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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 937 records · Page 52
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

A decision support tool for e-waste recycling operations using the hen-and-chicks bio-inspired optimization metaheuristic

E-waste from end-of-life electrical and electronic devices is one of the fastest growing waste streams from households and businesses. E-waste recycling yields environmental sustainability and economic benefits. Due to continuous changes in e-waste types and compositions, recycling businesses face challenges to optimize their operational configuration to achieve better economic and environmental performance. To help e-waste recyclers mitigate this problem, we have developed a modular decision support tool called the Comprehensive Manufacturing Assessment Tool (CMAT) that can simulate both e-waste recycling operations and economics. This tool can give valuable insights regarding the profitability of the entire operation and different e-waste types. In addition, a new bio-inspired metaheuristic optimization algorithm, hen-and-chicks optimization (HACO), was developed to assign manpower to different workstations to maximize operational efficiencies. According to the results of our case study, laptops, desktops, and computer peripherals are the three electronic waste products that produce the most profit. Our examination of the sensitivity of material prices shows that the price of steel has the most significant influence on total profit, because it is the most widely used material in the majority of electronic devices. We have released the decision support tool as open-source software under a general public license. It could be customized for other recycling industries beyond e-waste to achieve business sustainability by making their operations more efficient.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Preliminary Screening Techno-Economic Analysis of Industrial SOFC/SOEC and Reversible SOC Integration

National Energy Technology Laboratory (NETL) provides system-level process, cost, and market analyses on solid oxide cell (SOC) based technologies. Specifically, techno-economic analyses (TEA), market assessments, and other technology evaluations serve to guide the U.S. Department of Energy (DOE) Office of Fossil Energy and Carbon Management (FECM) Reversible Solid Oxide Fuel Cell (R-SOFC) Program technology goals and objectives. These studies are key to describing how the technologies contribute to improving domestic energy infrastructure in a clean, efficient manner. This effort seeks to elucidate the potential integration opportunities between reversible SOCs and industrial systems which would aid in SOC commercialization and deployment. These preliminary screening-level results show what opportunities exist for power generating SOFCs, hydrogen producing SOECs, and point-source carbon capture. Improvements can be seen through changes in cost of electricity, cost of hydrogen, and cost of carbon capture.

reversible SOC↗
DOE OSTI2022

Application of Ionic Liquids for the Recycling and Recovery of Technologically Critical and Valuable Metals

Population growth has led to an increased demand for raw minerals and energy resources; however, their supply cannot easily be provided in the same proportions. Modern technologies contain materials that are becoming more finely intermixed because of the broadening palette of elements used, and this outcome creates certain limitations for recycling. The recovery and separation of individual elements, critical materials and valuable metals from complex systems requires complex energy-consuming solutions with many hazardous chemicals used. Significant pressure is brought to bear on the improvement of separation and recycling approaches by the need to balance sustainability, efficiency, and environmental impacts. Due to the increase in environmental consciousness in chemical research and industry, the challenge for a sustainable environment calls for clean procedures that avoid the use of harmful organic solvents. Ionic liquids, also known as molten salts and future solvents, are endowed with unique features that have already had a promising impact on cutting-edge science and technologies. This review aims to address the current challenges associated with the energy-efficient design, recovery, recycling, and separation of valuable metals employing ionic liquids.

36 MATERIALS SCIENCE↗
DOE OSTI2020

2020 Review Panel Workshop on Energy Intensity Indicators: Summary Findings and Meeting Notes

On January 28-29, 2020, the U.S. Department of Energy (DOE) Office of Energy Efficiency and Renewable Energy (EERE), in coordination with Pacific Northwest National Laboratory (PNNL), sponsored an expert workshop focused on energy intensity indicators. The intent of the workshop was to support a comprehensive review of the EERE Energy Intensity Indicators (EII), a national system of indicators used to track changes in the energy intensity of economic sectors. One goal of the workshop was to gather input from a panel of experts who have experience and knowledge related to the EII methodological approach and key data sources used to calculate indicators for each of the end-use sectors of the economy—transportation, residential, commercial, industrial, and electricity. The current EERE EII methodology is documented in a 2017 PNNL report, A Comprehensive System of Energy Intensity Indicators for the U.S.: Methods, Data and Key Trends, which is available online. The workshop also included a presentation by Dr. Beng Ang, who discussed the Log Mean Divisia index (LMDI) approach to decomposition analysis, which was followed by a discussion concerning the methodological approaches that could be applied to future EII efforts.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
NASA NTRS2014

