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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

How Can Construction Process Simulation Modeling Aid the Integration of Lean Principles in the Factory-Built Housing Industry?

New and existing factories that produce and deliver factory-built housing can benefit from construction process simulation modeling to explore the integration of Lean principles in their operations. Construction process simulation modeling provides digital or virtual recreations of the real-world factory environments to visualize, quantify, analyze, and optimize their underlying behavior, including factory productivity, material flow, labor dynamics, bottlenecks, and work scope. One of the key benefits of process simulation modeling is the ability to create and compare "what-if" scenarios, including integrating Lean principles such as reducing waste (for example, transportation, waiting), line balancing, and just-in-time concepts. In general, three process simulation methods are widely used: discrete event simulation (DES), agentbased modeling (ABM), and system dynamics (SD). Myriad process simulation software also is available, but depending on the industry, complexity of the system, and purposes of the simulation, some software might be more appropriate. Similar to how computer-aided design (CAD) software such as AutoCAD and Rhinoceros enable building design of modular or factory-built housing, process simulation modeling software such as jStrobe, ProModel, and AnyLogic can enable factory design of new and existing factories to deliver modular affordable housing at scale, as opposed to traditional site-built construction. Software with DES capabilities can help generate a process model that is a logical representation of resources and activities in a factory. Software with CAD-DES integration can leverage product-process data integration to help spatially visualize a DES model of the factory in the CAD environment. Software with multimethod simulation capabilities, widely used in the manufacturing industry, brings together DES, ABM, and SD in a single platform that allows visualization, quantification, analyses, and optimization at varying data fidelities. Near-real-time data from an existing factory can be directly plugged into multimethod simulation software so that the construction process simulation model is a near-accurate representation of the real-world factory conditions. This report provides insights into the use of simulation as an aid to integrate Lean concepts in factories, including guidelines for selecting the appropriate process simulation modeling method and software. These insights have been developed as part of ongoing process simulation modeling research, development, and demonstration projects at the U.S. Department of Housing and Urban Development, the U.S. Department of Energy, and the National Renewable Energy Laboratory focused on how process simulation models can enable better integration of resilience, energy efficiency, and low-carbon design strategies.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2019

Techno-economic optimization of shale gas to dimethyl ether production processes via direct and indirect synthesis routes

The shale gas to dimethyl ether process via direct synthesis route with a syngas H2/CO=1 has a higher dimethyl ether yield than that via indirect synthesis route. However, the direct synthesis route involves various energy and capital-intensive processes, such as the complicated dimethyl ether separation process, and the CO2 recycle and comprssion process. In this study, a techno-economic analysis of the shale gas to dimethyl ether process via direct and indirect synthesis routes is performed using Aspen Process Economic Analyzer based on the rigorous process model developed in Aspen Plus. Effects of different CO2 removal technologies and dimethyl ether synthesis technologies from syngas are evaluated. Both, direct and indirect plants are optimized in Aspen Plus equation-oriented environment using the rigorous process models. The effects of key design parameters (i.e. H2/CO in the syngas) as well as investment parameters (i.e. prices of raw materials, products, and utilities, plant scale) on the process economics as been evaluated. The direct dimethyl ether synthesis route processing a syngas with H2/CO =1 and using the Rectisol process for CO2 capture has the highest overall thermal efficiency on the lower heat value basis is found to be much lower than the current U.S. market diesel price indicating the feasibility of the process.

Mevawala, Chirag↗
DOE OSTI2026

Opportunities and challenges in process modeling and simulation of electrochemical systems

Electrochemical technologies have garnered intense interest in both academic research and industrial applications due to their potential to increase energy efficiency and reduce carbon footprint. However, electrochemical process fundamentals have been absent from the chemical process simulators available to millions of chemical engineers worldwide. To expedite process research and development of electrochemical technologies in the chemical industry, it is imperative that essential electrochemical process fundamentals be incorporated into process simulators to support modeling and simulation of electrochemical processes. Here, this study examines three process fundamentals key to the research and development of electrochemical processes: electrochemical reaction kinetics, electrolyte thermodynamics, and heat and mass transfer. It further illustrates application of these process fundamentals with a case study modeling an electrochemical process for the conversion of acrylonitrile to adiponitrile. The modeling example highlights the roles of applied voltage on reaction rates, and electron flow rates on the performance of electrochemical processes. It suggests that the applied voltage and electron flow rates are two unique concepts that should be included in simulators for electrochemical processes.

