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DOE OSTI2026

Traveling Molten Zone Refining Process Development for Innovative Fuel Cycle Solutions

This ARPA-E ONWARDS project successfully developed and demonstrated an innovative immiscibility zone refining process for separating actinides from active fission products in metallic nuclear fuel applications. The technology addresses a critical challenge in advanced nuclear fuel cycles by providing a high-throughput, low-waste alternative to conventional electrorefining.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2019

A Study on the Use of Solid-Oxide Fuel Cells for Increased Power Generation on Small Aircraft

A growing demand for higher-power electrical equipment on aircraft is driving the exploration of alternative electrical power generation devices. “Hybrid-electric” aircraft architectures that leverage multiple or alternative power sources are also becoming more popular with rising concerns over efficiency. Fuel cells are particularly interesting as auxiliary or secondary electrical power generation devices, due to their relative efficiency and longevity, and could be used as a “power pod” for vehicles without enough on-board electrical generation capability. This paper examines the feasibility and potential value of using an externally-mounted, hybridelectric, solid-oxide fuel cell (SOFC) power system on a Class IV unmanned aerial vehicle (UAV) for the purpose of power generation in excess of the baseline electrical load. Moreover, the paper will demonstrate that a SOFC auxiliary power unit (APU) provides significant value to an aircraft by producing a relatively large amount of additional electrical power for a relatively low initial investment when compared to producing additional power by scaling the engine.

Litherland, Brandon L.↗

NASA NTRS2018

Managing Variability: A Cognitive Ethnography of the Work of Airline Dispatchers

Airline dispatchers' workflow is often described in broad terms like 'flight planning' and 'flight following'. Such high-level descriptions fail to recognize the number and complexity of tasks involved in these activities. An ethnographic study was conducted at three US airlines to understand the cognitive workload involved in flight planning. Fuel planning was identified as one of five key flight planning tasks. Fuel planning was conducted concurrently with other planning and monitoring tasks which often led to interruptions. Planning fuel was dynamic, with recalculations required whenever other factors varied (e.g., payload, route, alternates). This rework increased workload and opportunities for error while reducing efficiency. Four main factors contributed variability to fuel planning: contingency planning, load planning, pilots, and station operations. Strategies for managing variability included pattern identification, use of buffers, rounding up, and leveraging software tools. Software design often added to workload by forcing dispatchers to attend to low level tasks.

dispatcher↗

DOE OSTI2024

Hydrogen Leak Modeling for Development of Smart Distributed Monitoring Under Unintended Releases

