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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

Key Strategies in Industry for Circular Economy: Analysis of Remanufacturing and Beneficial Reuse

Manufacturing, in the effort to be more sustainable, is increasingly focusing on energy efficiency and waste reduction. DOE's Better Buildings Better Plants Program has established Waste Reduction Network that works with 32 industrial partners to achieve higher material efficiency and reduce waste. United States generates 7.6 Billion Tons of industrial solid waste as estimated by EPA. In a linear economy as the economy grows, so does the waste – increasing strain on resources and the environment. The Circular Economy (CE) model keeps the available resources in circulation for longer period of time easing the burden on the environment.Remanufacturing and (Beneficial) reuse are widely accepted channels in 9R methodology and established pillars of CE. This chapter reviews the two key strategies and their adoption in different industrial sectors. It reviews the key barriers faced by manufacturers in implementing these methodologies and discusses the possible solutions to those barriers. The chapter also reviews impact of these CE strategies on sustainability, material efficiency and the economic and social benefits. Finally, this chapter presents two case studies from DOE's Better Plants partners – one on remanufacturing of components in heavy vehicles industry and one on beneficial reuse of spent foundry sand, a non-hazardous solid waste, and discusses the project impacts.

Chaudhari, Subodh↗
DOE OSTI2021

Integrating Emerging Polymer Chemistries for the Advancement of Recyclable, Biodegradable, and Biocompatible Electronics

Abstract Through advances in molecular design, understanding of processing parameters, and development of non‐traditional device fabrication techniques, the field of wearable and implantable skin‐inspired devices is rapidly growing interest in the consumer market. Like previous technological advances, economic growth and efficiency is anticipated, as these devices will enable an augmented level of interaction between humans and the environment. However, the parallel growing electronic waste that is yet to be addressed has already left an adverse impact on the environment and human health. Looking forward, it is imperative to develop both human‐ and environmentally‐friendly electronics, which are contingent on emerging recyclable, biodegradable, and biocompatible polymer technologies. This review provides definitions for recyclable, biodegradable, and biocompatible polymers based on reported literature, an overview of the analytical techniques used to characterize mechanical and chemical property changes, and standard policies for real‐life applications. Then, various strategies in designing the next‐generation of polymers to be recyclable, biodegradable, or biocompatible with enhanced functionalities relative to traditional or commercial polymers are discussed. Finally, electronics that exhibit an element of recyclability, biodegradability, or biocompatibility with new molecular design are highlighted with the anticipation of integrating emerging polymer chemistries into future electronic devices.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

A Metal‐Organic Framework with Nonpolar Pore Surfaces for the One‐Step Acquisition of C 2 H 4 from a C 2 H 4 and C 2 H 6 Mixture

Abstract Because C 2 H 4 plays an essential role in the chemical industry, economical and energy‐efficient separation of ethylene (C 2 H 4 ) from ethane (C 2 H 6 ) is extremely important. With the exception of energy‐intensive cryogenic distillation, there are few one‐step methods to obtain polymer‐grade (≥99.95 % pure) C 2 H 4 from C 2 H 4 /C 2 H 6 mixtures. Here we report a highly stable metal‐organic‐framework (MOF) FJI‐H11‐Me(des) (FJI‐H=Hong's group in Fujian Institute of Research on the Structure of Matter) which features one‐dimensional hexagonal nonpolar pore surfaces constructed by aromatic rings and alkyl groups. This FJI‐H11‐Me(des) adsorbs C 2 H 6 rather than C 2 H 4 between 273 and 303 K. Practical breakthrough experiments with C 2 H 4 containing 1 % C 2 H 6 have shown that FJI‐H11‐Me(des) can realize the acquisition in one‐step of polymer‐grade, 99.95 % pure C 2 H 4 under various conditions including different gas flow rates, temperatures and relative humidity.

