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All sourcesNASA NTRSDOE OSTI
NASA NTRS1985

Evaluation of Superplastic Forming and Weld-brazing for Fabrication of Titanium Compression Panels

The two titanium processing procedures, superplastic forming and weld brazing, are successfully combined to fabricate titanium skin stiffened structural panels. Stiffeners with complex shapes are superplastically formed using simple tooling. These stiffeners are formed to the desired configuration and required no additional sizing or shaping following removal from the mold. The weld brazing process by which the stiffeners are attached to the skins utilize spot welds to maintain alignment and no additional tooling is required for brazing. The superplastic formed/weld brazed panels having complex shaped stiffeners develop up to 60 percent higher buckling strengths than panels with conventional shaped stiffeners. The superplastic forming/weld brazing process is successfully scaled up to fabricate full size panels having multiple stiffeners. The superplastic forming/weld brazing process is also successfully refined to show its potential for fabricating multiple stiffener compression panels employing unique stiffener configurations for improved structural efficiency.

Royster, D. M.↗
NASA NTRS2010

Possible Influences of Air Pollution, Dust and Sandstorms on the Indian Monsoon

In Asian monsoon countries, such as China and India, human health and safety problems caused by air pollution are becoming increasingly serious, due to the increased loading of atmospheric pollutants from waste gas emissions and from rising energy demand associated with the rapid pace of industrialization and modernization. Meanwhile, uneven distribution of monsoon rain associated with flash floods or prolonged drought, has caused major loss of human life and damage to crops and.property with devastating societal impacts. Historically, air-pollution and monsoons research are treated as separate problems. However recent studies have suggested that the two problems may be intrinsically linked and need to be studied jointly. Fundamentally, aerosols can affect precipitation through radiative effects cif suspended particles in the atmosphere (direct effect) and/or by interfering and changing: the cloud and precipitation formation processes (indirect effect). Based on their optical properties, aerosols can be classified into two types.: those that absorb solar radiation, and those that do not. Both types of aerosols scatter sunlight and reduce the amount of solar radiation from reaching the Earth's surface, causing it to cool. The surface cooling increases atmospheric stability and reduces convection potential, Absorbing aerosols, however, in addition to cooling the surface, can heat the atmosphere. The heating of the atmosphere may reduce the amount of low clouds by increased evaporation in cloud drops. The heating, however, may induce rising motion, enhance low-level moisture, convergence and, hence, increases rainfall, The latent heating from enhanced rainfall may excite feedback processes in the large-scale circulation, further amplify.the initial response to aerosol heating and producing more rain. Additionally, aerosols can increase the concentration of cloud condensation nuclei (CCN), increase cloud amount and decrease coalescence and collision rates, leading to reduced precipitation. However, in the presence of increasing moist and warm air, the reduced coalescence/collision may lead to supercooled drops at higher altitudes where ice precipitation falls and melts. The latent heat release from freezing aloft and melting below implies greater upward heat transport in polluted clouds and invigorate deep convection. In this way, aerosols may lead to increased local convection. Hence, depending on the ambient large-scale conditions and dynamical feedback processes, aerosols' effect on precipitation can be positive, negative or mixed. In the Asian monsoon and adjacent regions, the aerosol forcing and responses of the water cycle are even more complex, Both direct and indirect effects may take place locally and simultaneously, interacting with each other. in addition to local effects, monsoon rainfall may be affected by aerosols transported from other regions and intensified through large-scale circulation and moisture feedback. Thus, dust transported by the large-scale circulation from the adjacent deserts to northern India may affect rainfall over the Bay of Bengal; sulphate and black carbon front industrial pollution in central, southern China and northern India may affect the rainfall regime over the Korean peninsula and Japan; organic and black carbon front biomass burning from Indo-China may modulate the pre-monsoon rainfall regime over southern China and coastal regions, contributing to variability in differential heating and cooling of the atmosphere and to the land-sea thermal contrast. During the pre-monsoon season and monsoon breaks, it has been suggested that radiative forcing by absorbing aerosols have nearly the same order of magnitude as the forcing due to latent heating from convection and surface fluxes. The magnitude of the total aerosol radiative cooling due to sulphates and soot is of the order of 20-40 W/m2 over the Asian monsoon land region in the pre-monsoon season, compared to about 1-2 W/m2 for global warng. However, the combined forcing at the surface and in the atmosphere, including all species. if aerosols, and details of aerosol mixing, and impacts on the energy and water cycles in the monsoon land regions, are not well known.

