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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Roadmap for Optical Metasurfaces

Metasurfaces have recently risen to prominence in optical research, providing unique functionalities that can be used for imaging, beam forming, holography, polarimetry, and many more, while keeping device dimensions small. Despite the fact that a vast range of basic metasurface designs has already been thoroughly studied in the literature, the number of metasurface-related papers is still growing at a rapid pace, as metasurface research is now spreading to adjacent fields, including computational imaging, augmented and virtual reality, automotive, display, biosensing, nonlinear, quantum and topological optics, optical computing, and more. At the same time, the ability of metasurfaces to perform optical functions in much more compact optical systems has triggered strong and constantly growing interest from various industries that greatly benefit from the availability of miniaturized, highly functional, and efficient optical components that can be integrated in optoelectronic systems at low cost. This creates a truly unique opportunity for the field of metasurfaces to make both a scientific and an industrial impact. Furthermore, the goal of this Roadmap is to mark this “golden age” of metasurface research and define future directions to encourage scientists and engineers to drive research and development in the field of metasurfaces toward both scientific excellence and broad industrial adoption.

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

Opportunities for Using the Industrial Assessment Center Database for Industrial Water Use Analysis

The manufacturing sector accounted for approximately 5–6% of total U.S. water use in 2015. Of that amount, 75–80% is self supplied withdrawal from surface-water and groundwater sources and the remainder is from public water supplies. Although manufacturing facilities commonly locate in water-scarce areas, water scarcity still poses a great risk to the manufacturing sector. Reliable water is necessary for any facility that relies on it for process and comfort cooling, cleaning, employee use, and steam generation. One of these barriers to water efficiency is the lack of reliable data on overall U.S. industrial water use—how it is used and the quantities required for each sector. If a facility cannot be easily compared with a facility of similar size and sector, knowing if it is effectively using water conservation best practices is difficult. One potential source of industrial water use data is the U.S. Department of Energy (DOE)–sponsored Industrial Assessment Centers (IACs). IACs are university-based organizations that provide free audits to small- and medium-sized manufacturing facilities to identify productivity improvement and waste and energy reduction opportunities. The IACs also maintain a database of all the audits conducted, which currently holds more than 19,267 assessments and 145,000 recommendations (as of July 24, 2020). This database also contains energy utility (electricity, natural gas, and other fuels) and water utility data, making it a potential data source for industrial water use. This report attempts to create regression models to predict a small- or medium-sized industrial facility’s annual water use or cost based on its industrial subsector and several possible relevant variables. Using data collected by IAC assessments, models for several industrial subsectors were generated via stepwise regression techniques to determine which variables (annual sales, number of employees, facility/plant area, annual production hours, and a water stress metric) are relevant.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Aerotaxy: gas-phase epitaxy of quasi 1D nanostructures

Cost- and resource-efficient growth is necessary for many applications of semiconductor nanowires. We here present the design, operational details and theory behind Aerotaxy, a scalable alternative technology for producing quality crystalline nanowires at a remarkably high growth rate and throughput. Using size-controlled Au seed particles and organometallic precursors, Aerotaxy can produce nanowires with perfect crystallinity and controllable dimensions, and the method is suitable to meet industrial production requirements. Here, we explain why Aerotaxy is an efficient method for fabricating semiconductor nanowires and explain the technical aspects of our custom-built Aerotaxy system. Investigations using SEM (Scanning Electron Microscope), TEM (Transmission Electron Microscope)and other characterization methods are used to support the claim that Aerotaxy is indeed a scalable method capable of producing nanowires with reproducible properties. We have investigated both binary and ternary III–V semiconductor material systems like GaAs and GaAsP. In addition, common aspects of Aerotaxy nanowires deduced from experimental observations are used to validate the Aerotaxy growth model, based on a computational flow dynamics (CFD) approach. We compare the experimental results with the model behaviour to better understand Aerotaxy growth.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2023

