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NASA NTRSDate not supplied

Standalone Hazard Evaluation and Refinement From Instrument Findings (S.H.E.R.I.F.)

The Standalone Hazard Evaluation From Instrument Findings or SHERIF is a set of novel algorithms and associated framework designed to support the generation of Digital Elevation Maps (DEMs) from multiple LiDAR scans and perform Hazard Detection (HD) and Safe Site Selection with minimal input from other onboard systems. SHERIF can employ several techniques to perform Point Cloud registration(PCR) on disparate LiDAR scans of a planetary surface to generate a DEM which evolves over the course of a trajectory, with a flow designed to enable robustness. The framework also supports a variety of Hazard Detection and Safe Site Selection algorithms which can be run on the evolving DEM being produced. SHERIF features a robust and modular construction, allowing the user a high degree of flexibility in selecting and implementing whichever PCR and HD/SSL algorithms they may prefer, while maintaining the data products and sensor independence of the core SHERIF framework. SHERIF was recently tested in a hardware in the loop simulation at NASA JSC.

Entry Descent and Landing Guidance Navigation Cont↗

NASA NTRSDate not supplied

Standalone Hazard Evaluation and Refinement From Instrument Findings (S.H.E.R.I.F.)

The Standalone Hazard Evaluation From Instrument Findings (SHERIF) system is a set of novel algorithms and associated framework designed to support the generation of Digital Elevation Maps (DEMs) from multiple LiDAR scans and perform Hazard Detection (HD) and Safe Site Identification (SSI) with no dependencies on other onboard systems. SHERIF can employ several techniques to perform robust 3D keypoint extraction and Point Cloud registration (PCR) on disparate LiDAR scans of a planetary surface to generate a DEM which evolves over the course of a trajectory. The framework also supports a variety of Hazard Detection and Safe Site Identification algorithms which can be applied to the evolving DEM being produced. SHERIF features a robust and modular construction, allowing the user a high degree of flexibility in selecting and implementing whichever keypoint identificaiton, PCR and HD/SSI algorithms they may prefer, while maintaining the data products and sensor independence of the core SHERIF framework. SHERIF was recently evaluated via simulation and hardware-in-the-loop experimental testing at NASA Johnson Space Center.

hazard detection↗

NASA NTRSDate not supplied

Standalone Hazard Evaluation and Refinement From Instrument Findings (S.H.E.R.I.F.)

hazard detection↗

DOE OSTI2023

Modular Multi-family Construction: A Field Study of Energy Code Compliance and Performance through Offsite Prefabrication

Prefabrication in a controlled, factory setting may improve the energy code compliance and energy performance of modular buildings compared to traditional site-built buildings. To test this premise, the work detailed in this DOE-funded commercial field study (EE0009082) compares the energy code compliance of 25 modular and 30 site-built multifamily buildings under construction in Los Angeles, San Francisco, Philadelphia and Seattle representing climate zones 3B, 3C, 4A and 4C respectively. This dataset includes full data on 20 modular and site-built buildings and partial data on 35 modular and site-built buildings that had started prior to or were completed after the 18-month data collection period. This study also compares the post-occupancy energy performance or energy use intensity (EUI) of an additional 23 modular multifamily buildings and 128 site-built multifamily buildings.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

Affordable and Scalable Modular Multifamily Housing: A Case Study on Cost, Construction Time Savings, and Waste Reduction in California: Preprint

Modular construction can significantly reduce waste when compared to traditional methods. This case study evaluates cost, construction time, and waste metrics for a 195-unit stick-built project and for a 66-unit modular project both based in Los Angeles, CA. We partner with SoLa Impact (real estate developer) and Model/Z (modular manufacturer) to evaluate the impact of Model/Z's 1-bedroom modular unit which is produced in a 160,000 sq ft local factory in South Los Angeles. We compare them to similar stick-built/site-built multifamily construction by the same developer in Los Angeles. This study finds that modular production reduced construction waste through precise prefabrication, concentrated workforce expertise, and streamlined logistics while cutting transportation needs, improving project efficiency and lowering associated timelines and costs. Economies of scale are being realized as Model/Z has produced over 500 affordable housing units and supplied for projects up to 188 units, shortening schedules and lowering per-unit costs and supporting affordable housing goals in income-challenged South Los Angeles. Modular methods offer a scalable, resource-efficient pathway to increasing affordable housing supply while reducing total development costs by 10-15% and project timelines by 50%, while simultaneously creating local jobs and training opportunities.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Multifamily Air Leakage Evaluation: A Modular Case Study

