Surface Atmosphere Integrated Field Laboratory (SAIL) Aerosol Processes
Explore the source record for details and available documents.
climate, aerosol-cloud interactions, radiation bud↗
SEARCH · Engineering Papers
Results for “Process integration”
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.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
Large Format CMOS Imager Integration Utilizing an Indium Bonding Process and Buried ARC Reveal.
Abstract not provided.
Jordan, Matthew↗
Designing the PR100 Study: Puerto Rico Grid Resilience and Transition to 100% Renewable Energy
Puerto Rico has committed to meeting its electricity needs with 100% renewable energy by 2050, along with realizing interim goals of 40% by 2025, 60% by 2040, the phaseout of coal-fired generation by 2028, and a 30% improvement in energy efficiency by 2040 as established in Act 17. [1] To meet these goals and support widespread end-use electrification, the territory must explore how renewable energy and other generation technologies can be developed with energy storage, distributed generation, distribution control, electric vehicles, and energy efficient and responsive loads in each of Puerto Rico's cities and communities. To support Puerto Rico in reaching its renewable energy goals; help ensure energy system resilience against future extreme weather events; improve energy justice; and provide inputs to LUMA Energy's walk, jog, and run approach in its coordinated planning roadmap, the U.S. Department of Energy, National Renewable Energy Laboratory, Argonne National Laboratory, Lawrence Berkeley National Laboratory, Oak Ridge National Laboratory, Pacific Northwest National Laboratory and Sandia National Laboratories propose to evaluate 100% renewable energy pathways through an integrated analysis process. This talk will present steps in designing a two-year study entitled Puerto Rico Grid Resilience and Transitions to 100% Renewable Energy (PR100). [1] U.S. Energy Information Administration (EIA). 2020. Puerto Rico Territory Energy Profile.
100% renewable energy↗
High Volume Production of Nanoscale Elements
The utility of nanoscale elements spans numerous potential markets including healthcare, communications, energy, optics, and structures. The energy market in particular will require large volumes and is price sensitive. In this talk we will discuss strategies to scale nanoscale elements, including nanoparticle inks and nanoscale thin films, for the large area deposition (hundreds of square meters) using high through put processes. Historically, roll-to-roll production of thin films has been carried out at very high speeds over large areas using solution phase inks. Nanoparticles are produced in a bottom-up approach in solution phase that simplifies the processing and is amenable to ink formulations. Sintering and annealing of the thin films can be increased by using radiation thermal processing that integrates easily into roll-to-roll manufacturing. Results of printed films on the order of tens of nanometers to hundreds of nanometers are presented including studies of morphologies and uniformity over large areas. Solar cells devices using the roll-to-roll setup are demonstrated and a techno-economic analysis of the manufacturing is proposed. These results are presented with a comparison to the current photovoltaic technologies in production.
Druffel, Thad↗
Biomethanation to Upgrade Biogas to Pipeline Grade Methane
NREL is working closely with DOE, Electrochaea GmbH, and Southern California Gas Company (SoCalGas) to reduce costs of a biomethanation process capable of megawatt-scale deployment that upgrades organic biogas waste streams to produce pipeline quality renewable natural gas (RNG). Biomethanation is a two-step process using a single-celled methanogenic archaea that converts low-carbon low-cost hydrogen (H2) and waste carbon dioxide (CO2) to produce renewable methane (CH4). The process upgrades the biogenic CO2 - while allowing the CH4 to pass through - from biogas sources like dairies, wastewater treatment plants, and landfills. The CH4 produced is a drop-in direct replacement fuel and producers can participate in the growing number of carbon markets; like California's Low Carbon Fuel Standard and the Federal Renewable Fuel Standard. NREL and Argonne National Laboratory have completed a life cycle analysis using the GREET model to show that the biomethanation process produces RNG that is carbon negative even when H2 production via low-temperature water electrolysis is driven by the existing carbon intensity of California's electricity grid. And of course, even further carbon negative (-233 kg CO2e/kWh) when the electricity is produced from low-carbon sources like wind and solar. Leveraging lessons learned from operating SoCalGas' 700L 18-bar bioreactor system, NREL is designing and building a flexible RD&D platform that will enable field trials at biogas and other CO2 sources. A custom 16' long trailer will house a 20L 18-bar bioreactor, 3 - 25 kW proton exchange membrane electrolyzer, and dosing, thermal, and controls systems to support operations with only power, biogas, and water feedstocks required by the field locations. The end-of-project goal is to demonstrate pipeline quality RNG production (> 95% CH4, < 4% H2, <1% CO2, < 0.2% O2 and < 4 parts per million H2 sulfide) using real biogas feedstocks - thereby recycling both greenhouse gases for injection into the natural gas network or to be used onsite.
