SEARCH · Engineering Papers
Results for “engineering 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.
IDAES: A Next-Generation, Multi-Scale Process Systems Engineering Framework for Optimizing Energy Systems and Manufacturing Processes
The presentation was delivered at the 2022 Smart Manufacturing Experience event in Pittsburgh, PA.
Circular Economy - A challenge and an opportunity for Process Systems Engineering
Rising populations put huge stresses on natural resources. Extraction and depletion of raw materials and waste created throughout the supply chain of products have enormous environmental and socioeconomic impacts. One way to reduce these impacts is through the move towards the circular economy (CE). CE aims to solve resource, waste, and emission challenges confronting society by creating a production-to-consumption total supply chain that is restorative, regenerative, and environmentally benign. This article highlights research challenges and identifies process systems engineering (PSE) research opportunities to assist in the understanding, analysis and optimization of CE supply chains. A motivating example on the supply chain of coffee is introduced to illustrate the challenges of the transition towards a CE and to propose PSE research opportunities.
BETO 2021 Peer Review - Biological Upgrading of Sugars (BUS) 2.3.2.105
The Biological Upgrading of Sugars (BUS) project directly targets the anaerobic conversion of lignocellulosic feedstocks into intermediate molecules readily upgradeable to fuel precursors. Recent efforts on the BUS project have a particular emphasis on the biological production of butyric acid, an intermediate that can be readily upgraded to sustainable aviation fuel, diesel blend-stocks, and high value chemicals. The BUS project approaches this direction through a combination of strain engineering, fermentation process engineering, development of novel separations technologies, and the design and build of pilot scale systems. Our ultimate project goal is to develop an integrated cost-effective process at pilot scale to achieve DOE's MYPP targets of $2.50/GGE. The major thrust of the BUS project over the last project cycle was on the development of integrated processes surrounding the anaerobic production of carboxylic acids using diverse Clostridium species. We developed and expanded genetic tools for several Clostridium species and rewired microbial metabolism in an attempt to maximize substrate utilization and flux towards butyric acid. We designed and built novel bioreactors with an in situ product recovery system enabling the biological production and recovery of highly purified acids. We leveraged this system to generate 100s of grams of acid from corn stover hydrolysate. In this presentation we highlight data surrounding our proposed process and accompanying results from technoeconomic and life-cycle analyses of our integrated process. Finally, we detail plans of our pilot scale reactor system that is in process and discuss our future routes towards achieving economically viable and sustainable diesel and jet blendstocks.
Human Factors Principles in Information Dashboard Design
When planning for control room upgrades, nuclear power plants have to deal with a multitude of engineering and operational impacts. This will inevitably include several human factors considerations, including physical ergonomics of workstations, viewing angles, lighting, seating, new communication requirements, and new concepts of operation. In helping nuclear power utilities to deal with these challenges, the Idaho National Laboratory (INL) has developed effective methods to manage the various phases of the upgrade life cycle. These methods focus on integrating human factors engineering processes with the plant’s systems engineering process, a large part of which is the development of end-state concepts for control room modernization. Such an end-state concept is a description of a set of required conditions that define the achievement of the plant’s objectives for the upgrade. Typically, the end-state concept describes the transition of a conventional control room, over time, to a facility that employs advanced digital automation technologies in a way that significantly improves system reliability, reduces human and control room-related hazards, reduces system and component obsolescence, and significantly improves operator performance. To make the various upgrade phases as concrete and as visible as possible, an end-state concept would include a set of visual representations of the control room before and after various upgrade phases to provide the context and a framework within which to consider the various options in the upgrade. This includes the various control systems, human-system interfaces to be replaced, and possible changes to operator workstations. This paper describes how this framework helps to ensure an integrated and cohesive outcome that is consistent with human factors engineering principles and also provide substantial improvement in operator performance. The paper further describes the application of this integrated approach in the strategic modernization program at a nuclear power plant where legacy systems are upgraded to advanced digital technologies through a systematic process that links human factors principles to the systems engineering process. This approach will help to create an integrated control room architecture beyond what is possible for individual subsystem upgrades alone. In addition, several human factors design and evaluation methods were used to develop the end-state concept, including interactive sessions with operators in INL’s Human System Simulation Laboratory, three-dimensional modeling to visualize control board changes.
