM), aims to revolutionize metropolitan transportation. This paper explores an engineering process framework within National Aeronautics and Space Administration (NASA)’s Air Mobility Pathfinders (AMP) project, which is focused on the safe scaling and seamless integration of UAM operations within the National Airspace System (NAS). Progressing through three phases — Initial, Midterm, and Mature — the Federal Aviation Administration (FAA)’s UAM Concept of Operations (ConOps) describes a proposed path for the evolution of UAM operations, presenting multifaceted challenges in technology, regulation, and stakeholder engagement. With this ConOps as a basis, the AMP project is executing research, development, test, and evaluation activities aimed at delivering validated reference architectures for the Midterm phase. This paper illuminates the pivotal role of the systems engineering process in managing these technical efforts. Robust verification and validation methods, along with systematic bi-directional integration process, enhance the ability to conduct research into the design and evolution of safe, efficient, and reliable UAM systems. In this paper a systematic framework will be presented and shown to facilitate interactions between UAM stakeholders and to effectively manage the complex architecture of UAM operations in the NAS.

National Airspace System↗

DOE OSTI2021

Sustainable production of 5-hydroxymethyl furfural from glucose for process integration with high fructose corn syrup infrastructure

5-Hydroxymethyl furfural (HMF) is a platform chemical, which can be derived from lignocellulosic biomass, and used for production of liquid fuels and polymers. We demonstrate a process for production of HMF using sequential enzymatic and catalytic reactions of glucose to synthesize HMF, and simulated-moving-bed (SMB) separation to purify HMF. The adsorption thermodynamic parameters of glucose, fructose, and HMF on a commercial chromatography resin are experimentally determined for modeling the SMB-based HMF production process. The experimental data are used to develop a rigorous process model and then estimate the cost of production. Chromatographic separation of HMF has 16% lower operating costs compared to an extraction-based process and has a minimum selling price of approximately $1478 per ton. We demonstrate that the HMF process can be integrated with the high fructose corn syrup (HFCS) process, and we performed analyses considering two systems including construction of a new integrated facility and retrofitting an existing HFCS facility to produce HMF. Our analyses suggest that the latter approach is a promising short-term low-risk strategy to advance the HMF production technology to commercial scale.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Accelerating manufacturing for biomass conversion via integrated process and bench digitalization: a perspective

We present a perspective for accelerating biomass manufacturing via digitalization. We summarize the challenges for manufacturing and identify areas where digitalization can help. A profound potential in using lignocellulosic biomass and renewable feedstocks, in general, is to produce new molecules and products with unmatched properties that have no analog in traditional refineries. Discovering such performance-advantaged molecules and the paths and processes to make them rapidly and systematically can transform manufacturing practices. Furthermore, we discuss retrosynthetic approaches, text mining, natural language processing, and modern machine learning methods to enable digitalization. Laboratory and multiscale computation automation via active learning are crucial to complement existing literature and expedite discovery and valuable data collection without a human in the loop. Such data can help process simulation and optimization select the most promising processes and molecules according to economic, environmental, and societal metrics. We propose the close integration between bench and process scale models and data to exploit the low dimensionality of the data and transform the manufacturing for renewable feedstocks.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Development of Algal Biomass Yield Improvements in an Integrated Process (Final Report)

This project built on the success of Global Algae Innovations Algae Biomass Yield Phase 1 project to accelerate the commercialization of algal biofuels through development of an integrated, economical, photosynthetic, open raceway system to produce algal oil. Two parallel pathways to a biofuel were investigated. In the algal crude oil pathway, highlighted in blue, the dewatered algal biomass slurry is used as a feed to hydrothermal liquefaction to produce an algae crude oil and recycle aqueous stream. In the algal lipid oil pathway, highlighted in green, the algal biomass slurry is dried, and the oil is extracted to produce an algal lipid oil biofuel intermediate and a high protein algae meal co-product. Upgrading to drop-in fuels has been demonstrated for the biofuel intermediates in both pathways. Since the algal lipid oil pathway requires lipid accumulation, the productivity is generally lower than the algal crude oil pathway, but the required productivity for economical algal biofuel production is also lower because the coproduct value is greater. The outdoor cultivation was performed at the Kauai Algae Farm. The project team has expertise across the full breadth strain development, advanced algal cultivation, open raceway contamination control, CO 2 supply, harvesting, dewatering, extraction, hydrothermal liquefaction, technoeconomic analysis and life cycle analysis: Hildebrand laboratory at Scripps Institution of Oceanography – diatom strain development. Mayfield laboratory at UCSD - green algae strain development. TSD Management Associates- CO 2 supply, algal harvesting and dewatering, and algal drying and extraction. Qualitas - large-scale test site for algal harvesting technology. Texas A&M University - algal drying and extraction technology. Pacific Northwest National Laboratory - hydrothermal liquefaction technology. GE Water and Power - membrane technology. National Renewable Energy Laboratory - algal techno-economic analysis. Phase 1 of the project resulted in tremendous productivity and pre-processing improvements in an integrated, large-scale, low-cost cultivation and pre-processing process that moved algal technology closer to economic viability for biofuels than ever before. Phase 2 accomplishments further facilitate development of a commercial algal biofuel industry by adding: several top performing strains and strain development tools including breeding; open-pond cultivation innovations that achieved a 30% improvement in overall productivity, an 83% reduction in cost, and a 95% reduction in energy use relative to conventional technology; further improvements in harvesting that led to the Zobi harvester ® as a universal, economical, low energy, commercially available microalgae harvesting solution; breakthroughs in drying and extraction including a new low energy drying process and several new low energy extraction unit operations that together with the Zobi harvester ® achieve a 90% reduction in cost and 97% reduction in energy use relative to conventional technology. These improvements are sufficient to enable economical production of algae biofuel and protein meal co-product if the process were scaled up to a commercial-scale 5,000-acre algae farm.

