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NASA NTRS1977

Simplified and refined structural modeling for economical flutter analysis and design

A coordinated use of two finite-element models of different levels of refinement is presented to reduce the computer cost of the repetitive flutter analysis commonly encountered in structural resizing to meet flutter requirements. One model, termed a refined model (RM), represents a high degree of detail needed for strength-sizing and flutter analysis of an airframe. The other model, called a simplified model (SM), has a relatively much smaller number of elements and degrees-of-freedom. A systematic method of deriving an SM from a given RM is described. The method consists of judgmental and numerical operations to make the stiffness and mass of the SM elements equivalent to the corresponding substructures of RM. The structural data are automatically transferred between the two models. The bulk of analysis is performed on the SM with periodical verifications carried out by analysis of the RM. In a numerical example of a supersonic cruise aircraft with an arrow wing, this approach permitted substantial savings in computer costs and acceleration of the job turn-around.

Ricketts, R. H.↗

DOE OSTI2024

Retrofitting Holcim Ste. Genevieve Cement Plant with CO2 Capture Plant Using Air Liquide Cryocap™ FG Technology

The global cement manufacturing industry is a major contributor to carbon dioxide emissions. The International Energy Agency's "Net Zero Emissions by 2050 Scenario" identifies CCS as a major strategy for meeting that goal. This project is among the first attempts to transfer capture technology developed at coal-fired power plants to the cement industry. The main objective of the project is to execute and complete a front-end engineering and design (FEED) studies for commercial-scale, carbon capture projects that separates 95% of the total CO2 emissions at the Holcim (US) Ste. Genevieve cement manufacturing facility using Air Liquide’s Pressure Swing Adsorption system (PSA) assisted Cryocap™ technology. The Holcim Ste. Genevieve cement plant in Missouri, US, boasts one of the largest single cement production lines in the world, with a capacity of approximately 12,000 t/day. The plant currently uses traditional fuels, namely coal and petcoke. The captured CO2 will be pipeline and geological storage grade. The industrial host site emits approximately 3.0 million tonne CO2/yr. Air Liquide’s Cryocap™ technology has been developed over the last 18+ years for CO2 capture applications. It has been shown to be applicable to a variety of industrial applications (e.g., steel, cement, SMR, Fluidized Catalytic Crackers (FCCs)). Cryocap™ FG consists of a Pressure Swing Adsorption (PSA) unit coupled with a Cryogenic System. The PSA pre-concentrates the CO2 from the flue gas, while the cryogenic unit enables the CO2 purity to be increased to the desired level. The project team is led by the Prairie Research Institute at the University of Illinois at Urbana-Champaign. The tasks include: complete FEED study for retrofitting the industrial facility with a carbon capture system to support developing a detailed cost estimate; business case analysis outlining the anticipated revenue and credits if projects was built and operated; technoeconomic analysis (TEA) outlining how capture system achieves DOE capture goals; and life cycle (LCA) analysis demonstrating zero net carbon emissions. The FEED study was successfully completed. This includes completing the process basis of design; preliminary engineering; outside battery limits (OSBL) detailed engineering including a Zero Liquid Discharge (ZLD) wastewater treatment system; inside battery limits (ISBL) detailed engineering [1]. An overall project capital cost estimate within a -20%/+30% accuracy was developed. The major contributors to the Total Plant Cost (TPC), by system, are the costs associated with the Outside Battery Limit (OSBL) section of the plant which includes a new river water intake structure and a Zero Liquid Discharge (ZLD) system. By cost category, the major contributors to the TPC are equipment and subcontractor costs, followed closely by engineering, construction management, home office and contractor fees. The TEA has been created to reflect the findings of the project. It analyzes the economic performance of the Cryocap™ technology by reviewing the estimated capital costs, operating cost, and revenue. The Cost of Capture (COC) associated with the Cryocap™ technology for 95% CO2 capture, when considering NETL 2018 economic assumptions (42/58 debt/equity ratio, 5.15% interest on debt and 1.42% return on equity in real dollars) and 2022 economic assumptions (42/58 debt/equity ratio, 8.82% interest on debt and 4.90% return on equity in real dollars) was found to be much lower than that for the DOE-NETL’s base-line cases. The highest contributors to the COC are annualized capital expenditures (CAPEX) and electricity consumption which can be offset by using lower cost renewable sources. The LCA was conducted using OpenLCA which is an open-source software that is recommended by NETL. The database utilized for this study was a modified version of TRACI 2.1 (developed by the US. Environmental Protection Agency’s National Risk Management Research Laboratory and modified by NETL). The Cryocap™ FG technology does not consume fuels in significant quantities and does not utilize specialized chemical solvents subject to decomposition, such as those utilized in amine-based carbon capture systems. The Cryocap™ FG technology mainly utilizes electricity as its energy input; hence, its calculated emissions are mainly associated with the generation of electricity offsite and are dependent on the energy matrix of the grid at the time of project implementation. The water consumption impact of the Cryocap™ FG is mostly for makeup of the water lost by evaporation in the cooling tower; however, the carbon capture plant will be equipped with a ZLD system to avoid effluent streams and minimize water consumption. The successful construction and operation of this plant based on this study results will provide a means to demonstrate an economically attractive and transformational capture technology that can be used to retrofit existing plants and be deployed at new plants.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2023

