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All sourcesNASA NTRSDOE OSTI
NASA NTRS2020

Airborne Science Mission Capabilities of the NASA DC-8 and Possible Alternative Aircraft

Age-related concerns associated with operating the 50-year-old NASA Airborne Science Program DC-8 Flying Laboratory aircraft are raising concerns about the prospects of someday retiring the NASA DC-8. Given that eventuality, this study examines how current and anticipated science requirements can be incorporated with aeronautical performance and cost metrics for assessing, comparing, and down-selecting candidate replacement aircraft. A literature review of NASA DC-8 missions and interviews with current DC-8 science users provides context for the initial phase of this study and offers a pathway for collecting aircraft specifications. Performance models are developed and calibrated against published range-payload data for various mission fuel and payload weight combinations. The models are extended to three airborne science missions, with payload weights ranging from 30,000-52,000 lb and mission ranges up to 5,050 nmi. Results point towards the 767-200ER aircraft as a top contender offering a bit more experimenter floor-space, payload capacity, and range than the NASA DC-8, and to the U.S. Navy P-8 aircraft as a viable option offering perhaps not too much less of those items, with the relative benefit of using less fuel per mission.

Thomas A Ozoroski↗
DOE OSTI2025

Resource assessment of ocean thermal energy conversion in Puerto Rico and U.S. Virgin Islands

Island communities often struggle to establish and maintain traditional electric grids and are therefore heavily reliant on costly imported fossil fuels. In the case of Puerto Rico, these challenges are enhanced by extreme weather and other natural hazards that threaten the local electricity generation and transmission infrastructure. Ocean thermal energy conversion (OTEC) could play an important role in establishing a more resilient electrical grid in the region. Here, in this study, a detailed analysis is conducted to characterize the ocean thermal resource and power potential of OTEC in Puerto Rico based on a 14-year dataset of modeled ocean temperature. The assessment considers seasonal and interannual variability in the region's thermal resource and examines the operational limitations associated with minimal thermal gradients required to run a typical OTEC heat engine. Notably, the local thermal resource is found to be sensitive to El Niño-Southern Oscillation (ENSO) climate patterns, with La Niña conditions linked to greater OTEC power availability. Seven areas of opportunity are identified based on their resource potential and proximity to existing electrical distribution lines, including two that could benefit the nearby U.S. Virgin Islands. The greatest OTEC power potential is observed to the south of the main island of Puerto Rico in the Caribbean Sea with an estimated capacity of 138 MW for a plant pumping cold water from a depth of 1,000 m, or the equivalent amount of electricity required to power 219,000 households.

OTEC↗
DOE OSTI2023

Ectomycorrhizal effects on decomposition are highly dependent on fungal traits, climate, and litter properties: A model-based assessment

It has been proposed that competition between ectomycorrhizal (ECM) fungi and free-living saprotrophs for resources like nitrogen (N) slows decomposition and increases the soil carbon storage in ECM ecosystems compared to arbuscular (AM) ecosystems. However, empirical evidence for the generality of such ECM effects is equivocal, and confounding mechanisms have been proposed that affect the magnitude and direction of ECM effects on soil carbon. Here, for this work, we conduct a theoretical modeling experiment, where we explicitly incorporate mycorrhizal processes into the Carbon, Organisms, Rhizosphere, and Protection in the Soil Environment (CORPSE) model. We use the model to explore the conditions under which ECM N acquisition processes can induce stronger saprotrophic N limitation and result in slower decomposition rates and greater soil organic carbon accumulation compared to AM processes. We found that the ECM fungi more strongly inhibited decomposition when litter inputs were N-depleted and relatively recalcitrant and when ECM fungi possessed a strong capacity to mine N from both recalcitrant soil organic matter and microbial necromass. Climate and seasonality also played a role as the ECM competition effect was strongest at low mean annual temperatures and when litterfall peaked seasonally. Priming effects driven by high root exudation rates in ECM-dominated systems could overwhelm the competition effect and reduce soil carbon under some circumstances. The ECM effect on decomposition in our simulations was highly context dependent. Based on our model results, we expect to see a strong ECM competition effect in temperate deciduous and boreal forests with relatively recalcitrant litter inputs, and with ECM fungi that produce oxidases and necromass-degrading enzymes. However, even a relatively strong ECM competition effect on decomposition only increased soil organic carbon accumulation by ~10%.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2021

