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DOE OSTI2021

National Alliance for Water Innovation (NAWI) Agriculture Sector Technology Roadmap 2021

The National Alliance for Water Innovation (NAWI) is a research consortium formed to accelerate transformative research in desalination and treatment to lower the cost and energy required to produce clean water from nontraditional water sources and realize a circular water economy. NAWI's goal is to enable the manufacturing of energy-efficient desalination technologies in the United States at a lower cost with the same (or higher) quality and reduced environmental impact for 90 percent of nontraditional water sources within the next 10 years. The nontraditional source waters of interest include brackish water; seawater; produced and extracted water; power, mining, industrial, municipal, and agricultural waste waters. When these desalination and treatment technologies are fully developed and utilized, they will be able to contribute to the water needs for many existing end-use sectors. NAWI has identified five end-use sectors that are critical to the U.S. economy for further exploration: Power, Resource Extraction, Industry, Municipal, and Agriculture (PRIMA). This Agriculture Sector roadmap aims to advance desalination and treatment of nontraditional source waters for beneficial use in public water supplies by identifying research and development (R&D) opportunities that help overcome existing treatment challenges. Under NAWI's vision, the transition from a linear to a circular water economy with nontraditional source waters will be achieved by advancing desalination and reuse technologies in six key areas: Autonomous operations, Precision separations, Resilient treatment and transport, Intensified brine management, Modular membrane systems, and Electrified treatment systems, collectively known as the A-PRIME areas. Technological advances in these different areas will enable nontraditional source waters to achieve pipe parity with traditional supplies.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

National Alliance for Water Innovation (NAWI) Municipal Sector Technology Roadmap 2021

The National Alliance for Water Innovation (NAWI) is a research consortium formed to accelerate transformative research in desalination and treatment to lower the cost and energy required to produce clean water from nontraditional water sources and realize a circular water economy. NAWI's goal is to enable the manufacturing of energy-efficient desalination technologies in the United States at a lower cost with the same (or higher) quality and reduced environmental impact for 90 percent of nontraditional water sources within the next 10 years. The nontraditional source waters of interest include brackish water; seawater; produced and extracted water; power, mining, industrial, municipal, and agricultural waste waters. When these desalination and treatment technologies are fully developed and utilized, they will be able to contribute to the water needs for many existing end-use sectors. NAWI has identified five end-use sectors that are critical to the U.S. economy for further exploration: Power, Resource Extraction, Industry, Municipal, and Agriculture (PRIMA). This Municipal Sector roadmap aims to advance desalination and treatment of nontraditional source waters for beneficial use in public water supplies by identifying research and development (R&D) opportunities that help overcome existing treatment challenges. Under NAWI's vision, the transition from a linear to a circular water economy with nontraditional source waters will be achieved by advancing desalination and reuse technologies in six key areas: Autonomous operations, Precision separations, Resilient treatment and transport, Intensified brine management, Modular membrane systems, and Electrified treatment systems, collectively known as the A-PRIME areas. Technological advances in these different areas will enable nontraditional source waters to achieve pipe parity with traditional supplies.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

National Alliance for Water Innovation (NAWI) Industrial Sector Technology Roadmap 2021

The National Alliance for Water Innovation (NAWI) is a research consortium formed to accelerate transformative research in desalination and treatment to lower the cost and energy required to produce clean water from nontraditional water sources and realize a circular water economy. NAWI's goal is to enable the manufacturing of energy-efficient desalination technologies in the United States at a lower cost with the same (or higher) quality and reduced environmental impact for 90 percent of nontraditional water sources within the next 10 years. The nontraditional source waters of interest include brackish water; seawater; produced and extracted water; power, mining, industrial, municipal, and agricultural waste waters. When these desalination and treatment technologies are fully developed and utilized, they will be able to contribute to the water needs for many existing end-use sectors. NAWI has identified five end-use sectors that are critical to the U.S. economy for further exploration: Power, Resource Extraction, Industry, Municipal, and Agriculture (PRIMA). This Industrial Sector roadmap aims to advance desalination and treatment of nontraditional source waters for beneficial use in public water supplies by identifying research and development (R&D) opportunities that help overcome existing treatment challenges. Under NAWI's vision, the transition from a linear to a circular water economy with nontraditional source waters will be achieved by advancing desalination and reuse technologies in six key areas: Autonomous operations, Precision separations, Resilient treatment and transport, Intensified brine management, Modular membrane systems, and Electrified treatment systems, collectively known as the A-PRIME areas. Technological advances in these different areas will enable nontraditional source waters to achieve pipe parity with traditional supplies.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS2019