Di, Zhengyi↗
DOE OSTI2020

A scalable crosslinked fiberglass-aerogel thermal insulation composite

Ceramic aerogels are attractive for thermal insulation due to its lightweight and low thermal conductivity, while it is indispensable to address the obstacle of its brittleness nature and large-scale manufacturing for building efficiency applications. The economical manufacturing of large-scale elastic thermal insulation aerogels has remained challenging. Herein, we report a universal manufacturing of the fiberglass reinforced aerogel composites where the architectured three-dimensional fiber networks with the cross-linked silica aerogel exhibit superinsulation and mechanical elasticity. These remarkable performances are obtained through in-situ cross-linking reaction between molecular assembly induced aerogel and fiberglass under ambient pressure drying environment, in which the interfacial interactions are verified from its infrared spectra. The resulting ultralight aerogel composite sheet exhibits a density of 0.1 g cm -3 , large strain recovery (>50%), and low thermal conductivity (0.0253 W m –1 K –1 ). Here, the thermal insulation aerogel composites shed light on the super-elastic aerogel manufacturing with scalability for energy saving building applications.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Barriers to adopting artificial intelligence and machine learning technologies in nuclear power

Artificial intelligence and machine learning (AI/ML) technologies offer unique opportunities to transform nuclear plant operations and power generation. Benefits will be felt not only within existing analog and digital instrumentation and control, but also within work processes, the integration of people with technology and most importantly, the business case. The application of this new technology can help simplify complex problems and produce more effective decision-making, making nuclear power safer, more efficient, and more economically viable in the current energy market. Nonetheless, there are potential barriers to its adoption that must be overcome. The purpose of this paper is to categorize, review, and discuss barriers to AI/ML adoption within the nuclear power industry, with a focus on existing commercial reactors. Unique considerations for advanced reactors are also offered. Here we provide a comprehensive overview of the historical, technical, and business barriers that the industry faces, as well as stakeholder readiness, and end-user acceptance. We underscore the importance of user experience and offer potential solutions in overcoming each barrier. These include provisions for easier plant data access, a friendly regulatory environment, and investment in user trust and explainable AI.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Bisoxazoline-pincer ligated cobalt-catalyzed hydrogenation of alkenes

The efficient and atom economical hydrogenation of alkenes using a novel bisoxazoline ligated cobalt complex has been developed here. The hydrogenation of a variety of alkenes containing electron neutral and electron-donating groups proceeds in high yield, while electron-withdrawing and sterically hindered groups are not tolerated. Heterocycles and internal alkenes were further hydrogenated in moderate to high yields. While the catalyst is enantiopure, no enantioinduction was observed suggesting that other factors are involved in achieving enantiocontrol.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

srlife : A software tool for estimating the life of high temperature concentrating solar receivers. Part II – Ceramic receivers

As Concentrating Solar Power (CSP) technologies aim for higher operating temperatures to enhance efficiency and meet industrial process heat demands, high-temperature metallic materials, including nickel-based superalloys, face challenges in maintaining structural integrity. Advanced ceramics offer a promising alternative due to their superior high-temperature strength. However, accurately assessing the performance of ceramic components requires a fundamentally different approach from that used for metallic components. This Part II of a two-part paper describes the integration of ceramic statistical failure models within srlife – an open-source tool for predicting the life of high-temperature CSP receivers. These models account for the inherent variability in ceramic strength, as well as the effects of subcritical crack growth (SCG) under high temperature cyclic loads. Here, the paper includes an example problem that demonstrate the process of evaluating ceramic receivers using srlife. Part I details the life estimation process for metallic receivers (i.e. creep-fatigue life) along with input and output data structure, thermohydraulic analysis, and structural analysis. The complete tool is available as open-source software at https://github.com/srlife-project/srlife and can be installed via the PyPi package manager (https://pypi.org). By supporting both ceramic and metallic receiver analyses, srlife facilitates fair comparisons between competing metallic and ceramic designs, enabling accurate evaluations of plant efficiency and the economic benefits of ceramic solar receivers and other components.

