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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 1,081 records · Page 60
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Public Reference Data for Megawatt-Scale Hydrogen Electrolysis - NLR Historical Solar PV

The U.S. Department of Energy and National Laboratory of the Rockies (NLR) demonstrate hydrogen electrolysis from variable sources, hydrogen compression and storage, and hydrogen fuel cell power production using megawatt-scale equipment at NLR’s Flatirons Campus as part of the Advanced Research on Integrated Energy Systems (ARIES) research platform. This dataset represents part of that effort and is intended for academic, national laboratory, industrial, and other stakeholders to plan, design, and validate models of megawatt-scale hydrogen technologies and diverse energy infrastructure nationwide. These data provide a baseline for how existing hydrogen electrolysis technologies perform when coupled with various energy technologies. Future datasets will demonstrate how existing hydrogen fuel cell technologies can provide controllable, dispatchable, and variable power output for artificial intelligence data centers and other variable loads. This dataset entry describes the behavior of a 1.25-MW proton exchange membrane MC250 electrolyzer system, manufactured by Nel Hydrogen , [1] when fed historical data generated by the 430-kW, fixed-axis solar photovoltaic (PV) array located at NLR’s Flatirons Campus. (While the electrolyzer balance of plant supports up to 2.5 MW of electrolysis, NLR only has a single 1.25-MW electrolysis stack.) Solar PV power output data for the 2020 calendar year were categorized on a daily basis by total energy generation and standard deviation. Each day was then ranked by these metrics, and the 25th, 50th, and 100th percentiles were selected. The 75th percentile day did not exhibit sufficient variability to make for a valuable experiment. A similar process was used for the related historical wind dataset . [2] The historical days in 2020 that represented these percentiles are Dec. 19, March 29, and May 4, respectively. The entire solar day’s power profile was then fed through the MC250 electrolyzer. Due to its length, the 100th percentile day experiment was split into two parts, and the final 3 hours of the solar day were not captured. These final 3 hours contained no spikes or dips of interest and simply represented a slow decay of input solar power. Also, a single timestamp (13:13:47 on Jan. 14, 2026) was lost in the hydrogen system supervisory control and data acquisition. Finally, during the 25th percentile experiment (solar day Dec. 19, 2020) data recording was lost from 11:00:13 to 11:14:45. The roughly 15 minutes of the solar profile were rerun at the end of the experiment and spliced into this time slot during post-processing. The electrolysis system controls hydrogen production by varying direct current applied to the stack, from a maximum of 3,000 A to a minimum safe operation of 300 A, or 10%. Because the current–voltage characteristic changes as the stack ages and efficiency degrades, the actual minimum safe operating power changes over time. The historical solar profiles were translated from power (kilowatts) to current (amperes) using a curve fit with calibration data and sent to the electrolyzer power supply at 1-Hz frequency. For more details on the statistical analysis process, see the slide deck “Public Reference Data for Megawatt-Scale Hydrogen Electrolysis: NLR Historical Solar PV Analysis and Profile Generation” accessible with this data entry. These datasets report relevant hydrogen balance-of-plant and system data, all captured at 1 Hz, including hydrogen mass production measured with an Emerson Coriolis flow meter. Each .zip file represents a single solar PV electrolysis experiment and is formatted as: {technology}_{percentile}_{scaling factor} For instance, “solarPV-430kW_25_2x.zip” reports the experiment using the 25th percentile solar data from the historical 2020 solar PV dataset, scaled to 200%. Scaling factors were applied to the generated solar PV power output files to more closely match the 1.25-MW capacity of the electrolyzer. Each .zip folder contains the following files: A .csv file containing raw data. An .xlsx file explaining all the fields in the raw data. A .png plot showing the time series of hydrogen production, electrolysis power consumption, and solar power input. A PDF file detailing the historical solar data statistical analysis used to generate the solar profile. An experiment labeled “characterization_200.zip” demonstrates the MC250 electrolyzer steady-state response with 30-minute load steps for a total duration of 5 hours. Finally, a .csv file is provided with all experiments combined into one dataset labeled "combined_solarPV_experiments.csv". [1] nelhydrogen.com/product/mc-series-electrolyser . [2] data.nlr.gov/submissions/316 .