Lau, William K. M.↗
DOE OSTI2023

High precision tests of QCD without scale or scheme ambiguities: The 40th anniversary of the Brodsky–Lepage–Mackenzie method

A key issue in making precise predictions in QCD is the uncertainty in setting the renormalization scale μ r and thus determining the correct values of the QCD running coupling α s (μ r ) at each order in the perturbative expansion of a QCD observable. It has often been conventional to simply set the renormalization scale to the typical scale of the process Q and vary it in the range μ r $\in$ [Q/2, 2Q] in order to estimate the theoretical error. This is the practice of Conventional Scale Setting (CSS). The resulting CSS prediction will however depend on the theorist’s choice of renormalization scheme and the resulting pQCD series will diverge factorially. It will also disagree with renormalization scale setting used in QED and electroweak theory thus precluding grand unification. A solution to the renormalization scale-setting problem is offered by the Principle of Maximum Conformality (PMC), which provides a systematic way to eliminate the renormalization scale-and-scheme dependence in perturbative calculations. The PMC method has rigorous theoretical foundations, it satisfies Renormalization Group Invariance (RGI) and preserves all self-consistency conditions derived from the renormalization group. The PMC cancels the renormalon growth, reduces to the Gell-Mann–Low scheme in the N c → 0 Abelian limit and leads to scale- and scheme-invariant results. The PMC has now been successfully applied to many high-energy processes. In this article we summarize recent developments and results in solving the renormalization scale and scheme ambiguities in perturbative QCD. In particular, we present a recently developed method the PMC ∞ and its applications, comparing the results with CSS. The method preserves the property of renormalizable SU(N)/U(1) gauge theories defined as Intrinsic Conformality (iCF). This property underlies the scale invariance of physical observables and leads to a remarkably efficient method to solve the conventional renormalization scale ambiguity at every order in pQCD. This new method reflects the underlying conformal properties displayed by pQCD at NNLO, eliminates the scheme dependence of pQCD predictions and is consistent with the general properties of the PMC. A new method to identify conformal and β-terms, which can be applied either to numerical or to theoretical calculations is also shown. We present results for the thrust and C-parameter distributions in e + e - annihilation showing errors and comparison with the CSS. We also show results for a recent innovative comparison between the CSS and the PMC ∞ applied to the thrust distribution investigating both the QCD conformal window and the QED N c → 0 limit. In order to determine the thrust distribution along the entire renormalization group flow from the highest energies to zero energy, we consider the number of flavors near the upper boundary of the conformal window. In this flavor-number regime the theory develops a perturbative infrared interacting fixed point. These results show that PMC ∞ leads to higher precision and introduces new interesting features in the PMC. In fact, this method preserves with continuity the position of the peak, showing perfect agreement with the experimental data already at NNLO. We also show a detailed comparison of the PMC ∞ with the other PMC approaches: the multi-scale-setting approach (PMCm) and the single-scale-setting approach (PMCs) by comparing their predictions for three important fully integrated quantities R e+e- , R$_Τ$ and Γ (H→$b\bar{b}$) up to the four-loop accuracy.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2022

Evaluation of a Third Generation Single-Component Water-Lean Diamine Solvent for Post-Combustion CO 2 Capture

Here this study describes a comprehensive evaluation of a recently developed water-lean diamine solvent, N1-(2-ethoxyethyl)-N2, N2-diisopropylethane-1,2-diamine (2-EEDIPEDA), to probe its potential post-combustion CO 2 capture performance. This evaluation includes (1) fundamental sorption characterization such as vapor-liquid equilibria, sorption kinetics and viscosity impacts; (2) continuous capture characterization using laboratory scale flow system using flue gas simulant; as well as (3) technoeconomic analysis of the capture process at industrial scale with projections for critical capture performance metrics. Using this evaluation, we compare the performance of 2-EEDIPEDA to our current leading water-lean amine-based solvent, 2-EEMPA, using the same baseline process plant configuration/pricing. From this comparison, we observe lower total cost of capture as low as $46.8/tonne CO 2 with 2-EEDIPEDA (20% cheaper than CANSOLV), as a direct result of solvent chemistry tuning leading to notable cost savings.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Microchannel Reactor for Ethanol to Butene: CRADA 503 [Abstract only]

