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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 397 records · Page 22
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

A framework for hybrid manufacturing cost minimization and preform design

Here, this paper describes preform design optimization in hybrid additive-subtractive manufacturing. In hybrid manufacturing, the question of what form and what geometry the additive preform should take has largely been a matter of intuition and experience, or trial and error. The choice of a more optimal preform depends on the target parameters, such as stiffness, cost, or lead time. We demonstrate a framework for preform optimization using static stiffness, and then the combined cost of additive and subtractive manufacturing, while respecting stable cutting conditions for the tool-part combination. The procedure is illustrated by comparing three preform geometries for a thin wall.

42 ENGINEERING↗
DOE OSTI2022

A Dynamic Risk Framework for the Physical Security of Nuclear Power Plants

This paper describes ongoing work within the Light Water Reactor Sustainability pathway at Idaho National Laboratory (INL) to optimize the security and cost of nuclear power plants. It introduces the dynamic risk assessment tool developed at INL, Event Modeling Risk Assessment using Linked Diagrams (EMRALD). EMRALD is leveraged to optimize the security posture of a nuclear power plant by integrating force-on-force (FOF) simulations and operator mitigation actions, including dynamic and flexible coping strategies (FLEX). To illustrate the methodology, four attack scenarios are modeled in a commercially available FOF simulation tool using a hypothetical nuclear power plant facility. The simulation results provide valuable insights into possible attack outcomes, as well as the probabilistic risk of a core damage event given these outcomes. Safety mitigation procedures are modeled in EMRALD dependent on the attack outcomes by considering human operator uncertainties. The results demonstrate that the number of armed responders can be optimized, while still maintaining the same protection level as the initial security posture. The proposed modeling and simulation framework of integrating FLEX equipment with FOF models enables the nuclear power plants to credit FLEX portable equipment in the plant security posture, resulting in an efficient and optimized physical security system.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Can section 45Q tax credit foster decarbonization? A case study of geologic carbon storage at Acid Gas Injection wells in the Permian Basin

Carbon capture, utilization, and storage (CCUS) is an important pathway for meeting climate mitigation goals. While the economic viability of CCUS is well understood, previous studies do not evaluate the economic feasibility of carbon capture and storage (CCS) in the Permian Basin specifically regarding the new Section 45Q tax credits. We developed a technoeconomic analysis method, evaluated the economic feasibility of CCS at the acid gas injection (AGI) wells, and assessed the implication of Section 45Q tax credits for CCS at the AGIs. We find that the compressors, well depth, and the permit and monitoring costs drive the facility costs. Compressors are the predominant contributors to capital and operating expenditure driving the levelized cost of CO 2 storage. Strategic cost reduction measures identified include 1) sourcing of low-cost electricity and 2) optimizing operational efficiency in well operations. In evaluating the impact of the tax credits on CCS projects, facility scale proved decisive. We found that facilities with an annual injection rate exceeding 10,000 MT storage capacity demonstrate economic viability contingent upon the procurement of inputs at the least cost. The new construction of AGI wells were found to be economically viable at a storage capacity of 100,000 MT. The basin is heavily focused on CCUS (tax credit – $\$$65/MT CO 2 ), which overshadows CCS ($\$$85/MT CO 2 ) opportunities. Balancing the dual objectives of CCS and CCUS requires planning and coordination for optimal resource and pore space utilization to attain the basin's decarbonization potential. We also found that CCS on AGI is a lower cost CCS option as compared to CCS on other industries.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2020

Piecewise Linear Optimization for Public EV Charging Depots in Different Utility Environments

With the proliferation of electric vehicles (EVs), EV supply equipment technology is being pushed to increasingly higher power levels, such as extreme fast charging (XFC) at 300kW or more. As more public XFC depots are connected to electric distribution systems, utility operators will mitigate their impact with pricing schemes and programs such as demand response, demand charges, and time-varying prices. In this paper we describe an XFC management system that combines an on-site battery energy storage system and an optimization application that minimizes the cost to operate the depot in light of the utility pricing programs. We have designed the optimizer specially to use fast and simple linear programming so that it can be deployed to low-cost computing platforms. We also describe how several utility pricing schemes are integrated into a single piecewise model, reducing the engineering effort to implement the optimizer in different utility environments.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

