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All sources NASA NTRS DOE OSTI

DOE OSTI2022

Interregional Renewable Energy Zones

Interregional Renewable Energy Zones (IREZs) are a component of the National Transmission Planning Study (NTPS), which analyzes strategies for building out transmission infrastructure to support decarbonizing the electricity sector by 2035. In particular, IREZs envision long-distance transmission corridors for moving large amounts of low-cost renewable energy. An IREZ is a transmission collection point that is easily accessible to a very high volume of low-cost developable wind and solar energy potential. This dataset includes 155 IREZs identified across the continental United States where each IREZ is characterized by its primary and secondary resource.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

North America’s Potential for an Environmentally Sustainable Nickel, Manganese, and Cobalt Battery Value Chain

The Detroit Big Three General Motors (GMs), Ford, and Stellantis predict that electric vehicle (EV) sales will comprise 40–50% of the annual vehicle sales by 2030. Among the key components of LIBs, the LiNixMnyCo1−x−yO2 cathode, which comprises nickel, manganese, and cobalt (NMC) in various stoichiometric ratios, is widely used in EV batteries. This review reveals NMC cathodes from laboratory research. Furthermore, this study examines the environmental effect of NMC cathode production for EV batteries (including coating technologies), encompassing aspects such as energy consumption, water usage, and air emissions. Although gaps persist in NMC cathode environmental assessments (NMC111, NMC532, NMC622, and NMC811), limited life cycle assessments “(LCA)” have been conducted. Most available data originate from Asia (primarily China), accounting for 85% of the production of EV LIB cathode materials. The concept of battery passports for data collection on LIB components has been proposed to facilitate material traceability as a system for ensuring a sustainable supply chain for critical minerals. The automotive industry’s shift to electrification necessitates a sustainable supply chain from mine to vehicle end-of-life. As the critical mineral supply moves from Asia to North America, environmentally friendly industrial methods must be studied to provide this supply chain direction.

25 ENERGY STORAGE↗

DOE OSTI2022

Ammonium sulfate leaching of NaOH-treated monazite

Rare earth elements (REEs) can be extracted from monazite under aggressive decomposition and leaching conditions. Much of the waste rocks are removed prior to the extraction process to minimize the costs and waste generation, which is difficult with coal byproducts. The possibility of extracting REEs from low-grade monazite concentrates under relatively mild conditions has been explored to simulate the extraction of REEs from coal byproducts. It has been found that monazite can be decomposed in 10 to 50 % NaOH solutions at 80 °C, with the resulting hydrous oxide being subjected to the ammonium sulfate leaching at pH 4. Further, the ς-potential measurements conducted in the presence of the lixiviant suggest that the NH 4+ ions displace the hydrated Ln 3+ ions from the surface of Ln(OH) 3 (s) by an ion-exchange mechanism, which may be driven by the large differences in the hydration enthalpies between the charged species involved. This approach may be advantageous over acid leaching, including the regeneration of spent lixiviant, lower chemical consumption, and leaching at higher pH.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Critical review and future prospects for desiccant coated heat exchangers: Materials, design, and manufacturing

Solid desiccant dehumidification is a promising alternative to vapor compression-based air-dehumidification to reduce energy consumption and improve air quality. Desiccant coated heat exchanger (DCHE), as one type of solid desiccant dehumidification system, can improve system performance and efficiency. The thermal performance and moisture removal capability of the DCHE greatly influence its dehumidification performance.The present work aims to critically analyze the designs, materials, and manufacturing methods of heat exchangers used for solid desiccant coating and look into recent developments in regular heat exchangers, potentially deployed as a substrate for DCHE applications. A comprehensive literature review of publications regarding solid desiccant materials, heat exchangers, manufacturing and coating methods, binder materials, and the performance of heat exchangers has been developed. Alternative heat exchangers are described as better options than fin and tube heat exchangers that have been considered thus far for DCHE applications. Additionally, the heat exchanger's manufacturing process and materials over their thermal and mass exchange performance have been analyzed. Despite the widespread use of fin and tube heat exchangers for solid desiccant coating, recent developments in heat exchanger design, and related fields such as manufacturing methods and materials, open the possibilities for their application in solid desiccant dehumidification systems. Lastly, the authors provide their outlook on possible developments of DCHE technology, aiming to increase systems' energy and dehumidification performance.