2021 Cost of Wind Energy Review [Slides]

This analysis uses representative utility-scale and distributed wind energy projects to estimate the levelized cost of energy (LCOE) for land-based, offshore, and distributed wind power in the United States. Data and results detailed here are derived from 2021 commissioned plants and representative industry data as well as state-of-the-art modeling capabilities. Modeling is conducted to provide more granular detail on specific cost categories. This study represents the 11th annual installment and is intended to provide insight into current component-level costs as well as a basis for understanding variability in wind energy LCOE across the country.

17 WIND ENERGY↗

NASA NTRS1977

Composite hubs for low cost gas turbine engines

A detailed stress analysis was performed using NASTRAN to demonstrate theoretically the adequacy of composite hubs for low cost turbine engine applications. Composite hubs are adequate for this application from the steady state stress view point.

Chamis, C. C.↗

DOE OSTI2022

Electron dynamics in extended systems within real-time time-dependent density-functional theory

Due to a beneficial balance of computational cost and accuracy, real-time time-dependent density-functional theory has emerged as a promising first-principles framework to describe electron real-time dynamics. Here we discuss recent implementations around this approach, in particular in the context of complex, extended systems. Results include an analysis of the computational cost associated with numerical propagation and when using absorbing boundary conditions. Here we extensively explore the shortcomings for describing electron–electron scattering in real time and compare to many-body perturbation theory. Modern improvements of the description of exchange and correlation are reviewed. In this work, we specifically focus on the Qb@ll code, which we have mainly used for these types of simulations over the last years, and we conclude by pointing to further progress needed going forward.

2D materials↗

DOE OSTI2024

Woody Feedstock 2022 State of Technology Report

The U.S. Department of Energy promotes production of advanced liquid transportation fuels from lignocellulosic biomass by funding fundamental and applied research that advances the state of technology (SOT). As part of its involvement in this mission, Idaho National Laboratory completes an annual SOT report for n th -plant and 1 st -plant woody biomass feedstock logistics. The purpose of the SOT is to provide the status of feedstock supply system technology development for woody biomass to biofuels relative to technical targets and cost goals from specific design cases, based on data and experimental results. Conventional feedstock supply systems need to be modified to meet the demands of conversion pathways, specifically to have the ability to adjust the quality of the raw biomass materials. Advanced systems incorporate innovative methods of material handling, preprocessing and supply chain configuration. In advanced designs, variability of the raw biomass can be reduced to produce feedstocks of a uniform format, moving toward biomass commoditization. Against this backdrop, the 2022 Woody SOT for low-ash woody feedstocks utilizes feedstock fractionation by incorporating technologies that can separate the biomass into its anatomical fractions (wood, bark, needle, and extrinsic ash) to reduce impurities and attempt to maximize the retention of usable fractions that satisfy downstream quality considerations. By using a series of air classification steps, this strategy can reduce the extrinsic ash in forest residues, separate out a majority of the incoming needles (which can be supplied to alternate markets), and maximize the retention of whitewood in the usable fraction. The fractionated forest residues are then mixed with clean-pine chips in a 50-50 blend to prepare the feedstock for the desired conversion pathway. The n th -plant analysis estimated the delivered cost for the feedstock at $\$$69.23/dry ton (2016$\$$) which represents a $\$$6.64/dry ton decrease compared to the cost estimate of the 2021 Woody SOT supply system for low-ash woody feedstocks. The quality requirements in the 2022 Woody SOT were identical to those of the 2021 Woody SOT at = 1.00 wt % ash and = 50.51 wt% carbon. The cost savings derive primarily from reductions in dry matter losses during air classification. The GHG emissions for the n th -plant analysis were estimated at 178.39 kg CO2e/dry ton compared to 178.71 kg CO 2 e/dry ton in the 2021 Woody SOT, a decrease of 0.32 kg CO2e/dry ton. The small change stems from an increase in emissions attributed to preprocessing and slightly larger savings in emissions from transportation. In the 1 st -plant analysis of the 2022 Woody SOT system, the average throughput was estimated to be approximately 2,128 dry tons/day or 96.51% of the name plate capacity. During the simulation the daily throughput ranged from 1,090 dry tons/day to 2,200 dry tons/day, or 49.43% to 99.75% of the daily nameplate capacity. After the year of operation 722,403 tons of processed feedstock were produced in total without regard to quality considerations (99.64% of the annual nameplate capacity). The variability in throughput was primarily caused by equipment failures in the system. Regular failures, downtime caused by routine maintenance per manufacturer guidelines, contributed to a majority 62.50% of failures and 62.60% of downtime. Failures due to wear were the other cause of disruption within the system, impacting the rotary shear and orbital screen and accounting for 37.50% of the failures and 37.40% of the total downtime. Ultimately the system was on stream for 87.84% during the simulation period, which is only 2.16 percentage points below the nth-plant assumption for on-stream time. The production cost of the system averaged $\$$71.66/dry ton. The costs ranged from a minimum of $\$$71.23/dry ton to a maximum of $\$$2,115.30/dry ton. When dry matter losses (disposed low-quality fractions as well as other losses such as in grinders) were considered the costs increased to an average of $\$$75.11/dry ton with a minimum of $\$$74.69/dry ton and a maximum of $\$$2,136.86/dry ton...

