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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Bioblendstocks to Optimize Mixing Controlled Compression Ignition (MCCI) Engines

In this project, a team of researchers from the University of Massachusetts Lowell, the University of Maine, and Mainstream Engineering developed an integrated process for the product of bioblendstocks to optimize mixing controlled compression ignition (MCCI) engines. The objective was to improve the energy density, sooting propensity, and cetane number of base diesel fuel while maintaining cold weather behavior. The process converts woody biomass (e.g. sawmill residues) into bio-oil through selective fast pyrolysis; the bio-oil is then selectively upgraded to form selectively oxygenated, minimally-branched hydrocarbons using non-noble metal catalysts in combination with metal-catalyzed hydrogenation. Advanced predictive models, in conjunction with existing property databases, and experimental testing are used to evaluate overall bioblendstock properties and their impact on base diesel fuel. An iterative, targeted upgrading approach was implemented to optimize the proposed bioblendstock’s properties. Assessment methodologies included techno-economic analysis, life-cycle assessment, property testing, and engine testing. Ultimately, the project team successfully produced a viable bioblendstock while identifying critical process points related to scale-up efforts. It was found that producing pyrolysis oils at 500 degrees C and with pine particle sizes of 1-2 mm led to bio-oil with a higher yield (of approximately 45 wt%) and rich amounts of aromatic alcohols. The resultant pyrolysis oil was then upgraded using a sequence of mild hydrotreating, followed by catalytic etherification and esterification, followed by another final mild hydrotreating to produce a blendstock containing saturated species with a limited, but non-zero, amount of oxygen. The aromatic alcohols produced by pyrolysis were especially helpful in this regard, as the resulting bicycloethers and derivatives exhibited high cetane numbers. While most bulk properties of the bioblendstock met or exceeded targeted thresholds, viscosity and cloud point notably fell outside the expected range; this could be addressed by blending limits and/or through the use of additives that are commonplace in current refinding practices. Identification of a bioblendstock that can be produced economically at scale while improving the performance and emissions characteristics of internal combustion engines positively affects the economy by boosting domestic fuel production and the environment by decreasing harmful emissions and increasing efficiency.

09 BIOMASS FUELS↗
DOE OSTI2025

Conversion of Waste PET Plastic to Aramid Fiber

A three-step synthesis was used to convert waste polyethylene terephthalate (PET) into the high value polymer, poly-para-phenylene terephthalamide (PPTA), used in the production of high strength aramid fiber, such as Kevlar. Improvements to the polymerization reaction by addition of calcium chloride to the solvent, N-methyl-2-pyrrolidone (NMP), and rigorous anhydrous conditions enabled the production of a PET-derived PPTA with a 4.15 dL/g inherent viscosity in sulfuric acid that is amenable to fiber spinning. PPTA fibers were spun using a wet spinning apparatus under varied process parameters to assess their impact on fiber surface morphology, diameter, and the mechanical properties of the fibers. Select fibers were subjected to a post-spinning heat treatment at 150 °C , which improved the tensile strength and modulus by 100% and 30%, respectively, relative to the as-spun fibers. Techno-economic and life cycle analyses were conducted to evaluate the economic feasibility and the life-cycle greenhouse gases (GHG) emissions of the approach. In conclusion, the results suggest the potential for up to a 30% cost reduction, and comparable GHG emissions against conventional petroleum-based processes.

Lifecycle Analysis↗
DOE OSTI2022

Greenhouse gas emissions from the global transportation of crude oil: Current status and mitigation potential

