SEARCH · Engineering Papers

Results for “production process”

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 1,513 records · Page 84

All sources NASA NTRS DOE OSTI

NASA NTRS1979

Electrochemistry of lunar rocks

Electrolysis of silicate melts has been shown to be an effective means of producing metals from common silicate materials. No fluxing agents need be added to the melts. From solution in melts of diopside (CaMgSi2O6) composition, the elements Si, Ti, Ni, and Fe have been reduced to their metallic states. Platinum is a satisfactory anode material, but other cathode materials are needed. Electrolysis of compositional analogs of lunar rocks initially produces iron metal at the cathode and oxygen gas at the anode. Utilizing mainly heat and electricity which are readily available from sunlight, direct electrolysis is capable of producing useful metals from common feedstocks without the need for expendable chemicals. This simple process and the products obtained from it deserve further study for use in materials processing in space.

Lindstrom, D. J.↗

NASA NTRS1992

Removing Undesired Fine Powder From Silicon Reactor

Fluidized-bed reactor produces highly pure polycrystalline silicon particles with diameters approximately greater than 400 micrometers. Operates by pyrolysis of silane in reaction zone, which is bed of silicon seed particles fluidized by flow of silane and carrier gas. Above reaction zone, gas mixture flows rapidly enough to entrain silicon powders, but not larger seed and product particles. Entrained particles swept out of reactor. Applicable to other processes such as production of fine metal and ceramic powders where control of sizes of product needed.

Flagella, Robert N.↗

NASA NTRS2007

TRMM Gridded Text Products

NASA's Tropical Rainfall Measuring Mission (TRMM) has many products that contain instantaneous or gridded rain rates often among many other parameters. However, these products because of their completeness can often seem intimidating to users just desiring surface rain rates. For example one of the gridded monthly products contains well over 200 parameters. It is clear that if only rain rates are desired, this many parameters might prove intimidating. In addition, for many good reasons these products are archived and currently distributed in HDF format. This also can be an inhibiting factor in using TRMM rain rates. To provide a simple format and isolate just the rain rates from the many other parameters, the TRMM product created a series of gridded products in ASCII text format. This paper describes the various text rain rate products produced. It provides detailed information about parameters and how they are calculated. It also gives detailed format information. These products are used in a number of applications with the TRMM processing system. The products are produced from the swath instantaneous rain rates and contain information from the three major TRMM instruments: radar, radiometer, and combined. They are simple to use, human readable, and small for downloading.

Stocker, Erich Franz↗

DOE OSTI2020

Biodiesel production from engineered sugarcane lipids under uncertain feedstock compositions: Process design and techno-economic analysis

In this study, different process schemes were designed and evaluated for biodiesel production from engineered cane lipids with uncertain fatty acid compositions. Four different process schemes were compared under (i) thermal glycerolysis and (ii) enzymatic glycerolysis approaches. These schemes were based on the biodiesel yield and economic indicators such as the net present value (NPV) and the minimum selling price (MSP) of biodiesel. A scheme with polar lipid separation under thermal glycerolysis resulted in the maximum NPV ($\$96.5$ million) and minimum MSP ($\$1107$ /ton biodiesel), respectively. Through local sensitivity analysis, it was concluded that the cane lipid percentage is the most significant factor influencing process economics. A conjoint analysis of the lipid procurement price and cane lipid percent suggested that 15% cane lipids with a low lipid procurement price ($\$0.536$ /kg) results in a positive NPV. When the cane lipid price is higher (> $\$0.80$ /kg), a 20% lipid content should be considered to achieve a positive NPV. At 20% cane lipids, the worst-case and best-case scenarios were evaluated by analyzing the interplay of the three most important parameters, Here, the best-case scenario revealed that the minimum NPV under any process scheme could yield more than $\$100$ million (or MSP: $\$0.80$ /L), and the worst-case analysis showed that losses incurred by the plant could be as high as 80 million (MSP: $\$1.36$ /L). A Monte Carlo simulation indicated that there is a 70% chance of the plant being profitable (NPV > 0).