Lessons Learned from the Development and Implementation of the Atmosphere Resource Recovery and Environmental Monitoring Project

The Advanced Exploration Systems (AES) Program's Atmosphere Resource Recovery and Environmental Monitoring (ARREM) Project have been developing atmosphere revitalization and environmental monitoring subsystem architectures suitable for enabling sustained crewed exploration missions beyond low Earth orbit (LEO). Using the International Space Station state-of-the-art (SOA) as the technical basis, the ARREM Project has contributed to technical advances that improve affordability, reliability, and functional efficiency while reducing dependence on a ground-based logistics resupply model. Functional demonstrations have merged new process technologies and concepts with existing ISS developmental hardware and operate them in a controlled environment simulating various crew metabolic loads. The ARREM Project's strengths include access to a full complement of existing developmental hardware that perform all the core atmosphere revitalization functions, unique testing facilities to evaluate subsystem performance, and a coordinated partnering effort among six NASA field centers and industry partners to provide the innovative expertise necessary to succeed. A project overview is provided and the project management strategies that have enabled a multidiscipinary engineering team to work efficiently across project, NASA field center, and industry boundaries to achieve the project's technical goals are discussed. Lessons learned and best practices relating to the project are presented and discussed.

Roman, Monsi C.↗
DOE OSTI2026

Low-voltage syngas synthesis via BPM electrolysis of CO 2 capture and aldehyde solution

A bipolar membrane electrolyzer coupling bicarbonate electrolysis with formaldehyde oxidation directly produces syngas (H 2 : CO = 1) at 1.7 V and 200 mA cm −2 with 200% combined Faradaic efficiency. We demonstrate an electrochemical syngas production platform that couples bicarbonate electrolysis with formaldehyde oxidation in a bipolar membrane electrode assembly. This strategy doubles syngas (CO + H 2 ) throughput compared to conventional CO 2 electrolysis by generating CO at the cathode and H 2 at the anode. The system achieves a full-cell voltage of 1.7 V while operating at an industrially relevant current density of 200 mA cm −2 . The system maintained a combined Faradaic efficiency of 200% over 8 hours. The process produces syngas with a 1 : 1 H 2 : CO ratio, aligning with downstream requirements for Fischer–Tropsch synthesis. We further investigated how Cu anode active sites and electrolyte composition affect formaldehyde oxidation activity. Our integrated electrolytic system reduces levelized energy by 45–61% relative to conventional electrochemical syngas production platforms.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Portable and Cost-Effective Device for Reliable Detection of Counterfeit and Non-compliant Refrigerants in Diverse Applications

Counterfeit refrigerants pose significant challenges to safety, system reliability, and operational effectiveness due to their harmful contaminants or incompatible chemical compositions. Utilizing these noncompliant products can lead to reduced efficiency, equipment failures, and expensive repairs. Additionally, heightened demand for alternative refrigerants during the industry's transition has created supply gaps, enabling counterfeit products to proliferate. Accurate detection and analysis tools are therefore essential to verify refrigerant authenticity and ensure system integrity in diverse applications. This paper presents the development of a portable device designed for reliable identification and detailed analysis of refrigerant composition. By integrating precision gas sampling, controlled pressure regulation, and automated sensor technology, the device not only detects deviations from standard refrigerant properties but also provides a comprehensive composition breakdown. Pre-calibrated sensors measure the refrigerant gas to identify specific concentrations and contaminants, with an intuitive LED-based indicator system ensuring quick interpretation of results. The user-friendly interface enables operators to select refrigerant types for targeted testing, further enhancing accuracy and usability for field technicians. Comprehensive testing was conducted on mildly flammable A2L refrigerants, showcasing the device’s robustness and adaptability in analyzing composition and detecting discrepancies. The device demonstrated consistent accuracy across a range of refrigerant samples, affirming its reliability in diverse operational environments. Its design minimizes contamination risks during sampling and provides detailed composition results within 90 seconds, ensuring efficient and precise analysis. With a projected price point under $150, the proposed solution delivers affordability alongside its lightweight portability and straightforward operation. Unlike complex and costly alternatives, such as gas chromatography systems, this device provides an accessible option for technicians, customs personnel, and industry operators in need of quick and effective refrigerant verification. Compatible with both current formulations and emerging refrigerant technologies, the device addresses critical counterfeit detection needs across a range of applications. By delivering accurate composition analysis and counterfeit identification, this innovation enhances system performance, safety, and operational reliability in crucial industries.