09 BIOMASS FUELS↗

NASA NTRS2017

Need for Cost Optimization of Space Life Support Systems

As the nation plans manned missions that go far beyond Earth orbit to Mars, there is an urgent need for a robust, disciplined systems engineering methodology that can identify an optimized Environmental Control and Life Support (ECLSS) architecture for long duration deep space missions. But unlike the previously used Equivalent System Mass (ESM), the method must be inclusive of all driving parameters and emphasize the economic analysis of life support system design. The key parameter for this analysis is Life Cycle Cost (LCC). LCC takes into account the cost for development and qualification of the system, launch costs, operational costs, maintenance costs and all other relevant and associated costs. Additionally, an effective methodology must consider system technical performance, safety, reliability, maintainability, crew time, and other factors that could affect the overall merit of the life support system.

Costs↗

DOE OSTI2024

The Impact of Cement Plant Air Ingress on Membrane-Based CO2 Capture Retrofit Cost

This PowerPoint presentation summarizes the cost and performance results of the techno-economic analysis of membrane-based carbon capture retrofits at cement plants, published in June 2024, titled “The Impact of Cement Plant Air Ingress on Membrane-Based CO2 Capture Retrofit Cost.” The analysis report used as a basis for slide contents was developed by NETL for publication in the scientific journal Carbon Capture Science and Technology.

Hughes, Sydney↗

DOE OSTI2024

The Impact of Cement Plant Air Ingress on Membrane-Based CO2 Capture Retrofit Cost

Hughes, Sydney↗

NASA NTRS1981

Economics of ingot slicing with an internal diameter saw for low-cost solar cells

Slicing of silicon ingots using diamond impregnated internal diameter blade saws has been a standard technology of the semiconductor industry. This paper describes work on improvements to this technology for 10 cm diameter ingot slicing. Ingot rotation, dynamic blade edge control with feedback, mechanized blade dressing and development of thinner blades are the approaches tried. A comparison of the results for wafering with and without ingot rotation is also made. A sensitivity analysis of the major cost elements in wafering is performed for 10 cm diameter ingot and extended to the 15 cm diameter ingot case. Various parameter values such as machine cost, feed rate and consumable materials cost are identified both for single and multiple ingot slicing.

Daud, T.↗

DOE OSTI2022

DEVELOPMENT OF OIL FREE CENTRIFUGAL BLOWER AS ENABLING TECHNOLOGY FOR SOLID OXIDE FUEL CELL ANODE GAS RECYCLING

Broad commercialization of solid oxide fuel cells (SOFCs), requires anode offgas recycle blowers (AORB) that are specifically designed for handling the challenging operating conditions presented by the SOFC process gases. Otherwise, they can be susceptible to frequent maintenance, low reliability, and short life. This work presents details of the development and testing of an oil-free, low cost centrifugal AORB based on compliant foil bearing (CFB) technology for support of a 100 kW solid oxide fuel cell power plant. The advantages of this novel technology are discussed, particularly its long life and maintenance-free operation, which are derived from the use of CFBs. Also included are preliminary techno-economic analysis considerations for cost-effective deployment of the technology.

