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

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At least 883 records · Page 49
All sourcesNASA NTRSDOE OSTI
NASA NTRS2005

In-Space Cryogenic Propellant Depot Stepping Stone

An In-Space Cryogenic Propellant Depot (ISCPD) is an important stepping stone to provide the capability to preposition, store, manufacture, and later use the propellants for Earth-Neighborhood campaigns and beyond. An in-space propellant depot will provide affordable propellants and other similar consumables to support the development of sustainable and affordable exploration strategies as well as commercial space activities. An in-space propellant depot not only requires technology development in key areas such as zero boil-off storage and fluid transfer, but in other areas such as lightweight structures, highly reliable connectors, and autonomous operations. These technologies can be applicable to a broad range of propellant depot concepts or specific to a certain design. In addition, these technologies are required for spacecraft and orbit transfer vehicle propulsion and power systems, and space life support. Generally, applications of this technology require long-term storage, on-orbit fluid transfer and supply, cryogenic propellant production from water, unique instrumentation and autonomous operations. This paper discusses the reasons why such advances are important to future affordable and sustainable operations in space. This paper also discusses briefly R&D objectives comprising a promising approach to the systems planning and evolution into a meaningful stepping stone design, development, and implementation of an In-Space Cryogenic Propellant Depot. The success of a well-planned and orchestrated approach holds great promise for achieving innovation and revolutionary technology development for supporting future exploration and development of space.

Howell, Joe T.↗
NASA NTRS2006

Slow Crack Growth and Fracture Toughness of Sapphire for the International Space Station Fluids and Combustion Facility

The fracture toughness, inert flexural strength, and slow crack growth parameters of the r- and a-planes of sapphire grown by the Heat Exchange Method were measured to qualify sapphire for structural use in the International Space Station. The fracture toughness in dry nitrogen, K(sub Ipb), was 2.31 +/- 0.12 MPa(square root of)m and 2.47 +/- 0.15 MPa(squre root of)m for the a- and r-planes, respectively. Fracture toughness measured in water via the operational procedure in ASTM C1421 was significantly lower, K(sub Ivb) = 1.95+/- 0.03 MPa(square root of)m, 1.94 +/- 0.07 and 1.77 +/- 0.13 MPa(square root of)m for the a- , m- and r-planes, respectively. The mean inert flexural strength in dry nitrogen was 1085 +/- 127 MPa for the r-plane and 1255 +/- 547 MPa for the a-plane. The power law slow crack growth exponent for testing in water was n = 21 +/- 4 for the r-plane and n (greater than or equal to) 31 for the a-plane. The power law slow crack growth coefficient was A = 2.81 x 10(exp -14) m/s x (MPa(squre root of)m)/n for the r-plane and A (approx. equals)2.06 x 10(exp -15) m/s x (MPa(square root of)m)/n for the a-plane. The r- and a-planes of sapphire are relatively susceptible to stress corrosion induced slow crack growth in water. However, failure occurs by competing modes of slow crack growth at long failure times and twinning for short failure time and inert environments. Slow crack growth testing needs to be performed at low failure stress levels and long failure times so that twinning does not affect the results. Some difficulty was encountered in measuring the slow crack growth parameters for the a-plane due to a short finish (i.e., insufficient material removal for elimination of the damage generated in the early grinding stages). A consistent preparation method that increases the Weibull modulus of sapphire test specimens and components is needed. This would impart higher component reliability, even if higher Weibull modulus is gained at the sacrifice of absolute strength of the component. The current specification frequently used for the preparation of sapphire test specimens and components (e.g., a "60/40" scratch-dig finish) is inadequate to avoid a short finish.

Salem, Jonathan A.↗
NASA NTRS2006

Systems Integration Processes for NASA's Crew Launch Vehicle

NASA's Exploration Initiative will require development of many new elements to constitute a robust system of systems. New launch vehicles are needed to place cargo and crew in stable low earth orbit. This paper examines the systems integration processes NASA is utilizing to ensure integration and control of propulsion and non-propulsion elements within NASA's Crew Launch Vehicle (CLV). The objective of the CLV is to provide the transportation capabilities to meet the Constellation Program requirements for delivering a Crew Exploration Vehicle (CEV) or other payload to Low Earth Orbit (LEO) in support of the lunar and Mars missions. The CLV must successfully provide the capability within cost and schedule with an acceptable risk approach. This paper will describe in detail the systems engineering management processes that will be applied to assure CLV Project success through complete and efficient technical integration. Discussion of specific processes for requirements development and verification, integrated design and analysis, integrated simulation and testing and the integration of reliability, maintainability and supportability (RMS) into the design will also be included. The CLV Project is broken logically into elements by the major hardware groupings, and associated management, system engineering, and integration functions. The processes to be described herein are designed to integrate within these CLV elements and among the other Constellation projects. Launch vehicle stack integration (CLV to CEV, and Ground and Flight Operations integration) throughout the life cycle, including integrated vehicle performance through orbital insertion, recovery of the first stage, and reentry of the upper stage will also be discussed. The processes for decomposing requirements to the Elements and ensuring that requirements have been correctly validated, decomposed, allocated, and that the verification requirements are properly defined to ensure that the system design meets requirements will be discussed.