A flexible and differentiable coil proxy for stellarator equilibrium optimization

Balancing plasma performance and coil cost is a significant challenge when designing a stellarator power plant. Most current stellarator designs are produced through two-stage optimization: stage-1 for the equilibrium and stage-2 for a coil design that reproduces its magnetic configuration. Because few proxies connect both stages, two-stage optimization can produce plasmas that have high-quality physical properties but overly complex coils. In recent years, single-stage optimization has increasingly been used to optimize the plasma and coils simultaneously in order to improve the plasma–coil balance. However, all existing single-stage tools are specialized for filament coils, cannot model coil systems containing permanent magnets or dipole arrays, and continue to be challenged by numerical problems. The quasi-single-stage optimization finds a middle ground by integrating a coil optimization subproblem into stage-1 optimization. We present a flexible, differentiable coil complexity proxy based on the newly developed QUADCOIL coil optimization code. QUADCOIL is fast and can target realistic coil metrics and constraints that are unavailable to codes with comparable speed. We demonstrate the effectiveness and flexibility of the QUADCOIL proxy by presenting two QSS optimization studies. The first study produces a permanent magnet solution for the MUSE stellarator with 34% fewer magnets than previous solutions. The second study produces a coil solution for the ARIES-CS stellarator with 30% reductions in both peak and root-mean-square force.

Fu, Lanke [Princeton Plasma Physics Laboratory (PP↗
DOE OSTI2022

On the energy landscape of symmetric quantum signal processing

Symmetric quantum signal processing provides a parameterized representation of a real polynomial, which can be translated into an efficient quantum circuit for performing a wide range of computational tasks on quantum computers. For a given polynomial f , the parameters (called phase factors) can be obtained by solving an optimization problem. However, the cost function is non-convex, and has a very complex energy landscape with numerous global and local minima. It is therefore surprising that the solution can be robustly obtained in practice, starting from a fixed initial guess Φ 0 that contains no information of the input polynomial. To investigate this phenomenon, we first explicitly characterize all the global minima of the cost function. We then prove that one particular global minimum (called the maximal solution) belongs to a neighborhood of Φ 0 , on which the cost function is strongly convex under the condition ‖ f ‖ ∞ = O ( d − 1 ) with d = d e g ( f ) . Our result provides a partial explanation of the aforementioned success of optimization algorithms.

Wang, Jiasu↗
DOE OSTI2025

Game theoretic modeling and optimization of competition and collaboration in dual channel electronic waste supply chains

The rapid growth of electronic waste (e-waste) presents critical challenges for sustainable resource recovery and environmental protection. This study develops a dual-channel closed-loop supply chain (CLSC) model formulated as a hierarchical Stackelberg game, that integrates dynamic pricing and cost-sharing mechanisms to optimize both economic and environmental outcomes. The model explicitly captures strategic interactions between manufacturer-led and third-party recycling channels, accounting for consumer behavior, regulatory incentives, and market competition. Numerical simulations conducted (implemented over a four-iteration horizon using a commercial optimization solver) show that, relative to the baseline equilibrium, manufacturer profit increases from 11.6 thousand USD to 37.9 thousand USD (+226.8%), total recycled volume rises from 7,848 to 7,942 units (+1.2%), and collector profit nearly doubles under cost-sharing, enabling more equitable profit distribution. Furthermore, scenario-based simulations across Sub-Saharan Africa, high-income economies, and emerging Asian industrial countries reveal that infrastructure quality, policy intensity, and labor costs critically shape recycling efficiency and profit allocation. These findings demonstrate that subsidies alone are insufficient to ensure system efficiency. Instead, coordinated strategies that integrate internal incentive alignment with context-sensitive policy support are required. Overall, this study offers a robust framework for designing resilient, efficient, and regionally adaptable e-waste management systems.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

Robust Scheduling of Networked Microgrids for Economics and Resilience Improvement