Global crude-oil transportation contributes a significant portion of greenhouse gas (GHG) emissions in the marine transportation sector. In this work, we first compile a detailed country-level global crude-oil transportation network in 2018 and estimate that the direct and well-to-hull GHG emissions related to crude transportation were 97 and 109 million metric tons, respectively. Combining with the country-specific crude recovery GHG intensities, the consumption-based well-to-country-gate crude-oil GHG intensities are derived for individual countries, ranging from 2.99 to 27.32 g CO 2 eq/MJ, with a global crude-volume-weighted average of 8.67 g CO 2 eq/MJ. We then project the global crude transportation emissions at the regional level in 2050 under a static (no change) scenario (based on current ship energy efficiency) and a sustainable-development (SD) scenario (based on the International Energy Agency's projections of ship energy efficiency and penetration of alternative marine fuels). Results show that the global well-to-hull GHG emissions related to crude transportation would be 82 and 59 million metric tons in 2050 in the static and SD scenarios, respectively. To further evaluate the impact of potential fuel-switching on decarbonizing the crude oil transportation sector, we estimate the GHG emissions for 20 fuel/production options in 2050. We find that, in comparison to the static scenario, ~50% reduction in global well-to-hull GHG emissions from crude transportation could be achieved under the SD scenario if green ammonia further replaces conventional ammonia. The methodology developed here can be applied to other commodities to estimate the emissions associated with their global marine transportation and to evaluate the potential emission mitigation options.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

6.26 Low Cost Basalt Fiber for Automotive Applications

Vehicle lightweighting is an essential component to the automotive industry to improve fuel economy of internal combustion engine (ICE) vehicles to meet ever improving emission standards and to improve the range of electric vehicles (EV). Composite materials offer high specific modulus and specific strength, which makes them appealing for these light weighting efforts. Sheet molding compounds (SMC) are particularly interesting from an automotive perspective because of the relatively low cost and high volume of producing SMC parts. Traditionally, composite materials for automotive application are glass fiber reinforced because of the attractive price - performance ratio, but basalt fibers are a cost and recycling competitive reinforcement alternative in this market. The aim of this project was to examine the feasibility of utilizing basalt fiber for automotive applications. More specifically, an effort was made to examine different fiber sizings on basalt fiber combined with vinyl-ester (VE) resin, and their performance as part of an SMC process. In addition to offering vehicle lightweighting with fiber reinforced polymer composites, basalt fiber is a fully recyclable material and thus supports the IACMI technical goal of: Demonstrate that the technology is capable at a sufficient scale for >80% recyclability or reuse of fiber reinforced polymer composites in five years into useful components with projected cost and quality at commercial scale competitive with virgin materials on a pathway to 95% recyclability or reuse starting in ten years. Three different fiber sizings were applied to a continuous roving of basalt fiber and compared to a traditional Electrical/Chemical Resistance (E-CR) glass fiber that is typically used in these types of applications. Fiber tows were examined for Loss on Ignition percentage (LOI%), Tex, and tow strength. Some sizings clearly outperformed others, and the ability to process these fibers on a pilot scale SMC line was demonstrated. A test plan for the manufacturing and mechanical testing of SMC panels was developed. This work continues outside the time frame allocated for this project. When this work is completed, it will be added to this report and posted as Appendix C. Glass fiber reinforced SMC materials have already proven feasible as a light weighting method for traditionally steel parts like the Volkswagen (VW) Atlas lift-gate (Figure 1); this project team is seeking the feasibility of basalt fiber as a drop-in replacement for glass fiber reinforced SMC. Sizing development for basalt fibers has proven that the mechanical properties are better than E-glass and closer to S-glass, which makes it an interesting material for SMC applications. Better mechanical properties translate to less material needed to achieve load case requirement for target applications. The business case has already been demonstrated for 100,000 parts per year of glass fiber reinforced SMC Atlas lift-gates compared to traditional steel manufacturing processes. Reduced overhead and assembly costs are offset by glass fiber SMC higher cost per kg beyond 100,000 parts per year, which is still a relatively low volume for the automotive industry. For basalt fiber reinforced SMC to become feasible for automotive applications, the price-performance ratio has to be precisely determined. Based on the mechanical performance it is possible to establish a range of applications and technical solutions in which the potential of basalt SMC can be utilized, while the price of the material can be used to compile the business case for such applications. Based on these business cases and the sustainability indicators, glass fiber reinforcement (or other) materials can be directly substituted. Volkswagen’s commitment to reducing carbon emissions cannot be understated. Basalt fiber shows promise of reducing the carbon footprint in SMC materials, especially if sizing optimizations can be made with thermoplastic based SMC. To fully realize the value of basalt fiber reinforced materials, a lifecycle cost analysis should be performed on basalt’s production and recycling, and then compared against E-glass. From this assessment, a true judgement can be made on the commercialization potential of this material. Figure 1. Example of Fiber Reinforced Polymer Composite Liftgate As a conclusion, we can state that Mafic basalt fiber is not a direct replacement for E-glass or E-CR glass based on price, but should be considered a technical solution when E-glass does not provide adequate performance in a composite design and S-glass, aramid and carbon fibers are too costly. Mafic basalt fiber can be placed on the high-performance fiber spectrum next to S-glass for performance but at one third the price. It should be considered for more technically challenging structural designs wherein the performance can demonstrate 20-25% performance enhancement over E-glass to elicit more strength or a weight reduction. Both Michelman and Mafic produce thermoplastic sizings which, in combination with Nylon and polypropylene resin and fibers, can further advance high speed composite implementations while maintaining an eco-friendly manufacturing process.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Cement Plant TEA/LCA

