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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Bringing high-efficiency silicon solar cells with heterojunction contacts to market with a new, versatile deposition technique

Silicon heterojunction (SHJ) and tunnel-oxide-passivated-contacts (TOPCon) solar cells are the future for silicon technology after passivated-emitter-and-rear-contact (PERC) cells. However, the tool costs (CapEx) for SHJ (TOPCon) make the cell lines more than 2 (1.5) times of the cost of the PERC, which hinders the wide adoption these new technologies despite higher efficiencies. A common challenge for both cell types is that the passivation layers are sensitive to sputter damage. Furthermore, for TOPCon cells, it is desirable to have an inline (instead of batch) process for tunnel oxide and polysilicon to maximize the throughput and thus reduce the operation cost.

14 SOLAR ENERGY↗
DOE OSTI2024

Nanostructured Alumina Forming Austenitic Alloy (NAFA) Production using Advanced Manufacturing

Alumina-forming austenitic (AFA) alloys are well known for their exceptional corrosion-resistant properties due to the formation of a dense oxide scale beneficial in their application as a nuclear material. However, use of the alloys in core material applications is limited due to the high nickel-transmutation and helium generation rate in service, leading to swelling and reduced lifetimes. Enhancing the sink strength to pin gas bubbles and increasing gas management of the material may mitigate many of the degradation phenomena expected during alloy deployment (such as high-temperature helium embrittlement and cavity swelling for lead-cooled fast-reactor applications). Nanostructured materials are usually produced using a time-consuming and expensive batch process like mechanical alloying to achieve the fine homogenous distribution of nanoprecipitates throughout the matrix material. Integrating the nanoprecipitates in modern additive manufacturing processes has proven difficult, as the required nano-sizes or number densities cannot be achieved simultaneously. Efforts to increase the number density of precipitates by adding more precipitate-forming rare-earth elements led to agglomeration of such elements, while the nano-sized precipitates did not form in sufficient quantity when not enough rare-earth element was use. In this work a novel approach to advanced manufacturing and the fabrication of Nanostructured AFA (NAFA) materials was chosen. A dual precipitate-forming NAFA steel with a chemistry more suitable for advanced reactor applications was produced to create an environmentally resistant, high-sink-strength austenitic alloy for advanced reactor cladding applications.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Nanostructured Alumina-Forming Austenitic Alloy (NAFA) Production Using Advanced Manufacturing

Alumina-forming austenitic (AFA) alloys are well known for their exceptional corrosion-resistant properties due to the formation of a dense oxide scale beneficial in their application as a nuclear material. However, use of the alloys in core material applications is limited due to the high nickel-transmutation and helium generation rate in service, leading to swelling and reduced lifetimes. Enhancing the sink strength to pin gas bubbles and increasing gas management of the material may mitigate many of the degradation phenomena expected during alloy deployment (such as high-temperature helium embrittlement and cavity swelling for lead-cooled fast-reactor applications). Nanostructured materials are usually produced using a time-consuming and expensive batch process like mechanical alloying to achieve the fine homogenous distribution of nanoprecipitates throughout the matrix material. Integrating the nanoprecipitates in modern additive manufacturing processes has proven difficult, as the required nano-sizes or number densities cannot be achieved simultaneously. Efforts to increase the number density of precipitates by adding more precipitate-forming rare-earth elements led to agglomeration of such elements, while the nano-sized precipitates did not form in sufficient quantity when not enough rare-earth element was use. In this work a novel approach to advanced manufacturing and the fabrication of Nanostructured AFA (NAFA) materials was chosen. A dual precipitate-forming NAFA steel with a chemistry more suitable for advanced reactor applications was produced to create an environmentally resistant, high-sink-strength austenitic alloy for advanced reactor cladding applications.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Characterization Results for the August 2025 Tank Farm 2H Evaporator Overhead Sample

