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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

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

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

Park, Hyunji↗
NASA NTRS2005

REUSABLE PROPULSION ARCHITECTURE FOR SUSTAINABLE LOW-COST ACCESS TO SPACE

Two transportation architecture changes are presented at either end of a conventional two-stage rocket flight: 1) Air launch using a large, conventional, pod hauler design (i.e., Crossbow)ans 2) Momentum exchange tether (i.e., an in-space asset like MXER). Air launch has ana analytically justified cost reduction of approx. 10%, but its intangible benefits suggest real-world operations cost reductions much higher: 1) Inherent launch safety; 2) Mission Risk Reduction; 3) Favorable payload/rocket limitations; and 4) Leveraging the aircraft for other uses (military transport, commercial cargo, public outreach activities, etc.)

Bonometti, Joseph↗
DOE OSTI2022

High‐Efficiency Solar Cells Grown on Spalled Germanium for Substrate Reuse without Polishing

Abstract Radical reduction of III–V device costs requires a multifaceted approach attacking both growth and substrate costs. Implementing device removal and substrate reuse provides an opportunity for substrate cost reduction. Controlled spalling allows removal of thin devices from the expensive substrate; however, the fracture‐based process currently generates surfaces with significant morphological changes compared to polished wafers. 49 single junction devices are fabricated across the spalled surface of full 50 mm germanium wafers without chemo‐mechanical polishing before epitaxial growth. Device defects are identified and related to morphological spalling defects—arrest lines, gull wings, and river lines—and their impact on cell performance using physical and functional characterization techniques. River line defects have the most consistent and detrimental effect on cell performance. Devices achieve a single junction efficiency above 23% and open‐circuit voltage of 1.01 V, demonstrating that spalled germanium does not need to be returned to a pristine, polished state to achieve high‐quality device performance.

14 SOLAR ENERGY↗
DOE OSTI2021

Thermal energy grid storage: Liquid containment and pumping above 2000 °C

As the cost of renewable energy falls below fossil fuels, the key barrier to widespread sustainable electricity has become availability on demand. Energy storage can enable dispatchable renewables, but only with drastic cost reductions compared to current battery technologies. One electricity storage concept that could enable these cost reductions stores electricity as sensible heat in an extremely hot liquid (>2000°C) and uses multi-junction photovoltaics (MPV) as a heat engine to convert it back to electricity on demand hours, or days, later. Furthermore, this paper reports the first containment of silicon in a multipart graphite tank above 2000°C, using material grades that are affordable for energy storage at GWh scales. Low cost molded graphite with particle sizes as large as 10 μm successfully contained metallurgical grade silicon, even with as much as twothirds iron by mass for up to 10 hours and temperatures as high as 2300°C, in tanks as large as two gallons.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2020

Electrolytically Assisted Surface Decontamination (EASD{sup TM}) for POCO Operations - 20282

