Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “process”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 433 records · Page 24
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

System and process for capture of acid gasses at elevated pressure from gaseous process streams

A system, method, and material that enables the pressure-activated reversible chemical capture of acid gasses such as CO.sub.2 from gas volumes such as streams, flows or any other volume. Once the acid gas is chemically captured, the resulting product typically a zwitterionic salt, can be subjected to a reduced pressure whereupon the resulting product will release the captures acid gas and the capture material will be regenerated. The invention includes this process as well as the materials and systems for carrying out and enabling this process.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2017

INTEGRATION OF COST MODELS AND PROCESS SIMULATION TOOLS FOR OPTIMUM COMPOSITE MANUFACTURING PROCESS

Manufacturing cost of resin transfer molded composite parts is significantly influenced by the cycle time, which is strongly related to the time for both filling and curing of the resin in the mold. The time for filling can be optimized by various injection strategies, and by suitably reducing the length of the resin flow distance during the injection. The curing time can be reduced by the usage of faster curing resins, but it requires a high pressure injection equipment, which is capital intensive. Predictive manufacturing simulation tools that are being developed recently for composite materials are able to provide various scenarios of processing conditions virtually well in advance of manufacturing the parts. In the present study, we integrate the cost models with process simulation tools to study the influence of various parameters such as injection strategies, injection pressure, compression control to minimize high pressure injection, resin curing rate, and demold time on the manufacturing cost as affected by the annual part volume. A representative automotive component was selected for the study and the results are presented in this paper

42 ENGINEERING↗
DOE OSTI2022

The Modeling of the Synfuel Production Process: Process models of Fischer-Tropsch production with electricity and hydrogen provided by various scales of nuclear plants

Synthetic fuels (synfuels), also known as electro-fuels (E-fuels), are hydrocarbon fuels produced from waste CO2 streams and water electrolysis, with electricity as the primary source of energy. To achieve substantial reductions in greenhouse gas (GHG) emissions, electricity sources must release zero carbon or near-zero carbon, as is the case with solar, wind, hydro, and nuclear power. Nuclear power is one of the largest and steadiest domestic sources of clean energy in the United States. Moreover, nuclear power has the potential to produce hydrogen economically for less than $2/kg, reaching the DOE near-term target price. Thus, using nuclear power to produce synfuels has the unique potential to significantly reduce the GHG emissions of hydrocarbon fuels production and end-use applications. Fisher-Tropsch or FT fuel (a mixture of naphtha, jet fuel, and diesel) is of great interest because it is a drop-in fuel that can be blended with conventional petroleum counterparts and is compatible with existing infrastructure. By using the ASPEN Plus model, this report develops FT fuel production models on three scales, corresponding to nuclear plants with capacities of 1000 MWe, 437 Mwe, and 100 MWe, respectively. The FT model case with energy from a 437-MWe nuclear plant is used as a baseline case. This report summarizes the baseline ASPEN Plus model results with a detailed mass and energy analysis. Our modeled facility produces 507 MT/day (185,000 gal/day) of FT fuel by converting 255 MT/day of hydrogen and 1,580 MT/day of CO2. The FT fuel production energy efficiency from hydrogen and electricity energy inputs is 70% (lowerheating-value or LHV-based). Including the high-temperature electrolyzer in the system boundary, the FT fuel production LHV efficiency from electricity and thermal energy inputs is 51%, considering 39.8 kWh/kg of electricity and 6.86 kWh/kg of thermal energy use from a nuclear plant for hydrogen production. The FT production efficiency can potentially be increased by further integrating the heat exchange between nuclear plant and FT process, and this study is underway. The carbon conversion ratio in the baseline case is 99%, with process CO2 capture and recirculation and oxy-combustion using the oxygen by-product from water electrolysis. The hydrogen consumption is 1.38 kg/gal-FT fuel and the CO2 consumption is 8.56 kg/gal-FT fuel in the baseline case. With different FT production scales determined by the nuclear plant capacity, the FT model was scaled using the same operating parameters, which led to the same conversion efficiency regardless of scale. However, the different FT plant scales will impact the economics of FT fuel production; this impact will be examined in the next phase of this study.

Zang, Guiyan↗
DOE OSTI2026

Integrating Cybersecurity Risk Assessment with Process Safety in Chemical Process Industries

This dissertation bridges the gap between industrial cybersecurity and traditional process safety by introducing an integrated Cyber-LOPA framework that combines the Purdue Enterprise Reference Architecture, Cyber Kill Chain, and CVSS v4.0 metrics. Demonstrated on a High-Density Polyethylene slurry process, the work illustrates how cyber threats targeting automation systems can bypass physical protection layers, proving the necessity of unified risk assessments to prevent cyber-induced physical incidents in chemical manufacturing plants.