On an annual basis, Savannah River Mission Completion (SRMC) provides 2H and 3H evaporator overhead samples to Savannah River National Lab (SRNL) to be analyzed per Section 5.2 of the Effluent Treatment Project (ETP) Waste Compliance Plan (WCP) and the Waste Acceptance Criteria (WAC). This report presents the average characterization results for the August 2025 2H evaporator overhead sample. The sample was clear and colorless with no visible solids. The results provide measurements for cesium-137 ( 137 Cs), strontium-90 ( 90 Sr), and iodine-129 ( 129 I) with the radionuclide concentration limits specified by the WAC. These analyses were performed in duplicate, and all three measured radionuclide concentrations were within ETP WAC limits. A summary of the analytical results for this 2H evaporator overhead sample includes the following: The measured cesium-137 activity in the 2H evaporator overhead sample averaged 3.02E+02 dpm/mL, which is below the ETP WAC limit of 1.30E+03 dpm/mL. The strontium-90 activity in the 2H evaporator overhead sample averaged 3.33E+00 dpm/mL, which is below the ETP WAC limit of 1.76E+02 dpm/mL. The iodine-129 activity in the 2H evaporator overhead sample averaged 1.20E-01 dpm/mL, which is below the ETP WAC limit of 1.00E+00 dpm/mL. Although the measurements for Cs-137 and Sr-90 are lower compared to previous years, the results remain within a similar range to past measurements and are well below the WAC limits. Iodine-129 indicates detectable results compared to previous years, which can be attributed to recent salt batch processing trending close to the WAC limit for saltstone production. However, these results are still below the ETP WAC limit.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2017

Nano-Array Integrated Structured Catalysts: A New Paradigm upon Conventional Wash-Coated Monolithic Catalysts?

The monolithic catalyst, namely the structured catalyst, is one of the important categories of catalysts used in various fields, especially in catalytic exhaust after-treatment. Despite its successful application in conventional wash-coated catalysts in both mobile and stationary catalytic converters, washcoat-based technologies are facing multi-fold challenges, including: (1) high Pt-group metals (PGM) material loading being required, driving the market prices; (2) less-than ideal distribution of washcoats in typically square-shaped channels associated with pressure drop sacrifice; and (3) far from clear correlations between macroscopic washcoat structures and their catalytic performance. To tackle these challenges, the well-defined nanostructure array (nano-array)-integrated structured catalysts which we invented and developed recently have been proven to be a promising class of cost-effective and efficient devices that may complement or substitute wash-coated catalysts. This new type of structured catalysts is composed of honeycomb-structured monoliths, whose channel surfaces are grown in situ with a nano-array forest made of traditional binary transition metal oxide support such as Al 2 O 3 , CeO 2 , Co 3 O 4 , MnO 2 , TiO 2 , and ZnO, or newer support materials including perovskite-type ABO3 structures, for example LaMnO 3 , LaCoO 3 , LaNiO, and LaFeO 3 . The integration strategy parts from the traditional washcoat technique. Instead, an in situ nanomaterial assembly method is utilized, such as a hydro (solva-) thermal synthesis approach, in order to create sound structure robustness, and increase ease and complex-shaped substrate adaptability. Specifically, the critical fabrication procedures for nano-array structured catalysts include deposition of seeding layer, in situ growth of nano-array, and loading of catalytic materials. The generic methodology utilization in both the magnetic stirring batch process and continuous flow reactor synthesis offers the nano-array catalysts with great potential to be scaled up readily and cost-effectively. The tunability of the structure and catalytic performance could be achieved through morphology and geometry adjustment and guest atoms and defect manipulation, as well as composite nano-array catalyst manufacture. Excellent stabilities under various conditions were also present compared to conventional wash-coated catalysts.

