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Boost the biopharmaceutical industry’s research efficiency with hyperscale data distribution; DOE SBIR Phase I Final Technical Report
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Opportunity Assessment for U.S. Industry: Energy-Efficient Cooling Technologies in Mexico
Mexico's rapidly expanding room air conditioner (AC) market presents a strategic opportunity for U.S. manufacturers to strengthen North American supply chains while addressing critical energy infrastructure challenges. With demand for room AC units in residential and commercial buildings projected to drive a 26 GW increase in Mexico’s peak electrical load by 2050, high-efficiency air conditioning systems offer both substantial market opportunities and essential grid stability benefits.
Novel Additively Manufactured and Internally Cooled Airfoils for Increasing Small Industrial Gas Turbine Efficiency
ASME Turbo Expo 2023
Energy Efficiency for the Wastewater Industry
This information sheet discusses the technology pillar, Energy Efficiency, as a pathway toward improving wastewater infrastructure sustainability and resiliency.
Immersive Industrialized Construction Environments for Energy Efficiency Construction Workforce
The National Renewable Energy Laboratory is actively developing and testing Immersive Industrialized Construction Environments (IICE) for construction automation and worker-machine interaction to investigate possible solutions and increase workforce productivity. At full scope and matured functionality, IICE allows us to accelerate the development of and better explore industrialized construction approaches such as prefabrication. IICE also enables wider adoption of energy-efficient products and Industry 4.0 construction automation through worker-machine interaction pilots. Industry 4.0 and industrialized construction approaches can encourage workforce specialization in energy efficiency construction, address the lack of multi-skilled workers, and increase workforce productivity with construction automation. However, recent attempts to integrate these concepts with the industry have only been moderately successful. To address this, focusing the pedagogy on using a digital twin, its digital models, and virtual reality could make the experience of continuing education on construction automation more affordable, accessible, scalable, immersive, and safer, and could greatly improve the efficiency and robustness of the building and construction industry. IICE accurately represents the realities of construction uncertainties without having to create full scale physical prototypes of machines. In this paper, we address the following research question: How can a digital twin and its models in virtual reality enhance the learning experience and productivity of energy efficiency construction workers to gain the skills in operating Industry 4.0 components such as construction automation and handling energy-efficient products in industrialized construction factories and on-site? We introduce original research on developing IICE and present preliminary findings from time and motion pilot studies.
Magnetron R&D Progress for High Efficiency CW RF Sources of Industrial Accelerators
After the demonstration of using high efficiency magnetron power to combine and aim to drive a radio frequency accelerator at 2450MHz in CW mode [1], we have used trim coils adding to a water-cooled magnetron and three amplitude modulation methods in an open-loop control to further suppress the 120Hz side-band noise to -46.7dBc level. We have also successfully demonstrated the phase-locking to an industrial grade cooking magnetron transmitter at 915MHz with a 75kW CW power delivered to a water load by using a -26.6dBc injection signal. The sideband noise at 360Hz from the 3-Phase SCRs DC power supply can be reduced to -16.2dBc level. Their power combing scheme and higher power application to industrial accelerators are foreseeing.
Magnetron R&D for high efficiency CW RF sources for industrial accelerators
The scheme of using high-efficiency magnetrons to drive radiofrequency accelerators has been demonstrated at 2450 MHz in CW mode *. Magnetron test stands at JLab and GA have been set up to further test the noise figure and the locking speed of the injection phase-lock method. For higher power applications, power combining experiments using a TM010 cavity-type combiner and a magic tee for the binary combiner while using a single clean injection signal has been carried out at 2450 MHz. The frequency pulling effect between the magnetron and a low-Q cavity has been shown to enhance the frequency locking bandwidth compared to the injection phase-lock alone. The principle has been studied by the equivalent circuit simulation, analytical model, and finally confirmed experimentally on the magnetrons. Due to the pandemic delay in 2020, the equivalent high power tests using a 75kW, 915MHz industrial magnetron will be done in 2021 and will be reported in a future paper.
A 400-kWe high-efficiency steam turbine for industrial cogeneration
An advanced state-of-the-art steam turbine-generator developed to serve as the power conversion subsystem for the Department of Energy's Sandia National Laboratories' Solar Total-Energy Project (STEP) is described. The turbine-generator, which is designed to provide 400-kW of net electrical power, represents the largest turbine-generator built specifically for commercial solar-powered cogeneration. The controls for the turbine-generator incorporate a multiple, partial-arc entry to provide efficient off-design performance, as well as an extraction control scheme to permit extraction flow regulation while maintaining 110-spsig pressure. Normal turbine operation is achieved while synchronized to a local utility and in a stand-alone mode. In both cases, the turbine-generator features automatic load control as well as remote start-up and shutdown capability. Tests totaling 200 hours were conducted to confirm the integrity of the turbine's mechanical structure and control function. Performance tests resulted in a measured inlet throttle flow of 8,450 pounds per hour, which was near design conditions.