A key challenge facing most bioprocessing operations is that multiple unit operations are required, thereby resulting in complex, energy-intensive, and expensive processes. Further, biomass transportation costs drive the need for smaller, distributed processing plants. To incorporate the smaller scales desirable for biomass, novel processes must be developed with reduced capital costs. With over 20 years of experience in the development and commercialization of microchannel reactor technology, Oregon State University will partner with Pacific Northwest National Laboratory to demonstrate a microchannel reactor with lower capital costs for an alcohol-to-jet (ATJ) process technology that is currently being commercialized by LanzaTech. Ethanol can be produced from biomass feedstocks such as LanzaTech’s proprietary biochemical process using carbon from a number of possible feedstocks; syngas generated from biomass resources (e.g., MSW, organic industrial waste, agriculture waste) or reformed biogas, or from other biomass feedstocks such as corn kernel fiber. Ethanol then undergoes catalytic dehydration to form ethylene followed by a two-step oligomerization, hydrogenation, and fractionation to control the hydrocarbon product slate to the jet-range. Successful process development aided by a market pull for low carbon aviation fuel has spurred scale-up and commercial demonstration. However, Sustainable Aviation Fuel is a very price sensitive market and improved economics through process intensification will make the current ATJ process even more attractive. Recent efforts at PNNL have culminated in the development of a new catalyst technology for the conversion of ethanol to n-butene-rich olefins. A greater than 90% conversion, total olefin selectivity of 80-90% (n-butene selectivity ~60%), and good stability over a 100 hour test duration has been demonstrated at the bench scale. Producing butene-rich olefins directly from ethanol with high yield is new and impactful because the higher olefins can be selectively oligomerized to distillate-range hydrocarbons, thus eliminating one process step from the current ATJ process. Further, coupling the severely endothermic ethanol dehydration with exothermic C-C bond formation results in more energy efficient processing. Additional intensification and energy savings will stem from incorporating this new ethanol to n-butene catalyst technology within the ATJ process implemented using a microchannel reactor platform. Due to recent advances in microchannel manufacturing methods and associated cost reductions we believe the time is right to adapt this technology toward new commercial bioconversion applications.

02 PETROLEUM↗
DOE OSTI2025

FLAMINGO: combining kinetic SZ effect and galaxy–galaxy lensing measurements to gauge the impact of feedback on large-scale structure

Energetic feedback processes associated with accreting supermassive black holes can expel gas from massive haloes and significantly alter various measures of clustering on $\sim$Mpc scales, potentially biasing the values of cosmological parameters inferred from analyses of large-scale structure (LSS) if not modelled accurately. Here, we use the state-of-the-art FLAMINGO suite of cosmological hydrodynamical simulations to gauge the impact of feedback on large-scale structure by comparing to Planck + ACT stacking measurements of the kinetic Sunyaev–Zel’dovich (kSZ) effect of SDSS BOSS galaxies. We make careful like-with-like comparisons to the observations, aided by high precision KiDS and DES galaxy–galaxy lensing measurements of the BOSS galaxies to inform the selection of the simulated galaxies. In qualitative agreement with several recent studies using dark matter only simulations corrected for baryonic effects, we find that the kSZ effect measurements prefer stronger feedback than predicted by simulations which have been calibrated to reproduce the gas fractions of low redshift X-ray-selected groups and clusters. We find that the increased feedback can help to reduce the so-called $S_8$ tension between the observed and CMB-predicted clustering on small scales as probed by cosmic shear (although at the expense of agreement with the X-ray group measurements). However, the increased feedback is only marginally effective at reducing the reported offsets between the predicted and observed clustering as probed by the thermal SZ (tSZ) effect power spectrum and tSZ effect – weak lensing cross-spectrum, both of which are sensitive to higher halo masses than cosmic shear.

79 ASTRONOMY AND ASTROPHYSICS↗
NASA NTRS2018

Investigating Extreme Events in the NASA GEOS Multiscale Modeling System

Advances in computing capabilities and scientific development have come together to evolve general circulation models into multi-scale Earth system modeling tools. The Goddard Earth Observing System (GEOS) model is one such example of this evolution. The GEOS model is driven by the finite-volume cubed-sphere (FV3) non-hydrostatic dynamical core. Surrounding FV3 is a scale-aware physics package and data assimilation capability permitting multi-scale application of GEOS for sub-seasonal to seasonal climate prediction, medium range weather prediction, and global mesoscale modeling at convection allowing resolutions. GEOS also includes a comprehensive chemistry package representing a range of capabilities from basic chemistry and interactve aerosols and gaseous species, to carbon emissions and uptake, and complex ozone photochemistry. In this study, we apply the GEOS model to study the fidelity of these processes with increasing horizontal resolution and scale-aware processes in GEOS on extreme events. The GEOS model is run for 40-days beginning in August 2016 at three uniform global resolutions of 13-km (c768), 6-km (c1536) and 3-km (c3072) with 72 vertical levels up to 0.01mb. The model physics use the Grell-Freitas scale-aware convection scheme to dynamically reduce the role of parameterized deep convection as resolved scale processes in the model take over at higher resolutions. We will include high-resolution global emissions and fluxes of aerosols and carbon downscaled from recent satellite observations. We will compare these simulations with reanalyses and observations, focusing on rainfall, clouds and radiative forcing at hourly to monthly timescales. We will closely examine the probability distribution of precipitation intensities and radiative properties of clouds on a daily time scale. In addition, we will focus on extreme events, in particular the diurnal cycle of convection over the US and the frequency and physical nature of organized convection and heavy rain events across the globe.