NNL in collaboration with C-Tech Innovation Ltd and Sellafield Ltd has been exploring innovative technologies to enable a significant reduction of radiological hazards within facilities during the Post Operational Clean Out (POCO) phase of a nuclear plant's life cycle. Reducing the hazard by effectively decontaminating plants in-situ during POCO delivers huge cost reductions for future decommissioning operations. These cost reduction benefits are realized by reducing the number and complexity of remote operations as well as lowering the long-term waste disposal costs. Whilst chemical decontamination can achieve the desired level of decontamination, applying aggressive chemical reagents is hazardous, potentially difficult to control and requires there to be complimentary effluent treatment and waste routes. This work has aimed to develop flexible and controllable decontamination processes which could be operated without the additional complexity and issues associated with chemical decontamination. The processes needed to be relatively fast and effective to minimize the time operators would spend in an active area. In addition, there was a driver to produce decontamination methodologies which generated a secondary waste compatible with current routes and which takes advantage of current waste capacity. The strategy therefore was to come up with a solution that works with, rather than against, the science and engineering behind process plants at Sellafield. Electrolytically Assisted Surface Decontamination (EASD{sup TM}) is an innovative electrochemical decontamination process (developed by NNL and C-Tech Innovation Ltd) that can remove activity from contaminated metal in very short time periods. Application of the patented electric waveform to the surface when treating contaminated metal with nitric acid has been shown to significantly enhance the decontamination performance. When compared to proposed baseline washout procedures at Sellafield, the only change to the process is the applied electrical waveform which is temporary and controllable. The current causes dissolution of the metal surface being decontaminated which leads to activity transferring from the plant item into the nitric acid effluent stream. This innovation has the potential to transform the POCO process and allow a nitric acid based washout approach to deliver POCO quickly and cost effectively within the existing infrastructure. Several devices have now been designed that incorporate this EASD{sup TM} technology and enable the decontamination process to be applied to a range items commonly identified as being contaminated during nuclear decommissioning programmes such as pipework, tanks and hotspots of walls/floors. Inactive and active laboratory-scale testing has been completed using both simulated and 'real-life' contaminated (low level waste) metallic items retrieved from different nuclear sites. Active trials demonstrated that contaminated items could be treated to free release levels within minutes. Engineering scale tests are currently being performed, with guidance from Sellafield's system engineers and plant managers, to provide the necessary re-assurance the designed devices could be successfully deployed in an on-plant scenario. The final stage of this development work is to carry out an active demonstration of the decontamination technology on Thorp at Sellafield. This paper aims to highlight progress made to date with the EASD{sup TM} technology and, more specifically, the development of an in-situ decontamination device for deployment within radioactive pipework. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

2020 System Optimization Awardee: Pecos Wind Power

With support from the Competitiveness Improvement Project's System Optimization Award, Pecos Wind Power will help lower the cost of distributed wind technology and expand deployment. To do so, the company will optimize their PW85 distributed wind turbine to achieve a production levelized cost of energy of $0.099 per kilowatt hour, which is a 48% cost reduction in distributed wind energy costs. This reduction is a critical step toward Pecos Wind Power's ultimate target of $0.089 per kilowatt-hour. This fact sheet provides an overview of Pecos Wind Power's project, how the company will achieve the goals of the award, and how the project fits within the overall Competitiveness Improvement Project.

CIP↗
NASA NTRS1984

Polycrystalline Silicon Sheets for Solar Cells by the Improved Spinning Method

Cost reduction of silicon materials in the photovoltaic program of materials was examined. The current process of producing silicon sheets is based entirely on the conventional Czochralski ingot growth and wafering used in the semiconductor industry. The current technology cannot meet the cost reduction demands for producing low cost silicon sheets. Alternative sheet production processes such as unconventional crystallization are needed. The production of polycrystalline silicon sheets by unconventional ingot technology is the casting technique. Though large grain sheets were obtained by this technique, silicon ribbon growth overcomes deficiencies of the casting process by obtaining the sheet directly from the melt. The need to solve difficulties of growth stability and impurity effects are examined. The direct formation process of polycrystalline silicon sheets with large grain size, smooth surface, and sharp edges from the melt with a high growth rate which will yield low cost silicon sheets for solar cells and the photovoltaic characteristics associated with this type of sheet to include an EBIC study of the grain boundaries are described.

Maeda, Y.↗
DOE OSTI2021

Optimal design of solar-driven electrolytic hydrogen production systems within electricity markets

Hydrogen has the potential to be a key contributor toward a low-carbon economy. Generating hydrogen by electrolysis using renewable energy is one way to support a decarbonized economy; however, its cost is not typically competitive with the carbon-emitting incumbent technology, steam methane reforming. The ability of electrolysis to integrate with electricity markets presents a unique cost reduction opportunity due to the perceived future availability of low and zero-marginal cost renewable energy sources. Additionally, as renewables, and particularly, photovoltaics are installed on the grid, they have a value deflation effect. This work evaluates solar-electrolysis configurations using a mathematical programming framework to maximize system net present value. The framework has been tested with specific weather conditions and financial mechanisms in California. Our findings indicate that a spectrum of potential cost competitive solutions is available for systems that (i) have market configurations resembling hybrid retail/wholesale, resulting in a hydrogen production cost range of US$6.2 kg-1–US$6.6 kg-1, or full wholesale market participation, reducing production cost to US$2.6 kg-1–US$3.1 kg-1, and (ii) achieve projected future cost reductions.

