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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 523 records · Page 29
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Sources of Conservatism in Making Corrective Action Decisions at the NNSS - 20477

During the course of closing nuclear testing release sites at the Nevada National Security Site (NNSS) under the Federal Facility Agreement and Consent Order (FFACO) using the Risk-Based Corrective Action (RBCA) evaluation process, conservative assumptions and estimates were used in many phases of the work. These assumptions and estimates were agreed to during Data Quality Objective (DQO) meetings and published in the FFACO documents. However, the potential cumulative effect of these multiple sources of conservatism was not evaluated. The RBCA process ensures that corrective action decisions minimize the risk of making Type I errors (not applying corrective action to areas that exceed action levels) at the expense of making Type II errors (applying corrective action to areas that do not exceed action levels). Rather than fully characterizing the spatial distribution of contaminants throughout each site, the RBCA process uses a bounding methodology that conservatively estimates spatial boundaries beyond which contamination is not present that exceed corrective action levels. This process accepts that these boundaries may encompass areas that do not exceed corrective action levels and, therefore, may be somewhat larger than for fully characterized sites. This is justified at sites where the reduction in investigation costs are more than any potential increase in corrective action costs. To minimize the risk of making Type I errors, conservatism was used throughout the process. This study documents the many sources of conservatism used in the RBCA process. Conservatism was used in the RBCA process in determining potential receptors, determining action levels, collecting samples, converting sample results into receptor dose, and accounting for uncertainty. This provides decision-makers with a high level of confidence that unacceptable risk to receptors will not result from exposure to residual contamination outside the corrective action boundaries. However, it does not provide an estimate of the actual extent of areas exceeding action levels. This study provides an evaluation of the effects of compounding conservatism on RBCA process decisions. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS2013

Web Application Software for Ground Operations Planning Database (GOPDb) Management

A Web application facilitates collaborative development of the ground operations planning document. This will reduce costs and development time for new programs by incorporating the data governance, access control, and revision tracking of the ground operations planning data. Ground Operations Planning requires the creation and maintenance of detailed timelines and documentation. The GOPDb Web application was created using state-of-the-art Web 2.0 technologies, and was deployed as SaaS (Software as a Service), with an emphasis on data governance and security needs. Application access is managed using two-factor authentication, with data write permissions tied to user roles and responsibilities. Multiple instances of the application can be deployed on a Web server to meet the robust needs for multiple, future programs with minimal additional cost. This innovation features high availability and scalability, with no additional software that needs to be bought or installed. For data governance and security (data quality, management, business process management, and risk management for data handling), the software uses NAMS. No local copy/cloning of data is permitted. Data change log/tracking is addressed, as well as collaboration, work flow, and process standardization. The software provides on-line documentation and detailed Web-based help. There are multiple ways that this software can be deployed on a Web server to meet ground operations planning needs for future programs. The software could be used to support commercial crew ground operations planning, as well as commercial payload/satellite ground operations planning. The application source code and database schema are owned by NASA.

Lanham, Clifton↗
DOE OSTI2022

Multi-Fidelity Stochastic Economic Dispatch for Operating Low Carbon Power Grids

Grid operators can address the inherently stochastic nature of renewables by solving a two-stage stochastic programming model that minimizes the cost of dispatch decisions while accounting for the complex grid dynamics. It is common to use a sample average approximation to estimate the expectation of the second stage costs in this model. However, the large sample count needed for numerical accuracy makes effective modeling large-scale electric grids computationally intractable. We introduce a control variate multi-fidelity estimator for the second-stage recourse that enables high quality dispatch decisions in real-time with a reduced computational burden. We obtain a hierarchy of model fidelities by linearizing the AC power flow system representation to DC power flow, and by relaxing transmission and voltage network constraints. We evaluate the performance of our proposed method on a synthetic grid with 73 buses against a deterministic baseline with persistence forecast and a high-fidelity reference. Our analysis shows a computational speed-up of 7.62x with a minimal loss in accuracy. The multi-fidelity method is well suited to fidelity combinations that use a simplified network topology in their lower fidelity model and is an attractive option for applications where accurate grid modeling needed on a limited computational budget.

