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DOE OSTI2026

Heat Transfer Experiments of a 1st Stage Blade Cascade for Supercritical CO2 Oxy-Combustion Turbine Application

The results of internally cooled 1st stage blade (S1B) cascade testing in a supercritical CO2 environment is presented. The turbine blade design has been previously established for the end application of an oxy-combustion turbine operating in the Allam-Fetvedt cycle with turbine inlet conditions of 305 bar and 1150°C. The internally cooled blade features leading edge (LE) region impingement cooling, mid-section ribbed serpentine passages, and a pin-finned trailing edge (TE) region before cooling ejection holes. The geometry for the tested blade cascade has a cooled central blade with un-cooled blades on either side to match flowpath areas of the actual turbine. The flowpath reuses internal components previously employed for mid-section region ribbed serpentine passage experiments that established Nusselt number enhancement ratios over a range of Reynolds numbers from 100,000-400,000. New components include flow conditioning plates upstream and downstream of the blade cascade to adequately represent the flow field and blade external heat transfer coefficient profiles for the actual turbine. The cooled central blade utilizes uniform crystal temperature sensors (UCTS) with six sensors each on the blade pressure and suction surfaces distributed radially and from LE to TE. The post-processed UCTS quantified the maximum wall temperature seen at each installed sensor location. The test procedure consisted of establishing supercritical CO2 cooling flow temperature and flow rate and maintaining it throughout the test. The flow rate aims to match that for the actual in-service turbine blade design and is maintained through an orifice restriction to keep the pressure differential between internal cooling flow and external hot flow nearly constant. For the sCO2 flow path external to the blade, temperatures were ramped throughout the test via control of the test loop’s natural gas burner heater. The maximum temperature seen was 468°C and held constant for a duration of 10 minutes at which the blade metal temperature was predicted to be at its maximum before ramping down. For the turbine blade design for service inlet conditions, external flow path computational fluid dynamics (CFD) results and an internal cooling 1-D thermal and hydraulic flow network model using experimentally validated correlations served as thermal finite element (FE) boundary conditions to predict blade metal temperatures. These predicted temperatures were subsequently utilized in a structural FE model to predict blade life ratings dictated by Haynes 282 creep strength data, having a strong dependence on temperature. The boundary conditions experienced during testing are used in the same workflow and compared to the experimental results, with the goal of validating the analysis methodology and providing insight on the uncertainty in local metal temperature predictions.

20 FOSSIL-FUELED POWER PLANTS↗

NASA NTRS2012

On Shaft Data Acquisition System (OSDAS)

On Shaft Data Acquisition System (OSDAS) is a rugged, compact, multiple-channel data acquisition computer system that is designed to record data from instrumentation while operating under extreme rotational centrifugal or gravitational acceleration forces. This system, which was developed for the Heritage Fuel Air Turbine Test (HFATT) program, addresses the problem of recording multiple channels of high-sample-rate data on most any rotating test article by mounting the entire acquisition computer onboard with the turbine test article. With the limited availability of slip ring wires for power and communication, OSDAS utilizes its own resources to provide independent power and amplification for each instrument. Since OSDAS utilizes standard PC technology as well as shared code interfaces with the next-generation, real-time health monitoring system (SPARTAA Scalable Parallel Architecture for Real Time Analysis and Acquisition), this system could be expanded beyond its current capabilities, such as providing advanced health monitoring capabilities for the test article. High-conductor-count slip rings are expensive to purchase and maintain, yet only provide a limited number of conductors for routing instrumentation off the article and to a stationary data acquisition system. In addition to being limited to a small number of instruments, slip rings are prone to wear quickly, and introduce noise and other undesirable characteristics to the signal data. This led to the development of a system capable of recording high-density instrumentation, at high sample rates, on the test article itself, all while under extreme rotational stress. OSDAS is a fully functional PC-based system with 48 channels of 24-bit, high-sample-rate input channels, phase synchronized, with an onboard storage capacity of over 1/2-terabyte of solid-state storage. This recording system takes a novel approach to the problem of recording multiple channels of instrumentation, integrated with the test article itself, packaged in a compact/rugged form factor, consuming limited power, all while rotating at high turbine speeds.