Chapter 2: Global Value Chain and Manufacturing Analysis on Geothermal Power Plant Turbines

The global geothermal power market has shown significant growth since the last decade and is expected to reach a total installed capacity of 18.4 gigawatts electric (GWe) by the end of 2021 (GEA, 2016). The global geothermal power plant turbine market is dominated by a small number of manufacturers. Between 2005 and 2015, 82% of the geothermal steam turbines were manufactured in Japan, and 74% of the geothermal binary cycle turboexpanders were manufactured in Israel. During this period, the United States played an important role in the global trade flow of fully assembled turbine units and turbine parts, with a high volume of imports and exports. Another significant growth area was in Italian turbine/turboexpander manufacturers, who have increased their market share in the last couple of years. One other important change in the manufacturing market was in Turkey, where the bonus on feed-in-tariff (FIT) for domestic hardware components boosted the national manufacturing sector between 2010 and 2020. When planning geothermal power projects, developers customize their power plant size to fit the available geothermal resource capacity. The turbine is designed and sized to optimize the efficiency and utilization of resource and revenue production. The rest of the power plant components such as heat exchangers (HX), water-cooled cooling towers (WCCT), or air-cooled condensers (ACC) are then chosen to complement the turbine size and design. These one-off manufacturing custom design turbines have relatively higher manufacturing set-up costs, longer lead times, and higher capital costs than the standard design turbines manufactured in larger volumes. However, turbines produced in standard increments and in larger manufacturing volumes could result in lower costs per turbine, but potentially lower efficiency. Based on pipeline projects and resource assessments, there is significant potential value in creating standard turbine sizes that could offer an economic advantage, as is done for modular microturbines.

40 EE - Geothermal Technologies Office (EE-4G)↗
DOE OSTI2023

A Real-Time Degradation Estimation Approach for Batteries in PV and Battery Hybrid Plant Operation

Conventional cyclic degradation assessment for batteries is often limited in its ability to provide real-time degradation information during operation, because the estimation of degradation is commonly performed after a specific evaluation period. Modified methods can provide real-time evaluation but at the cost of high computation complexity. This paper proposes a novel estimation method that addresses these limitations. It efficiently determines the incremental degradation of any two consecutive state-of-charge (SOC) samples during battery operation, thus enabling real-time estimation. To validate the proposed method, measurement data from lithium-ion phosphate (LFP) battery testing was adopted, and the results were compared with the conventional model and the measured capacity. The results demonstrate accuracy over the evaluation period in terms of cumulative degradation, and a reduced computation cost compared with other methods. This approach has benefits in various applications, especially in cases where batteries experience irregular charging and discharging stress cycles such as PV and battery hybrid plants.

Wang, Shumeng↗
DOE OSTI2020

Solar Resource and Infrastructure Assessment for the Town of Wendell

This report is a solar resource and infrastructure assessment for the town of Wendell, Massachusetts. The assessment was funded through the National Renewable Energy Laboratory, Solar Energy Innovation Network (NREL SEIN) Solar in Rural Communities Program, as part of a project to develop a Community-Informed Proactive Solar Siting and Financing Model. As a first step, the project lead organization, UMass Clean Energy Extension prepared an assessment of existing infrastructure, resources, and potential solar development opportunities in participating municipalities, including Wendell. This assessment was designed to describe relevant bylaws and infrastructure within the town, identify the types of solar facilities that could be developed, and quantify the total space available for each type of facility. In this report, we reviewed existing electricity grid infrastructure, and the potential to interconnect additional solar facilities. At the present time, both distribution lines providing electricity to Wendell are over-saturated with authorized and proposed solar projects, and cannot accommodate additional solar projects to interconnect to the grid. It appears that National Grid is planning an upgrade to the Wendell Depot substation, which might then allow in-process projects are to proceed, and potentially free up additional capacity for new, large projects. Meanwhile, most three-phase lines could likely accommodate additional small-to-medium scale projects (under 200 kW), and most single-phase lines could likely accommodate additional projects under 50 kW in size. This description represents the local grid infrastructure as it is - planning for future scenarios of development could include recommendations for areas of grid infrastructure improvement to allow siting of distributed generation in locations preferred by the community. Future scenarios may also include the addition energy storage and other "non-wires alternatives."