The purpose of this case study is to compare the air leakage rates of modular and site-built multifamily dwelling units. The methods, materials, and equipment were observed to be very similar in the modular and site-constructed units in this case study. The installation quality of building envelope measures such as insulation and air barrier appeared to be better for modular construction, because they were installed in a controlled, factory setting. Through field observations, we identified cosmetic damage to the envelope of modular units following transport to the building site, but with no resulting significant air leakage pathways. However, we did see air leakage pathways resulting from field modifications to the envelope of modular units to accommodate structural and mechanical connections. We found that the extensive use of through-wall HVAC systems, combined with the transport, placement, and rework of modular units may compromise the high-quality envelope installation and airtightness observed in the factory without careful planning and/or design. Opportunities for improvement identified from the tested modular dwelling units include minimizing and optimally locating penetrations, pre-cutting and detailing penetrations at the factory where possible, properly sealing field modifications, and using split HVAC systems in place of through-wall packaged systems.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Contech to Accelerate Cleantech: Seeding Emerging Innovation Programs for Construction Productivity and Energy Efficiency Integration; Preprint

Investments in U.S.-based start-ups that focus on advanced building construction technologies to increase construction productivity (contech) surged to approximately $3.1 billion in 2018 (as per Crunchbase data). More recently, emerging programs by government funding agencies, philanthropic foundations, and venture capitalists have been instrumental in supporting contech start-ups for innovations that increase productivity of energy efficiency integration and accelerate clean energy technologies (cleantech) for the buildings sector. These programs include R&D support and funding mechanisms for contech and cleantech. Traditionally, contech and cleantech are considered as two different innovation ecosystems. To enhance and scale up energy efficiency in buildings, creative programs that bring together contech and cleantech are critical. This paper provides a landscape assessment of the "contech-for-cleantech" innovation ecosystem in the U.S. and its impact in accelerating technology readiness and the development pipeline of "contech-for-cleantech". Technologies highlighted are robotics for retrofits, prefabrication of energy-efficient products, and advanced manufacturing of low-carbon net-zero buildings construction. Programs discussed include those led by (1) government funding agencies: American-Made Challenges with prizes like E-ROBOT for retrofits with robotics, (2) philanthropic foundations: Wells Fargo Innovation Incubator (IN2) that includes focus on energy efficiency and prefabrication, and (3) venture capitalists: Shadow Ventures Green Building Accelerator program which provides funding support to start-ups with ambitious plans for decarbonizing the built environment. This paper will also expand upon robust processes and criteria involved in judging and down-selection of start-ups through vetting and feedback from national lab researchers and industry experts in both cleantech and contech.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Modularization of Small Modular Reactor Facilities: Physical Protection Recommendations

U.S. nuclear power facilities face increasing challenges in meeting dynamic security requirements caused by evolving and expanding threats while keeping costs reasonable to make nuclear energy competitive. In consideration of the economic viability of small modular reactor (SMR) facilities, many designers and utilities are considering a modular approach to the construction and operation of these facilities. This modular approach considers building and operating a first unit; once the first reactor is in operation, construction will begin on a second reactor. This process would allow the vendor or utility to ensure production of energy and financial income while the second reactor is under construction. This project evaluates the feasibility of modular construction in terms of physical protection and identifies several recommendations for vendors and utilities considering this approach. To conduct this evaluation, a hypothetical three-unit SMR facility was developed, a physical protection system (PPS) was considered for the design, and a hypothetical design basis threat (DBT) was used to evaluate this PPS. Multiple outsider sabotage scenarios were examined, with adversary team sizes ranging from 4-to-8 to determine security system effectiveness. The results of this work will influence PPS designs and facility designs for U.S. domestic SMRs. This work will also demonstrate how a series of experimental and modeling capabilities across the Department of Energy (DOE) complex can impact the design and completion of security-by-design (SeBD) for SMRs considering modular construction. The conclusions and recommendations in this document may be applicable to all SMR designs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