This presentation was prepared for the 2024 Carbon Management Project Review Meeting. The slides summerize recent NETL systems analysis work examining the application of carbon capture systems at cement plants. This includes a 2023 NETL report titled "Analysis of Carbon Capture Retrofits for Cement Plants" and a 2024 NETL authored journal article titled “The Impact of Cement Plant Air Ingress on Membrane-Based CO2 Capture Retrofit Cost”. The slide deck also highlights ongoing NETL techno-economic analysis and lifecycle assessment work on capture from cement plants & other industrial capture projects.

Homsy, Sally↗
DOE OSTI2025

Direct Air Reactive Capture and Conversion for Utility-Scale Energy Storage (Final Report)

This final report for FEW0277 summarizes the work performed over the project performance period of October 2021 – March 2025. This project was funded under the “Reactive Capture and Conversion R&D” lab call released in FY2021. The goal of the project was to develop dual-function materials and process for capturing CO 2 from the atmosphere and converting it into CH 4 . The work was organized into four parallel tracks in 1) direct air capture materials synthesis and characterization, 2) catalysts for CO 2 conversion, 3) mechanistic investigations via ab initio simulations, and 4) process modeling, technoeconomic analysis, and lifecycle assessment. The project was split into two budget periods. The first budget period focused on development of amine-based materials, due to their known performance for CO 2 direct air capture and their potential to act synergistically with metal catalysts to enable a low-temperature methanation pathway. The second budget period focused on development of alkali-based materials and a simulated-moving-bed process for high conversion catalytic reduction of captured CO 2 to CH 4 . All project milestones were completed during the project performance period and are summarized in this report. Our work resulted in publication of eight peer-reviewed manuscripts, one patent application, and numerous presentations given at domestic and international conferences and invited academic department seminars.

03 NATURAL GAS↗
DOE OSTI2026

Williston basin associated co 2 storage field laboratory

The Williston Basin Associated CO 2 Storage Field Laboratory (WBCFL), led by the Energy & Environmental Research Center (EERC) in partnership with Denbury (now ExxonMobil), was established to advance understanding of CO 2 enhanced oil recovery (EOR) and associated geologic CO 2 storage in the Williston Basin. The specific objective of the WBCFL was to conduct field and laboratory activities to inform decisionmakers regarding the 1) efficacy of associated storage in stacked geologic reservoirs during EOR operations; 2) CO 2 injectivity, oil production, and storage in residual oil zones (ROZs); 3) use of a novel CO 2 storage monitoring, verification, and accounting (MVA) technology (active seismoelectric [ASE] monitoring), and 4) life cycle and techno-economic factors for EOR development scenarios targeting ROZs. The project location was the Pennel Field in southeast Montana, which is part of the Cedar Creek Anticline (CCA) geologic structure within the Williston Basin.