03 NATURAL GAS↗

DOE OSTI2020

Potential Advantages to Employing an Onsite Laboratory at FUSRAP Sites Contaminated with Radionuclides and Metals - 20353

Various factors that support an evaluation of the relative costs, advantages and disadvantages of utilizing an onsite laboratory or an offsite laboratory for remediation of Formerly Utilized Sites Remedial Action Program (FUSRAP) sites contaminated with radionuclides and metals are presented. In terms of how much more quickly an onsite laboratory provides results versus an offsite laboratory, the results of this study provide tools for calculating the amount of cost savings per day for excavation of contaminated soils for various scenarios including: - State, municipal or local property remediation where the remediation schedule becomes time-critical due to the extra cost and inconvenience to the town or municipality caused by the need for increased security and safety personnel, possible road closures and detours, and the inconvenience to the public due to modified or decreased services of State or municipal facilities; - Residential property where the remediation schedule becomes time-critical due to the inconvenience to the homeowner as well as the importance of maintaining good community relations; - Commercial property where the remediation schedule becomes time-critical due to the hardship and potential loss of revenue endured by the property owner; - Open area where treatment of excavation water is required, and - Open area where treatment of excavation water is not required. For every scenario, the number of matrices, radionuclide and metal contaminants of concern and the project duration are important factors. The costs for the onsite laboratory included the capital costs associated with setting up the lab such as trailer(s) or building(s), power and water hookup, analytical testing equipment, balances, computers, desks and bookcases; support equipment such as hot plates, filtration assemblies, safety equipment, ovens, etc.; and supplies such as glassware, pipettes, filters, etc. and ongoing costs such as labor, chemicals and reagents, standards, cost of the laboratory obtaining certification and maintenance. Offsite laboratory sample testing costs are generally very competitive and typically substantially lower than onsite laboratory costs if only the sample testing costs are considered. The great disadvantage of using an offsite laboratory is that they often cannot guarantee rapid turnaround times for results which creates project delays associated with the remediation process including delays determining the completeness of the characterization and remediation processes, delays in backfilling a property and additional costs for treating wastewater (excavation water, stormwater or both). These costs will vary greatly depending upon the area of the country in which the project is located due to the wide range of labor costs for the onsite laboratory and field workers, as well as the contaminants of interest, matrices and most importantly the size of the impacted area and the number of properties located in that area. This paper provides guidelines for calculating the cost savings that may be realized if an onsite laboratory can generate results more quickly than an offsite laboratory by estimating the costs associated with the remediation process for the various scenarios noted above such as work crew labor costs, excavator and dump truck equipment rentals, wastewater treatment costs (if applicable) and the additional costs incurred by homeowners, commercial property owners and towns/municipalities that are reimbursed by the potentially responsible parties. Key assumptions involve the typical quickest turnaround time provided by the onsite and offsite laboratories. Costs for the operation of a wastewater treatment system and the remediation of a site area or property were provided by personnel who have been involved in the operation of a large FUSRAP site in New Jersey for many years. This study provides valuable information for determining the most cost-effective approach for analysis of project samples and therefore may be used on upcoming FUSRAP projects. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2023

A data analysis method to rapidly characterize gallium concentration in plutonium matrices using LIBS

The processing of actinide samples is a complex and costly endeavor that requires compositional analysis at various stages. Laser-induced breakdown spectroscopy (LIBS) has been used to analyze actinide-containing samples in many nuclear applications including waste management, fuel processing and forensics. The LIBS spectrum obtained from actinide materials are generally extremely complex, exhibiting many thousands of strong emission lines. This makes it difficult to identify other elements within the sample of interest, given the rich and dominant actinide spectrum. Here, in this article, we describe a recent effort to identify and quantify impurities and alloying constituents in plutonium matrices using a hand-held LIBS instrument that is used to rapidly and efficiently measure an emission spectrum from a material sample. We tabulate the emission line positions and intensities of plutonium. We report the development of machine-learning software that can identify gallium and quantify its concentration in plutonium matrices. This work has the potential to provide a rapid and nearly non-destructive technique that allows more confidence in characterizing the composition of materials that are present within complex actinide associated targets. We describe how our LIBS measurements and data analysis methods have successfully quantified the gallium concentration in a variety of samples.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

