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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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DOE OSTI2013

Diffusion-Welded Microchannel Heat Exchanger for Industrial Processes

The goal of next generation reactors is to increase energy ef?ciency in the production of electricity and provide high-temperature heat for industrial processes. The ef?cient transfer of energy for industrial applications depends on the ability to incorporate effective heat exchangers between the nuclear heat transport system and the industrial process. The need for ef?ciency, compactness, and safety challenge the boundaries of existing heat exchanger technology. Various studies have been performed in attempts to update the secondary heat exchanger that is downstream of the primary heat exchanger, mostly because its performance is strongly tied to the ability to employ more ef?cient industrial processes. Modern compact heat exchangers can provide high compactness, a measure of the ratio of surface area-to-volume of a heat exchange. The microchannel heat exchanger studied here is a plate-type, robust heat exchanger that combines compactness, low pressure drop, high effectiveness, and the ability to operate with a very large pressure differential between hot and cold sides. The plates are etched and thereafter joined by diffusion welding, resulting in extremely strong all-metal heat exchanger cores. After bonding, any number of core blocks can be welded together to provide the required ?ow capacity. This study explores the microchannel heat exchanger and draws conclusions about diffusion welding/bonding for joining heat exchanger plates, with both experimental and computational modeling, along with existing challenges and gaps. Also, presented is a thermal design method for determining overall design speci?cations for a microchannel printed circuit heat exchanger for both supercritical (24 MPa) and subcritical (17 MPa) Rankine power cycles.

42 ENGINEERING↗

DOE OSTI2014

Simulation of an Industrial Tangentially Fired Boiler Firing Metallurgical Gases

In industrial environments, boiler units are widely used to supply heat and electrical power. At an integrated steel mill, industrial boilers combust a variable mixture of metallurgical gases combined with additional fuels to generate high-pressure superheated steam. Most tangentially fired boilers have experienced water wall tube failures in the combustion zone, which are thought to be caused by some deficiency in the combustion process. The challenge faced in this present process is that there are very limited means to observe the boiler operation. In our study, a three-dimensional computational fluid dynamics (CFD) modeling and simulation of an industrial tangentially fired boiler firing metallurgical gases was conducted. Eddy dissipation combustion model was applied on this multiple fuel combustion process. Simulation results obtained from the developed CFD model were validated by industrial experiments. Furthermore, a quick comparison of the flame shape from the simulation to the actual flame in the boiler showed a good agreement. We also analyzed the flow field and temperature distribution inside the tangentially fired boiler under the operation conditions, and a wall water tube overheating problem was observed and directly related to the flow

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Industry 4.0 and Intelligent Manufacturing Processes: A Review of Modern Sensing Technologies

Digital Manufacturing technologies have quickly become ubiquitous in the manufacturing industry. The transformation commonly referred to as the fourth industrial revolution, or Industry 4.0, has ushered in a wide range of communication technologies, connection mechanisms, and data analysis capabilities. These technologies provide powerful tools to create a more lean, profitable, and data-driven manufacturing processes. In this paper, we review modern communication technologies and connection architectures for Digital Manufacturing and Industry 4.0 applications. An introduction to Cyber-Physical Systems and a review of digital manufacturing trends is followed by an overview of data acquisition methods for manufacturing processes. Numerous communication protocols are presented and discussed for connecting disparate machines and processes. Flexible data architectures are discussed and examples of machine monitoring implementations are provided. Finally, select implementations of these communication protocols and architectures are surveyed with recommendations for future architecture implementations.

42 ENGINEERING↗

DOE OSTI2012

Development of non-invasive acoustic characterization techniques for the oil and gas industry [Slides]

