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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 253 records · Page 14

Modular Processing of Flare Gas for Carbon Nanoproducts

This project demonstrated the technical viability and economic promise of a modular system for converting flared natural gas into valuable carbon nanoproducts (CNPs) through catalytic chemical vapor deposition (CVD). All major project milestones were successfully completed, including reactor design and commissioning, catalyst development, process optimization, technoeconomic analysis, and application testing in concrete systems. The overarching goal was to create a scalable, field-deployable process that valorizes stranded methane by producing high-value carbon materials for use in cementitious composites. At the lab scale, the team designed and built a fluidized bed reactor optimized for use with silica fume-supported nickel catalysts synthesized via atomic layer deposition (ALD). A statistically designed sintering study enabled precise tuning of nickel nanoparticle size, identifying the influence of oxygen partial pressure, time, and temperature on catalyst morphology and performance. These insights allowed the team to target catalyst conditions that maximize carbon nanofilament growth. Subsequent CVD experiments achieved up to 31.8 wt% carbon deposition under optimized conditions, with TEM confirming the presence of nanofilament structures and sustained hydrogen evolution during reaction. Reactor upgrades and empirical fluidization studies supported the development of reliable, repeatable experimental protocols. The modular pilot-scale skid reactor was fully constructed, instrumented, and commissioned. Capable of operating at 675–800°C and pressures up to 290 psig, the system was designed for continuous operation at a carbon production rate of 1 kg/hr. Initial demonstration runs confirmed solids handling, thermal control, and system leak-tightness, although a critical reactor component (the downfeed tube) was inadvertently omitted during final assembly. This omission limited gas–solid contact and prevented meaningful carbon deposition during pilot-scale CVD runs. Nonetheless, the system operated safely under design conditions, and the root cause of performance limitations was clearly identified. Complementary work on UHPC formulations demonstrated that small additions of carbon nanoproducts, including those derived from flare gas, can significantly enhance mechanical performance while preserving workability. A comprehensive study of CNF dispersion techniques and mix design optimization led to a clear protocol for integrating these nanomaterials into concrete. Incorporation of CNPs improved flexural toughness and reduced porosity, supporting their use in high-performance infrastructure applications. A technoeconomic analysis (TEA) confirmed that this process can produce CNP-loaded catalyst material at a levelized cost below $\$$7/kg across a range of catalyst loadings and reaction yields. With estimated market values for the carbon composite product ranging from $\$$14 to over $\$$60/kg, and the ability to blend CNPs into concrete at sub-percent levels with less than 10% added cost, the system presents a compelling economic case. While additional engineering work is needed to optimize fluidization and heat transfer at scale, this project establishes a strong foundation for commercial development. The process is not only technically sound but also economically promising, representing a viable pathway for flare gas mitigation through modular carbon nanomaterial production.

03 NATURAL GAS↗

Mars Sample Return Using Commercial Capabilities: Propulsive Entry, Descent, and Landing of a Capsule Form Vehicle

This paper describes a critical portion of the work that has been done at NASA, Ames Research Center regarding the use of the commercially developed Dragon capsule as a delivery vehicle for the elements of a high priority Mars Sample Return mission. The objective of the investigation was to determine entry and landed mass capabilities that cover anticipated mission conditions. The "Red Dragon", Mars configuration, uses supersonic retro-propulsion, with no required parachute system, to perform Entry, Descent, and Landing (EDL) maneuvers. The propulsive system proposed for use is the same system that will perform an abort, if necessary, for a human rated version of the Dragon capsule. Standard trajectory analysis tools are applied to publically available information about Dragon and other legacy capsule forms in order to perform the investigation. Trajectory simulation parameters include entry velocity, flight path angle, lift to drag Ratio (L/D), landing site elevation, atmosphere density, and total entry mass, in addition engineering assumptions for the performance of the propulsion system are stated. Mass estimates for major elements of the overall proposed architecture are coupled to this EDL analysis to close the overall architecture. Three synodic launch opportunities, beginning with the 2022 opportunity, define the arrival conditions. Results state the relations between the analysis parameters as well as sensitivities to those parameters. The EDL performance envelope includes landing altitudes between 0 and -4 km referenced to the Mars Orbiter Laser Altimeter datum as well as minimum and maximum atmosphere density. Total entry masses between 7 and 10 mt are considered with architecture closure occurring between 9.0 and 10 mt. Propellant mass fractions for each major phase of the EDL - Entry, Terminal Descent, and Hazard Avoidance - have been derived. An assessment of the effect of the entry conditions on the Thermal Protection System (TPS) currently in use for Dragon missions shows no significant stressors. A useful payload mass of 2.0 mt is provided and includes mass and grow allowance for a Mars Ascent Vehicle (MAV), Earth Return Vehicle (ERV), and mission unique equipment. The useful payload supports an architecture that receives a sample from another surface asset and sends it directly back to Earth for recovery in a high Earth orbit. The work shows that emerging commercial capabilities as well as previously studied EDL methodologies can be used to efficiently support an important planetary science objective. The work also has applications for human exploration missions that will also use propulsive EDL techniques

