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DOE OSTI2024

A Novel Integrated Fermentation Process with Engineered Microbial Consortia for Butanol Production from Lignocellulose Sugars without CO 2 Emission

The goal of this project was to develop a synthetic microbial consortium consisting of a lactic acid bacterium, a carboxydotrophic acetogen, and a solventogenic clostridia for the production of n butanol, an advanced biofuel and industrial chemical, from lignocellulose sugars (mainly glucose and xylose) and formate (produced from CO 2 by electrochemical reduction) in an integrated bioprocess (biorefinery), which can provide an effective solution to the technical challenges in developing energy and carbon optimized synthesis for the bioeconomy and achieve the program objectives of ARPA-E. The project focused on the design, modeling and construction of synthetic microbial consortia consisting of three bacterial species to maximize carbon conversion and butanol production with a 100% theoretical product yield from glucose and zero or negative CO 2 emission.

09 BIOMASS FUELS↗

DOE OSTI2020

Catalytic Bio-crude Production in a Novel, Short-Contact Time Reactor

RTI has developed a catalytic fast pyrolysis (CFP) process to produce biomass-based hydrocarbon replacement fuels. From a technology perspective, this advanced biofuels process produces liquid transportation fuels that can leverage capital expenditures in the existing petroleum distribution infrastructure. From a business perspective, this technology does not face potential market limitations caused by oxygenate blend limitations for light duty vehicle applications. A promising catalyst has been developed with excellent potential for deoxygenation to produce a hydrocarbon-rich biocrude that is more suitable for upgrading with traditional hydroprocessing technology. The role of the catalyst is to control the chemistry during biomass pyrolysis to produce a biocrude in a single step that has lower oxygen content and is more thermally stable than conventional biomass fast pyrolysis oil. Catalyst properties are optimized to minimize gas and coke production and improve catalytic deoxygenation and biocrude yields. Results from this project have demonstrated that biocrudes from catalytic fast pyrolysis contain <20 wt% oxygen, with the organic fraction as low as 12% oxygen. These oxygen numbers are > 50% lower compared to traditional fast pyrolysis oils. The biocrude produced from our CFP process can be upgraded to gasoline range hydrocarbons. A very conservative approach for upgrading included a preliminary stabilization step followed by a hydroprocessing step. The oxygen content in the upgraded product was decreased by 97% (to less than 3wt %) from the oxygen content of the biocrude sample. Additionally, the acid content was reduced by 99% from the acid content of the biocrude sample. In an optimized integrated process, the CFP step and the hydroprocessing (upgrading) step need to be carefully balanced to maximize the input biomass energy that is recovered in the finished biofuels. Hydrogen utilization and carbon recovery during both catalytic biomass pyrolysis and biocrude upgrading need to be optimized to maximize energy recovery in the finished biofuel. A nominal 1 ton per day (TPD) catalytic biomass pyrolysis system was designed based on the laboratory experimental data. The system was designed to achieve the short residence times (0.5–2 sec) and high heat transfer rates required for maximum liquid biocrude yields while optimizing process integration to maintain catalyst activity by continuous regeneration. The catalytic biomass pyrolysis reactor is a continuously circulating single-loop transport reactor design that is flexible enough to allow sensitivity studies around temperature, residence time, biomass feed rate, and catalyst-to-biomass ratio (i.e., catalyst circulation rate) for process optimization. For a nominal 100 lb/hr feed rate of dry biomass, the products include ~25 lb/hr char and coke, ~20 lb/hr permanent gases, and ~55 lb/hr condensable vapors. Pyrolysis temperatures are 350–600°C, and the system is operated close to ambient pressure. Production of the catalyst developed within the project was scaled up to provide enough material (200kg) for bench-scale testing. The 1TPD bench-scale unit was fabricated, installed and commissioned with this project. Biocrude samples from wood were produced in this unit with the CFP catalyst with material balance > 90%. The intermediate biocrude yields and chemical composition compare well with previous laboratory results and a hydroprocessing strategy for upgrading the resulting biocrude was developed. The experimental results obtained within this project were used to develop a process model for a 2000 TPD commercial facility. Detailed flow sheets were developed for all major unit operations in the process and provided a basis for an economic analysis to develop capital and operating costs. Estimates of the biofuel production costs were used to develop internal rates of return for the yields and compositions measured for the current state of technology at the end of this project and for the yields anticipated for an optimized (nth plant) scenario as additional process improvements are made.

