SEARCH · Engineering Papers

Results for “Process Engineering”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,477 records · Page 82

All sources NASA NTRS DOE OSTI

DOE OSTI2021

100+ RON Gasoline Blendstock for High Efficiency, Low Emissions (CRADA 493)

The PNNL/LanzaTech alcohol-to-Jet (ATJ) patented process converts ethanol from LanzaTech’s syngas fermentation process to low aromatic jet-range isoparaffins. Compounds are generated across a wide boiling range by the process. The project goal is to improve the viability of the ATJ process by increasing the RON of the gasoline fraction and determine what types of engines and vehicles can be fueled with this gasoline. PNNL experts’ team will investigate the impact of the process conditions and catalysts formulation on the blendstock composition in relation with the fuel properties. Co-optima capabilities for fuel properties measurements will be leveraged to assess the potential engines/ vehicles applications of the produced blendstock. A techno-economic-analysis will be conducted to assess the commercial viability of the process for generating a high RON gasoline-range fuel.

09 BIOMASS FUELS↗

DOE OSTI2021

Incentivizing Adoption of Software Quality Practices

Although many software teams across the laboratories comply with yearly software quality engineering (SQE) assessments, the practice of introducing quality into each phase of the software lifecycle, or the team processes, may vary substantially. Even with the support of a quality engineer, many teams struggle to adapt and right-size software engineering best practices in quality to fit their context, and these activities aren’t framed in a way that motivates teams to take action. In short, software quality is often a “check the box for compliance” activity instead of a cultural practice that both values software quality and knows how to achieve it. In this report, we present the results of our 6600 VISTA Innovation Tournament project, "Incentivizing and Motivating High Confidence and Research Software Teams to Adopt the Practice of Quality." We present our findings and roadmap for future work based on 1) a rapid review of relevant literature, 2) lessons learned from an internal design thinking workshop, and 3) an external Collegeville 2021 workshop. These activities provided an opportunity for team ideation and community engagement/feedback. Based on our findings, we believe a coordinated effort (e.g. strategic communication campaign) aimed at diffusing the innovation of the practice of quality across Sandia National Laboratories could over time effect meaningful organizational change. As such, our roadmap addresses strategies for motivating and incentivizing individuals ranging from early career to seasoned software developers/scientists.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗

DOE OSTI2013

Roadmap for development of an advanced head-end reactor

A novel dry treatment process for used nuclear fuel (UNF) using nitrogen dioxide is being developed to remove volatile and semi-volatile fission products and convert the monolithic fuel material to a fine powder suitable as a feed to many different separations processes. The process may be considered an advanced form of voloxidation, which was envisioned to remove tritium from the fuel prior to introduction of the fuel into the aqueous separations systems, where subsequent separation of tritium from the water would be difficult and expensive. The product from NO{sub 2} reaction can be selectively chosen to be U{sub 3}O{sub 8}, UO{sub 3}, or a nitrate by adjusting the processing conditions; all products are generated at temperatures lower than those used in standard voloxidation. All the fundamental tenants of the process have been successfully demonstrated as a proof of principle, and many aspects have been corroborated multiple times at laboratory scale. The goal of this roadmap is to define the activities required to develop the process to a technology-readiness level sufficient to an engineering-scale implementation. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

Extreme shear-deformation-induced modification of defect structures and hierarchical microstructure in an Al–Si alloy

Abstract Extreme shear deformation is used for several material processing methods and is unavoidable in many engineering applications in which two surfaces are in relative motion against each other while in physical contact. The mechanistic understanding of the microstructural evolution of multi-phase metallic alloys under extreme shear deformation is still in its infancy. Here, we highlight the influence of shear deformation on the microstructural hierarchy and mechanical properties of a binary as-cast Al-4 at.% Si alloy. Shear-deformation-induced grain refinement, multiscale fragmentation of the eutectic Si-lamellae, and metastable solute saturated phases with distinctive defect structures led to a two-fold increase in the flow stresses determined by micropillar compression testing. These results highlight that shear deformation can achieve non-equilibrium microstructures with enhanced mechanical properties in Al–Si alloys. The experimental and computational insights obtained here are especially crucial for developing predictive models for microstructural evolution of metals under extreme shear deformation.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Coordination of Plutonium Separations