The benefits of networked microgrids in terms of economics and resilience are investigated and validated in this work. Considering the stochastic unintentional islanding conditions and conventional forecast errors of both renewable generation and loads, a two-stage adaptive robust optimization is proposed to minimize the total operating cost of networked microgrids in the worst scenario of the modeled uncertainties. By coordinating the dispatch of distributed energy resources (DERs) and responsive demand among networked microgrids, the total operating cost is minimized, which includes the start-up and shut-down cost of distributed generators (DGs), the operation and maintenance (O&M) cost of DGs, the cost of buying/selling power from/to the utility grid, the degradation cost of energy storage systems (ESSs), and the cost associated with load shedding. The proposed optimization is solved with the column and constraint generation (C&CG) algorithm. The results of case studies demonstrate the advantages of networked microgrids over independent microgrids in terms of reducing total operating cost and improving the resilience of power supply.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2020

Efficient Ensemble-Based Stochastic Gradient Methods for Optimization Under Geological Uncertainty

Ensemble-based stochastic gradient methods, such as the ensemble optimization (EnOpt) method, the simplex gradient (SG) method, and the stochastic simplex approximate gradient (StoSAG) method, approximate the gradient of an objective function using an ensemble of perturbed control vectors. These methods are increasingly used in solving reservoir optimization problems because they are not only easy to parallelize and couple with any simulator but also computationally more efficient than the conventional finite-difference method for gradient calculations. In this work, we show that EnOpt may fail to achieve sufficient improvement of the objective function when the differences between the objective function values of perturbed control variables and their ensemble mean are large. On the basis of the comparison of EnOpt and SG, we propose a hybrid gradient of EnOpt and SG to save on the computational cost of SG. We also suggest practical ways to reduce the computational cost of EnOpt and StoSAG by approximating the objective function values of unperturbed control variables using the values of perturbed ones. We first demonstrate the performance of our improved ensemble schemes using a benchmark problem. Results show that the proposed gradients saved about 30–50% of the computational cost of the same optimization by using EnOpt, SG, and StoSAG. As a real application, we consider pressure management in carbon storage reservoirs, for which brine extraction wells need to be optimally placed to reduce reservoir pressure buildup while maximizing the net present value. Results show that our improved schemes reduce the computational cost significantly.

58 GEOSCIENCES↗
DOE OSTI2025

DEVELOPMENT AND APPLICATION OF RISK ANALYSIS TOOLKIT FOR PLANT RESOURCE OPTIMIZATION

This paper presents the development of methods and tools that are being designed to optimize plant operations (e.g., maintenance/replacement schedules and optimal maintenance postures for plant components) in a manner that is more cost effective than current approaches and makes better use of available component health and cost data. These methods include both data- and model-based optimization methods. Model-based optimization methods directly include reliability and cost models to determine an optimal plant operational strategy. We consider gradient-based and evolutionary (based on genetic algorithms) optimization methods. The second class of methods target more specific use cases (e.g., project schedule optimization) and are not based on reliability models directly, but they require specific component reliability and cost data. This class of methods is based on variants of the knapsack problem with an aim to determine an optimal project schedule that maximizes the overall NPV. This paper also presents multi-objective methods designed to identify an optimal maintenance posture based on a Pareto frontier analysis. Rather than dictating the “right” tradeoff (i.e., identify the absolute best posture), we show how it is possible to perform a trade space exploration approach (i.e., identify value and costs of several postures and let the analysis account for desired value and cost metrics). This is performed by identifying maintenance postures that maximize value (e.g., system availability) and minimize operational costs, i.e., the Pareto frontier in a value-cost trade space. For all these methods we present detailed applicative examples that show their validity from a decision-making perspective.

97 - MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Annual report for DOE VTO