Bench-scale Development of an Advanced Solid Sorbent-based CO 2 Capture Process for Coal-fired Power Plants
It is increasingly clear that CO 2 capture and sequestration (CCS) must play a critical role in curbing worldwide CO 2 emissions to the atmosphere. Development of these technologies to cost-effectively remove CO 2 from coal-fired power plants is very important to mitigating the impact these power plants have within the world’s power generation portfolio. Currently, conventional CO 2 capture technologies, such as aqueous-monoethanolamine based solvent systems, are prohibitively expensive and if implemented could result in a 75 to 100% increase in the cost of electricity for consumers worldwide. Solid sorbent CO 2 capture processes – such as RTI’s Advanced Solid Sorbent CO 2 , Capture Process – are promising alternatives to conventional, liquid solvents. Supported amine sorbents – of the nature RTI has developed – are particularly attractive due to their high CO 2 loadings, low heat capacities, reduced corrosivity/volatility and the potential to reduce the regeneration energy needed to carry out CO 2 capture. Previous work in this area has failed to adequately address various technology challenges such as sorbent stability and regenerability, sorbent scale-up, improved physical strength and attrition-resistance, proper heat management and temperature control, proper solids handling and circulation control, as well as the proper coupling of process engineering advancements that are tailored for a promising sorbent technology. The remaining challenges for these sorbent processes have provided the framework for the project team’s research and development and target for advancing the technology beyond lab- and bench-scale testing. Under a cooperative agreement with the US Department of Energy, and part of NETL’s CO 2 Capture Program, RTI has led an effort to address and mitigate the challenges associated with solid sorbent CO 2 capture. The overall objective of this project was to mitigate the technical and economic risks associated with the scale-up of solid sorbent-based CO 2 capture processes, enabling subsequent larger pilot demonstrations and ultimately commercial deployment. An integrated development approach has been a key focus of this project in which process development, sorbent development, and economic analyses have informed each of the other development processes. Development efforts have focused on improving the performance stability of sorbent candidates, refining process engineering and design, and evaluating the viability of the technology through detailed economic analyses. Sorbent advancements have led to a next generation, commercially-viable CO 2 capture sorbent exhibiting performance stability in various gas environments and a physically strong fluidizable form. The team has reduced sorbent production costs and optimized the production process and scale-up of PEI-impregnated, fluidizable sorbents. Refinement of the process engineering and design, as well as the construction and operation of a bench-scale research unit has demonstrated promising CO 2 capture performance under simulated coal-fired flue gas conditions. Parametric testing has shown how CO 2 capture performance is impacted by changing process variables, such as Adsorber temperature, Regenerator temperature, superficial flue gas velocity, solids circulation rate, CO 2 partial pressure in the Regenerator, and many others. Long-term testing has generated data for the project team to set the process conditions needed to operate a solids-based system for optimal performance, with continuous 90% CO 2 capture, and no operational interruptions. Data collected from all phases of testing has been used to develop a detailed techno-economic assessment of RTI’s technology. These detailed analyses show that RTI’s technology has significant economic advantages over current amine scrubbing and potential to achieve the DOE’s Carbon Capture Program’s goal of >90% CO 2 capture rate at a cost of < $40/T-CO 2 captured by 2025. Through this integrated technology development approach, the project team has advanced RTI’s CO 2 capture technology to TRL-4 (nearly TRL-5, with the missing variable being testing on actual, coal-fired flue gas), according to the DOE/FE definitions for Technology Readiness Levels. At a broader level, this project has advanced the whole of the solid sorbent CO 2 capture field, with advancements in process engineering and design, technical risk mitigation, sorbent scale-up optimization, and an understanding of the commercial viability and applicability of solid sorbent CO 2 capture technologies for the U.S. existing fleet of coal-fired power plants.
Perceptions of Value in Process-based Engineering in LANL's Intelligence and Space Research Division [Capstone Project]
This project studied a perceived aversion to process-based engineering in ISR Division. Thirty interviews were conducted with ISR staff to explore research questions including perceived advantages and disadvantages of process and ISR strengths and weaknesses. Results were analyzed for synergies between the research questions. Results indicate an unexpected willingness to adopt process so long as that process does not stifle creativity and is flexible enough that it can be applied if and when it provides the most value.
Multiparametric Programming in Process Systems Engineering: Recent Developments and Path Forward
The inevitable presence of uncertain parameters in critical applications of process optimization can lead to undesirable or infeasible solutions. For this reason, optimization under parametric uncertainty was, and continues to be a core area of research within Process Systems Engineering. Multiparametric programming is a strategy that offers a holistic perspective for the solution of this class of mathematical programming problems. Specifically, multiparametric programming theory enables the derivation of the optimal solution as a function of the uncertain parameters, explicitly revealing the impact of uncertainty in optimal decision-making. By taking advantage of such a relationship, new breakthroughs in the solution of challenging formulations with uncertainty have been created. Apart from that, researchers have utilized multiparametric programming techniques to solve deterministic classes of problems, by treating specific elements of the optimization program as uncertain parameters. In the past years, there has been a significant number of publications in the literature involving multiparametric programming. The present review article covers recent theoretical, algorithmic, and application developments in multiparametric programming. Additionally, several areas for potential contributions in this field are discussed, highlighting the benefits of multiparametric programming in future research efforts.