Reuter, James L.↗
NASA NTRS2009

Effect of Electrostatic Discharge on Electrical Characteristics of Discrete Electronic Components

This article reports on preliminary results of a study conducted to examine how temporary electrical overstress seed fault conditions in discrete power electronic components that cannot be detected with reliability tests but impact longevity of the device. These defects do not result in formal parametric failures per datasheet specifications, but result in substantial change in the electrical characteristics when compared with pristine device parameters. Tests were carried out on commercially available 600V IGBT devices using transmission line pulse (TLP) and system level ESD stress. It was hypothesized that the ESD causes local damage during the ESD discharge which may greatly accelerate degradation mechanisms and thus reduce the life of the components. This hypothesis was explored in simulation studies where different types of damage were imposed to different parts of the device. Experimental results agree qualitatively with the simulation for a number of tests which will motivate more in-depth modeling of the damage.

Wysocki, Phil↗
NASA NTRS2013

Deepak Condenser Model (DeCoM)

Development of the DeCoM comes from the requirement of analyzing the performance of a condenser. A component of a loop heat pipe (LHP), the condenser, is interfaced with the radiator in order to reject heat. DeCoM simulates the condenser, with certain input parameters. Systems Improved Numerical Differencing Analyzer (SINDA), a thermal analysis software, calculates the adjoining component temperatures, based on the DeCoM parameters and interface temperatures to the radiator. Application of DeCoM is (at the time of this reporting) restricted to small-scale analysis, without the need for in-depth LHP component integrations. To efficiently develop a model to simulate the LHP condenser, DeCoM was developed to meet this purpose with least complexity. DeCoM is a single-condenser, single-pass simulator for analyzing its behavior. The analysis is done based on the interactions between condenser fluid, the wall, and the interface between the wall and the radiator. DeCoM is based on conservation of energy, two-phase equations, and flow equations. For two-phase, the Lockhart- Martinelli correlation has been used in order to calculate the convection value between fluid and wall. Software such as SINDA (for thermal analysis analysis) and Thermal Desktop (for modeling) are required. DeCoM also includes the ability to implement a condenser into a thermal model with the capability of understanding the code process and being edited to user-specific needs. DeCoM requires no license, and is an open-source code. Advantages to DeCoM include time dependency, reliability, and the ability for the user to view the code process and edit to their needs.

Patel, Deepak↗
NASA NTRS2015

Turbo-Brayton Power Converter

Future NASA space missions will require advanced thermal-to-electric power converters that are reliable, efficient, and lightweight. Creare, LLC, is developing a turbo-Brayton power converter that offers high efficiency and specific power. The converter employs gas bearings to provide maintenance free, long-life operation. Discrete components can be packaged to fit optimally with other subsystems, and the converter's continuous gas flow can communicate directly with remote heat sources and heat rejection surfaces without the need for ancillary heat-transfer components and intermediate flow loops. Creare has completed detailed analyses, trade studies, fabrication trials, and preliminary designs for the components and converter assembly. The company is fabricating and testing a breadboard converter.