14 SOLAR ENERGY↗
DOE OSTI2023

Dependence of predicted bulk properties of hexagonal hydroxyapatite on exchange-correlation functional

Hydroxyapatite (HA) is the main component of human bones and teeth. HA has also been widely applied in various technological fields due to its unique properties. Reliable computational simulations for this critical material often require input parameters obtained from the first-principles density functional theory (DFT) calculations with appropriate exchange–correlation functionals. Previous DFT calculations are insufficient to verify the reliabilities of various functionals, particularly as they fail to assess predictions for multiple properties of the material. In this paper, we first select 18 different functionals to calculate geometric, elastic, electronic, and thermodynamic properties of hexagonal HA bulk crystal. We find that the results from optB86b-vdW and optB88-vdW functionals with dispersion corrections have the overall best agreement with available experimental data. Then, we choose optB88-vdW functional, as well as PBE functional without dispersion corrections as a comparison, to perform extensive first-principles DFT phonon calculations under the quasiharmonic approximation. Various thermodynamic properties (including phonon contributions to internal energy, entropy, and Helmholtz free energy) and thermal parameters (including thermal expansions of volume, thermal expansion coefficients, heat capacities, isothermal bulk moduli, etc.) versus temperature are consequently obtained. By comparing these quantities, we report that the results from optB88-vdW functional have significantly better agreement with available experimental data than those from PBE functional although the latter has been widely used in previous DFT calculations for HA-based material systems.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Secure biosystems design in Saccharomyces cerevisiae establishes effective biocontainment strategies and mechanisms of escape

The widespread application of recombinant DNA and synthetic biology approaches for microbial metabolic engineering pursuits has motivated the development of biocontainment strategies, targeting safe and secure deployment of genetically modified microorganisms (GMMs). However, the design rules and mechanistic drivers governing biocontainment efficacy, as well as impacts of biocontainment upon microbial fitness, remain to be comprehensively evaluated, hindering predictive design and application of these strategies. We have developed a platform for high-resolution analysis of a transactivated kill switch in laboratory and industrial strains of Saccharomyces cerevisiae to assess modes of biocontainment escape and establish design rules for development of kill switch systems in diverse microbes. A camphor-regulated, RelE toxin system was systematically deployed to assess the impacts of differential kill switch copy number and ploidy in laboratory vs industrial strains. CRISPR-mediated integration of the biocontainment system at various loci revealed rapid escape events driven, in part, by mutations to both the Cam-transactivator (cam-TA) and RelE toxin. Genetic engineering enabled recapitulation of escape phenotypes, confirming mechanisms of escape and establishing structure-function relationships in the cam-TA system. Interestingly, genomic resequencing of escape mutants also revealed a series of off-target mutations, implicating additional modes of kill switch escape. Multi-copy integration of the kill switch system mitigated these effects by orders of magnitude, without compromising the biosynthetic capacity of the microbes, but proved insufficient to establish sustained biocontainment. The resultant data define a series of key design rules for next-generation biocontainment strategies and add to a growing foundational knowledge base targeting establishment of secure biosystems designs.

59 BASIC BIOLOGICAL SCIENCES↗
NASA NTRS2016

Evaluation of Dynamic Coastal Response to Sea-level Rise Modifies Inundation Likelihood

Sea-level rise (SLR) poses a range of threats to natural and built environments, making assessments of SLR-induced hazards essential for informed decision making. We develop a probabilistic model that evaluates the likelihood that an area will inundate (flood) or dynamically respond (adapt) to SLR. The broad-area applicability of the approach is demonstrated by producing 30x30m resolution predictions for more than 38,000 sq km of diverse coastal landscape in the northeastern United States. Probabilistic SLR projections, coastal elevation and vertical land movement are used to estimate likely future inundation levels. Then, conditioned on future inundation levels and the current land-cover type, we evaluate the likelihood of dynamic response versus inundation. We find that nearly 70% of this coastal landscape has some capacity to respond dynamically to SLR, and we show that inundation models over-predict land likely to submerge. This approach is well suited to guiding coastal resource management decisions that weigh future SLR impacts and uncertainty against ecological targets and economic constraints.

