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All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Heavy-Duty Nonroad Material Handler Electrification Part 2: Energy Efficiency and Performance Evaluation

Decarbonization efforts achieved through electrification in nonroad mobile machinery can realize a reduction in fuel consumption of more than 20%, thanks to concepts familiar to light-duty passenger vehicles. This case study compares the results of a hybrid-electric material handler to its conventional counterpart, utilizing machine-specific drive cycles presented in part one of this paper series. The hybrid prototype features an extended-range electric vehicle (EREV) powertrain that demonstrated substantial energy efficiency improvements. Specifically, there was a reduction in equivalent fuel consumption of 75% when operating in electric-only mode, and 33% when maintaining the battery by charging with an on-board generator. Together, the efficiency improvements can be extrapolated over a low-intensity, 8-h shift characterized by significant idle time and highly dynamic engine load for a 47% reduction in net energy consumption. Key technologies that led to this improvement included engine downsizing and decoupling, regenerative braking, and an electrohydraulic pump unit with advanced controls. Finally, his study explains details of the powertrain architecture and subsystems that were implemented on a demonstration vehicle, control strategies used to meet project goals, and an analysis of energy consumption from testing on a closed course. Also included in this study is a discourse on comparison metrics that can be used for quantifying the energy consumption differences between hybrid-electric and conventional diesel powertrains in nonroad mobile machinery.

25 ENERGY STORAGE↗
DOE OSTI2012

Life-Cycle Analysis of Alternative Aviation Fuels in GREET

The Greenhouse gases, Regulated Emissions, and Energy use in Transportation (GREET) model, developed at Argonne National Laboratory, has been expanded to include well-to-wake (WTWa) analysis of aviation fuels and aircraft. This report documents the key WTWa stages and assumptions for fuels that represent alternatives to petroleum jet fuel. The aviation module in GREET consists of three spreadsheets that present detailed characterizations of well-to-pump and pump-to-wake parameters and WTWa results. By using the expanded GREET version (GREET1{_}2011), we estimate WTWa results for energy use (total, fossil, and petroleum energy) and greenhouse gas (GHG) emissions (carbon dioxide, methane, and nitrous oxide) for (1) each unit of energy (lower heating value) consumed by the aircraft or (2) each unit of distance traveled/ payload carried by the aircraft. The fuel pathways considered in this analysis include petroleum-based jet fuel from conventional and unconventional sources (i.e., oil sands); Fisher-Tropsch (FT) jet fuel from natural gas, coal, and biomass; bio-jet fuel from fast pyrolysis of cellulosic biomass; and bio-jet fuel from vegetable and algal oils, which falls under the American Society for Testing and Materials category of hydroprocessed esters and fatty acids. For aircraft operation, we considered six passenger aircraft classes and four freight aircraft classes in this analysis. Our analysis revealed that, depending on the feedstock source, the fuel conversion technology, and the allocation or displacement credit methodology applied to co-products, alternative bio-jet fuel pathways have the potential to reduce life-cycle GHG emissions by 55-85 percent compared with conventional (petroleum-based) jet fuel. Although producing FT jet fuel from fossil feedstock sources - such as natural gas and coal - could greatly reduce dependence on crude oil, production from such sources (especially coal) produces greater WTWa GHG emissions compared with petroleum jet fuel production unless carbon management practices, such as carbon capture and storage, are used.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2012

Life-Cycle Analysis of Alternative Aviation Fuels in GREET

The Greenhouse gases, Regulated Emissions, and Energy use in Transportation (GREET) model, developed at Argonne National Laboratory, has been expanded to include well-to-wake (WTWa) analysis of aviation fuels and aircraft. This report documents the key WTWa stages and assumptions for fuels that represent alternatives to petroleum jet fuel. The aviation module in GREET consists of three spreadsheets that present detailed characterizations of well-to-pump and pump-to-wake parameters and WTWa results. By using the expanded GREET version (GREET1_2011), we estimate WTWa results for energy use (total, fossil, and petroleum energy) and greenhouse gas (GHG) emissions (carbon dioxide, methane, and nitrous oxide) for (1) each unit of energy (lower heating value) consumed by the aircraft or(2) each unit of distance traveled/ payload carried by the aircraft. The fuel pathways considered in this analysis include petroleum-based jet fuel from conventional and unconventional sources (i.e., oil sands); Fisher-Tropsch (FT) jet fuel from natural gas, coal, and biomass; bio-jet fuel from fast pyrolysis of cellulosic biomass; and bio-jet fuel from vegetable and algal oils, which falls under the American Society for Testing and Materials category of hydroprocessed esters and fatty acids. For aircraft operation, we considered six passenger aircraft classes and four freight aircraft classes in this analysis. Our analysis revealed that, depending on the feedstock source, the fuel conversion technology, and the allocation or displacement credit methodology applied to co-products, alternative bio-jet fuel pathways have the potential to reduce life-cycle GHG emissions by 55–85 percent compared with conventional (petroleum-based) jet fuel. Although producing FT jet fuel from fossil feedstock sources — such as natural gas and coal — could greatly reduce dependence on crude oil, production from such sources (especially coal) produces greater WTWa GHG emissions compared with petroleum jet fuel production unless carbon management practices, such as carbon capture and storage, are used.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2018

