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At least 379 records · Page 21

All sources NASA NTRS DOE OSTI

DOE OSTI2021

Increasing CO2 Conversion Efficiency with Optical Thermal Management in Concentrated Solar Reactors: New Dual-Stage Solar Reactor Design for Reduction of CO2 to Fuels

The proposed project will result in a new dual-stage solar chemical reactor designed to convert carbon dioxide (CO2) to value-added chemicals. Using sunlight as the main power source, a sustainable process will be developed that closes the loop on our industrial carbon cycle in an energy efficient and environmentally friendly manner. The hybrid photochemical and photothermal reactor design will vastly increase utilization of the solar spectrum and increase CO2 conversion efficiencies over Dimensional Energy’s current state-of-the-art.

10 SYNTHETIC FUELS↗

DOE OSTI2024

Industrial Assessment Center

Established in 1990, San Diego State University’s (SDSU) Industrial Assessment Center (IAC) is proud of its years of service. During this period, it has served over 620 small and medium-sized manufacturing plants in Southern California. SDSU/IAC’s efforts to transfer state-of-the-art technologies to industry have increased revenues, cultivated creativity, improved energy efficiencies, and benefited the environment. The Center has contributed to the region's economic growth and stability by assisting small and medium size companies to better compete in the global market. It has helped mitigate climate change by reducing greenhouse gas emissions. IAC activities have fostered productive relationships between the University and local industry, assisted industrial sectors to improve their energy efficiency and enhance their manufacturing productivity, in turn impacting the material and working conditions of their employees. In addition to financial savings and environmental benefits, we have trained tens of students who became energy specialists in various companies. Thus, a substantial benefit of the IAC has been the ongoing training of engineering faculty and students. All IAC graduates were offered jobs before or within weeks of their graduation. The activities of the SDSU/IAC have expanded the institutional expertise of the College and improved the knowledge base of the faculties involved leading to several related publications, master’s theses, and senior student projects. Significant number of peer-reviewed publications of the IAC director at SDSU have greatly benefitted from the experience of the Center. As a result of this extensive exposure to manufacturing processes, the SDSU/IAC has grown to be an integral component of SDSU’s engineering research and training. We have successfully built upon these established achievements and academic excellence. IAC service to industry is particularly vital in Southern California, a region with one of the highest manufacturing concentrations in the country. SDSU/IAC has understood and implemented the overall objectives of DOE’s IAC program and guidelines except for the pandemic years when the country’s manufacturing sector was put in dire stress. In addition to student training and service to industry, IAC’s contribution to state and local governments as well as utility companies to assess energy policies and design rebate and incentive strategies cannot be undermined.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Onsite Energy Program: Technical Assistance to Adopt Clean Energy

The U.S. Department of Energy’s Onsite Energy Technical Assistance Partnerships help industrial and other large energy users transition to clean energy, lower costs, reduce emissions, and contribute to a clean energy economy.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS2016

Operational Characteristics Identification and Simulation Model Verification for Incheon International Airport