Hydrogen is a versatile and clean energy carrier that can be produced from various renewable sources such as wind, solar, and hydropower. Hydrogen has the potential to play a crucial role in decarbonizing industrial processes that are currently reliant on fossil fuels and provide long-duration and/or seasonal energy storage to enable electricity decarbonization. Hydrogen can also be used as a fuel for fuel cell vehicles, providing a zero-emission alternative to traditional internal combustion engines. DOE launched the Hydrogen Energy Earthshot (Hydrogen Shot) in June 2021 to reduce the cost of clean hydrogen by 80% to $1 per 1 kilogram in 1 decade ("1 1 1"). While promising, Hydrogen is highly-flammable, and in the presence of oxygen, it can form explosive mixtures. . Therefore, understanding leak scenarios is essential to evaluate and mitigate the safety risks associated with potential hydrogen leaks. An increased understanding of leak behavior, and having tools to model leaks, can help assess how hydrogen would disperse in different environments, influencing emergency response plans and safety measures, and identify potential issues with materials and design systems that can withstand the challenges posed by hydrogen. Recently, researchers have attempted to study hydrogen leaks for development of risk management strategies. However, the focus has been on closed or semi-closed spaces like storage rooms, vehicles, garages, and fueling stations - all promising locations for future hydrogen infrastructure. In this presentation, the modeling environment extends the span of research further by modeling hydrogen leak in an outdoor, open space. We will present the key challenges with modeling hydrogen leaks in an uncontrollable environment, how they were handled, and how modeling results informed sensor selection and placement. A Hydrogen research facility at the National Renewable Energy Laboratory (NREL) was used as a case study to model hydrogen leaks. In the future, Hydrogen wide area detection methodologies will be developed and tested at this site to monitor for unintended and operational hydrogen releases. The data generated from modeling will be used to develop a predictive model to detect hydrogen leak location based on concentration measured by sensors in this open space. Furthermore, the facility was also chosen because controlled hydrogen releases can be performed. A computational fluid dynamics (CFD) based modeling approach was taken to model hydrogen leak. The full-scale hydrogen facility was modeled with a large ambient domain. The electrolyzer at the facility can produce a controlled release rate of 27 kg-H2/hr. Site-specific atmospheric and weather condition data such as wind direction, wind speed at various altitudes, and temperature were used as inputs to the model. To capture the variability of weather conditions, a subset of the weather conditions experienced during daytime hours without precipitation over the course of three months was generated; using established data clustering techniques, a total of 100 condition sets were chosen. The results show statistical distributions and ranges of hydrogen concentrations at locations throughout the domain. These distributions are compared to experimental data from a constant mass flow, controlled hydrogen release at the facility. The stochastic wind conditions of the release make direct validation difficult, therefore, statistical comparison approaches were used. Wind conditions are found to significantly impact the release behavior, including direction and concentration. Sensor selection and placement is proposed for the facility and is now based on release behavior predicted for the facility given its weather patterns; this is much more informed than without the modeling results. The methodology and analysis procedure can be translated to other facilities using modified geometries and site-specific weather conditions. Hydrogen holds great promise as a renewable energy fuel, but ensuring safety in its production, storage, and use is paramount. Studying potential leak scenarios in an open space will help develop sensors to detect hydrogen on a large spectrum of concentration and eventually build a smart distributed monitoring system.

CFD↗

DOE OSTI2021

The Co-Optimization of Sustainable Aviation Fuel: Cost, Emissions, and Performance

The combustion of petroleum-based fuels contributes to increases in atmospheric CO2, contributing to climate change. As other sectors electrify, current battery technology makes this impractical for the aviation industry. The fastest pathway to reducing the carbon contributions of aviation is to create low or no net carbon-emitting drop-in petroleum alternatives. This research explores 3 potential sorghum derived jet fuel molecules from 4 different production routes, hydro-processed esters and fatty acids (HEFA), and Jet A, to identify how blends including these fuels could offer improved performance (MJ/kg, MJ/L) and improved emissions (gCO2/MJ) while minimizing costs. Different applications will value each target metric differently. This research utilizes the Jet Fuel Blend Optimizer (JudO) to create a 4-dimensional Pareto front across potential solutions. The molecules considered will not offer reduced cost compared to conventional jet fuel (Jet A), but they can be utilized to create blends with higher specific energy, greater energy density, and reduced greenhouse gas emissions. Considerations including carbon credits, the sale of byproducts, and the valuation of improved performance will make the proposed molecules more commercially viable. At the lowest region of GHG solutions, coupled with equivalent LCFS approximations, JudO determined blends that could achieve as high as 69% overall carbon reductions at a premium of $0.34/L.

Feldhausen, John J.↗

DOE OSTI2020

Process Model Development and Experimental Investigation for Spent Fuel Disposal in Crystalline Rocks: FY20 Report.

The U.S. Department of Energy Office of Spent Fuel Waste Disposition (SFWD) established in fiscal year 2010 (FY10) the Spent Fuel Waste Science & Technology (SFWST) Program (formerly the Used Fuel Disposition Campaign - UFDC) program to conduct the research and development (R&D) activities related to storage, transportation and disposal of used nuclear fuel and high level nuclear waste. The Mission of the SFWST is: To identify alternatives and conduct scientific research and technology development to enable storage, transportation and disposal of used nuclear fuel and wastes generated by existing and future nuclear fuel cycles. Significant progress has been made in FY20 in both experimental and modeling arenas in evaluation of used fuel disposal in crystalline rocks, especially in model demonstration using field data. The work covers a wide range of research topics identified in the R&D plan.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1989

