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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS2017

Vehicle-Level Oxygen/Methane Propulsion System Hotfire Testing at Thermal Vacuum Conditions

A prototype integrated liquid oxygen/liquid methane propulsion system was hot-fire tested at a variety of simulated altitude and thermal conditions in the NASA Glenn Research Center Plum Brook Station In-Space Propulsion Thermal Vacuum Chamber (formerly B2). This test campaign served two purposes: 1) Characterize the performance of the Plum Brook facility in vacuum accumulator mode and 2) Collect the unique data set of an integrated LOX/Methane propulsion system operating in high altitude and thermal vacuum environments (a first). Data from this propulsion system prototype could inform the design of future spacecraft in-space propulsion systems, including landers. The test vehicle for this campaign was the Integrated Cryogenic Propulsion Test Article (ICPTA), which was constructed for this project using assets from the former Morpheus Project rebuilt and outfitted with additional new hardware. The ICPTA utilizes one 2,800 lbf main engine, two 28 lbf and two 7 lbf reaction control engines mounted in two pods, four 48-inch propellant tanks (two each for liquid oxygen and liquid methane), and a cold helium system for propellant tank pressurization. Several hundred sensors on the ICPTA and many more in the test cell collected data to characterize the operation of the vehicle and facility. Multiple notable experiments were performed during this test campaign, many for the first time, including pressure-fed cryogenic reaction control system characterization over a wide range of conditions, coil-on-plug ignition system demonstration at the vehicle level, integrated main engine/RCS operation, and a non-intrusive propellant mass gauging system. The test data includes water-hammer and thermal heat leak data critical to validating models for use in future vehicle design activities. This successful test campaign demonstrated the performance of the updated Plum Brook In-Space Propulsion thermal vacuum chamber and incrementally advanced the state of LOX/Methane propulsion technology through numerous system-level and subsystem experiments.

Morehead, Robert L.↗
NASA NTRS2017

Smashing the Stovepipe: Leveraging the GMSEC Open Architecture and Advanced IT Automation to Rapidly Prototype, Develop and Deploy Next-Generation Multi-Mission Ground Systems

Satellite/Payload Ground Systems - Typically highly-customized to a specific mission's use cases - Utilize hundreds (or thousands!) of specialized point-to-point interfaces for data flows / file transfers Documentation and tracking of these complex interfaces requires extensive time to develop and extremely high staffing costs Implementation and testing of these interfaces are even more cost-prohibitive, and documentation often lags behind implementation resulting in inconsistencies down the road With expanding threat vectors, IT Security, Information Assurance and Operational Security have become key Ground System architecture drivers New Federal security-related directives are generated on a daily basis, imposing new requirements on current / existing ground systems - These mandated activities and data calls typically carry little or no additional funding for implementation As a result, Ground System Sustaining Engineering groups and Information Technology staff continually struggle to keep up with the rolling tide of security Advancing security concerns and shrinking budgets are pushing these large stove-piped ground systems to begin sharing resources - I.e. Operational / SysAdmin staff, IT security baselines, architecture decisions or even networks / hosting infrastructure Refactoring these existing ground systems into multi-mission assets proves extremely challenging due to what is typically very tight coupling between legacy components As a result, many "Multi-Mission" ops. environments end up simply sharing compute resources and networks due to the difficulty of refactoring into true multi-mission systems Utilizing continuous integration / rapid system deployment technologies in conjunction with an open architecture messaging approach allows System Engineers and Architects to worry less about the low-level details of interfaces between components and configuration of systems GMSEC messaging is inherently designed to support multi-mission requirements, and allows components to aggregate data across multiple homogeneous or heterogeneous satellites or payloads - The highly-successful Goddard Science and Planetary Operations Control Center (SPOCC) utilizes GMSEC as the hub for it's automation and situational awareness capability Shifts focus towards getting GS to a final configuration-managed baseline, as well as multi-mission / big-picture capabilities that help increase situational awareness, promote cross-mission sharing and establish enhanced fleet management capabilities across all levels of the enterprise.