24 POWER TRANSMISSION AND DISTRIBUTION↗
NASA NTRS2025

Localization of Ad-Hoc Lunar Constellations in Communication Failure Modes for Distributed Spacecraft Autonomy

As Lunar missions increase in complexity, inspired by NASA’s Artemis Program, they will require reliable and sufficient Position, Navigation, and Timing (PNT) capability to support the upcoming Lunar users. The navigation service should also be compatible with the smaller platforms, like CubeSats, being sent by the public and private sectors. A non-dedicated, ad-hoc Lunar navigation constellation can provide PNT services on-demand using the non-dedicated swarm assets. Swarm members cooperatively and autonomously localize themselves with minimal interaction from Earth, freeing up valuable bandwidth and ground segment resources. The autonomous localization of Lunar constellations utilizes neighbor two-way intersatellite link (ISL) measurements in a distributed extended Kalman filter (DEKF) system to minimize operating costs. Because the decentralized Lunar PNT system relies on relay communication amongst the agents, network failures or loss of assets among ad-hoc Lunar constellations may impact localization performance. This study presents an evaluation of localization performance under increasing levels of network degradation. A simulation of an ad-hoc Lunar PNT swarm is augmented to include system faults and the impacts of intermittent and permanent failures on localization performance are evaluated. We investigate three potential causes of network degradation: single spacecraft loss, multiple spacecraft loss, and antenna failure. The numerical assessments from the simulation show that the LPNT system under study, based on an autonomous decentralized concept of operation, is highly robust and resilient to communication failures. Minor faults, such as single spacecraft loss, solar interference, technical malfunctions, message delays, and antenna outages, have minimal impact on state estimation, with only a 4.47% and 3.75% degradation in median position error for assets and a representative ground user, respectively, compared to an ideal communication scenario. However, major faults, such as hardware failures or meteor strikes leading to the loss of multiple spacecrafts, are more concerning. The permanent loss of three spacecraft results in a more severe performance degradation, with median position error increasing by 23.3% for assets and 11.7% for a representative ground user, despite the Lunar PNT system remaining functional.

Yeji Kim↗
NASA NTRSDate not supplied

A Data-Driven Reduced Order Model of an Isolated Rotor

There are numerous conceptual design stage rotorcraft analysis tasks which demand a high-fidelity and low cost method for rotor load distribution predictions. Considering Urban Air Mobility (UAM) vehicles aim to operate in close proximity to buildings and with unique rotor configurations, there is a significant challenge in quickly and accurately modeling rotors operating in complex, turbulent flow fields. One potential path for deriving a high-fidelity, low cost rotor model is with data-driven surrogate modeling. In this study, an initial investigation is taken to apply a proper orthogonal decomposition (POD) based reduced order model (ROM) for the purpose of pressure distribution prediction. In this study, a POD ROM was derived to produce distributed pressure predictions on rotor blades subjected to topology change due to variation in twist and taper ratio. Rotor twist was varied between 0◦, 10◦, 20◦, and 30◦ while taper ratio was varied between 1.0, 0.9, 0.8, and 0.7. All rotors consisted of a single blade. The POD ROM was validated for three demonstration cases; a high thrust rotor in hover, a low thrust rotor in hover, and a rotor in forward flight with a flight speed of M = 0.1. Results showed highly accurate distributed load predictions could be achieved at minimal computational cost. Computational cost for hovering blade surface pressure modeling was reduced from 12 hours on 440 cores to 10−5 seconds on a single core. For blade in forward flight cost was reduced from 20 hours on 440 cores to 0.6 seconds on a single core. For cases of high thrust and low thrust rotors, POD ROM was used to undergo a design optimization of the rotor such that figure of merit was maximized. Total optimization time for each case was 1 minute.