FemtoMAX – an X-ray beamline for structural dynamics at the short-pulse facility of MAX IV

The FemtoMAX beamline facilitates studies of the structural dynamics of materials. Such studies are of fundamental importance for key scientific problems related to programming materials using light, enabling new storage media and new manufacturing techniques, obtaining sustainable energy by mimicking photosynthesis, and gleaning insights into chemical and biological functional dynamics. The FemtoMAX beamline utilizes the MAX IV linear accelerator as an electron source. The photon bursts have a pulse length of 100 fs, which is on the timescale of molecular vibrations, and have wavelengths matching interatomic distances (Å). The uniqueness of the beamline has called for special beamline components. This paper presents the beamline design including ultrasensitive X-ray beam-position monitors based on thin Ce:YAG screens, efficient harmonic separators and novel timing tools.

laser↗
DOE OSTI2019

Idaho-Developed Technologies, Processes Offer Unique Solutions to Waste Management Challenges - 19281

INL Site cleanup contractor Fluor Idaho, LLC (Fluor Idaho) and its predecessors have developed a host of state-of-the-art technologies and specialized processes for nuclear waste handling, treatment, storage, and shipping. The cleanup program has also repurposed and upgraded previously idled Cold War-era buildings to treat and repackage both on- and off-site generated radioactive and hazardous wastes. And lastly, Fluor Idaho is using one-of-a-kind equipment to protect waste management personnel as they undertake their work to meet cleanup commitments that the Department of Energy (DOE) made to the state of Idaho. Such applications, although developed for Idaho's wastes, have the potential to benefit other facilities within the DOE Complex. Engineers and fabricators have teamed up to develop truly unique devices made of specialized metals, like stainless steel alloys, and more readily available materials such as Lexan. All waste types that Fluor Idaho manages daily - spent nuclear fuel, both high- and low-level wastes, and both remote-handled (RH) and CH-TRU - benefit from these innovations. Without question, the greatest number of specialized equipment, processes, and worker-protection technologies developed are for the retrieving, characterizing, repackaging, and shipping of TRU wastes, which makes sense considering the INL Site stores the most TRU waste in the DOE Complex. On the CH-TRU retrieval front, crews are using specially modified Gradall excavators to protect workers while they exhume Rocky Flats Plant wastes that were sent to Idaho in the 1950's and 1960's and buried in a shallow landfill. The excavators are supplied with extra Lexan windows to protect operators from the potential for flying debris during exhumation. On-board supplied air, pumped into the cab, and individual air supplies protect workers from inhalation hazards. Also on-board infrared cameras allow operators to detect heat generating from reactive metals at the dig face. At the Advanced Mixed Waste Treatment Facility (AMWTP), Brokk robotic arm operators use a 'super clam' claw, designed and built at the INL Site, on the remotely operated heavy equipment to size-reduce waste boxes, drums, concrete, and metal containing TRU constituents. The super clam is so powerful and dexterous that operators can crush a 55-gallon drum into the size of a basketball, but also delicately turn the pages of a magazine. Boxes too large to be sized at the AMWTP's box-lines are sent to the Accelerated Retrieval Project VII facility to be sized by Waste Management personnel. Such waste boxes, which sometimes contain 'flighty' plutonium-238 material, have forced the project to employ a heavily ventilated and filtered interior tent. Not all technologies developed for the Waste Management program are high-technology; in fact, one piece of equipment is so simple it's literally ingenious. Operators who inspect and repackage RH-TRU inside a hot cell at the Idaho Nuclear Technology and Engineering Center (INTEC) needed a backup plan in case the hot cell port couldn't be closed in the event of a power outage. Engineers and fabricators collaborated to develop a port cover actuator mechanism, which allows operators to open and close the cell's hatch cover with nothing more than a cordless drill. Also at INTEC, Maintenance Shop fabricators developed a Lexan container or 'pig' suitable for shielding neutron-emitting TRU waste sources. Lexan was chosen as the preferred shielded container material for this special type of waste because neutrons are best shielded with materials containing lots of hydrogen, such as plastics, which are composed of carbon and hydrogen molecules. Once approved for shipment, the high-activity waste will be loaded into specialty casks and shipped to WIPP for permanent disposal. Although all these technologies and processes were initially developed for resolving challenges at the INL Site, their applications could be far-reaching. Like the INL Site, many other facilities in the DOE Complex manage, treat, store, and ship TRU, low-and high-level wastes, and spent nuclear fuel. The technologies and processes developed in Idaho protect Waste Management personnel as they undertake their work, but these benefits could be utilized by other facilities and personnel doing similar work. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Determining Proton Transport in Pseudo Catalyst Layers Using Hydrogen Pump DC and AC Techniques