Cheekatamarla, Praveen [ORNL] (ORCID:0000000248827↗
DOE OSTI2026

Through‐Plane Conductive Hydrophobic Electrodes for CO 2 Electrolysis to Ethylene

Copper catalyst gas diffusion electrodes (GDEs) have demonstrated unique electrochemical selectivity converting CO 2 to C 2 -hydrocarbons such as ethylene and ethanol but have been challenged by their hydrophobic chemical stability and internal electrical resistance leading to low energy efficiency. Carbon-supported GDEs have low electrical resistance but lack sufficient stability at industrially relevant current densities. While polymer-supported GDEs have improved hydrophobicity, they also display high in-plane electrical resistance, particularly at industrial scales. Here, in this work, we demonstrate a composite gas diffusion layer that combines hydrophobic porous polymers with an electrically conductive backbone addressing these core gas diffusion electrode (GDE) scaling challenges. We investigate the material properties of standalone porous perfluoropolyether (PFPE) polymers, including porosity and surface morphology, under varying processing conditions and then incorporate these polymers into a porous copper foam. This composite enhances the mechanical rigidity necessary for cell assembly and provides a through-plane electrical conduction path to reduce electrical resistive losses. This enhanced PFPE composite GDE displays efficient CO 2 reduction, achieving 15% ethylene energy efficiency at 100 cm 2 . These findings contribute to the development of advanced catalyst materials and electrode architectures and promote scalable strategies for electrochemical conversion of CO 2 into high-value carbon products.

Chemistry↗
DOE OSTI2020

Air-Stable Calcium Cyanamide-Supported Ruthenium Catalyst for Ammonia Synthesis and Decomposition

Efficient ammonia synthesis and decomposition processes under mild conditions are important to meet the expanding demand in major applications of ammonia as the energy carrier and to provide feedstock for chemical industry. In this study, we report that air-stable calcium cyanamide-supported ruthenium (Ru/CaCN 2 ) works as an efficient and stable catalyst for ammonia synthesis and decomposition. Ru/CaCN 2 exhibits greater catalytic performances for both reactions than Ru/Ca 2 N electride and Ru–Cs/MgO. The kinetic analysis for ammonia synthesis suggests that Ru/CaCN 2 exhibits low apparent activation energy and high resistance to hydrogen poisoning, which has characteristics similar to the kinetic parameters of Ru-supported electride catalyst. H 2 -temperature programmed reaction and temperature programmed desorption revealed that Ru promoted the formation of CN 2 vacancies on the CaCN 2 surface which in turn capture hydrogen as H – ions during the reaction. Density functional theory calculations provide insights into how the formation of CN 2 vacancies is promoted by Ru, which leads to the decrease in the work function of the CaCN 2 surface and the hydrogen capture at the Ru-support interface. These results suggest that the high catalytic performance of Ru/CaCN 2 can be attributed to the formation of a quasi-electride structure at the Ru–CaCN 2 interface.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1982

The economics of bootstrapping space industries - Development of an analytic computer model

A simple economic model of 'bootstrapping' industrial growth in space and on the Moon is presented. An initial space manufacturing facility (SMF) is assumed to consume lunar materials to enlarge the productive capacity in space. After reaching a predetermined throughput, the enlarged SMF is devoted to products which generate revenue continuously in proportion to the accumulated output mass (such as space solar power stations). Present discounted value and physical estimates for the general factors of production (transport, capital efficiency, labor, etc.) are combined to explore optimum growth in terms of maximized discounted revenues. It is found that 'bootstrapping' reduces the fractional cost to a space industry of transport off-Earth, permits more efficient use of a given transport fleet. It is concluded that more attention should be given to structuring 'bootstrapping' scenarios in which 'learning while doing' can be more fully incorporated in program analysis.

Goldberg, A. H.↗
DOE OSTI2023

MEASUR Up: Identifying opportunities in a facility

The commercial and industrial sectors account for nearly half of the total U.S. energy consumption. To help these sectors reduce their energy intensity, the U.S. Department of Energy (DOE) designed the Better Buildings, Better Plants Initiative. Through this initiative, more than 900 industrial, commercial, public and residential organizations commit to long-term sustainability goals and share their proven energy efficiency strategies, which inspire others to tap into the continued potential for energy efficiency. Collectively, these organizations have saved 2.5 quadrillion BTUs of energy, equivalent to US$15.3 billion, and 155 million metric tons of carbon dioxide. Within the initiative, the Better Plants side of the program focuses specifically on the industrial sector. More than 270 industrial partners have taken advantage of the unique selection of resources offered including workforce development programs, information sharing, peer-to-peer networking, diagnostic tool loans and software tools. One of the most powerful tools off ered is a revitalization of the legacy DOE software tools used by industry for decades. These have been transformed into a new, free, opensource software tool suite: MEASUR (Manufacturing Energy Assessment Software for Utility Reduction)