GMSEC↗
DOE OSTI2024

Nutri‐cereal tissue‐specific transcriptome atlas during development: Functional integration of gene expression to identify mineral uptake pathways in little millet ( Panicum sumatrense )

SUMMARY Little millet (Panicum sumatrenseRoth ex Roem. & Schult.) is an essential minor millet of southeast Asia and Africa's temperate and subtropical regions. The plant is stress‐tolerant, has a short life cycle, and has a mineral‐rich nutritional profile associated with unique health benefits. We report the developmental gene expression atlas of little millet (genotype JK‐8) from ten tissues representing different stages of its life cycle, starting from seed germination and vegetative growth to panicle maturation. The developmental transcriptome atlas led to the identification of 342 827 transcripts. The BUSCO analysis and comparison with the transcriptomes of related species confirm that this study presents high‐quality, in‐depth coverage of the little millet transcriptome. In addition, the eFP browser generated here has a user‐friendly interface, allowing interactive visualizations of tissue‐specific gene expression. Using these data, we identified transcripts, the orthologs of which inArabidopsisand rice are involved in nutrient acquisition, transport, and response pathways. The comparative analysis of the expression levels of these transcripts holds great potential for enhancing the mineral content in crops, particularly zinc and iron, to address the issue of “hidden hunger” and to attain nutritional security, making it a valuable asset for translational research.

Plant Sciences↗
DOE OSTI2014

Electricity Transmission, Pipelines, and National Trails: An Analysis of Current and Potential Intersections on Federal Lands in the Eastern United States, Alaska, and Hawaii

As has been noted in many reports and publications, acquiring new or expanded rights-of-way for transmission is a challenging process, because numerous land use and land ownership constraints must be overcome to develop pathways suitable for energy transmission infrastructure. In the eastern U.S., more than twenty federally protected national trails (some of which are thousands of miles long, and cross many states) pose a potential obstacle to the development of new or expanded electricity transmission capacity. However, the scope of this potential problem is not well-documented, and there is no baseline information available that could allow all stakeholders to study routing scenarios that could mitigate impacts on national trails. This report, Electricity Transmission, Pipelines, and National Trails: An Analysis of Current and Potential Intersections on Federal Lands in the Eastern United States, was prepared by the Environmental Science Division of Argonne National Laboratory (Argonne). Argonne was tasked by DOE to analyze the “footprint” of the current network of National Historic and Scenic Trails and the electricity transmission system in the 37 eastern contiguous states, Alaska, and Hawaii; assess the extent to which national trails are affected by electrical transmission; and investigate the extent to which national trails and other sensitive land use types may be affected in the near future by planned transmission lines. Pipelines are secondary to transmission lines for analysis, but are also within the analysis scope in connection with the overall directives of Section 368 of the Energy Policy Act of 2005, and because of the potential for electrical transmission lines being collocated with pipelines. Based on Platts electrical transmission line data, a total of 101 existing intersections with national trails on federal land were found, and 20 proposed intersections. Transmission lines and pipelines are proposed in Alaska; however there are no locations that intersect national trails. Source data did not indicate any planned transmission lines or pipelines in Hawaii. A map atlas provides more detailed mapping of the topics investigated in this study, and the accompanying GIS database provides the baseline information for further investigating locations of interest. In many cases the locations of proposed transmission lines are not accurately mapped (or a specific route may not yet be determined), and accordingly the specific crossing locations are speculative. However since both national trails and electrical transmission lines are long linear systems, the characteristics of the crossings reported in this study are expected to be similar to both observed characteristics of the existing infrastructure provided in this report, and of the new infrastructure if these proposed projects are built. More focused study of these siting challenges is expected to mitigate some of potential impacts by choosing routes that minimize or eliminate them. The current study primarily addresses a set of screening-level characterizations that provide insights into how the National Trail System may influence the siting of energy transport facilities in the states identified under Section 368(b) of the Energy Policy Act of 2005. As such, it initializes gathering and beginning analysis of the primary environmental and energy data, and maps the contextual relationships between an important national environmental asset and how this asset intersects with energy planning activities. Thus the current study sets the stage for more in-depth analyses and data development activities that begin to solve key transmission siting constraints. Our recommendations for future work incorporate two major areas: (1) database development and analytics and (2) modeling and scenario analysis for energy planning. These recommendations provide a path forward to address key issues originally developed under the Energy Policy Act of 2005 that are now being carried forward under the President’s Climate Action Plan.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2017