36 MATERIALS SCIENCE↗
DOE OSTI2024

High resolution hydrologic routing with machine learning assisted waterbody classification

This software contains the code for a machine learning-based pipeline for creating persistent waterbody databases used in hydrologic routing. It consists of three components, 1) a PyTorch library (TorchWBType) for classifying/labeling arbitrary waterbodies into lakes and non-lakes, 2) a batch processing orchestrator (wbextractor) for delineating waterbodies from remote sensing imagery, and 3) graphing/analysis scripts for reproducing the plots in an associated journal article (LA-UR-24-22590).

Stachelek, Jemma↗
DOE OSTI2018

Continuing Efforts on Efficiency and Performance Improvement of mdtmFTP

mdtmFTP is a high-performance data transfer tool: • Pipelined I/O-centric design to streamline data transfer • Multicore-aware data transfer middleware (MDTM) optimizes use of underlying multicore system • Extremely efficient in transferring of Lots Of Small Files • Various optimization mechanisms including Asynchronous I/O and Batch processing. • Sponsored by DOE/SC/ASCR. http://mdtm.fnal.gov $\bullet$Continuing efforts on efficiency and Performance Improvement: • Refactoring event queue mechanism • I/O optimization • Scalability evaluation

Zhang, L.↗
DOE OSTI2022

Evaluating the Feasibility of Higher Titers and Yields for 2,3-Butanediol Production to Achieve the Biofuel Industry Economic Goal of Under $3.50 GGE

To achieve the economic goal of producing biofuels that can compete with petroleum-based products, we increased titers of 2,3-butanediol (BDO) production. BDO has many advantages over ethanol; including lower toxicity, higher heat of capacity, and is a precursor to various valuable applications. To produce BDO for fuel upgrading, we have genetically modified Zymomonas mobilis (YC-1). Several materials and feed strategies were evaluated to determine the best titer and economic feasibility. Titers from DMR corn stover in a batch process were in the range of 70-80 g/L. The fully hydrolyzed material was easy to work with but suffered from dilution issues. We pushed the concentration of solids to above 25% w/w and were met with numerous challenges. This included an initial sugar concentration above 150 g/L, the high solid concentration altered the oxygen mass transfer rate and affected which products were produced, and the fermentation conditions were not optimal for the enzyme. Despite these challenges, our current results yielded 100 g/L of upgradeable products (70 g/L BDO and 30 g/L acetoin) and 83% fermentation process yield. However, the poor enzymatic hydrolysis yield of 64%, unconverted xylose, and the high acetoin levels warrant further exploration for optimization. Using unhydrolyzed solids as the feed material, we achieved titers in the range of 75-95 g/L BDO. The raw solids feed, though operationally more challenging to work with, proved to be promising as the rate of hydrolysis promoted co-utilization of the sugars. We reached 150 g/L BDO using concentrated DDR liquors under boules and continuous feeding strategies. The clarified liquors showed high titers, high productivity, high yield, and high sugar utilization with little drawback operationally. The target goal of under $3.50 GGE was achieved in several feeding strategies. Scale-up feasibility has also been demonstrated at the 100L scale using both whole slurry and liquor hydrolysates.

BIOMASS FUELS↗
DOE OSTI2023

Direct contact particle-fluid heat exchanger

The present disclosure is directed to systems and methods that transfer heat directly from hot particles to a cold fluid, such as sCO 2 , by bringing the hot particles and cold fluid into direct contact at the operating pressure of the cold fluid. These systems and methods can both stand-off large pressure differentials while allowing particles to pass through and limiting cold fluid leakage either continuously or through a batch process.