Enhancement of operational Flexibility of Power Plants Using IN740

Headers are crucial components within diverse industries, especially in the energy sector, as they enable the efficient transfer of fluids. The selection of materials for headers is determined by their specific applications; for example, Grade 91 and Grade 92 steels are commonly utilized. In our research, we recommend the adoption of INCONEL alloy 740 due to its exceptional robustness and heat-resistant characteristics. One critical parameter in header systems is the heat transfer coefficient, which directly influences the efficiency of heat exchange processes and can thereby impact the structural integrity of the headers. This coefficient is closely linked with factors such as the Nusselt number, which is influenced by fluid flow characteristics and thermal properties. The flow direction within headers, whether unidirectional or multidirectional—significantly affects the overall dynamics of heat transfer. This research focuses on exploring the behavior of headers, a specific pipeline system component, using ANSYS simulation software. The study aims to predict heat transfer and mechanical behavior within headers under various conditions through steady-state and transient simulations (parts 1 and 2 of the report). Key parameters such as heat transfer coefficient, velocity, and temperature are examined with the goal of optimizing header design. Part 3 of the report addresses the critical yet underexplored relationship between pressure drop and heat transfer coefficients in the transient flow regime within headers, specifically focusing on smooth horizontal circular tubes. Limited experimental work has been conducted in this area, prompting the need for comprehensive analysis. By leveraging machine learning techniques, this research aims to establish a correlation between pressure drop and heat transfer across various flow conditions, including laminar, transient, quasi-turbulent, and turbulent regimes. The data utilized for this analysis were meticulously gathered from existing literature, capturing simultaneous measurements of pressure drops and heat transfer. Part 4: In the context of power plants, header pipes are essential components that significantly influence system performance by facilitating the collection and distribution of steam. This report highlights the critical role of header pipes in enhancing reliability, efficiency, and overall power plant performance. A key aspect of this investigation is shape optimization, which aims to maximize performance while minimizing material usage. By focusing on shape optimization, this research contributes to improved efficiency and a reduced environmental footprint for power plant installations. The methodology developed in this study emphasizes optimizing header shapes to decrease reliance on expensive alloy materials and lower maintenance costs. Furthermore, a case study was conducted using a header from an operational power plant to validate the proposed optimization techniques. Finally, part 5 addresses the challenges associated with flexible operations in boiler systems, the study outlines several strategies for enhancing the durability and reliability of steam headers. Key approaches include material selection, which involves utilizing advanced materials with superior high-temperature properties and enhanced fatigue resistance to extend the lifespan of steam headers. Design modifications are also recommended, focusing on implementing changes that mitigate thermal stress and cyclic loading to reduce the likelihood of failures under varying operating conditions. Additionally, the study emphasizes the importance of regular inspection and monitoring by establishing rigorous protocols to detect early signs of damage, allowing for timely maintenance and minimizing the risks of catastrophic failures. Furthermore, operational guidelines are developed to minimize the frequency and severity of thermal transients, ensuring stable and efficient operations. Collectively, these strategies provide a robust framework for overcoming the unique challenges posed by flexible operation in boiler systems, ultimately contributing to improved reliability and performance in power plant operations. Through this comprehensive approach, the study not only enhances the understanding of pressure drop and heat transfer relationships but also promotes advancements in design and operation that will benefit the entire power generation industry.