MERRA-2 Data and Analytic Services at NASA GES DISC for Climate Extremes Study

NASA's climate reanalysis datasets from the Modern Era Retrospective-analysis for Research and Applications, Version 2 (MERRA-2) contains numerous long-term atmosphere, land, and ocean data products from 1980-present. MERRA-2 datasets, such as precipitation, soil moisture, and temperature, have been used widely to study extreme events. The native archived MERRA-2 data files are day-file (hourly time interval) and month-file, containing up to 125 parameters in one file. Due to the large number of data files and volumes, it is challenging for users, especially the applications research community, to handle the original hourly data files for long time periods to analyze extreme events. In this presentation, we review MERRA-2 data for studies of extreme conditions, and demonstrate analytic services at the NASA Goddard Earth Sciences Data and Information Services Center (GES DISC). One of the current operational services, 'subsetter', allows users to download only specific data of interest, i.e. data selected by parameter, region, and time period. New services are under development that will provide more 'on-the-fly' statistical calculations when downloading data; improve efficiency when accessing long time-series data. We will provide additional "How-to" resources that include step-by-step instructions on data access and usage. We have tested restructuring of day-files in an optimized data cube, which has significantly improved system performance for accessing long time-series. Overall performance is associated with cube size and structure, data compression method, and how the data are accessed. The optimized data cube structure will enable better online analytic services for statistical analysis and extreme events mining. To demonstrate the service, we use an extreme drought associated with the anomalous 2016 monsoon over southern Asia. This prototype time-series service may be augmented in the cloud infrastructure in the future.

data access↗

DOE OSTI2021

National Alliance for Water Innovation (NAWI) Resource Extraction Sector Technology Roadmap 2021

The National Alliance for Water Innovation (NAWI) is a research consortium formed to accelerate transformative research in desalination and treatment to lower the cost and energy required to produce clean water from nontraditional water sources and realize a circular water economy. NAWI’s goal is to enable the manufacturing of energy-efficient desalination technologies in the United States at a lower cost with the same (or higher) quality and reduced environmental impact for 90 percent of nontraditional water sources within the next 10 years. The nontraditional source waters of interest include brackish water; seawater; produced and extracted water; power, mining, industrial, municipal, and agricultural waste waters. When these desalination and treatment technologies are fully developed and utilized, they will be able to contribute to the water needs for many existing end-use sectors. NAWI has identified five end-use sectors that are critical to the U.S. economy for further exploration: Power, Resource Extraction, Industry, Municipal, and Agriculture (PRIMA). This Resource Extraction Sector roadmap aims to advance desalination and treatment of nontraditional source waters for beneficial use in public water supplies by identifying research and development (R&D) opportunities that help overcome existing treatment challenges. Under NAWI’s vision, the transition from a linear to a circular water economy with nontraditional source waters will be achieved by advancing desalination and reuse technologies in six key areas: Autonomous operations, Precision separations, Resilient treatment and transport, Intensified brine management, Modular membrane systems, and Electrified treatment systems, collectively known as the A-PRIME areas. Technological advances in these different areas will enable nontraditional source waters to achieve pipe parity with traditional supplies.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Water & Energy Interdependencies Across Economic Sectors of the United States

The motivation of the Integrated Water Power Resilience Project is to identify and develop opportunities for improving resilience in the water and power sectors through coordinated planning, investment, and operations and thereby provide benefits to power and water utilities, consumers, and the environment. Water and power systems are interdependent, subject to many of the same natural and manmade hazards, and are critical for the well-being of communities and society. Because of the interconnectedness of water and power systems, there are substantial economic, social, and environmental benefits to co-managing the market sectors for resilience instead of managing them separately. To support this initiative and future research in this area, a county level water and energy flow dataset was developed to build, calculate, and visualize interconnections in water and energy between various sectors. This report presents county and regional water and energy visualizations across nine economic sectors of the United States: agriculture, commercial, electricity generation, industrial, mining, public water supply, residential, transportation, and wastewater treatment.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