09 BIOMASS FUELS↗
DOE OSTI2024

Barium stars as tracers of s -process nucleosynthesis in AGB stars

Barium (Ba) stars help to verify asymptotic giant branch (AGB) star nucleosynthesis models since they experienced pollution from an AGB binary companion and thus their spectra carry the signatures of the slow neutron capture process (s process). For a large number (180) of Ba stars, we searched for AGB stellar models that match the observed abundance patterns. We aim to uncover any systematic deviations of the sample abundances from the predictions of the nucleosynthesis models. We employed three machine learning algorithms as classifiers: a Random Forest method, developed for this work, and the two classifiers used in our previous study. Compared to that work, we also expanded our observational sample with 11 Ba stars available in the supersolar metallicity range. We studied the statistical behaviour of the different s-process elements in the observational sample to investigate if the AGB models systematically under- or overpredict the abundances observed in the Ba stars and show the results in the form of violin plots of the residuals between spectroscopic abundances and model predictions. We inspected the correlations between the observed [Fe/H], the s-process elemental abundances, and the residuals. We employed the [Zr/Fe] and [Nb/Fe] abundances as a thermometer to constrain the operational temperature that rules the production of these elements in the sample stars, assuming a steady-state s process. We also investigated the mass distribution of the identified polluter AGB stars and the behaviour of the δ parameter, which describes the fraction of accreted AGB material relative to the Ba star envelope. We find a significant trend in the residuals that implies an underproduction of the elements just after the first s-process peak (Nb, Mo, and Ru) in the models relative to the observations. This may originate from a neutron-capture process (e.g. the intermediate neutron-capture process, i process) not yet included in the AGB models of metallicity from solar to roughly 1/5 solar, corresponding to the range of the Ba stars. Correlations are found between the residuals of these peculiar elements, suggesting a common origin for the deviations from the models. In addition, there is a weak metallicity dependence of the residuals of these elements. The s-process temperatures derived with the [Zr/Fe] – [Nb/Fe] thermometer have an unrealistic value for the majority of our stars. The most likely explanation is that at least a fraction of these elements are not produced in a steady-state s process, and instead may be due to processes not included in the AGB models. The mass distribution of the identified models confirms that our sample of Ba stars was polluted by low-mass AGB stars (< 4 M ⊙ ). Most of the matching AGB models require low accreted mass, but a few systems with high accreted mass are needed to explain the observations.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2015

Process assessment of small scale low temperature methanol synthesis

Biomass is a renewable energy resource and has the potential to make a significant impact on domestic fuel supplies. Biomass can be converted to fuel like methanol via several step process. The process can be split into following main steps: biomass preparation, gasification, gas cooling and cleaning, gas shift and methanol synthesis. Untill now these configuration still has a problem like high production cost, catalyst deactivation, economy of scale and a huge energy requirements. These problems become the leading inhibition for biomass conversion to methanol, which should be resolved to move towards the economical. To address these issues, we developed various process and new configurations for methanol synthesis via methyl formate. This configuration combining two reactors: the one reactor for the carbonylation of methanol and CO to form methyl formate, and the second for the hydrogenolysis of methyl formate and H{sub 2} to form two molecule of methanol. Four plant process configurations were compared with the biomass basis is 300 ton/day. The first configuration (A) is equipped with a steam reforming process for converting methane to CO and H{sub 2} for increasing H{sub 2}/CO ratio. CO{sub 2} removal is necessary to avoid poisoning the catalyst. COSORB process used for the purpose of increasing the partial pressure of CO in the feed gas. The steam reforming process in B configuration is not used with the aim of reducing the number of process equipment, so expect lower investment costs. For C configuration, the steam reforming process and COSORB are not used with the aim of reducing the number of process equipment, so expect lower investment costs. D configuration is almost similar to the configuration A. This configuration difference is in the synthesis of methanol which was held in a single reactor. Carbonylation and hydrogenolysis reactions carried out in the same reactor one. These processes were analyzed in term of technical process, material and energy balance and economic analysis. The presented study is an attempt to compile most of these efforts in order to guide future work to get cheaper low cost investment. From our study the interesting configuration to the next development is D configuration with methanol yield 112 ton/day and capital cost with 526.4 10{sup 6} IDR. The configuration of D with non-discounted and discounted rate had the break-even point approximately six and eight years.