01 COAL, LIGNITE, AND PEAT↗
NASA NTRS2007

Toward a III-V Multijunction Space Cell Technology on Si

High efficiency compound semiconductor solar cells grown on Si substrates are of growing interest in the photovoltaics community for both terrestrial and space applications. As a potential substrate for III-V compound photovoltaics, Si has many advantages over traditional Ge and GaAs substrates that include higher thermal conductivity, lower weight, lower material costs, and the potential to leverage the extensive manufacturing base of the Si industry. Such a technology that would retain high solar conversion efficiency at reduced weight and cost would result in space solar cells that simultaneously possess high specific power (W/kg) and high power density (W/m2). For terrestrial solar cells this would result in high efficiency III-V concentrators with improved thermal conductivity, reduced cost, and via the use of SiGe graded interlayers as active component layers the possibility of integrating low bandgap sub-cells that could provide for extremely high conversion efficiency.1 In addition to photovoltaics, there has been an historical interest in III-V/Si integration to provide optical interconnects in Si electronics, which has become of even greater relevance recently due to impending bottlenecks in CMOS based circuitry. As a result, numerous strategies to integrate GaAs with Si have been explored with the primary issue being the approx.4% lattice mismatch between GaAs and Si. Among these efforts, relaxed, compositionally-graded SiGe buffer layers where the substrate lattice constant is effectively tuned from Si to that of Ge so that a close lattice match to subsequent GaAs overlayers have shown great promise. With this approach, threading dislocation densities (TDDs) of approx.1 x 10(exp 6)/sq cm have been uniformly achieved in relaxed Ge layers on Si,5 leading to GaAs on Si with minority carrier lifetimes greater than 10 ns,6 GaAs single junction solar cells on Si with efficiencies greater than 18%,7 InGaAs CW laser diodes on Si,8 and room temperature GaInP red laser diodes on Si.9 Here we report on the first high performance dual junction GaInP/GaAs solar cells grown on Si using this promising SiGe engineered substrate approach.

Ringel, S. A.↗
DOE OSTI2022

Influence of Superlattice Structure on V-Defect Distribution, External Quantum Efficiency and Electroluminescence for Red InGaN Based µLEDs on Silicon

Achieving high quantum efficiency in long-wavelength LEDs has posed a significant challenge to the solid-state lighting and display industries. In this article, we use V-defect engineering as a technique to achieve higher efficiencies in red InGaN LEDs on (111) Si through lateral injection. We investigate the effects of superlattice structure on the V-defect distribution, the electroluminescence properties, and the external quantum efficiency. Increasing the relative thickness of In in the InGaN/GaN superlattice and the total superlattice thickness correlate with a reduction of active region defects and increased external quantum efficiencies. The highest measured on-chip EQE was 0.15% and based on Monte-Carlo ray tracing simulations for light extraction we project this would correspond to a flip-chip EQE of ~2.5%.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Corynebacterium glutamicum as an Efficient Omnivorous Microbial Host for the Bioconversion of Lignocellulosic Biomass

Corynebacterium glutamicum has been successfully employed for the industrial production of amino acids and other bioproducts, partially due to its native ability to utilize a wide range of carbon substrates. We demonstrated C. glutamicum as an efficient microbial host for utilizing diverse carbon substrates present in biomass hydrolysates, such as glucose, arabinose, and xylose, in addition to its natural ability to assimilate lignin-derived aromatics. As a case study to demonstrate its bioproduction capabilities, L-lactate was chosen as the primary fermentation end product along with acetate and succinate. C. glutamicum was found to grow well in different aromatics (benzoic acid, cinnamic acid, vanillic acid, and p-coumaric acid) up to a concentration of 40 mM. Besides, 13 C-fingerprinting confirmed that carbon from aromatics enter the primary metabolism via TCA cycle confirming the presence of β-ketoadipate pathway in C. glutamicum . 13 C-fingerprinting in the presence of both glucose and aromatics also revealed coumarate to be the most preferred aromatic by C. glutamicum contributing 74 and 59% of its carbon for the synthesis of glutamate and aspartate respectively. 13 C-fingerprinting also confirmed the activity of ortho-cleavage pathway, anaplerotic pathway, and cataplerotic pathways. Finally, the engineered C. glutamicum strain grew well in biomass hydrolysate containing pentose and hexose sugars and produced L-lactate at a concentration of 47.9 g/L and a yield of 0.639 g/g from sugars with simultaneous utilization of aromatics. Succinate and acetate co-products were produced at concentrations of 8.9 g/L and 3.2 g/L, respectively. Our findings open the door to valorize all the major carbon components of biomass hydrolysate by using C. glutamicum as a microbial host for biomanufacturing.

