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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 631 records · Page 35
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Operation and Optimization of Microwave-Heated Continuous-Flow Microfluidics

Microwave (MW) technology can be powerful for electrification and process intensification but limited fundamental understanding of scalability and design principles hinders its effective use. In this work, we build a continuous-flow microreactor inside a commercial single-mode MW applicator and the corresponding computational fluid dynamics model to simulate the temperature profile. The model is in good agreement with experiments for various microreactor dimensions and operating conditions. The model indicates that MW heating is greatly influenced by reactor geometry as well as the operating parameters. We observe a strong correlation between parameters and develop a gradient boost regression tree model to predict the outlet temperature accurately. This model is then applied to optimize the dimensions and operating conditions to maximize the outlet temperature and energy efficiency, resulting in a Pareto optimal. We demonstrate computationally and experimentally that it is possible to surpass the Pareto optimal and achieve an energy efficiency of ~90% or greater at temperatures relevant for liquid-phase chemistry via salting of the solvent. The present methodology can be applied to other complex MW reactors. Lastly, the combined numerical and experimental approach provides insights into and a framework for scale-up and optimization.

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

Continuous-Flow Centrifugal Solid/Liquid Separation for the Recovery of Rare-Earth Elements Containing Particles from Phosphoric Acid Sludge

Phosphoric acid sludge contains acid (~54% P 2 O 5 ) and solid precipitates including rare earth elements (REEs) at concentrations of ~2200 ppm. Low-cost recovery of valuable P 2 O 5 and simultaneous solid separation could be an economically feasible approach to recovering REEs while increasing the production of phosphoric acid. The sludge, however, is a complicated stream that cannot be separated by traditional technologies because of high viscosity and a large solid content (30–40%). Guided by a force balance model, an efficient solid/liquid separation method is demonstrated, using a continuous-flow centrifugal contactor. Additionally, the shear regime is bypassed by introducing the sludge directly into the rotor where a centrifugal force is exerted on the fluid, inducing phase separation. Solid particles are trapped in the contactor. High liquid recovery is demonstrated and the effects of process parameters on solid capture are investigated. Three contactors in series yield 94% recovery of solids containing 1500–2895 ppm of REEs.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Continuous Evolution of Eu 2+ /Eu 3+ Mixed Valency Driven by Pressure and Temperature

Continuous mixed valency involving Eu 2+ and Eu 3+ in Eu 4 Bi 6 Se 13 can be induced under applied pressure or at reduced temperatures. The monoclinic structure of Eu 4 Bi 6 Se 13 , crystallizing in the P2 1 /m space group (No. 11), features linear chains of Eu atoms aligned along the b-axis. Magnetic susceptibility measurements, conducted both parallel and perpendicular to the b-axis and analyzed using Curie–Weiss theory, alongside high-pressure partial fluorescence yield (PFY) data from X-ray absorption spectroscopy (XAS), indicate the material’s propensity to adopt a mixed-valent state. Within this state, the trivalent Eu 3+ configuration becomes increasingly favored as the pressure rises or the temperature decreases.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Throughput Optimization of Molybdenum Carbide Nanoparticle Catalysts in a Continuous Flow Reactor Using Design of Experiments

Transition metal carbides (TMCs) have attracted significant attention because of their applications toward a wide range of catalytic transformations. However, the practicality of their synthesis is still limited because of the harsh conditions in which most TMCs are prepared. Recently, a solution-phase synthesis of phase-pure a-MoC1-x nanoparticles was presented. While this synthetic route yielded nanoparticles with exceptional catalytic performance, the reaction parameter space was not explored, and catalyst throughput was not optimized for scale-up. Continuous flow platforms coupled with statistical design of experiments (DoE) can provide a powerful method for understanding the reaction parameter space for optimizations. Here, we demonstrate the use of statistical DoE in tandem with response surface methodology for a parametric screening analysis to optimize the throughput of a MoC1-x nanoparticle synthesis utilizing a millifluidic flow reactor. A full factorial design was implemented to evaluate four input variables (reaction temperature, flow rate, solvent fraction of oleylamine, and precursor concentration) that carry statistically significant effects on three responses (throughput, residence time, and isolated yield). A Doehlert matrix was implemented to investigate each significant variable at a higher number of levels to optimize throughput. Our results give a nonintuitive set of experimental conditions that resulted in an optimized throughput of 2.2 g h-1. This translates to a 50-fold increase in throughput compared to the previously reported batch method. The catalytic performance of the MoC1-x nanoparticles produced under optimized throughput was demonstrated in the CO2 hydrogenation reaction. This DoE screening analysis and throughput optimization of MoC1-x synthesis open the door to an increased feasibility for scale-up.