Incheon International Airport (ICN) is one of the hub airports in East Asia. Airport operations at ICN have been growing more than 5% per year in the past five years. According to the current airport expansion plan, a new passenger terminal will be added and the current cargo ramp will be expanded in 2018. This expansion project will bring 77 new stands without adding a new runway to the airport. Due to such continuous growth in airport operations and future expansion of the ramps, it will be highly likely that airport surface traffic will experience more congestion, and therefore, suffer from efficiency degradation. There is a growing awareness in aviation research community of need for strategic and tactical surface scheduling capabilities for efficient airport surface operations. Specific to ICN airport operations, a need for A-CDM (Airport - Collaborative Decision Making) or S-CDM(Surface - Collaborative Decision Making), and controller decision support tools for efficient air traffic management has arisen since several years ago. In the United States, there has been independent research efforts made by academia, industry, and government research organizations to enhance efficiency and predictability of surface operations at busy airports. Among these research activities, the Spot and Runway Departure Advisor (SARDA) developed and tested by National Aeronautics and Space Administration (NASA) is a decision support tool to provide tactical advisories to the controllers for efficient surface operations. The effectiveness of SARDA concept, was successfully verified through the human-in-the-loop (HITL) simulations for both spot release and runway operations advisories for ATC Tower controllers of Dallas/Fort Worth International Airport (DFW) in 2010 and 2012, and gate pushback advisories for the ramp controller of Charlotte/Douglas International Airport (CLT) in 2014. The SARDA concept for tactical surface scheduling is further enhanced and is being integrated into NASA's Airspace Technology Demonstration - 2 (ATD-2) project for technology demonstration of Integrated Arrival/Departure/Surface (ADS) operations at CLT. This study is a part of the international research collaboration between KAIA (Korea Agency for Infrastructure Technology Advancement)/KARI (Korea Aerospace Research Institute) and NASA, which is being conducted to validate the effectiveness of SARDA concept as a controller decision support tool for departure and surface management of ICN. This paper presents the preliminary results of the collaboration effort. It includes investigation of the operational environment of ICN, data analysis for identification of the operational characteristics of the airport, construction and verification of airport simulation model using Surface Operations Simulator and Scheduler (SOSS), NASA's fast-time simulation tool.

scheduling↗

NASA NTRS2016

Operational Characteristics Identification and Simulation Model Verification for Incheon International Airport

Incheon International Airport (ICN) is one of the hub airports in East Asia. Airport operations at ICN have been growing more than 5 percent per year in the past five years. According to the current airport expansion plan, a new passenger terminal will be added and the current cargo ramp will be expanded in 2018. This expansion project will bring 77 new stands without adding a new runway to the airport. Due to such continuous growth in airport operations and future expansion of the ramps, it will be highly likely that airport surface traffic will experience more congestion, and therefore, suffer from efficiency degradation. There is a growing awareness in aviation research community of need for strategic and tactical surface scheduling capabilities for efficient airport surface operations. Specific to ICN airport operations, a need for A-CDM (Airport - Collaborative Decision Making) or S-CDM (Surface - Collaborative Decision Making), and controller decision support tools for efficient air traffic management has arisen since several years ago. In the United States, there has been independent research efforts made by academia, industry, and government research organizations to enhance efficiency and predictability of surface operations at busy airports. Among these research activities, the Spot and Runway Departure Advisor (SARDA) developed and tested by National Aeronautics and Space Administration (NASA) is a decision support tool to provide tactical advisories to the controllers for efficient surface operations. The effectiveness of SARDA concept, was successfully verified through the human-in-the-loop (HITL) simulations for both spot release and runway operations advisories for ATC Tower controllers of Dallas-Fort Worth International Airport (DFW) in 2010 and 2012, and gate pushback advisories for the ramp controller of Charlotte-Douglas International Airport (CLT) in 2014. The SARDA concept for tactical surface scheduling is further enhanced and is being integrated into NASA's Airspace Technology Demonstration-2 (ATD-2) project for technology demonstration of Integrated Arrival-Departure-Surface (IADS) operations at CLT. This study is a part of the international research collaboration between KAIA (Korea Agency for Infrastructure Technology Advancement), KARI (Korea Aerospace Research Institute) and NASA, which is being conducted to validate the effectiveness of SARDA concept as a controller decision support tool for departure and surface management of ICN. This paper presents the preliminary results of the collaboration effort. It includes investigation of the operational environment of ICN, data analysis for identification of the operational characteristics of the airport, construction and verification of airport simulation model using Surface Operations Simulator and Scheduler (SOSS), NASA's fast-time simulation tool.

surface operations analysis↗

DOE OSTI2025

MSU IETC ML for Modbus (AN EDGE)

This study explores machine learning for decoding Modbus RTU data using K-Nearest Neighbors (KNN) models. An initial KNN model trained on 8,000 packets achieved 95.15% accuracy. Although ML improves generalization, accuracy still falls short of deterministic methods. These findings have implications for Modbus traffic analysis, intrusion detection in industrial networks, and adaptive error correction in real-time monitoring systems. By refining ML-based decoding, future work could enable more efficient anomaly detection and predictive maintenance in industrial automation and cybersecurity applications.