13C-fingerprinting↗
DOE OSTI2022

Dilute Alloys Based on Au, Ag, or Cu for Efficient Catalysis: From Synthesis to Active Sites

The development of new catalyst materials for energy-efficient chemical synthesis is critical as over 80% of industrial processes rely on catalysts, with many of the most energy-intensive processes specifically using heterogeneous catalysis. Catalytic performance is a complex interplay of phenomena involving temperature, pressure, gas composition, surface composition and structure over multiple length and time scales. In response to this complexity, the integrated approach to heterogeneous dilute-alloy catalysis reviewed here brings together materials synthesis, mechanistic surface chemistry, reaction kinetics, in-situ and operando characterization, and theoretical calculations in a coordinated effort to develop design principles to predict and improve catalytic selectivity. Dilute alloy catalysts—in which isolated atoms or small ensembles of the minority metal on the host metal lead to enhanced reactivity while retaining selectivity—are particularly promising as selective catalysts. Several dilute alloy materials using Au, Ag and Cu as the majority host element, including more recently introduced support-free nanoporous metals and oxide-supported nanoparticle "raspberry colloid templated (RCT)" materials, are reviewed for selective oxidation and hydrogenation reactions. Progress in understanding how such dilute alloy catalysts can be used to enhance selectivity of key synthetic reactions is reviewed, including quantitative scaling from model studies to catalytic conditions. The dynamic evolution of catalyst structure and composition studied in surface science and catalytic conditions and their relationship to catalytic function are also discussed, followed by advanced characterization and theoretical modeling that have been developed to determine the distribution of minority metal atoms at or near the surface. Furthermore, the integrated approach demonstrates the success of bridging the divide between fundamental knowledge and design of catalytic processes in complex catalytic systems, which can accelerate the development of new and efficient catalytic processes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

An integrated data management and informatics framework for continuous drug product manufacturing processes: A case study on two pilot plants

The pharmaceutical industry continuously looks for ways to improve its development and manufacturing efficiency. In recent years, such efforts have been driven by the transition from batch to continuous manufacturing and digitalization in process development. To facilitate this transition, integrated data management and informatics tools need to be developed and implemented within the framework of Industry 4.0 technology. Here, in this regard, the work aims to guide the data integration development of continuous pharmaceutical manufacturing processes under the Industry 4.0 framework, improving digital maturity and enabling the development of digital twins. This paper demonstrates two instances where a data integration framework has been successfully employed in academic continuous pharmaceutical manufacturing pilot plants. Details of the integration structure and information flows are comprehensively showcased. Approaches to mitigate concerns in incorporating complex data streams, including integrating multiple process analytical technology tools and legacy equipment, connecting cloud data and simulation models, and safeguarding cyber-physical security, are discussed. Critical challenges and opportunities for practical considerations are highlighted.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2021

Energy, Exergy, and Emission Analysis on Industrial Air Compressors

Abstract Air compressors, a key fluid power technology, play an essential role in industrial plants and office buildings, hospitals, and other types of facilities. The efficient use of the air compressor is crucial. By controlling unnecessary inefficiencies, high energy consumption can be reduced. This study aims to provide energy and exergy analysis on air compressors for different industries. Detailed case studies were also analyzed. The case study focuses on the energy and exergy analyses of the compressed air system of foundry industries. The results indicate that applying the six improvement recommendations yields significant amounts of energy and cost savings and significant improvements in the system's overall performance. The payback periods for different recommendations are economically feasible and worthwhile to use. The suggested improvement methods can provide cost savings with a low payback period.