09 BIOMASS FUELS↗
DOE OSTI2015

TU-AB-BRD-01: Process Mapping

Current quality assurance and quality management guidelines provided by various professional organizations are prescriptive in nature, focusing principally on performance characteristics of planning and delivery devices. However, published analyses of events in radiation therapy show that most events are often caused by flaws in clinical processes rather than by device failures. This suggests the need for the development of a quality management program that is based on integrated approaches to process and equipment quality assurance. Industrial engineers have developed various risk assessment tools that are used to identify and eliminate potential failures from a system or a process before a failure impacts a customer. These tools include, but are not limited to, process mapping, failure modes and effects analysis, fault tree analysis. Task Group 100 of the American Association of Physicists in Medicine has developed these tools and used them to formulate an example risk-based quality management program for intensity-modulated radiotherapy. This is a prospective risk assessment approach that analyzes potential error pathways inherent in a clinical process and then ranks them according to relative risk, typically before implementation, followed by the design of a new process or modification of the existing process. Appropriate controls are then put in place to ensure that failures are less likely to occur and, if they do, they will more likely be detected before they propagate through the process, compromising treatment outcome and causing harm to the patient. Such a prospective approach forms the basis of the work of Task Group 100 that has recently been approved by the AAPM. This session will be devoted to a discussion of these tools and practical examples of how these tools can be used in a given radiotherapy clinic to develop a risk based quality management program. Learning Objectives: Learn how to design a process map for a radiotherapy process Learn how to perform failure modes and effects analysis analysis for a given process Learn what fault trees are all about Learn how to design a quality management program based upon the information obtained from process mapping, failure modes and effects analysis and fault tree analysis. Dunscombe: Director, TreatSafely, LLC and Center for the Assessment of Radiological Sciences; Consultant to IAEA and Varian Thomadsen: President, Center for the Assessment of Radiological Sciences Palta: Vice President of the Center for the Assessment of Radiological Sciences.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2023

The s process in massive stars, a benchmark for neutron capture reaction rates

A clear definition of the contribution from the slow neutron-capture process (s process) to the solar abundances between Fe and the Sr-Zr region is a crucial challenge for nuclear astrophysics. Robust s-process predictions are necessary to disentangle the contribution from other stellar processes producing elements in the same mass region. Nuclear uncertainties are affecting s-process calculations, but most of the needed nuclear input are accessible to present nuclear experiments or they will be in the near future. Neutron-capture rates have a great impact on the s process in massive stars, which is a fundamental source for the solar abundances of the lighter s-process elements heavier than Fe (weak s-process component). In this work we present a new nuclear sensitivity study to explore the impact on the s process in massive stars of 86 neutron-capture rates, including all the reactions between C and Si and between Fe and Zr. We derive the impact of the rates at the end of the He-burning core and at the end of the C-burning shell, where the 22 Ne(α,n) 25 Mg reaction is is the main neutron source. We confirm the relevance of the light isotopes capturing neutrons in competition with the Fe seeds as a crucial feature of the s process in massive stars. For heavy isotopes we study the propagation of the neutron-capture uncertainties, finding a clear difference of the impact of Fe and Co isotope rates with respect to the rates of heavier stable isotopes. The local uncertainty propagation due to the neutron-capture rates at the s-process branching points is also considered, discussing the example of 85 Kr. The complete results of our study for all the 86 neutron-capture rates are available online. Finally, we present the impact on the weak s process of the neutron-capture rates included in the new ASTRAL library (v0.2).