36 MATERIALS SCIENCE↗

DOE OSTI2020

GradeIT (Road Grade Inference Tool)

The National Renewable Energy Laboratory (NREL) has developed the Road Grade Inference Tool, "GradeIT". This tool is a modular Python package the leverages the United States Geological Survey’s (USGS) 1/3 arc-second Digital Elevation Model (DEM), an open and free public dataset. Roadway gradient (slope) has a strong influence on vehicle energy consumption behavior and longitudinal dynamics. Therefore, any tools, models, or analyses that consider vehicle energy consumption or driving profiles is incomplete without accurate elevation and grade information. Despite the acute need for this data, it is rarely collected alongside GPS (latitude and longitude) data, and tools to post-process GPS data to append elevation and grade are difficult to come by. GradeIT satisfies this significant need in the research community. Utilization of the USGS DEM makes the underlying data available to any potential user and ensures continuous data anywhere in the continental United States. The USGS DEM is a great resource; however, in order to be useful for automotive and traffic engineering applications, significant interpolation and filtering is required to achieve an accurate representation of gradient on the roadway. GradeIT employs a two-dimensional interpolation to approximate elevation at a point on the road from the nearest nodes in the DEM. Then, GradeIT applies multiple filtering techniques to smooth the elevation profile to a realistic road topology. Finally, road grade is derived from the elevation profile and returned as the primary output.

Holden, Jacob↗

DOE OSTI2025

An assessment of the global cooling supply chain and implications for critical minerals

The global room air conditioner (AC) industry has undergone rapid growth, and the U.S. and India now face new supply chain risks due to China’s dominant role in manufacturing and driving demand. As India’s room AC market and related electricity consumption increases with continued economic development, it faces dual challenges of supply chain vulnerabilities and power grid blackouts from higher peak loads. To mitigate supply chain vulnerabilities for high-efficiency cooling equipment and critical mineral inputs to AC components, there is an increasing need to diversify the supply chain and address energy security and peak load risks to both the U.S. and India. This report assesses the potential for diversifying supply chains and scaling up manufacturing of highly efficient cooling equipment technologies and related critical mineral inputs in the U.S. and India. Successful cooperation on these technologies will enable the U.S., India, and their Quadrilateral Security Dialogue (Quad) partners to diversify AC supply chains while meeting India’s large and growing demand for efficient cooling. In the similarly concentrated supply chain for critical minerals, the U.S. and India can work with Japan and Australia to leverage each country’s strengths in diversifying mining, processing, and refining while pursuing alternatives to materials with high supply chain risks and supporting increased recycling and circular economy approaches.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2026

Building Energy Analysis of Manufactured and Multifamily Housing Types in Juneau, Alaska

This report details the results of building energy modeling analysis evaluating the potential energy savings, economic outcomes, and grid-level electricity reduction associated with cold climate air source heat pump (ccASHP) adoption across multifamily and manufactured housing (MMFH) building typologies in the City and Borough of Juneau (CBJ). Three building archetypes were evaluated: multifamily 4-plex apartments, multifamily 8-plex apartments, and manufactured housing units. Building energy models were developed using OpenStudio-HPXML and calibrated to actual utility consumption data and local meteorological data from the Juneau International Airport weather station using an automated calibration tool following the BPI-2400-S-2015 v.2 standard for model calibration. Occupant behaviors present the greatest variability in successful calibrations. Calibrated models were benchmarked against a baseline electric resistance heating condition, with the selected ccASHP modeled as the retrofit condition and typical meteorological year weather data for all results generation.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