biogas upgrading↗
Recent Metallic Fuel Data Recovery in FIPD
The Metallic Fuels Irradiation and Physics Database (FIPD) [1] is an organized collection of metallic fuel test pin data (U-xPu-yZr, = 0 ~ 28; y = 2 ~ 10) and documentation available to industry. FIPD mainly contains three types of data: (1) Fuel pin fabrication data, including fuel slug diameter, fuel slug length, cladding diameter, smear density, etc. (2) Fuel pin operation conditions, including axial distributions for power, temperatures, fluences, burnup, and isotopic densities, etc. and (3) Fuel pin post-irradiation examination (PIE) data, including fission gas release and gas chemistry, profilometry, and neutron radiography, etc. The operating conditions for pins with PIE data available in FIPD span significant ranges across key parameters. The fuel peak burnup extends from less than 5% up to 20 at%. The cladding peak temperature varies from about 490°C to 660°C. Finally, the cladding peak DPA shows a wide range from less than 5 to 120. These broad ranges reflect the diverse testing conditions and operational parameters captured in the available PIE data. More detail about FIPD can be found in ref. [2]. The database development is an ongoing effort covering metallic fuel experiments from the Experimental Breeder Reactor II (EBR-II) and the Fast Flux Test Facility (FFTF). As reported in the ref. [3, 4], most of the PIE data generated during the IFR program [5] has been collected, reviewed, processed, and integrated into FIPD. The most recently added PIE data can be found in ref. [4], which shows the collection of over 95% of the PIE data by the time of this paper. The recent improvements to the database are summarized in this paper.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Optimizing Energy Use in Pulp & Paper with DOE’s Energy Intensive Industries Resources
The U.S. pulp and paper industry is the third-largest energy consumer in manufacturing, accounting for roughly 10% of sector energy use. Improving energy efficiency reduces operating costs and strengthens competitiveness. To support this effort, the U.S. Department of Energy (DOE), through Oak Ridge National Laboratory (ORNL), launched the Energy Intensive Industries (EII) Initiative. A two-year pilot across 45 industrial sites identified more than 4 trillion Btu/year in potential energy savings. This presentation outlines plans for a follow-up technical assistance program tailored to pulp and paper mills. Available resources include a cost-savings scoping tool, implementation planning guidance, and technical support for applying advanced methods such as Pinch Analysis for integrated process-utilities optimization. The session introduces key Pinch Analysis principles and highlights case studies demonstrating measurable improvements. ORNL also seeks industry feedback on barriers to efficiency improvements, including technology gaps and resource needs. DOE’s broader objective is to accelerate productivity and economic competitiveness across U.S. energy-intensive industries.
Kamath, Dipti [ORNL] (ORCID:0000000278739994)↗
Development of an advanced spacecraft water and waste materials processing system
An Integrated Waste Management-Water System (WM-WS) which uses radioisotopes for thermal energy is described and results of its trial in a 4-man, 180 day simulated space mission are presented. It collects urine, feces, trash, and wash water in zero gravity, processes the wastes to a common evaporator, distills and catalytically purifies the water, and separates and incinerates the solid residues using little oxygen and no chemical additives or expendable filters. Technical details on all subsystems are given along with performance specifications. Data on recovered water and heat loss obtained in test trials are presented. The closed loop incinerator and other projects underway to increase system efficiency and capacity are discussed.
