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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

The cold high-pressure approach to hydrogen delivery

In view of the very expensive and wasteful nature of today's approaches to H 2 delivery, in this work we explore the possibility of transporting cold (200 K) high pressure (875 bar) H 2 in thermally insulated trailers and dispensing H 2 directly from the trailer, with the potential to eliminate station compressor, cascade, and refrigerator, leading to major reductions in station complexity, maintenance, electricity consumption, and cost, while improving functionality by enabling essentially unlimited back to back refuels, and improving safety due to reduced H 2 expansion energy at low temperature. Detailed techno-economic analysis shows promise for substantial delivery cost reductions through cold high pressure H 2 dispensed directly from the trailer. Results indicate that: (1) Terminal operations for cold high pressure H 2 delivery are $\$$0.32/kg H 2 more expensive than for 350 bar compressed gas delivery (today's lowest cost H 2 delivery technology) due to higher level of pressurization (to 1000 bar) and chilling needs (to 165 K). (2) Trailer cost drops slightly ($\$$0.73 vs. $\$$0.81/kg H 2 for a 350 bar trailer) due to increased capacity (1035 kg H 2 delivered vs. 700 kg) compensating for increased capital cost ($\$$906,900 for cold high pressure H 2 vs. $\$$634,000 for 350 bar trailer). (3) Cold hydrogen delivery presents major advantages in fueling station cost, reduced from $\$$1.27 to $\$$0.46/kg H 2 due to elimination of major system components: compressor, cascade, and chiller. (4) Total compression cost (terminal + station) drops from $\$$0.92/kg H 2 ($\$$0.32 terminal and $\$$0.60 station) for 350 bar trailers to $\$$0.55/kg H 2 (all at the terminal) for cold high pressure H 2 . (5) Elimination of small-scale station compressors is the main contributor to reduced delivery cost due to their inefficiency, capital expense, and maintenance needs. In summary, total delivery cost reduction vs. 350 bar trailer equals $\$$0.58/kg H 2 (from $\$$2.96 to 2.38/kg H 2 ), equivalent to 24% of the total delivery cost. This large cost advantage will improve the economics of H 2 vehicles facilitating the transition to a future of zero emission transportation.

08 HYDROGEN↗
DOE OSTI2026

Filament Extension Atomization for High Solids Loading in Energy Efficient Spray Drying Systems

We demonstrate that we could scale FEA to reach outputs needed by industrial production, while increasing solids loading of the sprayed product by at least 30% and maintaining equal or better spray powder. After testing a wide range of products, in collaboration with industry partners we decided on our primary spray products of dry whey and WPC-80, two common materials processed and sold by US manufacturers with different parameters. We sprayed these with FEA at solids loadings of 70% for dry whey and 45% for WPC-80 with a spray output with particle sizes similar to industrial particles sizes and reduced variation in particle size. We simultaneously scaled up FEA first with a multi-nip with 6 nips surrounding a central roller with parallel axis of rotation and eventually with a tapered design that solved problems we encountered with our initial design. We were able to achieve output from a single array from our first design of up to 4.7 liters per minute (L/min) and from an array of our second multi-nip of 8 L/min exceeding expectations. This demonstrates that FEA technology can indeed be scaled up to meet the needs of industrial production. More arrays can be added as necessary to meet a wide range of spray dryer designs. We also tested FEA to create dried powders from a small scale (10 L/hour of water removal) spray dryer. Though we were not able to produce large quantities of powder from FEA due to challenges in integration, the powder we produced was higher quality and produced from higher solids loading materials. From our technoeconomic analysis we for a typically sized spray dryer, we estimate a 27% cost reduction and 41% energy and carbon reduction for WPC-80 and a 39-57% cost reduction and 52-76% energy reduction for sweet dry whey (depending on the exact product).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Freeform thermoelectrics in single-step manufacturing: additive manufacturing of bismuth-telluride thermoelectrics