Communication Protocol↗

DOE OSTI2022

Dynamic optimization with flexible heat integration of a solar parabolic trough collector plant with thermal energy storage used for industrial process heat

There is an increasing need to reduce fossil fuel consumption used for industrial process heat to slow the effects of climate change. Using solar thermal heat is a viable way to replace fossil fuel use, but solar industrial process heat plants have limited implementation due to large upfront costs and inefficiencies from the inherent variability from solar energy. Having more flexible and optimized control over these plants can enable them to be more efficient. Here in this work, a solar industrial process heat plant with thermal energy storage that can flexibly collect and deliver heat to two industrial processes (flexible heat integration) is dynamically modeled with control setpoints found by a dynamic optimization method. The optimized case can increase the solar efficiency of the plant by 7.5% on average relative to a base case. The results show that it is best to collect heat at lower temperatures for all but ideal solar conditions, only medium to high quality heat should be stored in large quantities, and exchanging heat with a lower temperature heat sink is generally more efficient. The optimized case is able to reduce the levelized cost of heat of the plant to $31.83/MWh th compared to a base case value of $34.10/MWh th . The optimized case can reduce emissions by 22.2% compared to a plant which uses only natural gas. This work shows that dynamic optimization with flexible heat integration can be a cost-effective way to increase efficiency so that more of these types of plants can be implemented.

14 SOLAR ENERGY↗

DOE OSTI2024

3D printed carbon fiber reinforced carbon as an energy efficient alternative to graphite for EFAS tooling

As Electric Field Assisted Sintering (EFAS) gains more industrial acceptance and use, it becomes more important to develop more efficient means to implement this technology. To this aim, 3D printed continuous carbon fiber reinforced carbon (CCC) was manufactured and fabricated into tooling for EFAS systems as an alternative to traditional graphite tooling. The impact of fiber orientation on the thermal and electrical properties of the CCC was characterized. Sample material was sintered in Tokai G535 graphite tooling, under common processing conditions and compared with CCC tooling. There was nearly 50 % energy savings compared to graphite while maintaining equivalent sample density and microstructure plus keeping ram temperatures 39 % cooler. This is due to spatial control of generated heat and thermal diffusivity within the molds, by means of fiber orientation anisotropy. Finite element modeling of the tooling design supported the experimental results as well as displays the effect of optimization of this 3D printed CCC material.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Numerical simulation of frost formation and heat transfer on fin-and-tube heat exchangers in turbulent cross-flow

Frost formation in fin-and-tube heat exchangers in turbulent cross-flow presents significant challenges in industrial refrigeration applications, affecting heat transfer efficiency and operational reliability. The purpose of this work is to investigate frost deposition and growth on a staggered bank of a fin-and-tube freezer coil under turbulent forced convection conditions. The focus here is on investigating conditions that closely replicate real-world scenarios in large walk-in industrial freezers. Using a direct numerical simulation approach, we examine the flow dynamics and thermal behaviour in the presence of frost, considering turbulent regimes characterized by a Reynolds number in the range 1050 ≤ R e D , avg ≤ 4800 , with the characteristic length being the outer diameter of the tube and the velocity being the bulk fluid velocity between the plates (fins). Computational fluid dynamics simulations are employed to resolve the interactions between turbulent airflow and the frost layer. Our approach incorporates a modified immersed boundary method and a slow-time acceleration technique to address the complex dynamic interface between the continuously evolving frost layer and the flowing air stream. Our findings indicate that frost forms more on the sides of the finned surfaces (plates) and less on the tubes themselves. This article is part of the theme issue ‘Heat and mass transfer in frost and ice’.