Data-Driven↗
DOE OSTI2023

What’s the Difference? The Potential for Convolutional Neural Networks for Transient Detection without Template Subtraction

Abstract We present a study of the potential for convolutional neural networks (CNNs) to enable separation of astrophysical transients from image artifacts, a task known as “real–bogus” classification, without requiring a template-subtracted (or difference) image, which requires a computationally expensive process to generate, involving image matching on small spatial scales in large volumes of data. Using data from the Dark Energy Survey, we explore the use of CNNs to (1) automate the real–bogus classification and (2) reduce the computational costs of transient discovery. We compare the efficiency of two CNNs with similar architectures, one that uses “image triplets” (templates, search, and difference image) and one that takes as input the template and search only. We measure the decrease in efficiency associated with the loss of information in input, finding that the testing accuracy is reduced from ∼96% to ∼91.1%. We further investigate how the latter model learns the required information from the template and search by exploring the saliency maps. Our work (1) confirms that CNNs are excellent models for real–bogus classification that rely exclusively on the imaging data and require no feature engineering task and (2) demonstrates that high-accuracy (>90%) models can be built without the need to construct difference images, but some accuracy is lost. Because, once trained, neural networks can generate predictions at minimal computational costs, we argue that future implementations of this methodology could dramatically reduce the computational costs in the detection of transients in synoptic surveys like Rubin Observatory's Legacy Survey of Space and Time by bypassing the difference image analysis entirely.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2024

Gains in operational flexibility, safety margins, and cost efficiencies via integrated Plant Reload Optimization platform

The U.S. Department of Energy Light Water Reactor Sustainability Program Risk-Informed Systems Analysis Pathway Plant Reload Optimization Project aims to develop an integrated, comprehensive framework offering an all-in-one solution for reload evaluations with a special focus on optimizing core design. Optimizing the fuel loading pattern is one of the most important considerations in reducing the amount of new fuel used in the core. Due to thousands of possible core configuration options, finding optimal solutions is an unachievable task for a human. The Plant ReLoad Optimization platform, which supports artificial-intelligence-based reactor core designing, is now fully capable of handling realistic problems. The Plant ReLoad Optimization platform development project aims to build a reactor core design tool that includes reactor safety and fuel performance analyses and uses artificial intelligence to support the optimization of core design solutions. The NSGA-II (Non-dominated Sorting Genetic Algorithm II) optimizer was developed and tested within RAVEN (Risk Analysis and Virtual ENvironment) to handle many constraints by using an augmented objectives methodology. The demonstration was performed with constrained multiobjective optimization of a 17 × 17 pressurized-water reactor core loading patterns to minimize fuel cost and maximize fuel cycle length.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
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

Benefits of Dual Fuel Heat Pump Grid-responsive Control: A Model-based Control Optimization Approach Using Building and Equipment Co-simulation

Conventional dual fuel heat pumps lack the intelligent control mechanisms to efficiently manage the switch between heat pump and furnace, leading to sub-optimal energy usage and, in some cases, increased operating costs. To resolve this gap, this study applies optimized control on hybrid heat pumps. With a focus on equipment control strategies, we compare the performances of five spacing heating equipment, including a conventional heat pump (HP), a conventional furnace, a dual fuel heat pump (DFHP) with conventional control, a dual fuel heat pump with smart control, and a novel seamlessly fuel flexible heat pump (SFFHP). While DFHP runs on either gas or electricity at any given moment, SFFHP concurrently consumes gas and electricity by continuously optimizing the proportion of each. In this research, a co-simulation framework is developed by integrating a building envelope model with a physics-based heat pump simulation model to analyze the benefits of grid-responsive controls of DFHP and SFFHP. The model-based optimal controls adjust the operation of the heat pump and gas furnace based on utility price signals and marginal grid emission to minimize utility cost and CO 2 emissions for multiple climate zones, different utility tariffs, and marginal grid emission scenarios. Case studies in Chicago and Los Angeles demonstrate that SFFHP and DFHP, with model-based optimal control, can deliver significant reductions in peak demand, utility cost, and CO 2 emission. In Chicago, SFFHP and smart controlled DFHP yield up to 64.7% and 61.7% utility cost reduction and up to 15.7% and 8.5% CO 2 emission reduction compared to the gas furnace. In Los Angeles, SFFHP and smart controlled DFHP achieve up to 43.6% and 40.1% utility cost reduction and up to 13.8% and 14.1% CO2 emission reduction compared to conventional heat pumps. In conclusion, by leveraging the fuel flexibility nature of dual fuel heat pumps, the model-based control optimization approach makes dual fuel heat pump an attractive option for demand response programs.

