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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

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DOE OSTI2025

Structurally Regenerable High Entropy Aluminate Spinel Catalysts for Dry Reforming of Methane

The dry reforming of methane reaction is a promising means to convert two potent greenhouse gases, methane and carbon dioxide, into industrially valuable synthesis gas. However, the presence of reducing gases and high operating temperatures degrade conventional nickel catalysts via excessive coke formation and particle sintering. These catalysts are not readily regenerated because the oxidative heat treatments employed to remove coke further promote active particle sintering. In this work, we designed high entropy aluminate spinel oxides (MAl 2 O 4 where M = Co, Mg, Ni, and divalent site vacancies in nominal equimolar concentration) as selective and regenerable reforming catalysts. Under reaction conditions, reducible nickel and cobalt cations exsolved from the spinel lattice to form highly selective bimetallic particles on the oxide surface. Instead of sintering, these particles uniquely redissolved back into the aluminate lattice upon reoxidation and regained the original spinel structure. This phenomenon is ascribed to entropic stabilization, wherein an increase in configurational entropy creates a thermodynamic driving force for redispersing supported metal particles back into the multi‐cationic oxide structure. During the dry reforming reaction, nickel atoms similarly exsolved from a NiAl 2 O 4 sample and reduced to form metallic nickel particles. However, subsequent oxidation of this sample promoted sintering and oxidation of the nickel particles to an inactive state. High entropy materials thus provide a unique mechanism of regeneration, which is inaccessible in conventional catalysts.

coke deposition↗

DOE OSTI2025

Technoeconomic Analysis of Microwave-Assisted Dry Reforming Integrated with Chemical Looping for Production of Methanol

Methanol is a key component in producing formaldehyde, acetic acid, and methyl tert -butyl ether (MTBE) and supports a wide array of industries, including plastics, textiles, and automotive. It also plays a growing role in renewable energy solutions. However, the conventional production of methanol involves steam reforming of methane, which is very energy-intensive and produces significant quantities of the greenhouse gas carbon dioxide. In this research, a chemical looping scheme is combined with dry reforming of natural gas in a novel microwave reactor to produce an industrial quantity of methanol. A heat exchanger network is developed to substantially reduce hot and cold utility usage. The effect of the cost of purchasing carbon dioxide from an external source for dry reforming, the capital cost of the microwave reactor, and the cost of electricity on the net present value is analyzed. Technoeconomic comparison with the conventional industrial process that produces methanol via steam reforming of methane indicates that the chemical looping generates a significant positive net present value along with a substantial reduction in carbon dioxide emissions while producing methanol significantly below the U.S. Department of Energy’s goal of $800/ton.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Fuel Assembly and Irradiation Parametric Study for Extended-Enrichment and High-Burnup Light-Water Reactor Spent Nuclear Fuel in Dry Storage Casks and Transportation Packages

There is an increased interest in operating commercial light-water reactors (LWRs) in the United States with improved economics that would result from longer fuel cycle lengths, fewer and shorter refueling outages, and fewer fuel assemblies requiring storage at the back end of the fuel cycle. To support this, fuel discharge burnups, as well as initial 235 U enrichments, must be higher than those used in current commercial LWRs. The typical upper limit considered for assembly average burnup in this report is 75 gigawatt-days (GWd) per metric ton of uranium (MTU), as opposed to the current typical upper bound of approximately 62 GWd/MTU. The upper limit considered for initial 235 U enrichment is 8 weight percent (8 wt %), as opposed to the current regulatory limit of 5 wt %. The enrichment range from 5 to 8 wt % is referred to in this report as extended enrichment . To investigate the effect of high burnup and extended enrichment conditions on dose rates and burnup credit for dry storage casks and transportation packages, a fuel assembly and irradiation parametric study was performed. The conclusions from this study will assist U.S. Nuclear Regulatory Commission staff in reviewing applications for dry storage casks and transportation packages that contain high-burnup and extended enrichment fuel.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRSDate not supplied

