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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Commercialization of High-Density High Assay Low Enriched Uranium Fuel Systems

The Office of Reactor Conversion and Uranium Supply (NA 231) at the National Nuclear Security Administration leads the conversion effort for the United States High Performance Research Reactors (USHPRR). These reactors are the final civilian reactors in the US to transition from High Enriched Uranium (HEU) to high assay low enriched uranium (HALEU). Each of these reactors represents unique capabilities and no currently available fuel system meets their needs for conversion. The Fuel Fabrication (FF) Pillar of the USHPRR project is responsible for the fabrication of experimental elements, conversion elements, and establishing a commercial economical production capability. FF is also responsible to share with the domestic and international community the theoretical knowledge gained. Other pillars within the USHPRR project provide the experimental and conversion fuel designs, assist the reactors with licensing activities, and ensure the entire fuel cycle is evaluated. Over the last decade, FF has worked with the production partners at Y-12 National Security Complex (Y-12) and BWXT Nuclear Operations Group, Research and Test Reactors (BWXT). Y-12 has begun processing the alloy feedstock for the conversion elements with a qualified process. BWXT has started the final fabrication of the experimental elements. Once the experimental elements are complete, BWXT will begin conversion element fabrication. The FF Pillar resides at Pacific Northwest National Laboratory (PNNL) and uses PNNL, universities, commercial vendors, and the DOE national laboratory system to evaluate process development activities to improve the process steps. FF supports the fabrication of two high density fuel systems, monolithic U-10Mo (Figure 1) and Uranium Silicide (Figure 2). The U-10Mo fuel system is further along the development process. FF assists in long term planning with the production partners. This includes ramping production of the elements from experimental quantities to annual steady state needs. As part of the ramp up, opportunities to improve yield and product quality are identified to ensure the fuel systems are cost effective.

Catalan, Michael A. [BATTELLE (PACIFIC NW LAB)]↗
DOE OSTI2024

Digitalization mapping and assessment process supporting ION strategic transformation activities

The existing fleet of commercial nuclear power plants (NPPs) are an important asset in the nation’s portfolio of electrical generating resources. Their continued safe and reliable operation are critical to providing a large source of carbon-free electricity to power the nation’s economy. The United States Department of Energy’s (DOE) Light Water Reactor Sustainability (LWRS) Program develops the scientific bases, methods, and tools, for the continued safe and economical operation of the nation's commercial NPPs. The Plant Modernization Pathway within LWRS Program focuses on providing guidance to industry on the full-scale implementation of modernization solutions for NPPs that significantly reduce the technical and financial risks associated with modernization. This research is focused on helping the nuclear industry understand how to digitize and digitalize their NPPs so that they can design their modernization solutions to be scalable, sustainable, and integrated both laterally and horizontally within their organization. That is, this research creates a digital transformation in NPPs by reshaping cultural mindsets and by identifying business efficiencies. In partnership with industry, and using four previously established guiding principles for digitalization, this research supported NPP modernization through assessing readiness for digitalization as a means to achieve integrated operations for nuclear. Specifically, this research created an assessment to review an entire organization’s work processes to gather information about the digitalization health of the plant. The assessment tools were administered to plant employees, and the results were used to develop a digitalization plan. The survey assessment identified the optimal candidate processes that would most benefit from a digitalization initiative which were revealed through analytical frameworks. One analysis calculated mean digitalization health indicator scores for all endorsed activities which allowed the researchers to rank and color code the results for easy identification. Individual health indicator scores are also provided, should our industry partner wish to understand these findings according to their own organizational priorities, business considerations and desired end-state. The results were also analyzed from the perspective that organizations are comprised of different types of innovators (e.g., generators, optimizers, conceptualizers, and implementers), which differentially affects the organization’s ability to comprehend and adapt to change (i.e., opportunities to innovate). Understanding the relative composition of innovator types at an NPP allows them to gather insights into the strengths and weaknesses they have in innovating how work is performed. For the utility that partnered with this research team, the results showed that implementers make up the largest portion of respondents and conceptualizers the smallest portion. Knowing the proportion of innovator types gave this organization insights on how they can effectively implement their innovation solutions. Additionally, the results were analyzed from a technical, economic, and risk perspective to identify and quantify work reduction opportunities (WROs). Recognizing that not all cost-saving opportunities are the same, a Technical, Economic and Risk Assessment (TERA) was performed to evaluate WROs to identify areas of greatest potential and lowest risk. The key results from TERA included a digitalization opportunity score for each activity, and a calculation of potential cost savings. These two outputs formed the bases for calculating a priority index and rank for the activities/processes assessed. From the prioritization calculations, TERA can then help the utility 1) decide what digitalization priorities to invest money in implementing and then 2) calculates how much should be invested in the digitalization initiatives selected to achieve cost savings and/or an acceptable return on investment. Last, onsite interviews revealed several inefficiencies in the standard work processes that occur cross-departmentally that are due to the absence of digitized and digitalized processes. Examples of these include time spent scanning paper documents and then uploading the documents electronically, obtaining signatures, and searching for desired information. This represents a digital but not digitalized process. Over 15 opportunities to improve work processes were identified through this multi-method digitalization assessment. The various analytical assessments used (e.g., TERA, digitalization health indicator scores), as well as discussions with the utility partner, corroborated that all the opportunities identified had a strong potential to make work processes more efficient and to improve overall performance of the NPP.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