08 HYDROGEN↗
NASA NTRS2011

Evaluation of Tribocharged Electrostatic Beneficiation of Lunar Simulant in Lunar Gravity

The lunar regolith has high concentrations of aluminum, silicon, calcium, iron, sodium, and titanium oxides. Liberation of these metals would provide necessary materials for structural and building material fabrication, spare part, machine and tool production, and construction and site preparation in-situ on the moon or other extraterrestrial body (Rao et al 1979). Ilmenite (FeTi03) is a mineral of interest on the moon as a source of iron, titanium, and oxygen (Cameron 1992, Zhao and Shadman 1993) and therefore enrichment of this mineral in the feedstock before processing would be a considerable advantage in reducing energy requirements to process regolith. Not only for construction materials, but shipping oxygen and water from earth is weight prohibitive, and so investigations into the potential production of oxygen from the oxides of lunar regolith are a major research initiative by NASA (Sibille et al. 2009, Moscatello et al. 2009). In this paper, the results of electrostatic beneficiation of two sets of lunar simulants on two different reduced gravity flight series are presented.

Quinn, Jacqueline W.↗
DOE OSTI2026

A Kinetic Model-Driven Techno-Economic Analysis of Plastic Pyrolysis: Linking Process Dynamics to Economic Viability

This study employs a kinetic model integrated into Aspen Plus to predict pyrolysis product distribution under various conditions. A techno-economic assessment calculated the minimum selling price (MSP) of pyrolysis oil under different operating conditions for the baseline capacity of 100 kta, and across eight processing capacities ranging from 30 to 150 kta. The lowest MSP under the baseline capacity is estimated at $\$$420/ton, which is 33% lower than the 2023 average US crude oil price ($\$$74.6/bbl, equivalent to $\$$634/ton based on the density of pyrolysis oil). Under Monte Carlo simulation, accounting for variability in key economic and technical parameters, the mean MSP is estimated at $\$$1137/ton. The economic viability depends on feedstock price remaining below $\$$320/ton, defining the break-even feedstock price threshold. Sensitivity analysis further identifies capital investment and transportation cost as key economic drivers. Capacities beyond 90 kta show limited economies of scale benefits. Reducing product storage time cuts capital costs by 7% but raises operational risk. Uncertainty analysis suggests the economic feasibility of pyrolysis oil is unlikely to compete with crude oil without policy incentives.

petrochemicals↗
DOE OSTI2023

Decontamination Strategies to Increase Fuel and Product Conversion Yields of Municipal Solid Waste

Since the implementation of China’s Green Fence and National Sword policies, many areas lost a market for heavily contaminated municipal solid waste (MSW). Approximately 17.2 million tons of paper and 26.9 million tons of plastic were landfilled in the United States in 2018. This non-recyclable waste that would normally be landfilled can be converted into fuels and chemicals, but common contaminants that are present in non-recyclable waste can negatively affect low and high-temperature conversion yields. In addition, MSW is a heterogeneous feedstock whose composition can vary widely across geographical areas and socio-economic statuses. This presents a unique challenge for providing a consistent feedstock to biorefineries around the world. Techniques that are commonly used in other industries, in addition to pre-processing methods used for traditional biomass, can be used to increase conversion yields. Drawing on established techniques, as well as experimental decontamination strategies, non-recyclable MSW could represent a viable alternative to agricultural residues for biofuel production. Although many of the techniques explored in this chapter have been used extensively in other industries, the feedstock composition needs to be carefully considered when choosing prospective decontamination methods. It is likely that there is not a “one-size-fits-all” decontamination method for MSW. In conclusion, a pre-processing and decontamination plan will rely heavily on the composition of the individual waste stream.