An Open Source Extensible Smart Energy Framework

Aggregated distributed energy resources are the subject of much interest in the energy industry and are expected to play an important role in meeting our future energy needs by changing how we use, distribute and generate electricity. This energy future includes an increased amount of energy from renewable resources, load management techniques to improve resiliency and reliability, and distributed energy storage and generation capabilities that can be managed to meet the needs of the grid as well as individual customers. These energy assets are commonly referred to as Distributed Energy Resources (DER). DERs rely on a means to communicate information between an energy provider and multitudes of devices. Today DER control systems are typically vendor-specific, using custom hardware and software solutions. As a result, customers are locked into communication transport protocols, applications, tools, and data formats. Today’s systems are often difficult to extend to meet new application requirements, resulting in stranded assets when business requirements or energy management models evolve. By partnering with industry advisors and researchers, an implementation DER research platform was developed called the Smart Energy Framework (SEF). The hypothesis of this research was that an open source Internet of Things (IoT) framework could play a role in creating a commodity-based eco-system for DER assets that would reduce costs and provide interoperable products. SEF is based on the AllJoynTM IoT open source framework. The demonstration system incorporated DER assets, specifically batteries and smart water heaters. To verify the behavior of the distributed system, models of water heaters and batteries were also developed. An IoT interface for communicating between the assets and a control server was defined. This interface supports a series of “events” and telemetry reporting, similar to those defined by current smart grid communication standards. The results of this effort demonstrated the feasibility and application potential of using IoT frameworks for the creation of commodity-based DER systems. All of the identified commodity-based system requirements were met by the AllJoyn framework. By having commodity solutions, small vendors can enter the market and the cost of implementation for all parties is reduced. Utilities and aggregators can choose from multiple interoperable products reducing the risk of stranded assets. Based on this research it is recommended that interfaces based on existing smart grid communication protocol standards be created for these emerging IoT frameworks. These interfaces should be standardized as part of the IoT framework allowing for interoperability testing and certification. Similarly, IoT frameworks are introducing application level security. This type of security is needed for protecting application and platforms and will be important moving forward. Recommendations are that along with DER-based data model interfaces, platform and application security requirements also be prescribed when IoT devices support DER applications.

25 ENERGY STORAGE↗
NASA NTRS2016

Enabling International Data Relay at Mars

The most commonly used mode of communications be-tween Earth and a Mars surface mission is ultra-high fre-quency (UHF) radio relay via a Mars orbiter. There are four orbiters and two surface rovers operating at Mars and by October there should be five orbiters and three landers or rovers. There has been some collaboration between ESA’s Mars Express orbiter and NASA’s rovers, but 2016 is when Mars relay becomes fully international. In October, ESA will deliver the ExoMars Trace Gas Orbiter (TGO) and En-try, Descent, and Landing (EDL) Demonstrator Module (EDM) lander to Mars. The ExoMars program includes both ESA and ROSCOSMOS, with NASA participation (the Electra UHF transceiver on TGO). NASA orbiters will pro-vide relay for EDM and future ESA Mars landers and rov-ers. TGO will provide relay for NASA's current and future surface assets (as Mars Express will continue to do). Inter-national collaboration is enabled in several steps. At the in-struction of the space agencies, the Mars mission projects negotiate and write a “Service Agreement.” This describes at a high level how a new Mars orbiter would operate with its corresponding surface missions or how a new surface mis-sion would operate with its corresponding orbiters. It in-cludes the roles of the different projects, how the new mis-sion would communicate with existing or planned missions, the general flow of data and commands, and the capabilities or requirements of the new mission. After completing the Service Agreement, the projects write Interface Control Doc-uments (ICDs), each of which describes data and command flow in greater detail and quantitative aspects of the relay link and operations timeline between an orbiter and a cor-responding lander/rover. Interfaces and operations are test-ed before a new mission arrives at Mars. Once at Mars, a new orbiter performs some “practice” relay contacts with its partners. For a new lander (e.g. EDM), relay operations gen-erally begin before atmospheric entry at Mars, with record-ing of the UHF relay signal from the lander (including open-loop wide-bandwidth recording) as it enters and traverses Mars’s atmosphere and lands on its surface. After Mars EDL or orbit injection, each relay contact is negotiat-ed and scheduled using the Mars Relay Operations Service (MaROS). This paper describes the international approach to develop inter-agency agreements, inter-project interfaces, and specifics of how MaROS is used in actual relay opera-tions between international partners.

