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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 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Fermentation and purification processes for producing Glucaric Acid

Through DOE’s Bioenergy Technologies Office Industrial Seeding Program and the Energy Efficiency and Renewable Energy Small Business Voucher Program, Massachusetts-based Kalion received support to work with the ABPDU to reach full manufacturing-scale production of biobased glucaric acid. One of the “Top Value-Added Chemicals from Biomass” identified in a 2004 report, glucaric acid is most commonly found in detergents and can be a substitute for less environmentally friendly phosphates. Scaling up manufacturing processes is a common obstacle for small companies like Kalion. By working with the ABPDU, Kalion went from a 2-liter to a 300-liter run via fermentation and provided another point of validation to its investors.

09 BIOMASS FUELS↗
DOE OSTI2020

SFAI and Related Technologies

Researchers at Los Alamos have developed Swept-Frequency Acoustic Interferometry (SFAI) a technology that enables businesses to have greater control over their industrial processes, allowing for significantly improved efficiency by giving operators vital composition and flow rate information in real-time. This technology fills the information gap by providing this data non-invasively and at a fraction of the cost of traditional composition meters. SFAI uses engineered ultrasound and advanced signal processing to characterize multiphase flow (e.g., liquids, gasses, multi-phase mixtures) and other flows inside sealed containers and flow pipes. By being both low-cost and non-invasive, this technology is set to disrupt the current oil field monitoring state-of-the-art by providing individual well-level composition data, compared to the multi-well macroscopic information that is currently available. We are seeking a commercialization partner to license the technology or fund us through a Cooperative Research and Development Agreement (CRADA) to a further develop a usable product for commercial purposes.

03 NATURAL GAS↗
DOE OSTI2021

Industry Partnerships & Their Role In Reducing Natural Gas Supply Chain Greenhouse Gas Emissions – Phase 2

Our Nation’s Energy Future (ONE Future) is a natural gas industry partnership dedicated to improving the efficiency of the natural gas supply chain. The National Energy Technology Laboratory (NETL) is a United States (U.S.) Department of Energy (DOE) laboratory with world-class capabilities in energy research and analysis. This analysis is a collaboration between ONE Future and NETL, with the goal of characterizing methane (CH 4 ) and other greenhouse gas (GHG) emissions from ONE Future’s operations.

03 NATURAL GAS↗
DOE OSTI2023

Water Power Technologies Office: 2022 Project Peer Review

The Water Power Technologies Office (WPTO), part of the U.S. Department of Energy’s (DOE) Office of Energy Efficiency and Renewable Energy (EERE), held a virtual peer review on July 18–29, 2022. The purpose of peer review is to evaluate DOE-funded projects for their contributions to the mission and goals of the office, progress made against stated objectives, and the office’s overall management and performance. The peer review process enables external stakeholders to provide feedback on the most impactful use of taxpayer funding and develop recommendations for the most efficient and effective ways to accelerate industry development in power technologies. This report includes the results of WPTO’s 2022 Peer Review.

13 HYDRO ENERGY↗
DOE OSTI2025

Report for the 2024 ASCR Workshop on Energy-Efficient Computing for Science

In September 2024, the US Department of Energy’s Advanced Scientific Computing Research pro gram convened a Workshop on Energy-Efficient Computing for Science to address the critical research challenges and opportunities in this field. The workshop brought together experts from academia, government, and industry to explore innovative approaches to improve energy efficiency across the computing stack over the next two decades. Participants identified five priority research directions (PRDs) that emphasize the need for a holistic approach.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Kinetic and Mechanistic Understanding of Boron-Containing Catalysts for the Production of Light Olefins through Selective Oxidation

In recent years, an abundance of natural gas obtained from shale deposits has created opportunities for the US chemical industry to establish new and more efficient processes for the production of chemical intermediates and polymers. For example, the replacement of petroleum-derived naphtha as a to shale-derived ethane as feedstocks has made the production of ethylene/polyethylene less costly. However, this shift in feedstock has led to lower production of propylene from steam crackers, and new “on-purpose” light olefin production technologies have been implemented to bridge the gap between propylene supply and demand. The most important of these processes is direct propane dehydrogenation (PDH), but catalyst deactivation and high temperatures lead to high capital and operating costs. Oxidative dehydrogenation of propane (ODHP) is an efficient alternative to PDH, but high selectivity to CO2 from previous metal oxide catalyst prevents implementation. Hexagonal boron nitride (hBN) and other boron-containing materials have been recently developed as highly selective catalysts for both ODHP and oxidative cracking, surpassing previous systems. Much is still unknown in regard to the mechanism and the dynamic surface changes that occur under reaction conditions. This research project aims to combine in situ/operando spectroscopic investigation and kinetic studies to elucidate the interplay between the proposed gas-phase mechanism and the surface structures on the working catalyst. These insights will be leveraged to create a framework for optimizing reaction conditions and material synthesis for the next generation of boron-containing selective oxidation catalysts.