02 PETROLEUM↗
DOE OSTI2025

Refining Control, Charging, and Battery Chemistry for CO 2 e Savings in Heavy-Duty Off-Road Plug-In Series Hybrid

With current and future regulations continuing to drive reductions in carbon dioxide equivalent (CO 2 e) emissions in the on-road industry, the off-road industry is also likely to be regulated for fuel and CO 2 e savings. This work focuses on converting a heavy-duty off-road material handler from a conventional diesel powertrain to a plug-in series hybrid, achieving a 49% fuel reduction and 29% CO 2 e reduction via simulation. Control strategies were refined for energy savings, including a regenerative braking strategy to increase regenerative braking and a load-following hydraulic strategy to decrease electrical energy consumption. The load-following hydraulic control shuts off the hydraulic electric machine when it is not needed—an approach not previously seen in a load-sensing, pressure-compensated system. Furthermore, these strategies achieved a 24.1% fuel savings, resulting in total savings of 61% in fuel and 41% in CO 2 e in the plug-in series compared to the conventional machine. Beyond control strategies, this study evaluated battery chemistry and charging strategy refinements for total cost of ownership (TCO) and lifetime CO 2 e. LFP batteries emerged as the most cost-effective and least emitting due to their longer lifespan, which reduced replacement frequency. Charging comparisons showed that Level 2 charging (L2C) typically resulted in lower TCO but higher lifetime CO 2 e than DC fast charging (DCFC). DCFC costs were heavily influenced by local demand charges, and DCFC emissions were heavily influenced by local grid emissions.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS1988

Space-based laser-powered orbital transfer vehicle (Project SLICK)

The project SLICK (Space Laser Interorbital Cargo Kite) involves conceptual designs of reusable space-based laser-powered orbital transfer vehicle (LOTV) for ferrying 16,000 kg cargo primarily between low Earth orbit (LEO) and geosynchronous earth orbit (GEO). The power of LOTV is beamed by a single 32-MW solar-pumped iodide laser orbiting the Earth at an altitude of one Earth radius. The laser engine selected for the LOTV is based on a continuous-wave, steady-state propulsion scheme and uses an array of seven discrete plasmas in a flow of hydrogen propellant. Both all-propulsive and aerobraked LOTV configurations were analyzed and developed. The all-propulsive vehicle uses a rigid 11.5-m aperture primary mirror and its engine produces a thrust of 2000 N at a specific impulse of 1500 sec. For the LEO-to-GEO trip, the payload ratio, m(sub payload/m(sub propellant)+m(sub dry vehicle) = 1.19 and the trip time is about 6 days. The aerobraked version uses a lightweight, retractable wrapped-rib primary mirror which is folded for aerobraking and a 20-m-diameter inflatable-ballute aeroshield which is jettisoned after aeromaneuver. Lifecycle cost analysis shows that the aerobraked configuration may have an economic advantage over the all-propulsive configuration as long as the cost of launching the propellant to LEO is higher than about $500/kg in current dollars.

Source record↗
DOE OSTI2023

Data and Tools for Exploring New Pumped Storage Hydropower Deployment Opportunities

Pumped storage hydropower (PSH) is a flexible energy storage technology with the potential to facilitate variable renewable energy integration into the decarbonized electric grid of the future. NREL is developing new data and tools to help understand opportunities for new PSH deployment, including nationwide resource assessment data, a bottom-up component-level cost model, and a lifecycle greenhouse gas emissions calculator. These datasets lay the foundation for better-informed grid planning decisions about how PSH fits into a future portfolio of generation, transmission, and storage assets.

CEM↗
NASA NTRS2022

Advanced Statistical Methods in Spacecraft Flight Software Cost Estimation: Bayesian Regression and Nonlinear Principal Components Analysis to Support System Engineering in the Early Project Lifecycle

This paper provides an overview of the new features and model updates in the upcoming release of the NASA Analogy Software Cost Tool (ASCoT). ASCoT, hosted within the Online NASA Space Estimation Tools (ONSET) on the One NASA Cost Engineering (ONCE) Database, is a web-based tool that provides a suite of estimation tools to support early lifecycle NASA flight software cost analysis. In addition to the traditional parametric flight software costing method COCOMO II, ASCoT contains a Bayesian linear regression to predict total flight software development cost as a function of total spacecraft cost, as well as four analogic methods: k-Nearest Neighbors (kNN) and Clustering models to predict Effort (in work-months) and total source lines of code (SLOC). These methods are designed to work primarily with system-level inputs such as mission type (orbiter, lander, etc.), mission destination (Earth, Inner Planetary, etc.), and the number of instruments and deployables. Nonlinear principal components analysis (NLPCA) is performed to find the principal features of the data composed of both categorical and numerical variables and is necessary prior to defining our analogic methods. Sensitivity analyses and in- and out-of-sample model performance results are presented for the Bayesian CER and the analogic models.