Pedings, Marc↗

DOE OSTI2023

Plant-wide modeling and techno-economic analysis of a direct non-oxidative methane dehydroaromatization process via conventional and microwave-assisted catalysis

Direct non-oxidative methane dehydroaromatization (DHA) process via conventional and microwave (MW)-assisted thermo-catalytic catalysis is studied. Rate models for methane DHA reactions, including the effect of catalyst deactivation, are developed by using the in-house experimental data. Model results for gas concentration profile and catalyst deactivation are in good agreement with the experimental data. This rate model is then used for the development of dynamic multi-scale, multi-physics commercial-scale reactor models. Total number of fixed bed reactors desired for a cyclic steady state process is estimated. Plant-wide models are then developed for conventional and MW-assisted processes for producing products of desired specifications. Techno-economic analysis of the methane DHA process is undertaken. Economics of these methane DHA processes are compared with the typical multi-step natural gas to aromatics production process via methanol synthesis. Sensitivity of internal rate of return (IRR) and net present value (NPV) to various economic and process parameters such as plant scale, desired rate of return, reactor cost, feedstock and utility cost, catalyst variable cost, and MW reactor cost is studied. Here, electric equivalent efficiency of the conventional methane DHA process is found to be 69.2 % and 67.3 % at 750 °C and 800 °C, respectively, while the MW-assisted methane DHA process has the electric equivalent efficiency of 48.9 % at 800 °C. IRRs of the conventional methane DHA process at 750 °C and 800 °C, and MW-assisted process are 15.2 %, 17.5 %, and 18.8 %, respectively for a methane feed flowrate of 19,782 kg/h, while the IRR of the multi-step natural gas to aromatics production process is estimated to be 0 % for the same plant scale. Impact of change in the methane price, electricity price, and catalyst cost is found to be considerable on the process economics, while the cost of the MW reactor is found to have negligible impact.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRSDate not supplied