Climate-change impacts↗
NASA NTRS2019

Characterization of Flat-Plate Heat Pipe Functionality for Fuel Cell Application

For many exothermic systems such as proton exchange membrane (PEM) fuel cells, cooling is necessary to maintain consistent and uniform operating temperatures which are generally in the range of 60 to 80°C. A potential solution is a heat pipe employing the principle of conduction in combination with a phase change. The purpose of this study was to fully characterize the operation of a heat pipe with unique geometry designed for fuel cell heat removal at operating temperatures up to 100°C and to assess the suitability of the resulting performance for cooling system integration. Test variables consist of cold sink thermal contact conductance coefficient improving material usage, heat rejection temperature, contact pressure and area, heat pipe orientation, operational hours, and variability between units. The test results showed that heat pipe performance improves through increased condenser and heat sink contact pressure, thermal contact coating usage, greater condenser area utilization, and colder heat sink temperature. Higher initial heat pipe temperature and greater age or operation time reduce the heat pipe capabilities. Placing the condenser lower than the evaporator is the only heat pipe orientation that affects evaporator plate temperature. Condensing fluid in the lower section reduces heat transfer capacity as that orientation requires liquid water to transport by wicking against gravity.

Smith, Phillip J.↗
DOE OSTI2024

Exogenous erythropoietin increases hematological status, fat oxidation, and aerobic performance in males following prolonged strenuous training

Abstract This study investigated the effects of EPO on hemoglobin (Hgb) and hematocrit (Hct), time trial (TT) performance, substrate oxidation, and skeletal muscle phenotype throughout 28 days of strenuous exercise. Eight males completed this longitudinal controlled exercise and feeding study using EPO (50 IU/kg body mass) 3×/week for 28 days. Hgb, Hct, and TT performance were assessed PRE and on Days 7, 14, 21, and 27 of EPO. Rested/fasted muscle obtained PRE and POST EPO were analyzed for gene expression, protein signaling, fiber type, and capillarization. Substrate oxidation and glucose turnover were assessed during 90‐min of treadmill load carriage (LC; 30% body mass; 55 ± 5% V̇O 2 peak) exercise using indirect calorimetry, and 6‐6‐[ 2 H 2 ]‐glucose PRE and POST. Hgb and Hct increased, and TT performance improved on Days 21 and 27 compared to PRE ( p < 0.05). Energy expenditure, fat oxidation, and metabolic clearance rate during LC increased ( p < 0.05) from PRE to POST. Myofiber type, protein markers of mitochondrial biogenesis, and capillarization were unchanged PRE to POST. Transcriptional regulation of mitochondrial activity and fat metabolism increased from PRE to POST ( p < 0.05). These data indicate EPO administration during 28 days of strenuous exercise can enhance aerobic performance through improved oxygen carrying capacity, whole‐body and skeletal muscle fat metabolism.

Drummer, Devin J.↗
NASA NTRS1982

Utility experience with two demonstration wind turbine generators

Edison has committed 360 MW of nameplate generating capacity to wind energy by year 1990 in its long-range generation plan. To reach this goal the Company's wind energy program focuses on three areas: the continuous evaluation of the wind resource, the hands-on demonstration of wind turbine generators (WTG) and an association with wind park developers. Two demonstration WTGs have been installed and operated at Edison's Wind Energy Center near Palm Springs, California: a 3 MW horizontal axis Bendix/Schachle WTG and a 500 kW vertical axis Alcoa WTG. They are part of a one to two year test program during which the performance of the WTGs will be evaluated, their system operation and environmental impact will be assessed and the design criteria of future WTGs will be identified. Edison's experience with these two WTGs is summarized and the problems encountered with the operation of the two machines are discussed.