OSU/NETL/Sandia/LBNL IDAES (CRADA Final Report)

The objective of this CRADA is to facilitate the cooperation among the Ohio State Univesity and the collaborators for the Institute for the Design of Advanced Energy Systems (IDAES). The goal is to develop, validate, and use a suite of process models based on the Ohio State's Fe-based coal direct chemical looping (CDCL) combustion process. This collaboration will provide Ohio State with a greater fundamental understanding of their chemical looping process, will help to improve the process efficiency, and will thus enable a greater probability of developing a commercial success. This collaboration will provide the IDAES team with detailed real-world process data to validate and demonstrate the effectiveness of its toolset.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

Enhanced Convective Microphysics Scheme and Its Impacts on Mean Climate in E3SM

Abstract To improve the representation of microphysical processes in convective clouds and their interaction with aerosol and stratiform clouds, a two‐moment convective microphysics parameterization (CMP) scheme developed by Song and Zhang (2011, https://doi.org/10.1029/2010jd014833 ) is upgraded and implemented in E3SM. The new developments include: (a) implementing a parameterization for graupel to enhance the representation of ice‐phase microphysical processes; (b) representing the impact of spatial inhomogeneity of cloud droplets in cumulus ensembles on autoconversion and accretion processes to improve the representation of warm‐rain microphysical processes; (c) implementing a comprehensive Bergeron process parameterization to better represent mixed‐phase microphysical processes; and (d) representing the interactions between ice‐phase microphysics and cloud thermodynamics. Simulations show that the cloud microphysical properties simulated by the CMP are generally in good agreement with observations. It reasonably simulates the changes in droplets effective radius related to precipitation formation in convective clouds, as identified from satellite observations. It also successfully simulates the contrast in these processes between maritime and continental clouds, demonstrating its capability to simulate the impact of aerosols on convection. Analyses of the impact of CMP on climate mean state simulation demonstrate that the CMP slightly improves the simulations of precipitation, cloud macrophysical properties, longwave cloud radiative forcing, zonal wind, and temperature. However, a degradation in shortwave cloud radiative forcing occurs.

GCM↗
DOE OSTI2025

Noble-Metal-Free, Nickel-Based Dual Functional Materials for Improved Methane Production from In Situ Carbon Dioxide Capture and Conversion