High temperature ceramic receivers↗
DOE OSTI2022

Molecular Engineering of Biorefining Lignin Waste for Solid-State Electrolyte

Lignin is the second most abundant renewable biopolymer on Earth but also a waste in both the paper industry and lignocellulosic biorefineries. Recently, lignin valorization has been extensively sought after to return economics, enhance carbon efficiency, and improve the bioeconomy, but the commercial value and size compatibility still hinder its applications. In this study, we developed a facile strategy to apply lignin waste into a solid-state electrolyte (SSE), which represents a safe next generation energy storage. Here, lignin was grafted with polyethylene glycol (PEG), an efficient lithium-ion (Li + ) conductive polymer, to enable its ion conduction. The synthesized PEG-g-lignin was mixed with poly(vinylidene fluoride)-co-hexafluoropropylene (PVDF-HFP) and PEG-g-lignin-based bis(trifluoromethanesulfonyl)imide (LiTFSI) to prepare a solid polymer electrolyte (SPE), which has an ionic conductivity of 2.5 × 10 –5 S/cm at 25 °C. This result was further enhanced to 6.5 × 10 –5 S/cm by adding an ion-conductive ceramic of Li 6.4 La 3 Ga 0.2 Zr 2 O 12 (LLGZO), which is referred to as composite polymer electrolyte (CPE). These data represent the highest ones among reported polymer-based SSE. A mechanistic study by using 2D HSQC NMR revealed that PEG-g-lignin has increased ether type β–O–4 linkages that can promote the interchain hopping of Li+ between lignin polymer chains, and 31 P NMR revealed that the lignin phenolic end can be associated by Li + . Moreover, the abundant aromatic moieties and methoxyl in PEG-g-lignin also enhanced Li + association and improved its ionic conductivity. The superior ionic conductivity of PEG-g-lignin-based SSE can enable massive applications of this biorefining waste in all-solid-state lithium batteries (ASSLBs), which has potential to promote the energy sector by promoting the bioeconomy and enhancing the renewability and sustainability of future energy storage.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Analysis of the linear and nonlinear stability of Alfven eigenmodes and fish-bones in JET DT discharges: mode identification and shear flows generation

The plasma in future nuclear fusion reactors will be heated by neutral beam injectors (NBIs) and high frequency electromagnetic waves as well as fusion born alpha particles. Energetic particles (EPs), with energies up to two orders of magnitude larger than the thermal plasma, can trigger EP driven modes and induce harmful EP losses, reducing the plasma heating efficiency and the economical viability of the reactor. The present study is dedicated to analyze the Alfven Eigenmode (AE) activity in JET D–T discharges, the closest experiment to reactor-like operation performed until now. There, EP driven modes are induced by the combined effect of tangential NBIs and ion cyclotron resonance heating (ICRH) driven EP. Linear and nonlinear simulations are performed with the gyro-fluid FAR3d code to analyze the AE activity observed in the discharge 99896. The linear simulations reproduce the unstable n = 3 to 5 toroidal AEs (TAE) at the inner plasma region observed in the experiment, triggered by highly energetic passing deuterium populations injected by the tangential NBIs, further accelerated by the effect of the ICRH up to 1 MeV. In addition, fish-bones triggered by energetic trapped hydrogen induced by the ICRH are also reproduced. On the other hand, the alpha particles density is too small to destabilize AEs in the experiment. Nonetheless, increasing artificially the alpha density by one order of magnitude, an n = 1 beta induced AE can be destabilized in the inner plasma region. Nonlinear simulations indicate the generation of zonal structures during the AE/fish-bone saturation phase. TAE and fish-bones causes a rather weak increase of the passing D and trapped H EP (around 2%), respectively. Shear flows and zonal currents are generated during the saturation of TAE and fish-bones. Nonlinear simulations performed for D–T and pure deuterium thermal plasma indicate AE/fish-bone activity is weaker and shear flows are less intense in the pure deuterium case, trends consistent with the experimental observations that also indicates a deterioration of the thermal plasma confinement. Therefore, both numerical studies and experimental evidence indicate the generation of shear flows by AE/fish-bones could be connected with an improvement of the thermal plasma confinement.

AE↗
DOE OSTI2026

Detecting and Characterizing Fracture Zones Using a Convolutional Neural Network

This project directly supports the Geothermal Technologies Office (GTO) objectives outlined in the Multi-Year Program Plan (MYPP) by advancing two key research areas: “Exploration and Characterization” and “Data, Modeling, and Analysis.” This project has successfully demonstrated a pre-drilling ability to image and characterize the distribution and connectivity of subsurface faults and fractures, key parameters for identifying permeable pathways that enable geothermal fluids to circulate and produce energy. Specifically, we developed and implemented innovative machine learning methodologies to enhance geothermal exploration. Large-scale faults were detected using a Convolutional Neural Network (CNN), while small-scale fractures were characterized using a novel Double-Beam Neural Network (DBNN). These tools have proven both technically effective and cost-efficient by reducing reliance on expensive exploratory drilling. Through collaboration with our geothermal industry partner, this research has significantly advanced techniques for identifying hidden geothermal systems and extending the productive lifespan of existing geothermal fields. We applied our methods to two geothermal fields—Soda Lake (Nevada) and Lightning Dock (New Mexico)—to identify shallow steam-charged fracture zones and characterize deep faults at depths of 1.5-2 km. The steam zone identified at the Soda Lake geothermal field showed excellent agreement with prior drilling data, validating the effectiveness of our approaches. In addition, the analysis revealed three new prospective drilling targets for further development and verification. The outcomes of this project improve our scientific understanding of geothermal reservoir behavior, enhance exploration efficiency, extend the economic life of existing geothermal plants. Ultimately, these advancements contribute to GTO’s goal of achieving more sustainable, affordable, and data-driven geothermal energy development across the United States.