Energy-efficient carbon capture from industrial point sources via commercially available green solvent and hollow fiber membrane contactors
Solvent-based absorption systems have emerged in the carbon capture space due to their high absorption capacities, reusability, and favorable energy requirements. Using diethyl sebacate as a solvent for pre- and post-combustion carbon capture has advantages over other solvents, including high hydrophobicity, low viscosity, low vapor pressure, high CO 2 solubility, high CO 2 selectivity, and being commercially available in large quantities. Despite these advantageous properties, the use of diethyl sebacate as a solvent for post-combustion carbon capture has not been studied in detail. To examine the capability of diethyl sebacate, a scalable, energy-efficient, hollow fiber membrane (microporous polypropylene and polyvinylidene fluoride) contactor (HFMC)-based process with low-cost and high surface area is investigated. A purity of 95.3 % CO 2 with 46 % recovery in one absorption stage was achieved, with a permeate flux over one magnitude greater than using a deep eutectic solvent in the same system. Technoeconomic analysis determined a ∼ 0.8 GJ per ton of CO 2 at a processing cost of ∼$93 per ton of CO 2 . Results from this work underscore the potential for utilizing green solvents in HFMC-based separation processes for effective carbon capture and provide a pathway towards practical deployment.
Energy Efficiency's Role in Industrial Decarbonization
Around the world, efforts are increasing to drastically reduce greenhouse gas (GHG) emissions by 2050. The goal of the Paris Agreement is to hold the increase in global average temperature rise to below 2°C as compared with preindustrial levels, specifically aiming to limit it to 1.5°C. As of 2017, the global average temperature rise reached approximately 1°C. It is expected to hit the 1.5°C mark by 2040 if current trends continue. Limiting temperature rise to 2°C will require reaching net zero emissions in the latter half of the 21st century; GHG emissions would need to reach a near-zero value by 2050 to limit the rise to 1.5°C.
Atomically dispersed single Ni site catalysts for high-efficiency CO[subscript 2] electroreduction a
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High-Temperature Heat Pump Model Documentation and Case Studies
High temperature heat pumps (HTHPs) have the potential to serve two valuable functions in the U.S. industry. First, by valorizing and elevating waste heat streams, HTHPs can improve industrial energy efficiency. Second, by electrifying process heat generation, HTHPs can replace combustion technologies with less carbon-intensive sources of energy and reduce industrial greenhouse gas emissions. In certain applications, the combination of increased efficiency, cost savings, and emissions reduction makes HTHPs a promising component of strategies for industrial electrification and clean energy transition. Researchers at NREL have developed a HTHP model. This model has both a physics-based performance estimation component and an economic evaluation component designed to demonstrate the potential economic competitiveness of HTHPs. This document has three main sections. First, an overview of HTHPs is provided as a literature review of relevant information to provide the reader with state-of-the-art information. Second, a description of the HTHP model is provided along with detailed instructions about how to use the model. Third, case studies are provided to showcase the deployment of the HTHP model.
Efficient GO2/GH2 Injector Design: A NASA, Industry and University Cooperative Effort
Developing new propulsion components in the face of shrinking budgets presents a significant challenge. The technical, schedule and funding issues common to any design/development program are complicated by the ramifications of the continuing decrease in funding for the aerospace industry. As a result, new working arrangements are evolving in the rocket industry. This paper documents a successful NASA, industry, and university cooperative effort to design efficient high performance GO2/GH2 rocket injector elements in the current budget environment. The NASA Reusable Launch Vehicle (RLV) Program initially consisted of three vehicle/engine concepts targeted at achieving single stage to orbit. One of the Rocketdyne propulsion concepts, the RS 2100 engine, used a full-flow staged-combustion cycle. Therefore, the RS 2100 main injector would combust GO2/GH 2 propellants. Early in the design phase, but after budget levels and contractual arrangements had been set the limitations of the current gas/gas injector database were identified. Most of the relevant information was at least twenty years old. Designing high performance injectors to meet the RS 2100 requirements would require the database to be updated and significantly enhanced. However, there was no funding available to address the need for more data. NASA proposed a teaming arrangement to acquire the updated information without additional funds from the RLV Program. A determination of the types and amounts of data needed was made along with test facilities with capabilities to meet the data requirements, budget constraints, and schedule. After several iterations a program was finalized and a team established to satisfy the program goals. The Gas/Gas Injector Technology (GGIT) Program had the overall goal of increasing the ability of the rocket engine community to design efficient high-performance, durable gas/gas injectors relevant to RLV requirements. First, the program would provide Rocketdyne with data on preliminary gas/gas injector designs which would enable discrimination among candidate injector designs. Secondly, the program would enhance the national gas/gas database by obtaining high-quality data that increases the understanding of gas/gas injector physics and is suitable for computational fluid dynamics (CFD) code validation. The third program objective was to validate CFD codes for future gas/gas injector design in the RLV program.