Putman, William↗
DOE OSTI2023

Workflows Community Summit 2022: A Roadmap Revolution

Scientific workflows have become integral tools in broad scientific computing use cases. Science discovery is increasingly dependent on workflows to orchestrate large and complex scientific experiments that range from the execution of a cloud-based data preprocessing pipeline to multi-facility instrument-to-edge-to-HPC computational workflows. Given the changing landscape of scientific computing (often referred to as a computing continuum) and the evolving needs of emerging scientific applications, it is paramount that the development of novel scientific workflows and system functionalities seek to increase the efficiency, resilience, and pervasiveness of existing systems and applications. Specifically, the proliferation of machine learning/artificial intelligence (ML/AI) workflows, need for processing large-scale datasets produced by instruments at the edge, intensification of near real-time data processing, support for long-term experiment campaigns, and emergence of quantum computing as an adjunct to HPC, have significantly changed the functional and operational requirements of workflow systems. Workflow systems now need to, for example, support data streams from the edge-to-cloud-to-HPC, enable the management of many small-sized files, allow data reduction while ensuring high accuracy, orchestrate distributed services (workflows, instruments, data movement, provenance, publication, etc.) across computing and user facilities, among others. Further, to accelerate science, it is also necessary that these systems implement specifications/standards and APIs for seamless (horizontal and vertical) integration between systems and applications, as well as enable the publication of workflows and their associated products according to the FAIR principles.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS1997

Development of Statistical Process Control Methodology for an Environmentally Compliant Surface Cleaning Process in a Bonding Laboratory

Bonding labs at both MSFC and the northern Utah production plant prepare bond test specimens which simulate or witness the production of NASA's Reusable Solid Rocket Motor (RSRM). The current process for preparing the bonding surfaces employs 1,1,1-trichloroethane vapor degreasing, which simulates the current RSRM process. Government regulations (e.g., the 1990 Amendments to the Clean Air Act) have mandated a production phase-out of a number of ozone depleting compounds (ODC) including 1,1,1-trichloroethane. In order to comply with these regulations, the RSRM Program is qualifying a spray-in-air (SIA) precision cleaning process using Brulin 1990, an aqueous blend of surfactants. Accordingly, surface preparation prior to bonding process simulation test specimens must reflect the new production cleaning process. The Bonding Lab Statistical Process Control (SPC) program monitors the progress of the lab and its capabilities, as well as certifies the bonding technicians, by periodically preparing D6AC steel tensile adhesion panels with EA-91 3NA epoxy adhesive using a standardized process. SPC methods are then used to ensure the process is statistically in control, thus producing reliable data for bonding studies, and identify any problems which might develop. Since the specimen cleaning process is being changed, new SPC limits must be established. This report summarizes side-by-side testing of D6AC steel tensile adhesion witness panels and tapered double cantilevered beams (TDCBs) using both the current baseline vapor degreasing process and a lab-scale spray-in-air process. A Proceco 26 inches Typhoon dishwasher cleaned both tensile adhesion witness panels and TDCBs in a process which simulates the new production process. The tests were performed six times during 1995, subsequent statistical analysis of the data established new upper control limits (UCL) and lower control limits (LCL). The data also demonstrated that the new process was equivalent to the vapor degreasing process.