09 BIOMASS FUELS↗

NASA NTRS2002

Expedite the Processing of Unpressurized Payloads to the International Space Station Using the ExPRESS Pallet

The Expedite the PRocessing of Experiments to Space Station (ExPRESS) Pallet will be used as an experiment platform for external/unpressurized payloads to be flown aboard the International Space Station (ISS). The purpose of the ExPRESS Pallet is to provide an easy access to the ISS for Scientific Investigators that require an external platform for their experiment hardware. As the name of the ExPRESS Pallet implies, the objective of the ExPRESS program is to provide a simplified integration process in a short time period (24 months) for payloads to be flown on the ISS. The ExPRESS Pallet provides unique opportunities for research across many science disciplines, including earth observation, communications, solar and deep space viewing, and long-term exposure. The ExPRESS Pallet provides access to Ram, Wake, Nadir, Zenith and Earth Limb for viewing and exposure to the space environment. The ExPRESS Pallet will provide standard physical payload interfaces, and a standard integration template. The ExPS consists of the Pallet structure, payload Adapters, a subsystem assembly that includes data controller, power distribution and conversion, and Extra Vehicular Robotics compatibility. The ExPRESS Pallet provides the capability to changeout payloads on-orbit via the ExPRESS Pallet Adapter (ExPA). The following paragraphs will describe the Services and Accommodations available to the Payload developers by the ExPRESS Pallet and a brief description of the Integration process. More detailed information on the ExPRESS Pallet can be found in the ExPRESS Pallet Payload Accommodations Handbook, SSP 52000-PAH-EPP.

Bacskay, Allen S.↗

NASA NTRS2026

Improvement in the Thermal-to-Structural Model Mapping Process for Integrated Modeling for the Roman Space Telescope

Integrated Modeling has been a key component of verifying optical requirements for the Nancy Grace Roman Space Telescope (RST) that are either impossible or impractical to verify exclusively through ground testing. Two major areas for integrated Modeling are Jitter and Thermal Distortion that require the exchanges of model performance predictions across disciplines. In both cases, distortions are impressed on optical models to evaluate the impact on boresight alignment and wave front error. In the case of Jitter, the disturbances are driven by reactions to motions most often from actuators; however, in the case of thermal distortion, the motions are driven by thermal expansion or contraction as a result of changing temperatures. This then requires a link further upstream to the thermal model, which is used to predict the thermal performance and temperature gradients and stability. The process for mapping temperatures from a thermal model to a corresponding structural model has been performed numerous times through the RST project lifecycle, with improvements in the accuracy, verification, and effort sought throughout. This paper describes some of the recent improvements to the process, including: capture of the visualization parameters, automatic generation of the mapped images for both the thermal and structural model groupings, and reduction in the effort to assemble the full set of mapped temperatures. These upgrades have greatly reduced the manual effort associated with thermal mapping and allowed for faster turn-around of Integrated Modeling predictions.