Science & Technology - Other Topics↗

DOE OSTI2025

Amorphous electrocatalysts for oxygen and hydrogen evolution reactions: Advances in hydrogen production

The electrochemical splitting of water into oxygen and hydrogen is fundamental for renewable energy storage and conversion. The development of cost-effective and highly efficient electrocatalysts remains essential for industrial-scale implementation of this technology. Recent advances have highlighted the superior activity, stability and structural adaptability of amorphous electrocatalysts compared to their crystalline counterparts. This review critically examines synthesis strategies, characterisation techniques, and the electrochemical performance of amorphous materials for both oxygen evolution (OER) and hydrogen evolution (HER) reactions. Key factors influencing catalytic efficiency, including electronic structure and surface chemistry, are discussed in detail and contextualised with established literature. The review also highlights the critical role of enthalpic contributions in governing reaction energetics and catalyst performance, which aids in understanding and optimising electrocatalytic efficiency. Notably, ongoing research continues to reveal that amorphous catalysts consistently deliver improved performance in water-splitting applications, highlighting their growing relevance in electrocatalysis. The rationale for employing amorphous catalysts in water splitting is articulated, emphasising their unique advantages. By integrating recent findings and outlining future research directions, this review underscores the pivotal role of amorphous materials in advancing sustainable hydrogen production and identifies promising avenues for catalyst innovation.

Amorphous catalysts↗

DOE OSTI2024

Key Strategies in Industry for Circular Economy: Analysis of Remanufacturing and Beneficial Reuse

Manufacturing, in the effort to be more sustainable, is increasingly focusing on energy efficiency and waste reduction. DOE's Better Buildings Better Plants Program has established Waste Reduction Network that works with 32 industrial partners to achieve higher material efficiency and reduce waste. United States generates 7.6 Billion Tons of industrial solid waste as estimated by EPA. In a linear economy as the economy grows, so does the waste – increasing strain on resources and the environment. The Circular Economy (CE) model keeps the available resources in circulation for longer period of time easing the burden on the environment.Remanufacturing and (Beneficial) reuse are widely accepted channels in 9R methodology and established pillars of CE. This chapter reviews the two key strategies and their adoption in different industrial sectors. It reviews the key barriers faced by manufacturers in implementing these methodologies and discusses the possible solutions to those barriers. The chapter also reviews impact of these CE strategies on sustainability, material efficiency and the economic and social benefits. Finally, this chapter presents two case studies from DOE's Better Plants partners – one on remanufacturing of components in heavy vehicles industry and one on beneficial reuse of spent foundry sand, a non-hazardous solid waste, and discusses the project impacts.

Chaudhari, Subodh↗

DOE OSTI2023

Key Strategies in Industry for Circular Economy : Analysis of Remanufacturing and Beneficial Reuse

Manufacturing, in the effort to be more sustainable, is increasingly focusing on energy efficiency and waste reduction. DOE’s Better Buildings Better Plants Program has a Waste Reduction Network that works with 32 industrial partners to achieve higher material efficiency and reduce waste. United States generates 7.6 Billion Tons of industrial solid waste as estimated by EPA. In a linear economy as the economy grows, so does the waste – increasing strain on resources and the environment. The Circular Economy (CE) model keeps the available resources in circulation for longer period of time easing the burden on the environment. Remanufacturing and (Beneficial) re-use are widely accepted channels in 9R methodology and established pillars of CE. This paper reviews the two key strategies and their adoption in different industrial sectors. It reviews the key barriers faced by manufacturers in implementing these methodologies and discusses the possible solutions to those barriers. The paper also reviews impact of these CE strategies on sustainability, material efficiency and the economic and social benefits. Finally, this paper presents two case studies from DOE’s Better Plants partners – one on remanufacturing of components in heavy vehicles industry and one on beneficial reuse of spent foundry sand, a non-hazardous solid waste, and discusses the project impacts.