NASA and the Department of Energy (DOE) are currently working together to reestablish a 238Pu supply capability using DOE's existing facilities and reactors. The effort is being led by Oak Ridge National Laboratory (ORNL). Target rods, containing neptunium oxide (NpO2), are fabricated at ORNL and irradiated in the ORNL High Flux Isotope Reactor (HFIR) currently and soon will be irradiated in the Advanced Test Reactor (ATR) at Idaho National Laboratory (INL). Irradiated targets are processed in hot cells at the ORNL Radiochemical Engineering Center to recover the plutonium (Pu) product and unconverted neptunium (Np) for recycle. The 238PuO2 product is shipped to Los Alamos National Laboratory (LANL) for fabrication of heat source pellets. Key activities, such as the transport of the neptunium to ORNL, irradiation of neptunium, and chemical processing to recover the newly generated 238Pu, have been demonstrated with the initial amounts of ~100 g heat-source plutonium oxide (HS PuO2) produced. Product samples have been shipped to LANL for evaluation, including chemical impurity analysis. This paper will examine the status of producing new 238Pu from irradiated targets.

Wham, Robert↗

DOE OSTI2013

An Efficient Deterministic Parallel Algorithm for Adaptive Multidimensional Numerical Integration on GPUs

Recent development in Graphics Processing Units (GPUs) has enabled a new possibility for highly efficient parallel computing in science and engineering. Their massively parallel architecture makes GPUs very effective for algorithms where processing of large blocks of data can be executed in parallel. Multidimensional integration has important applications in areas like computational physics, plasma physics, computational fluid dynamics, quantum chemistry, molecular dynamics and signal processing. The computationally intensive nature of multidimensional integration requires a high-performance implementation. In this study, we present an efficient deterministic parallel algorithm for adaptive multidimensional numerical integration on GPUs. Various optimization techniques are applied to maximize the utilization of the GPU. GPU-based implementation outperforms the best known sequential methods and achieves a speed-up of up to 100. It also shows good scalability with the increase in dimensionality.

Arumugam, Kamesh↗

DOE OSTI2019

Aerodynamic Improvement of a Compact Centrifugal Compressor

For the example of the JetCat P-200RX turbojet engine, optimization of the diffuser and straightening unit of a compact centrifugal compressor is considered, on the basis of a mathematical model of viscous turbulent air flow. The goal of optimization is to increase the isentropic (adiabatic) efficiency of the compressor.

42 ENGINEERING↗

DOE OSTI2022

Evaluating the intrinsic resistance to balling of alloys: A High-throughput physics-informed and data-enabled approach

To date, the vast majority of work on metal additive manufacturing (AM) has been framed in terms of the need to tune processing conditions for a particular AM technology in order to print conventional alloys, oftentimes developed for fabrication methods other than AM. This approach overlooks the fact that historically, many engineering alloy system has been designed with a particular processing route in mind, e.g., ingot metallurgy, powder metallurgy, rapid quenching, etc. There are thus significant opportunities to design alloys specifically for AM. A key challenge is that alloy design requires performance metrics that can be optimized by exploring the alloy chemistry space. Here, we present a study in which we examine how intrinsic thermophysical properties can be used to estimate performance metrics related to the behavior of a solidifying metal droplet under AM-relevant conditions. By identifying these intrinsic properties, it is possible to directly incorporate ‘intrinsic printability’, specifically ‘intrinsic resistance to balling’, into AM-focused alloy design.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2018

Experimental and Computational Investigation of Subcritical Near-Nozzle Spray Structure and Primary Atomization in the Engine Combustion Network Spray D