02 PETROLEUM↗
DOE OSTI2025

Machine Learning for Automated Weld Quality Monitoring and Control

Resistance Spot Welding (RSW) is a critical process in the automotive industry, valued for its cost-effectiveness, short cycle time, and robustness. However, achieving consistent high-quality joints remains challenging due to the complex interplay of various factors, like materials, processes, and manufacturing uncertainties, etc. Under the collaborative project between Oak Ridge National Laboratory (ORNL) and General Motors (GM), we have developed a robust and expansible machine learning (ML) framework aimed at enhancing quality control in RSW. By harnessing the power of machine learning, we have developed the ability to ensure every aspect of the welding process, from the initial process design stage to the final weld joint quality. The framework operates by analyzing a variety of data streams, including in-line process signals, process parameters, materials, and postprocessed weld joint data. Through this analysis, the models have been trained to detect deviations from optimal quality standards, leveraging their ability to identify signature data patterns and anomalies within in-line signals and construct complex correlations between these signals and weld quality parameters. Meanwhile, the machine learning framework is designed to adapt to a variety of materials, including high strength steels and aluminum alloys, etc. Its flexible architecture facilitates the incorporation of diverse data sources and features, enabling precise modeling and prediction across a broad range of material properties and weld quality variables. The expansible ML frameworks represent a promising transformation in weld quality monitoring and control, empowering industry to achieve high levels of efficiency, consistency, and reliability in manufacturing.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

Innovative Polyhydroxyalkanoates (PHA) Production with Microbial Electrochemical Technology (MET)

The project “Innovative Polyhydroxyalkanoates (PHA) Production with Microbial Electrochemical Technology (MET)” addressed food waste disposal challenges by successfully converting food waste to bioplastics (known as PHAs). The novel process created by our team of researchers from universities, national labs, and industry substantially enhanced overall carbon conversion efficiency of food waste processing (> 50%), while reducing disposal costs (> 25%). The project showed economic viability potential at community scale through pilot-scale demonstration at a relevant scale (50 L reactor volume) with more than 100 hours of PHA production using realistic conditions. The project goal was to valorize food waste by shunting traditional anaerobic digestion processing and creating a value-added PHA processing route that improves the economics and sustainability of local, community-scale, wet organic waste treatment. First, the food waste undergoes microbial-based, dark fermentation to break down the food to small carbon chains known as volatile fatty acids (VFAs). Instead of microorganisms converting the VFAs into methane using normal anaerobic digestion processing, our innovative process inhibits methane production. This preserves the produced VFAs for extraction and use by a novel Haloferax mediterranei (HM) archaea, which effectively converts the VFAs to bioplastics. The project added microbial electrochemical cells (MEC) to the dark fermentation process to enhance the VFAs produced and optimize the type of bioplastics formed.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Novel High Resolution High Temperature In-Line Sensors for Steel Manufacturing

To support efficiency, productivity, yield improvements, and future industry 4.0 and SMART manufacturing objectives for a competitive and prosperous steel industry, this program has embarked on an effort to develop, demonstrate and deploy several novel sensing technologies based on fiber optics for use in production steel facilities. Over the duration of this program, our team has successfully demonstrated three of these technologies: (1) near continuous Rayliegh Scattering optical frequency domain reflectometry (OFDR) sensing with single mode silica fibers for temperature sensing to 700 C, (2) semi-distributed fiber Bragg grating (FBG) sensing with multimode sapphire fibers for temperature sensing to >1600 C, and (3) remote in-situ Raman analysis for slag and flux chemistry analysis at steelmaking temperatures >1550 C. Each of these sensor and interrogation systems was developed, refined, and tested in our labs at Missouri S&T and then successfully deployed at SSAB’s production facilities at two sites, one in Montpelier, IA and one in Mobile, AL.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Machine Learning for Automated Weld Quality Monitoring and Control

