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All sources NASA NTRS DOE OSTI

DOE OSTI2022

Investigation of Remanufacturing Methods Utilizing Mechanically-Generated and Gas-Atomized Feedstock Production for Directed Energy Deposition Processing Through Specific Energy Consumption Modeling

The goal of this work was to assess the energy consumption of a novel remanufacturing method that utilizes mechanically-generated feedstock for directed energy deposition. Gas-atomization is the state-of-the-art production process for directed energy deposition feedstock, and for this work was incorporated into a remanufacturing process path to provide a comparison method. Specific energy consumption models of remanufacturing utilizing both of these proposed process paths were developed and applied to a case study to investigate energy saving opportunities for future manufacturing paradigms. The energy modelling was done in three stages. First, the mechanically-generated feedstock production energy consumption model was generated from experimental observation. Second, the gas-atomized feedstock production energy consumption model was generated from a combination of experimental observation, reported estimates from the manufacturer, and data found in the literature. Lastly, the energy consumption model of directed energy deposition was derived from experimental observation and compares favorably with reported estimates in the literature. With the models, the specific energy consumption in the two process paths were compared and their application was demonstrated by estimating the energy consumption to remanufacture a bracket. The two feedstock production methods had similar specific energy consumptions. The specific energy consumption of the directed energy deposition process was the greatest component in the respective remanufacturing paths by an order of magnitude; increasing deposition rate is the most important factor for lowering the overall specific energy consumption. The analyzed remanufacturing technologies were estimated to consume less energy than replacement when repairing up to approximately 15% of the original part’s mass.

42 ENGINEERING↗

DOE OSTI2021

Energy Saving Analysis Using Energy Intensity Usage and Specific Energy Consumption Methods

This study presents the energy saving analysis reached through employing the energy intensity usage and specific energy consumption method. The energy analyses conducted in this study are used for implementing a new technology. However, they are additionally used to evaluate the latest concepts, techniques, processes, and uses for technologies, which are aimed at improvement of energy savings. This study shows the correlation between energy consumption, potential energy savings, and the impact of the energy assessment in different industrial sectors. The correlation is found by using two indicators: (1) the energy intensity usage (EIU) and (2) the specific energy consumption (SEC). The data analysis in this study considers the assessments for 67 industries from 2015 to 2019 and classifies those assessments using the Standard Industrial Classification (SIC) code. The results show that energy savings and energy consumption are linearly related. Also, the energy assessment improves energy performance in a more significant way for smaller companies than for larger industries. Furthermore, these results can be extrapolated by identifying the potential benefits of the energy management system (EMS) implementation.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2020

Scaling of pulsed nanosecond capillary plasmas at different specific energy deposition

Nano-second, capillary discharges (nCDs) are unique plasma sources in their ability to sustain high specific energy deposition ω dep approaching 10 eV/molecule in molecular gases. This high energy loading on short timescales produces both high plasma densities and high densities of molecular exited states. These high densities of electrons and excited states interact with each other during the early afterglow through electron collision quenching and associative ionization. In this paper we discuss results from a two-dimensional computational investigation of a nCD sustained in air at a pressure of 28.5 mbar and with a voltage amplitude 20 kV. Discharges were investigated for two circuit configurations—a floating low voltage electrode and with the low voltage electrode connected to ground through a ballast resistor. The first configuration produced a single ionization wave from the high to low voltage electrode. The second produced converging ionization waves beginning at both electrodes. With a decrease of the tube radius, the velocity of the ionization fronts decreased while the shape of the ionization wave changed from the electron density being distributed smoothly in the radial direction, to being hollow shaped where there is a higher electron density near the tube wall. For sufficiently small tubes, the near-wall maxima merge to have the higher density on the axis of the capillary tube. In the early afterglow, the temporal and radial behavior of the N 2 (C 3 Π u ) density is a sensitive function of ω dep due to electron collision quenching. Finally, these trends indicate that starting from ω dep $\geqslant$ 0.3 eV/molecule, it is necessary to take into account interactions of electrons with electronically excited species during the discharge and early afterglow.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2019

Specific energy cost for nitrogen fixation as NO x using DC glow discharge in air