08 HYDROGEN↗
DOE OSTI2026

Smart building HVAC control challenge: experience and solutions from the ADRENALIN project

A smart building HVAC control competition crowdsourced and compared algorithms on fair and equal ground using the standardized BOPTEST framework. The competition attracted 138 participants, but only 9% submitted valid solutions for the final stage, highlighting the complexity of advanced HVAC control design. The winning solutions showed significant potential to reduce energy use and cost by shifting demand, without compromising occupant comfort. Across scenarios, thermal energy cost reductions of 36–76% relative to a baseline, were achieved. In peak heat periods, the cost reduction leveraged limited energy use reduction (0–15%), but more significant energy price reduction (34–62%). This shows smart controls' ability to avoid as much as possible consumption during the morning peak hours, when spot prices are tendentially the highest. Hosting the competition has highlighted challenges in creating competitions that both are fair and promotes solutions that are transferable to real life implementation.

BOPTEST↗
DOE OSTI2023

Re-Designing the CSP Thermal Energy Storage System to Enable Higher-Temperature Performance at Reduced Cost (Final Technical Report)

Current commercial concentrating solar power (CSP) plants distinguish themselves from ordinary photovoltaic (PV) power plants by storing enough collected energy to enable generation for several hours after the sun goes down. CSP plants store this energy in the sensible heat of nitrate salts in large metallic storage tanks. Stainless-steel AISI 347H (SS347H) is needed for the hot tank operating at about 565 degrees C whereas carbon steel is sufficient for the cold-tank materials. Two-tank nitrate-salt thermal energy storage (TES) is presently in use in several trough-based CSP plants in Europe and in the U.S., operating up to about 390 degrees C. Three commercially operating tower-based CSP plants - Gemasolar in Spain, Crescent Dunes in Nevada, and Noor III in Morocco - use the same approach, storing nitrate salts at temperatures up to 580 degrees C. SS347H is many times more expensive than carbon steel and constitutes a significant cost element in today's CSP plants. Hence, CSP developers need to close the cost gap with PV-based solar plants by making cost reductions in every system of the plant. Redesigning the TES tanks is one opportunity for cost reduction.

14 SOLAR ENERGY↗
DOE OSTI2022

Expert Elicitation for Wave Energy LCOE Futures

As the world faces increasing threats from climate change, the importance of developing renewable energy technologies and reducing their costs have similarly increased. Marine energy technologies (which include wave, tidal, ocean current, ocean thermal and salinity gradient resources) are often referred to as the most nascent and newest suite of renewable technologies under development. There are vast marine energy resources available around the world and within U.S. territorial waters, and as the technologies have continued to develop, the long-term trajectory of cost reductions and performance improvements is of particular interest. This study specifically investigates the long-term cost reduction potential for commercial wave energy technologies, as wave energy represents the largest marine energy resource available to the continental U.S. Similar studies focused on other resources and technologies may follow in the future.

16 TIDAL AND WAVE POWER↗
NASA NTRS1992

Shared visions: Partnership of Rockwell International and NASA Cost Effectiveness Enhancements (CEE) for the space shuttle system integration program