Cyber-LOPA (CLOPA)↗
DOE OSTI2019

A Field Survey of Rare Earth Element Concentrations in Process Streams Produced by Coal Preparation Plants in the Eastern USA

I this work, a field study was undertaken to experimentally measure the concentrations of rare earth elements (REEs) contained in the process streams generated by a group of 20 coal preparation plants located in the eastern USA. For each site, representative samples of clean coal product, coarse refuse, and fine refuse were collected. Each sample was then partitioned into preselected size and density classes by wet screening/sieving and float-sink testing. The resultant products were dried and subjected to laboratory analyses to determine ash contents and rare earth element concentrations including Yttrium and Scandium. A detailed analysis of the database generated by this exercise showed that coal-based products from these preparation plants contained significant quantities of rare earth elements. In particular, the coarse refuse streams currently discarded by the 20 plants examined were found to contain a sufficient tonnage of REEs to satisfy the current domestic demand for these important elements. The data also showed a strong positive correlation between ash content and REE concentration, which suggested that the primary association of REEs in eastern USA bituminous coal sources is likely within fractions containing inorganic impurities. This association was well described using a simple power equation relating ash content and REE concentration. The ratio of heavy-to-light rare earth elements was discovered to be significantly higher in organically rich fractions of clean coal, suggesting that mineral impurities intimately associated with carbonaceous matter have elevated concentrations of heavy rare earth elements. A similar trend was observed for a grouping of rare earth elements (Y, Nd, Eu, Tb, and Dy) that are likely subject to near-term supply shortages. Finally, the database showed that a linear correlation existed between La for many REEs of interest, although there were several notable exceptions for some high-value REEs (Lu, Pr, and Tb).

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

Fiber orientation and porosity in large-format extrusion process: The role of processing parameters

Controlling fiber orientation and porosity in short-fiber thermoplastic composites is important for enhancing mechanical, electrical and thermal properties in large-format additive manufacturing. This study employs a factorial design of experiments (DoE) to assess the effects of nozzle diameter (5.08 mm–10.16 mm), temperature (230–250 °C), and extruder screw speed (150–280 rpm) on flow rate, shear rate, porosity, fiber orientation, fiber length and tensile strength in 20 % carbon fiber-filled acrylonitrile butadiene styrene. ANOVA results show that screw speed significantly impacts flow rate, while nozzle diameter and temperature have lesser effects. Shear rate increases with smaller nozzles and higher speeds. Porosity decreases from 5.58 % with a 10.16 mm nozzle to 3.11 % with a 5.08 mm nozzle at 150 rpm due to increased shear rates, which induce shear thinning, reducing viscosity and facilitating gas escape. Larger nozzles (10.16 mm) produce larger, more heterogeneous pores, while smaller nozzles (5.08 mm) yield smaller, uniform pores. Beads produced with the 5.08 mm nozzle exhibit longer fiber lengths due to reduced residence time, lower shear stress, and better alignment. Fiber orientation improves with smaller nozzles due to higher shear rates but decreases with higher screw speeds (280 rpm) due to shorter residence times. The highest fiber alignment (A xx ∼ 0.65) and low porosity (∼3%) were achieved with a 5.08 mm nozzle at 150 rpm, while equivalent additive manufacturing-compression molding samples exhibited better tensile strength (∼93 MPa) under these conditions. In conclusion, these findings emphasize the importance of optimizing processing parameters to enhance fiber alignment and reduce porosity for improved mechanical performance.

Design of experiments↗
DOE OSTI2021

Distribution of rare earth elements in the pilot-scale processing of fly ashes derived from eastern Kentucky coals: Comparisons of the feed and processed ashes

Beneficiated fly ash from the combustion of Central Appalachian high volatile bituminous coals was extracted with HNO 3 in a pilot-scale processing plant. Several major oxides (notably CaO and SO 3 , but also including Fe 2 O 3 , MgO, K 2 O, and P 2 O 5 ) and minor elements (Mn, As, Sr, Ba, and Pb) are depleted in the post-HNO 3 -extraction spent ash. The total lanthanides, Y, and Sc concentration is reduced by about 20% in the spent ash, with Gd showing the greatest decrease. Along with Gd, Nd and Dy are also well differentiated between the feed and spent ashes, with La and Sm showing minimal partitioning. The Gd decrease is correlated with the depletion of Fe 2 O 3 . The heavy rare earth elements (REE heavier than Eu) and Y are disproportionately concentrated in the HNO 3 -leachate compared to the light REE. For the ashes studied, Sc did not partition between the feed and spent ashes. Pozzolanicity tests show that the compressive strength and strength activity indices of the spent ash + ordinary Portland cement (OPC) mixes are comparable to 100% OPC, indicating that the spent ashes produced in the pilot-scale runs have the potential to be sold as a Class F fly ash. Finally, the beneficiated ash chemistry influences the chemistry of the post-HNO 3 -extraction spent ash and the HNO 3 -leachate. A 500-ppm-REE fly ash will presumably be a more economically favorable feedstock than an ash with a significantly lesser concentration.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2019