Wehrey, M. C.↗
DOE OSTI2026

California Price Response Potential Study

California's energy landscape is undergoing a significant transformation, driven by the increasing integration of renewable energy sources, the increased adoption of distributed energy resources, the electrification of end-use loads, and the growing need for grid efficiency. To address these challenges, recent revisions to the State’s Load Management Standards (LMS) require all of California’s large utilities and community choice aggregators (CCAs) to offer dynamic electricity pricing options to customers by 2027. Dynamic pricing, which involves varying electricity rates based on real-time supply and demand conditions, offers a promising solution for optimizing grid operations, reducing costs, and incentivizing efficient use of grid capacity. Effective implementation of dynamic pricing requires understanding the potential impacts on customer bills, system load, and the cost-effectiveness of automation technologies. This study aims to evaluate the load response of various end-use devices to hourly dynamic prices. The end-uses studied here are space cooling, space heating, water heating, crop irrigation, pool and spa pumps, and electric vehicle (EV) charging, all for both residential and commercial applications, except for crop irrigation. In 2030, these end uses are forecasted to account for 18% of annual electricity demand in the state, but 40% of demand in the peak net load hour. By modeling possible price-responsive load dispatch algorithms and assessing the resulting impacts on both individual bills and the overall grid, we seek to inform policymakers and utilities about the potential benefits and challenges associated with dynamic pricing, and considerations for the design of dynamic pricing tariffs. Additionally, we will explore the cost effectiveness of adopting automation technologies to enable devices to respond more effectively to real-time price signals. This study considers a range of price profiles, accounting for differences across utilities and customer classes, and presents scenarios for dynamic price design via variation in the percentage of total customer electric costs that are allocated dynamically (versus constituting a fixed portion of the hourly volumetric price). We present results focused primarily on 2030, forecasting electricity prices under both low and high-cost scenarios, to inform longer-term tariff design considerations. We design tariffs by starting with 2019 prices that were calculated according to CalFUSE guidance (CPUC, 2022) and that have been used in recent studies; these prices are all-in volumetric rates that vary by utility and are revenue-neutral to each customer class. They are developed by considering six electricity cost components that are allocated hourly based on system load indicators (gross and net load, and wholesale prices). These prices are forecasted to 2030 for low and high cost scenarios, considering recent trends in total electricity costs with and without years of substantial wildfire mitigation investments. These tariffs, which allocate all costs on an hourly basis, are considered our “Full” dynamic tariff design scenario, while two additional scenarios explore allocating a portion of costs as a flat volumetric charge: the “Medium” scenario allocates 50% of revenue dynamically (and keeps 50% flat), while the “Mild” scenario allocates 20% of revenue dynamically. The 20% dynamic allocation on the Mild scenario aims to represent a case where only the marginal operating costs of the grid are included in the dynamic price.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
NASA NTRS2013

Flight Deck Technologies to Enable NextGen Low Visibility Surface Operations

Many key capabilities are being identified to enable Next Generation Air Transportation System (NextGen), including the concept of Equivalent Visual Operations (EVO) . replicating the capacity and safety of today.s visual flight rules (VFR) in all-weather conditions. NASA is striving to develop the technologies and knowledge to enable EVO and to extend EVO towards a Better-Than-Visual operational concept. This operational concept envisions an .equivalent visual. paradigm where an electronic means provides sufficient visual references of the external world and other required flight references on flight deck displays that enable Visual Flight Rules (VFR)-like operational tempos while maintaining and improving safety of VFR while using VFR-like procedures in all-weather conditions. The Langley Research Center (LaRC) has recently completed preliminary research on flight deck technologies for low visibility surface operations. The work assessed the potential of enhanced vision and airport moving map displays to achieve equivalent levels of safety and performance to existing low visibility operational requirements. The work has the potential to better enable NextGen by perhaps providing an operational credit for conducting safe low visibility surface operations by use of the flight deck technologies.