Winton, Alistair J.↗
NASA NTRS2008

Interfacing Space Communications and Navigation Network Simulation with Distributed System Integration Laboratories (DSIL)

NASA's planned Lunar missions will involve multiple NASA centers where each participating center has a specific role and specialization. In this vision, the Constellation program (CxP)'s Distributed System Integration Laboratories (DSIL) architecture consist of multiple System Integration Labs (SILs), with simulators, emulators, testlabs and control centers interacting with each other over a broadband network to perform test and verification for mission scenarios. To support the end-to-end simulation and emulation effort of NASA' exploration initiatives, different NASA centers are interconnected to participate in distributed simulations. Currently, DSIL has interconnections among the following NASA centers: Johnson Space Center (JSC), Kennedy Space Center (KSC), Marshall Space Flight Center (MSFC) and Jet Propulsion Laboratory (JPL). Through interconnections and interactions among different NASA centers, critical resources and data can be shared, while independent simulations can be performed simultaneously at different NASA locations, to effectively utilize the simulation and emulation capabilities at each center. Furthermore, the development of DSIL can maximally leverage the existing project simulation and testing plans. In this work, we describe the specific role and development activities at JPL for Space Communications and Navigation Network (SCaN) simulator using the Multi-mission Advanced Communications Hybrid Environment for Test and Evaluation (MACHETE) tool to simulate communications effects among mission assets. Using MACHETE, different space network configurations among spacecrafts and ground systems of various parameter sets can be simulated. Data that is necessary for tracking, navigation, and guidance of spacecrafts such as Crew Exploration Vehicle (CEV), Crew Launch Vehicle (CLV), and Lunar Relay Satellite (LRS) and orbit calculation data are disseminated to different NASA centers and updated periodically using the High Level Architecture (HLA). In addition, the performance of DSIL under different traffic loads with different mix of data and priorities are evaluated.

Traffic Measuring and Monitoring↗
DOE OSTI2021

Deep Reinforcement Learning Enabled Physical-Model-Free Two-Timescale Voltage Control Method for Active Distribution Systems

Active distribution networks are being challenged by frequent and rapid voltage violations due to renewable energy integration. Conventional model-based voltage control methods rely on accurate parameters of the distribution networks, which are difficult to achieve in practice. This paper proposes a novel physical-model-free two-timescale voltage control framework for active distribution systems. To achieve fast control of PV inverters, the whole network is first partitioned into several subnetworks using voltage-reactive power sensitivity. Then, the scheduling of PV inverters in the multiple sub-networks is formulated as Markov games and solved by a multi-agent soft actor-critic (MASAC) algorithm, where each subnetwork is modeled as an intelligent agent. All agents are trained in a centralized manner to learn a coordinated strategy while being executed based on only local information for fast response. For the slower time-scale control, OLTCs and switched capacitors are coordinated by a single agent-based SAC algorithm using the global information with considering control behaviors of the inverters. Particularly, the two-level agents are trained concurrently with information exchange according to the reward signal calculated from the data-driven surrogate model. Comparative tests with different benchmark methods on IEEE 33-and 123-bus systems and 342-node low voltage distribution system demonstrate that the proposed method can effectively mitigate the fast voltage violations and achieve systematical coordination of different voltage regulation assets without the knowledge of accurate system model.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2019

Benchmarking Wind Power Operating Costs in the United States: Results from a Survey of Wind Industry Experts

This paper draws on a survey of wind industry professionals to clarify trends in the operational expenditures (OpEx) of U.S. land-based wind power plants. The paper also highlights key drivers of those trends. We find that average all-in lifetime OpEx has declined from approximately $\$$80/kW-yr ($\$$35/MWh) for projects built in the late 1990s to a level that is approaching $\$$40/kW-yr ($\$$11/MWh) for projects under construction in 2018. Turbine operations and maintenance (O&M) costs—inclusive of scheduled and unscheduled maintenance—represent the single largest component of overall OpEx and the primary source of cost reductions over the last decade. We observe wide ranges of OpEx over time; for example, survey respondents cite a range in average expected costs for projects commissioned between 2015 and 2018 from $\$$33/kW-yr to $\$$59/kW-yr. Notably, these broad ranges include high levels of variability in both turbine O&M costs and non-turbine OpEx. Potential technical and strategic drivers of this variability are highlighted. We also use historical OpEx learning rates, showing a 9% OpEx reduction for each doubling of global installed wind capacity, to project a further $\$$5–$\$$8/kW-yr (12%–18%) OpEx reduction from 2018 to 2040. When compared with the broader literature, these findings suggest that continued OpEx reductions may contribute 10% or more of the expected reductions in land-based wind’s levelized cost of energy. Moreover, these estimates may understate the importance of OpEx owing to the multiplicative effects through which operational advancements influence not only O&M costs but also component reliability, performance, and plant-level availability—thereby affecting levelized costs though OpEx reduction and by enhancing annual energy production and plant lifetimes. Given the limited quantity and comparability of previously available OpEx data, the data and trends reported here may usefully inform OpEx assumptions used by electric system planners, analysts, modelers, and research and development managers. The results may also provide useful benchmarks to the wind industry, helping developers and asset owners compare their OpEx expectations with historical experience and other industry projections.