Breedlove, Jeffrey↗
NASA NTRS2016

Model Based Mission Assurance: NASA's Assurance Future

Model Based Systems Engineering (MBSE) is seeing increased application in planning and design of NASA’s missions. This suggests the question: what will be the corresponding practice of Model Based Mission Assurance (MBMA)? Contemporaneously, NASA’s Office of Safety and Mission Assurance (OSMA) is evaluating a new objectives based approach to standards to ensure that the Safety and Mission Assurance disciplines and programs are addressing the challenges of NASA’s changing missions, acquisition and engineering practices, and technology. MBSE is a prominent example of a changing engineering practice. We use NASA’s objectives-based strategy for Reliability and Maintainability as a means to examine how MBSE will affect assurance. We surveyed MBSE literature to look specifically for these affects, and find a variety of them discussed (some are anticipated, some are reported from applications to date). Predominantly these apply to the early stages of design, although there are also extrapolations of how MBSE practices will have benefits for testing phases. As the effort to develop MBMA continues, it will need to clearly and unambiguously establish the roles of uncertainty and risk in the system model. This will enable a variety of uncertainty-based analyses to be performed much more rapidly than ever before and has the promise to increase the integration of CRM (Continuous Risk Management) and PRA (Probabilistic Risk Analyses) even more fully into the project development life cycle. Various views and viewpoints will be required for assurance disciplines, and an over-arching viewpoint will then be able to more completely characterize the state of the project/program as well as (possibly) enabling the safety case approach for overall risk awareness and communication.

Evans, John↗
NASA NTRSDate not supplied

Early Information Parameter-Set Analysis for Satellite Close Approaches using Machine Learning

Understanding orbital mechanics is essential in space flight and navigation applications, and leveraging modern force models for flight path projection remains an important aspect in space mission design and operation. However, force models do not capture all the dynamics or perturbations in the space environment and thus are subject to errors in predicting the state vectors. The further out the predicted miss distance between spacecraft is from the time of closest approach (TCA), the larger the propagated errors in the predicted miss distance at TCA is. The dependency on these force models for spacecraft flight state prediction calls for a more reliable method that can quantify, or even reduce, these propagated errors. With recent advances in the field artificial intelligence, specifically in machine and deep learning algorithms, a model that implements these approaches can improve on the modern force model approach. The goal for this work is to provide an early-information decision-making threshold, in order to prioritize risk assessment implementation, given the ongoing increase of space objects. In analyzing the relationship of several parameters from conjunction data messages(CDMs) and solar information, early information becomes viable in miss distance prediction with unsupervised learning techniques, which learn the parameters that are linked together with miss distance and probability of collision (Pc) variables. Another approach implemented for identifying relationships within CDMs is supervised learning, in which a shallow neural network binary classifier learns to distinguish events with Pc values¡108. These parameters detected in the unsupervised process are then applied to a regression neural network, which predicts the miss distance at TCA for a specific event within a given uncertainty bound. For the regression neural network, a Long Short Term Memory (LSTM) neural network is implemented, which yields memory about each time step in an event. Using an LSTM network, the model learns to predict miss distance within 0.2km of the value measured at TCA. Although there is a limited amount of "close miss" data to train a network, the network learns to associate parameters, like large energy dissipation rates with the secondary object, with an elevated Pc

Brianna I. Robertson↗
NASA NTRS2023

ChIPPS: Charged Information-storage Polymer Preparation System

Technological advances are required to support principal science objectives of missions to the solar system’s icy worlds to seek biosignatures of past/extant life. Sensitivity and reliability are key concerns due to small sample sizes (µL – mL) and the extraordinary import of the results. The preparation and processing of small samples can constrain limits of detection (LoDs); therefore, the Charged Information-storage Polymer Preparation System (ChIPPS) project is advancing the technologies of autonomous sample preparation and processing to add a new class of reliably detectable biosignatures: charged polymers and particles, which can be the information storage-and-transmission means for life. Specifically, we are developing an integrated microfluidic sample-processing unit to prepare icy-world samples to support complementary solid-state nanopore-based analyses: 1) charged-polymer analysis, to characterize variations in polymer chain size, shape, and charge vs. position along the chain; 2) polymer and nanoparticle sizing-and-counting, to characterize the relative abundance of polymer chains, as well as small (virus-sized) particles, by their dimensions and charge. Although no such autonomous system presently exists, such measurements can reveal the nature and abundance of charged polymers that could be used by biological systems to store and transfer information—as DNA and RNA are used terrestrially—without limitation to terrestrial nucleic acids, given that life elsewhere may utilize different information store-and-transfer moieties. Key system components include (a) a lysis unit for mechanical sample disruption; b) an ion-exchange column for charged macromolecule/nanoparticle purification; c) dialyzer to remove excess salt; d) concentrator to enhance signal; e) supporting pumps, valves, bubble traps, connectors, filters, etc.; f) interface to nanopore detection instruments.