Promoters for dual functional materials have not been well explored, but promoters could improve the efficiency of the process by improving the selectivity of the CO 2 methanation process. Utilizing integrated capture and conversion, where CO 2 is captured and converted to useful products, would allow for a useful avenue to control CO 2 emissions. One such way to accomplish this would be to utilize materials that can both capture and convert CO 2 to useful products. However, these materials are often based on costly noble metals, like ruthenium and platinum, decreasing their viability on an industrial scale. Less expensive metals, for example, nickel, would allow for dual functional materials to be more readily utilized in industrial settings. Nickel-based dual functional materials often do not react with the captured CO 2 and merely desorb the CO 2 rather than form a useful product. However, promoters have not been well explored for these types of materials to improve the catalytic properties, which would be beneficial to improve nickel-based materials. Herein, we report the addition of ytterbium on a nickel-based dual functional material and the improvements to the production of methane from captured CO 2 with the incorporated ytterbium promoter. The ytterbium promoter improves the selectivity of the catalysts for the hydrogenation of captured CO 2 to methane and increases the ability for the material to capture CO 2 due to additional basic sites being formed on the surface of alumina. As a result, the 12%Ni/4%Yb/6%Na 2 O/Al 2 O 3 catalyst was utilized to capture carbon dioxide and then convert the captured CO 2 to methane over five cycles, where both the amount captured and the amount converted remained stable, indicating the stability of the material over long-term use.

Catalysts↗
DOE OSTI2024

Machine learning for reducing noise in RF control signals at industrial accelerators

Industrial particle accelerators typically operate in dirtier environments than research accelerators, leading to increased noise in RF and electronic systems. Furthermore, given that industrial accelerators are mass produced, less attention is given to optimizing the performance of individual systems. As a result, industrial accelerators tend to underperform their own hardware capabilities. Improving signal processing for these machines will improve cost and time margins for deployment, helping to meet the growing demand for accelerators for medical sterilization, food irradiation, cancer treatment, and imaging. Our work focuses on using machine learning techniques to reduce noise in RF signals used for pulse-to-pulse feedback in industrial accelerators. Here we review our algorithms and observed results for simulated RF systems, and discuss next steps with the ultimate goal of deployment on industrial systems.

43 PARTICLE ACCELERATORS↗
DOE OSTI2026

A Coincident CdTe Detector Array for Enhanced Nuclear Process Monitoring

Nuclear fuel cycle aqueous separation processes desire improved real-time material characterization and process monitoring techniques; gamma coincidence spectroscopy has the potential to meet this need in these high throughput and high radiation environments based on its ability to reduce background noise, thereby enhancing detection limits and improving isotopic identification accuracy. A detector array composed of three CdTe detectors was designed to surround a chemical processing pipe in a reprocessing facility and evaluate the feasibility of passively assaying the nuclear materials flowing though this measurement point. This array uses commercial off the shelf components that are radiation hard and highly efficiency at low energies relevant to actinide photon signatures. Detector efficiency characterizations, coincidence detection, and potential configuration improvements are presented here.

Good, Erin C.↗
DOE OSTI2024

Improved titanium-44 purification process for establishing a high apparent molar activity titanium-44/scandium-44 generator

44 Sc-radiopharmaceuticals are gaining more interest but still lack availability. The proof of principle of a 44 Ti/ 44 Sc generator, which can produce 44 Sc daily, has been established but with some limitations and drawbacks. Despite recent advances, separation of 44 Ti from massive quantities of scandium target material is still cumbersome. Here, in this work, the improved radiochemical separation of 44 Ti from residual scandium target material was carried out by precipitation of Sc with fluoride ions. Furthermore, two approaches were used to set up a high apparent molar activity small-scale generator. The first method relied on extraction chromatography for fine purification using a DGA resin, followed by loading of the purified 44 Ti onto a ZR resin column. In the second method, 44 Ti was loaded on the ZR resin directly after the precipitation step. This second method was used to set up a generator of 370 kBq and evaluate by radiolabeling. An apparent molar activity of 2 MBq/nmol was obtained for the radiolabeling with DOTA, the most common and suitable chelate for scandium. This result is comparable with previously published data on 44m/44 Sc.