In order to improve understanding of the primary atomization process for diesel-like sprays, a collaborative experimental and computational study was focused on the near-nozzle spray structure for the Engine Combustion Network (ECN) Spray D single-hole injector. These results were presented at the 5th Workshop of the ECN in Detroit, Michigan. Application of x-ray diagnostics to the Spray D standard cold condition enabled quantification of distributions of mass, phase interfacial area, and droplet size in the near-nozzle region from 0.1 to 14 mm from the nozzle exit. Using these data, several modeling frameworks, from Lagrangian-Eulerian to Eulerian-Eulerian and from Reynolds-Averaged Navier-Stokes (RANS) to Direct Numerical Simulation (DNS), were assessed in their ability to capture and explain experimentally observed spray details. Due to its computational efficiency, the Lagrangian-Eulerian approach was able to provide spray predictions across a broad range of conditions. In general, this “engineering-level” simulation was able to reproduce the details of the droplet size distribution throughout the spray after calibration of the spray breakup model constants against the experimental data. Complementary to this approach, higher-fidelity modeling techniques were able to provide detailed insight into the experimental trends. For example, interface-capturing multiphase simulations were able to capture the experimentally observed bimodal behavior in the transverse interfacial area distributions in the near-nozzle region. Further analysis of the spray predictions suggests that peaks in the interfacial area distribution may coincide with regions of finely atomized droplets, whereas local minima may coincide with regions of continuous liquid structures. Lastly, the results from this study highlight the potential of x-ray diagnostics to reveal salient details of the near-nozzle spray structure and to guide improvements to existing primary atomization modeling approaches.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2019

Conversion of Diesel Engines to a Gas and Gas–Diesel Cycle

The conversion of diesel engines to gas and gas–diesel cycles during the production process is analyzed. The requirements for conversion to natural-gas operation are presented. The power, efficiency, and environmental impact of diesel engines, natural-gas engines, and gas–diesel engines are compared.

42 ENGINEERING↗

DOE OSTI2019

Decommissioning, Decontamination, and Disposal of LLW-LL, and ILW-LL at a Former Rare Earths Processing Facility in Malaysia - 19087

Geosyntec Consultants, Inc. (Geosyntec) was the design-build Contractor for a project involving the remediation and disposal of low level (LLW-LL and ILW-LL) NORM and TENORM wastes at a former rare earth processing facility in Malaysia. These sites were associated with a plant that extracted rare earth elements from local tin ores. Because of the naturally occurring radioactivity contained in the raw materials, these productions resulted in by-products and residues containing LLW-LL and ILW-LL thorium hydroxide and uranium hydroxide. The total mass of uranium (∼120 tons) and thorium (∼1,200 tons) managed in a single repository required the project design incorporate requirements related to inventory, security and safeguards around nuclear precursor materials. The requirement to consider a performance over a period of more than 10,000 years led to significant challenges in design and modeling of the disposal facility as this disposal facility was purposely designed and permitted as a final disposal for the LLW-LL and ILW-LL. The first phase of the project was the decommissioning, decontamination, and demolition of the 14- acre former rare earth processing plant and excavation of contaminated soils, construction of an engineered cell at the repository for waste disposal, and transportation and disposal of the waste materials into the cell. Final status surveys were carried out to allow the site to be successfully released by the Malaysian regulatory authorities as a clean site for re-development as common industrial use. Over 11,000 loads of material, including approximately 75,000 cubic meters of excavated soils and plant debris, were transported in specially designed steel transport boxes on public roads for disposal in the engineered cell. The second phase of the project included the design and construction of a second engineered cell, enhanced with protective barrier systems and a final cover system constructed of natural materials. Ancillary facilities such as substations, offices, processing buildings, and wastewater treatment plants were constructed to support retrieval and processing of the materials from more than 87,000 individual drums using a semi-automated process. The drums, waste packages, and other materials in the storage facility were systematically extracted, sorted, inventoried, solidified using Portland cement, transported, and disposed in the cell. All temporary facilities were decontaminated, demolished, and disposed in the cell. Radiological inventory and radiation safety programs were implemented to quantify the waste activity and to control exposure to workers and the public during the project. The total mass of radioactive contaminated waste disposed in the two projects is nearly 200,000 tons. The projects were carried out under a high level of scrutiny from Malaysian and international regulatory bodies. Between 2014 and 2017, performance monitoring and modeling activities were carried out to demonstrate that the disposal facility was performing in accordance with design requirements established by regulatory agencies. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2015