A Kinetic Model-Driven Techno-Economic Analysis of Plastic Pyrolysis: Linking Process Dynamics to Economic Viability

This study employs a kinetic model integrated into Aspen Plus to predict pyrolysis product distribution under various conditions. A techno-economic assessment calculated the minimum selling price (MSP) of pyrolysis oil under different operating conditions for the baseline capacity of 100 kta, and across eight processing capacities ranging from 30 to 150 kta. The lowest MSP under the baseline capacity is estimated at $\$$420/ton, which is 33% lower than the 2023 average US crude oil price ($\$$74.6/bbl, equivalent to $\$$634/ton based on the density of pyrolysis oil). Under Monte Carlo simulation, accounting for variability in key economic and technical parameters, the mean MSP is estimated at $\$$1137/ton. The economic viability depends on feedstock price remaining below $\$$320/ton, defining the break-even feedstock price threshold. Sensitivity analysis further identifies capital investment and transportation cost as key economic drivers. Capacities beyond 90 kta show limited economies of scale benefits. Reducing product storage time cuts capital costs by 7% but raises operational risk. Uncertainty analysis suggests the economic feasibility of pyrolysis oil is unlikely to compete with crude oil without policy incentives.

petrochemicals↗

DOE OSTI2024

Cost effectiveness of preemptive school closures to mitigate pandemic influenza outbreaks of differing severity in the United States

Background: Nonpharmaceutical interventions (NPIs) may be considered as part of national pandemic preparedness as a first line defense against influenza pandemics. Preemptive school closures (PSCs) are an NPI reserved for severe pandemics and are highly effective in slowing influenza spread but have unintended consequences. Methods: We used results of simulated PSC impacts for a 1957-like pandemic (i.e., an influenza pandemic with a high case fatality rate) to estimate population health impacts and quantify PSC costs at the national level using three geographical scales, four closure durations, and three dismissal decision criteria (i.e., the number of cases detected to trigger closures). At the Chicago regional level, we also used results from simulated 1957-like, 1968-like, and 2009-like pandemics. Our net estimated economic impacts resulted from educational productivity costs plus loss of income associated with providing childcare during closures after netting out productivity gains from averted influenza illness based on the number of cases and deaths for each mitigation strategy. Results: For the 1957-like, national-level model, estimated net PSC costs and averted cases ranged from $\$7.5$ billion (2016 USD) averting 14.5 million cases for two-week, community-level closures to $\$97$ billion averting 47 million cases for 12-week, county-level closures. We found that 2-week school-by-school PSCs had the lowest cost per discounted life-year gained compared to county-wide or school district–wide closures for both the national and Chicago regional-level analyses of all pandemics. The feasibility of spatiotemporally precise triggering is questionable for most locales. Theoretically, this would be an attractive early option to allow more time to assess transmissibility and severity of a novel influenza virus. However, we also found that county-wide PSCs of longer durations (8 to 12 weeks) could avert the most cases (31–47 million) and deaths (105,000–156,000); however, the net cost would be considerably greater ($\$88$-$\$103$ billion net of averted illness costs) for the national-level, 1957-like analysis. Conclusions: We found that the net costs per death averted ($\$180,000$-$\$4.2$ million) for the national-level, 1957-like scenarios were generally less than the range of values recommended for regulatory impact analyses ($\$4.6$ to 15.0 million). This suggests that the economic benefits of national-level PSC strategies could exceed the costs of these interventions during future pandemics with highly transmissible strains with high case fatality rates. In contrast, the PSC outcomes for regional models of the 1968-like and 2009-like pandemics were less likely to be cost effective; more targeted and shorter duration closures would be recommended for these pandemics.

60 APPLIED LIFE SCIENCES↗

NASA NTRS1990

Performance bounds on parallel self-initiating discrete-event

The use is considered of massively parallel architectures to execute discrete-event simulations of what is termed self-initiating models. A logical process in a self-initiating model schedules its own state re-evaluation times, independently of any other logical process, and sends its new state to other logical processes following the re-evaluation. The interest is in the effects of that communication on synchronization. The performance is considered of various synchronization protocols by deriving upper and lower bounds on optimal performance, upper bounds on Time Warp's performance, and lower bounds on the performance of a new conservative protocol. The analysis of Time Warp includes the overhead costs of state-saving and rollback. The analysis points out sufficient conditions for the conservative protocol to outperform Time Warp. The analysis also quantifies the sensitivity of performance to message fan-out, lookahead ability, and the probability distributions underlying the simulation.

