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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 1,423 records · Page 79
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Joining Study for Formed Plate Heat Exchangers (Final Report)

Plate heat exchangers (PHEs) have been used in numerous industrial applications, such as HVAC systems, power generation, transportation and manufacturing. The performance of plate heat exchangers is frequently undermined by corrosion, fouling, and scaling. These phenomena not only diminish heat transfer efficiency but also lead to increased operational costs, maintenance demands, and reduced equipment lifespan. In this project, the team addressed the widespread challenges of corrosion, fouling, and scaling, and explored alternative material solutions. While commonly used materials like stainless steel and titanium offer notable benefits, they can still experience corrosion under certain operating conditions. The advancement of new materials and surface engineering technologies, such as advanced coating, ceramics, composites materials, and high entropy alloys are promising for can help solve these issues, enable longer lifetime and high performance of plate heat exchangers.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Cost Projections for Utility-Scale Battery Storage: 2025 Update

In this work we describe the development of cost and performance projections for utility-scale lithium-ion battery systems, with a focus on 4-hour duration systems. The projections are developed from an analysis of recent publications that include utility-scale storage costs. The suite of publications demonstrates wide variation in projected cost reductions for battery storage over time. We present the suite of projected cost reductions collected from the literature as well as the low, mid, and high cost projections developed in this work. Storage cost projections are $\$$152/kWh, $\$$247/kWh, and $\$$349/kWh in 2035 and $\$$111/kWh, $\$$184/kWh, and $\$$333/kWh in 2050 for the low, mid, and high cases respectively. Battery variable operations and maintenance costs, lifetimes, and efficiencies are also discussed, with recommended values selected based on the publications surveyed.

25 ENERGY STORAGE↗
DOE OSTI2025

Scalable Unit Commitment with Security Constrained AC Power Flow via ADMM and Hybrid Modeling Strategies

This research introduces a more efficient way to optimize power grid operations, breaking the problem into manageable steps and using advanced mathematical techniques to speed up calculations. By incorporating smart heuristics, improved preprocessing, and contingency analysis, the approach allows operators to make better decisions faster. These innovations enhance our understanding of how to optimize energy generation, making it possible to anticipate failures before they happen, reduce system costs, and improve overall grid performance. Ultimately, this research helps bridge the gap between theoretical models and real-world applications, paving the way for a smarter, more resilient power grid. This research directly benefits the public by making electricity more affordable, reliable, and sustainable. By improving how power grids schedule and distribute electricity, the project helps energy providers reduce operational costs, which can lead to lower electricity prices for consumers. Additionally, the ability to predict and prevent power system failures enhances grid reliability, reducing the likelihood of blackouts that can disrupt homes, businesses, and critical infrastructure such as hospitals. From an environmental perspective, optimizing power generation reduces energy waste and lowers carbon emissions, contributing to cleaner air and a more sustainable energy system. Furthermore, with extreme weather events becoming more frequent, these advancements make the power grid more resilient, ensuring communities are better prepared for emergencies and natural disasters. By strengthening the nation's energy infrastructure, this research plays a crucial role in improving economic stability, public safety, and environmental sustainability.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2024

Microstructure Optimization and Novel Processing Development of ODS Steels for Fusion Environments (Final ARPA-E Report)

This project aimed to develop scalable, cost-effective fabrication of high-performance, oxide- dispersion-strengthened (ODS) steel using advanced manufacturing methods (AMMs) for fusion blanket-breeding applications. Gas atomization reaction synthesis (GARS) enables the synthesis of precursor ODS steel powders without prolonged mechanical alloying. This process creates a chromium (Cr)-enriched surface oxide with yttrium/titanium (Y/Ti)-enriched intermetallics in powder interiors. GARS powders were consolidated to >99% of the theoretical density using a first-of-a-kind shear assisted processing and extrusion (ShAPE) and laser-based powder bed fusion (L-PBF) AM processes. These processes led to ODS steels containing a high-density of nano-oxide dispersoids that enhance high-temperature mechanical properties. Such scalable, cost-effective fabrication of ODS steels can enable efficient power conversion cycles (=40%) at operating temperatures beyond 900 K in future fusion power plants.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Web-Based Tools for Data-Informed Remedy Optimization: Software Theory and User Guide