Abstract We report on factors influencing the specific energy costs of producing NO x from pin-to-pin DC glow discharges in air at atmospheric pressure. Discharge current, gap distance, gas flowrate, exterior tube wall temperature and the presence and position of activated Al 2 O 3 catalyst powder were examined. The presence of heated catalyst adjacent to the plasma zone improved energy efficiency by as much as 20% at low flows, but the most energy efficient conditions were found at the highest flowrates that allowed a stable discharge (about 10–15 l min −1 ). Under these conditions, the catalyst had no effect on efficiency in the present study. The lowest specific energy cost was observed to be between about 200–250 GJ/tN. The transport of active chemical species and energy are likely key factors controlling the specific energy costs of NO x production in the presence of a catalyst. Air plasma device design and operating conditions must ensure that plasma-generated active intermediate chemical species transport is optimally coupled with catalytically active surfaces.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2019

Specific Energy Analysis for the Manufacturing of Light-Weight Automobile Body

This manuscript analyses the specific energy requirements to produce two hybridised vehicle structures on current automotive assembly lines. It provides quantitative and specific electric (kWhr/vehicle) and fossil-fuel (MMBtu/vehicle) energy predictions of the body-in-white (BIW) manufacturing processes including body panel forming, welding, painting, and final assembly, in addition to the facility heating ventilation and air conditioning or HVAC consumption. Two hybridised BIW design criteria are analysed; the first is based on minimising the added cost per unit weight saved (+$/-kg), while the second is based on maximising the percentage of weight saved (% -kg). Also a new criterion; that is the added specific-energy per unit weight-saved or (+kWhr/vehicle/-kg) is proposed. The light-weight structures comprise body parts made of aluminium and steel. To compute energy consumptions, the study utilises the energy performance index (EPI) stochastic model in addition to complementing it with a panel-forming energy model. Cost analysis is also provided for all the major vehicle body-panels using an in-house Excel macro. The study reverse engineers a passenger vehicle BIW using a full-size coordinate measuring machine (CMM). The presented work further highlights the monetary value of the associated emissions when increasing the specific energy.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2016

Specific energy consumption and quality of wood pellets produced using high-moisture lodgepole pine grind in a flat die pellet mill

In the present study a Box–Behnken experimental design was used to understand the effect of the moisture content of lodgepole pine grind (33–39%, w.b.), die speed (40–60 Hz) and preheating temperature (30–90 °C) on the pellet quality and specific energy consumption. The partially dried pellets produced had high-moisture content in the range of 19–28% (w.b.), and were further dried to <9% (w.b.) in a mechanical oven set at 70 °C for 3 h. Dried pellets were further evaluated for pellet moisture content, unit, bulk, tapped density, and durability. Response surface models developed for the product properties have adequately described the process based on coefficient of determination values. Surface plots developed indicated higher unit, bulk, and tapped density (1050, 520, 560 kg/m 3 ) are achievable at 33–35% (w.b.) moisture content of the lodgepole pine grind, die speed of 60 Hz and preheating temperature of 30–60 °C. Higher moisture content of 39% (w.b) reduced unit, bulk, and tapped density to <912, 396, and 452 kg/m 3 . Higher durability values of >95% were obtained at 33–35% (w.b.) at lower preheating temperatures of 30–50 °C and higher die speed of >50 Hz. At 33% (w.b.) moisture content of the lodgepole pine grind, preheating temperature of 90 °C, and die speed of 60 Hz, the observed specific energy consumption was <116 kW h/ton. As a result, scanning electron microscope studies indicated that lignin crosslinking is the primary reason for binding of the lodgepole pine grind at high-moisture content.

09 BIOMASS FUELS↗

DOE OSTI2017

Mechanical specific energy versus depth of cut in rock cutting and drilling

The relationship between Mechanical Specific Energy (MSE) and the Rate of Penetration (ROP), or equivalently the depth of cut per revolution, provides an important measure for strategizing a drilling operation. This study explores how MSE evolves with depth of cut, and presents a concerted effort that encompasses analytical, computational and experimental approaches. A simple model for the relationship between MSE and cutting depth is first derived with consideration of the wear progression of a circular cutter. This is an extension of Detournay and Defourny's phenomenological cutting model. Wear is modeled as a flat contact area at the bottom of a cutter referred to as a wear flat, and that wear flat in the past is often considered to be fixed during cutting. But during a drilling operation by a full bit that consists of multiple circular cutters, the wear flat length may increase because of various wear mechanisms involved. The wear progression of cutters generally results in reduced efficiency with either increased MSE or decreased ROP. Also, an accurate estimate of removed rock volume is found important for the evaluation of MSE. The derived model is compared with experiment results from a single circular cutter, for cutting soft rock under ambient pressure with actual depth measured through a micrometer, and for cutting high strength rock under high pressure with actual cutting area measured by a confocal microscope. Lastly, the model is employed to interpret the evolution of MSE with depth of cut for a full drilling bit under confining pressure. The general form of equation of the developed model is found to describe well the experiment data and can be applied to interpret the drilling data for a full bit.