Decision Aid for Conjunction Risk Mitigation by Differential Drag

In the previous five years, the rate of conjunctions that the NASA Conjunction Assessment Risk Analysis (CARA) team processed and analyzed has more than tripled. (NASA CARA, 2024) New missions in the early development phases are now required to plan for dealing with conjunctions under the present space environment, and also projecting forward into a future likely with even further increased utilization of the space environment. Some missions are investigating the possibility of using differential drag to remediate conjunctions without expending limited fuel or for missions without propulsive capabilities. The NASA CARA team studied the historical record of conjunctions to evaluate the circumstances under which differential drag may be successfully applied and have developed a series of tables to use as a decision aid for missions considering differential drag. Currently, if a CARA-protected mission with maneuvering capabilities is predicted to have a conjunction with probability of collision (Pc) greater than 7E-5 (the default value of the ‘yellow threshold’, which may have some other value agreed by CARA and the mission during the Orbital Collison Avoidance Planning (OCAP) process), CARA will use its Maneuver Trade Space (MTS) tool to evaluate and recommend options for the timing and magnitude of a risk mitigation maneuver (RMM), based on the mission’s capabilities. If the conjunction’s Pc is greater than 1E-4, the ‘red threshold’, then an RMM must be executed per NASA Procedural Requirements (NPR) 8079.1 (NASA, 2023), although missions may execute an RMM even if the Pc is lower. The magnitude of the maneuver is typically a few cm/s, and CARA estimates how many will be required for the mission’s nominal lifetime – typically a few per year – during the OCAP process, to inform the mission’s delta-V requirement. For traditional satellites, this is usually smaller than other requirements for orbit insertion, maintenance, and disposal, but for CubeSats or other small satellite missions, a propulsion system may not provide much more than a few cm/s of delta-V or may not fit at all within the available budget of money, time, size, weight, and/or power (SWaP). Conversely, CubeSats often have deployable solar panels, which offer the capacity to have much higher areas facing some directions than others. Such a mission can instead use ‘differential drag’ to remediate a conjunction -- in other words, change its drag area (usually increasing) to deviate from the predicted collision course. This is how Planet’s Dove spacecraft maintain their formations and remediate conjunction risks without having on-board propulsion (Foster, et al., 2017) (Griffith, et al., 2021). CARA has been developing improvements to MTS to support differential-drag for NASA's missions -- where it is effective. CARA records all conjunctions of their protected payloads, with historical records starting in 2005 (with significant conjunction events starting to occur on or after 2013). From this record, approximately 7,300 had a Pc greater than 1E-4 at 3 days prior to the time of closest approach, the time analyzed for differential drag efficacy. Of those, approximately 4,300 had fully-defined covariance matrices stored for both the primary and secondary objects; this set of conjunctions is the basis for the analysis of this work. CARA’s MTS tool was used to propagate the primary satellite forward from that decision point with varying degrees of increase to ballistic coefficient (BC). Because these conjunctions came from multiple missions, the nondimensional ‘delta-BC’ factor was used to quantify and normalize the increase in ballistic coefficient, defined as follows: Delta-BC = BC_new / BC_old - 1 Positive delta-BC factors represent an increase in drag compared to the nominal attitude, while negative delta-BC factors (to a minimum of -1) represent a decrease in drag. At the conclusion of the differential-drag ‘maneuver’, the Pc was recalculated to evaluate whether or not the conjunction was mitigated (Pc < 3E-6). These results were then binned and sorted along several axes, including altitude, amount of delta-BC, and (pre-maneuver) rate of energy dissipation (EDR), to identify underlying patterns. The altitude plot is shown in Figure 1. To validate this analysis, we consulted the record of a NASA mission which uses differential drag to maintain its orbit and remediate conjunction risk. CARA’s empirical record of the mission’s orbit history suggests it achieves a delta-BC of 2.2. Of the twenty-one RMM plans that were submitted by this mission, eighteen were matched with conjunctions in the historical record; of those, twelve were successfully remediated (final measured Pc < 3E-6), and six were not. This is consistent with the expected efficacy for missions orbiting at that altitude. We are presently simulating this mission’s RMMs with MTS; this work is ongoing, but so far, the MTS results are qualitatively in agreement with the empirical results -- correctly predicting that a maneuver would or would not remediate a conjunction, if not exactly matching the final post-remediation Pc value. We found that differential drag was most successful for satellites with perigees below 560 km, and which could adopt an average delta-BC of 2 or greater (that is, increasing their ballistic coefficient by a factor of 3). However, this is a difficult threshold for a mission to clear; very few spacecraft are capable of adopting a high-drag configuration for 72 hours continuously. Planet’s Dove spacecraft use differential drag to remediate conjunctions (Griffith, et al., 2021), and they have a maximum delta-BC factor of 9, but in practice (with mission and charging constraints) they achieve a time-averaged delta-BC that is closer to 2 (Foster, et al., 2017). A mission’s differential drag utility strongly depends on the operational constraints that has the capacity to limit the time-averaged delta-BC. A mission with a high maximum delta-BC of 5 or more can have an effective delta-BC of less than 1 due to operational constraints such as instrument and solar panel pointing, especially if this constraint results in holding an intermediate drag value for most of its orbit. CARA has developed tables that can be used as decision aids to advise missions-in-development about the best way to utilize their differential drag capabilities. For missions below 560 km with the operational flexibility to devote multiple days to holding a high-drag configuration (or a sufficiently high drag ratio to compensate for limitations on that time), they are -- more likely than not -- able to successfully remediate high-risk conjunctions. Conversely, missions that do not meet these exacting criteria -- most missions -- can instead be advised to use on-board propulsion systems to perform RMMs, or to turn their minimum-area face towards the approach vector, thereby reducing Pc at the moment of conjunction due to the decreased Hard-Body Radius (HBR), that is a strongly correlated variable in the Pc calculations. (NASA, 2023)

conjunction assessment↗

DOE OSTI2026

Prediction of non-intuitive metabolic targets with bayesian metabolic control analysis to improve 3-hydroxypropionic acid production in Aspergillus niger