Space Biology↗
DOE OSTI2022

BFSVBF (BatFinder Smart Video BioFilter) [SWR-22-87] and Multi-class BatFinder Smart Video BioFilter Keras

Bats are notoriously difficult to study, therefore, identifying specific behavioral trends and the precise environmental conditions at the time of collision requires a monitoring solution that can reliably collect relevant data. To date, thermal infrared video surveillance has been extensively applied to study bats and has proven to be a powerful yet cumbersome tool. Current analytical approaches are time consuming because data processing data has not been fully automated. In the past, steps have been taken to record avian and bat activity in conjunction with complicated image processing techniques that separate species from other moving objects within the field of view (i.e. clouds and portions of the wind turbine). Once the videos are collected, the post-processing does not allow real time monitoring and identification, leading to a delay in both studying the behavior of these species and determining the effectiveness of any impact reduction strategy being studied. Moreover, object identification capability is lacking, thus limiting the usefulness of video data. To resolve these issues, we are using open source computer vision and machine learning techniques allowing for automatic detection of objects in real-time with the ability to correlate these objects with environmental variables and recording the flight paths of each object. The code has gone through five rounds of development with images used to train the models. This advancement allows for automated real-time data collection, identification, and tracking, thereby eliminating the need for long and tedious post-analysis processing of the videos. We will discuss the two open source and publicly available machine learning models developed within this scope of this work: 1) a binary model with a 97.5% accuracy in identifying the difference between an object and an empty scene, including wind turbine and clouds; and 2) a multiple classification model with the capability of identifying the type of object detected: bats (90% accuracy), birds (83% accuracy), insects (69% accuracy) and non-biological (99% accuracy).

Yarbrough, John↗
DOE OSTI2025

ACCELERATED DEPLOYMENT OF NOVEL MATERIALS BASED ON RELIABILITY INTEGRITY MANAGEMENT USING CUMULATIVE DAMAGE MODELING

There is currently no widely agreed, detailed general method for licensing a novel plant incorporating novel materials (or materials being deployed in novel environments); in many such situations, there are no directly applicable engineering code cases for decision-makers (including regulators) to rely on. This paper discusses a framework for solving this problem that is based on the Reliability and Integrity Management (RIM) approach delineated in ASME BPVC Section XI Division 2. NRC Regulatory Guide 1.246, Rev. 0, endorses, with conditions, the subject portion of the 2019 ASME Code. The proposed framework is meant to support development of a licensing case by addressing certain remaining technical challenges. The framework discussed here is compatible with the Licensing Modernization Project, but applying it in a specific case will call for advances in the state of practice, if not the state of the art. The RIM approach calls for applicants to (a) allocate reliability targets to plant structures, systems, and components (SSCs), (b) show that they are able to relate the currently observed physical condition of each SSC in the program to its failure probability well enough to determine whether the target reliability allocations are being satisfied, allowing for uncertainty related to the novelty of the materials/designs/operating environments, and (c) be able to demonstrate that the proposed program of surveillances will reliably detect unacceptable degradation of an SSC before SSC failure occurs. A modeling approach potentially applicable to item (b), based on cumulative damage modeling rather than failure rates, is briefly illustrated.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Velocity- and pressure-based metrics for estimating strike injuries during fish passage through hydro turbines

Hydropower is a crucial source of clean and reliable energy worldwide, and its importance will continue to grow. To enhance the environmental sustainability of hydropower development and operations, it is essential to predict the strike injury rates of fish passing through turbines accurately and cost-effectively. However, conventional experiments involving a large number of live fish are still commonly conducted in practice, and previous attempts mainly focused on the dose-response relationships at an individual level or relative comparisons of biological characterization between different conditions. Thus, this study proposes two novel strike metrics based on velocity and pressure (M V and M P ) measured by the cutting-edge Sensor Fish (SF) technology, designed to quantify the biological effects of strikes and collisions between fish and rigid hydraulic structures. SF measurements and 48-hour survival rates of live fish from a study conducted at the Ice Harbor Dam on the Snake River were used to establish thresholds for the two proposed metrics. These metrics and thresholds were then applied to three additional SF studies conducted at hydropower facilities featuring Kaplan turbines within the Columbia River basin. Results from the application of the strike metrics indicate that the estimated survival rates derived from both metrics agree well with previously reported live fish survival rates. Furthermore, the study identified specific passage regions with elevated risks of fish mortality due to strikes and collisions. Overall, the proposed strike metrics present a reliable and cost-effective approach to reducing reliance on live fish and lowering costs in fish passage studies.