Thermal Mapping↗

DOE OSTI2020

Fire Risk Investigation in 3D (FRI3D) Software and Process for Integrated Fire Modeling

Modeling and implementing fire safety for nuclear power plants is a costly activity. Because of the complexity of fire phenomena and multiple operational procedures, it is difficult to computationally provide assurance that mitigation methods are adequate for critical areas using current analysis methods in a cost-effective manner. The nuclear industry needs efficient methods to provide more accurate modeling and optimize mitigation methods to improve nuclear power plant understanding for fire scenarios. This report describes the work done over the last two year on the Fire Risk Investigation in 3D (FRI3D) software. This software simplifies the modeling process by importing existing plant models and data, incorporating a 3D modeling environment and coupling with the fire simulation software CFAST. This eliminates the manual labor and errors associated with much of the fire modeling process. The report lays out the status and path of FRID software for the Risk Informed Safety Analysis pathway of the Light Water Reactor Sustainability project at Idaho National Laboratory and industry collaborators to best help reduce costs and improve realism in fire probabilistic risk analysis.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2021

Identification of opportunities for integrating chemical processes for carbon (dioxide) utilization to nuclear power plants

The energy and industrial sectors are responsible for more than 75% of global carbon dioxide emissions, which are primary contributors to climate change. Decarbonization strategies to reduce overall carbon dioxide emissions are urgently needed. Among the numerous decarbonization strategies that are being defined and implemented, a particular strategy of interest for the present work is “the Re-X or zero waste” strategy, which involves recycling, reuse, repurposing, and remanufacturing of industrial emissions, by-products, and waste in general. A circular value chain or Circular Economy is embedded within this strategy. In a circular carbon economy, efficient reuse of emitted carbon dioxide is considered. However, the stability of carbon dioxide implies the requirement of significant amounts of energy for its transformation into value-added chemicals or products, which must be supplied by low carbon emitting energy sources. Nuclear power plants are low carbon energy sources that, additionally to electricity, could also supply heat and radiation for chemical transformations. This work identifies the opportunities and challenges for the development of integrated energy systems to upgrade and transform carbon dioxide, involving chemical and nuclear energy. The analysis encompasses possible use of the different forms of energy that can be obtain from nuclear reactors (i.e., radiation, electricity, and heat), by reviewing the published literature on potential routes for its conversion. Overall, our review indicates that an universal technology of the one-fits-all solution-type is an utopic dream. Instead, a suite of (contaminants tolerant) technologies for processing various concentrations CO 2 and producing a variety of products is currently needed.

08 HYDROGEN↗

DOE OSTI2022

Design, Processing, and Integration of Pouch-Format Cell for High-Energy Lithium-Sulfur Batteries

This project objective was to develop and demonstrate a lithium-sulfur (Li-S) battery in a pouch-format cell capable of achieving an energy density ≥ 500 Wh/kg while achieving a 1,000 cycle life. The research focused on cell optimization and fabrication addressing different technical barriers and challenges including: 1) thin lithium anode optimization; 2) current collector and tab attachment design; 3) cathode porosity control; 4) electrolyte to sulfur ratio control; 5) cell design; and 6) cell fabrication. The project developed and demonstrated various technologies to address these technical barriers and challenges. The project demonstrated a thin lithium anode by vapor deposition, a collector design and validation of laser welding of tab attachment method, a cathode porosity control strategy by binder optimization, a calendaring process control and surface/interface treatment, and an electrolyte to sulfur ratio control with influence on cell energy density. The sulfur cathode was optimized by tuning the formulation, optimizing the calendaring process, and introducing a novel electrode fabrication process. To address the electrolyte performance issue, the electrolyte optimization was achieved with additive and formulation tuning and the introduction of a dual-phase electrolyte system. In addition to the demonstration of the optimized electrode with a novel fast-curing coating process and dual-phase electrolyte, a coating separator was further developed to address the polysulfide shuttling issue. The resulting new cell design with these optimized cell components was demonstrated in the 1 Ah pouch cell with medium sulfur loading and moderate porosity (~ 4.5 mAh cm-2, 65% porosity) and showed an energy density of > 400 Wh/kg (with E/S ratio of 2.8). The Li-SPAN cell configuration was also evaluated in combination with a new dual-phase electrolyte system. Initial coin cell performance demonstrated cycle stability of >300 cycles with an estimated energy density of 300 Wh/kg at the pouch format level. The corresponding 1 Ah pouch format SPAN cells with the new polymer electrolyte were developed which has shown a stable capacity at 800-900 mAh for ~40 cycles so far.