Development of efficient bioconversion processes is limited by the ability to predictably improve metabolic flux. Here we deployed Bayesian Metabolic Control Analysis as a platform to integrate multi-omics data with metabolic modeling and evaluated its ability to predict genetic interventions that improve metabolic flux. Global Metabolomics and proteomics data was collected from 17 Aspergillus niger strains engineered to produce the platform biochemical 3-hydroxypropionic acid from which seven actional genetic interventions were predicted from significant flux control coefficients. Of the suggested genetic interventions, two were present within the intuitively designed strains used for training (malonic semialdehyde dehydrogenase and pyruvate carboxylase) while five predicted targets were present within non-intuitive areas of the metabolic network including 5-formyltetrahydrofolate deformylase and four mitochondrial enzymes, alcohol dehydrogenase, succinyl-CoA ligase, aspartate aminotransferase, and malate dehydrogenase. Six of the targets were validated in the highest performing 3-HP strain used for multi-omics data generation which contained a prior disruption of the highest scoring target malonic semialdehyde dehydrogenase. Predicted directional perturbation of five of the six tested targets significantly improved titer and rate of 3-HP production and two significantly improved yield. The greatest improvements were observed following disruption of the non-intuitive target succinyl-CoA ligase which increased titer by 39% and yield by 29% (to 20.4 g/L 3-HP and 0.31 g 3-HP/g glucose) over the strains used for training. This study demonstrates the utility of Bayesian Metabolic Control Analysis and highlights the ability to predict meaningful genetic targets in unexpected areas of metabolism to improve engineered strains for bioconversion.

3-hydroxypropionic acid↗

NASA NTRSDate not supplied

Architecture Options for Navigation in Cislunar Space for Human Landing System Vehicles

As part of architecture studies and insight analysis focused on requirements development into Human Landing System lunar architecture designs, multiple studies are underway to understand the sensitivities and options for achieving high precision landing on the lunar surface. The baseline approach utilizes a combination of multiple sensors to capture autonomous state observations of the lander with respect to the lunar surface. These systems are typically constrained in terms of operational altitudes by parameters such as onboard map size, camera focus, or sensor transmitted power (for altimeter observations). While these sensor suites do enable high precision landing, they are typically very complex and expensive. For a human-rated vehicle, fault detection algorithms are needed in addition to redundant sensors drive additional design complexity. Conversely, for these early missions, mass performance is key, so extended analysis is required to identify numbers of sensors, their ideal placement, and integration algorithms. A key part of this analysis is to help identify key sensor suites and options to help alleviate this design tension. An alternate approach is to take advantage and build out in-situ assets to allow for GPS-like navigation within the lunar regime through the use of navigation references or beacons. This can be achieved through the integration of navigation services into potential relays and pre-placed lunar surface assets. This research focuses on the capability of this infrastructure to support navigation in all areas of cislunar space such as: approach to the moon, in orbit around the moon, and ascent/descent operations to the surface. An augmented state linear covariance analysis (LinCov) and navigation state covariance analysis (NavCov) tools were used to assess a variety of navigation reference locations and how they can support vehicle operations through both understanding of state uncertainties and trajectory dispersions. This research helps to supplement existing studies focused on communication link analysis by providing additional insight into specific vehicle operational scenarios that are tied closely to potential Human Landing System scenarios. Key aspect of this analysis focus on the sensitivity to state knowledge of the references, the accuracy of inter-asset measurements, and placement in support of the various scenarios.

Evan J Anzalone↗

DOE OSTI2022

Techno-economic assessment for the production of algal fuels and value-added products: opportunities for high-protein microalgae conversion

Abstract Background Microalgae possess numerous advantages for use as a feedstock in producing renewable fuels and products, with techno-economic analysis (TEA) frequently used to highlight the economic potential and technical challenges of utilizing this biomass in a biorefinery context. However, many historical TEA studies have focused on the conversion of biomass with elevated levels of carbohydrates and lipids and lower levels of protein, incurring substantial burdens on the ability to achieve high cultivation productivity rates relative to nutrient-replete, high-protein biomass. Given a strong dependence of algal biomass production costs on cultivation productivity, further TEA assessment is needed to understand the economic potential for utilizing potentially lower-cost but lower-quality, high-protein microalgae for biorefinery conversion. Results In this work, we conduct rigorous TEA modeling to assess the economic viability of two conceptual technology pathways for processing proteinaceous algae into a suite of fuels and products. One approach, termed mild oxidative treatment and upgrading (MOTU), makes use of a series of thermo-catalytic operations to upgrade solubilized proteins and carbohydrates to hydrocarbon fuels, while another alternative focuses on the biological conversion of those substrates to oxygenated fuels in the form of mixed alcohols (MA). Both pathways rely on the production of polyurethanes from unsaturated fatty acids and valorization of unconverted solids for use as a material for synthesizing bioplastics. The assessment found similar, albeit slightly higher fuel yields and lower costs for the MA pathway, translating to a residual solids selling price of $899/ton for MA versus $1033/ton for MOTU as would be required to support a $2.50/gallon gasoline equivalent (GGE) fuel selling price. A variation of the MA pathway including subsequent upgrading of the mixed alcohols to hydrocarbon fuels (MAU) reflected a required solids selling price of $975/ton. Conclusion The slight advantages observed for the MA pathway are partially attributed to a boundary that stops at oxygenated fuels versus fungible drop-in hydrocarbon fuels through a more complex MOTU configuration, with more comparable results obtained for the MAU scenario. In either case, it was shown that an integrated algal biorefinery can be economical through optimal strategies to utilize and valorize all fractions of the biomass.