The project succeeded in producing crack-free Bismuth Telluride thermoelectric parts with density exceeding 98% through laser powder bed fusion (LPBF) additive manufacturing (AM). This greatly exceeded the highest previously reported density of 88% and is the highest among all semiconducting materials processed by LPBF. The additively manufactured material shows comparable Seebeck coefficient as conventional form and can be made into complex geometries with reduced material loss. On the other hand, measured properties are dramatically sensitive to the AM process parameters used, such that with identical composition, the Seebeck coefficient can be controllably tuned from +120 µV/K to -207 µV/K, which means the material switches between an n-type to a p-type semiconductor depending on processing. These changes are accompanied by significant differences in the as-processed microstructure due to rapid solidification. A machine learning protocol was developed and greatly reduced the experimental burden of the project, reducing the typical process optimization period of 2 years to 6 months. The project was fully successful in the objective of producing defect-free, complex geometry of bismuth-telluride parts through LPBF, but only partially successful in achieving performance goals. First, cost reduction of manufacturing, as measured by material waste, was successfully reduced by up to 70% compared to conventional manufacturing methods. This exceeded the proposed 30% reduction in materials waste needed to reach the 20% cost reduction goal of the project. On the other hand, the device performance, as measured by Seebeck coefficient, failed to reach the 40% improvement in efficiency. Rather, we observe comparable Seebeck coefficient between AM samples and conventionally processed counterparts. The device-level efficiency improvement does exceed 40% for complex geometry samples due to shape-induced increase in temperature gradients, but this was not the originally proposed metric. The machine learning approach developed in this project greatly accelerated the process optimization and can be adopted for fast development of AM processing parameters for other brittle and otherwise difficult-to-print materials. For the public, we deliver an efficient and widely adoptable process for incorporating waste-heat harvesting thermoelectric devices in both industrial and commercial heat exchangers. The geometric flexibility allows the capturing device to conform to the shape of the heat source to improve the system-level conversion efficiency. The technique can be deployed on any commercial LBPF systems with zero modifications, thus poses minimal adoption barrier for any manufacturer that already employed AM technology. Beyond bismuth-telluride, the machine-learning guided optimization protocol can be used in the future to reduce both the time and cost of process development for AM of other energy conversion and harvesting materials.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Huslia Tribal Council Biomass Project: A Project to Increase Sustainability and Reduce Energy Costs in Huslia, AK

The Huslia Tribal Council (HTC) and the Tanana Chiefs Conference (TCC), partnering with the City of Huslia, the Yukon-Koyukuk School District, and Alaska Native Tribal Health Consortium, applied to the U.S. Department of Energy Office of Indian Energy for funding of a community biomass boiler system. The biomass system contributes to heating three community buildings in Huslia, Alaska with locally harvested fuels: the clinic, the water treatment plant/washeteria, and the school. The remaining heating needs are supported by in-building oil-fired boilers, burning imported heating fuel. Some issues, such as control set points on the oil boilers, need to be resolved before the biomass heating system is used at full capacity. The project objectives of the community biomass boiler system were cost reduction, carbon reduction, community resilience, and economic development. Once fully operational, the cost reduction from decreased fuel oil usage due to support from the biomass boiler system is expected to more than offset the cost of purchasing locally harvested biofuel, resulting in overall savings to the community. Locally sourced wood is considered carbon-neutral, so the biomass boiler system decreases the carbon footprint of heating the community buildings. The project increases resilience by decreasing dependence on heating oil brought in from elsewhere. Lastly, it produces economic development by employing locals to gather the wood burned in the biomass boiler. This project satisfies all of the objectives that HTC set out to achieve.

09 BIOMASS FUELS↗
NASA NTRS1973

A simplified fuel control approach for low cost aircraft gas turbines.

Cost reduction in aircraft turbine engines may be obtained through performance reductions that are acceptable for ranges that are considerably shorter than the range for which current and costly engines were developed. Cost reduction in the fuel control for these cost engines must be achieved without significant performance reduction. This paper describes a fuel control approach that appears to meet this requirement and reviews the work that has been performed on it over the past few years.

Gold, H.↗
DOE OSTI2025

Research and Development on Advanced Electrochemical Energy Storage Devices Enabling a Spectrum of Electrified Vehicles