Energy & Fuels↗
DOE OSTI2020

Herbaceous Feedstock 2020 (State of Technology Report)

The Energy Independence and Security Act (EISA) of 2007 required a minimum supply of 36 million gallons of renewable fuels per year by 2022. In order to achieve these goals, the Bioenergy Technologies Office (BETO) has set cost and technology targets for producing advanced and cellulosic biofuels. One of the targets is to validate feedstock supply infrastructures and systems with 90% overall operating effectiveness and field-to-reactor throat delivered cost less than $85.51/dry ton (2016). As stated by the 2017 Multi-Year Program Plan (DOE 2017), the research and development focus of the Feedstock Technologies (FT) platform is reducing the cost, improving the supply chain logistic efficiency, improving biomass quality, and increasing the supply volume. In addition, BETO oversees annual State of Technology (SOT) report that assesses current technologies that are relevant to BETO’s targets based on actual data and experimental results. Feedstocks are essential to achieving BETO goals because the cost, quality, and quantity of feedstock available and accessible at any given time limit the maximum volume of biofuels that can be produced. In accordance with the 2016 Multi-Year Program Plan (DOE 2016a), FT focuses on (1) reducing the delivered cost of sustainably produced biomass, (2) preserving and improving the physical and chemical quality parameters of harvested biomass to meet the individual needs of biorefineries and other biomass users, and (3) expanding the quantity of feedstock materials accessible to the bioenergy industry. This is done by identifying, developing, demonstrating, and validating efficient and economical integrated systems for harvest and collection, storage, handling, transport, and preprocessing raw biomass from a variety of crops to reliably deliver the required supplies of high-quality, affordable feedstocks to biorefineries as the industry expands. The elements of cost, quality, and quantity are key considerations when developing advanced feedstock supply concepts and systems (DOE 2016a).

09 BIOMASS FUELS↗
DOE OSTI2021

A Scalable Process for Upcycling Carbon Dioxide (CO 2 ) and Coal Combustion Residues into Construction Products

Anthropogenic sources of carbon dioxide are generated from a number of sources, but the key among these are ordinary Portland cement (OPC) production and combustion of fossil fuels. Cement production is the largest global CO 2 source from the mineral decomposition of carbonates. Combination of the limestone decomposition and thermal requirements of the clinkering process causes cement production to contribute 8-9% of annual global CO 2 emissions. Combustion of fossil fuels (coal, oil and gas) was shown to contribute a much larger portion of global CO 2 emissions. As of 2018, combustion of fossil fuels accounted for 65% of global CO 2 , where 41% was derived from stationary sources for electricity and heat generation and the other 24% was related to transport. To reduce these contributions, key steps forward in CO 2 utilization technologies are required. The purpose of this project is to demonstrate the feasibility of the Reversa process evolving from a TRL-3 technology at the bench-scale up to TRL-6 technology at the pilot-scale. The reliability of the Reversa technology was tested to prove the effective production of concrete masonry units (CMUs) at bench scale, where the units exceeded the required 13.8 MPa compressive strength requirements. The overall goal of this project was to accelerate the development of a CO 2 mineralization process that synergistically utilizes CO 2 in flue gas and coal combustion residues (CCRs) to synthesize carbonated concrete, a functional replacement for traditional concrete. The culmination of this work resulted in 12 successful production runs at the Integrated Test Center (ITC), Gillette, WY using coal flue gas as a CO 2 source. This was followed by 6 production runs which were completed at the National Carbon Capture Center (NCCC), Wilsonville, AL, using coal-fired and natural gas (NG) flue gas as the CO 2 source. Over the course of the production runs at NCCC and ITC, the CO 2 utilization as a function of time, 24-h CO 2 uptake, electricity usage, and 28-d net area compressive strength recorded for each run. The ITC and NCCC demonstrations achieved an average of 0.19 and 0.1 g CO 2 /g reactant, respectively. Both demonstrations exceeded the project’s target goals of uptake > 0.05 g CO 2 /g reactant. Average compressive strength of the ITC blocks was 18.24 MPa at 28-days. This exceeded the target strength of 13.8 MPa specified by ASTM C90. ITC and NCCC produced an average CO 2 utilization efficiency of 74.9 and 57.9%, respectively. Both demonstration averages were within the target range of 50 to 90% utilization efficiency. For some production runs the NCCC demo did exceeded the a CO 2 utilization efficiency of 75%. An LCA of the Reversa process compared to an industry standard product revealed a net CO 2 reduction of 39% to 42%. This exceeded the target requirement of >25% net CO 2 reduction. Collection of this data was used to determine that the project was successful as the demonstration goals were achieved: (1) achieving in excess of 75% CO 2 utilization efficiency, (2) utilizing greater than 250 kg of CO 2 per production batch/run, and (3) ensuring compliance of carbonated blocks with industry standard specifications (ASTM C90).