25 ENERGY STORAGE↗

DOE OSTI2020

New Architecture to Support Integration and Processing of Seismic Data from Heterogeneous Sources

The Geophysical Monitoring Program (GMP) at Lawrence Livermore National Lab (LLNL) maintains a database and supporting infrastructure for geophysical data used in support of the Nuclear Detonation Detection mission. This database includes data from multiple sources, many of which do not distribute data to the public or for which there is no automated means of access. For example, Figure 1 shows (left) the distribution of waveform data in our database by source. The Incorporated Research Institutions for Seismology Data Management Center (IRISDMC) is our major source of waveform data and those data may be retrieved at will using the Federated Digital Seismograph Networks FDSN web Application Programming Interface (API). However, the next 6 most important sources of waveform data have no or only limited automated access to waveforms. As Figure 1 (right) shows, it is very common for waveform records associate with an event in our database to come from two or more sources, and in some cases data come from 10 sources. This diversity of data sources drives our need for efficient and correct integration of metadata, parametric data, and waveform data.

58 GEOSCIENCES↗

DOE OSTI2022

GDSA Framework Development and Process Model Integration FY2022

The Spent Fuel and Waste Science and Technology (SFWST) Campaign of the U.S. Department of Energy (DOE) Office of Nuclear Energy (NE), Office of Spent Fuel & Waste Disposition (SFWD) is conducting research and development (R&D) on geologic disposal of spent nuclear fuel (SNF) and high-level nuclear waste (HLW). A high priority for SFWST disposal R&D is disposal system modeling (Sassani et al. 2021). The SFWST Geologic Disposal Safety Assessment (GDSA) work package is charged with developing a disposal system modeling and analysis capability for evaluating generic disposal system performance for nuclear waste in geologic media. This report describes fiscal year (FY) 2022 advances of the Geologic Disposal Safety Assessment (GDSA) performance assessment (PA) development groups of the SFWST Campaign. The common mission of these groups is to develop a geologic disposal system modeling capability for nuclear waste that can be used to assess probabilistically the performance of generic disposal options and generic sites. The modeling capability under development is called GDSA Framework (pa.sandia.gov). GDSA Framework is a coordinated set of codes and databases designed for probabilistically simulating the release and transport of disposed radionuclides from a repository to the biosphere for post-closure performance assessment. Primary components of GDSA Framework include PFLOTRAN to simulate the major features, events, and processes (FEPs) over time, Dakota to propagate uncertainty and analyze sensitivities, meshing codes to define the domain, and various other software for rendering properties, processing data, and visualizing results.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2020

Feasibility Analysis of Converter-Interfaced Combined Heat and Power System

As a promising new design concept, the converter-interfaced combined heat and power (CHP) system is coupled to the bulk grid through a rectifier and a grid-ready tied inverter. Compared to the traditional directly-coupled CHP system, it removes the requirement for oversizing the CHP generator, limits the short-circuit contribution of the generator and simplifies the grid integration process of CHP system. This paper evaluates the economic benefits of this concept by calculating the annualized Return-on-Investment (ROI) and comparing it to the directly-coupled system. The economic analysis includes timeseries simulations to compute energy transactions with the bulk grid as well as sizing the equipment to calculate the capital and operational costs. Obtained results indicate that in majority of user cases evaluated, the converter-interfaced CHP systems can provide better ROI than directly-coupled systems. Given the additional technical benefits provided by inverter-based distributed energy resources (DERs), the proposed concept is proved to be technically viable and economically feasible.