NASA NTRS2014

MARGInS: Model-Based Analysis of Realizable Goals in Systems

Under NASAs Constellation effort, the Exploration Technology Development Program funded research toward a system validation capability that applied machine learning and test-case generation techniques to the analysis of black-box system behavior. The behavior analysis capability scaled to spaces of hundreds of input parameters and tens of thousands of test cases. Aerospace systems at the vehicle level, especially those systems which contain some level of autonomy, are best described by hybrid and non-linear mathematics. Even simplified models of such systems need parameter dimensionalities in the hundreds or thousands of parameters in order to capture sufficient fidelity. The System Safety Assessments (such as those described in the SAE ARP 4761A Safety Assessment Process guidelines) for these systems are prone to errorinteractions between the vehicles subsystems are complex, and can display emergent behaviors. NASA captured this new analysis in the Model-based Analysis of Realizable Goals in Systems (MARGInS) tool and applied it to the Pad Abort 1 (PA-1) simulation as part of the independent validation and verification cycle before the PA-1 flight test in May of 2010. MARGInS evaluated the adherence of the high-fidelity simulation to its requirements, and deter- mined the margins to failure from the expected nominal input conditions. Following the PA-1 test, the capabilities within the MARGInS framework have been extended with sophisticated statistical and white-box test case generation techniques and applied to other NASA missions. The frame- work now includes a critical factors analysis that was applied to NASAs Orion simulation and design. NASAs Aeronautics Research Mission Directorate (ARMD) leveraged the existing MARGInS framework for work on aviation safety for civil transport vehicles and for research on autonomy issues. The NASA ARMD effort created a time series output prediction capability that has been used to characterize trajectories for a plane with an adaptive control system, and a safety boundary detection capability that has been applied to an air traffic control concept of operation for the Federal Aviation Administration. The statistical and machine- learning based techniques within MARGInS have been successfully combined with concolic execution to improve the coverage of a critical unit by driving system-level inputs. The use case driving the concolic execution and MARGInS integration was inspired by the Air France 447 disaster in which the loss of a critical functionality (the airspeed calculation from the pitot tubes) led to loss of the entire plane with the people aboard. To illustrate capabilities and limitations, we will highlight the analyses for the applications listed above. We will then discuss the future plans for MARGInS and its interfaces with other tools.

Validation↗

DOE OSTI2025

Mineral Scale Formation during Crossflow Reverse Osmosis at Constant Flux and Constant Transmembrane Pressure Conditions

Mineral scale formation on membrane surfaces is a significant challenge in reverse osmosis water purification. Laboratory fouling experiments are typically run such that the transmembrane pressure (TMP) is fixed, and the permeate flux decreases over time as scales accumulate on the membrane surface. However, this change in flux means that the hydrodynamic conditions at the membrane surface are continuously changing, which could affect crystallization and foulant deposition processes. Operating under constant permeate flux conditions, in contrast, is advantageous because it keeps the hydrodynamic conditions relatively consistent, making it possible to compare how membrane properties (e.g., surface chemistry) affect fouling propensity. Industrial reverse osmosis operations are not run strictly in either constant TMP or constant flux mode; while they may start at a constant TMP, feed pressure may be periodically adjusted to maintain permeate water production within a specified range. Here, the scarcity of constant permeate flux reverse osmosis scaling experiments reported in the literature frustrates efforts to compare membrane fouling processes under constant TMP and constant flux conditions. For the first time, the evolution of the fouling layer resistance was compared as a function of cumulative permeate volume per membrane area during constant TMP and constant flux reverse osmosis filtrations. Scaling experiments were conducted by challenging commercial reverse osmosis membranes with a model feed solution nearly saturated with calcium sulfate dihydrate (gypsum). At low fluxes, the increase in fouling layer resistance was quantitatively similar for the two operational modes. In contrast, at high fluxes, the fouling layer resistance increased more rapidly in constant flux filtration than in constant TMP filtration. The mechanism of scale formation in constant TMP and constant flux operation was self-limiting and self-reinforcing, respectively.