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

Integrating Commercial Ready Autonomous Robotic Platforms to Enhance Worker Safety and Efficiency - 20053

This paper will explore the challenges and triumphs of implementing advanced robotic systems and the supporting technology for the waste management industry. Deployment-ready solutions for autonomous robotic platforms are new to the radioactive waste management industry and have been slow to implement across the complex. Specifically, it will explore Hanford Tank Operations Contractor's implementation of ground-based autonomous robotic platforms to enhance workforce safety and efficiency. The first objective of the project is to demonstrate safe operation of autonomous instrumented robots, followed by a scaling up of capabilities for the platform to meet any additional requests of internal stakeholders. Autonomous robotics platforms offer a fantastic range of capabilities that will aid in decreasing long-term liability of radioactive waste management industry by enhancing clean-up efforts and worker safety. Over the past five years, deployment-ready solutions for autonomous robotic platforms have come a long way. Autonomous robotic platforms are increasingly available to purchase from many vendors, often for prices under $100,000. Additionally, the vendors who produce these products are efficient in accommodating customized solutions to unique challenges, such as those often found in the radioactive waste management industry. However, the newness of this technology to the radioactive waste management industry and has resulted in a slow implementation across the complex. This paper will explore the challenges and triumphs of implementing advanced robotic systems and supporting technology for the waste management industry. Specifically, it will explore Hanford Tank Operations Contractor's implementation of ground based autonomous robotic platforms to enhance workforce safety and efficiency. While the company has utilized robots in many parts of the tank farms mission, this was first attempted in the deployment of an autonomous platform that required no operator with only minor maintenance and created challenges not yet encountered. These challenges included stakeholder buy-in, operational safety, procurement uncertainties, adaption of 'off the shelf products, overcoming the 'Fukushima complexity' perception, security concerns, and the initial criteria down select. Hanford Tank Operations Contractor's management identified the need for a workforce protecting low cost robotics solution in the fall of 2017. The project scope generated was part of the response to the Tank Vapor Assessment Team recommendation to enhance the safety of the workforce by utilizing new technology. Since the projects inception, it has been incorporated into the Tank Stewardship Plan. This project was unique to Hanford Tank Operations Contractor, as the company does not frequently incorporate advanced technology for field deployment quickly. The project was also progressive to the Hanford Tank Operations Contractor as it functions as a partnership project with a local university. The first objective of the project is to demonstrate safe operations of autonomous instrumented robotics, monitoring and collecting data, and the wireless transmission of data to a central computing system. Following the completion of this first objective, the project will scale up capabilities of the platform to meet the requests of additional internal stakeholders throughout the tank farms - including completion of specific in-field tasks. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Electrochemically Engineered, Highly Energy-Efficient Conversion of Ethane to Ethylene and Hydrogen below 550 °C in a Protonic Ceramic Electrochemical Cell