Resistance Spot Welding (RSW) is a critical process in the automotive industry, valued for its cost-effectiveness, short cycle time, and robustness. However, achieving consistent high-quality joints remains challenging due to the complex interplay of various factors, like materials, processes, and manufacturing uncertainties, etc. Under the collaborative project between Oak Ridge National Laboratory (ORNL) and General Motors (GM), we have developed a robust and expansible machine learning (ML) framework aimed at enhancing quality control in RSW. By harnessing the power of machine learning, we have developed the ability to ensure every aspect of the welding process, from the initial process design stage to the final weld joint quality. The framework operates by analyzing a variety of data streams, including in-line process signals, process parameters, materials, and postprocessed weld joint data. Through this analysis, the models have been trained to detect deviations from optimal quality standards, leveraging their ability to identify signature data patterns and anomalies within in-line signals and construct complex correlations between these signals and weld quality parameters. Meanwhile, the machine learning framework is designed to adapt to a variety of materials, including high strength steels and aluminum alloys, etc. Its flexible architecture facilitates the incorporation of diverse data sources and features, enabling precise modeling and prediction across a broad range of material properties and weld quality variables. The expansible ML frameworks represent a promising transformation in weld quality monitoring and control, empowering industry to achieve high levels of efficiency, consistency, and reliability in manufacturing.

42 ENGINEERING↗
DOE OSTI2025

A Scalable and Cost-Effective Solution to the U.S. Housing Crisis: A Case Study on Locally Manufactured Modular Multifamily Housing

This case study assesses waste management efficiencies in modular buildings compared to traditional construction methods. We focus on the modular 1-bedroom Model/Z unit by Model Z Modular, LLC. As part of the collaboration between Model Z Modular and the National Renewable Energy Laboratory, we analyzed waste metrics from design through construction, contrasting these findings against conventional stick-built and site-built multifamily buildings. The Model/Z unit is part of a strategic effort to address affordable housing shortages in South Los Angeles, where household income challenges are pronounced. The unit is produced in a state-of-the-art 150,000 sq. ft. modular manufacturing facility located within the city it is serving, and has so far supported the production of over 1,500 affordable housing units. Model/Z units have been used in projects with as many as 195 units, achieving large economies of scale and time. Our analysis demonstrates that modular construction reduces waste compared to traditional methods. This reduction is achieved through precise prefabrication techniques, the implementation of new framing methods, the concentration of workforce expertise, and streamlined logistics, which optimize material use and greatly reduce on-site handling. Additionally, local manufacturing minimizes transportation needs, improving overall project efficiency. The Model/Z unit exemplifies a scalable solution for enhancing housing affordability by optimizing resource utilization and minimizing associated costs. These methods support the delivery of high-quality units at reduced expenses, addressing critical urban housing shortages effectively. This case study underscores Model Z Modular's commitment to producing affordable, quality housing while fostering economic opportunities through job creation and training programs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Characterization and Stimulation of Selenium Reducing Microbial Consortia from Real Flue Gas Desulfurization Wastewater Biological Treatment System

Selenium is released into the environment via anthropogenic activities such as coal combustion. The U.S. Environmental Protection Agency’s Effluent Limitation Guideline (ELG) Rule limits the release of selenium species into U.S. waterways. To meet the ELG limit for selenium, coal-fired power plants must treat the wastewater produced by the flue gas desulfurization (FGD) systems. Selenium removal is of interest because small changes of the concentrations of selenium in the environment can cause detrimental ecological consequences. Biological treatment is used to remediate this wastewater, but little is known about the individual species in the microbial consortium that reduce toxic water-soluble selenium oxyanions to insoluble elemental selenium. To optimize current biological treatment capabilities of this water, the selenium-reducing capabilities must be leveraged. In order to do so, the selenium-reducing bacteria (SeRB) in biological treatment systems must be characterized. This study will be the first to characterize the microbial consortia from a real FGD WW biological treatment system and provide insights on how to better achieve selenium removal via biological treatment. This work will provide insights into the microorganisms predominantly responsible for the reduction of selenium oxyanions in FGD wastewater biological treatment systems, which can be used to better optimize more efficient biological treatment strategies of this industrial waste.

geomicrobiology↗
DOE OSTI2025

Additive Manufactured Composite Phase-Change Material for Thermal Energy Storage Applications

Phase-change materials play a critical role in industrial energy storage applications to drive efficiency improvements, thermal energy management, and carbon emissions reductions. Recently, it has been shown that rapid solidification of alloys with metastable immiscibility in the liquid phase has the potential to form unique microstructures in which a low-melting phase is uniformly distributed in a high-melting matrix. This feature can be exploited using additive manufacturing to produce components with complex geometries containing such unique phase-change microstructures. Phase-field simulations utilizing high-performance computing were used to provide a detailed description of the evolution of the active phase during service in terms of their morphology and composition in different polycrystalline matrix grain morphologies that are typically produced during additive manufacturing. Phase field simulations were performed using, MEUMAPPS-SL (Microstructure Evolution Using Massively Parallel Phase-field Simulations – Solid Liquid) code that was developed in-house by the Oak Ridge National Laboratory. The simulations utilized the capabilities of the Kestrel supercomputer at the National Renewable Energy Laboratory. The simulation results were compared with experimental results generated at Siemens Energy, Inc. The results indicate that the kinetics of liquid spreading along grain boundaries is largely determined by the mobility of the triple line along the intersection of the grain boundary liquid and the grain boundary plane.

