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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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517 records · Page 29
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Understanding Your Utility Bills: Natural Gas

As a fossil fuel NG is a colorless and odorless gas in its natural state and is one of the cleanest burning hydrocarbons. The factors that contribute to the popularity of natural gas in the US manufacturing sector include ease of availability, clean burning properties, market deregulation, and increased domestic production. Analyzing natural gas (NG) bills can sometimes pose unique problems. Learning to read your utility bills and understand why your utility charges different fees is critical in maximizing your cost savings through energy efficiency. A key to creating a baseline is collecting and analyzing natural gas utility data. Historical data from NG bills can identify trends and help to find the baseline usage for a manufacturing operation. This guide intends to help Better Plant Program partners in understanding natural gas bills and analyzing usage to reduce costs. The guide focuses on natural gas production and transportation, understanding key charges on bills, different rate structures, and saving opportunities. A fictitious worked out example in the final section demonstrates how readers could go about analyzing natural gas bills.

03 NATURAL GAS↗
DOE OSTI2025

PFAS Waste Management for Industrial, Water, and Wastewater Treatment Facilities

Per- and polyfluoroalkyl substances (PFAS), including perfluorooctanesulfonic acid (PFOS) and perfluorooctanoic acid (PFOA), are widely used in industrial and consumer products due to their unique water and oil repelling properties. These slow-degrading and bio-accumulating compounds, often called "forever chemicals," are not typically removed by conventional industrial and municipal water/wastewater (W/WW) treatment. This tip of the month provides comprehensive strategies for managing PFAS-contaminated waste streams. Understanding the various types of PFAS waste streams is the first step in managing them. Primary PFAS waste includes contaminated process W/WW and solid materials directly from the production and processing of PFAS-containing materials. These might come from manufacturing facilities, firefighting training areas, or other industrial operations where PFAS compounds are used or were historically present. Secondary PFAS waste results from treatment and disposal mechanisms of primary PFAS waste streams, including spent activated carbon, used ion exchange resins, membrane reject streams, PFAS-laden backwash water, landfill leachate, incineration residuals, etc. TABLE 1 lists examples of the most common PFAS waste streams in different industrial facilities.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Analyze Scrap Rate for Waste Reduction

Manufacturing scrap is a term used for denoting in-process raw material waste. Many manufacturers accept scrap as an unavoidable part of the manufacturing. Scrap is created in all the phases of a manufacturing process and represents varying value of wasted materials along with other resources. The scrap is usually created in the final phases. Quality testing is the most expensive type of scrap and represents highest waste creation.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Leverage modern artificial intelligence (AI) enabled systems for waste reduction

Manufacturing industries continue to face challenges in reducing waste, as upstream strategies such as source reduction and product redesign require a deeper understanding of processes compared to conventional recycling methods. Recent advancements in artificial intelligence (AI) and machine learning (ML) have opened new opportunities to integrate modern computational techniques with traditional waste minimization strategies. This paper explores AI-enabled approaches for product redesign, source reduction, and recycling that can significantly reduce waste generation while improving efficiency and sustainability. AI-driven material substitution and lightweighting in product design enable discovery of novel materials with optimized properties, reducing waste without compromising performance. Reinforcement learning models optimize process parameters, raw material specifications, and machine sequencing to minimize production losses, while Industrial Internet of Things (IIoT) systems paired with AI analytics enhance real-time waste tracking, predictive maintenance, and quality inspection. Furthermore, AI-based demand forecasting and production planning reduce overproduction and excess inventory, as demonstrated in industrial applications. In recycling, ML-powered pattern recognition and robotic sorting technologies achieve higher accuracy in waste segregation, directly improving recycling efficiency. Complementary solutions such as smart bins and AI-enabled waste pickup scheduling optimize collection logistics, reducing both costs and emissions. Although implementation requires upfront investment in infrastructure and training, the long-term benefits include higher material efficiency, reduced waste, improved product quality, and stronger sustainability outcomes across the supply chain. By leveraging AI-enabled systems, manufacturers can align waste minimization efforts with circular economy principles, creating scalable solutions for both industry and society.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Modeling Radiation-Induced Epithelial Cell Injury in Murine Three-Dimensional Esophageal Organoids