FORWARD AND INVERSE L-BAND RADIATIVE TRANSFER MODELING OVER THE DRY CHACO, USING SMOS OBSERVATIONS, LAND SURFACE MODELING AND IN SITU DATA

Passive microwave L-band remote sensing is well known for its sensitivity to surface soil moisture over land.The signal is also affected by other dynamic variables such as vegetation and soil salinity. In this research, L-band microwave observations of the Soil Moisture Ocean Salinity (SMOS) mission are used to explore soil surface salinity, moisture and vegetation, in the Argentinean Dry Chaco, an area with possible emerging dryland salinity. A Radiative Transfer Model (RTM) with inclusion of a correction to the soil’s dielectric constant for salinity was used in forward and inverse mode, using either in situ data or Catchment Land Surface Model (CLSM) simulations as RTM input. The forward analysis pointed out shortcomings in the modeled soil moisture and soil surface temperature estimates. The impact of salinity on forward simulations over the Dry Chaco was limited.The RTM inversion using 10 years of SMOS brightness temperature observations resulted in realistic estimates of vegetation and roughness, both with and withouto ptimizing a correction term for the dielectric constant in terms of salinity equivalents. However,the retrieval of the correction term to the dielectric constant was very uncertain and not representative of soil surface salinity, but rather of open water, texture uncertainty or soil moisture bias.

L-band↗

DOE OSTI2024

Melt compounding of spray-dried cellulose nanofibrils/polypropylene and their application in 3D printing

Abstract Micro- and nano-scale cellulosic fillers exhibit excellent dispersion and distribution within a thermoplastic matrix during the process of melt compounding or injection molding. In this study, spray-dried cellulose nanofiber (SDCNF) powders were manufactured using a pilot-scale rotating disk atomizer spray dryer. Bleached Kraft pulp (BKP), unbleached Kraft pulp (UKP), and old corrugated cardboard pulp (OCC) fibrillated at a fines level of 90% were used as feedstock materials for spray-drying. BKP-, UKP-, and OCC- SDCNFs were compounded with polypropylene using a twin screw co-rotating extruder. Maleic anhydride grafted polypropylene (MAPP) was used as a coupling agent in the composite formulations. The tensile, flexural, and impact properties of SDCNF-filled PP composites increased at 10 wt% SDCNF loading. The presence of SDCNFs in the PP matrix resulted in faster crystallization and a 12% reduction in the degree of crystallinity of the neat PP. The coefficient of thermal expansion (CTE) of neat PP was reduced by up to 31% attributable to the presence of the SDCNFs. Application of the SDCNF-reinforced PP composites in 3D printing reduced the shrinkage rate of the printed neat PP by 39%, and the printability of the PP was significantly improved with the addition of the SDCNFs.

Materials Science↗

DOE OSTI2025

Evaluation of dried blood spot sampling for verification of exposure to chemical threat agents

Abstract Purpose Exposure to chemical threat agents (CTAs), including nerve agents, the vesicating agent sulfur mustard, and opioids, remains a significant threat to warfighter and civilian populations. Definitive analytical methods to verify exposure to CTAs require shipping refrigerated or frozen biomedical samples to reference laboratories for analysis. Logistical and financial burdens arise as the transport of biomedical samples is subject to strict restrictions and complex packaging, which, if done incorrectly, can lead to sample deterioration. The use of dried blood spot (DBS) sampling could provide operational improvements for collecting, storing, and shipping important forensic samples. Therefore, this effort focuses on developing DBS techniques with Mitra® 30-µL volumetric absorptive microsampling (VAMS®) devices for use in CTA exposure verification. Methods VAMS® devices were loaded and dried with human whole blood that was exposed to the metabolites pinacolyl methylphosphonic acid (PMPA), ethyl methylphosphonic acid (EMPA), 1,1’sulfonylbis[2-(methylsulfinyl)ethane] (SBMSE), norfentanyl, norcarfentanil, norsufentanil, and norlofentanil. Following extraction from the VAMS® devices, metabolites were detected using liquid chromatography-tandem mass spectrometry (LC–MS/MS). The methods were validated for performance by assessing sensitivity, precision, accuracy, and recovery. Results These methods were sensitive to 1 ng/mL for SBMSE, 0.5 ng/mL for PMPA, EMPA, and norfentanyl; 0.1 ng/mL for norlofentanil, and 0.05 ng/mL for norsufentanil and norcarfentanil. All methods met acceptable precision and accuracy criteria with favorable recovery. Conclusions These results demonstrated the utility of VAMS® in stabilizing human whole blood and show promise as an improved collection method for verification of exposure to various CTAs.