36 MATERIALS SCIENCE↗

NASA NTRS2002

Method for Locating a Concealed Object

Apparatus and methods are disclosed for detecting anomalies in microwave penetrable material that may be used for locating plastic mines or pipes underneath the ground. A transmitter is positioned at a plurality of different positions above the ground. A microwave signal is transmitted that is stepped over a plurality of frequencies. At each position, a plurality of reflections are received corresponding to each of the plurality of frequencies that were transmitted. A complex target vector may be produced at each position that contains complex values corresponding to magnitude, phase, and time delay for each of the plurality of reflections received at that location. A complex reference data vector may be produced, either based on predetermined values or based on data from the received plurality of reflections. A comparison is made between the complex target vector and the complex reference data vector to produce a channel vector. In one embodiment, an operator may be applied to the channel vector such as a complex filter matrix or to add a complex conjugate. A response signal is produced and anomalies are detected by variations in the response signal with respect to the plurality of positions.

G Dickey Arndt↗

DOE OSTI2025

Predicting Initial Trans-Membrane Pressure for Optimized Operations in UF Unit Using Random Forest

With the growing scarcity of freshwater, innovative process design mechanisms like Reverse Osmosis (RO) are increasingly gaining attention among water treatment utilities to address the rising demand. Ensuring reliable water production necessitates efficient resource utilization, minimizing downtime in (ultra-filtration) UF systems. Recent advancements in machine learning (ML) have enabled the development of accurate data-driven models for Model Predictive Control (MPC), often requiring minimal prior knowledge of underlying physical processes. In this study, we present predictive regression models based on Random Forest (RF) and Auto-Regressive (AR) approaches to forecast the initial Trans-Membrane Pressure (TMP) for each filtration cycle in data generated by Direct Potable Reuse (DPR) systems. The proposed RF-based model demonstrates superior performance compared to baseline methods, including historical mean, Last Observation Carried Forward (LOCF), and naïve AR models, across various forecasting horizons in terms of root mean square error (RMSE) metric. To evaluate how different classes of process variables contribute to TMP dynamics over time, we examine the feature importance of independent covariates across multiple forecast horizons. This analysis provides insight into the temporal relevance of operational and sensor-derived features, guiding control and monitoring strategies. Additionally, the impact of hyperparameter tuning on TMP prediction performance is studied for both direct and recursive RF modelling approaches across increasing forecast horizons. Accurate prediction of initial TMP is critical for optimizing RO operations, as it enables the development of robust modelling frameworks by accurately estimating membrane fouling trends, thereby enhancing process efficiency and long-term reliability. The demonstrated efficacy of the RF-based approach highlights its potential as a tool for real-time decision-making in water treatment systems, paving the way for advanced process optimization and sustainable water resource management.

Mukherjee, Subrata [ORNL] (ORCID:0000000309930338)↗

NASA NTRS2015

Space Resource Utilization: Near-Term Missions and Long-Term Plans for Human Exploration

NASA's Human Exploration Plans: A primary goal of all major space faring nations is to explore space: from the Earth with telescopes, with robotic probes and space telescopes, and with humans. For the US National Aeronautics and Space Administration (NASA), this pursuit is captured in three important strategic goals: 1. Ascertain the content, origin, and evolution of the solar system and the potential for life elsewhere, 2. Extend and sustain human activities across the solar system (especially the surface of Mars), and 3. Create innovative new space technologies for exploration, science, and economic future. While specific missions and destinations are still being discussed as to what comes first, it is imperative for NASA that it foster the development and implementation of new technologies and approaches that make space exploration affordable and sustainable. Critical to achieving affordable and sustainable human exploration beyond low Earth orbit (LEO) is the development of technologies and systems to identify, extract, and use resources in space instead of bringing everything from Earth. To reduce the development and implementation costs for space resource utilization, often called In Situ Resource Utilization (ISRU), it is imperative to work with terrestrial mining companies to spin-in/spin-off technologies and capabilities, and space mining companies to expand our economy beyond Earth orbit. In the last two years, NASA has focused on developing and implementing a sustainable human space exploration program with the ultimate goal of exploring the surface of Mars with humans. The plan involves developing technology and capability building blocks critical for sustained exploration starting with the Space Launch System (SLS) and Orion crew spacecraft and utilizing the International Space Station as a springboard into the solar system. The evolvable plan develops and expands human exploration in phases starting with missions that are reliant on Earth, to performing ever more challenging and longer duration missions in cis-lunar space and beyond, to eventually being independent from Earth. The goal is no longer just to reach a destination, but to enable people to work, learn, operate, and live safely beyond the Earth for extended periods of time, ultimately in ways that are more sustainable and even indefinite.