Control↗
DOE OSTI2022

Two-Step Synthesis of Poly (urea formaldehyde) Microcapsules

Self-healing coatings have potential to reduce waste and minimize repair costs in industries where materials need to be protected from harsh environmental conditions and mechanical abrasion. These coatings can be created by embedding healing-agent filled microcapsules which release their contents and fill voids in the event of damage. To synthesize microcapsules that are ideal for self-healing coatings, they must have a diameter less than 100 microns, smooth surface morphology, and have improved dispersibility. Our current one-step method does not produce microcapsules within the desired size distribution, so a two-step route where oligomers of the shell wall material are formed prior to microcapsule formation was investigated. This was done by evaluating the effects of solution viscosity, size of reaction vessel, addition of poly (vinyl alcohol) (PVA), and core/shell ratio on microcapsule properties. Characterization of microcapsule size, morphology, and composition was done using optical microscopy, Fourier-transform infrared spectroscopy (FTIR), and thermogravimetric analysis (TGA). Microcapsules with an average diameter of 78 ± 16 microns were successfully synthesized. Further work must be done to minimize PUF crystallites on the surface of the microcapsules.

36 MATERIALS SCIENCE↗
DOE OSTI2021

An Approach to Bayesian Optimization for Design Feasibility Check on Discontinuous Black-Box Functions

The paper presents a novel approach to applying Bayesian Optimization (BO) in predicting an unknown constraint boundary, also representing the discontinuity of an unknown function, for a feasibility check on the design space, thereby representing a classification tool to discern between a feasible and infeasible region. Bayesian optimization is a low-cost black-box global optimization tool in the Sequential Design Methods where one learns and updates knowledge from prior evaluated designs, and proceeds to the selection of new designs for future evaluation. However, BO is best suited to problems with the assumption of a continuous objective function and does not guarantee true convergence when having a discontinuous design space. This is because of the insufficient knowledge of the BO about the nature of the discontinuity of the unknown true function. In this paper, we have proposed to predict the location of the discontinuity using a BO algorithm on an artificially projected continuous design space from the original discontinuous design space. The proposed approach has been implemented in a thin tube design with the risk of creep-fatigue failure under constant loading of temperature and pressure. The stated risk depends on the location of the designs in terms of safe and unsafe regions, where the discontinuities lie at the transition between those regions; therefore, the discontinuity has also been treated as an unknown creep-fatigue failure constraint. The proposed BO algorithm has been trained to maximize sampling toward the unknown transition region, to act as a high accuracy classifier between safe and unsafe designs with minimal training cost. The converged solution has been validated for different design parameters with classification error rate and function evaluations at an average of <1% and ~150, respectively. Finally, the performance of our proposed approach in terms of training cost and classification accuracy of thin tube design is shown to be better than the existing machine learning (ML) algorithms such as Support Vector Machine (SVM), Random Forest (RF), and Boosting.