Biological characterization↗
NASA NTRS2001

Reliability Analysis for AFTI-F16 SRFCS Using ASSIST and SURE

This paper reports the results of a study on reliability analysis of an AFTI-16 Self-Repairing Flight Control System (SRFCS) using software tools SURE (Semi-Markov Unreliability Range Evaluator and ASSIST (Abstract Semi-Markov Specification Interface to the SURE Tool). The purpose of the study is to investigate the potential utility of the software tools in the ongoing effort of the NASA Aviation Safety Program, where the class of systems must be extended beyond the originally intended serving class of electronic digital processors. The study concludes that SURE and ASSIST are applicable to reliability, analysis of flight control systems. They are especially efficient for sensitivity analysis that quantifies the dependence of system reliability on model parameters. The study also confirms an earlier finding on the dominant role of a parameter called a failure coverage. The paper will remark on issues related to the improvement of coverage and the optimization of redundancy level.

Wu, N. Eva↗
DOE OSTI2022

Photovoltaic Module R&D Considerations for Soiling Mitigation

Photovoltaic (PV) modules work best in the sunniest environments. Unfortunately, often the sunniest places also have substantial amounts of airborne "dust" that deposits on the front surface of the modules and blocks the sunlight; reducing energy output. In fact, natural soiling has reduced the energy output of PV systems since the technology was first used, and viable mitigation strategies have remained elusive ever since. With the ever-increasing deployments around the world, especially in dusty environments, soiling is becoming a billion-dollar problem, worldwide. While substantial work has been done to examine and resolve some of the issues with PV soiling, often mitigation comes down to physically cleaning the modules. However, a more systematic evaluation of the different module properties correlations to soiling mitigation needs to be done. In many instances, the causal connections between module properties and soiling are simply not known. This lack of knowledge results in a substantial increase in time and effort to evaluate and qualify appropriate soiling mitigation protocols based on site specific issues and the intrinsic module properties that are typically not optimized for mitigating soiling in a given environment. Thus, module property protocols and/or standards are needed to more quickly help identify appropriate module and site-specific mitigation.

mitagation↗
NASA NTRS2008

Fault-Tolerant Coding for State Machines

Two reliable fault-tolerant coding schemes have been proposed for state machines that are used in field-programmable gate arrays and application-specific integrated circuits to implement sequential logic functions. The schemes apply to strings of bits in state registers, which are typically implemented in practice as assemblies of flip-flop circuits. If a single-event upset (SEU, a radiation-induced change in the bit in one flip-flop) occurs in a state register, the state machine that contains the register could go into an erroneous state or could hang, by which is meant that the machine could remain in undefined states indefinitely. The proposed fault-tolerant coding schemes are intended to prevent the state machine from going into an erroneous or hang state when an SEU occurs. To ensure reliability of the state machine, the coding scheme for bits in the state register must satisfy the following criteria: 1. All possible states are defined. 2. An SEU brings the state machine to a known state. 3. There is no possibility of a hang state. 4. No false state is entered. 5. An SEU exerts no effect on the state machine. Fault-tolerant coding schemes that have been commonly used include binary encoding and "one-hot" encoding. Binary encoding is the simplest state machine encoding and satisfies criteria 1 through 3 if all possible states are defined. Binary encoding is a binary count of the state machine number in sequence; the table represents an eight-state example. In one-hot encoding, N bits are used to represent N states: All except one of the bits in a string are 0, and the position of the 1 in the string represents the state. With proper circuit design, one-hot encoding can satisfy criteria 1 through 4. Unfortunately, the requirement to use N bits to represent N states makes one-hot coding inefficient.

Naegle, Stephanie Taft↗
DOE OSTI2022

High Temperature Anode Recycle Blower for Solid Oxide Fuel Cell, Phase II (Final Report)