Non-noble electrocatalysts for alkaline fuel cells

Carbons activated with macrocyclics have attracted increasing attention as alternative electrocatalysts for oxygen reduction. Initial activity of these catalysts is good, but performance declines rapidly. Pyrolyzing the macrocyclic on the carbon support leads to enhanced stability and the catalysts retain good activity. The approach described is designed to develop bulk doped catalysts with similar structures to pyrolyzed macrocyclic catalysts. The transition metal and coordinated ligands are dispersed throughout the bulk of the conductive carbon skeleton. Two approaches to realizing this concept are being pursued, both involving the doping of carbon precursors. In one approach, the precursor is a solid phase carbon-containing ion-exchange resin. The precursor is doped with a transition metal and/or nitrogen, and the resulting mixture is pyrolyzed. In the other approach, the precursor is a gas-phase hydrocarbon. This is introduced with a transition metal species and nitrogen species into a reactor and pyrolyzed. Several studies have been conducted to determine if there is a synergistic effect between the transition metal and nitrogen and the effect of different methods of introducing the metal-nitrogen (M-N) coordination on performance. One approach was to introduce the metal and nitrogen separately, for example, by sequentially doping FeCl3 and NH4OH into the resin. Catalysts were prepared from an undoped ion-exchange resin, a resin doped only with N, a resin doped only with Fe, and a resin doped with both Fe and N. Introduction of nitrogen alone has no beneficial effect on the performance of the catalysts. The introduction of the Fe alone significantly improves the performance in both the high and low current density regions. When both Fe and N are introduced, the performance at lower current densities (catalytic activity) is increased beyond that of the Fe-doped carbon, but the performance at higher current densities is similar to the carbon containing only Fe. Catalysts prepared from resins-Fe(bipy)3SO4 precursors have performance that is only slightly less then CoTMPP adsorbed and pyroloyzed on Vulcan XC-72. Their performance is much better than carbons which have had the N and Fe introduced separately.

Sarangapani, S.↗

DOE OSTI2022

Plan for Developing TRISO Fuel Processing Technologies

This Plan demonstrates the availability of technologies for processing TRISO used nuclear fuel for waste management and actinide recovery purposes. These technologies are judged to be at a very low level of technology readiness and as such they constitute a fertile research area for the DOE-NE’s Office of Materials and Chemical Technologies. Strategies to mature the technologies to a point where they can reasonably be considered in engineering alternatives analyses typically involve laboratory-scale tests using fuel simulant to characterize process streams and demonstrate key engineering features. Several criteria are available to help selecting candidate technologies for further maturation

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Considerations for Defining G-Values for Aluminum-Clad Spent Nuclear Fuel

Sealed-canister dry storage of aluminum-clad spent nuclear fuel (ASNF) generated by research reactors is an alternative to current storage and disposition pathways as directed by the U.S. Department of Energy. The major challenge faced for this storage approach is radiolytic H 2 generation, including from the aluminum (oxy)hydroxide layers on the surface of ASNF. Experimental and modeling activities have been carried out to characterize the radiolytic yield as part of a DOE-sponsored research program to develop the technical basis for ASNF dry storage. The G-value is a commonly way to report results of radiolysis testing and is defined as the radiolytic yield of a species (e.g. molecular hydrogen) per unit radiation energy deposited into the material system. An independent technical review of the ASNF dry storage technical basis performed by Pacific Northwest National Laboratory raised questions about differences in G-value definitions used for experiments on ASNF surrogates consisting of aluminum samples with adherent (oxy)hydroxides compared to G-values reported in prior literature and how the magnitudes compared between different studies. Material systems resembling ASNF pose complications for measuring/defining G-values to predict the evolution of H 2 in a sealed canister, including i) accounting for radiolytic yields potentially arising from multiple sources, i.e., residual free (vapor), physisorbed, and chemisorbed/chemically bound waters; ii) deciding what portions of the multi-material system to include in the absorbed energy (radiation dose) calculation, considering possible energy exchange between materials as well as measurement limitations, and iii) capturing variations in G-value associated with non-linear yield vs. dose curves and/or dependence on the cover gas. This report summarizes previous literature information on radiolytic H 2 generation and associated G-values from mixed-material systems (generally oxides in contact with water or organic compounds) and from (oxy)hydroxides/hydrates to compare with the definitions and values for ASNF surrogate samples containing adherent aluminum (oxy)hydroxides.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1985