Authorization to proceed with production engineering for the waste treatment and immobilization plant's high-level waste facility - 15595

The U.S. Department of Energy restricted certain engineering, procurement, and construction work on the Waste Treatment and Immobilization Plant's (WTP) Pretreatment Facility, and to a lesser degree the High-Level Waste (HLW) Facility in 2012 and early 2013 because of the impact of unresolved technical issues on the facility design, and a misalignment between the facility design and nuclear safety basis. The U.S. Department of Energy, Office of River Protection (ORP) needed a way to minimize project management risk, while continuing limited critical path construction work for the HLW Facility and resolving the technical and safety basis issues. ORP developed a process to systematically address and resolve the technical, management, and quality issues that led DOE to restrict HLW Facility production activities in 2012 and 2013. This process provided for a phased resumption of HLW engineering, procurement, and construction activities on an incremental basis and a final decision for release to full production. In August 2014, ORP provided authorization for the WTP contractor to resume all engineering work necessary to finalize the HLW Facility design. The decision to proceed with production engineering in the HLW Facility, representing the first of two decision points, was based on significant progress in resolving HLW technical issues and improving work processes to align the HLW design and safety basis. Full release for HLW equipment procurements and construction is forthcoming based on conditions that must be fully satisfied and demonstrated during a transition period expected to continue for the next few years. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2026

ACDC (Automated Campbell Diagram Code) [SWR-26-042]

This application provides a web-based graphical user interface to generating Campbell Diagrams and visualizing mode shapes for OpenFAST turbine models. Determining the aeroelastic stability and dynamic characteristics of wind turbines is a critical step in turbine design and analysis. Historically, extracting natural frequencies and mode shapes from OpenFAST—the industry-standard whole-turbine simulation code—has been a fragmented and tedious process. It required manual model configuration, command-line linearization execution, and complex post-processing via proprietary scripts to handle rotating-frame dynamics. To address these workflow bottlenecks, we present the Automated Campbell Diagram Code (ACDC), an open-source graphical software tool developed by the National Laboratory of the Rockies (NLR) under the DOE-funded Distributed Wind Aeroelastic Modeling (dWAM) project. ACDC streamlines the end-to-end linearization and stability analysis workflow into a single, intuitive cross-platform application. The software guides users through OpenFAST model configuration, definition of operating points, and the automated execution of steady-state trim and linearization simulations. Under the hood, ACDC automates the complex mathematical post-processing steps required for rotating systems, including Multi-Blade Coordinate (MBC) transformations, eigenanalysis, and advanced modal tracking utilizing the Modal Assurance Criterion (MAC) and spectral clustering. Finally, ACDC processes these results to automatically generate Campbell diagrams and features a robust 3D visualization engine to animate full-system mode shapes. By eliminating the reliance on external post-processing environments and manual data manipulation, ACDC significantly accelerates dynamic analysis and lowers the barrier to entry for wind energy researchers and engineers.

Summerville, Brent [National Laboratory of the Roc↗

DOE OSTI2024

SMART Deliverable 6.1.2a: Application of the ORION tool to the IBDP Carbon Storage Site

Forecasting and managing potential induced seismic activity is one of the challenges facing commercialscale geologic carbon sequestration (GCS), as well as other geologic energy extraction and byproduct disposal technologies. Historically, the process to develop robust, science-based forecasts of induced seismicity has required an integrated effort from experts in seismology, geomechanics, and reservoir engineering to manage data, develop and evaluate models of subsurface processes, and to calibrate and interpret the results from a range of models to understand site behavior relative to prescribed standards and in the context of uncertainty in geologic characterization data, forecasting models, and operational scenario uncertainty. The Operational Forecasting of Induced Seismicity (ORION) toolkit is an open-source, observation-based forecasting toolkit that is being co-developed by two U.S. DOE-funded initiatives: the National Risk Assessment Partnership (NRAP) and the Scienceinformed Machine Learning for Accelerating Real Time Decisions in Subsurface Applications (SMART) Initiative. ORION is designed to provide functionality to support decision making about seismic hazard analysis and risk management for GCS stakeholders ranging from the public to site operators to expert seismologists. The tool, which is written as open-source code in the Python programming language, is composed of a desktop graphical user interface (GUI) and an underlying forecasting engine. The forecasting engine uses available reservoir properties, well and fluid injection scenario details, and observed seismic catalog data as inputs to produce a set of temporal and spatio-temporal seismic forecasts.