This report documents the development and application of two web-based decision-support tools for pump-and-treat (P&T) groundwater remediation systems: PTOLEMY (Pump-and-Treat Optimized Location Evaluation to Maximize Yields) and OPTIMA (Optimization for Pump-and-Treat Implementation, Management, & Assessment). These tools enhance remedy design and management by leveraging advanced computational methods – specifically deep learning and multi-objective optimization – within a user-friendly platform. By integrating data-driven models with established hydrogeological knowledge, PTOLEMY and OPTIMA enable more efficient evaluation of well placement and operational strategies, helping site managers balance multiple remediation objectives under complex conditions. Both tools are implemented as modules within the SOCRATES (Suite Of Comprehensive Rapid Analysis Tools for Environmental Sites) web platform, which provides data access, visualization, and analytics to support remedy optimization across sites in the U.S. Department of Energy Office of Environmental Management complex. PTOLEMY is a rapid screening module designed to identify promising locations for new extraction wells. It employs a multi-channel three-dimensional convolutional neural network (MC3D-CNN) trained on high-fidelity simulation data to predict the relative performance (in terms of contaminant mass recovery) of potential well sites. Through an interactive web interface, PTOLEMY visualizes the probability of high performance across a site, highlighting areas where an extraction well is likely to yield above-threshold contaminant removal over a multi-year period. PTOLEMY’s map-based displays and exportable results support transparent communication of screening analyses. By focusing attention on the most favorable candidate locations, the tool augments traditional engineering judgment and physics-based modeling, providing a data informed basis for subsequent detailed evaluations. OPTIMA is a multi objective optimization module designed to find wellfield layouts and operating schedules that meet various cleanup goals. It quickly evaluates thousands of candidate setups – combinations of well locations, timing, and rates – and returns a small set of best trade-off options for comparison. At its core, OPTIMA uses a U-Net-based surrogate model – a deep-learning emulator of a groundwater flow and transport simulator – to dramatically accelerate scenario evaluations. Coupling this fast surrogate with the NSGA-II (Non-dominated Sorting Genetic Algorithm II) evolutionary algorithm, OPTIMA explores a wide decision space of well locations and schedules to identify Pareto-optimal solutions that trade off key objectives (e.g., minimizing cleanup time, maximizing contaminant mass removal, and minimizing plume extent). The tool outputs a family of optimal configurations and visualizes their trade-offs (Pareto frontiers of cleanup metrics and maps of optimized well placements). Site managers can use these results to understand the range of viable strategies and to select candidate designs for more detailed verification. OPTIMA is currently under active development and not yet fully released; this guide provides early documentation to support planning and gather user feedback.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Port Technical Assistance Program: A Proposed Initiative to Support U.S. Ports Through Energy Innovation

This document highlights the crucial importance of the maritime sector within the United States (U.S.) economy, serving as a key node for trade and global goods transportation. U.S. ports are currently grappling with challenges posed by rising shipping demands, the health impacts of diesel fuel reliance, and the technology adoptions of global trade partners due to increasing environmental regulations. This document proposes forming a technical assistance program, led by Pacific Northwest National Laboratory (PNNL), to help U.S. ports transition to sustainable energy solutions that not only improve environmental and community outcomes, but also enhance resilience to unexpected weather events and reduce pressure on local utilities. Coordinated by PNNL, this initiative would offer a web-based platform of consolidated resources and tools for comprehensive strategic planning and cost-benefit analysis. It also seeks to establish a collaborative network between ports and national laboratories to facilitate the sharing of best practices. The document suggests that optimizing resource allocation and providing tailored support could be achieved through strategic categorization of ports within this network, with relevant attributes and examples detailed in the report. The anticipated benefits of such a program could include increased efficiency and cost savings in port operations and the advancement of scientific innovation via alternative energy research. Also, it could enhance economic growth and competitiveness in international trade by enabling ports to meet shipping demands and develop resilient critical infrastructure through informed, long-term strategies.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