Magnesium Alloy ZK60 Tubing made by Shear Assisted Processing and Extrusion (ShAPE)

ZK60 Magnesium tubing has been friction extruded from as-cast billets and T5 conditioned bars using Shear Assisted Processing and Extrusion (ShAPE). Tubes having an outer diameter of 50.8 mm and wall thickness of 1.9 mm were extruded with >20 times less ram force compared to conventional extrusion due to the unique shearing conditions and tooling inherent to ShAPE. Microstructures of the as-cast billet and T5 bar feedstock materials were significantly different from each other in terms of grain size, texture, and second phase distribution; yet the resulting microstructures after ShAPE were remarkably similar. An average grain size of 4-5 microns, 20o tilt of basal texture away from the extrusion axis, and refined second phases having a uniform distribution were achieved independent of the feedstock material. Hardness for as-extruded and artificially aged tubes are presented with isotropic behavior explained by detailed microstructural analysis. This work suggests that bulk ZK60 magnesium alloys extrusions may be fabricated in a single step, with microstructures that are unobtainable with conventional extrusion.

Friction Stir Extrusion, Friction Consolidation an↗
DOE OSTI2015

An atomic orbital-based formulation of the complete active space self-consistent field method on graphical processing units

Despite its importance, state-of-the-art algorithms for performing complete active space self-consistent field (CASSCF) computations have lagged far behind those for single reference methods. We develop an algorithm for the CASSCF orbital optimization that uses sparsity in the atomic orbital (AO) basis set to increase the applicability of CASSCF. Our implementation of this algorithm uses graphical processing units (GPUs) and has allowed us to perform CASSCF computations on molecular systems containing more than one thousand atoms. Additionally, we have implemented analytic gradients of the CASSCF energy; the gradients also benefit from GPU acceleration as well as sparsity in the AO basis.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2016

Application of temporal moments and other signal processing algorithms to analysis of ultrasonic signals through melting wax

Ultrasonic analysis is being explored as a way to capture events during melting of highly dispersive wax. Typical events include temperature changes in the material, phase transition of the material, surface flows and reformations, and void filling as the material melts. Melt tests are performed with wax to evaluate the usefulness of different signal processing algorithms in capturing event data. Several algorithm paths are being pursued. The first looks at changes in the velocity of the signal through the material. This is only appropriate when the changes from one ultrasonic signal to the next can be represented by a linear relationship, which is not always the case. The second tracks changes in the frequency content of the signal. The third algorithm tracks changes in the temporal moments of a signal over a full test. This method does not require that the changes in the signal be represented by a linear relationship, but attaching changes in the temporal moments to physical events can be difficult. This study describes the algorithm paths applied to experimental data from ultrasonic signals as wax melts and explores different ways to display the results.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Making two-photon processes dominate one-photon processes using mid-IR phonon polaritons

Phonon polaritons are guided hybrid modes of photons and optical phonons that can propagate on the surface of a polar dielectric. In this work, we show that the precise combination of confinement and bandwidth offered by phonon polaritons allows for the ability to create highly efficient sources of polariton pairs in the mid-IR/terahertz frequency ranges. Specifically, these polar dielectrics can cause emitters to preferentially decay by the emission of pairs of phonon polaritons, instead of the previously dominant single-photon emission. We show that such two-photon emission processes can occur on nanosecond time scales and can be nearly 2 orders of magnitude faster than competing single-photon transitions, as opposed to being as much as 8–10 orders of magnitude slower in free space. These results are robust to the choice of polar dielectric, allowing potentially versatile implementation in a host of materials such as hexagonal boron nitride, silicon carbide, and others. Our results suggest a design strategy for quantum light sources in the mid-IR/terahertz: ones that prefer to emit a relatively broad spectrum of photon pairs, potentially allowing for new sources of both single and multiple photons.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2016

Multi-scale processes of beech wood disintegration and pretreatment with 1-ethyl-3-methylimidazolium acetate/water mixtures