EDL↗

ARCUS Vertical-Axis Wind Turbine (Final Scientific/Technical Report)

While land-based wind energy has become economically competitive with traditional energy generation sources in the U.S., offshore wind is not. For floating offshore wind this difference is even more substantial where the levelized cost of energy (LCOE) is projected to be around 3-5 times more expensive than land-based wind. The turbine capital costs represent around 50% of the LCOE for land-based wind sites, but the increased system costs for floating offshore wind reduce this to 20%. The platform and mooring costs are the single largest contributor to the LCOE for floating offshore wind where their mass must counteract the overturning moment caused by the turbine’s thrust force. Despite the high costs of the platform and relatively low cost of the turbine, current offshore wind turbines are designed essentially the same as for land-based sites. Reducing the LCOE is the greatest challenge to realize the benefits of sustained development of floating offshore wind in the U.S. Reducing the complicated system costs of floating offshore wind will enable the industry to continue to grow and outpace current projections if reduced cost curves can be reached. The ideal wind energy system would remove all mass and cost that is not directly capturing energy from the wind. For floating offshore wind energy systems, this objective is even more significant as increased mass above the water level must be supported by larger and more expensive floating platforms. For this reason, vertical-axis wind turbines (VAWTs) are ideal for floating offshore sites and have several advantages over horizontal-axis wind turbines (HAWTs) at this scale. Large VAWTs offer opportunities for improved energy capture over HAWTs as single units and with reduced wind plant aerodynamic losses through enhanced wake recovery. Additionally, the platform-level placement of the VAWT drivetrain greatly reduces the demands placed on the floating platform and its mass and cost. The ARCUS vertical-axis wind turbine concept (U.S. 11,421,650 B2) is an iteration beyond traditional Darrieus-type VAWTs that replaces the rigid tower with blades that are bent into shape and held in place with tensioned center supports, like a bow. The ARCUS design has been shown to further decrease the VAWT rotor mass properties, with a 50% reduction over traditional Darrieus VAWTs quantified in the ATLANTIS program. The ARCUS VAWT’s efficient use of material for the rotor and turbine support structures combined with its lowered center of gravity enables a tension-leg platform (TLP) with simplified installation procedures. TLPs have been an emerging platform architecture in the Oil and Gas industry and demonstrated to have the lowest hull mass requirements while maintaining stability with minimal roll and pitch deflections in operation. A 22 MW ARCUS turbine has been designed with a three-column TLP that enables quayside integration of the turbine while maintaining system stability during tow-out and installation and having optimal mass and cost properties. A comprehensive analysis shows the optimal ARCUS TLP system design minimizes LCOE through efficient material usage and increased energy capture to yield a competitive LCOE estimate of $\$$55/MWh. A comparison with a reference HAWT, having the same swept area, quantifies the advantages that helped to produce this improved LCOE for the ARCUS concept: (1) 30% reduction in total turbine mass, (2) 70% reduction in turbine center of gravity, and (3) 45% increase in energy production over what is optimal for a HAWT. Intellectual property has been generated through the ATLANTIS program providing opportunities to further reduce the LCOE and improve the performance of the ARCUS turbine and TLP system, expanding the list of innovations to support commercial development of the ARCUS concept.