44Sc↗
DOE OSTI2025

Nature of innovations affecting photovoltaic system costs

Innovations improve technology costs through various kinds of engineering advancements, including changes to materials choices and device or process designs. Understanding how these innovations relate to cost change can reveal aspects of the process of technology evolution, yet developing such understanding is often not possible with a strictly quantitative approach due to data limitations. In this paper we develop a hybrid quantitative-qualitative framework for relating specific innovations to cost change by using the variables in a quantitative technology cost change model as an organizing principle. We demonstrate this framework by applying it to the cost decline in photovoltaic (PV) systems over the last five decades. This framework generates new understanding of a set of innovations that contributed to PV modules’ sustained cost decline and the more modest trends observed in balance-of-system (BOS) costs. The results show the great diversity of innovations that affected PV costs, drawing on wide-ranging fields of expertise within scientific research and practice. We find that there are differences in the characteristics of innovations that reduced the cost of PV modules compared to innovations influencing BOS costs. Numerous module innovations reduced costs by advancing manufacturing tools and processes that improved material quality. Many BOS innovations reduced costs through a combination of component design changes, integration, automation, digitalization, and standardization. Overall, most innovations in our sample affected PV hardware. However, some also target ‘soft technologies’ such as task durations through innovations like fast-track permitting, which require improved collaboration and process streamlining. This framework also provides insight into the nature of knowledge spillovers between technologies. Both module and BOS hardware innovations show the benefits of PV’s position within an ‘ecosystem’ of continuously advancing technologies in many industries, in particular semiconductors and electronics, and also point to the importance of public institutions for accelerating testing, permitting, and training.

14 SOLAR ENERGY↗
DOE OSTI2025

Semi‐Continuous Ex Situ Carbon Dioxide Mineralization in Produced Water for Calcite Production

ABSTRACT The mineralization of carbon dioxide (CO 2 ) to stable carbonate products is a desirable process for carbon capture utilization and storage (CCUS). However, improving the process economics through creative use of available reactants is necessary to develop a scalable mineralization process. This study details the development of a semi‐continuous CO 2 mineralization process that uses flue gas as a point CO 2 source, produced water (PW) as an alkaline source of Ca 2+ , and NaOH effluent (potentially sourced from integration with the chlor‐alkali process. Operating at a controlled pH allowed for both complete reaction of available Ca 2+ (100% carbonation potential or 9.9 g CO 2 .L –1 PW brine) and for reproducible control of the produced calcium carbonate (CaCO 3 ) product. A full factorial design of experiments was implemented to study the effects of reaction temperature, pH, and gaseous CO 2 concentration on the mineralization and CO 2 capture rates as well as product crystalline structure and morphology. A maximum CO 2 capture rate of 0.315 ± 0.007 kg.L –1 .d –1 was achieved at 25°C and 25% CO 2 . CO 2 gas to liquid phase mass transport is believed to be the rate limiting step. With improved reactor design and optimization, the proposed semi‐continuous mineralization process shows promise for scaling to a pilot scale CO 2 capture technology.

Bennett, Quinn [Institute for Sustainable Energy &↗
DOE OSTI2025

U.S. Department of Energy Competitiveness Improvement Project (CIP) 2024 Manufacturing Process Innovation Awardee: Bergey Windpower Co.

This fact sheet describes the 2024 Competitiveness Improvement Project (CIP) award received by Bergey Windpower Co. for manufacturing process innovation. The U.S. Department of Energy's (DOE's) CIP awards cost-shared subcontracts and technical support to manufacturers of small and medium-sized wind turbines. Managed by NREL on behalf of DOE's Wind Energy Technologies Office, CIP helps advance wind energy as a cost-effective, distributed generation technology option.

17 WIND ENERGY↗
DOE OSTI2026

Machine Tool Data Analytics for Digital Twin and Machine Predictive Maintenance

The primary objective of this project is to improve machining process performance using in-process machining data from the machine tool controller and external sensors. Advances in the Industrial Internet of Things (IIoT) enable monitoring of machines using controller data. Examples of the data provided by a controller include execution status of the controller, part count, block of code being executed, door status, tool position, the spindle and axis load, etc. MTConnect and OPC-UA are the two common protocols for capturing machine information. In this collaboration, methods for retrieving the machine controller data from selected machine tool controls and making these data accessible in different subsystems (such as digital twins and machine maintenance portals, etc.) will be developed and tested. In addition, analytics to improve machining process performance (by increasing productivity and reducing downtime) will be developed.