Sanders, Gerald B.↗

NASA NTRS2015

Space Resource Utilization: Near-Term Missions and Long-Term Plans for Human Exploration

A primary goal of all major space faring nations is to explore space: from the Earth with telescopes, with robotic probes and space telescopes, and with humans. For the US National Aeronautics and Space Administration (NASA), this pursuit is captured in three important strategic goals: 1. Ascertain the content, origin, and evolution of the solar system and the potential for life elsewhere, 2. Extend and sustain human activities across the solar system (especially the surface of Mars), and 3. Create innovative new space technologies for exploration, science, and economic future. While specific missions and destinations are still being discussed as to what comes first, it is imperative for NASA that it foster the development and implementation of new technologies and approaches that make space exploration affordable and sustainable. Critical to achieving affordable and sustainable human exploration beyond low Earth orbit (LEO) is the development of technologies and systems to identify, extract, and use resources in space instead of bringing everything from Earth. To reduce the development and implementation costs for space resource utilization, often called In Situ Resource Utilization (ISRU), it is imperative to work with terrestrial mining companies to spin-in/spin-off technologies and capabilities, and space mining companies to expand our economy beyond Earth orbit. In the last two years, NASA has focused on developing and implementing a sustainable human space exploration program with the ultimate goal of exploring the surface of Mars with humans. The plan involves developing technology and capability building blocks critical for sustained exploration starting with the Space Launch System (SLS) and Orion crew spacecraft and utilizing the International Space Station as a springboard into the solar system. The evolvable plan develops and expands human exploration in phases starting with missions that are reliant on Earth, to performing ever more challenging and longer duration missions in cis-lunar space and beyond, to eventually being independent from Earth. The goal is no longer just to reach a destination, but to enable people to work, learn, operate, and live safely beyond the Earth for extended periods of time, ultimately in ways that are more sustainable and even indefinite.

Sanders, Gerald B.↗

NASA NTRS2021

Peru Health & Air Quality: Land Use Change in the Rapidly Developing Peruvian Amazon and Implications on Zoonotic Disease Incidence

In the Madre de Dios region of the Peruvian Amazon, forests are being cleared for mining, timber harvesting, road construction, and hydroelectric dam development. These rapid land use changes are increasing human presence in previously sparsely populated areas, disrupting ecosystems and increasing the proximity of human settlement to zoonotic disease vectors. Dengue fever and leishmaniasis are two neglected tropical diseases which are prevalent in Madre de Dios and have been associated with urbanization and road construction. In partnership with the Peruvian Ministries of Health (MINSA) and the Environment (MINAM) and other in-country collaborators, our team examined Land Use Land Cover (LULC) correlations with reported dengue and leishmaniasis incidence in the Madre de Dios region to help partners understand the spatial relationship between land use change and zoonotic disease incidence. We created a LULC classification script using Google Earth Engine with Landsat 5 Thematic Mapper and Landsat 8 Operational Land Imager imagery to classify land cover in 2010, 2015, and 2020 and evaluate changes over this time period. We then used the quantified results of the LULC assessment in conjunction with reported disease cases to evaluate correlations between disease incidence and key land cover changes across Madre de Dios’s 11 districts. In the second term, the team will use these products to develop more detailed disease incidence risk maps and models. High risk areas will then be classified, using PeruSat-1 that allow for even higher resolution mapping at less than 3 meters. These products will allow the partners to understand hotspots of land cover change in Peru and the relationship with outbreaks to inform public health decision making and environmental policy.