Johnson, James K.↗
DOE OSTI2022

Lifecycle Assessment and Techno-Economic Analysis of Biochar Pellet Production from Forest Residues and Field Application

Biochar produced from low-value forest biomass can provide substantial benefits to ecosystems and mitigate climate change-induced risks such as forest fires. Forest residues from restoration activities and timber harvest and biochar itself are bulky and thus incur high logistic costs, so are considered major bottlenecks for the commercialization of the biochar industry. The objectives of this study were to assess the environmental footprints and techno-economic feasibility of converting forest residues in Pacific Northwest United States into biochar pellets using portable systems followed by delivery of the final product to end-users for land application (dispersion). Two portable systems (Biochar Solutions Incorporated (BSI) and Air Curtain Burner (ACB)) were considered for biochar production. A cradle-to-grave lifecycle assessment (LCA) and a discounted cash flow analysis method were used to quantify the environmental impacts and minimum selling price (MSP) of biochar. The global warming (GW) impact of biochar production through BSI and ACB was estimated to be 306–444, and 750–1016 kgCO₂eq/tonne biochar applied to the field, respectively. The MSP of biochar produced through BSI and ACB was 1674–1909 and 528–1051 USD/tonne biochar applied to the field, respectively. Pelletizing of biochar reduced GW impacts during outbound logistics (~8–20%) but increased emissions during pelletizing (~1–9%). Results show the BSI system was a more viable option in terms of GW impact, whereas the ACB system can produce biochar with lower MSP. The results of the study conclude that the production of biochar pellets through the two portable systems and applied to fields can be both an environmentally beneficial and economically viable option.

09 BIOMASS FUELS↗
NASA NTRS2001

Linking Science Analysis with Observation Planning: A Full Circle Data Lifecycle

A clear goal of the Virtual Observatory (VO) is to enable new science through analysis of integrated astronomical archives. An additional and powerful possibility of the VO is to link and integrate these new analyses with planning of new observations. By providing tools that can be used for observation planning in the VO, the VO will allow the data lifecycle to come full circle: from theory to observations to data and back around to new theories and new observations. The Scientist's Expert Assistant (SEA) Simulation Facility (SSF) is working to combine the ability to access existing archives with the ability to model and visualize new observations. Integrating the two will allow astronomers to better use the integrated archives of the VO to plan and predict the success of potential new observations more efficiently, The full circle lifecycle enabled by SEA can allow astronomers to make substantial leaps in the quality of data and science returns on new observations. Our paper examines the exciting potential of integrating archival analysis with new observation planning, such as performing data calibration analysis on archival images and using that analysis to predict the success of new observations, or performing dynamic signal-to-noise analysis combining historical results with modeling of new instruments or targets. We will also describe how the development of the SSF is progressing and what have been its successes and challenges.

Grosvenor, Sandy↗
NASA NTRS2001

Linking Science Analysis with Observation Planning: A Full Circle Data Lifecycle

A clear goal of the Virtual Observatory (VO) is to enable new science through analysis of integrated astronomical archives. An additional and powerful possibility of the VO is to link and integrate these new analyses with planning of new observations. By providing tools that can be used for observation planning in the VO, the VO will allow the data lifecycle to come full circle: from theory to observations to data and back around to new theories and new observations. The Scientist's Expert Assistant (SEA) Simulation Facility (SSF) is working to combine the ability to access existing archives with the ability to model and visualize new observations. Integrating the two will allow astronomers to better use the integrated archives of the VO to plan and predict the success of potential new observations. The full circle lifecycle enabled by SEA can allow astronomers to make substantial leaps in the quality of data and science returns on new observations. Our paper will examine the exciting potential of integrating archival analysis with new observation planning, such as performing data calibration analysis on archival images and using that analysis to predict the success of new observations, or performing dynamic signal-to-noise analysis combining historical results with modeling of new instruments or targets. We will also describe how the development of the SSF is progressing and what has been its successes and challenges.