As a result of limited resources and tight fiscal constraints over the past several years, the defense and aerospace industries have experienced a downturn in business activity. The impact of fewer contracts being awarded has placed a greater emphasis for effectiveness and efficiency on industry contractors. It is clear that a reallocation of resources is required for America to continue to lead the world in space and technology. The key to technological and economic survival is the transforming of existing programs, such as the Space Shuttle Program, into more cost efficient programs so as to divert the savings to other NASA programs. The partnership between Rockwell International and NASA and their joint improvement efforts that resulted in significant streamlining and cost reduction measures to Rockwell International Space System Division's work on the Space Shuttle System Integration Contract is described. This work was a result of an established Cost Effectiveness Enhancement (CEE) Team formed initially in Fiscal Year 1991, and more recently expanded to a larger scale CEE Initiative in 1992. By working closely with the customer in agreeing to contract content, obtaining management endorsement and commitment, and involving the employees in total quality management (TQM) and continuous improvement 'teams,' the initial annual cost reduction target was exceeded significantly. The CEE Initiative helped reduce the cost of the Shuttle Systems Integration contract while establishing a stronger program based upon customer needs, teamwork, quality enhancements, and cost effectiveness. This was accomplished by systematically analyzing, challenging, and changing the established processes, practices, and systems. This examination, in nature, was work intensive due to the depth and breadth of the activity. The CEE Initiative has provided opportunities to make a difference in the way Rockwell and NASA work together - to update the methods and processes of the organizations. The future success of NASA space programs and Rockwell hinges upon the ability to adopt new, more efficient and effective work processes. Efficiency, proficiency, cost effectiveness, and teamwork are a necessity for economic survival. Continuous improvement initiatives like the CEE are, and will continue to be, vehicles by which the road can be traveled with a vision to the future.

Bejmuk, Bohdan I.↗
NASA NTRS1977

Feasibility study on the design of a probe for rectal cancer detection

Rectal examination techniques are considered in terms of detection capability, patient acceptance, and cost reduction. A review of existing clinical techniques are considered in terms of detection capability, patient acceptance, and cost reduction. A review of existing clinical techniques and of relevant aerospace technology included evaluation of the applicability of visual, thermal, ultrasound, and radioisotope modalities of examination. The desired improvements can be obtained by redesigning the proctosigmoidoscope to have reduced size, additional visibility, and the capability of readily providing a color photograph of the entire rectosigmoid mucosa in a single composite view.

Anselm, V. J.↗
DOE OSTI2021

Expert elicitation survey predicts 37% to 49% declines in wind energy costs by 2050

Wind energy has experienced accelerated cost reduction over the past five years—far greater than predicted in a 2015 expert elicitation. Here we report results from a new survey on wind costs, compare those with previous results and discuss the accuracy of the earlier predictions. In this work, we show that experts in 2020 expect future onshore and offshore wind costs to decline 37–49% by 2050, resulting in costs 50% lower than predicted in 2015. This is due to cost reductions witnessed over the past five years and expected continued advancements. If realized, these costs might allow wind to play a larger role in energy supply than previously anticipated. Considering both surveys, we also conclude that there is considerable uncertainty about future costs. Our results illustrate the importance of considering cost uncertainty, highlight the value and limits of using experts to reveal those uncertainties, and yield possible lessons for energy modellers and expert elicitation.

17 WIND ENERGY↗
DOE OSTI2020

Evaluating the Adaptability of Reinforcement Learning Based HVAC Control for Residential Houses

Intelligent Heating, Ventilation, and Air Conditioning (HVAC) control using deep reinforcement learning (DRL) has recently gained a lot of attention due to its ability to optimally control the complex behavior of the HVAC system. However, more exploration is needed on understanding the adaptability challenges that the DRL agent could face during the deployment phase. Using online learning for such applications is not realistic due to the long learning period and likely poor comfort control during the learning process. Alternatively, DRL can be pre-trained using a building model prior to deployment. However, developing an accurate building model for every house and deploying a pre-trained DRL model for HVAC control would not be cost-effective. In this study, we focus on evaluating the ability of DRL-based HVAC control to provide cost savings when pre-trained on one building model and deployed on different house models with varying user comforts. We observed around 30% of cost reduction by pre-trained model over baseline when validated in a simulation environment and achieved up to 21% cost reduction when deployed in the real house. This finding provides experimental evidence that the pre-trained DRL has the potential to adapt to different house environments and comfort settings.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS2022