The production of crude oil and other liquid fuels in the US has been steadily rising since 2007 and according the International Energy Agency, the US will be entirely self-sufficient by 2030. This forecast is based on advancing new extraction methods and also developing smaller and more marginal reservoirs in a cost effective way. This requires highly efficient monitoring technology that can provide an accurate and realtime estimate of oil production from each and every well. The technologies currently used in oil-fields are either decades old, not very accurate, expensive to maintain and operate, and often incapable of delivering real-time information. Therefore, the oil and gas industry is looking for technology that can monitor multiphase (oil/water/gas) production fluids to address all these challenges and ensure energy security for the future. In this talk, I will discuss the development of an ultrasound-based noninvasive technique for the simultaneous and real-time measurement of both the composition (“water-cut”) and flow rate of crude oil and process water as these are pumped out from the ground. This technique relies on the accurate ultrasound propagation characterization of a flowing multiphase fluid through a thick-walled pipe. Time-dependent ultrasound transmission and its spatial coherence were used to determine several important physical parameters of the fluid mixture, such as sound speed, sound attenuation, and flow velocity. Different algorithms were developed to derive appropriate composition values from this data. The composition algorithm originates from the fundamental behavior of sound propagation in composite materials. A remotely-controllable portable instrument was built and tested extensively on location at various oil fields in the US. The technology developed has been licensed to industry and the final product is currently being manufactured. Upon deployment, the instrument is expected to positively impact reservoir management schemes and be applicable to various process control industries. I will conclude with brief descriptions of additional ultrasonic techniques currently being developed by the Acoustics and Sensors Team to address future challenges in the oil industry.

02 PETROLEUM↗

DOE OSTI2013

Emerging Energy-efficiency and Carbon Dioxide Emissions-reduction Technologies for the Iron and Steel Industry

Iron and steel manufacturing is among the most energy-intensive industries and accounts for the largest share, approximately 27 percent, of global carbon dioxide (CO 2 ) emissions from the manufacturing sector. The ongoing increase in world steel demand means that this industry’s energy use and CO 2 emissions continue to grow, so there is significant incentive to develop, commercialize and adopt emerging energy-efficiency and CO 2 emissions-reduction technologies for steel production. Although studies from around the world have identified a wide range of energy-efficiency technologies applicable to the steel industry that have already been commercialized, information is limited and/or scattered regarding emerging or advanced energy-efficiency and low-carbon technologies that are not yet commercialized. This report consolidates available information on 56 emerging iron and steel industry technologies, with the intent of providing a well-structured database of information on these technologies for engineers, researchers, investors, steel companies, policy makers, and other interested parties. For each technology included, we provide information on energy savings and environmental and other benefits, costs, and commercialization status; we also identify references for more information.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2013

Analysis of Energy-Efficiency Opportunities for the Pulp and Paper Industry in China

This study assesses the impact of 23 energy-efficiency measures that could be applied in China's pulp and paper industry. We analyze the fuel- and electricity-efficiency improvement potential of these technologies for the year 2010 using a bottom-up conservation supply curve (CSC) model. The fuel CSC model shows that the cost-effective fuel efficiency improvement potential for China's pulp and paper industry is 179.6 PJ, and the total technical fuel-savings potential is 254.3 PJ. These figures represent 26.8 percent and 38.0 percent, respectively, of total fuel used in China’s pulp and paper industry in 2010. The CO 2 emissions reduction potential associated with ii the cost-effective fuel savings is 16.9 Mt CO 2 , and the total technical potential for CO 2 emissions reduction is 24.2 Mt CO 2 . The electricity CSC model shows that the total technical electricity-efficiency potential to 2,316 gigawatt-hours (GWh) or 4.3 percent of total electricity use in the pulp and paper industry in 2010. All of the electricity-efficiency potential is cost effective. The CO 2 emissions reduction potential associated with the total electricity savings is 1.8 Mt CO 2 . Sensitivity analyses for adoption rate, discount rate, electricity and fuel prices, investment costs, and the energy savings from each measure show that these parameters have significant influence on the results. Therefore, the results presented in this report should be interpreted with caution.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2012

Assessment of Energy Efficiency Improvement and CO2 Emission Reduction Potentials in India's Iron and Steel Industry

India’s 2010 annual crude steel production was 68 Mt which accounted for nearly five percent of the world’s annual steel production in the same year. In 2007, roughly 1600 PJ were consumed by India’s iron and steel industry to produce 53 Mt of steel. We identified and analyzed 25 energy efficiency technologies and measures applicable to the processes in the Indian iron and steel industry. The Conservation Supply Curve (CSC) used in this study is an analytical tool that captures both the engineering and the economic perspectives of energy conservation. Using a bottom-up electricity CSC model and compared to an electricity price forecast the cumulative plant-level cost-effective electricity savings potential for the Indian iron and steel industry for 2010-2030 is estimated to be 66 TWh, and the cumulative plant-level technical electricity saving potential is only slightly greater than 66 TWh for the same period. The primary energy related CO2 emissions reduction associated with cost-effective electricity savings is 65 Mt CO2. Compared to a fuel price forecast, an estimated cumulative cost-effective fuel savings potential of 768 PJ with associated CO2 emission reduction of 67 Mt CO2 during 2010-2030 is possible. In addition, a sensitivity analysis with respect to the discount rate used is conducted to assess the effect of changes in this parameter on the results. The result of this study gives a comprehensive and easy to understand perspective to the Indian iron and steel industry and policy makers about the energy efficiency potential and its associated cost.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2012

