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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 361 records · Page 20
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Porous transport electrodes for oxygen evolution reaction in proton exchange membrane water electrolysis -cells: Materials, designs, and diagnoses

H 2 production using proton exchange membrane (PEM) water electrolysis (PEMWE) cells has received considerable attention because of the high efficiencies of these cells and no harmful emissions from the related process. In PEMWE cells, porous transport electrodes (PTEs) composed of a catalyst layer (CL) comprising O 2 evolution reaction (OER) catalysts, porous transport layer (PTL), and PEM play key roles in the stack performance and lifetime. Herein, Ir-based and non-precious-metal OER catalysts that are highly active and stable at low pH values and high anodic potentials are reviewed to understand their OER mechanisms. Various strategies are proposed for engineering CLs and PTLs to improve the interfacial properties and mass transfers of reactants and products to and from the active sites. Additionally, diagnoses of PTEs is significantly crucial for interpreting electrochemical processes and addressing their current challenges. Therefore, half-cell analyses, including diffusion electrode (DE), floating electrode (FE), and modified rotating disk electrode (MRDE) techniques, are explored, and membrane electrode assembly (MEA)-based analyses, such as the polarization technique, electrochemical impedance spectroscopy, and magnetic field analysis, are established. In conclusion, this study aims to provide an overview of recent technologies used for the engineering and diagnostic tools of PEMWE cells and insights into the advanced components and systems to be developed in this field.

Diagnosis of PEMWE Cells↗
DOE OSTI2021

Sorting for secreted molecule production using a biosensor-in-microdroplet approach

Significance The design–build–test cycle of metabolic engineering is swiftly becoming test limited owing to advances in DNA synthesis and library design. At the same time, improving extracellular production requires high-throughput studies to detect extracellular (not intracellular) content. Traditional approaches that utilize chromatography-based analysis or plate-based fluorescence assays are relatively throughput limited and require a high degree of liquid handling. These limitations are avoided here by creating a generalizable approach for small molecule production screening. Namely, this paradigm combines “off-the-shelf” biosensors with large library screening from producing cells in a cell-type agnostic manner.

Bowman, Emily K.↗
DOE OSTI2020

Multimodal Instrument Platform for High-Pressure MAS-NMR and IR Spectroscopic Interrogation

This project developed and tested a high-pressure (HP) flow-through instrument platform that combines HP- magic angle spinning nuclear magnetic resonance (MAS-NMR) spectroscopy for interrogating reactivity at interfaces between solid materials and HP fluids with HP- infrared (IR) spectroscopy for measuring fluid composition. Solid-fluid interfacial reactivity is usually dependent on concentrations of species within the fluid; thus, knowledge of the fluid composition measured by IR is critical to understanding solid-fluid interfacial reactivity probed by NMR. This new system adds to PNNL’s core capabilities in Chemical and Material Sciences to support fundamental programs in catalysis, interfacial molecular science, and geosciences, as well as in Earth and Biological Sciences to support energy production and storage, efforts to mitigate the impacts energy production systems, attenuation of contaminant plumes, and design of subsurface engineered systems for energy production and waste disposal.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Design, Manufacturing, Assembly, and Lessons Learned of the Pre-production 325 MHz Couplers for the PIP-II Project at Fermilab

Five 325 MHz high-power couplers will be integrated into the pre-production Single Spoke Resonator Type-II (ppSSR2) cryomodule for the PIP-II project at Fermilab. Couplers were procured by both Fermilab and IJCLAB for this effort. The design of the coupler is described, including design optimizations from the previous generation. This paper then describes the coupler life cycle, including design, manufacturing, and assembly, along with the lessons learned at each stage.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Model-based quantification of margins and uncertainties in metal additive manufacturing for process design and qualification