17 WIND ENERGY↗

Adaptive Laboratory Evolution for algal strain improvement: methodologies and applications

Originally developed in bacterial and fungal models, Adaptive Laboratory Evolution (ALE) experimentally selects for targeted phenotypes by allowing cells containing beneficial random genetic mutations to replicate more quickly in the presence of environmental stress. When applied to microalgae, this technique has been used to increase growth rate, stress tolerance, substrate utilization, and product yield. This review discusses ALE experimental design parameters, and summarizes key results and lessons learned from recent microalgal ALE studies. By documenting the current state of the field, we provide insight on the ways microalgal ALE might be used to develop commercially viable biotechnology strains.

09 BIOMASS FUELS↗

Analysis of the turbostratic structures in PAN-based carbon fibers with wide-angle x-ray diffraction

Carbon fiber (CF) is a versatile material renowned for its excellent mechanical, thermal, and electrical properties. Polyacrylonitrile (PAN)-based CFs dominate the market due to their high tensile strength, rendering them suitable for structural applications in a wide variety of applications ranging from sporting goods to aerospace. Over five decades of commercial development of PAN-based CF has resulted in a range of varieties with different tensile moduli and tensile strengths. The microstructures, nanostructures, and crystal structures of PAN-based CF play pivotal roles in the macroscale properties of this material. In particular, the crystal structure and crystallite orientation in CF is closely related to the mechanical properties. The crystal structure of PAN-based CF generally consists of turbostratic carbon, which is a disordered form of graphite, the characteristics of which can be effectively characterized in a bulk format through wide-angle x-ray diffraction (WAXD). In this work, we employed a three-part approach to the analysis of WAXD patterns collected from four intermediate modulus PAN-based CFs. The approach incorporates a Scherrer analysis, a Debye analysis, and an orientational analysis to provide precise estimates of crystallite sizes, crystallite distributions, and crystallite orientations with the fiber axis. Furthermore, the results presented here suggest that intermediate modulus PAN-based CF mostly consists of small turbostratic crystallites (<4 nm), with larger crystallites having increased orientation with the fiber axis. The results here imply the presence of curvature and/or wrinkling of the turbostratic layers within the CF structure.

36 MATERIALS SCIENCE↗

Farmer characteristics and decision-making: A model for bioenergy crop adoption

We report the commercial development of biofuels and bioproducts depends on whether renewable biomass feedstock is available while not directly competing with the production of food. Farmers are one of the most important stakeholders in the biofuel supply chain and confront a range of uncertainties while entering the bioenergy market. Their decision-making process is extremely complex and rarely purely rational. Modeling farmer behavior requires considering a wide range of individual-level factors, socio-temporal dynamics, institutional settings, and their interactions. These characteristics make agent-based modeling a suitable framework for evaluating such systems. We developed a model to simulate farmer bioenergy crop adoption behavior across a 50-county study region in Nebraska, Kansas, and Colorado. The analysis considers adoption decisions for two bioenergy feedstocks, crop residues and energy crops. We examine the influence of individual and farm characteristics, market structure, social networks, and media influence on farmer adoption decisions. Our results indicate that different factors can have varied impacts on the speed of adoption for the crop residues and energy crops. Identifying levers that have the most impact on grower adoption can inform the design of interventions both from policy and private sector standpoints with important implications for the future the bioenergy industry.

09 BIOMASS FUELS↗

A comparison of wrought and powder metallurgical FeCrAl claddings under simulated LWR accident transients