09 BIOMASS FUELS↗
DOE OSTI2024

Commercialization of High-Density High Assay Low Enriched Uranium Fuel Systems

The Office of Reactor Conversion and Uranium Supply (NA 231) at the National Nuclear Security Administration leads the conversion effort for the United States High Performance Research Reactors (USHPRR). These reactors are the final civilian reactors in the US to transition from High Enriched Uranium (HEU) to high assay low enriched uranium (HALEU). Each of these reactors represents unique capabilities and no currently available fuel system meets their needs for conversion. The Fuel Fabrication (FF) Pillar of the USHPRR project is responsible for the fabrication of experimental elements, conversion elements, and establishing a commercial economical production capability. FF is also responsible to share with the domestic and international community the theoretical knowledge gained. Other pillars within the USHPRR project provide the experimental and conversion fuel designs, assist the reactors with licensing activities, and ensure the entire fuel cycle is evaluated. Over the last decade, FF has worked with the production partners at Y-12 National Security Complex (Y-12) and BWXT Nuclear Operations Group, Research and Test Reactors (BWXT). Y-12 has begun processing the alloy feedstock for the conversion elements with a qualified process. BWXT has started the final fabrication of the experimental elements. Once the experimental elements are complete, BWXT will begin conversion element fabrication. The FF Pillar resides at Pacific Northwest National Laboratory (PNNL) and uses PNNL, universities, commercial vendors, and the DOE national laboratory system to evaluate process development activities to improve the process steps. FF supports the fabrication of two high density fuel systems, monolithic U-10Mo (Figure 1) and Uranium Silicide (Figure 2). The U-10Mo fuel system is further along the development process. FF assists in long term planning with the production partners. This includes ramping production of the elements from experimental quantities to annual steady state needs. As part of the ramp up, opportunities to improve yield and product quality are identified to ensure the fuel systems are cost effective.

Catalan, Michael A. [BATTELLE (PACIFIC NW LAB)]↗
DOE OSTI2022

Long term performance of pilot methanogenic digester filled with seashell wastes treating slaughterhouse wastes: Biogas production and environmental impact

High ammonia and organic acids contents of decomposed slaughterhouse waste (SHW) often result in the severe inhibition or even failure of the anaerobic digestion (AD). The two-stage AD system can alleviate the ammonia inhibition; however, addition of alkali is often needed to maintain the neutral condition. In this study, seashell wastes containing high percentage of calcium carbonate (CaCO 3 ) were for the first time added in a pilot scale methanogenic digester treating chicken blood waste to retain the microorganisms and provide pH buffers for the substrate. A long-duration performance of this digester was conducted for 400 days under different organic loading rates (OLRs). The results show that methane yields of the digester were 244.8 and 224.9 mL g –1 COD added at OLR of 0.4 and 0.6 g COD L –1 d –1 , respectively, higher than the results of previous studies treating the similar feedstock. An AD system treating blood wastes of a typical poultry slaughterhouse was also proposed for which energy balance and carbon footprint analyses were conducted. The energy production of 0.35 MJ kg –1 blood and carbon emissions reduction of 0.05 kg CO 2 -eq kg –1 blood can be achieved from treating blood waste of the broiler chicken. Finally, this study reveals that using seashell wastes in an AD treating SHW can facilitate the reuse of aquaculture wastes and improve the sustainability of meat industry.

09 BIOMASS FUELS↗
DOE OSTI2023

An Analysis of the Potential and Cost of the U.S. Refinery Sector Decarbonization

In 2019, U.S. petroleum refineries emitted 196 million metric tons (MT) of CO 2 , while the well-to-gate and the full life cycle CO 2 emissions were significantly higher, reaching 419 and 2843 million MT of CO 2 , respectively. This analysis examines decarbonization opportunities for U.S. refineries and the cost to achieve both refinery level and complete life-cycle CO 2 emission reductions. Here, we used 2019 life-cycle CO 2 emissions from U.S. refineries as a baseline and identified three categories of decarbonization opportunity: (1) switching refinery energy inputs from fossil to renewable sources (e.g., switch hydrogen source); (2) carbon capture and storage of CO 2 from various refining units; and (3) changing the feedstock from petroleum crude to biocrude using various blending levels. While all three options can reduce CO 2 emissions from refineries, only the third can reduce emissions throughout the life cycle of refinery products, including the combustion of fuels (e.g., gasoline and diesel) during end use applications. A decarbonization approach that combines strategies 1, 2, and 3 can achieve negative life-cycle CO 2 emissions, with an average CO 2 avoidance cost of $\$113$ - $\$477$/MT CO 2 , or $\$54$ - $\$227$/bbl of processed crude; these costs are driven primarily by the high cost of biocrude feedstock.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2023