09 BIOMASS FUELS↗

DOE OSTI2023

Guided construction of single cell reference for human and mouse lung

Accurate cell type identification is a key and rate-limiting step in single-cell data analysis. Single-cell references with comprehensive cell types, reproducible and functionally validated cell identities, and common nomenclatures are much needed by the research community for automated cell type annotation, data integration, and data sharing. Here, we develop a computational pipeline utilizing the LungMAP CellCards as a dictionary to consolidate single-cell transcriptomic datasets of 104 human lungs and 17 mouse lung samples to construct LungMAP single-cell reference (CellRef) for both normal human and mouse lungs. CellRefs define 48 human and 40 mouse lung cell types catalogued from diverse anatomic locations and developmental time points. We demonstrate the accuracy and stability of LungMAP CellRefs and their utility for automated cell type annotation of both normal and diseased lungs using multiple independent methods and testing data. We develop user-friendly web interfaces for easy access and maximal utilization of the LungMAP CellRefs.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2023

AI-accelerated protein-ligand docking for SARS-CoV-2 is 100-fold faster with no significant change in detection

Protein-ligand docking is a computational method for identifying drug leads. The method is capable of narrowing a vast library of compounds down to a tractable size for downstream simulation or experimental testing and is widely used in drug discovery. While there has been progress in accelerating scoring of compounds with artificial intelligence, few works have bridged these successes back to the virtual screening community in terms of utility and forward-looking development. We demonstrate the power of high-speed ML models by scoring 1 billion molecules in under a day (50 k predictions per GPU seconds). We showcase a workflow for docking utilizing surrogate AI-based models as a pre-filter to a standard docking workflow. Our workflow is ten times faster at screening a library of compounds than the standard technique, with an error rate less than 0.01% of detecting the underlying best scoring 0.1% of compounds. Our analysis of the speedup explains that another order of magnitude speedup must come from model accuracy rather than computing speed. In order to drive another order of magnitude of acceleration, we share a benchmark dataset consisting of 200 million 3D complex structures and 2D structure scores across a consistent set of 13 million “in-stock” molecules over 15 receptors, or binding sites, across the SARS-CoV-2 proteome. We believe this is strong evidence for the community to begin focusing on improving the accuracy of surrogate models to improve the ability to screen massive compound libraries 100 × or even 1000 × faster than current techniques and reduce missing top hits. The technique outlined aims to be a fast drop-in replacement for docking for screening billion-scale molecular libraries.