Carbon fiber (CF)/polymer composites are a transformative class of high-performance, lightweight material, where high aspect-ratio CFs reinforce a polymer matrix and exceed the strength of steel alloys at a fraction of the density. Despite the advantages of such a class of material, the broader implementation of CF composites in a range of automotive, aerospace, and energy applications is hindered by limitations of current manufacturing methods. These current techniques (e.g., hand lay-up, wet filament winding) are costly and impose severe limitations on fiber placement, orientation, and angle, and thus a composite’s ultimate properties. Today’s CF composites are expensive to manufacture, limited in form factor, and utilize costly and sub-optimal continuous filament CF. Advanced additive manufacturing (AM) processes, combined with computational design optimization and new approaches to resin development, offer alternative design and manufacturing paradigms that have the realistic potential to lift these constraints. Such integrated AM approaches could thus help to realize the full potential of CF composite materials. One relevant application of CF composite materials where manufacturing constraints limit the cost-benefit ratio is in the manufacture of high-performance composite pressure vessels for onboard compressed natural gas (CNG) storage. Current CNG storage vessels (Types 3–5) are made from load-bearing filament-wound carbon-fiber composite and are ~3.5 times as expensive as an all-metallic Type-1 vessel. This cost is invariably tied to the complex and labor-intensive nature of conventional filament winding processes and the large volumes of expensive high tensile-strength CF tow feedstock required in manufacture. Our proposed approach to CNG storage vessel manufacture is based on a combination of AM technologies for CF composite printing and design optimization tools that were pioneered at Lawrence Livermore National Laboratory (LLNL), with advances in resin/composite formulation enabled by chemical and nano-material modification. Through the successful development of this technology, LLNL seeks to demonstrate the capability for advanced CNG storage vessel manufacture at reduced cost with no reduction in performance versus the most advanced, extant Type-5 designs.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

A Cross-Domain Optimization Framework of PMU and Communication Placement for Multidomain Resiliency and Cost Reduction

Phasor measurement units (PMUs) play a crucial role in real-time monitoring and control of power grids. They rely on a communication network to transfer measurement data to the phasor data concentrator (PDC) for further processing and analysis. In this paper, a resilient cross-domain PMU and communication link placement method for minimizing the overall installation cost of the wide-area measurement system (WAMS) is proposed. Here, the main idea is to break down the barrier between the power grid domain and the communication domain, and consider the impact of one when design the other. The PMU placement in the power grid domain takes into account the cost of communication links by generating multiple solutions with equally minimum PMU costs for communication link placement evaluation. On the other hand, the communication link placement problem reduces the cost by customizing the routing policies based on the different roles of PMUs in grid observability. The proposed WAMS design is capable of withstanding any single component failure in the power domain (PMU failure or power branch failure) or in the communication domain (communication link failure or PDC failure). Numerical study on the IEEE 57-bus system reveals that the developed cross-domain optimization framework can significantly reduce the overall installation cost of WAMS while attaining multi-domain resiliency.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

High Performance Solvent for NGCC Flue Gas CO 2 Capture (Final Technical Report)

Amine-based solvent absorption is the most mature and reliable technology for large scale CO 2 capture, dating back to the 1930s when monoethanolamine (MEA) was used to treat acid gases from oil refineries. However, while strategic advancements have optimized the CO2 capture process, the cost of capture remains high, where current estimates suggest that CO 2 capture costs are around $\$$72/tonne of CO 2 . To address this, solvent development and optimization have become a focus of current research. This project sought to develop a high-performance solvent to reduce the overall cost of CO 2 capture from NGCC flue gas. Here, solvent optimization focused on: (1) reducing the energy required for CO 2 desorption in a reboiler, (2) improving CO 2 absorption and desorption reaction kinetics, (3) improving solvent stability, and (4) reducing environmental impacts. Susteon has developed and evaluated a promoted solvent, Sustenol™, for NGCC flue gas CO 2 capture. The optimized Sustenol™ also shows a higher dynamic CO 2 absorption capacity of ~0.5 mol CO2 /mol amine compared to 0.25 mol CO2 /mol amine for 30 wt% MEA. Additionally, the solvent is oxidatively, thermally and hydrothermally stable, which leads to lower solvent loss and emissions. These advancements have resulted in a solvent regeneration energy of 2.16 GJ/tonne of CO 2 which is >30% lower than current state-of-the-art commercial and emerging solvents. Combined with empirical data from the bench and pilot scale testing, this preliminary TEA study indicated the cost of CO 2 capture by Sustenol™ for 97% CO 2 removal at $\$$54/tonne and for 90% removal at $\$$49/tonne, with a pathway to achieve $\$$45/tonne of CO 2 with continued process and solvent advancements. Susteon has developed a technology roadmap to reduce the cost of CO 2 capture to <$\$$45/tonne for NGCC flue gas. Susteon plans to derisk this technology for commercial deployment through comprehensive solvent degradation testing, long-term testing in a pilot plant at 5 tonne CO2 /day and demonstration scale testing at 100 tonne CO2 /day with NGCC flue gas and engineering design studies to qualify Sustenol™ as a drop-in replacement solvent.