Coupled wave-current modeling for hydrodynamic load analysis of macroalgae cultivation farms

Large-scale cultivation of macroalgae is one of the most promising biofuel sources that could reduce our consumption of fossil fuels and would be particularly economically competitive when grown for the co-production of additional goods such as food and textiles. Current production of biofuel from algal biomass is limited by labor costs and lack of data on potential impacts of cultivation and harvesting on marine and coastal environments as well as a comprehensive characterization of the impact of environmental conditions on macroalgal feedstock and their bioproduct and biofuel yield and quality. Awarded by the United States (U.S.) Department of Energy Advanced Research Projects Agency-Energy (ARPA-E) Macroalgae Research Inspiring Novel Energy Resources (MARINER) program, which seeks to enable the U.S. as a global leader in the production of marine biomass, the Marine Biological Laboratory (MBL) has been developing a test system for tropical seaweed cultivation in the Gulf of Mexico and the Caribbean. An integral step in designing macroalgae cultivation farms is to adequately characterize the hydrodynamic climate at potential growth sites. In regions like the Gulf of Mexico and the Caribbean, which are highly exposed to tropical cyclones, it is critical to not only consider the day-to-day hydrodynamic conditions but to also assess the risk of extreme sea states to ensure the survivability of future macroalgae farms. Under these considerations, the Pacific Northwest National Laboratory (PNNL) is providing modeling support for MBL to inform the design and siting of the farm systems that have been proposed for their ARPA-E MARINER project. This report describes the development of a high-resolution coupled storm surge and wave model to simulate the hydrodynamics and wave climate at proposed macroalgae cultivation sites selected by MBL in Florida and Puerto Rico. Model results, including model validation, water level, current distributions, and sea states, are discussed for both selected sites in Florida and Puerto Rico coast. These simulations provide an accurate insight into the hydrodynamic conditions that a macroalgae farm is likely to experience during its operational lifetime, including current information to support fine-scale hydrodynamic load modeling, risk analysis and system design.

09 BIOMASS FUELS↗
DOE OSTI2022

Development of Large Scale Extrusion Deposition for Structural Applications

Large Scale Extrusion Deposition (LSED) is an evolving additive manufacturing (AM) technology that research, such as that taking place at Oak Ridge National Laboratory (ORNL) and companies like Local Motors, are continuing to utilize and develop new applications. A major LSED application of interest has been molds and tooling as it allows for much shorter production time and lower cost. However, interest has been expanding into using LSED for more structural applications due to more frequent use of high performing polymer composites as feedstock. The use of LSED for structural applications is of particular interest to Local Motors as it is currently being used to create commercially viable, energy efficient electric vehicles. LSED offers a unique opportunity when compared to traditional manufacturing methods as it can significantly reduce the number of components necessary, while decreasing embodied energy and carbon emissions. Even with these benefits however, it is important that LSED is properly understood from a structural aspect as this field has not been as heavily researched as tooling. To ensure a high level of safety and repeatability is an essential responsibility of a manufacturer whose products are structural in nature. As such it is important to understand the materials and LSED process to make structural objects that the manufacturer can be confident in. The main goals of this project were to: develop and investigate materials that are of interest for structural LSED applications, further develop and understand the current machines used in LSED and develop simulations tools of LSED and the mechanical properties of the created structure. Material development focused on composite materials that have high mechanical properties and are stable in a variety of environments. The materials were tested to determine their as printed mechanical and thermal properties as these are necessary for simulations. Once the materials were investigated thoroughly, it allowed for simulations to be performed to compare to experimental data with simulations. Materials were also vetted to determine candidates for multi-material printing. The machine development focused around the areas of process monitoring, non-destructive evaluation, and quality control. Finally, the goal of the simulations was to develop a realistic model of printed structures, including in-process simulation and dynamic simulation. The routes to get to some of these goals and the depth in which they were investigated changed throughout the project due to personnel changes and the COVID-19 pandemic. This project resulted in many valuable results such as the development of an nondestructive evaluation (NDE) technique for interlayer defects, proof of simulation for warpage in simple parts, the development and utilization of a profilometer to monitor a print for defects or inconsistencies, thorough investigation of a material used commercially for structural LSED applications and valuable experimental data on the applicability and advantages of multi-material crush structures versus their neat counterparts by creation and testing of samples.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Unlocking the biofuel power of cover crop in Washington State: Enhancing potential through hydrothermal liquefaction