Carlson, Matthew D.↗
DOE OSTI2016

Development of a Discrete Event Simulation Model for Pyroprocessing Safeguardability

Advanced nuclear energy systems offer benefits for energy sustainability, independence, security, economic growth, and carbon emission reduction. Nuclear fuel fabricated for these systems utilize remotely-handled facilities for batch processing in hot cells. Because special nuclear material is in both different physical and chemical form than that of the contemporary fuel cycle, new challenges arise in terms of safeguardability. To that end, we are developing a system model for a commercial pyroprocessing facility that can also produce quantitative metrics to assess facility design. This paper presents the progress of a first build of a material throughput model using discrete event simulation for the fuel fabrication subsystem. The intent is to study the Type I error, or false alarm, as a metric for safeguardability. Initiating events that could cause false alarms arise from safeguards, safety, and security. False alarms can necessitate a facility shutdown until the anomaly is resolved by facility inspection. A high number would be costly for the facility operator both in terms of operation throughput goals and possible compensatory penalties. Therefore, different conceptual facility designs exhibit different frequencies for the false alarm per initiating event, and this can provide a measure of the safeguardability of each design. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

Fed-batch hydrolysate addition and cell separation by settling in high cell density lignocellulosic ethanol fermentations on AFEX™ corn stover in the Rapid Bioconversion with Integrated recycling Technology process

Abstract The Rapid Bioconversion with Integrated recycling Technology (RaBIT) process uses enzyme and yeast recycling to improve cellulosic ethanol production economics. The previous versions of the RaBIT process exhibited decreased xylose consumption using cell recycle for a variety of different micro-organisms. Process changes were tested in an attempt to eliminate the xylose consumption decrease. Three different RaBIT process changes were evaluated in this work including (1) shortening the fermentation time, (2) fed-batch hydrolysate addition, and (3) selective cell recycling using a settling method. Shorting the RaBIT fermentation process to 11 h and introducing fed-batch hydrolysate addition eliminated any xylose consumption decrease over ten fermentation cycles; otherwise, decreased xylose consumption was apparent by the third cell recycle event. However, partial removal of yeast cells during recycle was not economical when compared to recycling all yeast cells.

Sarks, Cory↗
DOE OSTI2024

Defining Golden Batches in Biomanufacturing Processes From Internal Metabolic Activity to Detect Process Changes That May Affect Product Quality

ABSTRACT Cellular metabolism plays a role in the observed variability of a drug substance's Critical Quality Attributes (CQAs) made by biomanufacturing processes. Therefore, here we describe a new approach for monitoring biomanufacturing processes that measures a set of metabolic reaction rates (named Critical Metabolic Parameters (CMP) in addition to the macroscopic process conditions currently being used as Critical Process Parameters (CPP) for biomanufacturing. Constraint‐based systems biology models like Flux Balance Analysis (FBA) are used to estimate metabolic reaction rates, and metabolic rates are used as inputs for multivariate Batch Evolution Models (BEM). Metabolic activity was reproducible among batches and could be monitored to detect a deliberately induced macroscopic process shift (i.e., temperature change). The CMP approach has the potential to enable “golden batches” in biomanufacturing processes to be defined from the internal metabolic activity and to aid in detecting process changes that may impact the quality of the product. Overall, the data suggested that monitoring of metabolic activity has promise for biomanufacturing process control.

Biotechnology & Applied Microbiology↗
DOE OSTI2022

Kinetic modelling of an environmentally friendly carbamazepine synthesis via urea and iminostilbene in batch and continuous processes

Accurate kinetic models for reaction systems allow for improved process understanding and greater quality control, which is particularly beneficial as the pharmaceutical industry shifts from batch to continuous manufacturing (CM). In this work, a first principles kinetic model has been developed for the synthesis of carbamazepine (CBZ) from iminostilbene and urea, starting in a batch reactor and subsequently in a continuous flow reactor. An eco-friendly reaction pathway using urea was selected to avoid the toxic reagents that are typically used for synthesis of CBZ. The kinetic parameters determined from batch reactions were utilized in a MATLAB based kinetic model to simulate the yield for the continuous process. Overall, good agreement between the model prediction and corresponding experimental values was observed for the batch and continuous reaction systems within the full factorial design space. However, the model slightly overpredicted the yield of the continuous reaction system for higher conversion values (>60%) since it did not account for the reverse reaction that can occur at the studied reaction conditions. Here, the use of broken order kinetics was compared with whole number orders, and it was determined that the whole number orders resulted in better agreement at all conversion values for the continuous system.