Toxicology↗

DOE OSTI2025

A cradle-to-grave life-cycle-assessment of dry-processed Li-ion batteries for electric vehicles

Maxwell-type dry processing has emerged as a promising manufacturing technology for high-areal-loading Li-ion battery electrodes, offering a significant advantage by eliminating the use of the toxic and costly NMP solvent. This study developed a cradle-to-grave life-cycle-assessment model to evaluate the environmental impacts of this innovative technology, benchmarking the results against the conventional NMP-based technique for a configured 42 kWh NMC622-graphite battery pack. Furthermore, the findings reveal that the dry-processing method merits a 4.8% lower energy consumption and achieves environmental impacts up to 47.5% lower in 12 out of 13 categories, highlighting its environmental benefits compared with the NMP-based manufacturing processes.

Electrode↗

DOE OSTI2026

Perovskite design principles for efficient microwave dry reforming with noble metal free catalysts

Microwave absorbing catalysts have the potential to electrify high-temperature thermal reactions such as the dry reforming of methane process (DRM: CO 2 + CH 4 → 2CO + 2 H 2 ). However, microwave catalysts present unique challenges due to their dual requirements of maintaining microwave absorption in both oxidative and reductive environments and stability across a range of temperatures in inherently non-isothermal reactors. Here, catalyst candidates from the La 0.8 Sr 0.2 CoO 3 -La 0.8 Sr 0.2 NiO 3 -La 0.8 Sr 0.2 MnO 3 perovskite systems were screened (28 total) to identify promising microwave catalysts free of noble metals for dry reforming methane. The best performing candidates met two main criteria. First, they occurred at crystal phase boundaries, giving rise to a pseudocubic perovskite structure. The combined use of Goldschmidt tolerance factor and octahedral tolerance factors appeared to be suitable for predicting pseudocubic perovskites. Second, they provided a balance of reducible metal sites with an irreducible metal oxide support. The best performing catalyst was found to exsolve Ni-Co alloy particles as active sites for the DRM reaction which offered superior resistance to coking for excellent reforming efficiency and stability.

42 ENGINEERING↗

DOE OSTI2025

Surface modification of cathode material enhances electrochemical performance in dry-processed Li-ion battery electrodes

The transition to electric vehicles (EVs) is pivotal for achieving energy security and integrating grid stability, with lithium-ion batteries (LIBs) playing a central role in this transformation. However, the conventional wet electrode manufacturing relying on N-methyl-2-pyrrolidone (NMP) solvent is energy intensive and costly. Dry processing (DP) has emerged as a promising alternative, eliminating solvents and using polytetrafluoroethylene (PTFE) binder for electrode fabrications. Despite its advantages, DP faces a critical challenge: poor interfacial adhesion between the hydrophobic PTFE binder and the hydrophilic cathode active material (CAM), particularly LiNi 0.8 Mn 0.1 Co 0.1 O 2 (NMC811), which undermines electrode performance. Here, to address this, we introduced a novel vapor-phase trimethoxymethylsilane (TMMS) coating to hydrophobize the CAM surface, enhancing compatibility with PTFE. This surface modification significantly enhances binder – CAM interactions, enabling uniform mixing and robust electrode integrity without damaging the CAM particles. Our findings advance the feasibility of environmentally sustainable and cost-effective dry processing, representing a significant step toward sustainable battery manufacturing.