Engineering↗
NASA NTRS2016

HIAD on ULA (HULA) Orbital Reentry Flight Experiment Concept

This paper describes a proposed orbital velocity reentry flight test of a Hypersonic Inflatable Aerodynamic Decelerator (HIAD). The flight test builds upon ground development activities that continue to advance the materials, design, and manufacturing techniques for the inflatable structure and flexible thermal protection system (F-TPS) that comprise the inflatable heat shield. While certain aspects of material and system performance can be assessed using a variety of ground testing capabilities, only orbital velocity energy on a trajectory through the gradient density of the atmosphere can impart the combined aerodynamic and aeroheating design environments in real time. To achieve this at limited cost, the HIAD would be delivered to a spin-stabilized entry trajectory as a secondary payload on the Centaur stage of a United Launch Alliance (ULA) Atlas V launch vehicle. Initial trajectory studies indicate that the combination of launch vehicle capability and achievable reentry vehicle ballistic numbers make this a strategic opportunity for technology development. This 4 to 6 meter diameter scale aeroshell flight, referred to as HIAD on ULA (HULA), would also contribute to ULA asset recovery development. ULA has proposed that a HIAD be utilized as part of the Sensible, Modular, Autonomous Return Technology (SMART) initiative to enable recovery of the Vulcan launch vehicle booster main engines [1], including a Mid-Air Recovery (MAR) to gently return these assets for reuse. Whereas HULA will attain valuable aerothermal and structural response data toward advancing HIAD technology, it may also provide a largest-to-date scaled flight test of the MAR operation, which in turn would allow the examination of a nearly pristine post-entry aeroshell. By utilizing infrared camera imaging, HULA will also attain aft-side thermal response data, enhancing understanding of the aft side aerothermal environment, an area of high uncertainty. The aeroshell inflation will utilize a heritage design compressed gas system to minimize development costs. The data will be captured to both an onboard recorder and a recorder that is jettisoned and recovered separately from the reentry vehicle to mitigate risk. This paper provides an overview, including the architecture and flight concept of operations, for the proposed HULA flight experiment.

Dinonno, J. M.↗
DOE OSTI2023

Non-Fouling, Low Cost Electrolytic Coagulation & Disinfection for Treating Flowback and Produced Water for Reuse

Executive Summary This Final Report is composed of two major sections. The first section presents experimental results obtained in the laboratory during Budget Period 1. The second section presents results from the field test conducted during Budget Period 2. Laboratory Results This research investigated a novel electrochemical process for producing a ferric iron coagulant for use in treating flowback and produced water from hydraulic fracturing and oil production operations. The treatment system improves the effectiveness and lowers the cost of coagulation processes using Fe3+ as the coagulant. The electrolytic coagulant generation (ECG) system uses an electrochemical cell to produce acid and base from oilfield brine solutions. The acid is used to dissolve scrap iron to provide a Fe3+ coagulating agent. The base is used to neutralize the treated water. Compared to conventional electrocoagulation (EC), the main advantage of the ECG system is an order of magnitude lower cost for the source of iron. The second advantage over conventional EC is that it can deliver Fe3+ doses greater than 1 mM, since it is not limited by the amount of dissolved oxygen in the water required to oxidize ferrous to ferric iron. The capital costs for conventional EC and the ECG system are similar, but the operational costs for the ECG system are an order of magnitude lower than conventional EC. The combined costs for iron and electrical energy for treating 1 m3 of FPW with 1 mM Fe3+ is estimated to be $0.87 for conventional EC, and $0.087 for the ECG system. The estimated all-in cost for treating FPW with a 2 mM Fe3+ dose is $0.73/m3 ($0.12/bbl). Field Test Results The field test was conducted at the Paul Foster Central Tank Battery (CTB) in Lea County, New Mexico from November 10, 2022 through December 15, 2022. The feed water to the system was produced water from the Tatanka 1H formation. After approximately two weeks of testing, the initial batch of produced water had been treated and no untreated produced water was available. Thus, after this time, the feed water to the system consisted of previously treated water (i.e., recycled water). The recycled water had nearly all colloidal particles removed, and had a much lower alkalinity due to precipitation of carbonate minerals during the first pass through the system. Although the recycled water was not an ideal test solution due to its low particulate concentrations, its lower alkalinity did allow us to identify the main problem with the treatment system. The main problem with the treatment system was caused by the high alkalinity of the initial feed water (5.4 meq/L) that consumed a significant fraction of the electrochemically generated acid. This resulted in pH values exiting the iron contact tank that were too high to dissolve enough iron to effectively treat the produced water. Tests performed with recycled water with lower alkalinity did not have this issue, and dissolved iron concentrations greater than 20 mM could be achieved. One consistent observation was that effluent water from the iron contact tank was always free of particulates, even when fed with circumneutral solutions. This suggests that there is no need to dissolve high concentrations of iron if all the water to be treated is passed through the scrap iron canister. In this case, dissolved O2 and hypochlorous acid can promote sufficient iron corrosion to provide an effective coagulating agent – even in neutral pH water. This solves the problem resulting from highly alkaline produced water. Modifications to the design of the treatment system were made based on the field test results. These modifications will add minimal additional cost, and were tested in bench-scale laboratory experiments. In short-term testing, the modified treatment process was able to remove colloidal FeS particulates to levels below detection. Long-term, steady state testing will be required to determine whether the modified process is suitable for commercial treatment systems.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Demonstration of Scaled-Production of Rare Earth Oxides and Critical Materials from U. S. Coal-Based Sources (Final Report)