09 BIOMASS FUELS↗

DOE OSTI2023

Towards an Integrated Process for CO 2 Capture and Utilization: Cultivation of Scenedesmus acutus Using Gaseous CO 2 and NH 3

Integrating CO 2 scrubbing from flue gas with its utilization in algae cultivation represents a potential means of lowering the cost of CO 2 capture. Towards this goal, this study sought to assess the feasibility of using gaseous a CO 2 /NH 3 stream, derived from CO 2 capture using aqueous ammonia, as a C- and N-source for algae cultivation. Scenedesmus acutus was cultured in 800 mL photobioreactors using gaseous CO 2 /NH 3 in mole ratios varying from 7 to 18. Excellent growth of Scenedesmus acutus was observed, the average growth rate for CO 2 /NH 3 = 10 of 0.171 ± 0.015 g/L·day exceeding that obtained using 1% CO 2 /N 2 and urea as the N-source (0.099 ± 0.28 g/L·day). Under optimal growth conditions (CO 2 /NH 3 mole ratio of 10), CO 2 utilization ranged from 57% to 72%, while the NH 3 utilization was >90%. The CO 2 /NH 3 feed rate was also found to exert a significant effect on algae productivity, excessive feed rates leading to accumulation of NH 3 in the culture at concentrations that were toxic to the algae. Consequently, to avoid the toxic effects of high NH 3 concentrations (>2.0 mM), it proved necessary to balance the NH 3 supply with the algae growth rate so that excessive NH 3 accumulation was prevented. This indicates that for practical applications, a CO 2 /NH 3 feed control strategy would be required that takes into account the ammonium ion concentration in solution and the pH so as to avoid significant concentrations of free NH 3 . Furthermore, analysis of the harvested biomass revealed a high protein (≥ 47 wt%) and a low ash content (< 3.6 wt%), suggesting it would be well suited for use as animal feed or as a feedstock for the production of bioplastics.

03 NATURAL GAS↗

NASA NTRS2010

Integration Process for the Habitat Demonstration Unit

The Habitat Demonstration Unit (HDU) is an experimental exploration habitat technology and architecture test platform designed for analog demonstration activities The HDU project has required a team to integrate a variety of contributions from NASA centers and outside collaborators and poses a challenge in integrating these disparate efforts into a cohesive architecture To complete the development of the HDU from conception in June 2009 to rollout for operations in July 2010, a cohesive integration strategy has been developed to integrate the various systems of HDU and the payloads, such as the Geology Lab, that those systems will support The utilization of interface design standards and uniquely tailored reviews have allowed for an accelerated design process Scheduled activities include early fit-checks and the utilization of a Habitat avionics test bed prior to equipment installation into HDU A coordinated effort to utilize modeling and simulation systems has aided in design and integration concept development Modeling tools have been effective in hardware systems layout, cable routing and length estimation, and human factors analysis Decision processes on the shell development including the assembly sequence and the transportation have been fleshed out early on HDU to maximize the efficiency of both integration and field operations Incremental test operations leading up to an integrated systems test allows for an orderly systems test program The HDU will begin its journey as an emulation of a Pressurized Excursion Module (PEM) for 2010 field testing and then may evolve to a Pressurized Core Module (PCM) for 2011 and later field tests, depending on agency architecture decisions The HDU deployment will vary slightly from current lunar architecture plans to include developmental hardware and software items and additional systems called opportunities for technology demonstration One of the HDU challenges has been designing to be prepared for the integration of presently unanticipated systems Results of the HDU field tests will influence future designs of habitat systems.