Chaudhari, Subodh↗

DOE OSTI2022

The Future of Energy Efficiency for U.S. Buildings - Drivers and Market Scenarios

This paper identifies likely drivers of building efficiency over the next ten years and expectations for how efficiency markets may evolve over this period. To prepare these predictions, we conducted an extensive literature review, interviewed 22 experts, reviewed legislation and executive orders in 12 states, and implemented a detailed questionnaire completed by 41 efficiency practitioners. The two most important drivers revealed by our research are (1) public policies and regulations, particularly those associated with climate change mitigation and adaptation and (2) the cost of energy relative to the cost of delivering efficiency. Other important drivers are technology changes, economic conditions, social priorities, and industry (including utility) business practices for increasing the uptake of efficiency in buildings. Our research indicates that efficiency markets will increasingly focus on supporting building decarbonization and enabling demand flexibility through the use of controls in grid-interactive efficient buildings and communities. Efficiency improvements for specific technologies (e.g., heat pumps, controls, and windows) and technological advances not specific to energy technologies (e.g., interoperability, artificial intelligence, and universal internet access) will improve the efficacy of efficiency measures and actions. Marketing of efficient products and services will increasingly focus on grid services, decarbonization, non-energy benefits for consumers, and integration with other distributed energy resources (DERs). We anticipate increased investment in disadvantaged and historically underserved communities, recognizing the social, health, and safety benefits of efficient energy usage and remediating historical biases. Lastly, we predict that while state and local government actions will vary, jurisdictions will increase their efficiency goals overall.

Schiller, Steven R↗

DOE OSTI2020

Co(salen)-Catalyzed Oxidation of Lignin Models to Form Benzoquinones and Benzaldehydes: A Computational and Experimental Study

Lignin is a highly abundant polyphenolic polymer that imparts mechanical strength to plant biomass. Transition-metal complexes can catalyze lignin oxidation to produce value-added products, but low catalytic efficiency has hampered their use in industry. Identifying the chemical and structural factors that govern catalytic activity is a prerequisite to rational design of catalysts with improved activity. In this study, we combine computational and experimental approaches to investigate the mechanism of Co(salen)-catalyzed oxidation of the monomeric lignin models syringyl (S), vanillyl (G), and 4-hydroxybenzyl alcohol (H) to produce benzoquinone and benzaldehyde products. Experimentally, S oxidation to form dimethoxybenzoquinone proceeded efficiently with a Co(salen) catalyst coordinated by a pyridine ligand, but G and H did not undergo oxidation. Density functional theory calculations reveal that catalyst regeneration is energetically unfavorable in the presence of H, which prevents oxidation. In contrast, S readily facilitates catalyst regeneration. Formation of methoxybenzoquinone from G was achieved experimentally by adding bulky, noncoordinating bases. These findings provide a fundamental baseline for enhancing the activity of Co-Schiff base catalysts toward lignin-like molecules by adding sterically hindered nitrogenous bases or potentially by including a cocatalyst that promotes catalyst regeneration.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Black carbon emissions and reduction potential in China: 2015–2050

Black carbon is a product of the incomplete combustion of carbonaceous fuels and has significant adverse effects on climate change, air quality, and human health. China has been a major contributor to global anthropogenic black carbon emissions. This study develops a black carbon inventory in China, using 2015 as the base year, and projects annual black carbon emissions in China for the period 2016–2050, under two scenarios: a Reference scenario and an Accelerated Reduction scenario. The study estimates that the total black carbon emissions in China in 2015 were 1100 thousand tons (kt), with residential use being the biggest contributor, accounting for more than half of the total black carbon emissions, followed by coke production, industry, agricultural waste burning, and transportation. This study then projects the total black carbon emissions in China in 2050 to be 278 kt in the Reference scenario and 86 kt in the Accelerated Reduction Scenario. Compared to the Reference scenario, the Accelerated Reduction scenario will achieve much faster and deeper black carbon reductions in all the sectors. The dramatic reductions can be attributed to the fuel switching in the residential sector, faster implementation of high-efficiency emission control measures in the industry, transportation, and coke production sectors, and faster phase-out of agricultural waste open burning. This analysis reveals the high potential of black carbon emission reductions across multiple sectors in China through the next thirty years.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

Robust silane self-assembled monolayer coatings on plasma-engineered copper surfaces promoting dropwise condensation