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2024

Manuscript Workflows from and Processed Organic Matter Composition of Experimentally Burned Open Air and Muffle Furnace Vegetation Chars across Differing Burn Severity and Feedstock Types from Pacific Northwest, USA (v3)

This dataset includes processed organic matter chemistry data from an experimental study designed to compare how the chemical composition of organic matter changes across different burn conditions and vegetation materials representative of major land cover types of the Pacific Northwest, USA. Chars were created in a closed muffle furnace or on an open burn table from four different feedstock species representing vegetation commonly impacted by fire regimes across the Pacific Northwest, USA. Source data and associated metadata (including methods and geospatial information) can be found at https://data.ess-dive.lbl.gov/datasets/doi:10.15485/1894135 (Grieger et al. 2022). This dataset provides processing scripts and processed data for both solid and dissolved phase organic matter characterization data from experimentally generated chars. These processed data can be used to compare how different burn conditions may influence resultant organic matter chemistry and help further our understanding of potential biogeochemical impacts on river corridors post-fire. The processed data were subsequently analyzed; and the results and ecological implications of the findings were published in peer-reviewed manuscripts. The scripts and workflows used to develop the manuscripts are also included in this data package.This data package was originally published June 2024. It was updated September 2024 (new and modified files) and in January 2025 (modified files). See the change history section in the readme for more details.This dataset is comprised of one data package readme, one data dictionary (dd), one file level metadata (flmd), and folders containing (A) processed data; (B) general processing scripts; and (C) additional folders with specific manuscript analysis scripts and processed data. Step-by-step instructions to assist the user in recreating the workflow used to generate the results in the manuscripts is also provided. The processed data folder includes (1) a folder of processed Parallel Factor Analysis (PARAFAC) and spectra indices outputs from excitation emissions matrix (EEM) fluorescence and absorbance data; (2) a folder of processed solid state carbon-13 (13-C NMR) integrals; (3) folder of high resolution characterization of organic matter via 21 Tesla Fourier transform ion cyclotron resonance mass spectrometry (FTICR-MS) generated through the Environmental Molecular Sciences Laboratory (EMSL; https://www.pnnl.gov/environmental-molecular-sciences-laboratory) processed data outputs from Formultitude (https://github.com/PNNL-Comp-Mass-Spec/Formultitude), blank corrections and data aggregation, and calculated molecular indices. All files are .pdf, .csv, .html, .Rmd, .R, or .RData.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2017

Managing Zirconium Chemistry and Phase Compatibility in Combined Process Separations for Minor Actinide Partitioning

In response to the NEUP Program Supporting Fuel Cycle R&D Separations and Waste Forms call DEFOA- 0000799, this report describes the results of an R&D project focusing on streamlining separation processes for advanced fuel cycles. An example of such a process relevant to the U.S. DOE FCR&D program would be one combining the functions of the TRUEX process for partitioning of lanthanides and minor actinides from PUREX(UREX) raffinates with that of the TALSPEAK process for separating transplutonium actinides from fission product lanthanides. A fully-developed PUREX(UREX)/TRUEX/TALSPEAK suite would generate actinides as product(s) for reuse (or transmutation) and fission products as waste. As standalone, consecutive unit-operations, TRUEX and TALSPEAK employ different extractant solutions (solvating (CMPO, octyl(phenyl)-N,Ndiisobutylcarbamoylmethylphosphine oxide) vs. cation exchanging (HDEHP, di-2(ethyl)hexylphosphoric acid) extractants), and distinct aqueous phases (2-4 M HNO 3 vs. concentrated pH 3.5 carboxylic acid buffers containing actinide selective chelating agents). The separate processes may also operate with different phase transfer kinetic constraints. Experience teaches (and it has been demonstrated at the lab scale) that, with proper control, multiple process separation systems can operate successfully. However, it is also recognized that considerable economies of scale could be achieved if multiple operations could be merged into a single process based on a combined extractant solvent. The task of accountability of nuclear materials through the process(es) also becomes more robust with fewer steps, providing that the processes can be accurately modeled. Work is underway in the U.S. and Europe on developing several new options for combined processes (TRUSPEAK, ALSEP, SANEX, GANEX, ExAm are examples). There are unique challenges associated with the operation of such processes, some relating to organic phase chemistry, others arising from the variable composition of the aqueous medium. This project targets in particular two problematic issues in designing combined process systems: managing the chemistry of challenging aqueous species (like Zr 4+ ) and optimizing the composition and properties of combined extractant organic phases.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1985