Choi, Junbin [Oak Ridge National Laboratory (ORNL)↗

DOE OSTI2026

Dry-processed electrodes enabled by polytetrafluoroethylene fibrillation for high-performance lithium-ion batteries

The dry processing technique of polytetrafluoroethylene (PTFE) fibrillation offers significant advancements in cost reduction, environmental impact, and electrochemical performance. Dry processing alone allows for ∼ 20–60% cost reduction and increases of up to 40 mg cm⁻2 of areal loading – it typically comes at a reduction of rate capability. By leveraging the network structure of fibers, this method enhances rate capability and cycling performance, providing a compelling alternative to the conventional and currently predominant wet processing. The review delves into PTFE fibrillation mechanisms and examines critical influencing factors including material properties and processing parameters. It also discusses challenges associated with the electrodes fabricated by PTFE fibrillation, including structural instability due to insufficient PTFE fibrillization, compromised electrical conductivity from an insufficient conductive network, inhomogeneous dispersion resulting from the absence of solvents, restricted ionic transport due to increased electrode thickness, inadequate adhesion to current collector because of low surface energy of PTFE, electrochemical degradation due to low lowest unoccupied molecular orbital (LUMO) level of PTFE, particle damage during processing and environmental concerns related PTFE being a perfluoroalkyl and polyfluoroalkyl substances (PFAS). Recent research innovations aimed at mitigating these issues, their application in beyond-lithium batteries, and future research directions are thoroughly discussed.

Park, Hyunji↗

DOE OSTI2025

Pathways of Photocatalytic Oxidation of Formic Acid on Dry and Hydrated Anatase TiO 2 Surfaces

The photocatalytic oxidation of formic acid (FA), which is one of the most abundant volatile organic compounds, is a promising air remediation technology inspired by nature. However, the detailed mechanism of this photocatalytic reaction on the surface of TiO 2 , a typical photocatalyst, is not yet well-understood. In this work, we present a computational mechanistic study of the thermal vs photocatalytic oxidation of FA on dry and hydrated anatase TiO 2 (101) surfaces, based on periodic hybrid density functional theory (DFT) calculations, in which the photooxidation is treated as an excited-state process in a constrained triplet spin state. We first compare the adsorption modes of FA on the anatase (101) surface in the ground and excited states, followed by identification of the corresponding reaction intermediates that lead to the formation of CO 2 . We unveil the pivotal role of photogenerated holes localized at surface under-coordinated oxygen sites in mediating the C−H bond cleavage, thereby promoting CO 2 formation through a highly stable intermediate and an exergonic reaction step. Further investigation of the effect of coadsorbed water molecules shows that hydrogen bonding with water stabilizes FA in a monodentate configuration. This is favored over the unreactive bidentate structure that is the most stable under dry conditions, thus providing insight into the experimentally observed increase of the reaction rate in the presence of water.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Reducing Long‐Standing Surface Ozone Overestimation in Earth System Modeling by High‐Resolution Simulation and Dry Deposition Improvement