Murray, R. W.↗
Flexible cryogenic air separation unit—An application for low-carbon fossil-fuel plants
In this study, the rapid integration of intermittent renewable sources into the electricity grid is driving the need for a flexible cryogenic air separation unit (ASU) coupled with a low-carbon fossil-fuel plant. However, the state-of-the-art ASU process is highly integrated and nonlinear, which can significantly restrict its ramping rate. In this work, we study the fundamental dynamics of a state-of-the-art double-column ASU, focusing on the dynamic characteristics of the highly integrated and nonlinear heat and mass transfers, and we propose basic control methods for achieving high process ramping rates. We found that the vapor–liquid countercurrent flows in the low-pressure column are critical to the cryogenic rectification of air, which governs the ramp rate of the ASU. This countercurrent flow structure is created through a complex heat integration process in the ASU. Here, this process is simplified as a countercurrent heat transfer to reduce the complexity of studying the ASU dynamics. To preserve this flow structure, the heat integration is maintained so that its heat duty follows the ASU load, using several basic controllers on the critical stream flowrates. A flow-driven dynamic ASU model is built in Aspen Plus Dynamics to capture the basic ramping dynamics. This model revealed a fundamental mismatch in the dynamics in the ASU column that causes a significant loss of O 2 product purity when ramping down the ASU and slightly increases the purity when ramping up. Based on these findings, we propose a basic control method for rapidly ramping down/up the ASU while maintaining O 2 product purity. Simulation results show the ASU basic dynamic process successfully ramps at a rate up to 10 %/min (40–100 % load) while maintaining the O 2 product purity at 95.2–95.6 mol%.
42 ENGINEERING↗
Genome expansion by a CRISPR trimmer-integrase
CRISPR–Cas adaptive immune systems capture DNA fragments from invading mobile genetic elements and integrate them into the host genome to provide a template for RNA-guided immunity. CRISPR systems maintain genome integrity and avoid autoimmunity by distinguishing between self and non-self, a process for which the CRISPR/Cas1–Cas2 integrase is necessary but not sufficient. In some microorganisms, the Cas4 endonuclease assists CRISPR adaptation, but many CRISPR–Cas systems lack Cas4. Here we show here that an elegant alternative pathway in a type I-E system uses an internal DnaQ-like exonuclease (DEDDh) to select and process DNA for integration using the protospacer adjacent motif (PAM). The natural Cas1–Cas2/exonuclease fusion (trimmer-integrase) catalyses coordinated DNA capture, trimming and integration. Five cryo-electron microscopy structures of the CRISPR trimmer-integrase, visualized both before and during DNA integration, show how asymmetric processing generates size-defined, PAM-containing substrates. Before genome integration, the PAM sequence is released by Cas1 and cleaved by the exonuclease, marking inserted DNA as self and preventing aberrant CRISPR targeting of the host. Together, these data support a model in which CRISPR systems lacking Cas4 use fused or recruited exonucleases for faithful acquisition of new CRISPR immune sequences.
59 BASIC BIOLOGICAL SCIENCES↗
Expanded Accident Scenarios and Frequency Characteristics for a Fast Spectrum Molten Salt Reactor in an Integrated Energy System
Integration of advanced nuclear reactors to industrial processes in an integrated energy system (IES) has many potential advantages. The coupling of nuclear power to varied industrial processes introduces additional accident scenarios unique to the specific systems included in the IES. Similarly, noise in one system of the IES could potentially create negative effects in the other systems. Because of the limited amount of comparable nuclear IES operating experience, there is added value in scoping the inherent behavior of these systems in response to these transients. Here, this paper investigates the safety-related behavior of an open-source IES dynamic model of a fast spectrum molten salt reactor (MSR) powering a regenerative Rankine cycle for electricity production and a hybrid sulfur (HyS) cycle for hydrogen production. The simulations include a loss of cooling water to the Rankine cycle, a loss of sulfur in the HyS cycle, and the frequency characteristics of the entire IES across six orders of magnitude of frequency. The results show safe behavior in response to the two accident scenarios, wherein a disruption in heat transfer leads to increased salt temperatures and a decrease in reactor power. The frequency analysis shows that at higher frequencies, temperature changes propagating through an IES are increasingly damped to the point of negligibility.