Quantitative analysis of geomorphic processes using satellite image data at different scales

When aerial and satellite photographs and images are used in the quantitative analysis of geomorphic processes, either through direct observation of active processes or by analysis of landforms resulting from inferred active or dormant processes, a number of limitations in the use of such data must be considered. Active geomorphic processes work at different scales and rates. Therefore, the capability of imaging an active or dormant process depends primarily on the scale of the process and the spatial-resolution characteristic of the imaging system. Scale is an important factor in recording continuous and discontinuous active geomorphic processes, because what is not recorded will not be considered or even suspected in the analysis of orbital images. If the geomorphic process of landform change caused by the process is less than 200 m in x to y dimension, then it will not be recorded. Although the scale factor is critical, in the recording of discontinuous active geomorphic processes, the repeat interval of orbital-image acquisition of a planetary surface also is a consideration in order to capture a recurring short-lived geomorphic process or to record changes caused by either a continuous or a discontinuous geomorphic process.

Williams, R. S., Jr.↗
NASA NTRS1996

Cost Models for MMC Manufacturing Processes

The quality cost modeling (QCM) tool is intended to be a relatively simple-to-use device for obtaining a first-order assessment of the quality-cost relationship for a given process-material combination. The QCM curve is a plot of cost versus quality (an index indicating microstructural quality), which is unique for a given process-material combination. The QCM curve indicates the tradeoff between cost and performance, thus enabling one to evaluate affordability. Additionally, the effect of changes in process design, raw materials, and process conditions on the cost-quality relationship can be evaluated. Such results might indicate the most efficient means to obtain improved quality at reduced cost by process design refinements, the implementation of sensors and models for closed loop process control, or improvement in the properties of raw materials being fed into the process. QCM also allows alternative processes for producing the same or similar material to be compared in terms of their potential for producing competitively priced, high quality material. Aside from demonstrating the usefulness of the QCM concept, this is one of the main foci of the present research program, namely to compare processes for making continuous fiber reinforced, metal matrix composites (MMC's). Two processes, low pressure plasma spray deposition and tape casting are considered for QCM development. This document consists of a detailed look at the design of the QCM approach, followed by discussion of the application of QCM to each of the selected MMC manufacturing processes along with results, comparison of processes, and finally, a summary of findings and recommendations.