NASA NTRS1980

Application of imaging and ultrasound to the quality grading of beef

The results of a study conducted to assist the Department of Agriculture in the task of considering innovative methods for the grading of carcass beef for human consumption is presented. The processing of photographic, television and ultrasound images of the longissimus dorsi muscle at the 12/13th rib cut was undertaken. The results showed that a correlation could be developed between the quality grade of the carcass as determined by a professional grader, and the fat to area ratio of the muscle as determined by image processing techniques. In addition, the use of ultrasound shows the potential for grading of an unsliced carcass or a live animal.

Anselmo, V. J.↗

NASA NTRS2006

High Tensile Strength Amalgams for In-Space Fabrication and Repair

Amalgams are well known for their use in dental practice as a tooth filling material. They have a number of useful attributes that include room temperature fabrication, corrosion resistance, dimensional stability, and very good compressive strength. These properties well serve dental needs but, unfortunately, amalgams have extremely poor tensile strength, a feature that severely limits other potential applications. Improved material properties (strength and temperature) of amalgams may have application to the freeform fabrication of repairs or parts that might be necessary during an extended space mission. Advantages would include, but are not limited to: the ability to produce complex parts, a minimum number of processing steps, minimum crew interaction, high yield - minimum wasted material, reduced gravity compatibility, minimum final finishing, safety, and minimum power consumption. The work presented here shows how the properties of amalgams can be improved by changing particle geometries in conjunction with novel engineering metals.

Grugel, Richard N.↗

DOE OSTI2024

Electrodialysis and nitrate reduction (EDNR) to enable distributed ammonia manufacturing from wastewaters

Underutilized wastewaters containing dilute levels of reactive nitrogen (Nr) can help rebalance the nitrogen cycle. This study describes electrodialysis and nitrate reduction (EDNR), a reactive electrochemical separation architecture that combines catalysis and separations to remediate nitrate and ammonium-polluted wastewaters while recovering ammonia. By engineering operating parameters (e.g., background electrolyte, applied potential, electrolyte flow rate), we achieved high recovery and conversion of Nr in both simulated and real wastewaters. The EDNR process demonstrated long-term robustness and up-concentration that recovered >100 mM ammonium fertilizer solution from agricultural runoff that contained 8.2 mM Nr. EDNR is the first reported process to our knowledge that remediates dilute real wastewater and recovers ammonia from multiple Nr pollutants, with an energy consumption (245 MJ per kg NH 3 –N in simulated wastewater, 920 MJ per kg NH 3 –N in agricultural runoff) on par with the state-of-the-art. Demonstrated first at proof-of-concept and engineered to technology readiness level (TRL) 4–5, EDNR shows great promise for distributed wastewater treatment and sustainable ammonia manufacturing.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Enhancing nitrogen fixation efficiency in glow-like discharge by reducing cathode-fall voltage

In plasma nitrogen fixation devices, discharge electrodes are crucial yet susceptible to oxidation and corrosion due to plasma’s high temperatures and oxygen content, which could alter discharge modes. This research evaluates the impact of different electrode materials, including iron, chromium, nickel, copper, and 304 stainless steel, on nitrogen fixation efficiency in glow-like discharges driven by high-voltage DC power. Notably, iron and 304 stainless steel cathodes undergo a mode transition at increased currents, evident from plasma color shifts and significant voltage reductions. Fourier transform infrared spectroscopy analyses reveal that such mode changes minimally affect nitrogen oxide production rates, leading to a notable decrease in energy consumption for nitrogen fixation by up to 40%. OES and SEM-EDS measurements suggest that iron oxide, with its higher secondary electron emission, replaces metal as the cathode material, facilitating mode transitions and maintaining discharge current at lower voltages. Further, this voltage change is largely attributed to the cathode voltage drop, highlighting the minimal role of the cathode fall region in NO x synthesis. These findings underscore the potential for improving plasma nitrogen fixation energy efficiency by choosing suitable cathode materials to lower the cathode-fall voltage.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