CO 2 Saline Storage Demonstration in Colorado Sedimentary Basins. Applied Studies in Reservoir Assessment and Dynamic Processes Affecting Industrial Operations

This multitask research project was conducted in anticipation of a possible future increase in industrial efforts at CO 2 storage in Colorado sedimentary basins. Colorado is already the home to the oldest Rocky Mountain CO 2 storage site, the Rangely Oil Field, where CO 2 -EOR has been underway since the 1980s. The Colorado Geological Survey has evaluated storage options statewide, and as part of the SW Carbon Sequestration Partnership the Survey, is deeply engaged in and committed to suitable underground CO 2 storage. As a more sustainable energy industry is becoming a global priority, it is imperative to explore the range of technical options available to reduce emissions from fossil fuels. One such option is to store at least some emitted CO 2 underground. In this NETL-sponsored CO 2 sequestration project, the Colorado School of Mines and our partners at the University of Colorado have focused on a set of the major fundamental science and engineering issues surrounding geomechanics, mineralogy, geochemistry and reservoir architecture of possible CO 2 storage sites (not limited to Colorado). Those are the central themes of this final report and reported below in Tasks 2, 3, 4, and 6. Closely related to these reservoir geoscience issues are also legal, environmental and public acceptance concerns about pore space accessibility—as a precondition for CO 2 storage. These are addressed in Tasks 1, 5 and 7. Some debates about the future course of the energy industry can become acrimonius. It is true that the physics of combustion of hydrocarbons makes it impossible for fossil energy to attain a carbon footprint anywhere nearly as low as that of renewables. However, there are many offsetting benefits, not the least that fossil energy is still plentiful, it has a global and highly advanced distribution system in place, and the footprint that the fossil energy infrastructure occupies is orders of magnitude smaller than renewable energy facilities with equivalent energy capacity. Finally, inexpensive natural gas here in North America is pushing coal for electricity generation off the market, thus reducing US CO 2 emissions faster than any other large industrialized nation. These two big factors argue for renewed efforts to find technology solutions to reduce the carbon footprint (carbon dioxide as well as methane and trace gases) of conventional and unconventional oil and gas. One major such technology component is likely to be carbon capture, utilization and storage.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2012

Assessment of Energy Efficiency Improvement and CO 2 Emission Reduction Potentials in the Cement Industry in China

China’s annual cement production (i.e., 1,868 Mt) in 2010 accounted for nearly half of the world’s annual cement production in the same year. We identified and analyzed 23 energy efficiency technologies and measures applicable to the processes in the cement industry. The Conservation Supply Curve (CSC) used in this study is an analytical tool that captures both the engineering and the economic perspectives of energy conservation. Using a bottom-up electricity CSC model, the cumulative cost-effective electricity savings potential for the Chinese cement industry for 2010-2030 is estimated to be 251 TWh, and the total technical electricity saving potential is 279 TWh. The CO 2 emissions reduction associated with cost-effective electricity savings is 144 Mt CO 2 and the CO 2 emission reduction associated with technical electricity saving potential is 161 Mt CO 2 . The fuel CSC model for the cement industry suggests cumulative cost-effective fuel savings potential of 4,326 PJ which is equivalent to the total technical potential with associated CO 2 emission reductions of 406 Mt CO 2 . In addition, a sensitivity analysis with respect to the discount rate used is conducted to assess the effect of changes in this parameter on the results. We also developed a scenario in which instead of only implementing the international technologies in 2010-2030, we implement both international and Chinese domestic technologies during the analysis period and calculate the saving and cost of conserved energy accordingly. The result of this study gives a comprehensive and easy to understand perspective to the Chinese cement industry and policy makers about the energy efficiency potential and its associated cost.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2015