17 WIND ENERGY↗
DOE OSTI2026

Manufacturing Facility Inventory National Dataset (M-FIND)

This asset provides a high-fidelity, validated inventory of manufacturing facilities across the United States, filling a critical gap in publicly available industrial data. By integrating and cross-referencing thirteen distinct data sources, this dataset moves beyond the limitations of single-source registries to provide a harmonized list that includes precise geographic coordinates, industrial subsector designations, and—crucially—parcel-level spatial boundaries.

Billings, Blake [ORNL] (ORCID:0000000186021600)↗
DOE OSTI2017

(Project 14-6770) An Investigation to Establish Multiphysical Property Dataset of Nuclear Materials Based on in-situ Observations and Measurements

In-core nuclear materials including fuel pins and cladding materials fail due to issues including corrosion, mechanical wear, and pellet cladding interaction. In most such scenario microstructure dependent and corrosioninduced chemistry dependent property changes significantly affect performance of cladding, pellet, and housing. Emphasis of this work was on replace conventional pellet-cladding material models with a new straingradient viscoplasticity model that is informed by transmission electron microscopy (TEM) based measurements and by nanomechanical Raman spectroscopy (NMRS) based measurements. The TEM measurements are quantitative in nature and therefore reveal stress-strain relations with simultaneous insights into mechanisms of deformation at nanoscale. The NMRS measurements reveal the similar information at mesoscale along with additional information on relating local microstructural stresses with applied stresses. The resulting information is used to fit constants in the strain gradient viscoplasticity model as well as to validate one. During TEM measurements, a micro-electro-mechanical system based setup was developed with mechanical actuation, sensing, heating, and electrical loading. Contrary to post-mortem analysis or qualitative visualization, this setup combines direct visualization of the mechanisms behind deformation with measurement of stress, strain, thermal and electrical properties. The unique research philosophy of visualizing the microstructure at high resolution while measuring the properties led to fundamental understanding in grain size and temperature effects on measured mechanical properties such as fracture toughness. A key contribution is the role of mechanical loading boundary conditions to deconvolute the insitu TEM based nanoscale and NMRS based mesoscale data to bulk behavior. First the literature based pellet cladding mechanical interaction model based on the work of Retel’s and Williamson’s in literature work to predict tempurature and stress distribution in cladding and pellet at normal operating condition was analyzed. Later the data was fitted to find constants for a viscoplastic strain gradient model. The developed model still needs to be refined and calibrated using various experimental results. That remains the focus of future work. Overall, a major thrust of the work was therefore on active control of the microstructure (grain size, defect density and types) exploiting the multi-physics coupling in materials. In particular, using experiments the synergy of current density, mechanical stress and temperature were studied to annihilate defects and recrystallize grains. The developed model is being examined for implementation in BISON. Multiple invited talks, international journal publications, and conference publications were performed by students supported on this work. Another output is support multiple PhD and masters thesis students who will be an important asset for future basic nuclear research. Future Work Recommendations: A nuclear reactor operates under significant variations of thermal loads due to energy cycling and mechanical loads due to constraint effects. Significant thermal and chemical diffusion takes place at the pallet-cladding level. While the proposed work established new experimental approach and new dataset for Zircaloy-4, the irradiation level was in the range of 1-2 dpa. Samples with higher dpa need to be examined. Therefore, a continual of support of the performed work is essential. Currently, these are the only experiments that can measure the produced data. The work also needs to be extended to different fuel types and cladding types such as SiC and FeCrAl based claddings. A combination of datasets for these materials can then be used to analyze accurately predict behavior of critical pellet cladding systems in accident scenario with high heat flux and high thermal loads. This is a BIG unknown as if now.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Development and Application of a Risk Analysis Toolkit for Plant Resources Optimization