Dropwise condensation is well known to result in better heat transfer performance owing to efficient condensate/droplet removal, which can be harnessed in various industrial heat/mass transfer applications such as power generation and conversion, water harvesting/desalination, and electronics thermal management. The key to enhancing condensation via the dropwise mode is thin low surface energy coatings (<100 nm) with low contact angle hysteresis. Ultrathin (<5 nm) silane self-assembled monolayers (or SAMs) have been widely studied to promote dropwise condensation due to their minimal thermal resistance and scalable integration processes. Such thin coatings typically degrade within an hour during condensation of water vapor. After coating failure, water vapor condensation transitions to the inefficient filmwise mode with poor heat transfer performance. We enhance silane SAM quality and durability during water vapor condensation on copper compared to state-of-the-art silane coatings on metal surfaces. We achieve this via (i) surface polishing to sub-10 nm levels, (ii) pure oxygen plasma surface treatment, and (iii) silane coating integration with the copper substrate in an anhydrous/moisture-free environment. The resulting silane SAM has low contact angle hysteresis (≈20°) and promotes efficient dropwise condensation of water for >360 hours without any visible sign of coating failure/degradation in the absence of non-condensable gases. We further demonstrate enhanced heat transfer performance (≈5-7× increase over filmwise condensation) over an extended period of time. Surface characterization data post-condensation leads us to propose that in the absence of non-condensable gases in the vapor environment, the silane SAM degrades due to reduction and subsequent dissolution of copper oxide at the oligomer-substrate interface. The experiments also indicate that the magnitude of surface subcooling (or condensation rate) affects the rate of coating degradation. Finally, this work identifies a pathway to durable dropwise promoter coatings that will enable efficient heat transfer in industrial applications.

42 ENGINEERING↗

DOE OSTI2020

Staying cool: The development of India's pioneering energy efficiency policy for chillers

Abstract Chillers are the key energy‐consuming piece of equipment in most large space cooling systems. They can account for more than 40% of total energy consumption in any typical commercial building and in specific industrial building installations depending on the product and process. With climate change driving rapidly rising demand for commercial and industrial cooling, especially in emerging economies, energy efficiency policies for chillers are crucial to moderate future electricity demand and thereby minimize greenhouse gas emissions. However, most developing and emerging economies lack energy efficiency policies for this significant and growing cooling equipment sector. India recently announced new energy efficiency policies for chillers, projected to avoid 28 TWh of electricity consumption and 23 million tons of CO 2 emissions cumulatively through 2030. This article presents a case study of the unique challenges and solutions required to design a new energy efficiency policy for chillers in India. First, the energy consumed in chiller systems is sensitive to building occupancy, load changes, seasonal variations, operation and maintenance, and climatic conditions. In order to address these sensitivities, the chiller testing standard in India factors local weather and temperature conditions into energy performance ratings to account for these sensitivities. Further, every large chiller is a customized product, therefore developing a viable policy and implementation process required collaboration with international and national experts in standardization, manufacturers, building consultants, and testing laboratories. This article is categorized under: Energy Efficiency > Economics and Policy Solar Energy: Thermal ‐‐> Climate and Environment

Mukherjee, P. K.↗

DOE OSTI2022

High efficiency normal conducting linac for environmental water remediation

A continuous wave (CW) electron accelerator for the treatment of industrial streams including an electron beam source, a modified high efficiency slot coupled cavity, at least one focusing magnet positioned surrounding the accelerator to contain the beam in the accelerator, an efficient radio frequency power supply means for supplying power of a radio frequency to the cavity to induce a TM01 accelerating mode in the cavity, an electron beam spreader or raster, a fixed magnet array or two-dimensional scanning magnet for deflecting the accelerated beam into a desired shape, and an exit window for extracting the deflected electron beam. The accelerator includes a graded-beta cavity to enable use with a low-power pulsed electron source. The accelerator benefits from a low wall-power loss accelerating cavity that is energized with efficient RF sources, enabling it to be operated in continuous wave mode.

Hannon, Fay↗