The USABC Advanced Battery development plan had the following three focus areas: 1. Existing technology validation, implementation, and cost reduction 2. Identification of the next viable technology with emphasis on the potential to meet USABC cost and energy density goals. 3. Support high-risk, high-reward battery technology R&D The primary aim of this project was focused on the barriers that most impede wider public adoption of electrification in vehicles-cost, energy density, low-temp performance, calendar life, and improvements in abuse tolerance. The specific objectives are as follows: Cost Reduction: drive to significantly reduce battery cost to be in-line with the $\$$100/kWh or less (by the end of calendar year 2020) DOE cost goals. Additionally, goals of $\$$75/KWh were set for 2023 aligned with fast charge and some offset of energy density. Energy Density Increase: focus on improving the cell-level specific energy and energy densities to >350 watt hours per kilogram (Wh/kg) and >750Wh/L. Low Temperature Performance Increase: strive toward developments that improve the discharge power and eliminate or dramatically reduce the life limiting lithium plating associated with regenerative braking at low temperatures, during the program. Calendar Life Increase: drive to achieve a 15-year calendar life. Abuse Tolerance Improvement: strive to develop improvements in Li-ion abuse tolerance and/or development of electrochemical energy storage technologies with inherently better response to abuse circumstances. Emerging Areas: initiate new programs that address emerging technologies that arise during the contract period.

25 ENERGY STORAGE↗
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 OSTI2024

Investigation of precooling unit design options in hydrogen refueling station for heavy-duty fuel-cell electric vehicles

Precooling gaseous hydrogen fuel to a cold temperature before refueling a heavy-duty (HD) hydrogen fuel cell electric vehicle (HFCEV) is essential to avoid overheating the vehicle tank, as well as achieving a high state of charge (SOC). Because a large volume of hydrogen is dispensed during each fill, the need for a shorter fill time amplifies the need to precool each load for refueling a HFCEV. Thus, the design and operation of a precooling unit (PCU), as well as the associated capital and operating costs, plays a pivotal role in any plans for heavy-duty hydrogen refueling stations. Here, in this paper, we present a thermodynamic and technoeconomic analysis of a PCU in a gaseous hydrogen refueling station (HRS) for HD HFCEVs. By employing Argonne National Laboratory's hydrogen station cost optimization and performance evaluation (H2SCOPE) model, the refueling of 50 kg of hydrogen on-board type IV tank at ambient temperatures of 15–45 °C and varying fill rates is simulated. The required degree of precooling temperature to obtain either 100% or the maximum possible SOC is obtained from the simulation. Additionally, the simulation results demonstrate that the average flow rate of hydrogen is approximately 40% lower than the maximum flow rate during a typical fill; which motivates further evaluation of the instantaneous hydrogen mass flow rate profile and suggests the scope of improving precooling unit design. Accordingly, a hybrid strategy of precooling hydrogen has been proposed to address the cooling load by sizing the refrigeration unit for the average flow rate of hydrogen, while supplementing the above average peak hydrogen flow cooling load through thermal buffering. The combined technique enables the downsizing of the original PCU capacity by 25–40% and demonstrates a potential cost reduction of the PCU by approximately 30%, which translates to an installed cost reduction of ∼$125,000 per dispenser.

25 ENERGY STORAGE↗
DOE OSTI2023

Cummins R-SOFC System Development

The overall purpose of this project was to reduce the Reversible-Solid Oxide Fuel Cell (R-SOFC) system cost by developing two technologies, an improved cell design and the incorporation of an ejector in the fuel recycle loop instead of a blower. A Simulink model of the baseline SOFC system was developed and calibrated with experimental test data. The R-SOFC system model was built by integrating GT Suite developed models of the steam generation components into the baseline Simulink SOFC system model. The ability to run the stack in SOEC operating mode was also added to the model. The system model was used to explore the ability of the R-SOFC system to meet operational constraints on Steam/Carbon ratio and H2 concentration on the fuel side electrode. A CFD ejector model was developed and used to explore a range of ejector design parameters, leading to the final ejector design that was prototyped for testing. A prototype steam ejector was first tested in a laboratory environment using room temperature air. The steam ejector was subsequently tested using the full hot recycle loop with all relevant heat exchangers and steam generation components. The test conditions utilized temperatures, pressures, and flow rates expected in an R-SOFC application. Throughout the experimental testing work, ejector performance test data was used to improve and then validate the CFD ejector model. A CFD cell model was developed and used to optimize thermal gradients, voltage, and cost of a new cell substrate design. A CFD comparison of co-flow and cross-flow cell designs informed the decision to use a co-flow design for the new cell substrate. Multiple rounds of CFD simulation were used to improve the cell design to minimize the variation in air and fuel distribution across cell channels and to minimize the variation in air and fuel distribution across different cells in the stack. A few prototypes of the new cell substrate design were produced and validated in a laboratory environment by thermally spraying and verifying that they met established manufacturing specifications. The cell manufacturing process was adjusted in order to bring these metrics within acceptable tolerances. Cummins’ internal calculations show that the new cell design reduces cost ~50% compared to the baseline cell, while the ejector + superheater/boiler concept reduces cost of the recycle loop by ~40%. The impact of these cost reductions on the cost of producing H2 will depend on the specific system where they are applied. Therefore, a Techno-Economic Analysis was completed using system cost as a variable, and showing how the NREL Current and Future system costs translate into H2 production cost.