Exploring the Potential of Factory Installed Solar + Storage for Homebuilding

In recent years, an increasing number of grid disruptions due to intense weather events, natural disasters, and high peak loads resulted in increased interest in energy-resilient homes. Solar + storage (S+S) as an energy resiliency solution can provide continuity, onsite generation, and backup power during critical events. This project explored factory-installed solar plus storage (FISS) to overcome first cost and installation barriers and bring this resiliency solution to scale for single-family affordable and market-rate homebuyers. Guided by the principles of Lean manufacturing, the team explored how factories building high-performance zero energy modular homes can incorporate S+S into their existing construction system while improving quality and productivity and reducing the costs of the resilient energy system.

ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION,↗

NASA NTRS1981

A modular approach toward extremely large apertures

Modular antenna construction can provide a significant increase in reflector aperture size over deployable reflectors. The modular approach allows reflective mesh surfaces to be supported by a minimum of structure. The kinematics of the selected deployable design approach were validated by the subscale demonstration model. Further design refinements on the module structural/joints and design optimization on intermodule joints are needed.

Woods, A. A., Jr.↗

DOE OSTI2025

Final Technical Report (FTR) - DE-EE0009084: Prefabricated Construction: Guidance, Technical Assistance, and Virtual Inspections

This final technical report summarizes research, case studies, and resources developed from 2020–2025 on prefabricated construction and remote virtual inspections. It documents key findings on benefits, challenges, and best practices, highlights examples from multiple states, and provides guidance to support wider adoption of these innovations in the construction sector.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

A Scalable and Cost-Effective Solution to the U.S. Housing Crisis: A Case Study on Locally Manufactured Modular Multifamily Housing

This case study assesses waste management efficiencies in modular buildings compared to traditional construction methods. We focus on the modular 1-bedroom Model/Z unit by Model Z Modular, LLC. As part of the collaboration between Model Z Modular and the National Renewable Energy Laboratory, we analyzed waste metrics from design through construction, contrasting these findings against conventional stick-built and site-built multifamily buildings. The Model/Z unit is part of a strategic effort to address affordable housing shortages in South Los Angeles, where household income challenges are pronounced. The unit is produced in a state-of-the-art 150,000 sq. ft. modular manufacturing facility located within the city it is serving, and has so far supported the production of over 1,500 affordable housing units. Model/Z units have been used in projects with as many as 195 units, achieving large economies of scale and time. Our analysis demonstrates that modular construction reduces waste compared to traditional methods. This reduction is achieved through precise prefabrication techniques, the implementation of new framing methods, the concentration of workforce expertise, and streamlined logistics, which optimize material use and greatly reduce on-site handling. Additionally, local manufacturing minimizes transportation needs, improving overall project efficiency. The Model/Z unit exemplifies a scalable solution for enhancing housing affordability by optimizing resource utilization and minimizing associated costs. These methods support the delivery of high-quality units at reduced expenses, addressing critical urban housing shortages effectively. This case study underscores Model Z Modular's commitment to producing affordable, quality housing while fostering economic opportunities through job creation and training programs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Analyticity and the Unruh effect: a study of local modular flow

The Unruh effect can be formulated as the statement that the Minkowski vacuum in a Rindler wedge has a boost as its modular flow. In recent years, other examples of states with geometrically local modular flow have played important roles in understanding energy and entropy in quantum field theory and quantum gravity. Here I initiate a general study of the settings in which geometric modular flow can arise, showing (i) that any geometric modular flow must be a conformal symmetry of the background spacetime, and (ii) that in a well behaved class of “weakly analytic” states, geometric modular flow must be future-directed. I further argue that if a geometric transformation is conformal but not isometric, then it can only be realized as modular flow in a conformal field theory. Finally, I discuss a few settings in which converse results can be shown — i.e., settings in which a state can be constructed whose modular flow reproduces a given vector field.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2022