Optimizing electrode morphology with a more uniform ionomer distribution is key to reducing ohmic losses and increasing electrocatalyst utilization in polymer electrolyte fuel cells (PEFCs). Inherent ionomer conductivity, volume fraction and tortuosity determine effective ionic conductivity. We use hydrogen pump (HP) method to measure effective ionic conductivity of a pseudo catalyst layer (PCL) comprised of Vulcan XC-72 carbon black and 3M 825 EW ionomer with ionomer to carbon (I/C) ratios of 0.6, 1 and 1.4 and relative humidity (RH) range of 50 to 120%. These direct current (DC) experiments are then compared with electrochemical impedance spectroscopy (EIS). Both DC and EIS methods show good agreement, indicating that EIS can be used as an alternative to DC method in HP experiment. Ionic conductivity for PCL with I/C of 1 and 1.4 was found to be about one order of magnitude higher than I/C of 0.6 for most of the RH range. At 90% RH tortuosities for I/C = 1 and 1.4 were close to 1, whereas tortuosity for I/C = 0.6 was 3. With decrease in relative humidity tortuosities increased linearly and at 50% relative humidity a PCL with I/C = 0.6 had the highest tortuosity of 6.1.

25 ENERGY STORAGE↗
DOE OSTI2016

Carbon dioxide in an ionic liquid: Structural and rotational dynamics

Ionic liquids (ILs), which have widely tunable structural motifs and intermolecular interactions with solutes, have been proposed as possible carbon capture media. In order to inform the choice of an optimal ionic liquid system, it can be useful to understand the details of dynamics and interactions on fundamental time scales (femtoseconds to picoseconds) of dissolved gases, particularly carbon dioxide (CO 2 ), within the complex solvation structures present in these uniquely organized materials. The rotational and local structural fluctuation dynamics of CO 2 in the room temperature ionic liquid 1-ethyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide (EmimNTf2) were investigated by using ultrafast infrared spectroscopy to interrogate the CO 2 asymmetric stretch. Polarization-selective pump probe measurements yielded the orientational correlation function of the CO 2 vibrational transition dipole. It was found that reorientation of the carbon dioxide occurs on 3 time scales: 0.91 ± 0.03, 8.3 ± 0.1, 54 ± 1 ps. The initial two are attributed to restricted wobbling motions originating from a gating of CO 2 motions by the IL cations and anions. The final (slowest) decay corresponds to complete orientational randomization. Two-dimensional infrared vibrational echo (2D IR) spectroscopy provided information on structural rearrangements, which cause spectral diffusion, through the time dependence of the 2D line shape. Analysis of the time-dependent 2D IR spectra yields the frequency-frequency correlation function (FFCF). Polarization-selective 2D IR experiments conducted on the CO 2 asymmetric stretch in the parallel- and perpendicular-pumped geometries yield significantly different FFCFs due to a phenomenon known as reorientation-induced spectral diffusion (RISD), revealing strong vector interactions with the liquid structures that evolve slowly on the (independently measured) rotation time scales. To separate the RISD contribution to the FFCF from the structural spectral diffusion contribution, the previously developed first order Stark effect RISD model is reformulated to describe the second order (quadratic) Stark effect—the first order Stark effect vanishes because CO 2 does not have a permanent dipole moment. Through this analysis, we characterize the structural fluctuations of CO 2 in the ionic liquid solvation environment, which separate into magnitude-only and combined magnitude and directional correlations of the liquid’s time dependent electric field. This new methodology will enable highly incisive comparisons between CO 2 dynamics in a variety of ionic liquid systems.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS2007

Portable Apparatus for Electrochemical Sensing of Ethylene

A small, lightweight, portable apparatus based on an electrochemical sensing principle has been developed for monitoring low concentrations of ethylene in air. Ethylene has long been known to be produced by plants and to stimulate the growth and other aspects of the development of plants (including, notably, ripening of fruits and vegetables), even at concentrations as low as tens of parts per billion (ppb). The effects are magnified in plant-growth and -storage chambers wherein ethylene can accumulate. There is increasing recognition in agriculture and related industries that it is desirable to monitor and control ethylene concentrations in order to optimize the growth, storage, and ripening of plant products. Hence, there are numerous potential uses for the present apparatus in conjunction with equipment for controlling ethylene concentrations. The ethylene sensor is of a thick-film type with a design optimized for a low detection limit. The sensor includes a noble metal sensing electrode on a chip and a hydrated solid-electrolyte membrane that is held in contact with the chip. Also located on the sensor chip are a counter electrode and a reference electrode. The sensing electrode is held at a fixed potential versus the reference electrode. Detection takes place at active-triple-point areas where the sensing electrode, electrolyte, and sample gas meet. These areas are formed by cutting openings in the electrolyte membrane. The electrode current generated from electrochemical oxidation of ethylene at the active triple points is proportional to the concentration of ethylene. An additional film of the solid-electrolyte membrane material is deposited on the sensing electrode to increase the effective triple-point areas and thereby enhance the detection signal. The sensor chip is placed in a holder that is part of a polycarbonate housing. When fully assembled, the housing holds the solid-electrolyte membrane in contact with the chip (see figure). The housing includes a water reservoir for keeping the solid-electrolyte membrane hydrated. The housing also includes flow channels for circulating a sample stream of air over the chip: ethylene is brought to the sensing surface predominately by convection in this sample stream. The sample stream is generated by a built-in sampling pump. The forced circulation of sample air contributes to the attainment of a low detection limit.