Laser powder bed fusion (LPBF) Additive Manufacturing (AM) has the potential to enable the production of components with novel designs and material properties unachievable otherwise. However, process repeatability is a challenge, making qualification ill-defined and greatly reducing the utility of what could be an important manufacturing technology. In this work, a combination of modeling, uncertainty quantification (UQ), and experimentation are used in an effort to predict and bound the range of possible outcomes of the LPBF process. Quantities of interest predicted are melt pool dimensions, microstructure features, and mechanical distortions. A combination of high fidelity thermal-fluid models, microstructure growth models, and reduced fidelity, rapid thermal and mechanical models are used. Uncertainty propagation techniques are used to predict probability distributions of quantities of interest from estimates of process uncertainties. Repeated experiments are done to quantify observed probability distributions and compared to predicted distributions to determine if predictions are precise and accurate. Novel modeling methods are microstrucutre characterization techniques are also discussed. It is found that high fidelity models do a generally good job bounding experimentally observed melt pool morphologies for both bead-on-plate and powder bed cases. Microstructure models are able to bound a number of experimentally observed microstructure statistics, but with low precision due to challenges with calibrating the microstructure growth model parameters. A developed modified inherent strain distortion model does not accurately predict observed distortions. A lumped laser distortion model shows promise in being both accurately and precisely bounding observed outcomes from the deflection comb build, but requires further evaluation on more builds and geometries.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Elevated Temperature Graphite Mechanical Testing

High purity graphite will be used for core components within most High Temperature Reactor (HTR) designs. Several "high tech” industries currently utilize synthetic, high-purity, commercially available graphite components to fabricate photovoltaic cells, semi-conductors, optical fibers, and other high value electronic industry products. New advanced HTR designs are also interested in using these graphite grades for long-term, internal core component applications. Consequently, the US Department of Energy, Advanced Reactor Technologies (DOE-ART) program has spent several years testing different high purity graphite grades for potential use within these new nuclear reactor designs. A significant part of that effort has been in the development and improvement of American Society for Testing and Materials (ASTM) test standards specifically for nuclear graphite grades. Nearly all ASTM test standards have either been developed or improved by the DOE-ART program over the past 25 years. The ART program continues to assist in the development of new ASTM test standards in support of the future commercial HTR fleet currently being designed and built in the USA. The newest effort undertaken by ART is the development of high temperature mechanical testing practices that may be acceptable for a future ASTM test standard (or guide) for this critical material property measurement.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Uranium nitride tristructural-isotropic fuel particle

A summary of activities around concept development, design, manufacturing, and early irradiation testing of a novel coated fuel particle, uranium nitride tristructural-isotropic fuel is provided. This fuel particle offers significantly higher uranium density over historic manifestations of coated fuel particles and may be more optimal for a range of advanced reactor applications. After reviewing the design process, steps involving production of this fuel form are discussed. Low burnup irradiation data on this fuel particle are now available, indicating that performance metrics have been met to date based on the original design expectations.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Design of Multi-Engine Freight Locomotive

This final report documents the completed engineering design of a modular, multi-engine renewable natural gas (RNG) hybrid freight locomotive. The project delivered a full systems design, component selection, and production and test plans for a near-zero-emission, Tier 5–capable line-haul locomotive, but did not proceed to fabrication or field testing due to withdrawal of the designated engine supplier.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Designing a GIS-based supply chain for producing carinata-based sustainable aviation fuel in Georgia, USA

Carinata is a potential crop for sustainable aviation fuel (SAF) production in the southern USA. However, as a novel crop, the cost-effectiveness and environmental feasibility of carinata feedstock are unknown, and there are questions about the optimal supply chain configuration for carinata-based SAF production. This study aims to design a supply chain model for carinata-based SAF production by optimizing the location of farms and facilities (e.g. storage units, crushing mills, biorefineries) for a minimum transportation cost under a set of supply and demand conditions. An integrated mixed-integer linear programming (MILP) model was combined with geographical information system (GIS) analysis to design a spatially explicit supply chain configuration. The GIS-based network analysis considered all of the counties in Georgia to set the candidate locations of carinata farms and facilities, and determined minimum cost and emission routes between those counties and the airport using existing transportation networks and modes (e.g. road, rail and pipeline). The MILP model determined the final selection of the farms and the number of facilities and their locations over those minimum-cost routes. With this supply chain configuration, the minimum price of SAF was $\$$0.92 L –1 , which is $\$$0.44 higher than conventional aviation fuel (CAF). The associated carbon intensity of SAF was estimated at 940.7 g CO 2 e L –1 , a reduction of 66% relative to the carbon intensity of equivalent CAF. The study found that a carbon tax (or subsidy) of $\$$230.48 t CO 2 e –1 would be needed to overcome the cost differential with CAF and promote carinata-based SAF in Georgia.