Hutchens, Dale E.↗
NASA NTRS2007

Benchtop Detection of Proteins

A process, and a benchtop-scale apparatus for implementing the process, have been developed to detect proteins associated with specific microbes in water. The process and apparatus may also be useful for detection of proteins in other, more complex liquids. There may be numerous potential applications, including monitoring lakes and streams for contamination, testing of blood and other bodily fluids in medical laboratories, and testing for microbial contamination of liquids in restaurants and industrial food-processing facilities. A sample can be prepared and analyzed by use of this process and apparatus within minutes, whereas an equivalent analysis performed by use of other processes and equipment can often take hours to days. The process begins with the conjugation of near-infrared-fluorescent dyes to antibodies that are specific to a particular protein. Initially, the research has focused on using near-infrared dyes to detect antigens or associated proteins in solution, which has proven successful vs. microbial cells, and streamlining the technique in use for surface protein detection on microbes would theoretically render similar results. However, it is noted that additional work is needed to transition protein-based techniques to microbial cell detection. Consequently, multiple such dye/antibody pairs could be prepared to enable detection of multiple selected microbial species, using a different dye for each species. When excited by near-infrared light of a suitable wavelength, each dye fluoresces at a unique longer wavelength that differs from those of the other dyes, enabling discrimination among the various species. In initial tests, the dye/antibody pairs are mixed into a solution suspected of containing the selected proteins, causing the binding of the dye/antibody pairs to such suspect proteins that may be present. The solution is then run through a microcentrifuge that includes a membrane that acts as a filter in that it retains the dye/antibody/protein complexes while allowing any remaining unbound dye/antibody pairs to flow away. The retained dye/antibody/protein complexes are transferred to a cuvette, wherein they are irradiated with light from a miniature near-infrared laser delivered via a fiber-optic cable. The resulting fluorescence from the dye(s) is measured by use of a miniature spectrometer, the output of which is digitized, then analyzed by laptop computer. The software running in the computer identifies the protein species by the wavelengths of their spectral peaks and determines the amounts of the proteins, and thus, one day, microbes of the various species from the intensities of the peaks. The abovementioned removal of the unbound dye/antibody pairs during centrifugation prevents false positive readings. The process proves successful in detecting proteins in solution and thus can now be employed for use in microbe detection.

Scardelletti, Maximilian C.↗
DOE OSTI2023

Vectorization of CMSSW offline software

The CMS experiment has been utilizing vectorization, or SIMD, in parts of its data processing applications for over a decade. On x86 platforms the vectorization level is still SSE3. In the past attempts to use wider vector instruction sets such as AVX or AVX-512 have, in practice, not resulted in improvements in the overall event processing throughput, because the CPUs scale down their frequency when processing AVX instructions. In addition, a notable part of the global pool of CMS’ resources has been old systems either not supporting AVX, or where the CPU frequency downscaling impacts all cores of the CPU. CMS has nevertheless continued to vectorize more of its application code, and in this work we review profiling methods we have found effective to find out pieces of code that would benefit from vectorization, and techniques to transform those codes such that the GCC compiler is able to auto-vectorize those codes. The build system used for CMSSW, Scram, has also been enha nced to be able to build code for multiple CPU microarchitectures such that the shared libraries of desired microarchitecture level can be loaded based on the CPU of the system. This multi-microarchitecture setup is invisible to the workflow management system, which makes its deployment straightforward. We describe in detail how this multi-microarchitecture build is set up, and measure the impact of using wider vector units than SSE3 on the event processing throughput of CMS applications such as simulation and reconstruction on recent x86 CPUs.

Gartung, Patrick↗
DOE OSTI2021

Multi-Scale Land-Atmosphere Interactions: Modeling Convective Processes from Plants to Planet

Research accomplishments include: 1)Two case studies of the effects of heterogeneous soil moisture and surface energy budgets on organization and propagation of convective precipitation during MC3E. 2) Development and evaluation of a new approach for simulating the effect of heterogeneous soil moisture at ARM-SGP using an innovative modeling approach. 3) Investigation of the effects of spatial coupling scale using multidecade global simulations in CESM with the multiscale modeling framework. 4) Exploration of changes to future precipitation intensity resulting from two different climate change scenarios using the multiscale model. 5) Provision of the new cloud-scale coupled multiscale Earth System Model to the larger community through the CESM process.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS2021

Direct Multipoint Observations Capturing the Reformation of a Supercritical Fast Magnetosonic Shock