design of experiments↗
DOE OSTI2025

Manufacturing of Continuous Microporous Polymeric Fibers for Separation Applications

Polyolefin plastic waste, particularly polypropylene, is one of the most prevalent components in the plastic waste stream generated globally. However, only a small fraction of this waste is recycled and reintegrated into second applications. These materials have significant embedded energy that could be used for additional productivity if recycled properly. Therefore, there is a critical need to develop scalable processing techniques with high throughput to effectively recycle it. We report the continuous manufacturing of microporous fibers using waste polypropylene plastic and melt-processable lignin, a plant biomass constituent produced as a byproduct in paper mills or biorefineries, as a template to create pores. Further, these filaments with hierarchical porosity─created by controlled microphase separation during high-speed extensional flow followed by removal of lignin─exhibit exceptional capillary action for hydrophobic liquids. The resulting porous fibers can be used for various separation applications. For example, the oil uptake of the fibers is 9.59 ± 0.82 g/g for applications in oil recovery in bodies of water. In addition, polyethylenimine infiltration within these nanoporous fibers introduces cyclic room temperature sorption and thermal desorption potential of acidic gases such as CO 2 in a bench-scale experiment. The fibers exhibit multiple cycles of CO 2 absorption, with a range of 0.15 to 0.17 mmol/g. Thus, these polyethylenimine-infiltered nanoporous polypropylene fibers can also be used in removing acidic gases from a gas mixture.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Tracking Local pH Dynamics during Water Electrolysis via In-Line Continuous Flow Raman Spectroscopy

The performance of electrochemical devices, which play a critical role in decarbonization efforts, is often governed by proton-coupled electron transfer reactions at the electrode–electrolyte interface. These reactions are highly sensitive to the complex and dynamic microenvironment present at the electrode surface. However, characterizing this environment─particularly monitoring interfacial pH and its evolution under reaction conditions─remains challenging, necessitating the development of advanced analytical tools. Here, in this study, we introduce in-line continuous flow Raman spectroscopy (CFRS) as a spectroelectrochemical platform for quantifying interfacial pH swings generated during water-splitting. By monitoring phosphate ion speciation and controlling the hydrodynamics with a flow cell, we measure pH swings as a function of current density, flow rate, and distance from the electrode. Comparison with theoretical models reveals the impact of bulk pH, boundary layer thickness, and bubble dynamics at high current densities. Collectively, these findings establish CFRS as a platform for quantitatively investigating pH dynamics, offering critical insights for advancing electrochemical energy conversion technologies.

Marquez, Raul A. [Univ. of Texas, Austin, TX (Unit↗
DOE OSTI2025

Intercomparison of Three Continuous Monitoring Systems on Operating Oil and Gas Sites

We compare continuous monitoring systems (CMS) from three different vendors on six operating oil and gas sites in the Appalachian Basin using several months of data. We highlight similarities and differences between the three CMS solutions when deployed in the field and compare their output to concurrent top-down aerial measurements and to site-level bottom-up inventories. Furthermore, we compare vendor-provided emission rate estimates to estimates from an open-source quantification algorithm applied to the raw CMS concentration data. This experimental setup allows us to separate the effect of the sensor platform (i.e., sensor type and arrangement) from the quantification algorithm. We find that 1) localization and quantification estimates rarely agree between the three CMS solutions on short time scales (i.e., 30 min), but temporally aggregated emission rate distributions are similar between solutions, 2) differences in emission rate distributions are generally driven by the quantification algorithm, rather than the sensor platform, 3) agreement between CMS and aerial rate estimates varies by CMS solution but is close to parity when CMS estimates are averaged across solutions, and 4) similar sites with similar bottom-up inventories do not necessarily have similar emission characteristics. These results have important implications for developing measurement-informed inventories and for incorporating CMS-inferred emission characteristics into emission mitigation efforts.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Arsenic Removal by Continuous Flow-Through Iron Electrocoagulation and Downstream Steps under Environmentally Relevant Conditions