Ultra-High Operation Temperature SiC-matrix Solar Thermal Air Receiver (HOTSSTAR) enabled by additive manufacturing: Test Facility & Performance Evaluations

Solar Heat for Industrial Processes (SHIP) cavity receivers are capable of generating electricity or industrial process heat by absorbing thermal energy from solar radiation, focused on a small area. The concentration of solar radiation on the small area of the receiver enables the achievement of high temperatures (ranging from 400°C to 1,100°C) of a working fluid, thus making the SHIP technology thermodynamically comparable with conventional power plants. A volumetric receiver consists of a porous structure-generally made of silicon carbide or metal, which absorbs solar radiation and converts it into heat energy. Heat energy from the porous materials is then transferred to the fluid following through them. A volumetric receiver acts as a convective heat exchanger, transferring heat to the fluid through convection. Open-loop volumetric receivers work with air at atmospheric pressure and are suitable for single-cycle or multi-cycle energy plants. A Model Based Systems Engineering (MBSE) approach was used to develop a test bed at Sandia national Laboratories (SNL) capable of demonstrating an open-loop volumetric air receiver developed by General Electric Aerospace (GE Aerospace). This paper presents the development of the various MBSE methods, test bed, and testing operations for the GE air receiver, which was experimentally demonstrated to achieve 1,350°C for over 3 hours of operation and an approximate 70% receiver efficiency. By being able to achieve such high temperatures >1,000°C, this work provides the potential to support many SHIP industrial use cases.

14 SOLAR ENERGY↗
DOE OSTI2026

Online and Offline Analytical Techniques to Quantify Chloride Salts

This report serves as the deliverable for Milestone- M3FT-26AN080502017: Summary of Accomplishments for Online and Offline Analytical Qualification of Chloride Fuel Salts. The qualification of chloride fuel salts is a critical challenge for the development and deployment of molten salt reactors (MSRs), requiring precise control and verification of chemical and isotopic composition to ensure predictable neutronics, manageable radiological behavior, and safe plant operation. Currently, there is no universally accepted standard for fuel salt qualification, particularly for chloride-based systems, which underscores the need for robust, science-based analytical methodologies. This report presents a comprehensive evaluation of both online and offline techniques for quantifying chloride fuel salts, including multielectrode array voltammetry, differential thermal analysis (DTA) probes, inert gas fusion (IGF) analyzers, and gamma spectrometry using the Mirion NAIS-2x2 NaI(Tl) detector. The integration of these methods enables real-time monitoring of actinide concentrations, redox state, and thermophysical properties, as well as high-precision measurement of impurities and isotopic composition. The acquisition of advanced instruments such as the Bruker Leonardo G6 for IGF and the Mirion NaI detector enhances analytical capabilities, supporting the establishment of operational envelopes and impurity thresholds. These approaches provide essential data for neutronic impact evaluation, feedstock documentation, and compliance with nuclear safety standards. The methodologies developed and validated in this report lay the groundwork for future standardized protocols, bridging the gap between laboratory research and commercial reactor operation, and advancing the safe and efficient deployment of chloride-fueled MSRs.

Polke, Amber↗
DOE OSTI2025

P2P: Point Cloud to Panel Layout Optimization

Building envelope retrofits, despite their benefits on enhancing energy efficiency, progress slowly due to high operating costs. Overclad panelized systems present an attractive solution to make retrofits affordable and easy to install. However, several stages of the retrofit process remain disconnected, suboptimal, and require significant human intervention. This study aims to bridge the gap between digital twin generation and overclad panel installation by automating the design of an optimal panel layout directly from a building envelope point cloud. In this end-to-end approach, the dimensional twin is generated by segmenting the facade point cloud. The facade then undergoes a three-step process to generate an optimized panel layout for integration with automated placement systems.