The overestimation of surface ozone concentration in low‐resolution global atmospheric chemistry and climate models has been a long‐standing issue. We first update the ozone dry deposition scheme in both high‐ (0.25°) and low‐resolution (1°) Community Earth System Model (CESM) version 1.3 runs, by adding the effects of leaf area index and correcting the sunlit and shaded fractions of stomatal resistances. With this update, 5‐year‐long summer simulations (2015–2019) using the low‐resolution CESM still exhibit substantial ozone overestimation (by 6.0–16.2 ppbv) over the U.S., Europe, eastern China, and ozone pollution hotspots. The ozone dry deposition scheme is further improved by adjusting the leaf cuticle conductance, reducing the mean ozone bias by 19%, and increasing the model resolution further reduces the ozone overestimation by 43%. We elucidate the mechanism by which model grid spacing influences simulated ozone, revealing distinctive pathways in urban versus rural areas. In rural areas, grid spacing mainly affects daytime ozone levels, where additional NO x emissions from nearby urban areas result in an ozone boost and overestimation in low‐resolution simulations. In contrast, over urban areas, daytime ozone overestimation follows a similar mechanism due to the influence of volatile organic compounds from surrounding rural areas. However, nighttime ozone overestimation is closely linked to weakened NO titration owing to the redistribution of urban NO x to rural areas. Additionally, stratosphere‐troposphere exchange may also contribute to reducing ozone bias in high‐resolution simulations, warranting further investigation. This optimized high‐resolution CESM may enhance understanding of ozone formation mechanisms, sources, and changes in a warming climate.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Dry Deactivation of Sodium Metal in a Molten LiCl-KCl-CsCl-NaCl System

An experimental study was performed with the objective of investigating and characterizing a dry technique for deactivation of sodium metal in a molten salt system. The study was performed in three parts. First, proof-of-principle testing of the technique was performed at bench scale. It involved loading and melting tens of grams of clean sodium metal atop a pool of LiCl-KCl-CsCl eutectic at ∼300°C and then adding ammonium chloride particles while mixing. The ammonium chloride reacted with sodium to form sodium chloride and nitrogen/hydrogen off-gases. The sodium chloride assimilated into the salt pool, forming a quaternary salt mixture of LiCl-KCl-CsCl-NaCl. The proof-of-principle testing repeatedly exhibited complete deactivation of the loaded sodium metal. Second, characterization of a LiCl-KCl-CsCl-NaCl system was performed using differential scanning calorimetry to produce a partial phase diagram of LiCl-KCl-CsCl eutectic versus NaCl, which identified the liquidus, solidus, and two-phase regions of the quaternary system. Third, the dry deactivation technique was demonstrated at kg-scale in an inert atmosphere radiological glovebox with sodium metal that was previously separated in the same glovebox from uranium metal in unirradiated blanket elements for the Fermi-1 nuclear reactor. The quaternary salt product at the end of the demonstration was sampled and showed complete deactivation of the sodium metal. Here, in short, this study qualified a technique to completely deactivate batches of sodium metal in the absence of air or water. While this study focused on the deactivation of sodium metal, including bond sodium from unirradiated blanket elements, the technique is applicable to other sources of sodium metal, such as sodium metal from batteries. Furthermore, the technique could also be extended to other alkali metal systems, including lithium, sodium, potassium, rubidium, cesium, and mixtures thereof.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Comparative S/TEM study of superconducting Ta quantum resonators by wet and dry etching types

Superconducting resonators play a pivotal role in various quantum technology applications, such as quantum computing and high-frequency communication systems. The performance of these resonators is closely tied to the properties of the superconducting films used in their fabrication. Here, in this study, we investigated the impact of wet and dry etching on tantalum (Ta) films leveraging advanced scanning transmission electron microscopy-based characterization methods and examined the morphological, chemical, and strain changes caused by the etching processes. Consequently, we report the significant differences between the two etching methods, with dry etching resulting in straight slanted sidewalls and a thinner oxidized layer, while wet etching produced curved sidewalls and undercuts. Both methods led to the formation of a residual Ta wedge at the lower part of the sidewall, causing lattice deformation, which could adversely influence the homogeneous operations of superconducting devices. These insights enhance our understanding of how etching influences superconducting films, offering valuable guidance for optimizing resonators and related devices. Our findings mark a significant stride in advancing quantum technologies and high-frequency communication by enhancing our practical understanding of superconducting material fabrication.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Full-film dry transfer of MBE-grown van der Waals materials