Armstrong, Kristina↗
DOE OSTI2021

Low-temperature and effective ex situ group V doping for efficient polycrystalline CdSeTe solar cells

CdTe solar cell technology is one of the lowest-cost methods of generating electricity in the solar industry, benefiting from fast CdTe absorber deposition, CdCl 2 treatment and Cu doping. However, Cu doping has low photovoltage and issues with instability. Doping group V elements into CdTe is therefore a promising route to address these challenges. Although high-temperature in situ group V doped CdSeTe devices have demonstrated efficiencies exceeding 20%, they face obstacles including post-deposition doping activation processes, short carrier lifetimes and low activation ratios. Here, we demonstrate low-temperature and effective ex situ group V doping for CdSeTe solar cells using group V chlorides. For AsCl 3 doped CdSeTe solar cells, the dopant activation ratio can be 5.88%, hole densities reach >2 × 10 15 cm -3 and carrier lifetime is longer than 20 ns. Thus, ex situ As doped CdSeTe solar cells show open-circuit voltages ~863 mV, compared to the highest open-circuit voltage of 852 mV for Cu doped CdSeTe solar cells.

14 SOLAR ENERGY↗
DOE OSTI2025

High-efficiency frost and ice control via sensing-assisted nanovibrational slippery surfaces

Frost and ice accretions on surfaces pose persistent challenges across numerous industrial, residential and transportation systems. While various removal strategies exist, they often suffer from limited effectiveness or high energy consumption, such as frosting delay, ice crack generation, and Joule heating. Here, in this work, we report a novel integrated approach combining vibrational quasi-liquid surface (QLS) and capacitive sensing for efficient condensate, frost, and ice management. Compared to Joule heating, our approach does not rely on complete melting and evaporation for removal, resulting in 68% and 95% energy savings for frost and ice removal, respectively. Our QLS coating significantly reduces surface retention forces, achieving 91% and 87% less residual mass compared to hydrophilic surfaces for frost and ice removal through surface nanovibration, respectively. The integrated capacitive sensor provides real-time detection of different phase states, enabling on-demand removal in precise timeframes. This sensor-assisted approach showed 3.8 times lower energy consumption compared to conventional Joule heating for defrosting. This synergistic integration of surface engineering, nanovibration, and intelligent sensing represents a significant advancement in phase change processes, offering an energy-efficient solution for frost and ice mitigation in energy-intensive systems.

Shen, Yuchen [Univ. of Texas at Dallas, Richardson↗
DOE OSTI2022

Achieving American Leadership in the Semiconductors Supply Chain Factsheet

Semiconductors are a keystone technology that are essential for the operation of every electronic device, including those that are critical to a clean energy economy. The semiconductor industry has a complex, competitive, and highly integrated international supply chain in which the United States has historically enjoyed a dominant position, but where this position has been eroding over time. In 1995, 26% of global semiconductor manufacturing capacity was located in the United States; this had decreased to 10% by 2020. Investments in key semiconductor manufacturing technologies such as high-voltage power electronics, energy-efficient conventional devices, and advanced packaging point the way to secure a strong domestic semiconductor industrial base.

Source record↗
DOE OSTI2022

National Smart Manufacturing Strategic Plan: To Facilitate More Rapid Development, Deployment and Adoption of Smart Manufacturing Technologies

Smart manufacturing technologies provide real-time data and insight to improve the productivity, efficiency, and competitiveness of U.S. manufacturing, creating the potential for new jobs in the manufacturing sector. These technologies can support U.S. manufacturers’ ability to increase throughput and energy efficiency, and decrease waste, defects, and costs. A wide range of manufacturing and industrial subsectors, particularly energy-intensive and energy-dependent industries, have the potential to benefit from smart manufacturing technologies. There are technical improvements still needed to reduce the costs and barriers (trained workforce and upskilling, software-hardware integration, cost, and technical barriers to deployment of advanced sensors, computing, and communication technologies for existing manufacturing assets) to the adoption of smart manufacturing technologies, especially to small and medium-sized manufacturers, and subsequently, increase the overall adoption rate of smart manufacturing technologies. This report outlines the Department of Energy’s (DOE) strategic plan to accelerate the development and implementation of smart manufacturing technologies in the United States and the actions DOE has taken to use these technologies in smart manufacturing for the United States. DOE’s plan to facilitate more rapid development, deployment and widespread adoption of smart manufacturing technologies derive from the 2018 Strategy for American Leadership in Advanced Manufacturing. The strategy outlines a vision for America’s leadership in advanced manufacturing including the development of intelligent manufacturing systems to optimize manufacturing facilities and support the manufacturing of transformative materials. DOE’s Clean Energy Smart Manufacturing Innovation Institute (CESMII), a Manufacturing USA Institute, focuses on accelerating the development and adoption of advanced sensors, controls, platforms, and models needed for smart manufacturing. The objective is to enhance U.S. manufacturing productivity and global competitiveness through the research and development of these technologies. Smart manufacturing has the potential to improve the overall performance, energy productivity, and efficiency of manufacturing, fostering the economic competitiveness of the manufacturing sector.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2026