This report summarizes the R&D activities of the Risk Informed Asset Management (RIAM) project during fiscal year 2020 (FY20). This project focuses on the development of methods designed to optimize plant operations (e.g., maintenance/replacement schedule, optimal maintenance posture) provided system/component health/cost data. This project development lives in cooperation with the Plant Health Management (PHM) project which focuses on the development of methods that integrate component health data and propagate such information at the system level to evaluate most relevant sources of risk. This year’s activities for the RIAM project focused on the continuation of schedule optimization algorithms developed in FY19. While in FY19 we focused on both deterministic and stochastic capital budgeting methods, in FY20 we moved forward by implementing two versions of schedule optimization methods. The first one reformulates the capital budgeting problem in a distributionally robust form which allows the user to rely on data directly rather than proposing a distribution from the data itself. The second version reformulates the capital budgeting explicitly using risk measures as variables to maximize/minimize. Lastly, we focused on the development of methods designed to identify the optimal maintenance posture based on the Pareto Frontier analysis. Rather than performing a tradeoff analysis (i.e., identify the absolute best posture), the Pareto Frontier analysis performs a trade space exploration approach (i.e., identify value and costs of several postures and have the analyst perform the task of imposing desired value and cost constraints). This is performed by identifying maintenance postures that maximize value (e.g., system availability) and minimize operational costs, i.e., the Pareto frontier in a value-cost trade space.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2018

Industrial Scale Demonstration of Smart Manufacturing, Achieving Transformational Energy Productivity Gains

While many U.S. manufacturing operations utilize optimization for individual unit processes, smart manufacturing (SM) systems that integrate manufacturing intelligence in real time across an entire production operation are rare in large companies and virtually nonexistent in smaller organizations. One example of an area where SM systems can be applied is in the management of waste heat. A smart system that not only seeks to recover waste heat, but also to use energy more efficiently, is a more cost-effective approach because energy use, waste energy loss and product output are optimized together. The overall objective of this project was to develop an industry-accepted SM Platform that enables smart systems by accelerating and lowering the cost of development and implementation scales for use in diverse sets of manufacturing industry sectors, manufacturing operations and company sizes. Specifically, the project (1) designed and demonstrated the application of a prototype SM Platform for two diverse commercial test beds, (2) demonstrated at one and estimated for the other test bed the potential reduction in waste heat generation, and (3) worked with leading automation vendors to catalyze low-cost commercialization of the technology developed. The Smart Manufacturing Application and Data Platform (SM Platform) developed during this project is an innovative approach that marries IT virtualization technologies with operational data and modeling system requirements to construct a ready-to-go platform for enabling sensor – data – modeling – actuation systems, driven by real-time plant data and performance metrics. This SM Platform allows manufacturing organizations, regardless of their industry or size, to assemble new operational systems at a much lower cost, optimizing process knowledge and improving energy productivity by integrating with existing process control and automation systems. Also developed during this project is a methodology for developing energy productivity metrics that use real-time process information and provide comparisons for potential, practical, and actual performance, as well as examples and the methodology for provisioning of an Energy Dashboard that displays alternatives to optimize energy use within specific business contexts aimed at helping improve energy productivity and reduce emissions in U.S. manufacturing. The SM Platform designed utilizes current manufacturing, operational and IT industry standards. The platform can be used to expedite sensor – data – model – actuation system development and deployment in a cloud-based environment using a novel end-to-end workflow as a service capability that is already integrated with data connection, ingestion, and contextualization services. In addition, the methodology for development of energy productivity metrics and reusable application templates called Toolkits have been defined so that they can be tailored to a specific business situation. The project’s two test beds, one in a hydrogen production plant and the other in a forging, heat treatment, and machining operation, utilize sensor-driven modeling, measurement, and simulation systems. In these two test beds, the implementation of these as a comprehensive system has made it possible for energy productivity to be managed in real-time throughout the plant and enterprise using an energy dashboard. The development pathway to direct machine actuation was articulated. During the first year, the project team developed the most highly instrumented steam-methane reformer (SMR) in the U.S. using infrared cameras and thermocouples. Real-time data are streamed to high fidelity and reduced-order models for analysis. A high fidelity CFD model, parallelized in the SM Platform cloud environment, was demonstrated for operational use. This is the first real-time operational productivity system of a steam methane reformer using both high fidelity and data-driven models together in a real time situation to balance natural gas flow to the reformer tubes. An infrared camera system was developed and shown to outperform thermocouples in coverage, accuracy, reliability, and cost effectiveness for use in a high temperature, harsh environment. A forging, heat-treating, machining line operation test bed includes new instrumentation for data capture analysis, modeling, and simulation and will be integrated into SM Platform workflows so that business performance can be managed in real-time. Composable metrics were developed using the SM Platform to drive improvements in energy productivity, environmental performance, safety, asset management, costs, and overall operations. A major focus of the SM systems developed was optimization of energy productivity at the enterprise level, which resulted in reductions in waste heat generation for the two project test beds. Reductions in the waste heat generated will result in greater energy savings than will waste heat recovery due to inefficiencies in the heat transfer process. For the SMR test bed an efficiency improvement of 1 – 2% with a corresponding waste heat reduction of 5% were demonstrated. It should be noted that the test bed SMR unit had an efficiency of more than 90% as compared to 70 to 80% efficiencies of most SMR units. So implementation of similar SM systems at typical SMR units could yield more than 15 to 25% waste heat reductions. Similarly the forging, heat-treating, machining line operation test bed is a DOE AMO Platinum Level Superior Energy Performance plant with a much higher than typical overall operating efficiency. For this test bed heat integration using recuperators is estimated to result in fuel savings of 15.9% due to waste heat recovery compared to the base case without recuperators with negligible changes in part exit conditions. This results in an 18.9% energy efficiency improvement. The project team estimates that broad multi-sector adoption of the developed technology could reduce waste heat generation by an amount equivalent to 1.3% of total U.S. energy use. This waste heat reduction is associated with 69 million tons reduction in annual carbon dioxide emissions. Other potential benefits include reducing process times, solid and liquid wastes, environmental impacts, and water use. It is estimated that this investment has an anticipated payback period of less than one year in energy-intensive applications. The SM Platform could also reduce the costs of deploying SM systems by 50% in manufacturing operations. Commercialization of the SM Platform will require significant cross-industry collaboration and technology provider market changes. Steps taken toward commercialization included 1) analyzing savings from deployment of the SM Platform and 2) holding SM Platform workshops, webinars, and conferences with targeted individual industry segments, with a focus on small and medium-sized organizations. An upgraded community website has been established as a portal for accessing and distributing information. Most importantly, the SM platform enabling technology developed during this project and its commercialization will continue, evolve and expand under the Clean Energy Smart Manufacturing Innovation Institute (CESMII).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS2012