Elizabeth Stapleton↗

NASA NTRS1998

Requirements for Planetary Outpost Life-Support Systems and the Possible Use of In Situ Resources

If humans are ever to live and work on the Moon or Mars for extended periods of time, the operation of regenerative life-support systems at the planetary outposts will be a critical requirement. The substantial amount of materials consumed by humans and the inevitable waste products make open-loop life-support systems and resupply missions (as used in Space Shuttle and Mir operations) impractical and expensive. Natural resources found on the Moon and Mars could be used in conjunction with regenerative life support systems to further reduce the amount of material that would need to be delivered from Earth. There have been numerous studies and experiments conducted on the production of O from regolith materials on the Moon and from the atmosphere of Mars. One or several of these processes could undoubtedly be used to produce the O required by the crews at planetary outposts. Water is required in the greatest quantities, primarily for tasks such as personal hygiene and clothes washing, and it will be the most precious consumable. Again, several process have been described to produce water on the Moon using solar-wind implanted H and O, and if water ice can be found and mined at the lunar poles, another source of water may be available.

Gruener, John E.↗

NASA NTRS2013

Determining Component Probability using Problem Report Data for Ground Systems used in Manned Space Flight

During the shuttle era NASA utilized a failure reporting system called the Problem Reporting and Corrective Action (PRACA) it purpose was to identify and track system non-conformance. The PRACA system over the years evolved from a relatively nominal way to identify system problems to a very complex tracking and report generating data base. The PRACA system became the primary method to categorize any and all anomalies from corrosion to catastrophic failure. The systems documented in the PRACA system range from flight hardware to ground or facility support equipment. While the PRACA system is complex, it does possess all the failure modes, times of occurrence, length of system delay, parts repaired or replaced, and corrective action performed. The difficulty is mining the data then to utilize that data in order to estimate component, Line Replaceable Unit (LRU), and system reliability analysis metrics. In this paper, we identify a methodology to categorize qualitative data from the ground system PRACA data base for common ground or facility support equipment. Then utilizing a heuristic developed for review of the PRACA data determine what reports identify a credible failure. These data are the used to determine inter-arrival times to perform an estimation of a metric for repairable component-or LRU reliability. This analysis is used to determine failure modes of the equipment, determine the probability of the component failure mode, and support various quantitative differing techniques for performing repairable system analysis. The result is that an effective and concise estimate of components used in manned space flight operations. The advantage is the components or LRU's are evaluated in the same environment and condition that occurs during the launch process.

Monaghan, Mark W.↗

DOE OSTI2025

System Engineers and Decisions: It?s All about Knowledge

In order to guarantee that a system meets adequate levels of reliability and availability, system performances are continuously monitored and analyzed thanks to the technological advancements driving the Industry 4.0 revolution. An Industry 4.0 approach is typically based on advanced statistical, big data mining, machine learning, and internet-of-things methods designed to detect anomalies in the behavior of system, detect the most likely failure modes, and provide indications to system engineers on when maintenance activities should be performed before system performance are deemed unacceptable (which can be generated by diagnostic and prognostic methods). However, these analyses, which are designed to automatize and increase the efficacy of the system maintenance program, require large amount of data which can come in various forms: numeric, textual, images, sounds etc. Such data constitutes the historic knowledge benchmark to track system performances and support system engineer decisions. Here we claim that data is not sufficient to support this kind of analyses when applied to systems characterized by complex architectures and behaviors. Robust system engineer decisions require the ability to understand the system operational context that lies behind the observed data elements. In this respect, system models are in fact necessary to “put data in context” and capture relationships between data elements. Industry 4.0 methods require in fact contextual knowledge as a basis upon which hypotheses can be generated and assumptions tested. In our view, for complex systems, model-based system engineering (MBSE) models can afford this contextual knowledge, as they are typically used to describe systems architecture and dynamic behaviors. System knowledge is here intended as the blending of collected data and system architecture which takes the form of a “knowledge graph”. A knowledge graph is a database which consists of a large set of nodes (in our case an entity can be either a data or an MBSE element) which are linked to each other. The types of nodes and links follow a pre-defined topology, sometimes also refers as an ontology, that is designed to fit the actual decisions that needs to be performed. We show here how a knowledge graph can be defined to support system engineer maintenance decisions and how the same graph can be built based on system MBSE models and pre-processed data from numeric (through anomaly detections and diagnostic methods) and textual elements (through technical language processing TLP).