Arsenic (As) contamination in drinking water is a major health concern. This study investigated As(III) and As(V) removal by continuous flow-through iron electrocoagulation (EC) under varying iron doses and water chemistry conditions. Effective arsenic removal (>90% of 100 µg/L) was achieved with a low iron dose of 5 mg/L and a short EC reactor residence time of 11 s that was followed by flocculation and settling. Removal was primarily through adsorption of As(III) and As(V) to the EC-generated Fe(III) oxyhydroxide solids ferrihydrite and lepidocrocite. For influents containing As(III), oxidation of As(III) to As(V) also occurred. The removal processes occurred in both the EC reactor and downstream treatment. EC-generated reactive solids with high surface area and adsorption capacity provided better arsenic removal than with preformed adsorbents. The removed arsenic remained largely immobile in the EC-generated solids. The extent of arsenic removal was generally similar across pH 6 to 8. Phosphate (1 mg/L as P) inhibited the removal of both arsenic species. Dissolved silica (20 mg/L as SiO2) suppressed As(III) removal but had little effect on the amount of As(V) removed. In addition to thermodynamic effects on adsorption equilibria, pH and co-occurring phosphate and silica influenced removal rates by affecting iron oxidation, nucleation, and aggregation kinetics. The results integrate mechanistic understanding with treatment performance, providing insight relevant to both fundamental research and the application of EC in water treatment.

Arsenic, electrocoagulation, iron oxide, phosphate↗
DOE OSTI2024

Continuous Polymer Synthesis and Manufacturing of Polyurethane Elastomers Enabled by Automation

Connecting polymer synthesis and processing is an important challenge for streamlining the manufacturing of polymeric materials. In this work, the automated synthesis of acrylate-capped polyurethane oligomers is integrated with vat photopolymerization 3D printing. This strategy enabled the rapid manufacturing of a library of polyurethane-based elastomeric materials with differentiated thermal and mechanical properties. The automated semi-continuous batch synthesis approach proved enabling for resins with otherwise short shelf lives because the intimate connection between synthesis, formulation, and processing. Structure-property studies demonstrated the ability to tune properties through systematic alteration of crosslink density and chemical composition.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Continuous Wet Air Oxidation of the Hydrothermal Liquefaction Aqueous Product from Various Wet Wastes

Wet air oxidation (WAO) offers an effective method for treating waste streams, converting pollutants into benign substances, and holds significant potential for processing the aqueous product from the hydrothermal liquefaction (HTL-AP) of wet wastes, a promising renewable fuel technology. Here, we conducted a comprehensive study of the WAO of HTL-AP from four different wet wastes. Through continuous testing under various conditions, we produced samples with different chemical oxygen demand (COD) levels, enhancing understanding of reaction parameters necessary for substantial COD reduction (>95%). Chemical analysis revealed that alcohols and ketones in the HTL-AP rapidly oxidized to acetic acid through aldehyde intermediates, while acetic acid, other carboxylic acids, and phenols oxidized relatively slowly. The light N-containing compounds were found to exhibit a change in concentration only after the whole sample reaches an 80% COD reduction, indicating their refractory nature under applied conditions. Energy released in the WAO reaction was calculated, and anaerobic toxicity assay demonstrated that WAO treatment enhanced methane production kinetics due to reduced inhibitory effects, suggesting partial oxidative transformation of inhibitory compounds into less toxic derivatives. These findings provide insights into designing effective WAO processes for valorizing HTL aqueous products, addressing key barriers to HTL process commercialization.

anaerobic digestion↗
DOE OSTI2026

Continuous Directed Evolution of a Short-Lived Plant Histidinol Dehydrogenase

Enzyme protein turnover accounts for about half the maintenance energy budget in plants. Slowing turnover i.e., extending the effective working life (Catalytic Cycles till Replacement, CCR) of short-lived enzymes is thus a rational strategy to conserve energy and carbon and raise crop productivity. Arabidopsis histidinol dehydrogenase (HDH) is a short-lived enzyme that can sustain lifeshortening damage from its aminoaldehyde reaction intermediate. We used the yeast OrthoRep continuous directed evolution system in a his4 Δ strain to raise cumulative HDH function and, by proxy, lifespan as functional enzymes, by selecting for growth rate while tapering histidinol concentration and escalating that of the inhibitor histamine. Improved HDH variants carried diverse nonsynonymous mutations and ranged 20-fold in level. Improved HDH performance was associated with higher HDH abundance in some cases and with greater catalytic efficiency or histamine resistance in others. These findings indicate that OrthoRep-based directed evolution can extend enzyme working life in vivo in addition to, as expected, altering kinetic properties.

directed evolution↗
DOE OSTI2025

Examining Daily Temporal Characteristics of Oil and Gas Methane Emissions in the Delaware Basin Using Continuous Tower Observations