The project objective was to demonstrate scaled production of high purity rare earth oxides (REO), nominally exceeding 90% grade, from coal refuse sources using innovative technologies that reduce cost and improve environmental outcomes relative to traditional rare earth processing technologies. The project utilized a critical material pilot plant constructed and tested as part of a previous U.S. Department of Energy project. Target performance criteria was a 50% reduction in production cost based on previous optimum values, 150% increase in recovery and greater than 2% concentrates of rare earth oxides, cobalt and manganese. Concentrate production goals were to produce a rare earth mix oxide product at a rate of 200 grams per day having a minimum purity of 50% as well as products of cobalt and manganese having a minimum purity of 2%. A previous pilot plant investigation identified acid cost as the major contributor to an operating cost that made the recovery of rare earth and other critical metals from bituminous coal sources economically challenging. As such, acid cost reduction was a major target using bio-oxidation reactors to produce sulfuric acid from naturally occurring coal pyrite. Based on laboratory data, a bio-oxidation circuit was designed for the pilot plant to produce 7.5 l/min of acid using two 11-m3 (3000 gallon) reactors equipped with 40 hp aerators for air dispersion. The pilot-scale tests revealed that acid concentration equivalent to as high as 1.0 M sulfuric acid could be continuously produced. However, the bio-acid contained exceptionally high iron concentrations, which complicated downstream processing of the pregnant leach solution (PLS). A TEA of the bio-oxidation circuit showed that production cost was approximately $0.13 per kg acid equivalent if produced using a four-day retention time in the reactors. This value represents a 48% reduction from that of purchased bulk sulfuric acid. Calcination (or roasting) studies were conducted on coarse refuse from West Kentucky No. 13 and Fire Clay coal seam sources. The test results revealed the potential to increase recovery by nearly 100% using temperatures between 500°C to 700°C with light REE recovery value being the most improved. Acid baking of the calcined products using sulfuric acid at 250°C increased heavy rare earth recovery from around 40% to 80% while decreasing the acid requirements by over 50%. The existing pilot plant was upgraded for the pilot scale demonstration of REE and CM recovery. The primary feedstocks were West Kentucky No.13 and heap leach pregnant leach solution (PLS) while a secondary feedstock was a lignite waste material from a construction sand operation. The pilot scale operation started with PLS generation through leaching followed by iron and aluminum removal, nominally at 3.3 and 4.5 pH, respectively. Leaching lixiviants used for the test were industrial grade sulfuric acid or bio-acid generated at the pilot scale facility. For most of the tests, the solid feed rate was 200 lb/hr whereas lixiviant was added at 2 gpm to provide an optimal residence time of 45 minutes. Following the contaminant removal step, several different process schematics were tested with the goal of maximizing REE recovery and purity. In the first test, direct processing of aluminum precipitation raffinate for REE recovery using oxalic acid at pH 1.5 was investigated. Overall REE recovery was approximately 45%. Unfortunately, elevated calcium content in the PLS significantly impacted the RE-Oxide product grade. Similarly, high calcium content decreased both the product purity and grades of CM products. As such, a new flowsheet was tested with the same initial process schematic but different precipitation stages for REEs and CMs at pH 6.0 and 9.0, respectively. It was noted that the overlapping precipitation behavior of Co, Ni and Zn with REEs limited the applicability of this process schematic. While this change increased the RE-Oxide grade from 36% in the first test to 87%, the loss of critical metals to the REE cake and bypass of the REEs to the CM cake significantly impacted the recovery of both REEs and CMs. Therefore, the modified process flowsheet combined oxalic acid precipitation stage raffinate and redissolved CM cake filtrate to maximize both the recovery and purity of the products. Consequently, a RE-Oxide product with 85% purity and CM cakes with over 19% Co, 38% Ni, 14% Zn and 9% Mn content were generated with significantly higher recoveries. While the modified process flowsheet improved recoveries and grades, elemental losses observed in separate precipitation and redissolution losses inspired the adaptation of a single precipitation stage at pH 9.0 for both REEs and CMs. This change was anticipated to maximize the REE recovery while minimizing the costs associated with separated redissolution and processing stages. As expected, REE recovery in this new circuit arrangement was over 56% with a product grade of over 87% RE-Oxide content. Similarly, Co, Ni, Mn, and Zn recoveries of 54%, 40%, 67%, and 66%, respectively, were achieved. Unfortunately, the elevated calcium content present in the solution due to its precipitation at pH 9.0 caused a decrease in the CM cake quality. Therefore, the final process flowsheet involved the addition of calcium oxalate precipitation following the oxalic acid precipitation stage, which effectively eliminated calcium contamination of the CM products. Finally, the pilot scale experiments conducted using bio-acid achieved comparable REE leaching recoveries to the conventional sulfuric acid leaching. Elevated iron concentration in the solution caused the co-precipitation of REEs with the iron and aluminum cake, resulting in the REE losses. Furthermore, elevated iron content bypassing the iron and aluminum precipitation stages contaminated the metal sulfide and manganese cake, respectively. A techno-economic analysis was performed based on a commercial facility capable of treating 500 tph of coal-based material. The production cost for West Kentucky No. 13 coarse refuse material ranged from approximately $500-$700/kg of total rare earth oxide whereas the lignite source had significantly lower production cost of $100-$300/kg. The significant difference in cost was due to the easier leaching characteristics of the lignite material and the higher feed concentrations. All process scenarios resulted in a negative net present value (NPV). For the lignite feedstock, laboratory REE leach recovery values were about 30% higher than the pilot plant data. Using the lab leach results, a positive net present value was achieved and the production cost decreased from $100-$300 $/kg to less than $150/kg of total REO.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