59 BASIC BIOLOGICAL SCIENCES↗

NASA NTRS2007

Space Weather Nowcasting of Atmospheric Ionizing Radiation for Aviation Safety

There is a growing concern for the health and safety of commercial aircrew and passengers due to their exposure to ionizing radiation with high linear energy transfer (LET), particularly at high latitudes. The International Commission of Radiobiological Protection (ICRP), the EPA, and the FAA consider the crews of commercial aircraft as radiation workers. During solar energetic particle (SEP) events, radiation exposure can exceed annual limits, and the number of serious health effects is expected to be quite high if precautions are not taken. There is a need for a capability to monitor the real-time, global background radiations levels, from galactic cosmic rays (GCR), at commercial airline altitudes and to provide analytical input for airline operations decisions for altering flight paths and altitudes for the mitigation and reduction of radiation exposure levels during a SEP event. The Nowcast of Atmospheric Ionizing Radiation for Aviation Safety (NAIRAS) model is new initiative to provide a global, real-time radiation dosimetry package for archiving and assessing the biologically harmful radiation exposure levels at commercial airline altitudes. The NAIRAS model brings to bear the best available suite of Sun-Earth observations and models for simulating the atmospheric ionizing radiation environment. Observations are utilized from ground (neutron monitors), from the atmosphere (the METO analysis), and from space (NASA/ACE and NOAA/GOES). Atmospheric observations provide the overhead shielding information and the ground- and space-based observations provide boundary conditions on the GCR and SEP energy flux distributions for transport and dosimetry simulations. Dose rates are calculated using the parametric AIR (Atmospheric Ionizing Radiation) model and the physics-based HZETRN (High Charge and Energy Transport) code. Empirical models of the near-Earth radiation environment (GCR/SEP energy flux distributions and geomagnetic cut-off rigidity) are benchmarked against the physics-based CMIT (Coupled Magnetosphere- Ionosphere-Thermosphere) and SEP-trajectory models.

Mertens, Christopher J.↗

NASA NTRS2013

Pilot Workload and Speech Analysis: A Preliminary Investigation

Prior research has questioned the effectiveness of speech analysis to measure the stress, workload, truthfulness, or emotional state of a talker. The question remains regarding the utility of speech analysis for restricted vocabularies such as those used in aviation communications. A part-task experiment was conducted in which participants performed Air Traffic Control read-backs in different workload environments. Participant's subjective workload and the speech qualities of fundamental frequency (F0) and articulation rate were evaluated. A significant increase in subjective workload rating was found for high workload segments. F0 was found to be significantly higher during high workload while articulation rates were found to be significantly slower. No correlation was found to exist between subjective workload and F0 or articulation rate.

Bittner, Rachel M.↗

NASA NTRSDate not supplied

Aerothermodynamic Analysis of a Flexible Thermal Protection System under Reentry Loads

The Carryall Block 1 reentry vehicle being developed by Outpost Space utilizes a strut supported semirigid deployable heatshield. This consists of a flexible thermal protection system, a heat-resistant fabric stack, stretched over actuated spars. The advantages of a deployable heatshield include reduced heat loading and earlier deceleration in the trajectory. However, the nature of the flexible thermal protection system necessitates considering the loaded shape of the heat shield. The flexible thermal protection system will deflect under reentry loads leading to areas of higher heating rates as well as a reduced axial coefficient as compared to the nominal shape. The Carryall Block 1 is analyzed using NASA’s FUN3D and DPLR CFD solvers with a deflected shape based on the catenary equations. The aerodynamic results are found to be within a percent for both solvers and both structured and unstructured mesh types. Fluid Structure Interaction (FSI) analysis is currently a work in progress, using file I/O to communicate between FUN3D and LS-DYNA, a commercial nonlinear structural solver. Challenges in deforming the geometry, mesh, and initial results are presented here.

thermal protection system↗

DOE OSTI2022

A multi-stage stochastic programming model for adaptive biomass processing operation under uncertainty

Variations of physical and chemical characteristics of biomass reduce equipment utilization and increase operational costs of biomass processing. Biomass processing facilities use sensors to monitor the changes in biomass characteristics. Integrating sensory data into the operational decisions in biomass processing will increase its flexibility to the changing biomass conditions. In this paper, we propose a multi-stage stochastic programming model that minimizes the expected operational costs by identifying the initial inventory level and creating an operational decision policy for equipment speed settings. These policies take the sensory information data and the current biomass inventory level as inputs to dynamically adjust inventory levels and equipment settings according to the changes in the biomass' characteristics. We ensure that a prescribed target reactor utilization is consistently achieved by penalizing the violation of the target reactor feeding rate. A case study is developed using real-world data collected at Idaho National Laboratory's biomass processing facility. We show the value of multi-stage stochastic programming from an extensive computational experiment. Our sensitivity analysis indicates that updating the infeed rate of the system, the processing speed of equipment, and bale sequencing based on the moisture level of biomass improves the processing rate of the reactor and reduces operating costs.