42 ENGINEERING↗
DOE OSTI2025

High Throughput Solvent-free Manufacturing of Battery Electrodes

The project goal is to develop and demonstrate an advanced solvent-free lithium-ion battery electrode process through proposed Advanced Dry Electrode Process (ADEP) equipment, which is expected to exhibit a better binder fibrillization and high throughput and suitable for high performance electrode manufacturing, and commonize the anode and cathode dry processing equipment, supply chain and operation for lithium-ion battery OEMs for replacing the solvent-based slurry casting. Our proposed approach will facilitate low-cost battery production by addressing the following gaps in present dry electrode processing: • Extend the dry electrode fabrication process to lithium-ion battery anode manufacturing • Increase the active material content for anodes and cathodes • Intensify the process through improved mixing, powder rheology and surface modifications • Enable processing of next-generation electrode materials that are not stable to solvent or ambient air exposure. The project objectives include the development of anode-compatible binder and binder fibrillization promoter for low irreversible capacity loss, low electrode binder content yet higher film mechanical strength, and the optimization of solvent-free anode and cathode process for low cost (>60% electrode cost reduction), high performance (10% increase in energy density without sacrificing cycle life) and high throughput to enable next generation lithium-ion battery electrode production. Solvent-free electrode manufacturing will also enable next-generation cell designs based on prelithiated anodes or solid-state electrolytes.

25 ENERGY STORAGE↗
DOE OSTI2025

Crossing the Finish Line: Integration of Data-Driven Process Control for Maximization of Energy and Resource Efficiency in Advanced Water Resource Recovery Facilities

Improvements in process monitoring and control at water resource recovery facilities (WRRFs) could result in reductions in electricity consumption, chemical inputs, and greenhouse gas emissions, as well as improved energy recovery. Many current WRRF data collection, monitoring, and control approaches use 20th century process monitoring and control systems, which require large design safety factors to ensure reliability in the absence of more advanced, precise controls. Implementation of more modern data-driven control tools could lead to more efficient operations that provide intrinsic reliability with better overall process performance at full-scale. This project (1) developed and demonstrated data-driven process controls at full-scale facilities for five promising WRRF process technologies that provide whole-plant approaches and offer substantial energy and resource recovery benefits, and (2) created a Machine Learning (ML) Toolkit and an implementation guide of new process control approaches that walks users through each step of the ML workflow and illustrates the steps through case study examples.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Additive Manufacturing Evaporative Casting

Traditional lost foam casting has been around for decades. The process uses foam forms blown by an injection molding like process or CNC milled into the desired shape, then pouring molten metal over the foam pattern to create a metallic object. Additive Manufacturing Evaporative Casting (AMEC) is a new process that eliminates foam forms by using additive manufacturing to 3D print the desired cast geometry. This not only saves time and money but allows for more advanced and complex designs that can’t be achieved by carving foam. Additionally, AMEC doesn’t require molds and tooling like other casting and foundry options. Because the AMEC process is new, extensive testing is needed to develop a better understanding of the process to minimize defects, quantify material properties, and start computer modeling for the process. This CRADA (collaborative research and development agreement) between ORNL and Skuld seeks to improve the process, develop a computational model, characterize material properties, and explore new applications.