Elzey, Dana M.↗
NASA NTRS1994

The r-, s-, and p-Processes in Nucleosynthesis

Burbidge et al (1957) and Cameron (1957) laid out the framework for our understanding of the formation of the heavy nuclei (those nuclei with mass number A approx. greater than 70). From systematics in the solar system abundance distribution, Burbidge et al determined that the heavy nuclei were formed in three distinct nucleosynthetic processes, which they termed the r-, s-, and p-processes. That we still use these terms today is a credit to the soundness of this work done 37 years ago. We may understand how Burbidge et al and Cameron arrived at their conclusions from Figure 1. One population of nuclei, the s-nuclei, shows an abundance distribution with peaks near mass numbers 87, 138, and 208. These nuclei are made in a slow neutron-capture process, the s-process. A rapid neutron-capture process, the r-process, is responsible for the r-nuclei, whose abundance distribution shows peaks at mass numbers 80, 130, and 195. The p-process is responsible for production of the rarer, more proton-rich heavy isotopes (the p-nuclei) that cannot be made by neutron capture. The first quantitative evaluations of the ideas of Burbidge et al and Cameron came to light in the early 1960s with work on the s-process (Clayton et al 1961, Seeger et al 1965) and the r-process (Seeger et al 1965). These calculations further elucidated the mechanisms for heavy-element formation and showed the plausibility of the framework developed in the 1950s. Subsequent work has focused on determining the astrophysical sites where the r-, s-, and p-processes occurred with the help of improved nuclear details, stellar models, and abundances. A goal of this paper is to review the recent progress astrophysicists, astronomers, and physicists have made in these directions and to point out the problems that remain in our understanding of the formation of the heavy nuclei. Another, perhaps deeper, goal is to to seek some understanding of why there are three major processes available to nature for synthesis of heavy elements. It is impossible for a single paper to cover all relevant aspects of the r-, s-, and p-processes; therefore, where possible, references to other reviews are given. Readers should turn to these reviews for more details. Nevertheless, it is hoped that the present paper gives some flavor for the rich field of heavy-element synthesis.

Meyer, Bradley S.↗
DOE OSTI2015

Collaborative Research: Process-resolving Decomposition of the Global Temperature Response to Modes of Low Frequency Variability in a Changing Climate

El Niño-Southern Oscillation (ENSO) and Annular Modes (AMs) represent respectively the most important modes of low frequency variability in the tropical and extratropical circulations. The future projection of the ENSO and AM variability, however, remains highly uncertain with the state-of-the-art coupled general circulation models. A comprehensive understanding of the factors responsible for the inter-model discrepancies in projecting future changes in the ENSO and AM variability, in terms of multiple feedback processes involved, has yet to be achieved. The proposed research aims to identify sources of such uncertainty and establish a set of process-resolving quantitative evaluations of the existing predictions of the future ENSO and AM variability. The proposed process-resolving evaluations are based on a feedback analysis method formulated in Lu and Cai (2009), which is capable of partitioning 3D temperature anomalies/perturbations into components linked to 1) radiation-related thermodynamic processes such as cloud and water vapor feedbacks, 2) local dynamical processes including convection and turbulent/diffusive energy transfer and 3) non-local dynamical processes such as the horizontal energy transport in the oceans and atmosphere. Taking advantage of the high-resolution, multi-model ensemble products from the Coupled Model Intercomparison Project Phase 5 (CMIP5) soon to be available at the Lawrence Livermore National Lab, we will conduct a process-resolving decomposition of the global three-dimensional (3D) temperature (including SST) response to the ENSO and AM variability in the preindustrial, historical and future climate simulated by these models. Specific research tasks include 1) identifying the model-observation discrepancies in the global temperature response to ENSO and AM variability and attributing such discrepancies to specific feedback processes, 2) delineating the influence of anthropogenic radiative forcing on the key feedback processes operating on ENSO and AM variability and quantifying their relative contributions to the changes in the temperature anomalies associated with different phases of ENSO and AMs, and 3) investigating the linkages between model feedback processes that lead to inter-model differences in time-mean temperature projection and model feedback processes that cause inter-model differences in the simulated ENSO and AM temperature response. Through a thorough model-observation and inter-model comparison of the multiple energetic processes associated with ENSO and AM variability, the proposed research serves to identify key uncertainties in model representation of ENSO and AM variability, and investigate how the model uncertainty in predicting time-mean response is related to the uncertainty in predicting response of the low-frequency modes. The proposal is thus a direct response to the first topical area of the solicitation: Interaction of Climate Change and Low Frequency Modes of Natural Climate Variability. It ultimately supports the accomplishment of the BER climate science activity Long Term Measure (LTM): "Deliver improved scientific data and models about the potential response of the Earth's climate and terrestrial biosphere to increased greenhouse gas levels for policy makers to determine safe levels of greenhouse gases in the atmosphere."