Prinzel, Lawrence (Lance) J., III↗
DOE OSTI2021

Early season prediction of within-field crop yield variability by assimilating CubeSat data into a crop model

Accurate early season predictions of crop yield at the within-field scale can be used to address a range of crop production, management, and precision agricultural challenges. While the remote sensing of within-field insights has been a research goal for many years, it is only recently that observations with the required spatio-temporal resolutions, together with efficient assimilation methods to integrate these into modeling frameworks, have become available to advance yield prediction efforts. Here we explore a yield prediction approach that combines daily high-resolution CubeSat imagery with the APSIM crop model. The approach employs APSIM to train a linear regression that relates simulated yield to simulated leaf area index (LAI). That relationship is then used to identify the optimal regression date at which the LAI provides the best prediction of yield: in this case, approximately 14 weeks prior to harvest. Instead of applying the regression on satellite imagery that is coincident, or closest to, the regression date, our method implements a particle filter that integrates CubeSat-based LAI into APSIM to provide end-of-season high-resolution (3 m) yield maps weeks before the optimal regression date. The approach is demonstrated on a rainfed maize field located in Nebraska, USA, where suitable collections of both imagery and in-situ data were available for assessment. The procedure does not require in-field data to calibrate the regression model, with results showing that even with a single assimilation step, it is possible to provide yield estimates with good accuracy up to 21 days before the optimal regression date. Yield spatial variability was reproduced reasonably well, with a strong correlation to independently collected measurements (R 2 = 0.73 and rRMSE = 12%). When the field averaged yield was compared, our approach reduced yield prediction error from 1 Mg/ha (control case based on a calibrated APSIM model), to 0.5 Mg/ha (using satellite imagery alone), and then to 0.2 Mg/ha (results with assimilation up to three weeks prior to the optimal regression date). Such a capacity to provide spatially explicit yield predictions early in the season has considerable potential to enhance digital agricultural goals and improve end-of-season yield predictions.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Computational Modeling of Heterogeneity of Stress, Charge, and Cyclic Damage in Composite Electrodes of Li-Ion Batteries

Charge heterogeneity is a prevalent feature in many electrochemical systems. In a commercial cathode of Li-ion batteries, the composite is hierarchically structured across multiple length scales including the sub-micron single-crystal primary-particle domains up to the macroscopic particle ensembles. The redox kinetics of charge transfer and mass transport strongly couples with mechanical stresses. This interplay catalyzes substantial heterogeneity in the charge (re)distribution, stresses, and mechanical damage in the composite electrode during charging and discharging. We assess the heterogeneous electrochemistry and mechanics in a LiNi x Mn y Co z O 2 (NMC) cathode using a fully coupled electro-chemo-mechanics model at the cell level. A microstructure-resolved model is constructed based on the synchrotron X-ray tomography data. We calculate the stress field in the composite and then quantitatively evaluate the kinetics of surface charge transfer and Li transport biased by mechanical stresses. We further model the cyclic behavior of the cell. The repetitive deformation of the active particles and the weakening of the interfacial strength cause gradual increase of the interfacial debonding. The mechanical damage impedes electron transfer, incurs more charge heterogeneity, and results in the capacity degradation in batteries over cycles.

25 ENERGY STORAGE↗
DOE OSTI2026

Microchannel-based Membrane-less Extraction of Li from Unconventional Lithium Sources & the Separation of REE