Esophageal squamous cell carcinoma (ESCC) is a deadly consequence of radiation exposure to the esophagus. ESCC arises from esophageal epithelial cells that undergo malignant transformation and features a perturbed squamous cell differentiation program. Understanding the dose- and radiation quality-dependence of the esophageal epithelium response to radiation may provide insights into the ability of radiation to promote ESCC. We have explored factors that may play a role in esophageal epithelial radiosensitivity and their potential relationship to ESCC risk. We have utilized a murine three-dimensional (3D) organoid model that recapitulates the morphology and functions of the stratified squamous epithelium of the esophagus to study persistent dose- and radiation quality-dependent changes. Interestingly, although high-linear energy transfer (LET) Fe ion exposure induced a more intense and persistent alteration of squamous differentiation and 53BP1 DNA damage foci levels as compared to Cs, the MAPK/SAPK stress pathway signaling showed similar altered levels for most phospho-proteins with both radiation qualities. In addition, the lower dose of high-LET exposure also revealed nearly the same degree of morphological changes, even though only ~36% of the cells were predicted to be hit at the lower 0.1 Gy dose, suggesting that a bystander effect may be induced. Although p38 and ERK/MAPK revealed the highest levels following high-LET exposure, the findings reveal that even a low dose (0.1 Gy) of both radiation qualities can elicit a persistent stress signaling response that may critically impact the differentiation gradient of the esophageal epithelium, providing novel insights into the pathogenesis of radiation-induced esophageal injury and early stage esophageal carcinogenesis.

3D organoid culture↗
DOE OSTI2020

Effect of inorganic-to-organic mass ratio on the heterogeneous OH reaction rates of erythritol: implications for atmospheric chemical stability of 2-methyltetrols

The 2-methyltetrols have been widely chosen as chemical tracers for isoprene-derived secondary organic aerosols. While they are often assumed to be relatively unreactive, a laboratory study reported that pure erythritol particles (an analog of 2-methyltetrols) can be heterogeneously oxidized by gas-phase OH radicals at a significant rate. This might question the efficacy of these compounds as tracers in aerosol source-apportionment studies. Additional uncertainty could arise as organic compounds and inorganic salts often coexist in atmospheric particles. To gain more insights into the chemical stability of 2-methyltetrols in atmospheric particles, this study investigates the heterogeneous OH oxidation of pure erythritol particles and particles containing erythritol and ammonium sulfate (AS) at different dry inorganic-to-organic mass ratios (IOR) in an aerosol flow tube reactor at a high relative humidity of 85 %. The same reaction products are formed upon heterogenous OH oxidation of erythritol and erythritol–AS particles, suggesting that the reaction pathways are not strongly affected by the presence and amount of AS. On the other hand, the effective OH uptake coefficient, $γ_{eff}$, is found to decrease by about a factor of ~20 from 0.45±0.025 to 0.02±0.001 when the relative abundance of AS increases and the IOR increases from 0.0 to 5.0. One likely explanation is the presence of dissolved ions slows down the reaction rates by decreasing the surface concentration of erythritol and reducing the frequency of collision between erythritol and gas-phase OH radicals at the particle surface. Hence, the heterogeneous OH reactivity of erythritol and likely 2-methyltetrols in atmospheric particles would be slower than previously thought when the salts are present. Given 2-methyltetrols often coexist with a significant amount of AS in many environments, where ambient IOR can vary from ~1.89 to ~250, our kinetic data would suggest that 2-methyltetrols in atmospheric particles are likely chemically stable against heterogeneous OH oxidation under humid conditions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Reducing uncertainties in satellite estimates of aerosol–cloud interactions over the subtropical ocean by integrating vertically resolved aerosol observations

Satellite quantification of aerosol effects on clouds relies on aerosol optical depth (AOD) as a proxy for aerosol concentration or cloud condensation nuclei (CCN). However, the lack of error characterization of satellite-based results hampers their use for the evaluation and improvement of global climate models. We show that the use of AOD for assessing aerosol–cloud interactions (ACIs) is inadequate over vast oceanic areas in the subtropics. Instead, we postulate that a more physical approach that consists of matching vertically resolved aerosol data from the Cloud-Aerosol Lidar and Infrared Pathfinder Satellite Observations (CALIPSO) satellite at the cloud-layer height with Moderate Resolution Imaging Spectroradiometer (MODIS) Aqua cloud retrievals reduces uncertainties in satellite-based ACI estimates. Combined aerosol extinction coefficients (σ) below cloud top (σBC) from the Cloud-Aerosol Lidar with Orthogonal Polarization (CALIOP) and cloud droplet number concentrations (N d ) from MODIS Aqua yield high correlations across a broad range of σBC values, with σBC quartile correlations ≥0.78. In contrast, CALIOP-based AOD yields correlations with MODIS Nd of 0.54–0.62 for the two lower AOD quartiles. Moreover, σBC explains 41% of the spatial variance in MODIS N d , whereas AOD only explains 17%, primarily caused by the lack of spatial covariability in the eastern Pacific. Compared with σBC, near-surface σ weakly correlates in space with MODIS N d , accounting for a 16% variance. It is concluded that the linear regression calculated from ln(N d )–ln(σBC) (the standard method for quantifying ACIs) is more physically meaningful than that derived from the Nd–AOD pair.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