Ethylene is one of the largest building blocks in the petrochemical industry, mainly produced by steam cracking of ethane derived from naphtha or shale gas at high temperatures (>800 °C). Despite its technical maturity and economic competitiveness, the thermal steam cracking of ethane is highly energy-intensive. In this work, an electrochemically engineered direct conversion process of ethane to produce hydrogen and ethylene using a planar protonic ceramic membrane reactor with a bi-functional three-dimensional catalytic electrode is reported, with a single-pass ethane conversion of 40% and ethylene yield of 26.7% at 550 °C. Compared with the industrial ethane steam cracking, this method saves process energy input by 45.1% and improves process energy efficiency by 50.6%, based on comprehensive process simulation using Aspen Plus software. Further, steam electrolysis treatment under the solid oxide electrolysis cell mode can regenerate the system’s catalytic performance and significantly alleviate catalytic degradation by 74%, demonstrating high techno-economic viability.

bi-functional electrode↗
DOE OSTI2022

Thermal Process Intensification: Transforming the Way Industry Uses Thermal Process Energy (Workshop Report)

The US Department of Energy’s (DOE’s) Advanced Manufacturing Office held the virtual workshop entitled “Thermal Process Intensification: Transforming the Way Industry Uses Thermal Process Energy” in November and December 2020. The workshop brought together participants from universities/laboratories, industries, equipment manufacturers, technology vendors, nongovernmental organizations, and subject-matter experts to discuss transformative technologies and strategies to substantially improve the performance (e.g., energy productivity, thermal efficiency, reduced greenhouse gas [GHG] emissions, reduced number of process steps) of thermal processing systems in the industrial sector. The US industrial sector accounts for 32% of the nation’s primary energy use (including feedstocks), and refining, chemicals, pulp and paper, iron and steel, and food products represent the top energy-consuming sectors. Thermal processing or process heating represents the largest energy use category; it accounts for 63% of all energy use in manufacturing. Additionally, thermal processing is the largest contributor of carbon dioxide (CO2) generation, resulting from combustion of fuels and process related chemical reactions, such as in the case of cement and lime production. The challenge of achieving net-zero industrial GHG emissions is colossal considering the established industrial base that depends mainly on carbon-based processes and energy sources; the time frame and cost to replace carbon-based energy sources and feedstocks; and the long-term outlook for development with large-scale adaptation of alternative non carbon–based technologies. The goals of the DOE Advanced Manufacturing Office Thermal Process Intensification Workshop were as follows: (1) Identify R&D gaps and opportunities to facilitate transformative improvement in industrial thermal processes beyond current technologies and allow for entirely new methods for processing materials; (2) Gain insight into new and innovative approaches to thermally intensify processes, reduce heat demand, harness waste heat, and use fuels and hydrocarbon feedstocks more efficiently; (3) Identify the R&D pathways to thermal process intensification (TPI) with the highest potential for impact and adoption by the industrial sector; (4) Define areas of research, development, and demonstration (RD&D) activities to accelerate development and application of emerging and transformative technologies to intensify thermal processes in industry. The scope and focus of the workshop were defined to meet these goals. Based on the available data for energy use and GHG emissions, the industries that collectively use more than 80% of the total process heating energy consumption were selected as primary focus areas. The chosen industries were combined into the following four groups based on similarities in their thermal processes: high-temperature metal processing (iron and steel industry, alumina-aluminum industry); high-temperature nonmetal and mineral processing (cement and glass industry); medium- to low-temperature thermal processing (food processing and pulp and paper industry as part of forest products sector); and hydrocarbon processing (petroleum refining and chemical industry). Furthermore, all potential TPI technologies associated with the processes defined were considered as part of the workshop. Different types of TPI technologies possible in industrial in the document.