42 ENGINEERING↗

DOE OSTI2023

Analytical nonadiabatic coupling and state-specific energy gradient for the crystal field Hamiltonian describing lanthanide single-ion magnets

Paramagnetic molecules with a metal ion as an electron spin center are promising building blocks for molecular qubits and high-density memory arrays. However, fast spin relaxation and decoherence in these molecules lead to a rapid loss of magnetization and quantum information. Nonadiabatic coupling (NAC), closely related to spin-vibrational coupling, is the main source of spin relaxation and decoherence in paramagnetic molecules at higher temperatures. Predicting these couplings using numerical differentiation requires a large number of computationally intensive ab initio or crystal field electronic structure calculations. To reduce computational cost and improve accuracy, we derive and implement analytical NAC and state-specific energy gradient for the ab initio parametrized crystal field Hamiltonian describing single-ion molecular magnets. Our implementation requires only a single crystal field calculation. In addition, the accurate NACs and state-specific energy gradients can be used to model spin relaxation using sophisticated nonadiabatic molecular dynamics, which avoids the harmonic approximation for molecular vibrations. To test our implementation, we calculate the NAC values for three lanthanide complexes. Finally, the predicted values support the relaxation mechanisms reported in previous studies.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Device and method for improving specific energy requirement of plasma pyrolyzing or reforming systems

Devices and methods for reducing the specific energy required to reform or pyrolyze reactants in plasmas operating at high flow rates and high pressures are presented. These systems and methods include 1) introducing electrons and/or easily ionized materials to a plasma reactor, 2) increasing turbulence and swirl velocity of the flows of feed gases to have improved mixing in a plasma reactor, and 3) reducing slippage from a plasma reactor system. Such plasma systems may allow plasma reactors to operate at lower temperatures, higher pressure, with improved plasma ignition, increased throughput and improved energy efficiency. In preferred embodiments, the plasma reactors are used to produce hydrogen and carbon monoxide, hydrogen and carbon, or carbon monoxide through reforming and pyrolysis reactions. Preferred feedstocks include methane, carbon dioxide, and other hydrocarbons.

Bromberg, Leslie↗

DOE OSTI2019

A sustainable sulfur–carbonaceous composite electrode toward high specific energy rechargeable cells

The micrometer-scale reticulated structure of highly sulfur-philic nitrogen-doped graphene oxide (NrGO) that is achieved by chemically controlling the nitrogen-doping degree improves the chemical and electrochemical stability of the active sulfur while providing sufficient sulfur/electrolyte interface for a facile electrochemical process so that a high specific energy of 325 W h kg -1 can be achieved.

25 ENERGY STORAGE↗

DOE OSTI2018

From charge storage mechanism to performance: A roadmap toward high specific energy sodium-ion batteries through carbon-anode optimization

Serious critical issues hamper the arrival on the market of sodium-ion batteries (SIBs) as a lower cost substitute to Li-ion batteries (LIBs). Among these, the negligible sodium uptake into graphite, which is the keystone of the present LIB technology, appears to be one of the toughest to tackle. Although hard carbon is known for years as one of the best substitutes, its performance remains below that of graphite in Li-ion batteries, while its mechanism of sodium storage is still under debate. Many other carbons are studied since a few years, some of which presenting capacities far beyond that of graphite. However, they tend to present larger voltage and high first cycle loss, leading to limited benefit in terms of specific energy at full cell level. Overcoming this preoccupying tradeoff requires a deep understanding of the charge storage mechanisms and the correlation between structure, microstructure and performance. The present Review aims at bringing light to this question by drawing a roadmap of the emerging routes for the optimization of carbon materials as SIB anode, on the basis of a critical survey of their reported electrochemical performance and charge storage mechanisms.