Henrichsen, Lars↗
NASA NTRS1972

Design guide for low cost standardized payloads, volume 1

Concept point designs of low cost and refurbishable spacecraft, subsystems, and modules revealed payload program savings up to 50 percent. The general relationship of payload approaches to program costs; cost reductions from low cost standardized payloads; cost effective application of payload reliability, MMD, repair, and refurbishment; and implementation of standardization for future spacecraft are discussed. Shuttle interfaces and support equipment for future payloads are also considered

Source record↗
NASA NTRS1974

Clean fuels from biomass

The feasibility of converting biomass to portable fuels is studied. Since plants synthesize biomass from H2O and CO2 with the help of solar energy, the conversion methods of pyrolysis, anaerobic fermentation, and hydrogenation are considered. Cost reduction methods and cost effectiveness are emphasized.

Hsu, Y. Y.↗
NASA NTRS1978

Analysis and evaluation of process and equipment in tasks 2 and 4 of the Low Cost Solar Array project

Several experimental and projected Czochralski crystal growing process methods were studied and compared to available operations and cost-data of recent production Cz-pulling, in order to elucidate the role of the dominant cost contributing factors. From this analysis, it becomes apparent that substantial cost reductions can be realized from technical advancements which fall into four categories: an increase in furnace productivity; the reduction of crucible cost through use of the crucible for the equivalent of multiple state-of-the-art crystals; the combined effect of several smaller technical improvements; and a carry over effect of the expected availability of semiconductor grade polysilicon at greatly reduced prices. A format for techno-economic analysis of solar cell production processes was developed, called the University of Pennsylvania Process Characterization (UPPC) format. The accumulated Cz process data are presented.

Goldman, H.↗
NASA NTRS1995

Advanced solar panel designs

This paper describes solar cell panel designs that utilize new hgih efficiency solar cells along with lightweight rigid panel technology. The resulting designs push the W/kg and W/sq m parameters to new high levels. These new designs are well suited to meet the demand for higher performance small satellites. This paper reports on progress made on two SBIR Phase 1 contracts. One panel design involved the use of large area (5.5 cm x 6.5 cm) GaAs/Ge solar cells of 19% efficiency combined with a lightweight rigid graphite fiber epoxy isogrid substrate configuration. A coupon (38 cm x 38 cm) was fabricated and tested which demonstrated an array specific power level of 60 W/kg with a potential of reaching 80 W/kg. The second panel design involved the use of newly developed high efficiency (22%) dual junction GaInP2/GaAs/Ge solar cells combined with an advanced lightweight rigid substrate using aluminum honeycomb core with high strength graphite fiber mesh facesheets. A coupon (38 cm x 38 cm) was fabricated and tested which demonstrated an array specific power of 105 W/kg and 230 W/sq m. This paper will address the construction details of the panels and an a analysis of the component weights. A strawman array design suitable for a typical small-sat mission is described for each of the two panel design technologies being studied. Benefits in respect to weight reduction, area reduction, and system cost reduction are analyzed and compared to conventional arrays.

Ralph, E. L.↗
NASA NTRS2002

A Virtual Mission Operations Center - Collaborative Environment

Development of technologies that enable significant reductions in the cost of space mission operations is critical if constellations, formations, federations and sensor webs, are to be economically feasible. One approach to cost reduction is to infuse automation technologies into mission operations centers so that fewer personnel are needed for mission support. But missions are more culturally and politically adverse to the risks of automation. Reducing the mission risk associated with increased use of automation within a MOC is therefore of great importance. The belief that mission risk increases as more automation is used stems from the fact that there is inherently less direct human oversight to investigate and resolve anomalies in an unattended MOC. The Virtual Missions Operations Center - Collaborative Environment (VMOC-CE) project was launched to address this concern. The goal of the VMOC-CE project is to identify, develop, and infuse technology to enable mission operations between onsite operators and on-call personnel in geographically dispersed locations. VMOC-CE enables missions to more readily adopt automation because off-site operators and engineers can more easily identify, investigate, and resolve anomalies without having to be present in the MOC. The VMOC-CE intent is to have a single access point for all resources used in a collaborative mission operations environment. Team members will be able to interact during spacecraft operations, specifically for resolving anomalies, utilizing a desktop computer and the Internet. Mission operations management can use the VMOC-CE as a tool to participate in and monitor status of anomaly resolution or other mission operations issues. In this paper we present the VMOC-CE project, system capabilities and technologies, operations concept, and results of its pilot in support of the Earth Science Mission Operations System (ESMOS).