25 ENERGY STORAGE↗
NASA NTRS1989

Development of an atmospheric monitoring plan for space station

An environmental health monitoring plan for Space Station will ensure crew health during prolonged habitation. The Space Station, Freedom, will operate for extended periods, 90+ days, without resupply. A regenerative, closed loop life support system will be utilized in order to minimize resupply logistics and costs. Overboard disposal of wastes and venting of gases to space will be minimal. All waste material will be treated and recycled. The concentrated wastes will be stabilized and stored for ground disposal. The expected useful life of the station (decades) and the diversity of materials brought aboard for experimental or manufacturing purposes, increases the likelihood of cabin contamination. Processes by which cabin contamination can occur include: biological waste production, material off-gassing, process leakage, accidental containment breach, and accumulation due to poor removal efficiencies of the purification units. An industrial hygiene approach was taken to rationalize monitoring needs and to identify the substances likely to be present, the amount, and their hazard.

Casserly, Dennis M.↗
NASA NTRS2002

One-Dimensional Spontaneous Raman Measurements of Temperature Made in a Gas Turbine Combustor

The NASA Glenn Research Center is working with the aeronautics industry to develop highly fuel-efficient and environmentally friendly gas turbine combustor technology. This effort includes testing new hardware designs at conditions that simulate the high-temperature, high-pressure environment expected in the next-generation of high-performance engines. Glenn has the only facilities in which such tests can be performed. One aspect of these tests is the use of nonintrusive optical and laser diagnostics to measure combustion species concentration, fuel/air ratio, fuel drop size, and velocity, and to visualize the fuel injector spray pattern and some combustion species distributions. These data not only help designers to determine the efficacy of specific designs, but provide a database for computer modelers and enhance our understanding of the many processes that take place within a combustor. Until recently, we lacked one critical capability, the ability to measure temperature. This article summarizes our latest developments in that area. Recently, we demonstrated the first-ever use of spontaneous Raman scattering to measure combustion temperatures within the Advanced Subsonics Combustion Rig (ASCR) sector rig. We also established the highest rig pressure ever achieved for a continuous-flow combustor facility, 54.4 bar. The ASCR facility can provide operating pressures from 1 to 60 bar (60 atm). This photograph shows the Raman system setup next to the ASCR rig. The test was performed using a NASA-concept fuel injector and Jet-A fuel over a range of air inlet temperatures, pressures, and fuel/air ratios.

Hicks, Yolanda R.↗
NASA NTRS2010

Electrostatic Separator for Beneficiation of Lunar Soil

A charge separator has been constructed for use in a lunar environment that will allow for separation of minerals from lunar soil. In the present experiments, whole lunar dust as received was used. The approach taken here was that beneficiation of ores into an industrial feedstock grade may be more efficient. Refinement or enrichment of specific minerals in the soil before it is chemically processed may be more desirable as it would reduce the size and energy requirements necessary to produce the virgin material, and it may significantly reduce the process complexity. The principle is that minerals of different composition and work function will charge differently when tribocharged against different materials, and hence be separated in an electric field.

Quinn, Jacqueline↗
NASA NTRS2015

Ubiquitous Supercritical Wing Design Cuts Billions in Fuel Costs

A Langley Research Center engineer’s work in the 1960s and ’70s to develop a wing with better performance near the speed of sound resulted in a significant increase in subsonic efficiency. The design was shared with industry. Today, Renton, Washington-based Boeing Commercial Airplanes, as well as most other plane manufacturers, apply it to all their aircraft, saving the airline industry billions of dollars in fuel every year.

Source record↗
NASA NTRS2018

A Generalized Power System Architecture Sizing and Analysis Framework

The aeronautics industry has been challenged to increase efficiency, reduce noise and emissions, and decrease dependency on carbon-based fuels. To address these needs, NASA has identified and begun to pursue electrified aircraft as a possible solution. The power system for an electric aircraft can exist in many different forms, however; at the early design stage the engineer(s) must identify whether a hybrid- or turbo- electric solution may be best, whether the power transmission system is to be AC or DC, and to ultimately answer the question: does the electric solution provide a net system benefit compared to the fully mechanical solution? This paper describes a generalized power system architecture sizing and analysis framework to provide a mechanism to answering these questions, along with an example based on the STARC-ABL Architecture.

Turbo-Electric↗