58 GEOSCIENCES↗

DOE OSTI2020

Boride-Carbon Hybrid Technology to Produce Ultra-Wear and Corrosion Resistant Surfaces for Applications in Harsh Conditions (Final Technical Report)

Engineered functional surfaces play an important role to enable new products and manufacturing processes that can endure harsh service conditions such as high impact and contact loads, highly abrasive wear, extreme temperatures, and corrosive environments. Engineered surfaces can also be instrumental to improving the efficient use of energy by reducing frictional losses and extending service life. The main objective of this project was to develop a hybrid surface engineering technology that combines the advantages of a novel ultrafast boriding process with the next generation of superhard carbon coatings. The hypothesis was that this hybrid process will offer an unprecedented combination of wear and corrosion resistance, low frictional losses and affordability for treated parts so that it can be utilized in many applications. During this project, a duplex process was developed that combines the advantages of ultra-fast electrochemical boriding with those of hard tetrahedral amorphous carbon coatings. Both technologies can be combined to form a hybrid technology that is characterized by low friction and wear properties combined with corrosion and fatigue resistance. Good adhesion of both layers to each other was one main goal of this project, that has been achieved with HF1 adhesion through the Rockwell-C adhesion test. In this project, the mechanical properties of the hybrid coating were modeled through a finite-element analysis approach. We can conclude that the FEA model resembles the actual samples and be utilized to predict mechanical behavior under impacts. Based on this model, application-oriented load conditions can be simulated for optimal layer design regarding thickness and mechanical properties. To exemplify, one conclusion that can be drawn from the nanoindentation model is a boride layer thickness of 50 µm is sufficient to effectively support the carbon coating on the identified AISI 1045 low carbon steel substrate material. The duplex treatment yields wear rates as low as 6 x 10 -8 mm 3 N -1 m -1 and a coefficient of friction of 0.14 when tested against a steel counter face in a ball-on-disk test setup. On the other hand, the wear rate of the only-borided AISI 1045 steel was 5 x 10 -5 mm 3 N -1 m -1 , about three orders of magnitude higher than the duplex coating. At the same time, duplex treated samples experience corrosion resistance, which could not be achieved with single-layer carbon coatings. The developed surface treatment withstands a 3-hour exposure to 15% HCl, while the only carbon coated counter sample shows severe delamination of the coating due to pin hole corrosion. The boride layer is chemically stable and pin hole free because it is formed through an electrochemical process under high current densities (700 mA/cm 2 ) and high temperature. Additionally, the hybrid coating led to at least 3x increase in fatigue strength of the steel substrate, which exceeds the target performance of 30% improvement. There are numerous potential applications for the duplex coatings. A representative application is bearing ball coatings for off-shore windmills. Compared to currently employed surface technologies in this field, the initial costs of applying our technology might be higher due to more process steps but the performance benefits lead to an increased life time of treated parts, which will lower the maintenance and replacement costs in the long-term. To validate the technology for this specific application, the team is currently investigating the process of white etching crack initiation of the duplex coating in collaboration with ANL. Overall, this project successfully validated that the boride-carbon hybrid technology can withstand harsh conditions. One possible approach to commercialization under consideration is to transfer the technology to a startup or an existing coatings company.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Abstract for CRADA between NETL and the University of Massachusetts Lowell (AGMT-1275)