This study evaluates cover crops in Washington State (WA) as a renewable feedstock for hydrothermal liquefaction (HTL), supported by techno-economic (TEA) and life cycle (LCA) analysis. In the Pacific Northwest, fallow land is the common winter practice, generating no income for farmers. Over three years, field trials at two representative sites—Puyallup (cool, wet) and Othello (irrigated, no-till)tested triticale, hairy vetch, crimson clover, winter pea, and fava bean preceding cash crops. Biomass yields, composition, soil impacts, and net revenue were assessed across removal treatments. HTL conversion produced 32–37 wt% biocrude, lower than 48 wt% for sewage sludge, with modeled cradle-to-grave carbon intensities of 26–31 g CO 2 e/MJ and minimum fuel selling prices (MFSP) of $\$$6.75–$\$$7.18 per gallon gasoline equivalent (GGE), comparable to other lignocellulosic feedstocks. No significant changes were observed in soil carbon, nitrogen, or subsequent cash crop yields after cover crop removal. Farmer profitability was possible, particularly for triticale and hairy vetch at $\$$60 per dry ton. To address seasonal variability, blending with wastewater sludge was evaluated. All scenarios delivered >70 % carbon intensity reductions relative to fossil fuels, and with Renewable Identification Number (RIN) credits, MFSPs below $\$$2.5 GGE were achievable. These results demonstrate that cover crops can generate new revenue streams for farmers while serving as a flexible, low-carbon feedstock. Integrating cover crops with waste biomass offers a practical pathway to expand the bioeconomy and support year-round renewable fuel production.

Biofuels↗
DOE OSTI2024

Characterizing value-added pellets obtained from blends of miscanthus, corn stover, and switchgrass

The current pellet industry primarily relies on woody biomass. Inclusion of a diverse feedstock, such as herbaceous biomass, is necessary to meet the rising demand for pellets in heat and power generation, and for biofuel production. This study was motivated by the need to densify biomass, improving its naturally low energy density, to reach the required pellet standards for biofuel conversion. Here, we developed value-added miscanthus pellets blended with different ratios of corn stover and switchgrass and analyzed their chemical, physical, and mechanical properties. Pure miscanthus pellet durability index (PDI) was less than 85 %, well below the ISO 17225-6 standard for herbaceous pellets. While increasing switchgrass and corn stover ratios increases durability beyond 94 %, it also increases ash content from 1.6 % to 4.6 %, a quality unfavorable for biofuel conversion. The moisture content of the blended pellets varied from 7.12 % to 12.45 %, and positively correlated with the durability of the pellets. Pure miscanthus pellets had the highest bulk density, 633 kg/m 3 , while pellets containing 75 % miscanthus and 25 % corn stover had the lowest density, 564 kg/m 3 . The findings of this study also identified a decrease in the pellet bulk density with the increase in ash content and pellet diameter.