Using multipoint Magnetospheric Multiscale (MMS) observations in an unusual string-of-pearls configuration, we examine in detail observations of the reformation of a fast magnetosonic shock observed on the upstream edge of a foreshock transient structure upstream of Earth’s bow shock. The four MMS spacecraft were separated by several hundred km, comparable to suprathermal ion gyro-radius scales or several ion inertial lengths. At least half of the shock reformation cycle was observed, with a new shock ramp rising up out of the “foot” region of the original shock ramp. Using the multipoint observations, we convert the observed time-series data into distance along the shock normal in the shock’s rest frame. That conversion allows for a unique study of the relative spatial scales of the shock’s various features, including the shock’s growth rate, and how they evolve during the reformation cycle. Analysis indicates that: the growth rate increases during reformation, electron-scale physics play an important role in the shock reformation, and energy conversion processes also undergo the same cyclical periodicity as reformation. Strong, thin electron-kinetic-scale current sheets and large-amplitude electrostatic and electromagnetic waves are reported. Evidence is also presented of nonlinear wave decay from electromagnetic whistler-mode “lion roars” to electrostatic solitary waves in the downstream plasma regime. Results highlight the critical cross-scale coupling between electron-kinetic-and ion-kinetic-scale processes and details of the nature of nonstationarity, shock-front reformation at collisionless, fast magnetosonic shocks.

D L Turner↗
DOE OSTI2024

Performance Testing of a Moving-Bed Gasifier Using Coal, Biomass, and Waste Plastic Blends with Washed and Unwashed Legacy Coals and Other Waste Fuels to Generate White Hydrogen

The objective of this effort, primarily funded by the United States Department of Energy (DOE), and led by the Electric Power Research Institute, Inc. (EPRI), with support by Hamilton Maurer International (HMI) and Sotacarbo S.p.A. (Sotacarbo), has been to qualify coal, biomass, and plastic waste blends based on performance testing of selected fuel pellet compositions in a pilot-scale updraft moving-bed (UDMB) gasifier. The testing provided relevant data to advance the commercial-scale design of the moving-bed gasifier to be able to successfully use these feedstocks to produce hydrogen. In particular, the effects of waste plastics on feedstock development (i.e., blending and pelletizing) and the resulting products (i.e., syngas compositions, organic condensate production, and ash characteristics) are the focus. The gasifier used for testing is HMI’s moving-bed gasifier, which has been proven capable of gasifying nearly all coal ranks. It has also shown the ability in prior testing work to gasify wood chips (biomass). However, mixtures of these fuels with plastic wastes have not been prepared and gasified together. The three feedstocks were densified and pelletized by California Pellet Mill (CPM) to meet the feedstock size required by Sotacarbo’s 30mm ID UDMB gasifier, under contract to HMI. The technical tasks and results from this two-year research project included: (1) Feed Procurement and Preparation: Nine different tri-fuel pellets were prepared from varying compositions of fresh mined PRB coal, corn stover biomass, and car fluff waste plastics. Tri-fuel pellets were produced by CPM and shipped to Sotacarbo’s test facility in Carbonia, Sardinia, Italy. (2) Test Plan Development: A test plan was created to define the test runs to be performed. The test plan detailed the different UDMB gasification tests to be performed in Sotacarbo’s 12-inch ID pilot scale gasifier, the process monitoring instrumentation used, and the extractive samples recovered for analysis of the total gasification process mass and energy balance. (3) Gasifier Testing: Nine different gasification runs were performed in the pilot-scale gasifier at Sotacarbo using nine different fuel feedstock compositions generated from varying mixtures of PRB coal, biomass, and plastic wastes. The testing generated performance data on gasification reaction efficiency and performance, yielding relevant data for models used to scale up the gasifier design. This task also included work to refurbish and reassemble the pilot gasifier at Sotacarbo and perform a baseline 100% PRB coal run. (4) Data Analysis and Reporting: Review of the data, determination of figures of merit, and interpretation of the results are reported in the project’s final report, published in March 2024. The results show that all tri-fuel pellets gasified well and maintained structural integrity throughout the gasification process. The syngas generated can be shifted to hydrogen by using commercial syngas shifting technologies. (5) High Fidelity computational fluid dynamics (CFD) Simulation: The National Energy Technology Laboratory (NETL) team performed CFD simulations of the UDMB gasifier for two of the tri-fuel pellets gasified in Sotacarbo’s pilot scale gasifier. The kinetic mechanisms for the pyrolysis of each constituent, PRB coal, corn stover biomass, and waste plastics are based on thermogravimetric analysis performed by Sotacarbo. The gasification model was validated by comparing the predicted syngas composition at the exit of the gasifier with the measured syngas composition. In addition, the reactor’s measured internal temperature profile agreed well with the predicted internal reactor temperature profile. These results validate that the model can be used to predict the performance of the updraft moving bed gasifier for different feedstocks and operating conditions. This paper summarizes the results of the completed work in which the pelletizing procedure was validated to ensure the viability of the tri-fuel pellets for the gasification runs performed at Sotacarbo’s 30 mm UDMB gasifier. The gasification performance data from this series of nine runs will enable modeling of a full-scale HMI industrial scale gasifier supporting both combined heat and power, and Hydrogen production from coal (both fresh mined and legacy) combined with various biomass and waste plastics. Additionally, plans and progress on a follow-up project, being executed by the same project team, will be presented. In this project, a total of twenty (20) different feedstocks are being prepared from varying compositions of biomass (both woody biomass and corn stover) with a mixture of legacy coal waste, plastic waste, and refuse-derived fuel (RDF). The testing will provide information on gasification reaction efficiency/performance, yielding relevant data for models used to scale up the gasifier design to 50 megawatt electric (MWe) (equivalent hydrogen production). Tests will also be performed on a bench-scale fluidized-bed gasifier for comparison purposes. The results of this testing will be used to specify the range of feedstock blends that can be successfully gasified as well as quantify gasifier outputs based on specific blends.