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

Accelerating Laboratory-Based, All-Solid-State Battery Research and Development: Industrially Relevant Small-Batch Dry-Processing, Small and Low-Cost Test Fixtures, and Short-Tolerant Separators

This work presents improvements to mixing (for dry-processed electrodes), separator robustness, and cell testing jigs for all-solid-state batteries (ASSBs). These developments combine synergistically to enable rapid research and development of ASSB catholytes. A mechanical "kneader" is designed and built which emulates the mixing and fibrillation of poly-tetrafluoroethylene binder that occurs in industrially relevant twin-screw extruders. A modest improvement in the mixing and dispersion catholyte materials is observed using micro-resolution X-ray computed tomography (X-ray CT). Catholytes are paired with an In-metal anode and separated by a novel, dual-layer, polyaramid-fiber-supported, sulfide-solid electrolyte (Li6 PS5 Cl) separator. This separator achieves high short tolerance which enabled a 95% success rate across 20 attempted cells and to date over 100 successful cells have been built. ASSBs were tested in a 2032 coin-cell format. Simultaneous cycling of a large number of cells is further enabled by a compact and low cost (~ 38 USD per jig) pressure application jig of which 100 have been constructed to date. The utility of these advances is demonstrated through a brief study on the effect cathode-side conductive carbon and current collector type has on capacity and rate performance.

25 ENERGY STORAGE↗
DOE OSTI2018

Validation and optimization of batch and continuous particle separation processes

Recent advances in simulation capabilities coupled with advanced manufacturing can be leveraged to create highly efficient compact reactors with low emissions, low cost, high reliability, and high flexibility for energy conversion. This type of reactor is especially important for conversion of bio-mass, a storable, renewable and fast-growing energy source, considering the distributed nature of raw material and cost of biomass collection and transportation. To achieve this goal, it is critical to developing new process technologies that are significantly more efficient than traditional processes for which the added manufacture provides a fast way of realization and evaluation. Based upon the flagship MFiX multiphase computational fluid dynamic software suite, NETL has developed an Optimization Toolset to facilitate the CFD simulation based reactor design and optimization, and process intensification. This technical report presents the recent development and application of the Optimization Toolset and the framework for process optimization of particle separation in batch and continuous processes. In these processes, a fluidized bed reactor under proper operating condition was used to separate particles of different physical properties. MFiX-DEM simulations were conducted for a batch system to simulate the process covering a wide range of superficial gas velocities from which the optimal operational parameter can be determined through analyzing the system response. After successful demonstration of the framework, a continuous system for particle separation was designed based on CFD simulations. Similar optimization exercises were conducted for the continuous particle separation considering multiple operating parameters. The design was then fabricated in the laboratory through 3D printing for testing. The particle separation performance was carefully measured through high-speed video for particle tracking. Quantitative comparison between numerical results and experimental measurements were conducted for confirmation and validation.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2017

Modular Caustic-Side Solvent Extraction Unit (MCU) Improved Solvent Quality and Processing Results - 17496