Cathode Upcycling for Direct Recycling of Lithium‐Ion Batteries Using a Precipitation Approach

With the increased production of electric vehicles to reduce carbon emissions, the lithium-ion battery market to supply those vehicles has grown dramatically. To enhance battery sustainability and circularity, direct recycling methods aim to recover intact cathode materials. However, end-of-life cathode materials are typically 15–20 years old and often have lower energy density compared to current cathode materials. To address this challenge, a rapid precipitation process is developed to boost energy density by converting low Ni-compositions, LiNi 0.33 Co 0.33 Mn 0.33 O 2 (NMC111), into higher Ni-compositions (NMC622). This process forms a Ni-rich coating on cathode particles that diffuses into the core upon high-temperature relithiation, increasing compositional homogeneity. The upcycling process leverages existing infrastructure, offering low capital cost and minimal additional chemical input. Through ex situ tomographic transmission X-ray microscopy (TXM), 3D Ni:Co elemental mixing is quantified, confirming that elemental content evens at the secondary particle level with a mean NMC622 composition upon relithiation. However, elemental gradients remain in the single crystalline primary particles. Ex situ high-resolution and in situ wide-angle X-ray diffraction reveals concurrent structural changes during the relithiation process. These findings provide key insights into the structural and chemical mechanisms of elemental diffusion to obtain further improvements of increased capacity and retention through compositional conversion of cathode materials.