09 BIOMASS FUELS↗

DOE OSTI2020

Data from Biodiesel Production from Engineered Sugarcane Lipids under Uncertain Feedstock Compositions: Process Design and Techno-Economic Analysis

In this study, different process schemes were designed and evaluated for biodiesel production from engineered cane lipids with uncertain fatty acid compositions. Four different process schemes were compared under (i) thermal glycerolysis and (ii) enzymatic glycerolysis approaches. These schemes were based on the biodiesel yield and economic indicators such as the net present value (NPV) and the minimum selling price (MSP) of biodiesel. A scheme with polar lipid separation under thermal glycerolysis resulted in the maximum NPV ($96.5 million) and minimum MSP ($1107/ton biodiesel), respectively. Through local sensitivity analysis, it was concluded that the cane lipid percentage is the most significant factor influencing process economics. A conjoint analysis of the lipid procurement price and cane lipid percent suggested that 15% cane lipids with a low lipid procurement price ($0.536/kg) results in a positive NPV. When the cane lipid price is higher (>$0.80/kg), a 20% lipid content should be considered to achieve a positive NPV. At 20% cane lipids, the worst-case and best-case scenarios were evaluated by analyzing the interplay of the three most important parameters, The best-case scenario revealed that the minimum NPV under any process scheme could yield more than $100 million (or MSP: $0.80/L), and the worst-case analysis showed that losses incurred by the plant could be as high as $80 million (MSP: $1.36/L). A Monte Carlo simulation indicated that there is a 70% chance of the plant being profitable (NPV > 0).

Conversion↗

NASA NTRS2022

Quantifying Earth System Interactions for Sustainable Food Production Via Expert Elicitation

Several safe boundaries of critical Earth system processes have already been crossed due to human perturbations; not accounting for their interactions may further narrow the safe operating space for humanity. Using expert knowledge elicitation, we explored interactions among seven variables representing Earth system processes relevant to food production, identifying many interactions little explored in Earth system literature. We found that green water and land system change affect other Earth system processes strongly, while land, freshwater and ocean components of biosphere integrity are the most impacted by other Earth system processes, most notably blue water and biogeochemical flows. We also mapped a complex network of mechanisms mediating these interactions and created a future research prioritization scheme based on interaction strengths and existing knowledge gaps. Our study improves the understanding of Earth system interactions, with sustainability implications including improved Earth system modelling and more explicit biophysical limits for future food production.

Expert knowledge elicitation↗

NASA NTRS1981

Evaluation and verification of epitaxial process sequence for silicon solar-cell production

To achieve the program goals, 28 minimodules were fabricated and tested, using 600 cells made from three-inch-diameter wafers processed by the sequence chosen for this purpose. Of these 600 cells, half were made from epitaxially grown layers on potentially low-cost substrates. The other half were made from commercial semiconductor-grade (SG), single-crystal silicon wafers that served as controls. Cell processing was normally performed on mixed lots containing significant numbers of each of these two types of wafers. After evaluation of the performance of all cells, they were separated by types for incorporation into modules that were to be tested for electrical performance and response to environmental stress. A simplified flow chart displaying this scheme, for quantities representing half of the planned total to be processed, is presented.

Redfield, D.↗

DOE OSTI2024

High-Temperature Fe-Based Fischer–Tropsch Synthesis: Experimentally Validated Kinetic Models Implemented at Pellet and Reactor Scales

Pellet- and reactor-scale models for Fischer–Tropsch synthesis (FTS) with a Fe–K/silica catalyst were developed to investigate the sensitivity of the hydrocarbon products and carbon dioxide selectivity to process conditions and feed composition at high temperature (350–400 °C), moderate pressure (1–10 bar), and a range of H 2 /CO ratios (3–1). The major objective of this paper is to develop, validate, and evaluate a high-temperature FTS model that is then used to assess the feasibility of process integration with syngas production. Since there is limited kinetic data available, in literature at these conditions, bench-scale reactor tests were conducted to obtain operational data for parameter fitting of kinetic expressions used in the model. This resulting kinetic model demonstrated agreement with the experimental data with an R 2 of 0.97 to the testing data set and, thus, was feasible to apply at pellet and reactor scales. Here, multiple pellet sizes were modeled to detail the role of transport limitations as the sphere’s diameter approached and exceeded 1 mm. Application of the reactor model indicated that hydrocarbon selectivity depended strongly on temperature, whereas the ratio of olefin to paraffin products decreased with increasing temperature, pressure, and H 2 /CO ratio. Product selectivity was not sensitive to the conversion of carbon monoxide. Furthermore, the roles of the pressure and H 2 /CO ratio were closely coupled. At a H 2 /CO ratio of 3, only slight variations in selectivity occurred over a pressure range of 1–20 bar, whereas at a ratio of 1, selectivity could vary by as much as 30% over the same pressure range. At pressures below 5 bar and temperatures above 350 °C, minimal selectivity to heavy hydrocarbons (C 12+ ) is obtained, and selectivity to midrange products (C 5–11 ) rapidly declined as pressure dropped below 5 bar, which indicated that an operational pressure of at least 5 bar is needed to achieve reasonable yields in this temperature range. These results, while tentative, provide guidelines for further experimentation and evaluation of integrated FTS processes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2004