Saurel, Damien↗

DOE OSTI2024

Investigation of Benchmark $k$ eff Sensitivity and Uncertainty for 239 Pu fission in Specific Energy Ranges

Nuclear data at intermediate energies (from 1 to 100s of keV) are evaluated based on scarce differential data and theory unable to capture physics’ expected structure. There is also a lack of integral data. This is a known deficiency and is challenging to address. Calculated effective multiplication factor, k eff , values for intermediate energy experiments are ~25× further from experiment than for fast energies and are often well outside the experimental uncertainties. The goal of the PARADIGM (PARallel Approach of Differential and InteGral Measurements) project is to significantly re duce the uncertainties of intermediate energy nuclear data for 239 Pu. To this end, PARADIGM simultaneously optimizes experiments at both the Los Alamos Neutron Science Center (LANSCE) and National Criticality Experiments Research Center (NCERC). The combined set of data will inform new intermediate-energy nuclear data. By execution of differential and integral experiments, establishment of new theory, and undertaking nuclear data evaluation in parallel, the timeline to deliver improved nuclear data to users will be reduced significantly that is to three years. For the PARADIGM project, it was decided to optimize an integral experiment for two neutron energy ranges, within the full intermediate energy range. The low energy range goes from 1 to 30 keV, while the higher energy range goes from 30 to 600 keV. This work focuses on nuclear data sensitivities and uncertainties for 239 Pu fission for existing experiments in the International Criticality Safety Benchmark Evaluation Project (ICSBEP). When designing new experiments, it is important to understand what benchmarks currently exist. For a more traditional experiment design (in which a specific application model(s) exists), comparisons would be made between the application model(s) and existing benchmarks. For PARADIGM, there is no specific application model, but instead the specific nuclear data reaction and energy ranges of interest can be explored for existing benchmarks.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2019

High lithium sulfide loading electrodes for practical Li/S cells with high specific energy

To date, Li 2 S has drawn significant attention as a positive electrode active material for rechargeable lithium cells due to its high theoretical specific capacity and capability of pairing with a lithium-free anode which can obviate any safety concern of the lithium metal anode when using sulfur. In recent years, various approaches have been employed to develop Li/Li 2 S rechargeable cells for commercialization that meet the performance goals for high energy/power applications. It is expected that high lithium sulfide-loading cells with long cycle life, an excellent capacity delivery and low electrolyte:sulfur weight ratio (E/S ratio) can be achieved. Here, we report a Li 2 S electrode comprised of a novel Li2S/KB@Cf nanocomposite which delivers an areal capacity of 7.56 mAh cm-2 and good cycling stability with a mass loading of 11.29 mg cm -2 and a robust 3-dimensional (3D) aluminum foam current collector with a high open area. The high conductivity and scalability of the active material, the availability of 3D current collection for the active material and the control of the electrolyte/sulfur ratio offer the potential of realization of practical Li/S cells.

25 ENERGY STORAGE↗

DOE OSTI2022

Compartment-specific energy requirements of photosynthetic carbon metabolism in Camelina sativa leaves

Abstract Main conclusion The oxidative pentose phosphate pathway provides cytosolic NADPH yet reduces carbon and energy use efficiency. Repressing this pathway and introducing cytosolic NADPH-dependent malate dehydrogenase may increase crop yields by ≈5%. Abstract Detailed knowledge about plant energy metabolism may aid crop improvements. Using published estimates of flux through central carbon metabolism, we phenotype energy metabolism in illuminated Camelina sativa leaves (grown at 22 °C, 500 µmol photons m −2 s −1 ) and report several findings. First, the oxidative pentose phosphate pathway (OPPP) transfers 3.3% of the NADPH consumed in the Calvin–Benson cycle to the cytosol. NADPH supply proceeds at about 10% of the rate of net carbon assimilation. However, concomitantly respired CO 2 accounts for 4.8% of total rubisco activity. Hence, 4.8% of the flux through the Calvin–Benson cycle and photorespiration is spent on supplying cytosolic NADPH, a significant investment. Associated energy requirements exceed the energy output of the OPPP. Thus, autotrophic carbon metabolism is not simply optimised for flux into carbon sinks but sacrifices carbon and energy use efficiency to support cytosolic energy metabolism. To reduce these costs, we suggest bioengineering plants with a repressed cytosolic OPPP, and an inserted cytosolic NADPH-dependent malate dehydrogenase tuned to compensate for the loss in OPPP activity (if required). Second, sucrose cycling is a minor investment in overall leaf energy metabolism but a significant investment in cytosolic energy metabolism. Third, leaf energy balancing strictly requires oxidative phosphorylation, cofactor export from chloroplasts, and peroxisomal NADH import. Fourth, mitochondria are energetically self-sufficient. Fifth, carbon metabolism has an ATP/NADPH demand ratio of 1.52 which is met if ≤ 21.7% of whole electron flux is cyclic. Sixth, electron transport has a photon use efficiency of ≥ 62%. Last, we discuss interactions between the OPPP and the cytosolic oxidation–reduction cycle in supplying leaf cytosolic NADPH.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2018