The Modular Caustic-Side Solvent Extraction (CSSX) Unit (MCU) is a process for Cs-137 removal from legacy nuclear waste. MCU began hot operations in 2008 with an initial planned operating life of three years and a design life of five years. After eight years of operation, MCU has processed more than 23.8 million liters (6.3 million gallons) of waste. The MCU process uses a solvent developed by Oak Ridge National Laboratory (ORNL) to extract the fission product Cs-137 from liquid salt waste, or salt solution (SS), stored in the Tank Farms at Savannah River Site (SRS) after the material has been treated through the Actinide Removal Process (ARP). Batches of SS are prepared and first fed to the ARP, where it is treated to become clarified SS (CSS), then fed to MCU. Once the Cs-137 has been extracted by the solvent, the CSS becomes decontaminated SS (DSS), which is ultimately processed into a cementitious grout at the Saltstone Production Facility (SPF) and subsequently disposed of at the Saltstone Disposal Facility (SDF). The Cs-137 is then stripped from the solvent into an aqueous strip effluent (SE) stream for incorporation into borosilicate glass at the Defense Waste Processing Facility (DWPF). The solvent used in the MCU process is made of four components: the extractant (extracts Cs-137 from CSS), the modifier (increases solubility of extractant and suppressor in the diluent), the suppressor (suppresses the effects of anions and improves stripping), and the diluent (controls density and viscosity). There have been two solvents utilized during the lifetime of MCU. The first solvent was developed by ORNL and was used to design the plant based on its cesium removal capability. Due to the extended life of MCU, in order to continue to minimize the curies disposed at SDF, a new solvent capable of removing more cesium from the CSS was developed by ORNL and implemented at MCU. The second MCU solvent, Next-Generation Solvent (NGS), uses the same modifier and diluent as the original solvent, but a different extractant and suppressor. Subsequent changes to the overall MCU flowsheet were made for the use of NGS. The success of cesium removal from the CSS is often presented as the cesium decontamination factor (DF) achieved for each batch processed. The DF is the ratio of the concentration of cesium in the CSS to the cesium concentration in the DSS. The BOBCalixC6 based solvent was capable of achieving DFs between 100 and 400 for each DSS batch. The NGS solvent is capable of achieving DFs greater than 40,000 for each DSS batch. The NGS blend solvent is currently meeting the goals of the pure NGS solvent. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Direct internal recycling fractions approaching unity

Direct internal recycling (DIR) refers to the process of recovering pure hydrogen isotopes (D/T) from helium and other impurities in the fusion plasma exhaust and directing them back to the fuel injection system. Increasing the exhaust fraction purified through DIR significantly reduces the size and cost of the tritium plant and provides additional benefits including reduced requirements for both the tritium startup inventory and tritium breeding ratio. Metal foil pumps (MFPs) are the dominant technology for this separation, relying on the concept of superpermeation. We recently demonstrated that PdCu foils operated at low temperature provide both exceptional flux and resilience to helium absorption as the DIR fraction is increased. Herein we design and demonstrate continuous and semi-batch DIR processes using PdCu MFPs. Under continuous processing, stable performance was observed for DIR fractions up to 92 %. In addition, we demonstrate a semi-batch process capable of extending the DIR fraction to unity (> 99.8 %). Under the experimental conditions described within a PdCu MFP area of ~22 m 2 would be sufficient to process the fusion exhaust with 92 % DIR fraction at expected flowrates of 100 Pa·m 3 ·s -1 for a future fusion power plant.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2019

Determination of Reportable Radionuclides for Defense Waste Processing Facility (DWPF) Sludge Batch 9 (Macrobatch 11)

This report documents analyses and calculations performed by the Savannah River National Laboratory (SRNL) of Tank 40 sludge as part of the Waste Acceptance Product Specifications (WAPS) requirements for Sludge Batch 9 (SB9) for the Defense Waste Processing Facility (DWPF). Tank Farm sample HTF-40-17-5 was received by SRNL Shielded Cells Operations (SCO) and was prepared for radionuclide analyses in addition to various other physical and chemical characterizations. Radionuclide analyses were performed by SRNL Analytical Development (AD). Based on criteria set forth in the Department of Energy (DOE) WAPS and DWPF’s Waste Form Compliance Plan (WCP), as well as, historical lessons from previous sludge batch analyses, a list of radionuclides was developed for which the sample was analyzed. The results of these analyses were then used as input into commercially available software, RadDecay version (v) 5.01. The software was used to calculate the activity of the measured analytes in index years 2017 through 3115 in 100-year increments. Radionuclides with half-lives greater than 10 years and activities that comprised more than 0.01% of the total sludge batch activity are reportable.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