Predictive modeling of a subcritical pulverized-coal power plant for optimization: Parameter estimation, validation, and application

As renewable power generation deployment increases, fossil fuel plants are increasingly required to operate more flexibly. Many coal-fired power plants were originally designed to operate at base load and do not operate optimally at partial load. Predictive first-principles plant-wide models can be employed to identify opportunities for flexibility improvements and diagnose low-load operating issues. This paper describes the application of the Institute for the Design of Advanced Energy Systems Integrated Platform (IDAES) to model and optimize flexible power plant operations. The key benefits of using IDAES are that it provides an open-source, fully equation-oriented modeling framework for efficient modular model construction, reuse, and customization, together with a mathematical optimization framework leveraging powerful, state-of-the-art solvers. The process systems engineering workflow from predictive process simulation to parameter estimation, model validation, and plant optimization is applicable to a variety of existing and next-generation energy systems as well as other chemical and environmental processes. Here, to demonstrate this capability, a physics-based, steady-state model was developed to improve full- and part-load performance of the Escalante Generating Station, a 245 MWe (net) subcritical pulverized coal-fired power plant owned and operated by Tri-State Generation and Transmission Association. Specifically, sixty-nine model parameters were simultaneously estimated from several months of operating data enabling prediction of flow rates, temperatures, pressures, and steam quality throughout the plant. The validated model was leveraged by Escalante to reduce the minimum operating load from 90 MW to 50 MW by diagnosing a low-load water-hammer issue, enabling coal usage and emissions reductions during periods of low power demand. Additionally, opportunities for heat rate reduction (i.e., efficiency improvement) through a steeper sliding-pressure approach to load-following and optimization of other boiler operating variables were also identified and quantified. For example, a potential efficiency improvement of 0.7 percentage points was observed at half-load operation.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2024

Insights from FEED studies for retrofitting existing fossil power plants with carbon capture technology

Recent United States Department of Energy (DOE) sponsored front-end engineering design (FEED) studies for retrofitting existing fossil-fueled power plants with state-of-the-art carbon capture technology contain previously overlooked real-world design considerations for near-term deployment of carbon capture. Insights from examining seven recently published FEED study reports are summarized in this paper. This includes a discussion of the design, performance, and cost implications associated with (1) location-specific considerations such as water availability, land availability, and accessibility; (2) host-plant-specific factors such as flue gas specifications, allowable degree of integration between the capture system and host plant, and operational mode; and (3) miscellaneous factors such as market conditions, permitting requirements, and business case incentives. In conclusion, this manuscript highlights (1) water availability as a key design and cost driver, with host plant steam extraction increasing capture system cooling water availability, (2) modularization and constructability impacts on the number of capture trains, (3) the impacts of host plant operational mode and capacity factor on the business case for installing capture, and (4) the merit of continued research, development, and demonstration efforts addressing steam extraction, host plant tie-in at the stack, solvent reclamation and air emissions control.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

Estimating coil features from an equilibrium

We present an explicit theoretical framework for constructing artificial modular coils for vacuum stellarator fields based solely on equilibrium properties, achieved through the formulation of a current potential defined on flux surfaces. Contours of constant Boozer toroidal angle can be directly interpreted as proxy coils, and so we demonstrate that key measures of coil complexity—particularly coil non-planarity—are strongly governed by local magnetic-field properties. This approach shows promise as predictor for more realistic coil configurations, providing both a pathway toward deeper understanding of equilibrium–coil relationships and a potential practical proxy for coil design.