Top-down studies have found consistent underestimations in the United States Environmental Protection Agency (EPA) methane emissions inventory from the oil and gas (O&G) sector. Many of these studies use observations that bias toward hours when worktime activity occurs. In this study, we analyze over 2 years of methane measurements from a tower network in the Delaware basin to analyze hourly temporal emission patterns. Inversion results suggest a range in emissions from 137 Mg/hr at night to 197 Mg/hr during the day, present during both weekdays and weekends. If these results are applicable to other basins, daytime-influenced methodologies may overestimate daily emission rates by up to 27%. This bias does not reconcile the more than 200% difference between the EPA inventory and top-down estimates in the Delaware basin. This study demonstrates how continuous measurement networks can be combined with detailed activity data to improve bottom-up inventories.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

A continuous metal-insulator transition driven by spin correlations

While Mott insulators induced by Coulomb interactions are a well-recognized class of metal-insulator transitions, insulators purely driven by spin correlations are much less common, as the reduced energy scale often invites competition from other degrees of freedom. Here, we demonstrate a clean example of a spin-correlation-driven metal-insulator transition in the all-in-all-out pyrochlore antiferromagnet Cd 2 Os 2 O 7 , where the lattice symmetry is preserved by the antiferromagnetism. After the antisymmetric linear magnetoresistance from conductive, ferromagnetic domain walls is removed experimentally, the bulk Hall coefficient reveals four Fermi surfaces of both electron and hole types, sequentially departing the Fermi level with decreasing temperature below the Néel temperature, T N = 227 K. In Cd 2 Os 2 O 7 , the charge gap of a continuous metal-insulator transition opens only at T ~ 10 K << T N . The insulating mechanism parallels the Slater picture, but without a folded Brillouin zone, and contrasts sharply with Mott insulators and spin density waves, where the electronic gap opens above and at T N , respectively.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Dense, continuous membrane labeling and expansion microscopy visualization of ultrastructure in tissues

Abstract Lipid membranes are key to the nanoscale compartmentalization of biological systems, but fluorescent visualization of them in intact tissues, with nanoscale precision, is challenging to do with high labeling density. Here, we report ultrastructural membrane expansion microscopy (umExM), which combines an innovative membrane label and optimized expansion microscopy protocol, to support dense labeling of membranes in tissues for nanoscale visualization. We validate the high signal-to-background ratio, and uniformity and continuity, of umExM membrane labeling in brain slices, which supports the imaging of membranes and proteins at a resolution of ~60 nm on a confocal microscope. We demonstrate the utility of umExM for the segmentation and tracing of neuronal processes, such as axons, in mouse brain tissue. Combining umExM with optical fluctuation imaging, or iterating the expansion process, yields ~35 nm resolution imaging, pointing towards the potential for electron microscopy resolution visualization of brain membranes on ordinary light microscopes.

Science & Technology - Other Topics↗
DOE OSTI2026

Continuity of reaction kinetics across the pressure and materials gaps in CO oxidation on FeO–Pt interfaces

Translating atomic-scale insights from surface science studies of model catalysts to practical powder catalysts remains a persistent challenge in heterogeneous catalysis. Here, in this study, we demonstrate mechanistic continuity across the pressure and materials gaps during CO oxidation at the FeO-Pt interface using in situ microscopy, spectroscopy and computational modelling. Under reaction conditions, coordinatively unsaturated Fe (Fe cus ) sites at the interface enable selective O 2 activation on CO-saturated surfaces, circumventing the CO-poisoning limitation of platinum-group metals. We identify parallel reaction pathways involving the *O 2 -*CO intermediate. Remarkably, activation energies remain consistent at 12-15 kJ mol −1 (0.12-0.16 eV) from ultrahigh vacuum to atmospheric pressures and from FeO/Pt(111) model catalysts to FeO/Pt powder catalysts, validating mechanistic insights derived from surface science studies. Our findings show an example of bridging the long-standing divide between model and practical catalyst systems, establishing an effective approach to capture catalytic behaviours under operational conditions and advancing mechanism-driven catalyst design.

03 NATURAL GAS↗
DOE OSTI2022

In vivo hypermutation and continuous evolution

Directed evolution has revolutionized biomolecular engineering by applying cycles of mutation, amplification and selection to genes of interest (GOIs). However, classical directed evolution methods that rely on manually staged evolutionary cycles constrain the scale and depth of the evolutionary search that is possible. Here we describe genetic systems that achieve cycles of rapid mutation, amplification and selection fully inside living cells, enabling the continuous evolution of GOIs as cells grow. These systems advance the scale, evolutionary search depth, ease and overall power of directed evolution and access important new areas of protein evolution and engineering.

59 BASIC BIOLOGICAL SCIENCES↗