97 - MATHEMATICS AND COMPUTING↗

DOE OSTI2026

Solar Heat for Industrial Processes: Integration with Chemical Reactors

The integration of solar thermal systems with chemical reactors has been proposed as part of a larger effort to develop and deploy solar heat for industrial processes (SHIP) technologies. A strong motivation for SHIP processes and technologies is the potential for high thermal efficiency coupled with low-cost thermal energy storage (TES) which can enable commercial deployment of such systems. While there are different ways to categorize SHIP technologies, one important such distinction is between directly irradiated systems and indirect off-sun process driven by a SHIP system. While directly irradiated systems can provide high thermal efficiencies and high fluxes, they usually require complex engineering solutions due to the need for redesigning the established processes and unit operations. In most cases, it is also more challenging to couple such a process to a TES system, losing some of the benefits of SHIP. On the other hand, using a SHIP system to drive an industrial process off-sun can allow better integration with existing process chains, easier TES capabilities, and potential for more applications fitting a specific SHIP technology. However, the integration of SHIP systems with the industrial processes is not fully explored in detail, especially in the case of high-temperature processes such as reforming, cracking, cement manufacturing, and iron/steelmaking. Many of these systems require heating fluxes of >50 kW/m^2, supplied via combustion of hydrocarbons in a fire box and benefitting from radiative heat transfer between the flue gases and the reaction zones. As such, using SHIP systems for such processes is more complex than providing the same thermal input in the form of a heat transfer medium (HTM) entering the reactor, kiln, or furnace. Moreover, in case convective heat transfer using SHIP is envisioned, for example using supercritical CO2 as the HTM from a particle receiver, the thermal integration might be more challenging than initially envisioned: lower heat transfer coefficients and limited approach temperature might require large flow rates, causing a mismatch between the process thermal requirements and the thermal capacity of the SHIP system. In addition, even if the heat exchange between SHIP and reactor is effective, there is still a cold leg HTM at the reaction temperature or slightly below it. Chemical plants usually include a set of heat exchangers, heat recovery steam generators, and even power generation units - in a tightly integrated design - to recover the flue gases which are eventually vented. With SHIP systems mostly operating on a closed HTM loop, bottoming the cold leg is crucial. In this talk, we will present different modeling results for a variety of syngas production reactions, using catalytic and chemical looping processes, and discuss some of the challenges and design considerations for off-sun chemical reactors using SHIP systems.

14 SOLAR ENERGY↗

DOE OSTI2026

Durable Thin‐Film Porous Transport Electrodes for High Current Density PEM Water Electrolysis

Proton exchange membrane water electrolyzers rely on relatively expensive Ir-based catalysts for efficient and durable hydrogen production. To reduce system costs, Ir loadings can be reduced if performance and durability are maintained. Sputter deposition is a readily scalable method to synthesize uniform, low-loading catalyst layers with controlled composition. A catalyst applied directly to the porous transport layer can have advantages for performance, manufacturing simplicity, and catalyst recovery. Suitable porous transport layer porosity can minimize activity losses when reducing loadings. Here, methods are presented to deposit metallic Ir as well as amorphous and rutile Ir oxides. The activity and durability of these materials in the porous transport electrode architecture is evaluated. The metallic and amorphous forms have better initial activity, however, operation at 3 A cm −2 with 0.1 mg Ir cm −2 shows that only rutile IrO 2 maintains performance beyond 100 h with a 50 mV improvement after 700 h. A >10x reduced dissolution rate is shown for rutile IrO 2 . With a low-porosity transport layer and 0.4 mg Ir cm −2 , a steady-state voltage decay rate of 6 µV h −1 is achieved. The results demonstrate that sputter-deposited rutile IrO 2 porous transport electrodes with low Ir loading can be operated at high current density to reduce hydrogen production costs.

08 HYDROGEN↗