Dunkle, Nicholas [Univ. of Tennessee, Knoxville, T↗
7 Innovations in high-rate composite manufacturing: integrating additive manufacturing with compression molding process
Advanced composites play a pivotal role in modern engineering, offering exceptional strength-to-weight ratios and tailored properties, essential for various industries. High-rate composite manufacturing techniques have rapid production capabilities, which are essential for meeting the demands of industries requiring cost-saving, efficiency, and quick turnaround times. This chapter explores the Additive Manufacturing- Compression Molding (AM-CM) system developed by Oak Ridge National Laboratory (ORNL) for advanced composites manufacturing. The AM-CM system integrates additive manufacturing with compression molding, facilitating the production of polymer composite parts with superior mechanical properties and meticulously controlled microstructures. This innovative system not only ensures precise material deposition but also operates as a fast composite manufacturing process, enhancing productivity and performance, which are needed attributes across industrial applications. Through comprehensive mechanical testing and microstructural analysis, AM-CM promotes remarkable fiber alignment and reduced porosity in composite parts compared to alternative thermoplastic high-rate composite manufacturing methods. Furthermore, AM-CM enables overmolding reinforcement using continuous carbon fiber and supports selective reinforcement through customizable toolpaths. It also facilitates the production of hybrid materials to achieve tailored mechanical properties. Future advancements in AM-CM technology aim to enhance process efficiency, broaden material versatility, and improve part performance. This involves exploring novel materials, advancing process monitoring, implementing automation technologies, and integrating artificial intelligence (AI) and machine learning (ML) for predictive modeling and real-time optimization in composite manufacturing. These developments will establish the AM-CM system as a transformative technology in composite manufacturing, driving innovation across industries.
Hassen, Ahmed [ORNL] (ORCID:0000000328521222)↗
Conducting Research on the International Space Station Using the EXPRESS Rack Facilities
EXPRESS Racks provide capability for payload access to ISS resources. The successful on-orbit operations and versatility of the EXPRESS Rack has facilitated the operations of many scientific areas, with the promise of continued payload support for years to come. EXPRESS Racks are currently deployed in the US Lab, Columbus and JEM. Process improvements and enhancements continue to improve the accommodations and make the integration and operations process more efficient. Payload Integration Managers serve as the primary interface between the ISS Program and EXPRESS Payload Developers. EXPRESS Project coordinates across multiple functional areas and organizations to ensure integrated EXPRESS Rack and subrack products and hardware are complete, accurate, on time, safe, and certified for flight. NASA is planning to expand the EXPRESS payload capacity by developing new Basic Express Racks expected to be on ISS in 2018.
Thompson, Sean W.↗
Cost-Benefit Analysis for the Advanced Near Net Shape Technology (ANNST) Method for Fabricating Stiffened Cylinders
Low Technology Readiness Levels (TRLs) and high levels of uncertainty make it challenging to develop cost estimates of new technologies in the R&D phase. It is however essential for NASA to understand the costs and benefits associated with novel concepts, in order to prioritize research investments and evaluate the potential for technology transfer and commercialization. This paper proposes a framework to perform a cost-benefit analysis of a technology in the R&D phase. This framework was developed and used to assess the Advanced Near Net Shape Technology (ANNST) manufacturing process for fabricating integrally stiffened cylinders. The ANNST method was compared with the conventional multi-piece metallic construction and composite processes for fabricating integrally stiffened cylinders. Following the definition of a case study for a cryogenic tank cylinder of specified geometry, data was gathered through interviews with Subject Matter Experts (SMEs), with particular focus placed on production costs and process complexity. This data served as the basis to produce process flowcharts and timelines, mass estimates, and rough order-of-magnitude cost and schedule estimates. The scalability of the results was subsequently investigated to understand the variability of the results based on tank size. Lastly, once costs and benefits were identified, the Analytic Hierarchy Process (AHP) was used to assess the relative value of these achieved benefits for potential stakeholders. These preliminary, rough order-of-magnitude results predict a 46 to 58 percent reduction in production costs and a 7-percent reduction in weight over the conventional metallic manufacturing technique used in this study for comparison. Compared to the composite manufacturing technique, these results predict cost savings of 35 to 58 percent; however, the ANNST concept was heavier. In this study, the predicted return on investment of equipment required for the ANNST method was ten cryogenic tank barrels when compared with conventional metallic manufacturing. The AHP study results revealed that decreased final cylinder mass and improved quality assurance were the most valued benefits of cylinder manufacturing methods, therefore emphasizing the relevance of the benefits achieved with the ANNST process for future projects.