Cathode Upcycling↗
DOE OSTI2024

Toolpath considerations for 5-axis systems

There have been many studies that show how additive manufacturing (AM) has been able to improve the performance of a component, reduce manufacturing costs, or minimize lead times. As the adoption of AM significantly increased, so did the complexity of designs for AM. Many designs require advanced systems, and in response to this, there is an increasing number of systems now capable of additional degrees of motion. 5-axis systems, which include two rotary axes, are becoming more common in the additive manufacturing community. These systems are capable of depositing material on a nonplanar surface and lend themselves to many industrial applications, further extending the design space for AM. However, computer-aided manufacturing (CAM) for AM has been dominated by 3-axis slicing software that do not typically accomodate 5-axis motion. This chapter introduces 5-axis motion and presents the unique considerations that need to be accounted for when generating toolpath trajectories for 5-axis systems.

Feldhausen, Thomas↗
DOE OSTI2022

Conceptual core design of the molten metal fueled microreactor with self-regulating capability

The microreactor concept has received significant attention in the United States for its lower capital investment, siting flexibility and high mobility. A microreactor aims to provide reliable electricity in remote communities, mining areas, or isolated islands, which will save the high fuel transportation cost. Thus, minimizing the staff level for operating and maintaining a microreactor is desirable. The objective of the study is to design a self-regulated Molten Metal fueled microReactor core (MMR) and to demonstrate the self-regulating capability of the MMR core. The control of the reactor is solely relying on reactivity feedbacks from fuel temperature perturbation. Molten UMn (liquid form at the temperature over 720°C) was utilized as the fuel material in MMR due to the larger thermal expansion coefficient compared to the conventional solid fuel. The MMR core has a fast neutron spectrum, which corresponds to a small burnup reactivity swing. The core design parameters were selected based on DAKOTA, REBUS, and ANLHTP calculations. The MMR is designed to run for 10 years at a power level of 15 MWth. Furthermore, no refueling is needed during the reactor lifetime. The system dynamic analyses were performed, and it was found that the reactor can be self-regulating within a temperature range of 800 ± 80°C for a loss of heat sink transient.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

Spectral properties of three-dimensional Anderson model

The three-dimensional Anderson model represents a paradigmatic model to understand the Anderson localization transition. In this work we first review some key results obtained for this model in the past 50 years, and then study its properties from the perspective of modern numerical approaches. Our main focus is on the quantitative comparison between the level sensitivity statistics and the level statistics. While the former studies the sensitivity of Hamiltonian eigenlevels upon inserting a magnetic flux, the latter studies the properties of unperturbed eigenlevels. We define two versions of dimensionless conductance, the first corresponding to the width of the level curvature distribution relative to the mean level spacing, and the second corresponding to the ratio of the Heisenberg time and the Thouless time obtained from the spectral form factor. We show that both conductances look remarkably similar around the localization transition, in particular, they predict a nearly identical critical point consistent with other well-established measures of the transition. We then study some further properties of those quantities: for level curvatures, we discuss particular similarities and differences between the width of the level curvature distribution and the characteristic energy studied by Edwards and Thouless (1972) in their pioneering work, in which the hopping at one lattice edge is changed from periodic to antiperiodic boundary conditions. In the context of the spectral form factor, we show that at the critical point it enters a broad time-independent regime, in which its value is consistent with the level compressibility obtained from the level variance. Finally, we test the scaling solution of the average level spacing ratio in the crossover regime using the cost function minimization approach introduced recently in Šuntajs et al. (2020). The latter approach seeks for the optimal scaling solution in the vicinity of the crossing point, while at the same time it allows for the crossing point to drift due to finite-size corrections. We find that the extracted transition point and the scaling coefficient agree with those from the literature to high numerical accuracy.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