Philips, Nisha Deborah [ORNL]↗
DOE OSTI2019

Design and implementation of a real-time underwater acoustic telemetry system for fish behavior study and environmental sensing

Underwater acoustic telemetry is an important tool for studying the behavior of aquatic animals and assessing the environmental impact of man-made structures such as water power turbines. However, current design of the acoustic telemetry system lacks the ability to transmit collected data continuously in real-time and requires manual retrieval of the recorded measurements, leading to a long delay of data retrieval, high operational cost associated with manpower as well as safety risk for the operators. In addition, there is no efficient way to monitor the status of the acoustic telemetry system, including acoustic transmitters and receivers. For example, if multiple receivers in an array fail, the detection efficiency could be significantly reduced. Herein, we developed a cloud-based, real-time underwater acoustic telemetry system that can be used to estimate behavior or survival of tagged aquatic animals and monitor environmental parameters in near-real-time (< 2 hours). The system incorporates microcontrollers and integrated circuits to create real-time data communication and processing units with a cloud-based service that processes the transmitted data stream to derive behavior and survival information of the tagged animals.

Yang, Yang↗
DOE OSTI2025

Numerical Simulation Studies of Ultrasonic De-Icing for Heating, Ventilation, Air Conditioning, and Refrigeration Structures

Ice accumulation on heating, ventilation, air conditioning, and refrigeration (HVACR) structures presents significant operational challenges. These challenges include reduced efficiency, increased energy consumption, and potential damage to equipment. Traditional de-icing methods, such as chemical treatments, mechanical scraping, or heating-based techniques, are often labor-intensive, costly, and environmentally harmful. Here, this study uniquely investigates ultrasonic de-icing as an energy-efficient alternative for HVACR applications, focusing on the specific structural geometries found in these systems. A comprehensive numerical simulation framework was developed using finite element analysis to explore ultrasonic wave propagation across four distinct HVACR structures. Key parameters such as ultrasonic frequency, power levels, and the number and placement of actuators were examined for their impact on ice detachment efficiency. Results from simulations on a plate structure reveal that ultrasonic excitation can propagate effectively across large areas (at least 150 × 150 mm), enhancing the de-icing coverage. Lower frequency (e.g., 30 to 45 kHz) excitation results in greater displacement, improving de-icing performance, while increased actuator numbers with the same total power input also enhance effectiveness. Two actuators seem sufficient for the de-icing of a 300 × 300 mm plate. For tube-and-fin structures, specific high-power ultrasonic frequencies selectively excite the fin plates, demonstrating efficient ice removal when actuated on the tube. However, optimal performance requires careful design of actuator placement and vibration modes to accommodate the irregular shapes of these structures.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Simulator for Hydrologic Unstructured Domains (SHUD v1.0): numerical modeling of watershed hydrology with the finite volume method

Abstract. Hydrologic modeling is an essential strategy for understanding and predicting natural flows, particularly where observations are lacking in either space or time or where complex terrain leads to a disconnect in the characteristic time and space scales of overland and groundwater flow. However, significant difficulties remain for the development of efficient and extensible modeling systems that operate robustly across complex regions. This paper introduces the Simulator for Hydrologic Unstructured Domains (SHUD), an integrated, multiprocess, multiscale, flexible-time-step model, in which hydrologic processes are fully coupled using the finite volume method. SHUD integrates overland flow, snow accumulation/melt, evapotranspiration, subsurface flow, groundwater flow, and river routing, thus allowing physical processes in general watersheds to be realistically captured. SHUD incorporates one-dimensional unsaturated flow, two-dimensional groundwater flow, and a fully connected river channel network with hillslopes supporting overland flow and baseflow. The paper introduces the design of SHUD, from the conceptual and mathematical description of hydrologic processes in a watershed to the model's computational structures. To demonstrate and validate the model performance, we employ three hydrologic experiments: the V-catchment experiment, Vauclin's experiment, and a model study of the Cache Creek Watershed in northern California. Ongoing applications of the SHUD model include hydrologic analyses of hillslope to regional scales (1 m2 to 106 km2), water resource and stormwater management, and interdisciplinary research for questions in limnology, agriculture, geochemistry, geomorphology, water quality, ecology, climate and land-use change. The strength of SHUD is its flexibility as a scientific and resource evaluation tool where modeling and simulation are required.