Manoukian, Mourad↗
NASA NTRS2007

Thermodynamic Vent System Performance Testing with Subcooled Liquid Methane and Gaseous Helium Pressurant

Due to its high specific impulse and favorable thermal properties for storage, liquid methane (LCH4) is being considered as a candidate propellant for exploration architectures. In order to gain an -understanding of any unique considerations involving micro-gravity pressure control with LCH4, testing was conducted at the Marshall Space Flight Center using the Multipurpose Hydrogen Test Bed (MHTB) to evaluate the performance of a spray-bar thermodynamic vent system (TVS) with subcooled LCH4 and gaseous helium (GHe) pressurant. Thirteen days of testing were performed in November 2006, with total tank heat leak conditions of about 715 W and 420 W at a fill level of approximately 90%. The TVS system was used to subcool the LCH4 to a liquid saturation pressure of approximately 55.2 kPa before the tank was pressurized with GHe to a total pressure of 165.5 kPa. A total of 23 TVS cycles were completed. The TVS successfully controlled the ullage pressure within a prescribed control band but did not maintain a stable liquid saturation pressure. This was likely. due to a TVS design not optimized for this particular propellant and test conditions, and possibly due to a large artificially induced heat input directly into the liquid. The capability to reduce liquid saturation pressure as well as maintain it within a prescribed control band, demonstrated that the TVS could be used to seek and maintain a desired liquid inlet temperature for an engine (at a cost of propellant lost through the TVS vent). One special test was conducted at the conclusion of the planned test activities. Reduction of the tank ullage pressure by opening the Joule-Thomson valve (JT) without operating the pump was attempted. The JT remained open for over 9300 seconds, resulting in an ullage pressure reduction of 30 kPa. The special test demonstrated the feasibility of using the JT valve for limited ullage pressure reduction in the event of a pump failure.

Flachbart, R. H.↗
DOE OSTI2023

Evaluation of High Level Waste Sludge Processing Behavior

The U.S. Department of Energy’s (DOE) Hanford Site has 177 underground storage tanks that contain wastes from past nuclear fuel reprocessing and waste-management operations. Over 20% of this waste is in the form of an insoluble sludge that will require slurry modification before its transfer to the Waste Treatment and Immobilization Plant (WTP). Specific WTP acceptance criteria for waste feed delivery describe the physical and chemical characteristics of the waste that must be met before the waste is transferred to the WTP. One challenging requirement relates to the undissolved solids (UDS) composition in a waste feed because the waste contains solid particles that settle, and their concentration and relative proportion can change during the transfer of the waste in individual batches. A key uncertainty is the ability to transfer and mix wastes with large variations in UDS concentrations and resulting settling rates. To address this uncertainty, a number of small scale mixing and settling tests have been conducted to determine the mobilization performance of variable chemistry simulants. Comparison of the size and density of the particulate for each simulant to that of southeast area Hanford sludge was made using metrics for particle mobilization, suspension, settling, and pipeline transfer where dependance on particle size and density may be different, including: 1. Settling velocity, 2. Critical shear stress for erosion, 3. Just-suspended impeller speed, and 4. Pipeline critical transport velocity. Existing high-level waste sludge data has shown the effect that increasing Al concentration has on resulting settled solids. This differential settling of particles in the sludge has the possibility of resulting in solids segregation during feed preparation and uneven particle distribution during pipeline transportation or mixer jet pump operations. Understanding the predictive capabilities of HLW solids settling and transport as well as potential remedies for addressing disparate sludge behaviors can help provide technical guidance during HLW flowsheet planning.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2018

Immobilization of Organic Liquid Radioactive Waste (LWR) in a Sulfur Composite Matrix at the BN-350 Fast Neutron Reactor Site, Kazakhstan - 18031

The immobilization treatment and final disposition of all forms of organic radioactive liquids, such as pump oil, spent solvent, tri-butyl-phosphate (TBP) and scintillation fluids, remain a significant challenge for nuclear waste generators and national regulators. The majority of nuclear nations have instituted regulations that require some form of encapsulation of treated organic liquid, notwithstanding LLW organic liquids that can be safely incinerated. In most cases cement is the designated material for encapsulation; however, cement can pose certain problems with the containment of treated organic liquids. In 2013, with funding from the U.S. Department of Energy - National Nuclear Security Administration through its Global Initiative for Proliferation Prevention Program (GIPP), a proven U.S. technology for the treatment of radioactive organic liquids was introduced at the BN-350 fast neutron reactor facility in Aktau, Kazakhstan. As the facility was undergoing full decommissioning, one hundred and sixty cubic meters of contaminated pump oil (including Cs-137, Sr-90 and U-235/238) contained in large above ground tanks had to be treated for final disposal. As a result of the research conducted over a two-year period, a new 2-step treatment process was invented by combining the U.S. solidification technology with a newly developed inorganic filler and molecular sulfur, referred to as radiation-resistant composite (RRC) to fully encapsulate the waste oil. The outcome of extensive test program indicates that the final form can reach up to 60 wt.% with a compressive strength of about 100 kg/cm{sup 2}. Preliminary conclusions indicate that RRC outperforms cement as an encapsulation form for final waste treatment which meets U.S. Nuclear Regulatory requirements for final disposal. This paper examines the preliminary experimental work that was conducted in Kazakhstan with the U.S. polymer technology and radioactive pump oil, and the subsequent secondary process of combining the solidified material into a homogeneous final form utilizing RRC. Topics covered in the paper include: - Kazakhstan's regulatory requirements for attaining an achievable waste form for acceptance, which led to the RRC invention; - Technical objectives for the application of polymer technology and RRC materials to radioactive liquid waste; - Polymer solidification with radioactive oil and the result; step one of the RRC process; - Description of RRC materials, their origin and chemical characteristics; - Process of combining the solidified polymer mass with RRC materials into a solid, homogeneous matrix; step two of the RRC process; - Experimental results including leaching data, waste loading estimates and heat process calculations to create the matrix; - Cost advantages of the RRC process over cementation; - Limitations of the RRC process; - Next steps to verify conformance of the RRC technology to the U.S. requirements. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