Institute for the Design of Advanced Energy Systems Process Systems Engineering Framework (IDAES PSE Framework)
IDAES PSE capabilities support the design and optimization of innovative new advanced Process Systems Engineering (PSE) capabilities to improve the efficiency and reliability of the existing fleet of coal-fired power plants while accelerating the development of a broad range of advanced fossil energy systems.
Lab-Scale Development of a Solid Sorbent for CO 2 Capture Process for Coal-Fired Power Plants
It is increasingly clear that CO 2 capture and sequestration (CCS) must play a critical role in curbing worldwide CO 2 emissions to the atmosphere. Development of these technologies to cost-effectively remove CO 2 from coal-fired power plants is very important to mitigating the impact these power plants have within the world’s power generation portfolio. Currently, conventional CO 2 capture technologies, such as aqueous-monoethanolamine based solvent systems, are prohibitively expensive and if implemented could result in a 75 to 100% increase in the cost of electricity for consumers worldwide. Solid sorbent CO 2 capture processes – such as RTI’s 3rd Generation Solid Sorbent CO 2 Capture Process – are promising alternatives to conventional, liquid solvents. Supported amine sorbents – of the nature RTI has developed – are particularly attractive due to their potential for high CO 2 loadings, excellent stability over multiple cycles, reduced corrosivity/volatility and a potential to reduce the regeneration energy needed to carry out CO 2 capture. The remaining challenges for these sorbent processes have provided the framework for the project team’s research and development and target for advancing the technology beyond lab-scale testing. Previous work in this area has failed to adequately address various technology challenges such as sorbent stability and regenerability, sorbent scale-up, improved physical strength and attrition-resistance, proper heat management and temperature control, proper solids handling, as well as the proper coupling of process engineering advancements that are tailored for a promising sorbent technology. Under a cooperative agreement with the US Department of Energy, and part of NETL’s CO 2 Capture Program, RTI has led an effort to address and mitigate the challenges associated with solid sorbent CO 2 capture. The overall objective of this project was to mitigate the technical and economic risks associated with the performance and scale-up of solid sorbent-based CO 2 capture processes, enabling subsequent larger pilot demonstrations and ultimately commercial deployment. An integrated development approach has been a key focus of this project in which sorbent development, process development, and economic analyses have informed each of the other development processes. Development efforts have focused on developing novel hybrid solids-based CO 2 capture sorbents and improving their performance stability, refining process engineering and design, and evaluating the viability of the technology through detailed economic analyses. Sorbent advancements have led to a next generation, commercially-viable CO 2 capture sorbent exhibiting performance stability in various gas environments and a physically strong fluidizable form. The team has reduced sorbent production costs and optimized the production and scale-up of novel metal-organic framework (MOF) hybrid solids-based CO 2 capture sorbents, fluidizable sorbents. Refinement of the process engineering and design at the lab-scale research unit has demonstrated promising CO 2 capture performance in simulated coal-fired flue gas conditions. Long-term testing has informed the project team on the process conditions needed to operate a solids-based system for optimal performance. Data collected from all phases of testing has been used to develop a detailed techno-economic assessment of RTI’s technology. These detailed analyses show that RTI’s technology has significant economic advantages over current amine scrubbing and potential to achieve the DOE’s Carbon Capture Program’s goal of >90% CO 2 capture rate at a cost of almost $40/tonne CO 2 captured by 2025. Through this integrated technology development approach, the project team has advanced RTI’s 3rd generation CO 2 capture technology to TRL-3, according to the DOE/FE definitions for Technology Readiness Levels. At a broader level, this project has advanced the whole of the solid sorbent CO 2 capture field, with advancements in process engineering and design, technical risk mitigation, sorbent scale-up optimization, and an understanding of the commercial viability and applicability of solid sorbent CO 2 capture technologies for the U.S. existing fleet of coal-fired power plants.