58 GEOSCIENCES↗
DOE OSTI2019

Flow Characterization of Compressed Woody Biomass

Global interest for using terrestrial biomass as an energy source has been increasing recently due to potentially significant socio-economic and environmental benefits relative to fossil energy. Thermochemical biomass processes converting biomass to fuels are relatively well developed, e.g. for direct combustion, gasification, and pyrolysis. However, critical problems often arise when attempting to feed biomass into commercial-scale reactors continuously and without interruption. Biomass particles, whether derived from woody or agricultural feedstock, vary greatly in size, shape, density, and moisture content. High cohesiveness, low bulk density, and poor material flow characteristics often prevent continuous feeding due to bridging, rat-hole formation, blockage, and seal failures. Among all different types of feeders utilized to feed biomass into reactors, screw feeding has received significant attention in recent years. Screw feeders are fuel-specific and require careful design to be reliable, efficient, and economical, especially for reactors operating at elevated pressures. In order to mimic the flow properties of compressed biomass inside a compression-screw feeder, rheological properties of three types of compressed lignocellulosic biomass were investigated using a co-rotating twin screw microcompounder. Experiments were conducted to find the impact of moisture content, particle size and type, and screw speed on rheological properties of forest residual particles as well as sawdust. Increasing moisture from 10 to 50% reduced the apparent viscosity of the compressed biomass. Also, higher screw speeds (10 to 90 rpm) led to a lower relative viscosity. At elevated screw speeds, significant temperature differences were measured between the initial and final states, which should be accounted for in equipment design and operation.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

Semi-automated Design of Artificial Intelligence Earth Science Models

Prediction and observation of water cycles involve not only patterns isolated in space and time, but rather modeling complex spatio-temporal relationships across multiple sources of data and domains. For instance, Evapotranspiration (ET) and Leaf Area Indexes (LAI) are two critical components in DOE’s Energy Exascale Earth System Model (E3SM). Accurate assessments of ET and LAI are critical for understanding hydrological processes, deforestation, crop yield, and irrigation impacts. However, current ET estimates for global simulations are available at very coarse spatial resolution. They are usually derived from satellite data based on broad plant functional types (PFT), which fail to capture the fine-scale variations due to change in vegetation type across the globe. Within this context and in light of the data-model integration challenges highlighted in the EESSD Strategic Plan, the new era of AI model development for geosciences calls for data-driven methods that provide domain scientists with estimations of parameters such as PFT and LAI in an efficient, interpretable, and easy-to-operate manner.