Comparative evaluation of three alternative power cycles for waste heat recovery from the exhaust of adiabatic diesel engines

Three alternative power cycles were compared in application as an exhaust-gas heat-recovery system for use with advanced adiabatic diesel engines. The power cycle alternatives considered were steam Rankine, organic Rankine with RC-1 as the working fluid, and variations of an air Brayton cycle. The comparison was made in terms of fuel economy and economic payback potential for heavy-duty trucks operating in line-haul service. The results indicate that, in terms of engine rated specific fuel consumption, a diesel/alternative-power-cycle engine offers a significant improvement over the turbocompound diesel used as the baseline for comparison. The maximum imporvement resulted from the use of a Rankine cycle heat-recovery system in series with turbocompounding. The air Brayton cycle alternatives studied, which included both simple-cycle and compression-intercooled configurations, were less effective and provided about half the fuel consumption improvement of the Rankine cycle alternatives under the same conditions. Capital and maintenance cost estimates were also developed for each of the heat-recovery power cycle systems. These costs were integrated with the fuel savings to identify the time required for net annual savings to pay back the initial capital investment. The sensitivity of capital payback time to arbitrary increases in fuel price, not accompanied by corresponding hardware cost inflation, was also examined. The results indicate that a fuel price increase is required for the alternative power cycles to pay back capital within an acceptable time period.

Bailey, M. M.↗

NASA NTRS2015

Deployment Technology of a Heliogyro Solar Sail for Long Duration Propulsion

Interplanetary, multi-mission, station-keeping capabilities will require that a spacecraft employ a highly efficient propulsion-navigation system. The majority of space propulsion systems are fuel-based and require the vehicle to carry and consume fuel as part of the mission. Once the fuel is consumed, the mission is set, thereby limiting the potential capability. Alternatively, a method that derives its acceleration and direction from solar photon pressure using a solar sail would eliminate the requirement of onboard fuel to meet mission objectives. MacNeal theorized that the heliogyro-configured solar sail architecture would be lighter, less complex, cheaper, and less risky to deploy a large sail area versus a masted sail. As sail size increases, the masted sail requires longer booms resulting in increased mass, and chaotic uncontrollable deployment. With a heliogyro, the sail membrane is stowed as a roll of thin film forming a blade when deployed that can extend up to kilometers. Thus, a benefit of using a heliogyro-configured solar sail propulsion technology is the mission scalability as compared to masted versions, which are size constrained. Studies have shown that interplanetary travel is achievable by the heliogyro solar sail concept. Heliogyro solar sail concept also enables multi-mission missions such as sample returns, and supply transportation from Earth to Mars as well as station-keeping missions to provide enhanced warning of solar storm. This paper describes deployment technology being developed at NASA Langley Research Center to deploy and control the center-of-mass/center-of-pressure using a twin bladed heliogyro solar sail 6-unit (6U) CubeSat. The 6U comprises 2x2U blade deployers and 2U for payload. The 2U blade deployers can be mounted to 6U or larger scaled systems to serve as a non-chemical in-space propulsion system. A single solar sail blade length is estimated to be 2.4 km with a total area from two blades of 720 m2; total allowable weight of a 6U CubeSat is approximately 8 kg. This makes the theoretical characteristic acceleration of approximately 0.75 mm/s2 at I AU (astronomical unit), when compared to IKAROS (0.005 mm/s2) and NanoSail-D (0.02 mm/s2).