Integrating Cyber-Informed Engineering into Process Automation
As organizations increasingly automate their core missions and essential functions to address business risks and enhance efficiency, process automation becomes pivotal. This shift, involving minimal or no manual intervention, significantly impacts an organization's cyber-risk landscape. While automation drives efficiencies, it also introduces new cyber risks if not properly managed. Cyber-Informed Engineering (CIE) provides a proactive framework for managing these digital risks, enhancing cyber-resilience in process automation. This document supports organizations in applying CIE principles to mitigate the cyber risks associated with automation. The outlined approach can be independently implemented to improve any organization’s cyber-resilience, ensuring that the advantages of automation do not result in unaddressed or unmanaged digital risks. It serves as a starting point, offering considerations for integrating CIE principles and practices into organizational processes. CIE is presented as an iterative process, fostering continuous improvement and reinforcing the engineering and operational cultures to manage digital risks effectively. The document is structured as follows: Section 1 provides background on CIE and process automation, and their integration. Section 2 explores the twelve CIE principles in the context of process automation, highlighting key questions, engineering considerations, and implications for digital risk management. Section 3 synthesizes the findings and offers recommendations to advance resilience by design.
Techno-economic analysis and life-cycle analysis of two light-duty bio-blendstocks: isobutanol and aromatic rich hydrocarbons
Isobutanol and aromatic-rich hydrocarbons (ARHC) are two biomass-derived high octane blendstocks that could be blended with petroleum gasoline for use in optimized spark-ignition engines in light-duty vehicles, potentially increasing engine efficiency. To evaluate technology readiness, economic viability, and environmental impacts of these technologies, we use detailed techno-economic analysis (TEA) and life-cycle analysis (LCA). We assumed isobutanol is produced via biochemical conversion of an herbaceous feedstock blend while ARHC is produced via thermochemical conversion of a woody feedstock blend.The minimum estimated fuel selling price (MFSP) of isobutanol ranged from $5.57/gasoline gallon equivalent (GGE) based on today’s technology to $4.22/GGE with technology advancements. The MFSP of ARHC could decline from $5.20/GGE based on today’s technology to $4.20/GGE as technology improves. Both isobutanol and ARHC offer about 73% GHG emission reduction relative to petroleum gasoline per LCA of these two bio-blendstocks. On the other hand, water consumption in the production of both bio-blendstocks exceeds that of conventional gasoline although process engineering offers routes to cutting water consumption. Over their life cycles, both isobutanol and ARHC emit more NOx and PM2.5 than petroleum gasoline.Improving the energy efficiency and lowering air emissions from agricultural equipment will reduce the life-cycle air pollutant emissions of these bio-blendstocks.
American Nuclear Society Winter Meeting – Chemistry Tutorial
What is a Process Engineer?; What is a typical uranium flow sheet (e.g. process flow diagram)?; Process Engineering Considerations; Common miscommunications; Common operational “upsets” (e.g. expected abnormal or off-normal events)
Characterization of the Fe-Co-1.5V soft ferromagnetic alloy processed by Laser Engineered Net Shaping (LENS)
Processing of the low workability Fe-Co-1.5V (Hiperco® equivalent) alloy is demonstrated using the Laser Engineered Net Shaping (LENS) metals additive manufacturing technique. As an innovative and highly localized solidification process, LENS is shown to overcome workability issues that arise during conventional thermomechanical processing, enabling the production of bulk, near net-shape forms of the Fe-Co alloy. Bulk LENS structures appeared to be ductile with no significant macroscopic defects. Atomic ordering was evaluated and significantly reduced in as-built LENS specimens relative to an annealed condition, tailorable through selection of processing parameters. Fine equiaxed grain structures were observed in as-built specimens following solidification, which then evolved toward a highly heterogeneous bimodal grain structure after annealing. The microstructure evolution in Fe-Co is discussed in the context of classical solidification theory and selective grain boundary pinning processes. In conclusion, magnetic properties were also assessed and shown to fall within the extremes of conventionally processed Hiperco® alloys.