08 HYDROGEN↗
DOE OSTI2022

Melt-Spun PAN Precursor for Cost-Effective Carbon Fibers in High Pressure Compressed Gas Tankage

The objective of this program was to synthesize melt-spinnable polyacrylonitrile (PAN) precursor that will lead to carbon fiber 25% less expensive than carbon fiber produced from conventional PAN precursor when produced in large volumes. The carbon fiber produced from this precursor needs to achieve ≥ 700 ksi tensile strength with this cost reduction to replace the incumbent fiber. In this program, the technology for producing precursor and then converted carbon fiber (CF) capable of meeting the 700 ksi target was to be demonstrated at a small scale in tows, containing ≥ 100 filaments. If this program moved on to a “Phase 2”, the processes would be scaled up to produce and test Type IV compressed gas storage tanks capable of meeting the 700-bar ultimate targeted FOA performance level. Precursor fiber production typically contributes a large fraction (~50%) to finished CF manufactured cost. Presently, all high strength CFs are manufactured from solution spun PAN precursor, accomplished at low temperatures using large amounts of environmentally unfriendly solvents that impart major impact to line speed and costs involved with handling and reclaiming the solvents and associated “waste streams” required in spinning and extracting those solvents. PAN melt spinning was demonstrated by the company BASF in CF precursor production and used in production of some other acrylic fibers, but significant production challenges remain for meeting the established CF metrics. Melt spinning requires use of plasticizers to suppress the melt temperature of the predominantly PAN formulation to a point sufficiently below the temperature of significant cross-linking. Fortunately, BASF and this team’s earlier work had demonstrated acrylic formulations melt spun with combinations of plasticizing solvents at much lower solvent levels. This project team made significant progress in understanding technical issues and identifying formulation pathways in earlier work in this area where >250ksi strength was achieved. The goal of this program was to pursue a more comprehensive approach with a larger, more diverse team having greater equipment design and overall production capabilities to push rapidly beyond the science to resolve remaining “engineering” issues associated with establishing stable, continuous processes for precursor fiber leading to enhanced, cost-effective CF and composite tank production.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Development of Low-Cost, High-Performance, Easy-To-Apply, Non-Flammable, Inorganic Phase Change Material (PCM) Technology (Project Final Report)