A Bi-Layer Dense/Porous Solid Electrolyte Interphase for Enhanced Lithium-Metal Stability

Due to its high theoretical capacity and low electrochemical potential, lithium metal is a highly investigated anode for next-generation high-energy batteries. However, the unstable chemical and topographical heterogeneous surface of lithium gives rise to safety and efficiency concerns that prevent it from being utilized in practical applications. Exposure to electrolyte leads to non-uniform, mixed organic-inorganic solid-electrolyte interphase (SEI) formation, starting a cascading to non-uniform flux distribution, consumption of active materials, and dendrite growth. The SEI is the key feature that will lead to harnessing the capabilities possible with lithium metal. In this work, the formation of a closed-host bi-layer solid electrolyte interphase (SEI) improves the stability of lithium anode. This is successfully realized by forming an interconnected porous LiF-rich artificial SEI in contact with Li metal, and a dense, stable in-situ formed upper layer SEI. The porous layer increases the number of Li/LiF interfaces, which reduces local volume fluctuations and improves Li+ diffusion along these interfaces. Additionally, the tortuous porous structure guides uniform Li+ flux distribution and mechanically suppresses dendrite propagation. The dense upper layer of the SEI accomplishes a closed-host design through reaction with LiNO3 additive and prevents continuous consumption of active materials seen without the additive included in the electrolyte. The duality of a dense top layer with porous bottom layer led to extended cycle life and improved rate performance, evidenced with symmetric cell testing, as well as full cell testing paired with sulfur and LiFePO4 (LFP) cathodes. This work is a good example of a rational design of the SEI, based on comprehensive consideration of various critical factors to improve Li-metal anode stability, and highlights a new pathway to improve cycling and rate performances of Li metal batteries.

25 ENERGY STORAGE↗

DOE OSTI2020

Sensor Impacts Evaluation and Verification: Expert Interview Responses

The sensor configuration/deployment method has critical impacts on energy efficient building control and thermal comfort. However, traditional sensor techniques for building operation and fault detection and diagnostics (FDD) are not necessarily optimal in terms of energy efficiency and thermal comfort, and their global effects are not thoroughly investigated. In an effort to address and overcome this limitation, a multilaboratory and multiyear project, “Sensor Impact Evaluation and Verification,” was proposed. Its purpose is to develop a framework to investigate the impacts of sensor deployment and configuration on building energy optimization, FDD, occupant thermal comfort, and potentially grid efficiency. The first project task was a literature review to establish a solid knowledge of and a background related to sensor technologies and placement. To accomplish this task, an extensive review of previous research literature was performed. A series of expert interviews were conducted to augment the findings of the literature review. This report summarizes the interview design and interview results and findings. The interview was designed and performed to (1) investigate the current status and limitations of sensor configuration, (2) identify the research gaps and expectations for potential improvements in sensor configuration and deployment, and (3) integrate expert (e.g., researcher, building operation practitioner) knowledge and experience to develop use-case scenarios.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS1982

JT90 Ceramic Outer Air Seal System Refinement Program, Phase 2

The sprayed ceramic gas turbine outer air seal system was tested in two JT9D engines to substantiate the abradability and durability of the seals. Of particular significance was that one of the tests, a 150 hour 1000 cycle endurance program at nominal JT9D operating conditions, was completed with minimal effect on the seals and received Federal Aviation Administration cognizance with respect to potential field service use by the airlines. The other engine test completed 1825 endurance cycles at severe operating conditions and no burn through or other serious defects in the structural integrity of a seal segment was observed. These test results combined with other Pratt and Whitney Aircraft engine tests substantiate the potential of the ceramic outer air seal system to attain the durability goal of 50000 hour engine operating capability. Both engine tests subjected the seals to intentional blade rubs and demonstrated good abradability with volume wear ratios greater than 100, far exceeding the design goal of 10. The improved volume wear ratio will allow the turbine tip clearance to be reduced, thereby resulting in an estimated thrust specific fuel consumption improvement of 0.3 percent.