09 BIOMASS FUELS↗
DOE OSTI2021

Microbe-Encapsulated Silica Gel Biosorbents for Selective Extraction of Scandium from Coal Byproducts

Establishing an inexpensive and environmentally friendly scandium (Sc) supply is critical for the development of clean energy technologies. However, refining Sc from Sc-bearing sources using current technologies poses economic and environmental challenges due to its low concentration relative to base metals and chemically similar lanthanides. In this work, we developed a biosorption-based flow-through process for extraction of Sc from low-grade feedstocks. A novel biosorbent material was synthesized by encapsulating Arthrobacter nicotianae, a bacterium that selectively adsorbs Sc, within a porous silica matrix. Through the use of several complementary microscopy techniques, we demonstrated a highly porous biosorbent structure with a high cell-loading density and a homogenous cell distribution. Batch adsorption assays revealed selective Sc adsorption over lanthanides and common based metals, with the exception of Fe(III), as evidenced by separation factors greater than 50. The MESG particles were packed into fixed-bed columns to enable adsorption under flow-through conditions, which demonstrated effective Sc extraction at flow rates up to 0.08 cm/s and high stability for reuse; greater than 95% of the adsorption capacity was maintained after 10 consecutive adsorption/desorption cycles. When applied to a lignite coal leachate, whose Fe content was depleted through pH-mediated precipitation, the MESG particles yielded Sc breakthrough at 30 bed volumes, whereas all other metals broke through after only a few bed volumes. Following desorption, an eluate with a 124-fold increase in Sc purity was achieved relative to the lignite leachate with Sc constituting 96.4% of the total REEs. This study established a rapid, facile, and scalable cell immobilization approach that enables the use of microbial biomass for Sc recovery from low-grade sources.

Dong, Ziye↗
DOE OSTI2024

Insights into Sustainable Nitrogen Fixation by Gas-phase Spectroscopic Measurements and Global Modeling of Reaction Intermediates in Humid Nitrogen Plasma

In this article, there is growing interest in reacting molecular nitrogen and water to sustainably synthesize fixed forms of nitrogen such as ammonia. In particular, low-temperature plasmas can activate these relatively inert feedstocks at or near room temperature without a catalyst. However, because of the enhanced reactivity and nonequilibrium chemistry, a diverse range of products is formed, and the underlying reaction mechanisms are exceedingly complex. In this work, we studied a simplified reactor consisting of a gaseous plasma containing controlled mixtures of nitrogen gas and water vapor. Densities of key chemical species such as N, H, OH, NH, and NO were measured by emission and laser-based spectroscopy as a function of the relative humidity. A global model was constructed and the reaction network was validated by comparing calculated species densities with experiments. We discover that N, a key initial intermediate for ammonia, strongly decreases in the presence of water vapor, and as a result, ammonia formation becomes limited at high relative humidity. This decrease is surprisingly not because N itself reacts, but because one of its main sources, an excited molecular nitrogen state, is reacted away. In addition, oxidation pathways for nitrogen, which lead to NO and related products, are found to be favored over reduction pathways because the corresponding reverse reactions are less significant. Together, this understanding helps explain previously reported observations of selectivity toward nitrogen oxides over ammonia, particularly at higher relative humidities.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

RECLAIM: Electrochemical Lithium and Nickel Extraction with Concurrent Carbon Dioxide Mineralization

This project aims to develop technologies toward the production of Li and Ni from CO 2 -reactive minerals and rocks that contain Ca and Mg, while sequestering CO 2 . The technologies include acoustic stimulation and electrolytic proton production, which use electricity to liberate valuable metal ions from the surrounding mineral matrix at sub-boiling temperatures (~20-80°C). Feedstocks include Li/Ni/Ca/Mg-rich igneous and sedimentary rocks and minerals such as holmquistite, hectorite, lateritic Ni ores enriched in Mg-rich serpentine. Other examples of feedstocks that could be used include coarse grained orthocumulate, mine tailings, etc. In the first step, the electrolytic breakdown of water to H + and OH – (as well as O 2 and H 2 ) will be induced by applying an electric potential to simultaneously produce acidity and alkalinity. The solid feedstocks will be dissolved in the acidic anolyte under acoustic stimulation. Solubilized species will then undergo separation using our unique Li + -selective membranes driven by electrodialysis, leading to concentration of Li as soluble lithium silicate, from which Li 2 CO 3 can be derived by reaction with CO 2(g) while supplying cathode alkalinity. Also at the cathode, stepwise electrolytic precipitation of metal hydroxides, including Ni(OH) 2 , Ca(OH) 2 , and Mg(OH) 2 is performed along a cascade reactor in which both the applied potential and pH increase downstream, thereby simultaneously extracting and separating the metals. Finally, exposure of Ca(OH) 2 and Mg(OH) 2 to dilute CO 2 will result in CO 2 uptake in the form of Ca and Mg carbonates. The primary accomplishments include sample procurement and characterization. Progress has been made on precursor identification and mapping, establishing protocols for assessing metal extractability under sonication, and preliminary technoeconomic analysis (TEA) and life cycle analysis (LCA).