This report describes a 45-months long research program focused on the development of novel, easy-to-apply, non-flammable, and high-performance inorganic phase change materials (PCMs) for building and industrial applications. The University of Massachusetts Lowell (UML) formed a world-class team consisting of researchers form InsolCorp (only N. American manufacturer of inorganic PCM systems for building applications), and a group of industrial advisors, to develop a universal/multipurpose, simple-to-manufacture and cost-effective PCM technology. The project team expects that the results of this work will spur in the future the adoption of thermal storage materials – a key building energy saving technology as identified by DOE BTO – for a variety of building envelope applications. The main goal of this project was to demonstrate a suite of low-cost, multipurpose, and durable inorganic PCM formulations with phase transition temperatures encompassing typical building applications (between +5 o C and +55 o C). The first objective was to design, fabricate, and experimentally validate a performance of inexpensive, durable, highly efficient, non-flammable, and easy to manufacture PCMs. To allow a variety of building applications, the project team focused on formulations that exhibit repeatable phase transitions between +5 o C and +55 o C. To follow the DOE BTO cost efficiency target without compromising thermal performance, our work was based on inorganic compounds (mostly salt hydrates) and their blends, which represent a fraction of the cost of most of organic PCMs with about twice as high density as well as significantly higher thermal conductivity and phase change enthalpy. The second objective was to develop easy-to-manufacture and -install packaging/encapsulation designs that are 1) a superior barrier to current state-of-the-art macro-packaging, which significantly reduces the risk of loss of hydration water and PCM leak, and 2) optimal in enhancing the heat exchange rates with the surroundings and within the PCM core to ensure complete charging/discharging of the entire PCM within the product. Finally, the project’s intend was to scale-up the fabrication process to demonstrate installation on system-scale applications, and to validate the performance under field conditions. This work aimed at developing low-cost, high-energy storage, and reliable latent heat storage technology for building applications. This development was realized by formulating and integrating the following two technology components: 1) inorganic salt hydrate based PCMs that have high latent enthalpies and are low-cost and durable, and 2) PCM encapsulation (packaging) technology that maximizes PCM concentration and enhances heat transport characteristics in the product and with the external environment/materials. High thermal storage capacity, low cost and fire resistance are key to the building market entry for PCM technology. Therefore, the project’s focus was on salt-hydrate-based formulations which satisfy all these criteria. Packaging and/or encapsulation of PCM is a key processing step. The project team recognized that a low-cost and simple-to-manufacture salt hydrate-based PCM technology holds the best chance to be successful in the building construction market, a market which is traditionally extremely sensitive to cost and where commodity thermal insulations are the benchmark for envelope-related energy saving measures. That is why, in this project, the main intention was to minimize the production cost and maximize the product energy storage density without sacrificing the PCM performance. It was achieved through: 1. Minimizing the non-PCM components (plastics, additives, packaging/encapsulation materials, etc.) because they are significantly more expensive than salt hydrates, 2. Using highly thermally conductive and lightweight PCM carrier (packaging material) to facilitate more complete phase cycling, and 3. Optimizing the thickness and minimizing air spaces in product design (such as in pouched PCM). For this purpose, our approach was to enable an easy system design, including selection of the PCM operating temperatures, optimizing the necessary heat storage capacity (by stacking together several layers of PCM products), and if needed, a synchronized usage of PCM products of different temperatures. A specially designed, robust, highly thermally conducting and highly impermeable packaging (to retain salt hydrate water during phase transition cycles) was designed and tested to increase the overall system thermal performance and durability. All PCM products developed during this project were tested in both lab scale and in full scale field conditions. It is expected that, after further developments and commercialization, the developed PCM technologies may be also applied in space conditioning, energy storage technologies, and heat transfer applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Characterizing Land-Atmosphere Interactions During the Afternoon-to-Evening Transition Using ARM SGP Observations

The land-atmosphere (LA) system consists of the soil, vegetation, and lowest layer of the atmosphere. The energy and water transport processes in this system contribute to the structure and the daily cycle of the atmospheric boundary layer (ABL), which is the layer between the land surface and the free troposphere that controls the exchange of momentum, energy, and water. The state of the ABL is the result of complex two-way interactions between local processes such as surface fluxes and entrainment at the ABL top as well as large-scale and mesoscale processes such as advection and subsidence.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Implications of Sea Breeze Circulations on boundary layer aerosols in the southern coastal Texas region

The Sea Breeze Circulation (SBC) influences atmospheric processes at multiple scales in coastal regions. Understanding how SBCs impact the aerosol number budget and aerosol–cloud interaction processes is essential. This study investigates sea breeze–aerosol interactions (SAIs) during 46 summertime SBC events using data from the TRacking Aerosol Convection Interactions Experiment (TRACER) field campaign across urban (main) and rural (supplemental) coastal sites in southern Texas. Weather Research and Forecasting model coupled with Chemistry (WRF-Chem) simulations complement observations to explore spatio-temporal meteorological controls on boundary layer aerosols. During the summertime, Sea Breeze Fronts (SBF) penetrating inland transported cool, moist air over the land, introducing air masses with distinct properties compared to the preexisting continental air. These SAIs cause variability in number concentrations of up to a factor of two, with events typically lasting ∼ 5 h before returning to background conditions. SAI impact on aerosols varies with site proximity to water and the preceding sea breeze (SB) history, primarily affecting the marine-influenced accumulation mode. The main site, influenced by both Galveston Bay and the Gulf of Mexico, reflects a stronger marine influence. In contrast, a supplemental site, at a similar shoreline distance but exposed only to the Gulf of Mexico and typically upstream of the urban core, samples SB air that has traversed land and partially regained continental characteristics. Simulations show that the regional SAIs extend ∼ 50 km inland and reach up to the boundary layer height. SAIs further decrease cloud condensation nuclei relevant aerosol number concentrations in ∼ 20 % of events during SBF passage.

54 ENVIRONMENTAL SCIENCES↗