Nicol, David M.↗

NASA NTRS2016

Kickstarting a New Era of Lunar Industrialization via Campaign of Lunar COTS Missions

To support the goals of expanding our human presence and current economic sphere beyond LEO, a new plan was constructed for NASA to enter into partnerships with industry to foster and incentivize a new era of lunar industrialization. For NASA to finally be successful in achieving sustainable human exploration missions beyond LEO, lessons learned from our space history have shown that it is essential for current program planning to include affordable and economic development goals as well as address top national priorities to obtain much needed public support. In the last 58 years of NASA's existence, only Apollo's human exploration missions beyond LEO were successful since it was proclaimed to be a top national priority during the 1960's. However, the missions were not sustainable and ended abruptly in 1972 due to lack of funding and insufficient economic gain. Ever since Apollo, there have not been any human missions beyond LEO because none of the proposed program plans were economical or proclaimed a top national priority. The proposed plan outlines a new campaign of low-cost, commercial-enabled lunar COTS (Commercial Orbital Transfer Services) missions which is an update to the Lunar COTS plan previously described. The objectives of this new campaign of missions are to prospect for resources, determine the economic viability of extracting those resources and assess the value proposition of using these resources in future exploration architectures such as Mars. These missions would be accomplished in partnership with commercial industry using the wellproven COTS Program acquisition model. This model proved to be very beneficial to both NASA and its industry partners as NASA saved significantly in development and operational costs, as much as tenfold, while industry partners successfully expanded their market share and demonstrated substantial economic gain. Similar to COTS, the goals for this new initiative are 1) to develop and demonstrate cost-effective, cis-lunar commercial services, such as lunar transportation, lunar mining and lunar ISRU operations; 2) enable development of an affordable and economical exploration architecture for future missions to Mars and beyond; and 3) to incentivize the creation of new lunar markets through use of lunar resources for economic benefit to NASA, commercial industry and the international community. These cost-effective services would not only enable NASA to economically and sustainably achieve its human exploration missions to the Moon, Mars and beyond but it would also kickstart a new era of lunar industrialization. This paper will describe the goals, objectives and approach for implementing this new campaign of missions. It will also describe the potential benefits and progress that can be accomplished with these low-cost, Lunar COTS missions. Lastly, a preliminary economic analysis approach is proposed for understanding the cost and potential return on investment in the use of lunar resources to reach the goal of lunar industrialization and an expanded and sustainable human presence into cis-lunar space and beyond.

Lunar Exploration↗

DOE OSTI2021

Project Final Report - Advanced Oxygen Separation from Air Using a Novel Mixed Matrix Membrane

This report describes a summary of the findings of the project. The technical work was divided into three activities: 1) technoeconomic analysis; 2) membrane component development (support layer, selective layer development, and gutter layer formulation); and 3) hollow fiber formation. The technoeconomic analysis includes operating, capital, and materials costs of an oxygen enrichment system with 1-3 stages. The analysis concluded that the desired gas quality (90-95% O2) cannot be reached with a single stage. The triple stage system yielded the best overall product quality at lower membrane performance levels but with the highest cost. For the membrane development activities, functionalized nanodiamonds have been shown to slightly improve membrane formation behaviors and gas permeability performance. For example, support layers based on polysulfone-nanodiamond composites have been formed that increase the material’s O2 permeability by over a factor of 150, however, at the cost of selectivity that suggests a change in transport mechanism. Furthermore, nanodiamonds have been found to improve membrane durability. Improvements in selective and gutter layers also have been accomplished. An additional accomplishment is the demonstration of phase inversion of polysulfone-nanodiamond composites that ensures that hollow fiber formation can be performed. Finally, the interfaces between support, gutter, and selective layers were briefly examined and the resulting membrane material consisting of all three layers gave good performance in an O2 separation from N2. The three-layer prototype membrane gave permeability of 29.2-32.2 Barrers, which equates to permeance of approximately 290-320 GPU, which is lower than the TEA informed goal of 500 GPU. O2/N2 selectivity ranged from 5.2-6.2, which is consistent with the less costly two-stage implementation of the technology. In summary, new materials have been developed for O2 concentration from air and are well-suited to a hollow fiber format.

20 FOSSIL-FUELED POWER PLANTS↗