Gill, Tracy↗

NASA NTRS2020

Assembly and Integration Process of the High-Density Detector Array Readout Modules for the Simons Observatory

The Simons Observatory will measure the cosmic microwave background tempera-ture and polarization using a suite of new telescopes in the Atacama Desert in Chile. The Simons Observatory will use dichroic transition edge sensor (TES) bolometer arrays spanning six frequency bands from 27 to 280 GHz. The Simons Observa-tory will pioneer the use of a densely packed multiplexing architecture based on the microwave SQUID multiplexer ( 𝜇mux), housing ∼2000 microwave resonators, each coupled to a TES. The Simons Observatory aims to multiplex each array of ∼2000 detectors with a single pair of coaxial cables and requires a multiplexing factor of ∼1000 . The Simons Observatory cryogenic readout system is called the universal microwave multiplexing module (UMM). The UMM couples to both horn and lenslet-coupled detector arrays and is integrated into the universal focal-plane module (UFM) after being independently characterized. We present processes we have developed for highly repeatable and automated integration methods of UMMs, which will be needed for the production of the 49 UFMs required for the first stage of the Simons Observatory.

CMB↗

DOE OSTI2020

Solution-processable integrated CMOS circuits based on colloidal CuInSe2 quantum dots

Abstract The emerging technology of colloidal quantum dot electronics provides an opportunity for combining the advantages of well-understood inorganic semiconductors with the chemical processability of molecular systems. So far, most research on quantum dot electronic devices has focused on materials based on Pb- and Cd chalcogenides. In addition to environmental concerns associated with the presence of toxic metals, these quantum dots are not well suited for applications in CMOS circuits due to difficulties in integrating complementary n - and p -channel transistors in a common quantum dot active layer. Here, we demonstrate that by using heavy-metal-free CuInSe 2 quantum dots, we can address the problem of toxicity and simultaneously achieve straightforward integration of complimentary devices to prepare functional CMOS circuits. Specifically, utilizing the same spin-coated layer of CuInSe 2 quantum dots, we realize both p - and n -channel transistors and demonstrate well-behaved integrated logic circuits with low switching voltages compatible with standard CMOS electronics.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1986

Integral processing in beyond-Hartree-Fock calculations

The increasing rate at which improvements in processing capacity outstrip improvements in input/output performance of large computers has led to recent attempts to bypass generation of a disk-based integral file. The direct self-consistent field (SCF) method of Almlof and co-workers represents a very successful implementation of this approach. This paper is concerned with the extension of this general approach to configuration interaction (CI) and multiconfiguration-self-consistent field (MCSCF) calculations. After a discussion of the particular types of molecular orbital (MO) integrals for which -- at least for most current generation machines -- disk-based storage seems unavoidable, it is shown how all the necessary integrals can be obtained as matrix elements of Coulomb and exchange operators that can be calculated using a direct approach. Computational implementations of such a scheme are discussed.

Taylor, P. R.↗

NASA NTRS1988

Addressable test matrix for measuring analog transfer characteristics of test elements used for integrated process control and device evaluation

A set of addressable test structures, each of which uses addressing schemes to access individual elements of the structure in a matrix, is used to test the quality of a wafer before integrated circuits produced thereon are diced, packaged and subjected to final testing. The electrical characteristic of each element is checked and compared to the electrical characteristic of all other like elements in the matrix. The effectiveness of the addressable test matrix is in readily analyzing the electrical characteristics of the test elements and in providing diagnostic information.

Buehler, Martin G.↗

NASA NTRSDate not supplied

Pt/HTCC Alumina based Electronic Packaging System and Integration Processes for High Temperature Harsh Environment Applications

Electronic devices capable of operation at 500°C are required for long term Venus surface missions, as well as for in situ monitoring and control of next generation aeronautical engines. High temperature sensors and electronics can also find many applications in military, and energy and automobile industries. Various silicon carbide (SiC) sensors and electronic devices have been developed for operation at 500 °C, and a compatible packaging system is needed for long term test and deployment of these high temperature devices. High temperature co-fired ceramics (HTCC) alumina with platinum (Pt) conductor was proposed for high temperature electronic packaging. A prototype Pt/HTCC alumina packaging system including chip-level package and circuit board has been briefly reported previously for long-term electrical testing of SiC integrated circuits at 500 °C, and brief testing at much higher temperatures. HTCC alumina is an excellent dielectric material with acceptable dielectric constant and low dielectric loss over wide temperature and frequency ranges. Pt is chemically noble and can be co-fired with HTCC alumina in air ambient producing a viable electronic packaging material system for high temperature applications. This paper presents a more detailed description of this packaging system including prototype low power packages and circuit boards based on HTCC alumina and Pt metallization for 500°C and other harsh environment applications. The key technical considerations for chip-level packaging and circuit board assembly, including materials and processes for 500 °C durable wire-bonding and SiC die attach, and integration of multi-chip circuit boards, are presented. Experimental test results of this packaging approach applied to SiC integrated circuits at 500 °C and 700°C are discussed as well.

High temperature↗

NASA NTRSDate not supplied

Pt/HTCC Alumina based Electronic Packaging System and Integration Processes for High Temperature Harsh Environment Applications

electronic packaging↗