Inverse design of hypoeutectoid pearlite steel microstructures using a deep learning and genetic algorithm optimization framework

Goal-oriented microstructure design in metallic materials is a challenging task due to complex structure-property relationships. Traditional experimental and computational approaches are time-intensive and economically inefficient, limiting their applicability for large-scale design space exploration. Here, in this work, we propose an end-to-end framework that integrates deep learning models with genetic optimization to design microstructures with targeted mechanical properties. Deep learning models enable accurate forward design, while their integration with genetic optimization enables efficient inverse design within a few hours, compared to days or weeks using conventional finite element simulations. The framework combines experimental characterization and finite element modeling to analyze the influence of microstructural features on the mechanical behavior of hypoeutectoid steels. Data from both experiments and simulations are used to train the deep learning models. To demonstrate its effectiveness, we apply the framework to 0.63% carbon steel with proeutectoid ferrite and pearlite phases, commonly used in industrial applications. In this study, 2D microstructures were used for modeling, selected primarily for computational efficiency and to establish proof of concept. The framework successfully optimizes microstructures for targeted yield strength, ultimate strength, and stress concentration factors while significantly reducing computational time. Beyond hypoeutectoid steels, this scalable framework can be extended to other material systems and integrated with additive manufacturing, offering an efficient approach for accelerating microstructure design for specific engineering applications.

ConvLSTM↗
NASA NTRSDate not supplied

Comparative Analysis of Thermal Conversion Technologies for Deep Space Missions

Radioisotope power systems (RPS) utilizing Plutonium-238 as a heat source for thermal-to-electric energy conversion have been used as a reliable power source for NASA’s deep space missions for sixty years. Recent innovations and improvements to thermal energy technologies show potential increases to radioisotope system efficiencies from current measurements of ~5-7% to efficiencies upwards of 20%. This report surveys and ranks recent, innovative thermal-to-electric energy conversion research technologies. Technologies being developed at universities and industry are compared with respect to thermal conversion method and relevant key performance parameters. Key performance parameters are identified as system specific power per kg, efficiency, power output, technology readiness level, and system mass. Analytical Hierarchy Process (AHP) was utilized to create weighted values for each evaluation criterion. The AHP tables combined with decision matrices create table scores for past, present, and potential future systems. The table score was combined with a conversion method score in an adjustable system to add value to flight-proven or well-tested thermal conversion technologies such as thermoelectrics. While the three highest-ranking systems reviewed are currently being developed by NASA’s RPS Program, the additional highest-ranking systems not under-development by RPS could warrant further research.

Radioisotope Power System↗
DOE OSTI2026

Reaction Optimization for Enzymatic Deconstruction of Industrially Relevant Nylon Composites

Plastics such as polyamides (PAs) possess unique physicochemical properties that make them indispensable in modern society. However, their energy‐intensive production and challenging end‐of‐life management highlight the urgent need for efficient recycling or remanufacturing solutions. Enzymatic depolymerization offers a promising route toward circular recycling, yet remains constrained by limited enzyme characterization, lack of validation under industrially relevant conditions and substrates, and overall performance. Here, we optimized the reaction conditions for three recently discovered nylon‐degrading enzymes. One of them, Nyl12, achieved product titers with PA6 and PA66 that exceed previously reported values, without enzyme engineering or substrate pretreatment. We further demonstrated the scalability of the process and its application to complex PA‐based materials used in microelectronic components. Analysis of substrate features, including surface area and particle size, revealed key parameters governing enzymatic activity and provided a framework for future pretreatment and process optimization efforts. In combination, these efforts provide a new benchmark for enzymatic nylon recycling.

nylon↗