Medina, Barbara↗
NASA NTRS2017

Radiation Hardness Assurance (RHA): Challenges and New Considerations

Radiation Hardness Assurance (RHA) challenges associated with the use of commercial-off-the-shelf (COTS) components and emerging technologies are cause for risk acceptance in space flight missions. The RHA flow includes environment definition, hazard evaluation, requirements definition, evaluation of design, and design trades to accommodate the risk a project or program takes. The varied missions profiles and environments don't necessarily benefit from the same risk reduction efforts or cost reduction attempts. The level of effort within the RHA flow can be tailored to minimize risk based on the environment or design criticality.

Space Technology↗
NASA NTRS2017

Radiation Hardness Assurance (RHA): Challenges and New Considerations

Use of commercial-off-the-shelf (COTS) components and emerging technologies often require space flight missions to accept elevated risk. The Radiation Hardness Assurance (RHA) flow includes environment definition, hazard evaluation, requirements definition, evaluation of design, and design trades to accommodate and mitigate the risk a project or program takes. Depending on the mission profile and environment, different missions may not necessarily benefit from the same risk reduction efforts or cost reduction attempts. While this poses challenges for the radiation engineer, it also presents opportunities to tailor the RHA flow to minimize risk based on the environment or design criticality while remaining within budget. This presentation will focus on an approach to RHA amidst the present challenges, using the same RHA flow as in the past, with examples from recent radiation test results. The current challenges and the types of risk will be identified. How these risks drive requirements development and realization will be explained with examples of device results and data for single event effects (SEE) and in one case total ionizing dose (TID).

Radiation Hardness Assurance (RHA); Risk Managemen↗
NASA NTRSDate not supplied

Should Oxygen, Hydrogen, and Water on the Moon Be Provided by Earth Supply, Life Support Recycling, or Regolith Mining?

The water needed for space life support has so far been provided by either direct supply from Earth on most missions or by life support wastewater recycling on the International Space Station (ISS). With the recent large reduction in launch cost, Earth resupply has become more attractive, but recycling always costs less than resupply for a large enough crew on a long enough mission. Water is also needed to make up recycling losses and oxygen and hydrogen are needed for propulsion fuel. This paper compares the costs of oxygen, hydrogen, and water on the moon for Earth supply, lunar recycling, and lunar mining. While Earth supply is the most expensive by far, lunar recycling and mining costs are not much different. Life support wastewater provides a large but limited supply, so lunar mining will always be needed. Minor cost reductions may make mining less expensive than recycling.

Harry W Jones↗
DOE OSTI2021

High-temperature Pumping of Silicon for Thermal Energy Grid Storage

As the cost of renewable energy falls below fossil fuels, the key barrier to widespread sustainable electricity has become availability on demand. Energy storage can enable dispatchable renewables, but only with drastic cost reductions compared to current batteries. One electricity storage concept that could enable these cost reductions stores electricity as sensible heat in an extremely hot liquid (>2000 °C) and uses multi-junction photovoltaics (MPV) as a heat engine to convert it back to electricity on demand, hours or days later. This paper follows previously reported technoeconomics and liquid containment, examining equipment that would be needed to exchange heat between resistive heaters, a molten silicon storage tank above 2000 °C, and a heat engine. Herein, we report on a pump that was designed and tested to circulate the liquid silicon between these three regions and the effect of spatial thermal cycling was simulated in models and experiments. While the pump successfully circulated silicon between 1800-2080 °C for ten hours, circulation with a temperature gradient caused it and other non-isothermal experiments to dissolve significantly due to the temperature dependent solubility of not only carbon, but also silicon carbide which otherwise protected the graphite infrastructure. Furthermore, methods to reduce dissolution and an alternative embodiment are presented.

24 POWER TRANSMISSION AND DISTRIBUTION↗