Chemical models for simulating single-walled nanotube production in arc vaporization and laser ablation processes

Chemical kinetic models for the nucleation and growth of clusters and single-walled carbon nanotube (SWNT) growth are developed for numerical simulations of the production of SWNTs. Two models that involve evaporation and condensation of carbon and metal catalysts, a full model involving all carbon clusters up to C80, and a reduced model are discussed. The full model is based on a fullerene model, but nickel and carbon/nickel cluster reactions are added to form SWNTs from soot and fullerenes. The full model has a large number of species--so large that to incorporate them into a flow field computation for simulating laser ablation and arc processes requires that they be simplified. The model is reduced by defining large clusters that represent many various sized clusters. Comparisons are given between these models for cases that may be applicable to arc and laser ablation production. Solutions to the system of chemical rate equations of these models for a ramped temperature profile show that production of various species, including SWNTs, agree to within about 50% for a fast ramp, and within 10% for a slower temperature decay time.

Nanotubes, Carbon/chemistry↗

DOE OSTI2025

Slicing Solutions for Wire Arc Additive Manufacturing

Both commercial and research applications of wire arc additive manufacturing (WAAM) have seen considerable growth in the additive manufacturing of metallic components. However, there remains a clear lack of a unified paradigm for toolpath generation when slicing parts for WAAM deposition. Existing toolpath generation options typically lack the appropriate features to account for all complexities of the WAAM process. This manuscript explores the key slicing challenges specific to toolpaths for WAAM geometry and pairs each consideration with multiple solutions to mitigate most negative effects on completed components. These challenges must be addressed to minimize voids, prevent bead collapse, and ensure deposited components accurately approximate the desired geometry. Slicing considerations are grouped into four general categories: geometric, process, thermal, and productivity. Geometric considerations are addressed with overhang compensation, corner-sharpening, and toolpath-smoothing features. Process considerations are addressed with start point configuration and controls for the bead lengths and end points. Thermal and productivity considerations are addressed with island optimization, multi-material printing, and connected insets. Finally, tools for the post-processing of generated G-code are explored. Overall, these solutions represent a critical set of slicing features used to improve generated toolpaths and the quality of the components deposited with those toolpaths.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Fast Quasi-Static Time-Series Simulation for Accurate PV Inverter Semiconductor Fatigue Analysis with a Long-Term Solar Profile

Power system simulations with long-term data typically have large time steps varying from one second to a few minutes. However, for PV inverter semiconductors, the minimum thermal stress cycle occurs over the fundamental grid frequency (50 or 60 Hz). This requires the time step of the fatigue simulation to be around 100 µs. This small time step requires long computation times to process yearly power production profiles. This paper proposes a fast fatigue simulation for inverter semiconductors using the quasi-static time series (QSTS) simulation concept. The proposed simulation calculates the steady state of the semiconductor junction temperature by using a Fast Fourier Transform (FFT). The small thermal cycling during a switching period and even over the fundamental waveform is disregarded to further accelerate the simulation speed. The resulting time step of the fatigue simulation is 15 minutes, which is consistent with the solar dataset. The error of the proposed simulation is 0.16% compared to the fatigue simulation results using the complete thermal stress profile. A PV inverter that responds to a Transactive Energy System (TES) is simulated to demonstrate the use of the proposed fatigue simulation. The proposed simulation has the potential to co-simulate with system level simulation tools that also adopt the QSTS concept.

Liu, Yunting↗

NASA NTRS2012

Role of MODIS Vegetation Phenology Products in the ForWarn System for Monitoring of Forest Disturbances in the Conterminous United States