58 GEOSCIENCES↗
DOE OSTI2018

Loquacious-PD removes phosphate inhibition of Dicer-2 processing of hairpin RNAs into siRNAs

Highlights: • Inorganic phosphate inhibits Dicer-2 processing of hairpin RNAs. • Phosphate does not inhibit Dicer-2 + Loqs-PD processing of blunt-end hairpin RNAs. • Loqs-PD removes phosphate inhibition of Dicer-2 processing of blunt hairpin RNAs. Drosophila Dicer-2 processes RNA substrates into short interfering RNAs (siRNAs). Loquacious-PD (Loqs-PD), a dsRNA-binding protein that associates with Dicer-2, is required for processing of a subset of RNA substrates including hairpin RNAs into siRNAs. Inorganic phosphate—a small molecule present in all cell types—inhibits Dicer-2 from processing precursor of microRNAs (pre-miRNAs), which are processed by Dicer-1. Whether or how Loqs-PD modulates the inhibitory effect of inorganic phosphate on Dicer-2 processing of RNA substrates is unknown. To address this question, I performed in vitro hairpin RNA processing assay with Dicer-2 in the presence or absence of Loqs-PD and/or inorganic phosphate. I found that inorganic phosphate inhibits Dicer-2 alone, but not Dicer-2 + Loqs-PD, from processing blunt-end hairpin RNAs into siRNAs. Thus, Loqs-PD removes the inhibitory effect of inorganic phosphate on Dicer-2 processing of blunt-end hairpin RNAs, allowing siRNA production in the presence of inorganic phosphate.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2022

Process-informed adsorbent design guidelines for direct air capture

Direct air capture using solid adsorbents is a proven technology critical to reducing our net greenhouse gas emissions to zero and beyond. Currently, academic research into the technology mainly focuses on the development of new adsorbents. However, there is a discord between the adsorbent design and process performance. Many materials scientists focus on maximising metrics such as the CO 2 capacity of their adsorbent. Here, we combine detailed process modelling, machine learning, and extensive global sensitivity analysis, which entails varying all of the model parameters together, on a direct air capture process to show that the dry CO 2 adsorption capacity does not influence process performance for an amine-functionalised adsorbent operating in a temperature vacuum swing adsorption (TVSA) process, while it is important in a steam-assisted TVSA (S-TVSA) process. In fact, adsorption kinetics, density, and thermal conductivity are all critical attributes to obtaining a low energy penalty and reduced costs. The analysis also highlights the importance of heat transfer, directing process engineers to (alternative) adsorber designs that maximise this. By an in-depth evaluation of how process performance indicators are affected by materials properties and process operating parameters, this work provides guidance to both material scientists and process engineers towards the design of a “unicorn adsorbent” and intensified DAC processes. This will improve the performance of solid adsorbent direct air capture and help drive down the costs of this vital technology to avert the worst impacts of climate change.

42 ENGINEERING↗
NASA NTRSDate not supplied

Metal Additive Manufacturing Process Selection and Development for Propulsion Components

Metal additive manufacturing (AM) is a generic term that captures a variety of fabrication processes. Each of these manufacturing process has unique advantages and challenges for use in aerospace propulsion applications. The most commonly used AM processes include Powder Bed Fusion (PBF), Directed Energy Deposition (DED), and solid-state processes as in Cold Spray, Ultrasonic Additive Manufacturing, and Additive Friction Stir Deposition. While detailed research has been conducted among many of the AM processes to mature processing parameters and material properties, navigating which processes are best to select is difficult as it is based on specific component requirements. The focus of this presentation is to provide an overview of considerations for each of metal AM process selection for aerospace components based on various key attributes. These key attributes include geometric considerations, metallurgical characteristics, cost basis, post-processing and maturity of the processes. The data for these trade selections are based on studies that NASA as performed internally and with academic and industry partners. These studies include multiple AM build experiments to evaluate (1) geometric variations and constraints within the processes, (2) alloy characterization and mechanical testing, (3) pathfinder component development and hot-fire evaluations, and (4) certification approaches. This presentation summarizes these results and is meant to introduce specific examples which show what to consider when designing a metal AM component for aerospace propulsion applications.