Earth System Model Parameter Adjustment Using a Green's Functions Approach

We demonstrate the practicality and effectiveness of using a Green's functions estimation approach for adjusting uncertain parameters in an Earth system model (ESM). This estimation approach has previously been applied to an intermediate-complexity climate model and to individual ESM components, e.g., ocean, sea ice, or carbon cycle components. Here, the Green's functions approach is applied to a state-of-the-art ESM that comprises a global atmosphere/land configuration of the Goddard Earth Observing System (GEOS) coupled to an ocean and sea ice configuration of the Massachusetts Institute of Technology general circulation model (MITgcm). Horizontal grid spacing is approximately 110 km for GEOS and 37–110 km for MITgcm. In addition to the reference GEOS-MITgcm simulation, we carried out a series of model sensitivity experiments, in which 20 uncertain parameters are perturbed. These “control” parameters can be used to adjust sea ice, microphysics, turbulence, radiation, and surface schemes in the coupled simulation. We defined eight observational targets: sea ice fraction, net surface shortwave radiation, downward longwave radiation, near-surface temperature, sea surface temperature, sea surface salinity, and ocean temperature and salinity at 300 m. We applied the Green's functions approach to optimize the values of the 20 control parameters so as to minimize a weighted least-squares distance between the model and the eight observational targets. The new experiment with the optimized parameters resulted in a total cost reduction of 9 % relative to a simulation that had already been adjusted using other methods. The optimized experiment attained a balanced cost reduction over most of the observational targets. We also report on results from a set of sensitivity experiments that are not used in the final optimized simulation but helped explore options and guided the optimization process. These experiments include an assessment of sensitivity to the number of control parameters and to the selection of observational targets and weights in the cost function. Based on these sensitivity experiments, we selected a specific definition for the cost function. The sensitivity experiments also revealed a decreasing overall cost as the number of control variables was increased. In summary, we recommend using the Green's functions estimation approach as an additional fine-tuning step in the model development process. The method is not a replacement for modelers' experience in choosing and adjusting sensitive model parameters. Instead, it is an additional practical and effective tool for carrying out final adjustments of uncertain ESM parameters.

Green's Function↗
NASA NTRS1982

Research possibilities? No! Needs for research to make PV solar energy utilization broadly competitive

The historical progression of efficiency improvements, cost reductions, and performance improvements in modules and photovoltaic systems are described. The potential for future improvements in photovoltaic device efficiencies and cost reductions continues as device concepts, designs, processes, and automated production capabilities mature. Additional step-function improvements can be made as today's simpler devices are replaced by more sophisticated devices.

Wolf, M.↗
DOE OSTI2020

Mesoscopic analyses of the impact of morphology and operating conditions on the transport resistances in a proton-exchange-membrane fuel-cell catalyst layer

Exploring the origins of local transport resistance and characterizing the oxygen transport resistances in the catalyst layer (RCL) are critical for cost reduction. In this paper, a comprehensive mesoscopic model for simulating coupled transport processes of oxygen and water vapor for different structural parameters under different operating conditions in reconstructed microstructures is proposed. The local transport resistance is calculated after achieving the limiting current density and the effective diffusivity of oxygen. The results demonstrate that RCL increases greatly with decreasing platinum loading (LPt) and the transport resistances in other components of the cell dominate for high-loadings. Both the reduced oxygen permeation coefficient in the ionomer thin-film and the adsorption resistance account for the origins of local transport resistance. The local transport resistance increases with the bare carbon ratio for a constant LPt and Pt/C ratio due to the decreased effective ionomer surface, and increases with the I/C ratio due to the increased ionomer thickness and decreased Knudsen diffusivity. Due to the presence of liquid water, a slight decrease followed by an increase of the local transport resistance versus relative humidity is obtained. The contribution of ionomer thin-films to RCL is more sensitive to liquid saturation compared with that of pores. This journal is

Mu, YT↗