Shiembob, L. T.↗

NASA NTRS1987

The supersonic through-flow turbofan for high Mach propulsion

A study was done to evaluate the potential improvements in aircraft turbine engine performance by incorporating unique supersonic through-flow fans. Engine performance, weight, and mission studies were carried out for conventional turbofan engines using supersonic through-flow fans. A Mach 3 commercial transport mission was considered. The advantages of the supersonic fan engines were evaluated in terms of mission range comparisons between the supersonic fan engines and conventional engines. The installed specific fuel consumption of the supersonic fan engines was 12 percent better than the conventional engines and the installed weight was projected to be 25 percent lighter. For a takeoff gross weight of 550,000 lbs, the aircraft powered by supersonic fan engines had a range capability of 6600 nm compared to 5300 nm (a 25% improvement) for conventional engines.

Franciscus, Leo C.↗

NASA NTRS1987

The supersonic through-flow turbofan for high Mach propulsion

Franciscus, Leo C.↗

NASA NTRSDate not supplied

Combining Disparate Measures of Metabolic Rate During Simulated Spacewalks

Scientists from NASA's Extravehicular Activities (EVA) Physiology Systems and Performance Project help design space suits for future missions, during which astronauts are expected to perform EVA activities on the Lunar or Martian surface. During an EVA, an astronaut's integrated metabolic rate is used to predict how much longer the activity can continue and still provide a safe margin of remaining consumables. For EVAs in the Apollo era, NASA physicians monitored live data feeds of heart rate, O 2 consumption, and liquid cooled garment (LCG) temperatures, which were subjectively combined or compared to produce an estimate of metabolic rate. But these multiple data feeds sometimes provided conflicting estimates of metabolic rate, making real-time calculations of remaining time difficult for physician/monitors. Currently, designs planned for the Constellation Program EVAs utilize an automated, but largely heuristic methodology for incorporating the above three measurements, plus an additional one - CO 2 production, ignoring data that appears in conflict; however a more rigorous model-based approach is desirable. In this study, we show how principal axis factor analysis, in combination with OLS regression and LOWESS smoothing can be used to estimate metabolic rate as a data-driven weighted average of heart rate, O 2 consumption, LCG temperature data, and CO 2 production. Preliminary results suggest less sensitivity to occasional spikes in observed data feeds, and reasonable within-subject reproducibility when applied to subsequent tasks. These methods do not require physician monitoring and as such can be automated in the electronic components of future space suits. With additional validation, our models show promise for increasing astronaut safety, while reducing the need for and potential errors associated with human monitoring of multiple systems.

Alan H Feiveson↗

DOE OSTI2023

Techno-Economic Analysis of Dynamic Building Envelopes Comprising Phase Change Materials and Switchable Insulations: Preprint

Integrating phase change materials (PCMs) in building envelopes is a recognized technique to reduce the space heating/cooling loads and provide load shedding and shifting capacity. However, PCM benefits have been found to reduce dramatically with increase in the insulation requirements. Dynamic building envelopes that can alter their thermal resistance based on the indoor and outdoor conditions can effectively harness free ambient heating/cooling, thereby greatly enhancing the benefits of the PCM-integrated envelope in managing thermal loads. In this study, we examine various combinations of PCMs and switchable insulations and compare their combined impact on heat flow through the building envelope. Using numerical analysis, we investigate the PCM- and switchable insulation-integrated building walls, calculate the potential energy saving benefits compared to the conventional static walls, and finally perform technoeconomic analysis to estimate the acceptable cost of the technology under various payback period scenarios.

dynamic building envelopes↗