Additive Manufacturing↗
NASA NTRSDate not supplied

Powder Bed Fusion Laser Beam Metals Additive Manufacturing: Process Monitoring Approaches for Qualification and Certification

The use of in-situ process monitoring is of interest to lower the cost of inspection for the qualification of powder bed fusion laser beam metal (PBF-LB/M) additively manufactured (AM) parts. Precise monitoring of the PBF-LB/M AM build process constitutes a multi-scale and multi-discipline task. There are several significant challenges to the in-situ approach: the synchronization of sensor signals to process steps; the physical interpretation and classification of sensor signals; managing very large datasets; and comparing the inputs with the observed monitoring signals. At NASA Langley Research Center, a configurable architecture additive testbed has been developed to monitor the build process with synchronized sensors. The philosophy and method adopted for the synchronization of the cameras with laser power and position throughout a complex PBF-LB/M AM build will be described. The synchronized in-situ monitoring signals are compared with ex-situ nondestructive inspection, x-ray computed tomography (XCT). Such comparisons permit a better understanding of how the sequential process actions of LPBF-AM can affect build quality. The multi-scale and complex process of printing additively manufactured (AM) parts can have unexpected, but predictable, build conditions that result in material microstructure variability. This presentation will describe an additive manufacturing model-based process metric (AM-PM) computational method that is a fully parallel reduced order modeling approach developed to evaluate the evolution of AM processes. This method couples the known sequence of the AM process with a physically informed nearest neighbors’ calculation to map the conditions of a part-scale build. The result is a map of the build that is derived directly from build files or in-situ process monitoring sensors. The methodology of the approach will be described and mapped to the porosity observed from XCT for a complex PBF-LB/M build. Such comparative results develop understanding of how the sequential process actions can affect the PBF-LB/M AM build quality and microstructure variability.

Laser Powder Bed Fusion↗
DOE OSTI2022

Optimal Control of Biomass Feedstock Processing System Under Uncertainty in Biomass Quality

Planning of biorefinery operations is complicated by the stochastic nature of physical and chemical characteristics of biomass feedstock, such as, moisture level and carbohydrate content. Biomass characteristics affect the performance of the equipment which feed the reactor and the efficiency of the conversion process in a biorefinery. We propose a stochastic optimization model to identify a blend of feedstocks, inventory levels, and operating conditions of equipment to ensure a continuous flowing of biomass to the reactor while meeting the requirements of the biochemical conversion process. We propose a sample average approximation (SAA) of the model, and develop an efficient algorithm to solve the SAA model. A feedstock preprocessing process consists of two-stage grinding and pelleting is used to develop a case study. Extensive numerical analysis are conducted which lead to a number of observations. Our main observation is that sequencing bales based on moisture level and carbohydrate content leads to robust solutions that improve processing time and processing rate of the reactor. We provide a number of managerial insights that facilitate the implementation of the model proposed. Note to Practitioners—This paper is motivated by the challenges faced in the bioenergy industry. The focus of this paper is on plants which use the biochemical conversion process to generate liquid fuels. It has been observed that variations in biomass characteristics, such as moisture content, cause variations in feeding of the system which lead to under-utilization of equipment. A requirement of biochemical conversion process is to maintain the carbohydrate content of biomass processed by the reactor, larger than a threshold. We propose a model that identifies the inventory levels and operating conditions of equipment to ensure a continuous flowing of biomass to the reactor. The goal is to improve equipment utilization while satisfying the requirements of the conversion process. The model is tested using real-life data. We found out that by sequencing bales based on moisture level and carbohydrate content, a plant can reduce variability in the system leading to improved system reliability, higher processing rates of the reactor, and higher throughput.

09 BIOMASS FUELS↗