09 BIOMASS FUELS↗

DOE OSTI2022

Front-End Engineering Design for Piperazine with the Advanced Stripper

This Department of Energy (DOE) funded project was executed with the goal of preparing a Front-End Engineering Design (FEED) for the capture and compression of 90% of the CO2 that would normally be emitted from an existing natural gas combined cycle (NGCC) plant. The FEED focused on the application of the piperazine advanced stripper (PZAS) process at Mustang Station of the Golden Spread Electric Cooperative (GSEC), which consists of two gas turbines with common heat recovery steam generator (HRSG). The University of Texas at Austin (UT) served as the prime contractor, and subcontracted AECOM Technical Services and Trimeric Corporation to support FEED development. This project team has worked together to advance PZAS for more than a decade. ExxonMobil, Chevron, and Total provided project co-funding. The objectives of this work included: 1. To advance engineering design such that a comprehensive estimate for the total installed cost of a full-scale PZAS CO2 Capture Plant with CO2 compression can be developed on an existing NGCC power plant. a. These detailed costs can also be used to qualify PZAS and other related second generation (2G) amine scrubbing processes for use on cogeneration facilities in refineries and chemical plants that use gas turbines with HRSGs to produce steam. b. These detailed costs will help qualify 2G amine scrubbing for use on NGCC power plants and establish a more accurate baseline cost to be used as a target by other capture technologies. 2. To provide cost details to be used in the economic optimization of the process features of PZAS and other 2G amine scrubbing processes. 3. To provide DOE with a more detailed understanding of carbon capture costs in a commercial application, enabling DOE to better design its R&D program to improve the economics for carbon capture. 4. To provide the host site and cost share partners with the information necessary to determine whether a commercial project to capture and use CO2 for enhanced oil recovery (EOR) or for sequestration can be justified (when accounting for the 45Q tax credit). A key component of the FEED is the estimated total installed cost, which provides a basis for the likely capital investment necessary to implement the PZAS carbon capture process at this location and scale. In combination with the included economic analysis, which accounts for potential revenue from the produced CO2, potential avenues to profitability are explored. The major findings of the FEED are as follows: The Mustang Station PZAS CO2 Capture Plant estimated total project cost of $698 MM of which $384 MM was direct costs. The annual operating costs were $32.6 MM. The total investment for a PZAS facility at Mustang Station is $725 MM. This estimate includes owner’s cost of $25 million and a contingency of $110 MM. • The study estimated the CO2 capture plant at Mustang Station would generate CO2 at $110/tonne for EOR, assuming a 12% IRR (internal rate of return) and an 85% capacity factor. For CO2 storage, the same case would achieve a 12% IRR at about $114/tonne. At a capacity factor of 52%, the storage and EOR cases would break even when carbon is priced ~$150/tonne. The economic analysis determined that the capacity factor and utility pricing, among other variable factors, had a significant effect on the economics and will need additional studied. • The energy penalty of the PZAS plant would be about 46 MW in connected power and 35 MW in operating load. The natural gas requirement (for the Gas Boiler package) would be about 354 MMBTU/hr. • The FEED revealed no major risks in process maturity. However, some areas were outlined for further engineering during detailed design, which included the Gas Boiler system, general arrangement and site layout, air coolers, schedule development, and optimization of the process for higher CO2 removal. • If PZAS were to be implemented at another host site, additional opportunities for cost reduction for would include cost reduction through use of cooling water and steam extraction.

03 NATURAL GAS↗

DOE OSTI2024

Numerical Simulation of Biogenic Fluid Catalytic Cracking (BFCC) Regenerators at Different Scales with MFIX-Exa

Catalytic Fast Pyrolysis (CFP) is a process that converts biomass into liquid intermediates suitable for transportation fuels by rapidly heating it in the presence of a catalyst, aiming to produce stable oils with reduced oxygen content. During CFP, the catalyst can become deactivated by the accumulation of coke, a carbon-rich deposit formed from the decomposition of biomass components. Unlike in petroleum refining, regenerating coked catalysts from biomass pyrolysis requires specific approaches due to the different chemical nature of the coke formed. An experimental technique, Temperature Programmed Oxidation (TPO), was used to study the de-coking process by gradually increasing temperature while monitoring the production of CO and CO2, which provides data for kinetic modeling. Utilizing data from TPO experiments, coke combustion kinetic model was developed to describe the rate of coke removal at different temperatures, allowing for simulation of regeneration processes. Then kinetic model is integrated into MFIX-Exa for the simulation of Biogenic Fluid Catalytic Cracker (BFCC) regenerator at different scales, enabling analysis of catalyst flow, temperature distribution, and regeneration efficiency under various operating conditions.