This presentation discusses MODIS vegetation phenology products used in the ForWarn Early Warning System (EWS) tool for near real time regional forest disturbance detection and surveillance at regional to national scales. The ForWarn EWS is being developed by the USDA Forest Service NASA, ORNL, and USGS to aid federal and state forest health management activities. ForWarn employs multiple historical land surface phenology products that are derived from MODIS MOD13 Normalized Difference Vegetation Index (NDVI) data. The latter is temporally processed into phenology products with the Time Series Product Tool (TSPT) and the Phenological Parameter Estimation Tool (PPET) software produced at NASA Stennis Space Center. TSPT is used to effectively noise reduce, fuse, and void interpolate MODIS NDVI data. PPET employs TSPT-processed NDVI time series data as an input, outputting multiple vegetation phenology products at a 232 meter resolution for 2000 to 2011, including NDVI magnitude and day of year products for seven key points along the growing season (peak of growing season and the minima, 20%, and 80% of the peak NDVI for both the left and right side of growing season), cumulative NDVI integral products for the most active part of the growing season and sequentially across the growing season at 8 day intervals, and maximum value NDVI products composited at 24 day intervals in which each product date has 8 days of overlap between the previous and following product dates. MODIS NDVI phenology products are also used to compute nationwide NRT forest change products refreshed every 8 days. These include percent change in forest NDVI products that compare the current NDVI from USGS eMODIS products to historical MODIS MOD13 NDVI. For each date, three forest change products are produced using three different maximum value NDVI baselines (from the previous year, three previous years, and all previous years). All change products are output with a rainbow color table in which forests with the most severe NDVI decreases are assigned hot colors (yellow to red) and forests with prominent NDVI increases are assigned cold colors (blue tones). All mentioned products have been integrated as data layers into ForWarn s geospatial data viewer known as the U.S. Forest Change Assessment Viewer (FCAV). The latter is used to view and assess the context of the mentioned forest change products with respect to ancillary data layers, such as land cover, elevation, hydrologic features, climatic data, storm data, aerial disturbance surveys, fire data, and land ownership. The FCAV also includes a temporal NDVI profiler for viewing phenological change in multi-year NDVI associated with known or suspected regionally apparent forest disturbances (e.g., from fire and insects). ForWarn forest change products have been used to detect, track, and assess several biotic and abiotic regional forest disturbance events across the country, including ephemeral and longer lasting damage from storms, drought, and insects. Such change products are most effective for viewing severe disturbances affecting multiple MODIS pixels. MODIS vegetation phenology products contribute vital current information on forest conditions to the ForWarn system and this role is expected to grow as these products are refined and derivative products are added.

Spruce, Joseph P.↗

DOE OSTI2022

High-Silicon Steel Strip by Single-Step Shear Deformation Processing

It is well known that Fe-Si alloys with Si content higher than in conventional electrical sheet steels (>3.2% Si) can make a significant impact in improving the efficiency of electrical motors if they are available in sheet/foil (strip) forms at suitable cost. While the magnetic and electrical attributes (e.g., resistivity, core loss) of these high-Si Fe alloys, of relevance to electrical motor core laminations, are known to be exceptional, the alloys have limited workability, making them difficult to produce consistently in sheet/foil (strip) forms. Current processing techniques such as rolling, while adequate for producing conventional electrical steel sheet, do have important disadvantages - large energy consumption and emissions, limitations in processing of low-workability alloys (e.g., high-Si content steels), large-scale plant infrastructure, and less than adequate capability to engineer sheet metals with specific microstructures (e.g., fine-grained) and crystallographic textures (e.g., shear textures). It is therefore of interest to have an alternative commercial process that can produce sheet/foil (strip) from high-Si Fe alloys and which can also overcome some of the deficiencies of current multistage strip processes. The goal of the present project was design and demonstration of a new energy-efficient pilot process for producing high-Si electrical steel strip of commercial widths and thickness, and with superior electrical and magnetic properties than current electrical steels (Fe-3.2% Si as benchmark). The applications domain for these steels is electrical motor core laminations. We have addressed this goal by accomplishment of the following specific objectives and tasks: a) Development of an Fe-4Si-4Cr alloy with electrical resistivity >80 μΩ-cm, induction flux density >1.48 T at 5000 A/m and core loss 35% lower than the benchmark 3.2% Si alloy. The alloy which meets DOE target specifications for motor core attributes was designed with the Si content controlled for the electrical properties and the Cr content tailored to meet material/process workability requirements. b) A unique machining-based deformation processing system was designed and scaled-up to produce strip of commercial width (25 mm to 150 mm) and thickness (up to 0.5 mm) from the Fe-4Si-4Cr alloy and other alloys of varied workability including copper, Al6061-T6 and naval brass. The key attributes of the machining-based strip production are deformation processing by concentrated simple-shear; single-step production of strip from ingot using compact machine infrastructure; strip surface finish of Ra 0.35 to 1 micrometer that is comparable/superior to that of rolled strip; discrete production of strip that can potentially be done at point of use; and controllability of strip mechanical/formability properties by deformation control. c) The electrical, magnetic, surface quality, mechanical, formability, and metallurgical properties/attributes of the machining-based strip were established by direct ASTM standard or equivalent measurement techniques. d) Punching characteristics of the strip in terms of load, edge quality and macro defects were similar to those of conventional 3.2% Si electrical steels. These punching characteristics are critical from a manufacturability perspective for motor/transformer core applications. e) A modeling framework for energy analysis of multistage rolling and the machining-based deformation processing has been established. Application of this modeling to the two strip-processes showed that the machining-based process requires significantly lower specific energy for processing, ~ 25% of that for rolling. The modeling framework can be adapted for a range of sheet-metal forming, bulk metal forming, and machining processes. It can be used to identify key parameters controlling process specific energy. f) A comparative analysis of advantages and disadvantages of machining-based processing against rolling for strip production. The single stage machining-based processing, with compact infrastructure, represents a new manufacturing paradigm for sheet and foil manufacturing that can potentially also be applied to advanced titanium, aluminum, copper and magnesium alloys. The goals and objectives were accomplished by a cross-disciplinary project team comprising of personnel from Purdue University; M4 Sciences LLC, a small-business focused on advanced manufacturing technology development; the Pacific Northwest National Labs; and tool manufacturers. The team is currently in advanced discussions with multiple entities for future process development for commercialization.