36 MATERIALS SCIENCE↗
DOE OSTI2024

Sustainable Aviation Fuel (SAF) State-of-Industry Report: State of SAF Production Process

GHG emissions related to commercial air travel were already significant, at 10% of the domestic transportation emissions and 3% of the global greenhouse gas emissions prior to the pandemic, and are expected to double by 2050, even with modest projected growth in air travel. Since Sustainable Aviation Fuel (SAF) is the only way that medium to long haul commercial aviation can be decarbonized, a US government wide "SAF Grand Challenge" was issued to encourage industry to develop capabilities to produce SAF, to reduce cost, improve sustainability, build value chains, and to scale production capabilities (1). The targets are to expand current domestic SAF 2022 production by 200X to 3 billion gallons per year by 2030, and then further by 12X to 35 billion gallons by 2050, while achieving life cycle GHG reduction of 50% relative to fossil Jet A. Following the SAF Grand Challenge, the DOE, USDA, EPA and FAA collaboratively developed a comprehensive strategy, outlined in the "SAF Grand Challenge Roadmap" (2), to inform stakeholders of the actions necessary to achieve the above volumetric targets. The purpose of this study is to provide an assessment of the current state of the SAF production industry and identify challenges and hurdles that industry may face in delivering the 2030 goals. This assessment is for the potential feedstocks and conversion pathways expected to contribute to 2030 goals and will generally follow action areas in the SAF Grand Challenge: feedstocks, conversion technology, supply chain, and policy & valuation.

09 BIOMASS FUELS↗
NASA NTRS1983

California methanol assessment. Volume 2: Technical report

Energy feedstock sources for methanol; methanol and other synfuels; transport, storage, and distribution; air quality impact of methanol use in vehicles, chemical methanol production and use; methanol utilization in vehicles; methanol utilization in stationary applications; and environmental and regulatory constraints are discussed.

Otoole, R.↗
NASA NTRS2006

Materials

NASA Langley Research Center has successfully developed an electron beam freeform fabrication (EBF3) process, a rapid metal deposition process that works efficiently with a variety of weldable alloys. The EBF3 process can be used to build a complex, unitized part in a layer-additive fashion, although the more immediate payoff is for use as a manufacturing process for adding details to components fabricated from simplified castings and forgings or plate products. The EBF3 process produces structural metallic parts with strengths comparable to that of wrought product forms and has been demonstrated on aluminum, titanium, and nickel-based alloys to date. The EBF3 process introduces metal wire feedstock into a molten pool that is created and sustained using a focused electron beam in a vacuum environment. Operation in a vacuum ensures a clean process environment and eliminates the need for a consumable shield gas. Advanced metal manufacturing methods such as EBF3 are being explored for fabrication and repair of aerospace structures, offering potential for improvements in cost, weight, and performance to enhance mission success for aircraft, launch vehicles, and spacecraft. Near-term applications of the EBF3 process are most likely to be implemented for cost reduction and lead time reduction through addition of details onto simplified preforms (casting or forging). This is particularly attractive for components with protruding details that would require a significantly large volume of material to be machined away from an oversized forging, offering significant reductions to the buy-to-fly ratio. Future far-term applications promise improved structural efficiency through reduced weight and improved performance by exploiting the layer-additive nature of the EBF3 process to fabricate tailored unitized structures with functionally graded microstructures and compositions.

Glaessgen, Edward H.↗