The valorization of biomass for chemicals and fuels requires efficient pretreatment. One effective strategy involves the pretreatment with ionic liquids which enables enzymatic saccharification of wood within a few hours under mild conditions. This pretreatment strategy is, however, limited by water and the ionic liquids are rather expensive. The scarce understanding of the involved effects, however, challenges the design of alternative pretreatment concepts. This work investigates the multi length-scale effects of pretreatment of wood in 1-ethyl-3-methylimidazolium acetate (EMIMAc) in mixtures with water using spectroscopy, X-ray and neutron scattering. The structure of beech wood is disintegrated in EMIMAc/water mixtures with a water content up to 8.6 wt%. Above 10.7 wt%, the pretreated wood is not disintegrated, but still much better digested enzymatically compared to native wood. In both regimes, component analysis of the solid after pretreatment shows an extraction of few percent of lignin and hemicellulose. In concentrated EMIMAc, xylan is extracted more efficiently and lignin is defunctionalized. Corresponding to the disintegration at macroscopic scale, SANS and XRD show isotropy and a loss of crystallinity in the pretreated wood, but without distinct reflections of type II cellulose. Hence, the microfibril assembly is decrystallized into rather amorphous cellulose within the cell wall. The molecular and structural changes elucidate the processes of wood pretreatment in EMIMAc/water mixtures. In the aqueous regime with >10.7 wt% water in EMIMAc, xyloglucan and lignin moieties are extracted, which leads to coalescence of fibrillary cellulose structures. Dilute EMIMAc/water mixtures thus resemble established aqueous pretreatment concepts. In concentrated EMIMAc, the swelling due to decrystallinization of cellulose, dissolution of cross-linking xylan, and defunctionalization of lignin releases the mechanical stress to result in macroscopic disintegration of cells. The remaining cell wall constituents of lignin and hemicellulose, however, limit a recrystallization of the solvated cellulose. These pretreatment mechanisms are beyond common pretreatment concepts and pave the way for a formulation of mechanistic requirements of pretreatment with simpler pretreatment liquors.

09 BIOMASS FUELS↗
DOE OSTI2015

Design of the Laboratory-Scale Plutonium Oxide Processing Unit in the Radiochemical Processing Laboratory

This report describes a design for a laboratory-scale capability to produce plutonium oxide (PuO 2 ) for use in identifying and validating nuclear forensics signatures associated with plutonium production, as well as for use as exercise and reference materials. This capability will be located in the Radiochemical Processing Laboratory at the Pacific Northwest National Laboratory. The key unit operations are described, including PuO 2 dissolution, purification of the Pu by ion exchange, precipitation, and re-conversion to PuO 2 by calcination.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2016

Influences of upwind emission sources and atmospheric processing on aerosol chemistry and properties at a rural location in the Northeastern U.S.

Continuous real-time measurements of atmospheric aerosol with an Aerodyne high-resolution time-of-flight aerosol mass spectrometer coupled with a fast temperature-stepping thermodenuder were carried out in summer 2011 at Brookhaven National Laboratory (BNL, 40.871°N, 72.89°W) during the Department of Energy Aerosol Life Cycle Intensive Operational Period campaign. BNL was frequently downwind of emissions from the New York metropolitan area and was exposed to various combinations of anthropogenic, biogenic, and marine emissions based on air mass history. The average concentration of submicrometer aerosol (PM1) during this study was 12.6 µg m –3 with 64% of the mass being organic. Organic aerosol (OA) at BNL was found to be overwhelmingly secondary, consisting of (1) a fresher, semivolatile oxygenated organic aerosol (SV-OOA; oxygen-to-carbon ratio (O/C) = 0.54; 63% of OA mass) that was strongly influenced by transported urban plumes; (2) a regional, more aged, low-volatility OOA (LV-OOA; O/C = 0.97; 29% of OA mass) influenced by aqueous-phase processing; and (3) a nitrogen-enriched OA (NOA; nitrogen-to-carbon ratio (N/C) = 0.185; 8% of OA mass) likely composed of amine salts formed from acid-base reactions in industrial emissions. Urban emissions from the New York metropolitan areas to the W and SW in particular led to elevated PM1 mass concentration and altered aerosol composition at BNL. Transported urban plumes and local biogenic emissions likely interacted to enhance secondary organic aerosol production, primarily represented by SV-OOA. Lastly, these results suggest an important role that urban anthropogenic emissions play in affecting ambient PM concentration, composition, and physical-chemical properties at rural areas in the Northeast U.S.

54 ENVIRONMENTAL SCIENCES↗