Ivanco, Marie L.↗
A study on airborne integrated display system and human information processing
The cognitive behavior of pilots was examined in an experiment involving mock ups of an eight display electronic attitude direction indicator for an airborne integrated display. Displays were presented in digital, analog digital, and analog format to experienced pilots. Two tests were run, one involving the speed of memorization in a single exposure and the other comprising two five second exposures spaced 30 sec apart. Errors increased with the speed of memorization. Generally, the analog information was assimilated faster than the digital data, with regard to the response speed. Information processing was quantified as 25 bits for the first five second exposure and 15 bits during the second.
Mizumoto, K.↗
Modular Adaptive Packing for Integrally Cooled Absorbers
Process intensification is one cornerstone in ION Clean Energy’s (ION) efforts to lowering CO2 capture cost. ION has modeled, designed, and fabricated an innovative gas-liquid contactor known as Modular Adaptive Packing (MAP). During two successful SBIR Phase I and II projects entitled: “Rapid Design and Testing of Novel Gas-Liquid Contacting Devices for Post-Combustion CO2 Capture via 3D-printing”, ION developed and proved this new technology at bench scale. MAP, a 3D-printed lattice-structured packing, combines the absorber gas/liquid contactor with an innovative in-situ heat-exchanger. Thanks to the capabilities of 3D-printing, the lattice structure of MAP contains hollow channels through which coolant water can be pumped to remove the heat of reaction from CO2 absorption. ION refers to this novel method of heat exchange as intracooling. After 25.4 cm (10 in) diameter MAP modules were fabricated, ION built and tested a packing characterization rig at its pilot facility in Boulder, Colorado, U.S.A. To provide baseline results for the characterization rig, ION tested Sulzer’s Mellapak™ 250Y (MP250Y) as a standard structured packing. ION’s MAP was then compared directly to the baseline MP250Y packing to evaluate key indicators including pressure drop, liquid hold-up, and effective area. MAP has a higher pressure drop than MP250Y at the same gas velocities in addition to greater liquid holdup. However, ION found that MAP displays a higher wetting coverage of 93% compared to 65% for MP250Y and reduces shearing forces that result in undesirable droplet formation. Using Optimized Gas Treating’s (OGT) rate-based simulation software ProTreat®, a conceptual evaluation of MAP was modeled for a CO2 absorber using 30 wt% MEA solvent over a range of lean loadings at 90% CO2 capture from a coal-fired power plant. ION modeled a 25-meter column absorber for both the standard MP250Y packing and a hybrid column. The hybrid absorber contained 10 m of MP250Y packing at the top and bottom with the middle 5 meters comprised of MAP. Compared to a traditional intercooled absorber, MAP can remove 22% more heat and increase overall MEA carrying capacity by 4% without increasing overall pressure drop.
20 FOSSIL-FUELED POWER PLANTS↗
Doppler lidar processing for atmospheric turbulence measurements
A Doppler lidar is described, its processing methods are characterized, and two alternate techniques are considered. The described system uses a CO2 laser transmitting at 10.6 microns and a bank of narrow band filters for the spectrum analysis. Typical results obtained with this system are presented. The two alternate techniques involve computation of the discrete spectrum by use of the discrete Fourier transform. The first technique involves single-pulse processing and incoherent integration, while the second technique performs coherent processing on the train of received pulses.
Polge, R. J.↗
Exact triple integrals of beam functions
Definite triple integrals encountered in applying the Galerkin method to the problem of heat and mass transfer across rectangular enclosures are discussed. Rather than evaluating them numerically, the technique described by Reid and Harris (1958) was extended to obtain the exact solution of the integrals. In the process, four linear simultaneous equations with triple integrals as unknowns were obtained. These equations were then solved exactly to obtain the closed form solution. Since closed form representations of this type have been shown to be useful in solving nonlinear hydrodynamic problems by series expansion, the integrals are presented here in general form.
Jhaveri, B. S.↗