Curbing Air Pollution and Greenhouse Gas Emissions from Industrial Boilers in China

China’s industrial boiler systems consume 700 million tons of coal annually, accounting for 18% of the nation’s total coal consumption. Together these boiler systems are one of the major sources of China’s greenhouse gas (GHG) emissions, producing approximately 1.3 gigatons (Gt) of carbon dioxide (CO 2 ) annually. These boiler systems are also responsible for 33% and 27% of total soot and sulfur dioxide (SO2) emissions in China, respectively, making a substantial contribution to China’s local environmental degradation. The Chinese government - at both the national and local level - is taking actions to mitigate the significant greenhouse gas (GHG) emissions and air pollution related to the country’s extensive use of coal-fired industrial boilers. The United States and China are pursuing a collaborative effort under the U.S.-China Climate Change Working Group to conduct a comprehensive assessment of China’s coal-fired industrial boilers and to develop an implementation roadmap that will improve industrial boiler efficiency and maximize fuel-switching opportunities. Two Chinese cities – Ningbo and Xi’an – have been selected for the assessment. These cities represent coastal areas with access to liquefied natural gas (LNG) imports and inland regions with access to interprovincial natural gas pipelines, respectively.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2015

Energy-Efficiency and Air-Pollutant Emissions-Reduction Opportunities for the Ammonia Industry in China

As one of the most energy-intensive and polluting industries, ammonia production is responsible for significant carbon dioxide (CO 2 ) and air-pollutant emissions. Although many energy-efficiency measures have been proposed by the Chinese government to mitigate greenhouse gas emissions and improve air quality, lack of understanding of the cost-effectiveness of such improvements has been a barrier to implementing these measures. Assessing the costs, benefits, and cost-effectiveness of different energy-efficiency measures is essential to advancing this understanding. In this study, a bottom-up energy conservation supply curve model is developed to estimate the potential for energy savings and emissions reductions from 26 energy-efficiency measures that could be applied in China’s ammonia industry. Cost-effective implementation of these measures saves a potential 271.5 petajoules/year for fuel and 5,443 gigawatt-hours/year for electricity, equal to 14% of fuel and 14% of electricity consumed in China’s ammonia industry in 2012. These reductions could mitigate 26.7 million tonnes of CO 2 emissions. This study also quantifies the co-benefits of reducing air-pollutant emissions and water use that would result from saving energy in China’s ammonia industry. This quantitative analysis advances our understanding of the cost-effectiveness of energy-efficiency measures and can be used to augment efforts to reduce energy use and environmental impacts.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2016

Bioelectrochemical Integration of Waste Heat Recovery, Waste-to- Energy Conversion, and Waste-to-Chemical Conversion with Industrial Gas and Chemical Manufacturing Processes

Many U.S. manufacturing facilities generate unrecovered, low-grade waste heat, and also generate or are located near organic-content waste effluents. Bioelectrochemical systems, such as microbial fuel cells and microbial electrolysis cells, provide a means to convert organic-content effluents into electric power and useful chemical products. A novel biochemical electrical system for industrial manufacturing processes uniquely integrates both waste heat recovery and waste effluent conversion, thereby significantly reducing manufacturing energy requirements. This project will enable the further development of this technology so that it can be applied across a wide variety of US manufacturing segments, including the chemical, food, pharmaceutical, refinery, and pulp and paper industries. It is conservatively estimated that adoption of this technology could provide nearly 40 TBtu/yr of energy, or more than 1% of the U.S. total industrial electricity use, while reducing CO 2 emissions by more than 6 million tons per year. Commercialization of this technology will make a significant contribution to DOE’s Industrial Technology Program goals for doubling energy efficiency and providing a more robust and competitive domestic manufacturing base.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2013

Perspective on the U.S. Coal Industry 2013

This presentation provides an overview of the coal industry, focusing on the United States, but within a global context. Areas covered include coal prices, consumption, production, imports, exports, reserves, productivity measures, and more. Juxtapositions between the U.S. and other countries' coal industries are provided. In addition to providing a current snapshot of the U.S. coal industry, this work portrays both historical and projected aspects of the coal industry.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2015