In situ estimation of ice crystal properties at the South Pole using LED calibration data from the IceCube Neutrino Observatory

The IceCube Neutrino Observatory instruments about 1 km 3 of deep, glacial ice at the geographic South Pole. It uses 5160 photomultipliers to detect Cherenkov light emitted by charged relativistic particles. An unexpected light propagation effect observed by the experiment is an anisotropic attenuation, which is aligned with the local flow direction of the ice. We examine birefringent light propagation through the polycrystalline ice microstructure as a possible explanation for this effect. The predictions of a first-principles model developed for this purpose, in particular curved light trajectories resulting from asymmetric diffusion, provide a qualitatively good match to the main features of the data. This in turn allows us to deduce ice crystal properties. Since the wavelength of the detected light is short compared to the crystal size, these crystal properties include not only the crystal orientation fabric, but also the average crystal size and shape, as a function of depth. By adding small empirical corrections to this first-principles model, a quantitatively accurate description of the optical properties of the IceCube glacial ice is obtained. In this paper, we present the experimental signature of ice optical anisotropy observed in IceCube light-emitting diode (LED) calibration data, the theory and parameterization of the birefringence effect, the fitting procedures of these parameterizations to experimental data, and the inferred crystal properties.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Foil-based additive manufacturing system and method

An additive manufacturing system, method of manufacturing, and fabricated part. The system uses a material joining laser system to join together foil sheets to form a metal part. The material joining laser system can be configured to join adjacent foil sheets together in a substantially uniform manner. The manufacturing system also includes a material removal system that removes material from selected locations of the foil sheets to shape the foil sheets to correspond with selective slices of the part. The material removal system can be a laser system, such as a laser system configured to remove material from a foil sheet without removing material from an underlying layer. One embodiment involves the manufacture of amorphous alloy components.

Tsai, Hai-Lung↗
DOE OSTI2022

Microfluidic aspirator and multi-purpose flow sensor and methods of making and using the same

Devices that include a liquid chamber including at least two ports, wherein the opening of a first port is larger than the opening of a second port, an air chamber including at least one port, and a membrane located between the liquid chamber and the air chamber, and a pressure sensor coupled to the port in the air chamber are provided. Systems including the disclosed devices are also provided. The systems include liquid in the liquid chamber of the device. Methods of using the devices and systems include measuring one or more properties of a liquid by flowing the liquid through the liquid chamber of the system and measuring the pressure produced due to the difference in size of the ports in the liquid chamber.

42 ENGINEERING↗
DOE OSTI2023

Control systems and methods using parametric driver model

A control system of a vehicle includes: a target speed module configured to, using a parametric driver model and based on first driver parameters, second driver parameters, and vehicle parameters, determine a target vehicle speed trajectory for a future predetermined period; a driver parameters module configured to determine the first driver parameters based on conditions within a predetermined distance in front of the vehicle; and a control module configured to adjust at least one actuator of the vehicle based on the target vehicle speed trajectory and a present vehicle speed.

Hegde, Bharatkumar↗
DOE OSTI2023

US Department of Energy Better Plants Program’s Approach to Manufacturing Workforce Development

Multiple studies suggest that by 2030, millions of jobs may go unfilled because of a significant skills gap between the current manufacturing workforce and the workforce needed to support the shift toward advanced and sustainable manufacturing. According to US manufacturers, finding the right talent is more difficult now than in previous years. Developing a well-trained workforce will play a critical role in transforming the manufacturing sector into a net-zero contributor of greenhouse gas emissions by 2050. To help reduce energy, water, waste, and greenhouse gas emissions as well as build a strong, sustainable manufacturing workforce, the US Department of Energy created the voluntary Better Plants program in 2011. This study discusses the program’s various workforce development activities, including in-plant trainings, virtual in-plant trainings, and in-person bootcamps. The target audiences, training objectives, and topics designed to upskill workers for a low-carbon manufacturing future are described. Feedback that was collected (e.g., new training topics, certifications, hands-on activities) while working with more than 270 US manufacturers for the past 12 years on workforce development are discussed. Finally, some strategies are proposed to address the feedback.

Guo, Wei↗
DOE OSTI2023

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

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

Chaudhari, Subodh↗