09 BIOMASS FUELS↗
DOE OSTI2024

Critical design load case fatigue and ultimate failure simulation for a 10-m H-type vertical-axis wind turbine

While previous studies investigating critical VAWT design load cases have focused on large and relatively flexible Darrieus designs, the bulk of current commercial products seeking certification fall in the relatively small, stiff, and H-type configuration, such as the XFlow Energy Corporation turbine that this study compares against. Understanding the critical design load case impacts for both fatigue and ultimate failure for this size and type of VAWT are imperative for certification. The abil

Brownstein, Ian↗
DOE OSTI2023

Effect of Lateral Conduction in a Rectangular Fuel Plate and Optimum Stripe Widths for the OPAL Reactor

The impetus for this work is the Proliferation Resistance Optimization (PRO-X) program, which was created by the National Nuclear Security Administration (NNSA) of the US Department of Energy (DOE) to provide a framework for developing reactor designs that minimize the production of special nuclear materials while maximizing performance for peaceful uses. The Argentine company INVAP and Argonne National Laboratory collaborated to share knowledge and expertise regarding the thermal analysis of research reactors. Working together, they designed a series of test problems based on the Open Pool Australian Light Water (OPAL) reactor, whose fuel is in the form of flat plates cooled by water flowing through narrow rectangular channels. ANL used their PLTEMP/ANL code. INVAP used their TERMIC code (and its new multi-plate version, TERMIC-MP). Then, INVAP and ANL compared the two sets of results. 1-D models were used during the collaboration since for research reactor analysis, largely 1-D thermal-hydraulics models are commonly used because they are simple to apply and technically defendable. The collaboration between the two organizations aims for improvements in thermal-hydraulic models. Improvements to methods and models can reduce modeling uncertainties and excessive conservatism, allowing greater reactor performance without reducing predicted safety margins. Therefore, these improvements potentially expand the design space, making additional designs feasible, which, in turn, may achieve better fuel utilization and proliferation resistance in the designs. This report provides justification for the lateral node size (stripe width) chosen for the 1-D computer models during the collaboration. The lateral heat conduction in OPAL fuel plates is evaluated using the two-dimensional conduction capability of PLTEMP/ANL to determine a representative hot-stripe width that can be conservatively used for one-dimensional steady-state thermal-hydraulic analysis. Basically, a representative hot-stripe width needs to be selected so that the actual heat flux averaged over this stripe width is greater than or equal to the maximum heat flux obtained by the two-dimensional analysis. Detailed results in this report show that a hot-stripe width of 8.125 mm can be conservatively used for the one-dimensional thermal-hydraulics analysis of all plates. Therefore, eight equal stripes (8.125 mm each) are recommended to be modeled in the MCNP and PLTEMP/ANL full core models of the OPAL reactor.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Designing Cost‐Effective Carbon Payments to Induce Cellulosic Feedstock Production for Sustainable Aviation Fuel

Perennial bioenergy crops, such as miscanthus and switchgrass, and crop residues have the potential to scale up sustainable aviation fuel (SAF) production and mitigate carbon emissions. However, high establishment costs, delayed returns, and risk–return profiles that diverge from those of conventional crops can hinder incentives to adopt bioenergy crops. We develop an economic model that incorporates spatially varying joint yield and price distributions for the multiple crop choices a farmer faces and apply it to examine the incentives for risk-averse, present-biased, and credit-constrained farmers to produce cellulosic feedstocks under various biomass prices. We link this model to a biogeochemical model to quantify the spatially varying carbon mitigation benefits from these feedstocks in the rainfed region of the United States. We also analyze the cost-effectiveness of two carbon payment policies: annual and upfront. We find that risk-averse, present-biased, or credit-constrained farmers prefer to grow the lower-yielding but less risky switchgrass and harvest corn stover instead of the lower carbon, higher-yielding but riskier feedstock miscanthus, resulting in lower SAF production. Upfront carbon payments incentivize higher quantities of less carbon-intensive SAF production by risk-averse, credit-constrained, and present-biased farmers because they offset a part of the establishment costs of miscanthus. We also find that when farmers are credit-constrained, upfront payments are more cost-effective in terms of carbon mitigation per dollar spent. In contrast, annual payments are more cost-effective when farmers can access credit.