Peerawan, Wiwattananon↗

DOE OSTI2025

Characterization of Kariya ( Hildegardia barteri (Mast.) Kosterm) Seed Oil Fatty Acid Methyl Ester Prepared from Basic Catalytic Transesterification

The rising global energy demand, alongside concerns regarding environmental deterioration due to the use of fossil fuels, has spurred extensive investigation into renewable energy alternatives. Biomass-derived biodiesel, especially from lesser-known oil sources, emerges as a promising option. This research focuses on analyzing the fatty acid methyl esters (FAMEs) derived from Kariya (Hildegardia barteri (Mast.) Kosterm) seed oil through basic catalytic transesterification using gas chromatography–flame ionization detector (GC–FID) analysis, assessing its potential as a biodiesel feedstock. Oil extraction from Kariya seeds was carried out using three solvents (n-hexane, ethanol, and a 1:1 blend of hexane and ethanol), followed by transesterification with methanol. Gas chromatography–mass spectrometry (GC–MS) and GC–FID analyses were utilized to identify and quantify FAMEs in the resulting biodiesel. The results revealed various FAMEs, including methyl myristate, methyl palmitate, methyl stearate, methyl oleate, methyl linoleate, and methyl linolenate. Significant differences in FAME composition were observed among the samples, with hexane–ethanol Kariya oil biodiesel (HE-KOB) showing the highest FAME content (76.1%). This combination of solvents exhibited synergistic effects on the composition of HE-KOB, suggesting potential optimization strategies for biodiesel production. Fourier transform infrared spectroscopy (FTIR) provided additional insights into the molecular composition of the biodiesel samples, confirming their biodiesel nature through the identified functional groups such as methyl, methylene, hydrocarbon, ester, aldehyde, and alkene. Thermogravimetric analysis (TGA) for thermal decomposition also gave an insight into FAME composition and its contribution to the degree of conversion of biodiesel to energy. These findings highlight the feasibility of utilizing Kariya seed oil as a biodiesel feedstock, emphasizing the importance of solvent selection and transesterification conditions in optimizing FAME yield and composition. This research contributes to the exploration of underutilized oil sources for sustainable biodiesel production, aligning with the global shift towards cleaner and renewable energy sources.

09 BIOMASS FUELS↗

NASA NTRS1978

ECAS Phase I fuel cell results

This paper summarizes and discusses the fuel cell system results of Phase I of the Energy Conversion Alternatives Study (ECAS). Ten advanced electric powerplant systems for central-station baseload generation using coal were studied by NASA in ECAS. Three types of low-temperature fuel cells (solid polymer electrolyte, SPE, aqueous alkaline, and phosphoric acid) and two types of high-temperature fuel cells (molten carbonate, MC, and zirconia solid electrolyte, SE) were studied. The results indicate that (1) overall efficiency increases with fuel cell temperature, and (2) scale-up in powerplant size can produce a significant reduction in cost of electricity (COE) only when it is accompanied by utilization of waste fuel cell heat through a steam bottoming cycle and/or integration with a gasifier. For low-temperature fuel cell systems, the use of hydrogen results in the highest efficiency and lowest COE. In spite of higher efficiencies, because of higher fuel cell replacement costs integrated SE systems have higher projected COEs than do integrated MC systems. Present data indicate that life can be projected to over 30,000 hr for MC fuel cells, but data are not yet sufficient for similarly projecting SE fuel cell life expectancy.