Ambrozio Dias, Philipe↗
DOE OSTI2021

Development of Integrated Mechanical Pods

This presentation highlights early wins, updated progress, and upcoming developments on ‘national-scale shared development platform’ for rapid prototyping, testing and validation of various integrated Mechanical Pod solutions and form factors. Such pod solutions consist of a set of all-electric heat pump mechanical equipment that have integrated functionalities through built-in controls, with heating, cooling, hot water, ventilation (including energy recovery), electrical management, and battery storage within a single package. The presentation draws inspiration from the success of bathroom pods in the US modular construction industry, UK’s efforts with unitizing mechanical systems as ‘utility cupboards’, and VEIC’s early wins in design-build of all-electric Mechanical Pod solutions in Vermont. The presentation includes researchers and partners involved with NREL in Design for Manufacturing and Assembly (DfMA), Virtual Design and Construction (VDC), and digital twin based process optimization modeling of integrated Mechanical Pod solutions. The presentation aims to highlight early wins from such a platform and how various physical and virtual tools are currently being employed as part of NREL’s ongoing multi-year project funded by US DOE. Streamlined procurement, coordination, installation, and O&M of Mechanical Pods such that the majority of work is delegated to the off-site modular factory implies monetary savings. Such a seemingly basic shift in location of the construction process leads to great reduction in complexity, first cost, lead time, and waste, and greater opportunities for innovative compartmentalization and integration of mechanical systems appropriately sized for each apartment or hotel guest room. However, past studies on unitized combination systems show that high installation costs, maintenance issues, challenges with system integration, limitations in existing electrical infrastructure, and lack of architecturally appealing solutions are key barriers. NREL and partners aim to address key barriers through DfMA approach, rapid prototyping and testing, and digital twin process optimization modeling. The presentation is also a call for interested entities to partner with NREL as part of the national-scale development platform, help drive both product and process innovation, and encourage open source sharing of learnings. Learning objectives include (1) learn about the vision of national-scale shared development platform for process-product innovation on integrated mechanical pod solutions and how to get involved, (2) gain an understanding of the components of an all-electric, high performance home, design characteristics and equipment included in an all-electric mechanical pod, integration of mechanical systems within a modular factories’ assembly line, and the system’s commissioning, operation and maintenance. The pre-planning and coordination with the factory and sub-contractors are also highlighted, (3) gain an understanding of using process modeling tools to quantify resource-constrained performance of operations (such as integration of energy efficiency strategies) to manufacture modules of varying design, (4) gain insights on virtual design, rapid prototyping, and emulated testing of various form factors across different climatic conditions. The need for such preliminary testing with open source sharing of learnings will also be highlighted.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2022

Mechanical Characterization of Loblolly Pine

Biorefineries are faced with various material flow challenges during feeding and handling, due to inherent variability and inhomogeneity of biomass feedstocks. This impacts the efficiency of refinery processes and unit operations. Proper characterization of bulk properties allows for optimal process design and reduction of overall costs. This work is aimed at evaluating the physical and mechanical properties that impact bulk flow of loblolly pine. Cyclic axial compression tests are performed to elucidate consolidation behavior under different stress conditions. The results are then used to develop correlations between material parameters (particle size, tissue type, moisture content) and Elastic Modulus of bulk samples.

09 BIOMASS FUELS↗
DOE OSTI2022

Alkyl dialkoxyalkanoates as bioderived, high cetane diesel fuels

A fuel for an internal combustion engine includes a C 5 to C 30 dialkoxyalkanoate corresponding to formula (I), wherein the R 1 group is —H or a —CH 3 group, the R 2 and R 2 ′ groups are alkyl groups independently selected to have 1 to 9 carbon atoms; and the R 3 group is selected to have 1 to 9 carbon atoms. The compounds described herein may be used as neat fuels or mixed fuels (with diesel, biodiesel, jet fuel, marine fuel or other fuel compounds) in autoignition or spark ignition engines, such as diesel engines, gasoline (spark ignition) engines, MCCI, Homogeneous Charge Compression Ignition (HCCI) engines, or more generally in Low-Temperature Gasoline Combustion (LTGC) engines (using gasoline-like fuels), that have the high-efficiency advantages of HCCI but can operate with some level of charge inhomogeneities. Methods of making these compounds are environmentally friendly and can be done in a continuous manner.

Myllenbeck, Nicholas↗
DOE OSTI2023

Indirect searches at CMS

In these proceedings, we present several new measurements of Standard Model (SM) processes, in the Higgs sector and beyond, that push the precision frontier forward at CMS. Results are presented in the context of a framework parameterizing deviations in Higgs boson couplings, as well as in the context of SM Effective Field Theory, where new analyses targeting Higgs, top, and multi-boson processes probe an increasingly diverse set of operators. Within these frameworks, CMS is efficiently exploring a large space of new physics models. No significant deviation from SM expectations is found.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