High operating temperature heat transfer fluids for solar thermal power generation. Final report

This is the final technical report for the DOE MURI project on developing high-operating temperature heat transfer fluids for solar thermal power generation. This project aimed to evaluate liquid metals as a heat-transport fluid and potential energy storage medium for concentrated solar powered (CSP) systems. The project consisted of five phases, starting with fluid selection and screen and ending with potential CSP integration. The initial fluid selection arrived at heavy liquid metals as candidate fluids such as lead bismuth eutectic (LBE) as the prime liquid-alloy candidate to be studied, given the conditions above. Fifty-seven liquid compositions were initially identified with liquidus temperatures lower than 200°C, composed of elements that provide no driving force to the reduction of Cr 2 O 3 or Al 2 O 3 passivation layers in pipe material which is required for corrosion prevention. LBE was identified as the primary candidate fluid after these compositions were compared against computational thermodynamic modeling to screen all of the selected systems that would be compatible with our design objectives. Twenty-eight of these compositions were also investigated with the rapid characterization methods; the accuracies of the liquidus temperature and the specific heats predicted by the computations were better than 3 percent and 9 percent, respectively. We conducted numerus corrosion tests of various Fe-Cr-Al based steels in LBE and its variants at temperate as high as 800°C. It was found that minor additions to the liquid did not provide sufficient corrosion protection to warrant their use in real applications. Furthermore, we investigated the detailed mechanism of corrosion between heavy liquid metal and the pipe material at these very high temperatures. A liquid metal loop was constructed to operate at these high temperatures. The loop construction and operation lead to valuable lessons learned that will be needed for industrial scale loops. Furthermore, we learned that electromagnetic pumps at these extreme temperatures will have to be reengineered and redesigned to be used for CSP applications.

14 SOLAR ENERGY↗
NASA NTRS2006

Marshall Space Flight Center Autumn 2005

The East Test Area at Marshall Space Flight Center has five major test stands, each of which has two or more test positions, not counting the SSME and RD-180 engine test facilities in the West Test Area. These research and development facilities are capable of testing high pressure pumps, both fuel and oxidizer, injectors, chambers and sea-level engine assemblies, as well as simulating deep space environments in the 12, 15 and 20 foot vacuum chambers. Liquid propellant capabilities are high pressure hydrogen (liquid and gas), methane (liquid and gas), and RP-1 and high pressure LOX. Solid propellant capability includes thrust measurement and firing capability up to 1/6 scale Shuttle SRB segment. In the past six months MSFC supported multiple space access and exploration programs in the previous six months. Major programs were Space Exploration, Shuttle External Tank research, Reusable Solid Rocket Motor (RSRM) development, as well as research programs for NASA and other customers. At Test Stand 115 monopropellant ignition testing was conducted on one position. At the second position multiple ignition/variable burn time cycles were conducted on Vacuum Plasma Spatter (VPS) coated injectors. Each injector received fifty cycles; the propellants were LOX Hydrogen and the ignition source was TEA. Following completion of the monopropellant test series the stand was reconfigured to support ignition testing on a LOX Methane injector system. At TS 116 a thrust stand used to test Booster Separation Motors from the Shuttle SRB system was disassembled and moved from Chemical Systems Division s Coyote Canyon plant to MSFC. The stand was reassembled and readied for BSM testing. Also, a series of tests was run on a Pratt & Whitney Rocketdyne Low Element Density (LED) injector engine. The propellants for this engine are LOX and LH2. At TS 300 the 20 foot vacuum chamber was configured to support hydrogen testing in the Multipurpose Hydrogen Test Bed (MHTB) test article. This testing, which went 24/7 for fourteen consecutive days, demonstrated long duration storage methods intended to minimize losses of propellant in support of the Space Exploration Initiative. The facility is being converted to support similar research using liquid methane. The 12 foot chamber at TS 300 was used to create ascent profiles (both heat and altitude effects) for foam panel testing in support of the Shuttle External Tank program. At TS 500, one position was in build-up to support ATK Thiokol research into the gas dynamics associated with high pressure flow across the propellant joint in segmented solid rocket motors. The testing involves flowing high pressure gas through a 24 motor case. Initial tests will be conducted with simulated aluminum grain, followed by tests using actual propellant. The second position at TS 500 has been in build-up for testing a LOX methane thruster manufactured by KT Engineering. At the Solid Propulsion Test Area (SPTA), the first dual segment 24 solid rocket motor was fired for ATK Thiokol in support of the RSRM program. A new axial thrust measurement stand was designed and fabricated for this testing. Real Time Radiography (RTR) will be deployed to examine nozzle erosion on the next dual segment motor.