A Multifaceted Analysis of Chemical-Absorption Heat Pump Technology for Integrated Energy Systems
Integrated Energy Systems (IES) research and development is essential for improving the economic usage of lowcarbon energy sources such as nuclear power, solar, and wind in the U.S. An ideal IES uses various energy sources and delivers energy to the power grid and industry as efficiently as possible. As part of this effort, there are many opportunities to use low-carbon energy for industries requiring process heat for production of many chemicals and fuels [1]. Currently, industries only have the option to burn CO2 emitting fuels or use resistance heaters for this process heat. Using resistance heaters is one way to electrify a process, allowing for low-carbon energy sources to be used, but is an inefficient method unless temperatures exceed 1000?C. Heat pumps have long been used to provide efficient heating or cooling by moving heat instead of generating it. More traditional heat pumps such as vapor compression heat pumps and absorption heat pumps are limited to temperatures below 300?C due to refrigerant and component material limits. However, chemical heat pumps have been investigated as an option for pumping heat at temperatures above 600?C [2], making the heat more applicable to many more chemical and fuel production processes.
Advanced Non-Tread Materials for Fuel-Efficient Tires
PPG Industries, Inc. proposes to develop a new silica filler that can increase fuel efficiency by 2% while maximizing key performance properties in non-tread tire components compared to current carbon black/silica filler blends. In this project PPG focused on a sidewall compound. The developed compounds/components will reduce energy losses by approximately 25%, with no more than a 5% loss of resistance to degradative forces (targeting better performance). PPG plans to achieve this goal by characterizing the impact the silica filler can have on rubber properties and then tuning the silica morphology and surface chemistry for this end use. PPG will also provide guidance in optimizing the compound formulation to make the best use of this new filler. A key aspect is to understand and maintain, if not improve, the aging performance as evaluated by crack growth resistance under ozone environment. Two key strategies were used to meet the rolling resistance goal while maintaining other performance properties. The first factor was understanding the surface treatments and chemical makeup of the silica and its effects on compound performance. The second factor was using the best performing silicas and determining the optimum compound modifications to achieve the final sidewall compound performance. Using statistical analysis throughout the optimization process, it was determined that changing the silica morphology played a role in improving the reduction of tear strength while reducing rolling resistance and the improvements observed varied depending on the CB type.
Experimental Investigation of Gaseous Mixtures of Ethane, Methane, and Carbon Dioxide as an Alternative to Conventional Fuel in Spark Ignition Engines
This study investigates the viability and performance of certain synthetic fuels in spark ignition internal combustion engine based stationary power generation wherein the fuel comprises a mixture of methane and ethane in high dilutions of carbon dioxide (CO 2 ). The fuel of concern is a byproduct of a novel method for producing ethylene from ethane. The byproduct gas mixture has a concentration of approximately 41% CO 2 , 40% ethane, and 5% methane by weight along with other minor compounds. Varying mixtures of ethane and methane combined with between 42% and 46% by weight CO 2 were used to evaluate the viability and efficiency of this fuel to operate in existing internal combustion engines as a means of reducing emissions and increasing industrial process efficiency. A 13 hp gasoline generator was repurposed as a test stand by incorporating a modified fuel induction system and instrumentation for data collection. A gas metering and mixing system was installed to precisely control the mass flow of gases induced into the engine. Various instrumentations were installed to monitor in-cylinder pressure, temperature at various locations, emissions, and fuel and airflow rates. Varying fuel mixtures and loads were tested and compared to gasoline. It was found that under a high load, the mixed gas was able to generate comparable thermal efficiency and power to gasoline. But under no load or a part load condition the indicated thermal efficiency was found to be about 21% lower than that of gasoline. Further, the mixed gas also resulted in up to 50% reduction in CO and NOx emissions when compared to gasoline.
Industrial Assessment Center Program (Final Report)
Final technical report for the Nebraska Industrial Assessment Center.