Abstract Molecular beam epitaxy (MBE) has been used to create high-quality, large-scale two-dimensional van der Waals (2D vdW) materials. However, due to the strong adhesion between the substrate and deposited materials, the peel-off and dry transfer of MBE-grown vdW films onto other substrates has been challenging. This limits the study and use of MBE films for heterogeneous integration including stacked and twisted heterostructures. In this work, we develop a polymer-assisted dry transfer method and successfully perform full-film transfer of various MBE-grown 2D vdW materials including transition metal dichalcogenides, topological insulators and 2D magnets. In particular, we transfer air-sensitive 2D magnets, characterize their magnetic properties, and compare them with as-grown materials. The results show that the transfer technique does not degrade the magnetic properties, with the Curie temperature and hysteresis loops exhibiting similar behaviors after the transfer. Our results enable further development of heterogeneous integration of 2D vdW materials based on MBE growth.

Li, Ziling (ORCID:0000000203537036)↗

DOE OSTI2026

Data and scripts associated with “Moisture content modulates DOM thermodynamic regulation of oxygen consumption in drying streambed sediments”

This data package is associated with the publication “Moisture content modulates DOM thermodynamic regulation of oxygen consumption in drying streambed sediments” published in Scientific Reports (Garayburu-Caruso et al., 2026). The package contains processed data products and scripts used to quantify how drying and re-inundation of riverbed sediments influence dissolved organic matter (DOM) thermodynamic properties and their relationship with sediment oxygen (O₂) consumption across 33 stream sites in the contiguous United States. The data package contains DOM thermodynamic metrics (e.g., Gibbs free energy of carbon oxidation and thermodynamic efficiency), and O₂ consumption along with watershed-scale climate and land-cover metrics used as explanatory variables in the analyses. Underlying unprocessed and processed ultrahigh-resolution mass spectrometry data, oxygen consumption rates from laboratory moisture-manipulation experiments, within-sample environmental properties, sediment moisture content and contextual field measurements are archived separately at https://data.ess-dive.lbl.gov/datasets/doi:10.15485/2428003 (Laan et al., 2024) and https://data.ess-dive.lbl.gov/datasets/doi:10.15485/1923689 (Forbes et al.,2023). A preliminary version of this data package was published in February 2026 at the time of manuscript submission. It was updated in June 2026, at the time of manuscript acceptance, to include the finalized data and additional metadata (readme, data dictionary, and file level metadata). For details on how to navigate data packages generated by this project, see https://data.ess-dive.lbl.gov/portals/PNNLRiverCorridorSFA/About. In addition to a readme, this data package also includes a file-level metadata (FLMD) file that describes each file and a data dictionary (DD) that describes all column/row headers and variable definitions. At the top level, the data package is organized into five main folders: (1) Data, (2)Figures, (3) Map, (4) GAM_Reulsts, and (5) src. The Data folder contains analysis-ready tabular files with oxygen consumption rates, DOM thermodynamic properties by site and treatment, site-level environmental variables, watershed-scale metrics, and other derived variables referenced in the manuscript. The Figures folder contains static image files associated with the main text and supplemental figures, while the Map folder includes spatial data and map-layer files used to create the sampling-location map. The GAM results folder contains the results for each of the general additive model (GAM).The src folder contains R scripts used to perform data processing, statistical analyses (including clustering, generalized additive models, and threshold analysis), and figure generation. This data package is associated with a GitHub repository found at https://github.com/WHONDRS-Hub/ECA_DOM_Thermodynamics.

Dissolved organic matter↗

DOE OSTI2025

[LCA UP] Biomass Drying (2022)

This unit process quantifies the energy requirements and airborne emissions that are expected to result from the biomass drying process, where the biomass type being dried is woody crop biomass.

LCA Unit Process↗

NASA NTRS1965

Double gloves reduce contamination of dry box atmosphere

Pair of encased low permeability hand gloves between which an inert gas circulates reduces dry box contamination. This innovation is applicable to dry boxes using radioactive and alkali metal compounds, submicron powders, and liquid metals.

Herbell, T. P.↗