Allen, Mike↗
DOE OSTI2024

Investigation of powertrain system decarbonization using electrically assisted turbocharging and hybridization in off-road vehicles

In recent years, the causes, effects, and existential threat of a global anthropogenic climate shift have drawn significant attention and stimulated mitigation efforts from all genres of scientific, political, and industrial bodies. The greenhouse effect and the detrimental environmental impact of excess greenhouse gas (GHG) emissions, like carbon dioxide, is well studied and targeted as the primary culprit for aversive action. However, some fields exist where reducing GHG emissions is met by considerable challenges. One such field is the production and operations of off-road vehicles. Applications of these vehicles are highly diverse and are often characterized by rugged, especially transient, and power intensive duty cycles that make one-fits-all vehicle configuration solutions impractical. This research surveys existing literature to identify the modern technologies packages and challenges that face development and configuration of powertrain systems which currently navigate the regulated emissions and unique duty cycle requirements of this market space. A novel powertrain concept is proposed and evaluated with respect to the pinnacle objectives of load performance improvement, criteria pollutant reduction, and reducing the life cycle GHG intensity of its operation. A sure-fire path to vehicular GHG reduction is through improving the fuel efficiency of internal combustion engines (ICEs), an entrenched component of the off-road vehicle sector. Unfortunately, this is more easily said than done. An approach that has proven successful in this endeavor is engine downsizing and turbocharging, where a larger engine is replaced with a smaller one with added air system boosting via turbocharger to reduce frictional and pumping losses while also enabling access to additional fuel energy. However, practical realization of these potential benefits is often impeded by the transient response capability of the smaller engine across the operating space. For this reason, downsized ICE powertrains have turned to electrified forced induction systems (EFISs) for a decoupling of exhaust energy and engine speed from boost capability. Platformed on 48V hybrid technology, these systems introduce the need for more sophisticated controls around the engine gas-exchange process for the management of boost performance and exhaust gas emissions. On this account, simulation studies utilizing a GT-POWER model of a turbocharged 4.5 L engine outfit with an EFIS using an electrically driven compressor (eBooster®) are conducted to provide insight into the performance of this air handling architecture on an off-road engine. The results show that improvement in transient torque response time in sync with reduction in engine-out soot and NOx emissions are possible with an engine recalibration that leverages the transient air-fuel ratio authority of the eBooster®. Benefits are further demonstrated when duty cycle simulations of the 48V mild-hybrid engine concept are exercised, showing an acute decrease in cumulative fuel usage and soot production. Powertrain hybridization is another technological pathway achieving pronounced GHG reduction successes in modern on-road vehicle applications through integration of Li-ion battery technology. In the off-road vehicle segment, a review of available literature concludes that hybridized architectures are present but generally lack the depth of technologies that have both high specific energy and power capabilities, and thus are limited in their inclusion of Li-ion batteries for ICE assistance and enhanced energy storage capability. Therefore, building on the mild-hybrid engine results, the downsized and eBoosted engine concept was integrated into a larger high-voltage battery-hybrid series-electric powertrain system. Hybrid powertrain parameter sensitivity studies were carried out in a numerical charge-sustaining framework, providing novel insights into power flows between the battery and the engine and how their respective capabilities and operation contribute to GHG and criteria pollutant emissions of diverse duty cycles. Application of supervisory power management introduced robustness into the power sourcing and battery SOC control process and showed that optimum specification of battery properties can yield synergies between GHG emissions and battery energy capacity. Furthermore, examination of recent literature on Li-ion batteries has shown that pack manufacturing is a highly energy intensive process, thereby producing considerable quantities of GHGs that scale with energy storage capacity. Also scaling with a battery’s energy storage capacity is its investment cost. In consideration of these factors, an inclusive technoeconomic and GHG life cycle analysis is conducted. This analysis systematically compares the carbon footprint and total cost of ownership associated with the proposed hybrid powertrain concept to reference and alternative powertrain configurations, facilitating a thorough evaluation of the decarbonization effectiveness and economic viability.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2019

Remote Technology to Retrieve Waste Below the 324 Building at the Hanford Site - 19622