The demand for printed electronics over conventional electronics is growing each year due to their low costs, low material waste during manufacturing, and compatibility with flexible substrates. The development of inks for printed electronics is a challenge because each printing technology requires different viscosities and curing behaviors to create devices with controlled structures at the micron scale, or smaller. Carbon is a great candidate for fabricating printed electronics devices because it is inexpensive and earth abundant, easily functionalized to impart miscibility with solvent systems, and has electrical properties that can be tuned from insulating to conducting. Despite these advantages, carbons are rarely used for printed electronics because there is a scarcity of inks available for non-contact printing technologies. To address these challenges, the National Energy Technology Laboratory (NETL) will collaborate with the University of Massachusetts Lowell (Participant) through its Printed Electronics Research Collaborative (PERC) to develop engineered carbons and ink formulations optimized specifically for printing radio- and microwave-frequency electronic devices using ink jet, aerosol jet, syringe dispensing, and other additive manufacturing techniques. NETL will process coal, petroleum, and other carbon feedstocks to make engineered carbons with the appropriate composition, microstructure, surface functionalization, and particle morphologies needed to stabilize ink suspensions and impart useful electronic properties to printed devices. The University of Massachusetts Lowell will utilize these engineered carbons to determine which solvent systems and ink additives are needed to achieve the appropriate viscosity, stability, and printability to make useful ink formulations. The University of Massachusetts Lowell will then utilize these inks to manufacture printed resistors and conductors using inkjet, aerosol jet, and syringe dispensing printing methods and will characterize device performance using four-point probe resistivity measurements, contact angle measurements to assess wettability, adhesion evaluation to various substrates, and focused ion beam and scanning electron microscopy for surface and density investigations of printed devices.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Image-Based Fracture Surface Defect Characterization Methods for Additively Manufactured Ti-6Al-4V Tested in Fatigue

Abstract Fatigue initiation in additively manufactured samples/parts often occurs at processed-induced defects such as lack-of-fusion (LoF), keyhole, or other morphological/microstructural defects that have unique characteristics and measurable qualities. Attempts at identifying and minimizing such defects have utilized optimized processing conditions along with in situ and ex situ characterization that includes metallography and/or X-ray computed tomography (XCT). This paper highlights the benefits of using fracture surface analyses to detect and quantify defects that may not be detected by metallography/XCT due to sectioning and resolution limits. In addition to using manual quantification of fatigue initiating LoF and keyhole defects on fracture surfaces, image-based machine learning using convolutional neural networks such as U-Net were also used to automate the process. Statistical analyses were used to identify the extreme cases of defects that initiated and accelerated fatigue and to model the distribution of defect size and shape characteristics to distinguish the type of defect. Initial results show agreement between trained machine learning models and ground truth data in defect segmentation, and the distributions of defect characteristics are distinguishable to particular process-induced defect types.

Materials Science↗

DOE OSTI2021

Wood-to-Fuel Demonstration Project for California's Transportation Sector using Autothermal Pyrolysis (Non-Proprietary Summary Process Hazard Assessment)

Frontline has prioritized personnel safety, equipment preservation, and environmental protection throughout the design process of the autothermal pyrolysis unit. To facilitate a safe design, Frontline completed an informal hazards and operability (HAZOP) study and a formal HAZOP study, and employ management of change procedures. The result of these safety procedures is a plant that will function in a safe manner with a limited and acceptable amount of risk. Frontline took an approach it used in previous projects to execute a preliminary, internally facilitated hazards and operability (HAZOP) study. While this HAZOP study was performed without any subsequent change tracking, it enables a group of well-trained engineers to consider the safety implications of each part of the plant in a thorough and methodical manner. Frontline chose to bring in a pyrolysis consultant (Daren Daugaard of Burning Oak Energy) to participate in the review. Following the preliminary HAZOP and once the detailed design work was nearing completion, Frontline performed a formal HAZOP with a third-party facilitator, Jason Stittleburg of Novetus Engineering. Although the plant is not subject to process safety management (PSM) requirements, this formal HAZOP was performed in accordance with OSHA regulations deemed reasonable for PSM. Finally, after the formal HAZOP was conducted, Frontline maintained a safe system by implementing and following management of change procedures on each substantial change to the process. Frontline has kept a record of each subsequent change made to the formal HAZOP P&IDs. The process hazard assessment process allowed Frontline to find and correct several unacceptable configurations within the plant.

09 BIOMASS FUELS↗