Broad commercialization of solid oxide fuel cells (SOFCs) requires anode offgas recycle blowers (ARCB) that are specifically designed for handling the challenging operating conditions presented by the SOFC process gases. Otherwise, they can be susceptible to frequent maintenance, low reliability, and short life. This report presents details of a DOE-funded Phase II effort conducted by Mohawk Innovative Technology, Inc. (MiTi®) for the development and testing of an oil-free, low cost, high-temperature centrifugal ARCB based on compliant foil bearing (CFB) technology for support of a 100 kW solid oxide fuel cell power plant. This Phase II builds on the results of a successful Phase I development project that resulted in the demonstration of a low TRL-6 prototype, shown in Figure 1. This Phase II final report presents design improvements over the Phase I prototype, presents the assembled test ARCBs, and discusses the advantages of this novel technology, particularly its long life and maintenance-free operation, which are derived from the use of CFBs. Also included are preliminary techno-economic analysis considerations for cost-effective deployment of the technology. The specific objectives of this project, as stated in the statement of program objectives (SOPO) were 1) to follow the methodology of design for manufacturing (or manufacturability) and assembly for implementing improvements identified as part of the Phase I effort with the purpose of reducing cost, enabling mass production, and facilitating the commercialization of a revised ARCB design, and 2) to fabricate four complete ARCB units based on the revised design and demonstrating their performance in both a laboratory setting and in an actual SOFC power plant. Execution of this SOPO would be supported by a number of technical tasks resulting in the fabrication and testing of the prototypes. To this end, MiTi continued the teaming relationship started during Phase I of the program with subcontracting partner FuelCell Energy, Inc. (FCE), which integrated (under a parallel effort funded by DOE Award DE-FE0026199) a modular 200 kWe SOFC power plant. MiTi and FCE coordinated to ultimately incorporate one of MiTi’s ARCB prototypes into one of the 100 kWe SOFC Modular Power Blocks (MPB) that constitute the core of FCE’s SOFC power plant for in-situ long-duration testing. Additionally, MiTi would explore the scalability and extendibility of the technology to other applications, as well as conduct a basic techno-economic analysis.

03 NATURAL GAS↗
DOE OSTI2022

A Causal Approach to Integrate Component Health Data into System Reliability Models

Two of the challenges of current plant reliability approaches are the ability to integrate plant health data, and to support decision making. Condition based data and diagnostic/prognostic information are in fact not considered into plant reliability models to inform system engineers on the most critical components. Currently, the propagation of quantitative health data from the component to the system level is a challenge given the diverse nature/structure of the data. On the other hand, plant reliability methods (which are typically based on fault-trees or reliability block diagrams) can effectively propagate data from the component to the system level, but values of failure rates or failure probabilities are an approximated integral representation of the past industry-wide operational experience, and it neglects the present component health status (e.g., diagnostic and condition-based data) and health projection (when available from prognostic data). Our first claim is that system reliability models should propagate health information from the component to the system/plant level in order to provide a quantitative snapshot of system/plant health and identify the most critical components. Our second claim is that component health should be informed solely by that specific component current and historical performance data and should not be an approximated integral representation of the past industry-wide operational experience. This paper is directly supporting these two claims by proposing a different approach to perform reliability modeling which relies on available component diagnostic, prognostic and condition-based data to measure component health, and it propagates this information through fault tree models. The propagation of health data from the component to the system level is performed not in terms of probability, but in terms of margins where margin is defined as the “distance” between the present actual status and an undesired event (e.g., failure or unacceptable performance). Through a cause-effect lens, while classical reliability models target the effect associated to a component performance, a margin-based approach focuses on the cause of an undesired component performance (i.e., component health). Hence, thinking of reliability in terms of margins implies decision making based on causal reasoning. We will show how fault tree models can be solved using a margin language and how this process can effectively assist system engineers to identify the most critical components.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Biomanufacturing from gaseous C1 feedstocks: A perspective on opportunities and challenges

Single-carbon (C1) substrates including carbon dioxide, carbon monoxide, and methane are abundantly available from natural and anthropogenic sources and present potential feedstocks for biomanufacturing. Utilizing these C1 gas feedstocks in bioprocesses for sustainable production of chemicals and fuels could prove pivotal in removing excess carbon from the atmosphere. This perspective describes the spectrum and sources of CO2, CO, and CH4 and examines emerging opportunities in microbial bioconversion and bioelectrochemical processes for these feedstocks. We discuss existing challenges in bioprocess development that currently restrict the commercialization of C1 biomanufacturing technologies. We detail different aerobic and anaerobic bioconversion approaches for C1 feedstocks employing pure and mixed cultures and examine the suitability of each scenario for producing specific molecules. Beyond strain engineering and bioprocess constraints, we address often overlooked factors that limit the development of efficient and reliable bioprocesses, including technology availability for research and safety considerations. We then discuss and recommend the necessary safety features and technological research tools for developing fast, safe, and efficient bioprocesses using gaseous feedstocks to support the scale-up and commercialization of C1 biomanufacturing technologies. This perspective provides an overview of the current scientific and industrial state of the art and offers insights into future technological needs that must be addressed to realize the potential of biomanufacturing from gaseous feedstocks. Synopsis: C1 gases offer a sustainable feedstock for biomanufacturing of fuels and chemicals. This work analyzes bioconversion methods, challenges, and safety considerations, and emphasizes the need for improved technology to enable commercialization.

Biomanufacturing↗