03 NATURAL GAS↗
DOE OSTI2026

Sparsity Applications for Gradient‐Based Optimization of Wind Farms

Optimizing wind farms is essential for designing efficient energy systems, especially as farms grow larger and span multiple sites. However, this optimization becomes increasingly challenging due to the rising computational cost associated with more turbines. Gradient‐based optimization methods scale better than gradient‐free approaches for large problems, but the most computationally expensive component remains the calculation of gradients for the objective function and constraint Jacobians. To address this, we propose leveraging sparsity to accelerate gradient evaluations and reduce the size of the constraint Jacobian. Wind farms naturally exhibit sparsity—many turbines do not influence each other under certain wind directions. However, unlike traditional sparse problems with fixed patterns, wind farm sparsity is dynamic, requiring new strategies to handle changing interactions efficiently. This paper presents a study of sparsity in wind farm optimization and introduces several methods to exploit it. These strategies are tested on multiple farms using the analytic Cumulative Curl model, with gradients computed via automatic differentiation (AD). The same sparsity‐aware techniques are also applicable to finite difference (FD) methods, where they can yield even greater speedups due to the high cost of directional evaluations. Results show that sparse methods achieve up to a 10x speedup with less than ± 5% variance in optimized wake losses compared to traditional methods. These findings suggest that sparsity‐aware optimization not only maintains solution quality but also scales efficiently with farm size, enabling more comprehensive design exploration at reduced computational cost.

17 WIND ENERGY↗
DOE OSTI2024

Integrated Technology for Cost-Effective CO2 Capture and Formic Acid Production: Modeling, Optimization, and Economic Analysis

A novel reactive technology is being investigated that electrochemically converts CO2 into valuable chemicals, particularly formic acid. This work focuses on identifying the optimal design and operation of an integrated membrane-based CO2 capture unit with the electrochemical conversion process. In this setup, the CO2 in the flue gas permeates through a CO2-selective membrane and enters an electrolyzer to produce formic acid, creating an integrated reaction module. To refine the chemical product, gas products from the electrolyzer are directed to a pressure swing adsorption unit, while the liquid product undergoes refinement to achieve commercial-grade formic acid using reactive distillation. A membrane CO2 capture model and an electrochemical conversion model have been developed using the IDAES Integrated Platform (Institute for the Design of Advanced Energy System), facilitating rigorous flowsheet modeling and process design and optimization.

Wang, Maojian↗
DOE OSTI2021

Resilience-based Recovery Scheduling of Transportation Network in Mixed Traffic Environment: A Deep-Ensemble-Assisted Active Learning Approach

Devising effective post-hazard recovery strategies is critical in enhancing the resilience of transportation networks (TNs). However, existing work does not consider the multiclass users’ travel behavior in network functionality quantification and the metaheuristic solution procedures often suffer from extensive computational burden due to the exploration need in large solution space and the expensive functionality quantification. Here, this study develops a bilevel decision-making framework for the resilience-based recovery scheduling of the TN in a mixed traffic environment with connected and autonomous vehicles (CAVs) and human-driven vehicles (HDVs). The lower level quantifies the TN's functionality over time considering different travel behavior of CAV and HDV users arisen from their different levels of information perception. The upper level presents a novel deep-ensemble-assisted active learning approach to balance optimization performance and computational cost. This framework can help decision makers better quantify the TN's functionality to support effective recovery scheduling of TN with different mixed traffic scenarios ranging from HDV-only to future CAV-dominant traffic. The optimization approach bears the potential to be extended to solving general large-scale network recovery scheduling problems effectively and efficiently. The proposed methodology is demonstrated using a real-world traffic network in Southern California under earthquake considering deterministic and stochastic repair durations.

42 ENGINEERING↗