2022 American Conference on Neutron Scattering (ACNS 2022)
The 11th American Conference on Neutron Scattering (ACNS 2022) will be held on June 5-9, 2022, in Boulder, CO. The Conference will provide essential information on the breadth and depth of current neutron-related research worldwide. Hosted by the Neutron Scattering Society of America, this year’s Conference will feature a combination of invited and contributed talks, poster sessions, and tutorials. Topics of the conference are: Advances in Neutron Facilities, Instrumentation and Software: Developments in sources, instrumentation, sample environments and control software. Hard Condensed Matter: Magnetism, correlated metals, quantum/topological materials, superconductors, ferroelectrics, multiferroics, glasses, and disorder phenomena. Submissions outlining examples of neutron scattering in industrial and engineering applications involving hard condensed matter systems are also encouraged. Soft Matter: Neutron studies of soft materials and related fields including in situ and in operando studies. Polymers, surfactants, emulsions, gels, nanoparticles, colloidal suspensions and more. Submissions of computational studies or applications of machine learning beneficial to neutron scattering experiments, as well as examples of neutron scattering in industrial and engineering applications are strongly encouraged. Biology, Biophysics and Biotechnology: Neutron studies of biological and biologically relevant systems. Proteins, bio membranes, biological assemblies, natural materials, nucleic acids, drug-delivery platforms and biomedical systems. Submissions of computational studies or applications of machine learning beneficial to biological neutron scattering experiments, as well as examples of neutron scattering in applied research involving biological systems, are strongly encouraged. Materials Chemistry and Energy: Neutron-based studies of functional materials and materials for energy applications. Examples include porous materials such as metal organic frameworks (MOFs), zeolites; phosphors; novel pigments; electrolytes; catalysts; ionic conductors/cathode materials; photovoltaic materials (hybrid perovskites); thermoelectrics; magnetocalorics/electrocalorics. Structural Materials and Engineering: Neutron scattering studies of materials and engineering processes including structural materials, concrete and metals, as well as engineering processes including combustion, corrosion, additive manufacturing, and others. Neutron Physics: Fundamental physical studies of the neutron and related areas. Emerging Applications in Neutron Scattering: Machine Learning and Data Science: Advances in computing power have contributed to rapidly evolving machine learning and data science fields that can be leveraged to the benefit of the neutron scattering community. The purpose of this session is to highlight recent advances in machine learning and data science and to serve as the foundation of a parallel data and computation track highlighting computation advances and applications in neutron scattering throughout the conference.
Process-informed adsorbent design guidelines for direct air capture
Direct air capture using solid adsorbents is a proven technology critical to reducing our net greenhouse gas emissions to zero and beyond. Currently, academic research into the technology mainly focuses on the development of new adsorbents. However, there is a discord between the adsorbent design and process performance. Many materials scientists focus on maximising metrics such as the CO 2 capacity of their adsorbent. Here, we combine detailed process modelling, machine learning, and extensive global sensitivity analysis, which entails varying all of the model parameters together, on a direct air capture process to show that the dry CO 2 adsorption capacity does not influence process performance for an amine-functionalised adsorbent operating in a temperature vacuum swing adsorption (TVSA) process, while it is important in a steam-assisted TVSA (S-TVSA) process. In fact, adsorption kinetics, density, and thermal conductivity are all critical attributes to obtaining a low energy penalty and reduced costs. The analysis also highlights the importance of heat transfer, directing process engineers to (alternative) adsorber designs that maximise this. By an in-depth evaluation of how process performance indicators are affected by materials properties and process operating parameters, this work provides guidance to both material scientists and process engineers towards the design of a “unicorn adsorbent” and intensified DAC processes. This will improve the performance of solid adsorbent direct air capture and help drive down the costs of this vital technology to avert the worst impacts of climate change.
Increasing ROI Using Your Digital Twin for Model Based Engineering
The purpose of this work is to identify innovative ways of using the plant reference simulator or digital twin differently than it has traditionally been used in the past. This paper will identify reasons that the plant reference simulator will support varying levels of model based design and engineering. I will point out real world examples in which the plant reference simulator was used to identify problems with engineering designs, digital control systems and plant modifications. The earlier these issues can be identified and resolved, the less impact they have on the plant modification or upgrade. By using the plant reference simulator earlier in the engineering process, utilities and engineering organizations can minimize costly outage extensions and increase the return on the investment made in the simulator.
High-level co-production of 3-hydroxypropionic acid and 1,3-propanediol from glycerol: Metabolic engineering and process optimization
3-Hydroxypropionic acid (3-HP) and 1,3-propanediol (1,3-PDO) are value-added chemicals with versatile applications in the chemical, pharmaceutical, and food industries. Nevertheless, sustainable production of 3-HP and 1,3-PDO is often limited by the lack of efficient strains and suitable fermentation configurations. We report attempts have been made to improve the co-production of both metabolites through metabolic engineering of Escherichia coli and process optimization. First, the 3-HP and 1,3-PDO co-biosynthetic pathways were recruited and optimized in E. coli, followed by coupling the pathways to the transhydrogenase-mediated cofactor regeneration systems that increased cofactor availability and product synthesis. Next, pathway rebalancing and block of by-product formation significantly improved 3-HP and 1,3-PDO net titer. Subsequently, glycerol flux toward 3-HP and 1,3-PDO synthesis was maximized by removing metabolic repression and fine-tuning the glycerol oxidation pathway. Lastly, the combined fermentation process optimization and two-stage pH-controlled fed-batch fermentation co-produced 140.50 g/L 3-HP and 1,3-PDO, with 0.85 mol/mol net yield.