15 GEOTHERMAL ENERGY↗
DOE OSTI2026

Development of a High-Efficiency Hybrid Dry Cooler System for sCO 2 Power Cycles in CSP Applications

This project addressed a major gap in supercritical CO 2 (sCO 2 ) power cycle research by focusing on the pre-cooler, a component that had received little attention despite its significant impact on cycle efficiency and plant economics. The team developed a compact dry cooler using brazed/diffusion-bonded microchannel passages paired with formed air-side fins, advancing the technology from TRL-2 toward commercial readiness. Compared to conventional fin-tube coolers, the design cuts installation footprint by roughly half for 10+ MWth systems while achieving better heat transfer and lower approach temperatures, translating into a projected LCOE reduction from 6.04 ¢/kWh to between 5.85 and 5.94 ¢/kWh. While fabrication of an aluminum MW-scale prototype revealed brazing and sealing challenges at larger scales, lessons learned informed a subsequent 1 MWth unit that was successfully built and delivered for integration into Sandia's Gen3 Particle Pilot Plant, advancing the technology to TRL-7 with a path toward TRL-8 pending successful testing.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2022

In Hot Water! The Challenges and Barriers of Decarbonizing Water Heating in Multifamily Buildings: Preprint

Domestic hot water heating is responsible for 32% of the total energy consumption in multifamily buildings and offers a significant decarbonization opportunity. An extensive market assessment was conducted to understand and document key technical and economic barriers to electrification of domestic water heating in multifamily buildings throughout the U.S. Through the program, 77 interviews were conducted to understand key market drivers and technical challenges associated with electrification of water heating systems in both retrofit and new construction scenarios. Interviewees encompassed a wide range of stakeholders in the ecosystem surrounding water heating systems, including suppliers, manufacturers, designers, owners, utilities, and developers. This paper documents key interview takeaways, including an extensive list of market barriers, technical challenges, and sought-after technology attributes that can inform pertinent design criteria for electric water heating research, development, and deployment efforts. Among economics and energy efficiency features, interviewees overwhelmingly alluded to space constraints, cold air exhaust, and lack of clear guidance regarding distributed versus centralized design selections as key challenges associated with mass adoption of electric water heating. Owners and developers seek systems with minimal footprint, which maximize rentable space and profits. Moreover, distributed heat pump solutions should balance ducting costs that mitigate cold exhaust entrainment into conditioned zones. Lastly, the market needs clear guidance regarding the selection of distributed versus central electric hot water systems.

challenges of water heating electrification↗
DOE OSTI2023

Scaling Wind Power Innovation Assessment for Rapid Energy Transition with Artificial Intelligence

Planning for energy system decarbonization requires new insights into the potential of renewable technologies, deployed at unprecedented scale, to meet urgent sustainability goals. However, limited scalability of current wind energy research tools restricts characterization of innovation impacts to isolated reference sites, challenging investment and decision making under rapid growth. We demonstrate the transformative potential of artificial intelligence (AI) to inform future technology advancement and energy systems design by leveraging a state-of-the-art surrogate model to conduct a series of fleet-wide wind plant layout optimizations for greater than 6,800 projected U.S. onshore buildout locations. We show how innovative wake steering technology can address an array of barriers to large-scale deployment and integration of wind power. Specifically, wake steering reduces required plant area by an average of 18% and could preserve upwards of 13,000 km2 for future greenfield deployment, potentially easing siting challenges associated with wind energy infrastructure. Further, by enabling reduced turbine spacing and increased energy production, flexible operations of wake steering improve levelized cost of energy, particularly for large plants and in land-constrained settings. Finally, optimizations that consider dynamic energy prices can deliver increased power production and revenue capture during high-value (often low-wind) periods, further bolstering plant economics. Our computationally efficient approach offers a pathway to accelerate nationwide geographic evaluation of innovative technologies.