42 ENGINEERING↗
DOE OSTI2020

Technologies and policies to decarbonize global industry: Review and assessment of mitigation drivers through 2070

Fully decarbonizing global industry is essential to achieving climate stabilization, and reaching net zero greenhouse gas emissions by 2050–2070 is necessary to limit global warming to 2 °C. This paper assembles and evaluates technical and policy interventions, both on the supply side and on the demand side. It identifies measures that, employed together, can achieve net zero industrial emissions in the required timeframe. Key supply-side technologies include energy efficiency (especially at the system level), carbon capture, electrification, and zero-carbon hydrogen as a heat source and chemical feedstock. There are also promising technologies specific to each of the three top-emitting industries: cement, iron & steel, and chemicals & plastics. These include cement admixtures and alternative chemistries, several technological routes for zero-carbon steelmaking, and novel chemical catalysts and separation technologies. Crucial demand-side approaches include material-efficient design, reductions in material waste, substituting low-carbon for high-carbon materials, and circular economy interventions (such as improving product longevity, reusability, ease of refurbishment, and recyclability). Strategic, well-designed policy can accelerate innovation and provide incentives for technology deployment. High-value policies include carbon pricing with border adjustments or other price signals; robust government support for research, development, and deployment; and energy efficiency or emissions standards. These core policies should be supported by labeling and government procurement of low-carbon products, data collection and disclosure requirements, and recycling incentives. In implementing these policies, care must be taken to ensure a just transition for displaced workers and affected communities. Similarly, decarbonization must complement the human and economic development of low- and middle-income countries.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
NASA NTRS2017

The Power for Flight: NASA's Contributions to Aircraft Propulsion

The New York Times announced America's entry into the 'long awaited' Jet Age when a Pan American (Pan Am) World Airways Boeing 707 airliner left New York for Paris on October 26, 1958. Powered by four turbojet engines, the 707 offered speed, more nonstop flights, and a smoother and quieter travel experience compared to newly antiquated propeller airliners. With the Champs-Elysees only 6 hours away, humankind had entered into a new and exciting age in which the shrinking of the world for good was no longer a daydream. Fifty years later, the New York Times declared the second coming of a 'cleaner, leaner' Jet Age. Decades-old concerns over fuel efficiency, noise, and emissions shaped this new age as the aviation industry had the world poised for 'a revolution in jet engines'. Refined turbofans incorporating the latest innovations would ensure that aviation would continue to enable a worldwide transportation network. At the root of many of the advances over the preceding 50 years was the National Aeronautics and Space Administration (NASA). On October 1, 1958, just a few weeks before the flight of that Pan Am 707, NASA came into existence. Tasked with establishing a national space program as part of a Cold War competition between the United States and the Soviet Union, NASA is often remembered in popular memory first for putting the first human beings on the Moon in July 1969, followed by running the successful 30-year Space Shuttle Program and by landing the Rover Curiosity on Mars in August 2012. What many people do not recognize is the crucial role the first 'A' in NASA played in the development of aircraft since the Agency's inception. Innovations shaping the aerodynamic design, efficient operation, and overall safety of aircraft made NASA a vital element of the American aviation industry even though they remained unknown to the public. This is the story of one facet of NASA's many contributions to commercial, military, and general aviation: the development of aircraft propulsion technology, which provides the power for flight.

Kinney, Jeremy R.↗
DOE OSTI2023

High Performance Adaptive Deep-Reinforcement-Learning-based Real-time Emergency Control (HADREC) to Enhance Power Grid Resilience in Stochastic Environment (Final Report)

The HADREC technology developed in this project features real-time, validated, and predictive emergency control capabilities needed to effectively safeguard the grid against costly disturbances from extreme weather and other disruptive events. It has the potential to revolutionize the emergency control by providing faster and more effective solution for power grid emergency control. The technology can reduce the grid emergency control action time from minutes to seconds and mitigate the impact of outages and reduce system recovery time. The evaluation results using the models and data from PacifiCorp system have shown ~20% improvement in responding time and 70% improved in tripped generator output, comparing against today’s industrial application. This performance can help reduce preventive measurements and improve network utilization and market efficiency, and help lead to a more reliable and resilient power grid with renewable integration. The project has generated significant interest from industry, academic and commercial companies.

24 POWER TRANSMISSION AND DISTRIBUTION↗