This final report provides an overview of the Project's entire duration, covering July 1, 2021 to December 31, 2023. It primarily focuses on the achievements, technological developments, and unique challenges the team faced while working on separating and extracting Lithium from produced waters. The project's primary aim was to create an integrated, high-throughput, membrane-less, and modular microfluidic platform that could extract Lithium from unconventional sources. We have successfully met all goals and milestones envisioned in the SOPO document. The most critical primary milestones, including the Go-No-Go milestone (refer to the Gantt chart in the Appendices), were successfully accomplished. We demonstrated phase separation (>90%) and extraction (>85%) performance in the MPSE using synthetic, and representative produced water composition feed at 50 ml/min total flow through MPSE 36. We have also performed a parametric study of the MPSE operations, beyond the scope of SOPO, exploring operating conditions of current and broader interest. The extended investigation of operational parameters is concurrent with our efforts to seek further development of the MPSE technology beyond the scope of the Project. Along these lines of development, we have made efforts to be responsive to DOE calls for technological developments of other types of resources (beyond PW) for the recovery of Critical Materials and higher TRL development (beyond TRL 4). During the work on this Project, we developed and implemented three innovative technical approaches that emerged from our efforts to successfully meet the Project milestones. The innovative & original technical approaches developed and implemented in this Project are now the contributions to process engineering that could be clearly credited to the Project. First, Convergent Design Approach is a comprehensive feedforward & feedback loop of four design phases: i) design for functionality, ii) design for manufacturing, iii) design for sustainability, and iv) design for market. Next was Process Intensification. A major aim of this Project was to create an innovative phase separation & extraction microscale-based technology for Li separation – thus the words microchannel-based in the Project title. A microscale-based technology is intrinsically in the center of the Process Intensification domain as defined by its unique principles. Therefore, Process Intensification was implicitly envisioned in the Project’s SOPO. Lastly, Time Scale Analysis is a novel tool for discovering the needs and directions of Process Intensification implementations in any process technology. This Project is fully credited for developing and implementing the three novel technical approaches mentioned above. These are general contributions to process engineering that emerged from this Project. Beyond the original SOPO scope, the OSU-U.Pitt research group utilized a Convergent Design methodology, integrating first-principles mathematical modeling with experimental validation on the Minimum Development Vehicle. By creating these Digital Twins, the team rapidly assessed manufacturing iterations to support TEA analysis. This framework further enabled the development of advanced Surface Modification Techniques, where hydrophobic and oleophobic coating strategies were optimized via Digital Twin tools and validated through rigorous 100-hour longevity testing. TEA Analysis: The closing efforts of this Project were focused on the TEA analysis. TEA analysis had two primary functions: i) enabling critical assessments of design variations withing 10 the Concurrent Design Approach, thus enabling evolution of the MPSE design to reach faster- better-cheaper alternatives; and ii) to create a bridge between the accomplishments of this Project and future projects of higher TRL, beyond TRL 6 level. It is important to note that the TEA model created in the Project stirred the technological solutions for the recovery of critical materials toward a vision of a very profitable modular plant that has unique zero-waste water discharge signature. More importantly, thanks to our experimental performance data and conservative assumptions, the TEA model predicts minimal technological and investment risks. Low cost of a modular unit of a nominal capacity of [1000 tons of Li 2 CO 3 /year] positions the MPSE based technology within the reach of community investors, thus offering a paradigm shift in the development of critical technologies. The project successfully navigated two primary challenges: solvent selection and manufacturing adaptation. Restricted by the SOPO to existing literature for lithium recovery, the team identified a critical need for a "material excellence program" to develop next-generation solvents, eventually concluding with a preliminary investigation into promising Ionic Liquids (ILs). Simultaneously, COVID-19 supply chain disruptions forced a pivot from traditional manufacturing to advanced additive methods at ATAMI-OSU. By transitioning from stainless steel to 3D-printed polymer substrates, the team achieved a transformative three-order-of- magnitude reduction in manufacturing costs and compressed prototyping timelines from several months to just two days. The MPSE technology offers significant energy, environmental, and economic advantages by overcoming the traditional bottlenecks of phase-separation hardware and contactor size. Unlike conventional mixer-settlers or membrane-based systems, MPSE operates without moving parts or fouling-prone membranes, achieving robust performance even with challenging, viscous, or particulate-heavy feeds. Key performance metrics include an energy intensity reduction of 5–50x (3–40 kJ/m 3 ) compared to incumbent technologies and a dramatic reduction of processing time to under 60 seconds, which drastically reduces the physical plant footprint. These technical efficiencies translate into superior economic outcomes; for a 100 t/year Li 2 CO 3 facility, implementing MPSE is projected to nearly halve contactor CAPEX (from $\$$6.08M to $\$$3.01M) and significantly increase the project's Net Present Value (NPV), derisking new investment and enabling distributed critical-mineral processing configurations. The commercialization of MPSE technology is being spearheaded by Vigsur Dynamics Inc., which has adopted a structured, parallel approach to technical and business development since its formation in January 2026. Following extensive customer discovery and engagement with the Oregon State University accelerator, Vigsur Dynamics is working to establish a business model that transitions from pilot demonstrations to modular hardware sales, ultimately aiming for a "build-own-operate" service strategy. Current technical milestones—including 100 hours of continuous operation, superior energy efficiency, and successful 6-unit modular scale-up— provide a foundation for this transition. Backed by ongoing IP licensing and a growing network of industrial and venture advisors, the company is actively de-risking the platform to replace conventional mixer-settler systems in the critical minerals market.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