Warshay, M.↗

NASA NTRSDate not supplied

The Effect of Reduced Pressure on the Characteristics of Spreading Flames

Flame spread over solid fuels is a canonical problem in fire science, due to its direct implications on material flammability and importance in fire development. In a microgravity environment, such as onboard a spacecraft, flames can behave very differently than on Earth. This is concerning for spaceflight life safety, especially in higher-oxygen environments. Due to the difficulties associated with microgravity testing, low-pressure environments have been proposed as an alternative to approximately replicate the burning behavior of solid fuels observed in reduced gravity conditions because of similar diffusion and heat transfer mechanisms. However, the roles played by gravity and pressure on flame length, standoff distance, and flame spread rate vary with the burning configuration. In concurrent flame spread, the buoyant flow enhances the spread rate by bringing the flame closer to the fuel surface and increasing the heating of the solid fuel. In opposed flame spread, the sample is preheated by the flame ahead of the flame leading edge, which is strongly affected by the surrounding flow field. In this work, we consider flames spreading over thin cotton samples in both downward (opposed) and upward (concurrent) configurations to investigate the effect of pressure (30-100 kPa) on flame characteristics, such as spread rate and standoff distance. A small forced flow is induced upward so that the flames are exposed to a mixed (forced and free) flow. By reducing pressure, flames become less bright, their standoff distance increases, and their spread rates decrease similar to what is observed in low-gravity environments. These results could in help understanding the differences between flames spreading at low pressure and low gravity environments for these similar, yet very different, spreading configurations. They could also provide more information about potential Earth-based flammability testing of materials for spacecraft applications.

fire safety↗

NASA NTRSDate not supplied

The effect of reduced pressure on the characteristics of spreading flames

fire safety↗

DOE OSTI2021

Spatial and Temporal Analysis of the Total Cost of Ownership for Class 8 Tractors and Class 4 Parcel Delivery Trucks

The medium- and heavy-duty transportation sector is experiencing rapid changes in powertrain technology innovation, with recent announcements of battery electric and fuel cell electric trucks being offered. The economics of these alternative powertrain vehicles are uncertain and difficult to compare directly. This analysis seeks to provide a rigorous, techno-economic analysis of all of these alternative powertrain vehicles within the same analytic framework. Specifically, this report evaluates the total cost of ownership (TCO) of six different truck powertrain technologies (diesel, diesel hybrid electric, plug-in hybrid electric, compressed natural gas, battery electric, and fuel cell electric) for three different truck vocations (Class 8 long haul [750-mile range and 500-mile range], Class 8 short haul [300-mile range], and Class 4 parcel delivery [120-mile range]), for three different time frames (2018, 2025, and Ultimate).

08 HYDROGEN↗

DOE OSTI2023

Hydrocarbon Ionomeric Binders for Fuel Cells and Electrolyzers

Abstract Ionomeric binders in catalyst layers, abbreviated as ionomers, play an essential role in the performance of polymer–electrolyte membrane fuel cells and electrolyzers. Due to environmental issues associated with perfluoroalkyl substances, alternative hydrocarbon ionomers have drawn substantial attention over the past few years. This review surveys literature to discuss ionomer requirements for the electrodes of fuel cells and electrolyzers, highlighting design principles of hydrocarbon ionomers to guide the development of advanced hydrocarbon ionomers.

25 ENERGY STORAGE↗

DOE OSTI2020

Expression of the Trichoderma reesei expansin-like protein, swollenin, in poplar results in biomass with improved sugar release by enzymatic hydrolysis

Ethanol production from lignocellulosic biomass has been considered an alternative to corn-based ethanol and fossil fuel. However, the secondary cell wall structure prevents efficient degradation of cellulose. Expression of cell wall degrading enzymes has been suggested as one solution to generate suitable feedstocks for lignocellulosic ethanol production. Swollenin (SWO), originating from Trichoderma reesei, disrupts cellulose structure with low-level hydrolytic activity to the glucan chain. Previously, characterization of T. reesei SWO has been carried out in multiple microorganisms and tobacco. This study heterologously overexpressed T. reesei SWO in hybrid poplar (Populus tremula × alba), a promising feedstock for biofuel production, under the control of either the constitutive Cauliflower Mosaic Virus 35S (CaMV 35S) promoter or the putative vascular tissue specific Subterranean Clover Stunt Virus S7 (SCSV) promoter. Transgenic poplar lines with high or moderate SWO expression level showed abnormal growth and reduced biomass production, along with increased glucose and reduced lignin contents. Increased cellulose crystallinity was observed in two transgenic events. This study also investigated the effect of in planta SWO expression on cellulose saccharification efficiency and found that transgenic events improved glucan conversion rates compared to wild type poplar. The results suggest SWO-overexpressing transgenic poplar lines could be a potential feedstock for ethanol production.

09 BIOMASS FUELS↗