graph neural networks↗
DOE OSTI2023

Key Strategies in Industry for Circular Economy : Analysis of Remanufacturing and Beneficial Reuse

Manufacturing, in the effort to be more sustainable, is increasingly focusing on energy efficiency and waste reduction. DOE’s Better Buildings Better Plants Program has a Waste Reduction Network that works with 32 industrial partners to achieve higher material efficiency and reduce waste. United States generates 7.6 Billion Tons of industrial solid waste as estimated by EPA. In a linear economy as the economy grows, so does the waste – increasing strain on resources and the environment. The Circular Economy (CE) model keeps the available resources in circulation for longer period of time easing the burden on the environment. Remanufacturing and (Beneficial) re-use are widely accepted channels in 9R methodology and established pillars of CE. This paper reviews the two key strategies and their adoption in different industrial sectors. It reviews the key barriers faced by manufacturers in implementing these methodologies and discusses the possible solutions to those barriers. The paper also reviews impact of these CE strategies on sustainability, material efficiency and the economic and social benefits. Finally, this paper presents two case studies from DOE’s Better Plants partners – one on remanufacturing of components in heavy vehicles industry and one on beneficial reuse of spent foundry sand, a non-hazardous solid waste, and discusses the project impacts.

Chaudhari, Subodh↗
DOE OSTI2025

Initial Design of SABRE Fueled Molten Salt Experiment Irradiation Vehicle

Molten Salt Reactors (MSRs) are emerging as promising advanced reactor technologies, utilizing molten salts for both fuel and primary cooling. These reactors may offer advantages such as passive safety, enhanced economic viability, and efficient waste reprocessing while operating at high temperatures and low pressures, which leads to increased system efficiency and reduced mechanical stress on containment structures. However, challenges arise from the complex chemistry and high corrosion rates of fueled molten salts, alongside the volatility of certain fission products during irradiation. The accumulation of these fission products can alter the fuel salt chemistry, affecting corrosion potential and radioactive source terms. Therefore, understanding these phenomena under neutron irradiation is essential for future MSR designs. The SABRE (Salt and Actinide Burnup in a Reactor Environment) experiment, currently in conceptual design at Idaho National Laboratory (INL), aims to investigate these challenges by conducting a drop-in capsule experiment in the Advanced Test Reactor (ATR). The primary objectives include achieving a minimum burnup of 2 GWd/MTU and characterizing fission products while studying corrosion behavior in molten salt systems. This innovative experiment will leverage recent advancements in ATR capabilities, allowing for the safe irradiation of molten salts, thereby advancing the understanding and qualification of MSR technology for future nuclear power generation.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Development of Digital Twin-Informed Predictive Maintenance for Critical Components in Advanced Reactors

Small modular reactors (SMRs) and microreactors, along with other advanced reactor (AR) technologies, are key to the future of nuclear energy. For these systems to achieve low operating costs, high reliability, and flexibility across applications, their operation and maintenance must be optimized. Digital twin (DT) technology is one of the technologies that enables real-time (or faster than real-time) monitoring and prognosis of critical components which are vital for operational efficiency, low costs, and enhanced safety of ARs, accelerating their deployment. DT technology provides dynamic virtual representation of physical assets by integrating real-time data, physics-based models, and advanced analytics, which is critical to optimizing the performance of the entire energy system throughout the life cycle. DTs empower engineers and operators to virtually explore different scenarios, configurations, and control strategies, allowing for the identification of optimal solutions that maximize reactor efficiency, safety, and economics.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Challenges and Roadmap for Solar-Thermal Desalination

Decarbonizing desalination systems requires combining renewable energy technologies with desalination systems. Solar thermal desalination, which combines a thermal desalination system (e.g., distillation, multistage flash, etc.) with a concentrated solar system is attractive in geographic regions with an abundance of saline water and solar energy. However, the high economic cost and low efficiency limits its adoption. This review provides an overview of the techno-economic, materials, and performance challenges that need to be overcome to realize solar-desalination. The review describes the four most prominent pathways for overcoming thermodynamic and cost limitations present in current systems. Specifically, methodologies and approaches such as direct solar evaporation structures, low-cost thermal energy storage, solar cogeneration schemes for power and desalination, and solar hybrid desalination are discussed. Furthermore, these strategies can enable solar thermal desalination technologies that are resilient to intermittent solar energy.

14 SOLAR ENERGY↗