NASA/FAA North Texas Research Station Overview

NTX Research Staion: NASA research assets embedded in an interesting operational air transport environment. Seven personnel (2 civil servants, 5 contractors). ARTCC, TRACON, Towers, 3 air carrier AOCs(American, Eagle and Southwest), and 2 major airports all within 12 miles. Supports NASA Airspace Systems Program with research products at all levels (fundamental to system level). NTX Laboratory: 5000 sq ft purpose-built, dedicated, air traffic management research facility. Established data links to ARTCC, TRACON, Towers, air carriers, airport and NASA facilities. Re-configurable computer labs, dedicated radio tower, state-of-the-art equipment.

Borchers, Paul F.↗
DOE OSTI2026

Automatic Lane-Level Road Network Extraction from Aerial Imagery for Transportation Digital Twins

Accurate road networks are essential for credible traffic microsimulation and transportation digital twins, yet high-definition maps are often difficult to obtain due to limited availability, high cost, or proprietary restrictions. Some build networks from crowdsourced data, such as OpenStreetMap, but these sources often contain geometric and semantic inconsistencies. Others create networks manually, a process that is labor-intensive and difficult to scale. To address these limitations, this work presents an end-to-end pipeline that automatically extracts georeferenced, lane-level road networks from publicly available high-resolution satellite imagery and converts them into simulation-ready assets. The developed end-to-end pipeline has three primary modules: (1) A computer-vision-based module first detects directed lane geometries and intersection layouts. (2) A heuristic-based topology construction module then identifies approach and exit legs and establishes conflict-free lane-to-lane connections. (3) Finally, an automatic simulation-building module converts the extracted network into standard formats, e.g., OpenDRIVE, and generates routable SUMO networks. The framework supports both complete network construction from scratch and local-scale refinement of existing networks through lane-count correction, transition recovery, and geometric regularization. The proposed pipeline provides a practical pathway to generate traffic simulation networks from satellite imagery, significantly reducing manual reconstruction effort and enabling scalable, continuously updated transportation digital twins.

Guo, Hetian [University of Georgia, Athens] (ORCID↗
DOE OSTI2022

FECM/NETL Unconventional Shale Well Economic Model (UShWEM)