03 NATURAL GAS↗

DOE OSTI2023

Universal Passive Synchronization Method for Grid-Forming Inverters Without Mode Transition

Power systems are transforming with increasing levels of inverter-based resources (IBRs). This transformation requires critical roles of grid-forming (GFM) inverters replacing synchronous generators for bulk power system stabilization and ancillary services, also allowing flexible power system operation, such as microgrid that is operated by multiple GFM IBRs to achieve system resilience against contingencies. To realize the resilient power systems allowing flexible in-and-out operation of GFM IBRs potentially programmed with different primary controls, a synchronization method universally applicable, i.e., independent of control types, would be beneficial to ease the integration process, but it has not been actively studied. To fill the gap, this paper proposes a universal synchronization method that achieves a passive synchronization to enable a smooth transition in a grid with off-nominal system parameters, i.e., voltage and frequency. The logic proposed requires no modification on the primary control, thus applicable to any type of GFMs with a voltage reference input. To validate the concept, a simulation of an IEEE 13-bus benchmark system modified with 3 GFM inverters is presented. It simulates an inverter-driven black start scenario in which GFM inverters autonomously turn on and connect to the grid under heavy loading, using the synchronization logic. The case study demonstrates that GFM inverters can tune their voltage reference to smoothly synchronize without severe transients, and contribute to a seamless black start of the grid under unbalanced load conditions. Two GFM methods - Droop and dispatchable virtual oscillator control - are used for the demo to validate feasibility and interoperability of the passive synchronization.

black start↗

NASA NTRS1994

Applying Costs, Risks and Values Evaluation (CRAVE) methodology to Engineering Support Request (ESR) prioritization

Given limited budget, the problem of prioritization among Engineering Support Requests (ESR's) with varied sizes, shapes, and colors is a difficult one. At the Kennedy Space Center (KSC), the recently developed 4-Matrix (4-M) method represents a step in the right direction as it attempts to combine the traditional criteria of technical merits only with the new concern for cost-effectiveness. However, the 4-M method was not adequately successful in the actual prioritization of ESRs for the fiscal year 1995 (FY95). This research identifies a number of design issues that should help us to develop better methods. It emphasizes that given the variety and diversity of ESR's one should not expect that a single method could help in the assessment of all ESR's. One conclusion is that a methodology such as Costs, Risks, and Values Evaluation (CRAVE) should be adopted. It also is clear that the development of methods such as 4-M requires input not only from engineers with technical expertise in ESR's but also from personnel with adequate background in the theory and practice of cost-effectiveness analysis. At KSC, ESR prioritization is one part of the Ground Support Working Teams (GSWT) Integration Process. It was discovered that the more important barriers to the incorporation of cost-effectiveness considerations in ESR prioritization lie in this process. The culture of integration, and the corresponding structure of review by a committee of peers, is not conducive to the analysis and confrontation necessary in the assessment and prioritization of ESR's. Without assistance from appropriately trained analysts charged with the responsibility to analyze and be confrontational about each ESR, the GSWT steering committee will continue to make its decisions based on incomplete understanding, inconsistent numbers, and at times, colored facts. The current organizational separation of the prioritization and the funding processes is also identified as an important barrier to the pursuit of cost-effectiveness. Perhaps the greatest barrier is that, at the working level, KSC's culture is so preoccupied with technical concerns that it seems almost oblivious to any cost concerns, let alone cost-effectiveness concerns. It is recommended that we must urgently begin to change that culture and seek a better balance between these two concerns.

Joglekar, Prafulla N.↗

DOE OSTI2025

Temporal Galactose‐Manganese Feeding in Fed‐Batch and Perfusion Bioreactors Modulates UDP‐Galactose Pools for Enhanced mAb Glycosylation Homogeneity