The Waste Technology Engineering Laboratory (324 Building) is a Category 2 Nuclear Facility at Hanford. The 324 Building Disposition Project is responsible for the removal and remedial actions under CERCLA. Additionally, there are RCRA Dangerous Waste Management Units which the CERCLA actions are presumed to satisfy. The Radiochemical Engineering Complex (REC) is a group of four hot cells (A, B, C and D Cells) with an interconnecting airlock inside of the 324 Building. Underneath the REC B-Cell are contaminated soils that have an estimated 12,793 R/Hr dose rate and remediation is under CERCLA 300-FF-2 Operable Unit. The current action consists of debris removal from the floor of B-Cell, B-Cell floor removal, and excavation of the soils beneath the floor to a depth of up to twelve feet with four Remote Excavator Arms (REA). This paper provides insight into the preparation and performance of high tolerance core drilling into a hot cell complex. Installation of the REA Through Support (REA TS) mechanism through the 4'-6' concrete shield walls is a complex series of tasks with demanding tolerances at each of four locations around the perimeter of B-Cell. The use of training mock ups was included in the completion of this work. The REA TS is two 11 inch diameter high strength steel sleeves that have expandable collars at each end allowing the interstitial space between the outside of the sleeve and inside of the core drill to be grouted to form a substantial structural connection, and a 10 inch pipe with hydraulic hoses to power the REA. There are three cores required for each REA location. The REAs themselves are customized excavator arms, mounted on support columns to be used in the excavation and transfer of the contaminated soil into storage facilities. The tasks for the installation of the REA TSs are: 1) Characterization of B-Cell Cubicles. 2) Embedded Pipe Fill. 3) Interference Removal. a. Internal Walls, b. External Walls. 4) Core Drilling. 5) Go/No-Go gauge, and video inspection. 6) Installation of REA Through Support Assembly. The 324 Building REC Hot Cells have internal, external, and embedded utilities throughout the shield walls in conflict with the REA TS locations. Some of the embedded utilities have connection points inside of the B-Cell Cubicles. There were two separate issues at the conflicted locations. The first issue was the core drill cooling water would flow along the embedded utility potentially spreading legacy chemical and radiological contamination to areas of the facility that was unwanted. The second issue was that the REA TS required a substantial structural connection to the B-Cell wall, the cored diameter is larger than the REA TS and these interstitial areas required a full grouted connection. The embedded utilities posed a hazard that if unfilled, the interstitial grout would flow into the embedded utility and destabilize the required grouted structural connection. The B-Cell Cubicles had not been opened in over 10 years. A mockup was completed to install a glovebag over the cubicle opening and then to verify functionality and port requirements. The embedded utility pipe connections in the cubicles were then opened inside a glovebag to verify the correct connection points, connection method for future embedded pipe fill material delivery system, radiological characterization, and air flow to show that the embedded utility pipes were not blocked and would not pressurize. The embedded pipe fill material and grout system was mocked up and run several times to verify methodology and functionality. The B-Cell Cubicles were then reentered and the embedded utility pipe fill was completed using a hand pump. External interferences at the core drill locations were removed using standard interference removal techniques. Internal interferences at the core drill locations were removed using a remote cutting tool that was controlled through the use of the B-Cell crane, remote cameras and remote lighting. The core drilling was mocked up two separate times, the project's purpose built 'Mock Up Facility' was core drilled to verify tolerances and methodology prior to subcontract award, the core drill subcontractor built a 'dummy wall' to train and practice on achieving the demanding tolerances, coordinated alignments between the cores, short term and long term dose shielding techniques, and contamination control techniques. A core drill template, and additional anchoring techniques were used to maximize accuracy and precision of the REA TS core drills. A 'Go/No-Go' gauge was built and installed at each of the four REA TS locations to verify that the core drill met tolerances. The core drill locations were visually inspected using a boroscope. The REA TS installation was mocked up at the projects 'Mock Up Facility' beginning with basic hazard controls, then with intermediate hazard controls, and finally with full occupational safety, industrial hygiene, and radiological controls. The REA TSs were installed and grouted into place. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2016

Climate Change Feedbacks from Interactions Between New and Old Carbon

Priming effects, or responses of SOM decomposition rates to inputs of new, labile carbon (C), have the potential to dramatically alter projections of ecosystem C storage. Priming effects occur in most ecosystems, are significant in magnitude, and are highly sensitive to global changes. Nevertheless, our mechanistic understanding of priming effects remains poor, and this has prevented the inclusion of these dynamics into current Earth system models (ESMs). We conducted two manipulative experiments in the field to quantify how priming effects influence SOM dynamics. Specifically, we asked: To what extent do inputs of “new” root-derived carbon (C) influence “older” C in SOM, and are the magnitude and direction of these effects sensitive to climate? We addressed these questions within the Boston-Area Climate Experiment - an old-field ecosystem that has been subjected to three precipitation treatments (ambient, -50%, and +50% of each precipitation event during the growing season) and four warming treatments (from ambient to +4°C) since 2008. In the first experiment, we installed root and fungal ingrowth cores into the plots. Each core was filled with SOM that had an isotopic signature (of its C compounds) that differed from the vegetation in the plots such that inputs of “new” C from roots/fungi could be quantified using the change in isotopic signatures of C in the cores. Further, we used cores with different mesh sizes to isolate root vs. mycorrhizal fungal inputs. We found that belowground C fluxes were dominated by root inputs (as opposed to mycorrhizal inputs), and that root-derived inputs were greatest in the plots subjected to experimental warming. Given that that the warming-induced increase in belowground C flux did not result in a net increase in soil C, we conclude that the warming treatment likely enhanced priming effects in these soils. In the second experiment, we experimentally dripped dissolved organic C compounds into soils in the BACE plots to simulate root-derived C fluxes. Specifically, we constructed artificial roots attached to an automated peristaltic pump to deliver the compounds to soil semi-continuously during the peak of the growing season. We found that changes in exudate quality had small but significant effects on microbial activities, often interacting with N availability and temperature-induced changes. These results further underscore the importance of priming effects, especially under warming conditions. Collectively, our results provide some of the first field-based estimates of how soil moisture and temperature can directly and indirectly alter root-induced changes in SOM dynamics. This exploratory project lays the groundwork for further research on priming that incorporates effects of plant species and microbial communities to global changes. Such information should enable the development of more mechanistic and better predictive models of SOM decomposition under increased greenhouse gas levels, with the ultimate goal of reducing the level of uncertainty in projections of future climate.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2019