Rodríguez, Eduardo [Max Planck Institute for Plasm↗

DOE OSTI2024

Strategies for connecting whole-building LCA to the low-carbon design process

Abstract Decarbonization is essential to meeting urgent climate goals. With the building sector in the United States accounting for 35% of total U.S. carbon emissions, reducing environmental impacts within the built environment is critical. Whole-building life cycle analysis (WBLCA) quantifies the impacts of a building throughout its life cycle. Despite being a powerful tool, WBLCA is not standard practice in the integrated design process. When WBLCA is used, it is typically either speculative and based on early design information or conducted only after design completion as an accounting measure, with virtually no opportunity to impact the actual design. This work proposes a workflow for fully incorporating WBLCA into the building design process in an iterative, recursive manner, where design decisions impact the WBLCA, which in turn informs future design decisions. We use the example of a negative-operational carbon modular building seeking negative upfront embodied carbon using bio-based materials for carbon sequestration as a case study for demonstrating the utility of the framework. Key contributions of this work include a framework of computational processes for conducting iterative WBLCA, using a combination of an existing building WBLCA tool (Tally) within the building information modeling superstructure (Revit) and a custom script (in R) for materials, life cycle stages, and workflows not available in the WBLCA tool. Additionally, we provide strategies for harmonizing the environmental impacts of novel materials or processes from various life cycle inventory sources with materials or processes in existing building WBLCA tool repositories. These strategies are useful for those involved in building design with an interest in reducing their environmental impact. For example, this framework would be useful for researchers who are conducting WBLCAs on projects that include new or unusual materials and for design teams who want to integrate WBLCA more fully into their design process in order to ensure the building materials are consciously chosen to advance climate goals, while still ensuring best performance by traditional measures.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Advanced Anode for Internal Reforming and Thermal Management in Solid Oxide Fuel Cells

Solid oxide fuel cell (SOFC) is an efficient and clean electrical power generation system compared to conventional combustion based technologies with energy efficiency reaching as high as 85-90% in co-generation mode (electricity and heat). Other advantages of SOFCs are hybridization, modularity of construction, small CO 2 foot print per kWh of generated electricity and fuel flexibility. Hydrocarbons present in the gaseous fuel is utilized in SOFCs by internal or external reforming. There are two different internal reforming concepts: Direct Internal Reforming (DIR) and Indirect Internal Reforming (IIR). For DIR operation, the endothermic reforming reaction and the exothermic reaction from the oxidation reaction are operated together in the single unit eliminating the requirement for a separate fuel reformer. This configuration also simplifies the overall system design, making SOFC more attractive and efficient means of producing electrical power. The main advantage of the DIR type of operation is that the H 2 or CO consumption by the electrochemical reaction could directly promote the conversion of methane at the anode side of the fuel cell resulting in high conversion and high efficiency. The DIR operation, however, requires an anode material that has desired dual catalytic (hetero and electro) properties for reforming reaction and electrochemical reactions. The anode materials also need to remain resistant to carbon formation at the operating temperature and atmosphere with stable cell performance. Another requirement is to match the reforming reactions and electrochemical reactions to avoid local cooling or overheating, which can result in mechanical failure due to thermally induced stresses. Direct internal reforming (DIR) of hydrocarbon fuels simplifies the overall SOFC system design making it more attractive and efficient for producing electrical power. Low cost alloy anodes for distributed internal reforming of methane and other hydrocarbon fuels offer increased fuel-flexibility, reliability, and long term performance stability of solid oxide fuel cells (SOFC). The research program examined modification of the chemical compositions and microstructure of high entropy alloy (HEA) anode materials using thermochemical calculations and process simulation and modeling to achieve distributed reforming over the entire anode to eliminate hot zones. Cell fabrication and testing of the HEA anodes using button cell configuration has been performed to demonstrate the advantages of new anode over traditional Ni-YSZ anodes for distributed reforming and carbon free operation. Technical accomplishments include identification and synthesis of HEA carbon-resistant anode, demonstration of reduction in reforming rate confirmed by GC and modelling data validating effectiveness for thermal management in cell/stacks, electrochemical testing of HEA anode in single cell (HEA-GDC||YSZ||LSM-YSZ) and Characterization of pretest and posttest anode materials by TEM and SEM-EDS confirming carbon-free operation.

30 DIRECT ENERGY CONVERSION↗