Perspective on the U.S. Coal Industry 2015

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2017

U.S. Coal Industry Perspective

This report provides an overview of the coal industry, focusing on the United States. Some of the areas covered include coal prices, consumption, production, stockpiles, imports, exports, reserves, and productivity measures. Juxtapositions between the United States and other countries' coal industries are provided. In addition to providing a current snapshot of the U.S. coal industry, this work portrays both historical and projected aspects of the coal industry.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2019

Initial Industry Collaborations of the Center of Excellence

The NEAMS program aims to develop an integrated multi-physics simulation capability “pellet-to plant” for the design and analysis of future generations of nuclear power plants. In particular, the Reactor Product Line code suite's multi-resolution hierarchy is being designed to ultimately span the full range of length and time scales present in relevant reactor design and safety analyses, as well as scale from desktop to petaflop computing platforms. In particular the NEAMS program is supporting the development of novel thermal-hydraulic codes. The Center of Excellence for Thermal Fluids Application in Nuclear Energy, launched in 2018, has as its key goals to serve as a front door to industry. The Center of Excellence for Thermal Fluids Applications in Nuclear Energy has recently launched a program to start collaborative efforts between the laboratories and industry with the objective of stimulating cooperation and increasing adoption of T/H tools developed under NEAMS by the industry-at-large. In particular, two industry partners agreed to participate in pilot short-term collaborations aimed at demonstrating the value of NEAMS tools to their designs. These are BWXT and Kairos who proposed projects related to HTGR and FHR designs respectively. In this report we present the results of these collaborations.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2019

Final Report for Industrial Base Cybersecurity Initiative (IBCI) Project (FY2019)

Information security issues impact all manufacturing sectors and are particularly troublesome when designs for advanced weapons systems are lost via attacks that propagate through the relatively unprotected lower tiers of the nation's supply chains. The US Manufacturing Industrial Base (MIB) consists of suppliers and distributors that range in size from large prime contractors with extensive cybersecurity resources to small shops with little or no in-house information technology capabilities. The acquisition and maintenance of the technologies, systems, and financial resources needed to assure secure collaborations can be an overwhelming challenge for many manufacturers yet the cost of poor cybersecurity practices can lead to the compromise of national security information worth hundreds of millions of dollars. The Department of Defense Manufacturing Industrial Base Policy organization and the Department of Energy, Energy Efficiency and Renewable Energy Advanced Manufacturing Office have chartered the Los Alamos National Laboratory (LANL) and the Oak Ridge Y-12 National Security Complex (Y-12) to design, develop, and demonstrate a Manufacturing Threat Evaluation Wargaming System (MTEWS). The MTEWS concept is based on the use of a virtual model of the computer networks and cybersecurity protocols used across the MIB that will be continuously updated to reflect the dynamic threat environment. The MTEWS cyber-physical test range will demonstrate a prototype wargaming system that analyzes the impact of new and existing cybersecurity threats while also providing the information needed to sustain the integrity of the MIB supply chains. A long-term goal is the establishment of an enduring national manufacturing operations center that proactively responds to the continuously changing attacks that threaten the MIB and US national security. LANL and Y-12 have formed an Industrial Base Cybersecurity Initiative Team (IBCI), consisting of partners from the public, private and academic sectors, that is developing the MTEWS. To date, most of the project tasks have been centered on the technologies required to create a representative model of the MIB because this is a foundational element for the entire project. Modeling activities at the University of North Carolina at Charlotte (UNC Charlotte) have demonstrated a VMware-based prototype system that can accommodate a network model with up to 350 nodes and includes features such as the option to incorporate network scanning information when building the model and the ability to down select the elements of duplicative networks to a statistically significant subset that avoids redundantly duplicating network configurations. Broad Ordering Agreements have been established with UNC Charlotte and the University of West Florida (UWF) that support a variety of cybersecurity for manufacturing tasks and wide-spread endorsement has been received from government, industry and academia sectors concerning the IBCI goals and technical direction.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

DOE OSTI2020

U.S. Coal Industry Perspective (2020) [Slides]

This report provides an overview of the coal industry, focusing on the United States. Some of the areas covered include coal prices, consumption, production, stockpiles, imports, exports, reserves, and productivity measures. Juxtapositions between the United States and other countries coal industries are provided. In addition to providing a current snapshot of the U.S. coal industry, this work portrays both historical and projected aspects of the coal industry.

01 COAL, LIGNITE, AND PEAT↗