Mesoscopic modeling of transport resistances in a polymer-electrolyte fuel-cell catalyst layer: Analysis of hydrogen limiting currents

Understanding transport resistances in a polymer-electrolyte fuel cell (PEFC) catalyst layer (CL) is essential to mitigate the unexpected voltage loss when using low loadings of precious metals. In this paper, we explore through mesoscopic modeling the quantification analyses of the transport resistances in CL as derived using hydrogen-pump limiting current. Numerical treatments on the conjugated interfacial conditions at interfaces of ionomer/pore and Pt/ionomer are proposed to describe the mesoscopic transport processes of hydrogen and proton. Characterizations of the reconstructed microstructure of CL are performed. Parameter analyses on the influences of the critical transport properties such as the permeation coefficient and the dissolution and adsorption reaction rates at the surfaces of ionomer/pore and Pt/ionomer on the local transport resistance are presented. It is found that the local transport resistance is mainly originated from the diffusion resistance of the ionomer thin-film, which is more resistive than its bulk analogue with its permeation coefficient fitted to be 5.9% of the bulk one. The interfacial transport resistances and the diffusion resistance are coupled. The local transport resistance increases with I/C ratio due to thicker ionomer coated on the particles. Higher Pt/C ratio and bare carbon fraction lead to higher local transport resistance since the ionomer loading relative to Pt roughness factor decreases. The local transport resistance decreases with the porosity. Furthermore, the contribution of pores to the CL resistance, which decreases with the porosity, is comparatively small at low loadings.

25 ENERGY STORAGE↗
DOE OSTI2022

Clean Condensing Gas Furnace

Natural gas furnaces are the most common space heating equipment in the U.S. residential and commercial building markets. However, current residential natural gas condensing furnaces generate substantial acidic condensate as well as significant emissions of sulfur oxides (SOx), nitrogen oxides (NOx), carbon monoxide (CO), hydrocarbons (HC), and methane (CH 4 ) contributing to environmental degradation of air, water, and soil. This report describes a novel solution to reduce the environmental impact of natural gas condensing furnaces based on the technology of a monolithic acidic gas reduction (AGR) catalyst for SOx trapping, NOx redox to nitrogen, and oxidation of formic acid, CO, HC, and CH 4 . The AGR technology offers the following benefits: (1) a neutral furnace condensate with a pH of ~7, allowing its safe release into the sewer system thus eliminating a second drainage system; (2) trapping and removing nearly all SOx emissions; (3) NOx emissions nearly at nearly 1-2 ng/J, more than 95% lower than new emissions standards in California; (4) the use of a low-cost heat exchanger as a condensing heat exchanger (HX) since the condensate is not acidic, avoiding the need for expensive stainless steel alloys; and (5) unburnt fuel energy recovery to boost efficiency.The AGR component and AGR-enabled furnace performance were broadly tested to determine their effects on long-term reliability and durability, as well as SOx storage and regeneration activity. The AGR regeneration does not impair the performance in achieving neutral condensate and ultra-low NOx emissions, and the AGR catalyst subjected to regeneration activities continued to function well and achieved slightly better annual fuel utilization efficiency (AFUE). The 400-hour reliability and durability test of the retrofitted condensing furnace with the AGR component shows that the furnace unit still achieves a neutral furnace condensate with a pH of ~7 and enables 0~3 ng/J of NOx emissions. However, the 400-hour operation slightly degraded the AFUE because of soot particle accumulation caused by frequent incomplete combustion owing to inappropriate condensate drainage during testing. Thus, proper condensate drainage is critical for AGR-enabled furnaces. Furthermore, neutron computed tomography was employed to survey the aged AGR component and demonstrate high-resolution 2D and 3D representations for the nondestructive diagnosis of the AGR component. The tomography showed that the AGR component did not deform or suffer broken AGR channels. A new AGR catalyst with low precious metal loading was preliminarily explored to identify a pathway of optimizing AGR material loading and maximizing acidic gas reduction at low cost. The new AGR component can reduce precious metal loading by 38% and still achieve neutral condensate and ultralow NOx emissions. The furnace with the AGR component of low Pt/Rh loading enables a maximum AFUE of 97%, which is meaningfully higher than the original furnace. Long-duration testing for the furnace enabled with the low precious metal loading AGR component will be vital in future research. Although the current work demonstrates a proof of concept for the AGR-enabled furnace, the AGR assembly needs to be optimized and integrated into the design of new OEM furnace products. Furthermore, the AGR technology can be applied not only for residential gas furnaces, but also for commercial rooftop units, gas heat pumps, gas-fired water heaters, combustion boilers, and other systems.

03 NATURAL GAS↗