36 MATERIALS SCIENCE↗
DOE OSTI2025

The Natural Products Magnetic Resonance Database (NP-MRD) for 2025

The Natural Products Magnetic Resonance Database or NP-MRD (https://np-mrd.org) is a comprehensive, freely accessible, web-based resource for the deposition, distribution, extraction and retrieval of nuclear magnetic resonance (NMR) data on natural products. The NP-MRD was initially established to support compound de-replication and data dissemination for the natural products community. However, that community has now grown to include many users from the metabolomics, microbiomics, foodomics and nutrition science fields. Indeed, since its launch in 2021, the NP-MRD has expanded enormously in size, scope and popularity. The current version of NP-MRD now contains nearly 7X more compounds (281,859 vs. 40,908) and 7X more NMR spectra (5.1 million vs. 817,000) than the first release. More specifically, an additional 4.6 million predicted spectra and another 11,000 spectra simulated from experimental chemical shifts were deposited into the database. Likewise, the number of NMR raw spectral data depositions has grown from a 165 spectra per year to more than 10,000 per year. As a result of this expansion, the number of monthly webpage views has grown from 55 to 20,000 and the number of monthly visitors has increased from 7 to 2500. To address this growth and to better support the expanding needs of its diverse community of users, many additional improvements to the NP-MRD have been made. These include significant enhancements to the data submission process, important improvements to the visualization and display of NMR spectra, notable updates to the database’s spectral search utilities and useful additions to support better NMR spectral analysis/prediction. Significant efforts have also been undertaken to remediate and update many of NP-MRD’s database entries. This manuscript describes these database improvements and expansion efforts, along with how they have been implemented and what future upgrades to the NP-MRD are planned.

Artifical Intelligence↗
DOE OSTI2026

Integrating Resilience Planning in Distribution System Planning

Electric utilities, regulators, and stakeholders face increasing risks of severe storms, freezes, floods, and heat waves damaging grid infrastructure and causing power outages—and increasing risks of utility equipment igniting wildfires. At the same time, customer electricity rates have risen substantially in recent years, due in part to replacing aging infrastructure and improving resilience to natural hazards and physical threats. To address these challenges, utilities are beginning to move beyond traditional, siloed planning processes to balance resilience with other fundamental grid objectives such as affordability, reliability, safety, and serving new loads. This study presents a framework for states and utilities that want to advance integration of resilience and distribution planning processes to improve planning efficiency, better prioritize cost-effective grid expenditures, and balance planning objectives. The framework includes 7 key integration points between these planning processes: -Strategy process -Data -Threat assessments -Solution identification and prioritization -Optimization opportunities -Consideration of other grid needs -Metrics Lawrence Berkeley National Laboratory reviewed utility distribution system plans and interviewed subject matter experts to identify emerging practices for each of the 7 integration points. This report presents these practices, which can be used as a guide toward more holistic planning and cohesive investment strategies. It also includes 3 case studies to provide practical examples of how utilities apply such integrated planning processes: two pole hardening programs and one microgrid planning effort. The report concludes by identifying opportunities for future research.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2026

Characterizing the impact of water uptake on light absorption by aerosol particles

Absorbing aerosols (AA) have an important impact on the global radiation budget. The composition and properties of AA can vary substantially throughout the atmosphere, depending on the particle source and the influence of chemical aging. Uncertainties associated with the radiative effects of AA remain substantial. A key contributor to this uncertainty is understanding the extent to which water uptake alters absorption by AA particles and how this depends on particle composition. We have used new and existing experimental tools to systematically characterize the relationship(s) between AA chemical and physical characteristics, relative humidity, and mixing of AA with other aerosol components through a combination of laboratory and field measurements. We have developed fundamental understanding through laboratory experiments that will enable interpretation of field observations at DOE ARM sites and facilitate process-based improvements in the simulation of absorption by carbonaceous aerosols in climate models. In the laboratory experiments we have considered a variety of different AA types, including fullerene soot (a surrogate for refractory black carbon, or BC) and nigrosine (a surrogate for partially soluble brown carbon, or BrC). By examining a range of AA types we will develop insight into how the chemical and physical properties of AA particles (e.g. whether they are refractory or soluble) impact the influence of water uptake on absorption. These AA particles will also be mixed—both internally and externally—with compounds having a wide range of hygroscopic properties to establish how the impact of water uptake on absorption will vary with photochemical processing. These laboratory observations have been compared with commonly used theoretical models, enabling development of empirical models that will facilitate improved representation of absorption by AA particles in regional and global climate models. Overall, our study has contributed to the mission of the Atmospheric System Research program by quantifying how interactions between aerosols and radiation depend on relative humidity. Through this, our work will improve understanding and model representation of aerosol processes as they affect the Earth’s radiation budget.

54 ENVIRONMENTAL SCIENCES↗