36 MATERIALS SCIENCE↗

NASA NTRS2011

Developing and Evaluating RGB Composite MODIS Imagery for Applications in National Weather Service Forecast Offices

Satellite remote sensing has gained widespread use in the field of operational meteorology. Although raw satellite imagery is useful, several techniques exist which can convey multiple types of data in a more efficient way. One of these techniques is multispectral compositing. The NASA Short-term Prediction Research and Transition (SPoRT) Center has developed two multispectral satellite imagery products which utilize data from the Moderate Resolution Imaging Spectroradiometer (MODIS) aboard NASA's Terra and Aqua satellites, based upon products currently generated and used by the European Organization for the Exploitation of Meteorological Satellites (EUMETSAT). The nighttime microphysics product allows users to identify clouds occurring at different altitudes, but emphasizes fog and low cloud detection. This product improves upon current spectral difference and single channel infrared techniques. Each of the current products has its own set of advantages for nocturnal fog detection, but each also has limiting drawbacks which can hamper the analysis process. The multispectral product combines each current product with a third channel difference. Since the final image is enhanced with color, it simplifies the fog identification process. Analysis has shown that the nighttime microphysics imagery product represents a substantial improvement to conventional fog detection techniques, as well as provides a preview of future satellite capabilities to forecasters.

Oswald, Hayden↗

DOE OSTI2020

Technical Program Plan for INL Advanced Reactor Technologies Advanced Gas Reactor Fuel Development and Qualification Program

High-temperature gas cooled reactors (HTGRs) are graphite moderated nuclear reactors cooled with helium. Their high outlet temperatures and thermal energy conversion efficiency enable efficient and cost effective integration with non electricity generating applications. These applications include process heat and hydrogen production for petrochemical and other industrial processes that require operating temperatures between 300 and 900°C. HTGRs will supplement the use of premium fossil fuels such as oil and natural gas, improve overall energy security in the United States by reducing dependence on foreign fuels, and reduce carbon dioxide (CO2)/greenhouse gas emissions. The HTGR design uses helium as a coolant, graphite as a neutron moderator, and ceramic particle fuel. Helium is chemically inert and neutronically transparent. The graphite core slows down the neutrons, retains its strength at high temperatures, provides structural stability, and acts as a substantial heat sink during transient conditions. The ceramic particle fuel is extremely robust and retains the radioactive by products of the fission reaction within the coated particle under normal and off normal conditions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Technical Program Plan for INL Advanced Reactor Technologies Advanced Gas Reactor Fuel Development and Qualification Program

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Technical Program Plan for INL Advanced Reactor Technologies Advanced Gas Reactor Fuel Development and Qualification Program

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1976

Hydrogen production from coal using a nuclear heat source

A strong candidate for hydrogen production in the intermediate time frame of 1985 to 1995 is a coal-based process using a high-temperature gas-cooled reactor (HTGR) as a heat source. Expected process efficiencies in the range of 60 to 70% are considerably higher than all other hydrogen production processes except steam reforming of a natural gas. The process involves the preparation of a coal liquid, hydrogasification of that liquid, and steam reforming of the resulting gaseous or light liquid product. A study showing process efficiency and cost of hydrogen vs nuclear reactor core outlet temperature has been completed, and shows diminishing returns at process temperatures above about 1500 F. A possible scenario combining the relatively abundant and low-cost Western coal deposits with the Gulf Coast hydrogen users is presented which provides high-energy density transportation utilizing coal liquids and uranium.

Quade, R. N.↗