FECM/NETL Unconventional Shale Well Economic Model (UShWEM) is an Excel-based model that evaluates the economics of an unconventional shale well on a per-well and per-pad basis. The model calculates the net cash flow, internal rate of return (IRR), net present value (NPV), earnings before interest, taxes, depreciation, and amortization (EBITDA), payout month and year, and breakeven price (for either oil- or gas-wells). The model can be used to estimate the economics of a well or pad over its lifetime (development through site reclamation) based on (1) the capital and operating costs associated with well/pad development and operations, (2) the revenue associated with oil, gas, and condensate production streams, and (3) accounting for relevant tax policies and asset depreciation applicable for oil and gas operations. The main input for the model is the completion design and production data. Key financial considerations in the model include oil, gas, and condensate market prices, tax-related settings, royalty rates, the discount rate, minimum economic hurdle (IRR) [if performing break-even analysis], and project contingency. The financial consideration can be adjusted to reflect the level of granularity the user requires as input when calculating the economics for a well or pad development. In addition, the model affords users the option to provide their user inputs for all cost categories considered. As a result, the model can be used to generate a multitude of scenario cases for sensitivity analysis of the various financial considerations, as well as production and cost profiles. To make this seamless, the model has the capability for key economic outputs to be exported in large batches through macros-enabled functions on its “Model Output Summary” and “Multi-Well Cost Analysis. The spreadsheet model includes macros and user-defined functions, so the user must enable Excel’s macro capability for the model to function correctly.

Sheriff, Alana↗
NASA NTRS2007

Comprehensive Shuttle Foam Debris Reduction Strategies

The Columbia Accident Investigation Board (CAIB) was clear in its assessment of the loss of the Space Shuttle Columbia on February 3, 2003. Foam liberated from the External Tank (ET) impacting the brittle wing leading edge (WLE) of the orbiter causing the vehicle to disintegrate upon re-entry. Naturally, the CAB pointed out numerous issues affecting this exact outcome in hopes of correcting systems of systems failures any one of which might have altered the outcome. However, Discovery s recent return to flight (RTF) illustrates the primacy of erosion of foam and the risk of future undesirable outcomes. It is obvious that the original RTF focused approach to this problem was not equal to a comprehensive foam debris reduction activity consistent with the high national value of the Space Shuttle assets. The root cause is really very simple when looking at the spray-on foam insulation for the entire ET as part of the structure (e.g., actual stresses > materials allowable) rather than as some sort of sizehime limited ablator. This step is paramount to accepting the CAB recommendation of eliminating debris or in meeting any level of requirements due to the fundamental processes ensuring structural materials maintain their integrity. Significant effort has been expended to identify root cause of the foam debris In-Flight Anomaly (FA) of STS-114. Absent verifiable location specific data pre-launch (T-0) and in-flight, only a most probable cause can be identified. Indeed, the literature researched corroborates NASNTM-2004-2 13238 disturbing description of ill defined materials characterization, variable supplier constituents and foam processing irregularities. Also, foam is sensitive to age and the exposed environment making baseline comparisons difficult without event driven data. Conventional engineering processes account for such naturally occurring variability by always maintaining positive margins. Success in a negative margin range is not consistently achieved. Looking at the ET S spray-on foam insulation as part of the structural system (e.g., glass half full mentality) will create an environment where ET debris levels as low as reasonably achievable (ALARA) can be realized. ALARA is a NASA requirements philosophy deployed for the complex, mission altering radiation exposure requirements for life safety of astronauts. In the Shuttle s case, reasonableness is established by exhaustive engineering rigor, allowable debris size/quantity, technology maturity and programmatic constraints. A more robust urethane foam thermal protection system (TPS) will enhance the hctionality of the new Ares I Crew Launch Vehicle (CLV) Upper Stage. This paper will outline the strategy for a comprehensive effort to reduce ET foam debris and outline steps leading to an improved foam TPS. The NASA must remain committed to such an approach no matter what becomes of the next flight s actual debris field lest we fall back into a false sense of security. This commitment along with full implementation of all the other CAB recommendations such as orbiter hardening will significantly improve the Shuttle system, the engineering workforce, future capabilities & alternate policy offramps, national human resource protection, high value national asset protection and increase the level of service to the overall NASA mission.

Semmes, Edmund B.↗
NASA NTRS2011

Solar Cycle Prediction

Solar cycle predictions are needed to plan long-term space missions; just like weather predictions are needed to plan your next vacation. Fleets of satellites circle the Earth collecting many types of science data, protecting astronauts, and relaying information. All of these satellites are sensitive at some level to solar cycle effects. Predictions of drag on LEO spacecraft are one of the most important. Launching a satellite with less propellant can mean a higher orbit, but unanticipated solar activity and increased drag can make that a Pyrrhic victory. Energetic events at the Sun can produce crippling radiation storms that endanger all assets in space. Testing solar dynamo theories by quantitative predictions of what will happen in 5-20 years is the next arena for solar cycle predictions. I will describe the current state of solar cycle predictions and anticipate how those predictions could be made more accurate in the future.

Pesnell, William Dean↗