09 BIOMASS FUELS↗
DOE OSTI2024

Reference Piping and Instrumentation Diagrams for Heat Transport Systems for Methanol Plants

This report aims to bridge the gap between advanced nuclear reactor vendors and methanol producers seeking decarbonization. It equips both parties with tools and preliminary information for integrating clean heat from advanced reactors into novel methanol production processes. The proposed investigation in this report involves a three-step approach: 1. Design of Current and Decarbonized Process Models for Methanol Production. This report initiates process modeling of two novel methanol production pathways, with their overall energy requirements comparative to classical methanol production (see Figure ES1). The two process models provide the foundation for analyzing integration of hermos-electric generation from advanced nuclear reactors. 2. Identification of Coupling Points to Integrate Advanced Reactors. This report investigates the integration with two advanced reactor technologies: light-water reactors (LWRs) and high-temperature gas reactors (HTGRs). The key coupling points between advanced nuclear reactors and the production facilities associated with the two decarbonized methanol process pathways are identified. 3. Preliminary Heat and Electricity Transfer Design from Reactors to Methanol Production Sites. The preliminary designs for piping and instrumentation to transfer heat from the boundary of advanced reactor technology location to the boundary of methanol production site are evaluated within the context of decarbonized pathways. The pipe analysis for heat transfer adheres to relevant codes and specifications from American Society of Mechanical Engineering. A simplified design for transmission of electricity to the industrial site has been provided.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Target fabrication fields first NIF shot with new 3D-printed microfluidic target design

Capable of producing ultrafine features, two-photon polymerization (2PP) 3D printing made it possible to field a first-of-its-kind leak-proof liquid-filled diffraction target. These targets are used for shots aimed at using laser pressure instead of low temperatures turn water into ice. The shot is the product of months of design, assembly, and installation work by LSEO’s target fabrication team, in collaboration with 3D printing experts Widi Moestopo (MED) and Xiaoxing Xia (MED) and PLS researcher Neal Bhandarkar.

42 ENGINEERING↗
DOE OSTI2025

Numerical simulation for the design of induction heating based radio frequency reactor for ethylene production

Ethylene is a vital petrochemical compound produced in vast amounts yearly by manufacturers that have enough scale to overcome the inherent thermodynamic inefficiencies of the process. In order to address the inefficiencies that prevent smaller scale or intermittent production ethylene, investigation of new production methods are required. In this work, we investigate the use of a radio frequency (RF) based reactor system that generates heat internally as opposed to applying heat externally via steam or direct combustion of fossil fuels. In order to guide the design of an electromagnetic based reactor system, we have created a macroscale model capable of capturing heat generation at the susceptors from a produced electromagnetic field and subsequent chemical reactions. Several susceptor and induction coil designs were investigated to better understand the performance of the system.

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

Effect of Protic Ionic Liquids in Sugar Cane Bagasse Pretreatment for Lignin Valorization and Ethanol Production

Ionic liquids have been called designer solvents because it is possible to fine-tune their properties from a huge range of possible combinations of cations and anions. In this work, we evaluate the potential of protic ionic liquids (PILs) in the fractionation of sugar cane bagasse in a biorefinery context. Here, the PILs were designed to selectively solubilize lignin and leave a polysaccharides solid fraction. The carbohydrate fraction was further hydrolyzed to obtain pentose and hexose sugars, which were fermented using a pentose-consuming yeast. The results have shown that, differently from pretreatments that solubilize hemicelluloses, pentoses could be fermented together with hexoses without a prior detoxification step with high yield and productivity. The lignin recovered was characterized by 2D HSQC NMR, 31 P NMR, and GPC, showing that the design of the PIL influences lignin characteristics, but pretreatment temperature and time do not. The lignins obtained are sulfur-free, and the richness of their functional groups makes them attractive for conversion into a diversity of value-added products, which can make a biorefinery based on the proposed process viable.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