Jones, Jeremy↗
DOE OSTI2025

The Impact of Demographic Lifecycle States on Time to Vehicle Purchase: Insights from the Panel Study of Income Dynamics

This study examines the impact of demographic lifecycle stages on the timing of vehicle purchases, using data from the Panel Study of Income Dynamics from 1999 to 2021. Survival analysis was employed to model the duration until households purchase vehicles, incorporating key lifecycle variables such as age, employment status, marital status, childbirth, home ownership, and the presence of school-going children. The life table results indicate that early adulthood (ages 20–35) is the prime period for vehicle acquisition, with significant peaks around ages 25 to 30. Additionally, the instantaneous hazard of purchasing a vehicle is highest in the late 40s and early 50s. According to the Cox proportional hazards model, employment, marital status, and home ownership significantly increase the likelihood of purchasing a vehicle, while living in multi-unit dwellings decreases it. Interaction effects reveal that married individuals with employed spouses are substantially more likely to purchase vehicles. In conclusion, this study serves as a steppingstone toward integrating demographic lifecycle analysis into car ownership modeling that better reflects real-world scenarios and increases the accuracy of policy and strategic planning.

Car ownership↗
NASA NTRS2006

State Analysis Database Tool

The State Analysis Database Tool software establishes a productive environment for collaboration among software and system engineers engaged in the development of complex interacting systems. The tool embodies State Analysis, a model-based system engineering methodology founded on a state-based control architecture (see figure). A state represents a momentary condition of an evolving system, and a model may describe how a state evolves and is affected by other states. The State Analysis methodology is a process for capturing system and software requirements in the form of explicit models and states, and defining goal-based operational plans consistent with the models. Requirements, models, and operational concerns have traditionally been documented in a variety of system engineering artifacts that address different aspects of a mission s lifecycle. In State Analysis, requirements, models, and operations information are State Analysis artifacts that are consistent and stored in a State Analysis Database. The tool includes a back-end database, a multi-platform front-end client, and Web-based administrative functions. The tool is structured to prompt an engineer to follow the State Analysis methodology, to encourage state discovery and model description, and to make software requirements and operations plans consistent with model descriptions.

Rasmussen, Robert↗
NASA NTRSDate not supplied

Satellite Tracking of Shallow Cumulus during CAMP2Ex: The Aerosol and Organization Connection

Shallow moist convection is ubiquitous throughout the tropics and represents a key player in boundary layer processes. Shallow clouds come in many forms, from scattered, short-lived cumulus to organized features that include cold pool boundaries and lines reaching O(100 km) scale lasting several hours. In this study, we explore how cloud morphology and environmental aerosol affect shallow cumulus lifecycle properties. Measuring such influences requires a broad, detailed view of these cloud fields as they grow and decay. Geostationary satellites provide a means to follow the clouds with enhanced spatiotemporal sampling from space. We apply a cloud-tracking tool to study lifecycle properties of shallow cumulus sampled during the NASA Cloud, Aerosol, and Monsoon Processes Philippines Experiment (CAMP2Ex) field campaign of 2019. The mission conducted airborne and shipborne operations over the West Pacific Ocean, in tandem with Rapid Scan imagery from the Advanced Himawari Imager (AHI) on the Japan Meteorological Agency’s (JMA) Himawari-8 satellite. We segment shallow cumulus on AHI 0.5-km visible reflectance during the daylit hours of several research flights that exhibited ideal atmospheric conditions for tracking. We collect the resulting cloud tracks by regions containing airborne sampling of the cloud environments and by two specific segmentation techniques: one optimized for small, disorganized cumulus and the other for larger, organized clouds using suitable thresholds for reflectance and blurring. We present an analysis of cloud lifecycle properties using our dual segmentation approach for various sampled environments of CAMP2Ex. A total of 7 research flights (RFs) exhibited ideal conditions for generating cloud-track ensembles under similar thermodynamic and kinematic profiles but with varying aerosol load. We consider lifetime, track-achieved metrics, and ensemble-fitted growth rates to evaluate the aerosol effect. Cloud elongation, a factor in cloud morphology, is also considered for any potential influence in observed shifts in growth rates. The results suggest that aerosol affects cloud lifecycles more significantly for clouds with larger areas and independent of the elongation factor.

Cloud Tracking↗