ABSTRACT Monoclonal antibodies (mAbs) represent a majority of biotherapeutics in the market today. These glycoproteins undergo posttranslational modifications, such as N‐linked glycosylation, that influence the structural & functional characteristics of the antibody. Glycosylation is a heterogenous posttranslational modification that may influence therapeutic glycoprotein stability and clinical efficacy, which is why it is often considered a critical quality attribute (CQA) of the mAb product. While much is known about the glycosylation pathways of Chinese Hamster Ovary (CHO) cells and how cell culture chemical modifiers may influence the N‐glycosylation profile of the final product, this knowledge is often based on the final cumulative glycan profile at the end of the batch process. Building a temporal understanding of N‐glycosylation and how mAb glycoform composition responds to real‐time changes in the biomanufacturing process will help build integrated process models that may allow for glycosylation control to produce a more homogenous product. Here, we look at the effect of specific nutrient feed media additives (e.g., galactose, manganese) and feeding times on the N‐glycosylation pathway to modulate N‐glycosylation of a Herceptin biosimilar mAb (i.e., Trastuzumab). We deploy the N‐GLYcanyzer process analytical technology (PAT) to monitor glycoforms in near real‐time for bench‐scale bioprocesses operated in both fed‐batch and perfusion modes to build an understanding of how temporal changes in mAb N‐glycosylation are dependent on specific media additives. We find that Trastuzumab terminal galactosylation is sensitive to media feeding times and intracellular nucleotide sugar pools. Temporal analysis reveals an increased desirable production of single and double galactose‐occupied glycoforms over time under glucose‐starved fed‐batch cultures. Comparable galactosylation profiles were also observed between fed‐batch (nutrient‐limited) and perfusion (non‐nutrient‐limited) bioprocess conditions. In summary, our results demonstrate the utility of real‐time monitoring of mAb glycoforms and feeding critical cell culture nutrients under fed‐batch and perfusion bioprocessing conditions to produce higher‐quality biologics.

Biotechnology & Applied Microbiology↗

DOE OSTI2025

Integrated process-structure–property–performance optimization of cold-sprayed zinc coatings on AZ91 magnesium alloy

High-pressure die cast (HPDC) AZ91 magnesium alloy is widely used in automotive components such as transmission housings and brackets for its excellent strength-to-weight ratio. Zinc-based cold spray coatings can be applied selectively to vulnerable areas to enhance corrosion resistance, minimize galvanic coupling with dissimilar metals, and eliminate the need for full-surface oxide coatings, making the process more efficient and targeted. A comprehensive evaluation of 16 combinations of nitrogen carrier gas temperatures and pressures led to the identification of an optimal range of process parameters, yielding Zn coatings with porosity <0.5 % by area, wear rates reduced by a factor of two compared to uncoated AZ91, and adhesion strengths up to 35 MPa. The enhanced mechanical performance of the coating is attributed to the low porosity and the formation of a metallurgical bond at the coating-substrate interface. Corrosion studies using macroscale potentiodynamic polarization (PDP) and electrochemical impedance spectroscopy (EIS) revealed a significant decrease in corrosion rate and a shift to more noble corrosion potentials (ZCP) for coated substrates. Furthermore, the Zn cold-sprayed samples exhibited significantly lower corrosion-induced evolved hydrogen content compared to the base AZ91 substrate and AZ91 coated with industrial coatings, demonstrating that the Zn layer effectively protects the substrate from the corrosive environment. Overall, cold spray Zn coatings significantly improve the mechanical and corrosion performance of AZ91 Mg alloys, addressing key material challenges and enabling their broader use in automotive applications.

Corrosion performance↗

DOE OSTI2020

Advances in GDSA Framework Development and Process Model Integration

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

GDSA Framework Development and Process Model Integration FY2021

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

GDSA Framework Development and Process Model Integration FY2023

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2024

GDSA Framework Development and Process Model Integration FY2024

The Disposal Research & Development (Disposal R&D) Campaign of the U.S. Department of Energy (DOE) Office of Nuclear Energy (NE), Office of Spent Fuel & High-Level Waste Disposition is conducting research and development (R&D) on geologic disposal of spent nuclear fuel (SNF) and high-level nuclear waste (HLW). A high priority for Disposal R&D is disposal system modeling (Sassani et al. 2023). The Geologic Disposal Safety Assessment (GDSA) work package is charged with developing a disposal system modeling and analysis capability for evaluating generic disposal system performance for nuclear waste in geologic media.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