biogenic fluid catalytic cracking↗

DOE OSTI2026

A Community Guide to Regulatory Barriers Affecting Microgrids (Reports 1-3)

In response to growing risks of power outages from extreme weather and aging infrastructure, communities are increasingly exploring the potential of microgrids to provide reliable energy access. Microgrids offer promising solutions to meet this challenge but face a complex landscape of non-technical barriers, particularly regulations concerning the provision and distribution of energy. Most existing legal and regulatory frameworks were designed for a centralized, one-way power system, and are often poorly suited to handle systems that independently balance distributed energy resources with local load. This three-part report series provides a strategic analysis of existing regulatory and legal factors affecting microgrid deployments to help non-technical community leaders and decision-makers better understand the feasibility of a microgrid in their community. -Report No. 1: Foundational Issues Facing Microgrids details the universal policy barriers all microgrids face, including utility interconnection processes, rate structures, and local permitting. -Report No. 2: Single Property Microgrids outlines how direct asset ownership and operating behind-the-meter can bypass some regulatory oversight, using the Blue Lake Rancheria microgrid as a case study. -Report No. 3: Multi-Property Microgrids tackles the complex challenges of crossing public rights-of-way and navigating utility franchise rights, highlighting the Coventry microgrid project. The series equips decision-makers with phased frameworks to navigate financial and regulatory complexities, engage effectively with local utilities and Authorities Having Jurisdiction (AHJs), and structure successful microgrid projects.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS2011

The J-2X Fuel Turbopump - Turbine Nozzle Low Cycle Fatigue Acceptance Rationale

The J-2X Fuel Turbopump (FTP) turbine, which drives the pump that feeds hydrogen to the J-2X engine for main combustion, is based on the J-2S design developed in the early 1970 s. Updated materials and manufacturing processes have been incorporated to meet current requirements. This paper addresses an analytical concern that the J-2X Fuel Turbine Nozzle Low Cycle Fatigue (LCF) analysis did not meet safety factor requirements per program structural assessment criteria. High strains in the nozzle airfoil during engine transients were predicted to be caused by thermally induced stresses between the vane hub, vane shroud, and airfoil. The heritage J-2 nozzle was of a similar design and experienced cracks in the same area where analysis predicted cracks in the J-2X design. Redesign options that did not significantly impact the overall turbine configuration were unsuccessful. An approach using component tests and displacement controlled fracture mechanics analysis to evaluate LCF crack initiation and growth rate was developed. The results of this testing and analysis were used to define the level of inspection on development engine test units. The programmatic impact of developing crack initiation/growth rate/arrest data was significant for the J-2X program. Final Design Certification Review acceptance logic will ultimately be developed utilizing this test and analytical data.

Hawkins, Lakiesha V.↗

DOE OSTI2020

Deciphering Degradation: Machine Learning on Real-World Performance Data

The solar investment community is in need of up-to-date and data-derived system degradation rates to use in financial models that calculate the risk and expectation of energy revenue. To date, financial models choose degradation rates from past studies that are limited and may not be representative of solar projects in development today. As the solar industry expands in all sectors (residential, commercial, and utility), there is a growing amount of energy generation data available to analyze. With the help of the open source degradation analysis code (RdTools) it is now possible to derive degradation on an ongoing basis and continuously provide up-to-date durability statistics to the investment community. Ongoing and accurate statistics of fielded photovoltaic systems allows financial stakeholders to constrain energy revenue projections, lower financial risk, and increase the bankability of solar. This presentation will provide a mid-term progress update on a 2 year SETO-funded degradation project that involves applying RdTools analysis on kWh Analytics’ industry database. With results from the RdTools analysis in hand, machine learning methods are employed to quantify how much variance of system performance degradation can be explained by predictor variables such as environmental factors, equipment bill of materials characteristics, and system design information. The goal of this presentation is to promote the usage of RdTools on an ongoing to data owners and to solicit feedback from researchers and stakeholders on how to maximize impact of the SETO-funded kWh Analytics degradation project.

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