Iron-chromium-aluminum (FeCrAl) alloys are potential accident tolerant fuel (ATF) cladding candidates for light-water reactors but are difficult to fabricate as thin-walled tubes via conventional cast-and-wrought routes. Powder metallurgy (PM) offers a manufacturing alternative with improved compositional control, but its transient accident performance has not been directly benchmarked against wrought variants. This study evaluates the burst behavior of commercially developed PM-processed FeCrAl alloys, PM-C26M (Fe-12Cr-6Al-2Mo) and the high precipitate density FA-SMT (Fe-22Cr-5Al-3Mo), under simulated light-water reactor accident transient conditions. Burst testing was conducted using the Severe Accident Test Station with heating rates of 5 °C/s and 50 °C/s and internal pressures ranging from 25 MPa to 100 MPa. PM-C26M reproduced wrought C26M burst behavior within 7–37 °C across the stress range, indicating that PM processing does not compromise transient strength. FA-SMT exhibited markedly higher burst temperatures and reduced heating-rate sensitivity, consistent with its engineered precipitate strengthening. FA-SMT rupture exhibited axial "unzipping" rather than the lateral tearing characteristic of PM- and wrought C26M. Post-test EBSD and fractography indicate that this behavior is strongly correlated with strain-gated intergranular void nucleation associated with the dense precipitate architecture of FA-SMT, a response absent in the comparatively clean PM-C26M matrix and consistent with rupture morphologies reported for oxide-dispersion strengthened (ODS) FeCrAl of similar base-matrix chemistry to PM-C26M. These findings highlight the potential of powder metallurgy as a viable fabrication route for ATF claddings from an accident performance standpoint.

Bell, Sam [ORNL] (ORCID:0000000251905657)↗

Rapid scalable plasma processing of thin-film Li–La–Zr–O solid-state electrolytes

Solid-state electrolytes, such as lithium lanthanum zirconium oxide (LLZO), show promise as technologies for next-generation high-energy-density batteries, but commercial development has been hindered by a lack of scalable processing methods. Current fabrication methods are costly or require long annealing steps to create dense films. We report an atmospheric pressure blown-arc nitrogen plasma jet process to rapidly form sub-micrometer-thick, dense amorphous LLZO (a-LLZO) films from sol-gel precursors. Films are processed in less than 2 min, an order of magnitude faster than what has previously been reported. We demonstrate 500-nm-thick a-LLZO films processed at 350°C with an ionic conductivity of 2 × 10 −6 S/cm at 30°C and 2 × 10 −3 S/cm at 100°C and a conductance of 19 S at 100°C, the highest conductance of any LLZO phase to date. Here, the films exhibit outstanding smooth surface morphology with low defectivity, advancing atmospheric plasma processing as a scalable processing method for solid-state electrolytes.

25 ENERGY STORAGE↗

Heterodoxy in Fast Pyrolysis of Biomass

As the field of fast pyrolysis has matured, it has been accompanied by a kind of orthodoxy in its practice. Among these orthodoxies are the following: (1) oxygen should be excluded from the pyrolysis process; (2) little sugar is produced during pyrolysis; and (3) the major product of pyrolysis is a low-value emulsion in water. Adherence to these tenets is an impediment to the commercial development of fast pyrolysis. Over the past 15 years, research at Iowa State University’s Bioeconomy Institute has challenged these tenets with what might be called heterodoxy in the science and engineering of fast pyrolysis: adding oxygen producing sugars, and fractionating bio-oil into valorized products. This paper reviews these new approaches to pyrolysis and concludes with an outlook for further developing them.

42 ENGINEERING↗

Total Protein Analysis in Algae via Bulk Amino Acid Detection: Optimization of Amino Acid Derivatization after Hydrolysis with O -Phthalaldehyde 3-Mercaptopropionic Acid (OPA-3MPA)

The analysis of protein in algal biomass is one of the most critical areas of commercial development of algae characterization for nutritional or other high value applications. A new rapid and accurate method is required that can be widely implemented and that is free from interferences from the complex algal biomass matrix. We developed a simple spectrophotometric method for primary amino acid quantification bulk measurement in an acid hydrolyzed algal biomass preparation, as an alternative to the more labor-intensive amino HPLC acid analysis or less specific nitrogen-to-protein conversion. We have validated an O -phthalaldehyde (OPA)-based derivatization method, showing accurate and linear quantification for standard reference amino acids as well as mixtures, mimicking the amino acid complexity found in algal biomass. The presence of interferences that may be derived from the complex biomass biochemical composition was tested during the method validation phase. We document the application of a novel method of OPA derivatization with 3-mercaptopropionic acid (3MPA) to determine the total amino acid content of harvested algal biomass collected from different, controlled cultivation conditions and demonstrated a within 10% accuracy against a reference measurement of amino acid content in at least 4 species and 10 algal biomass samples, across early, mid, and late-stages of cultivation.

09 BIOMASS FUELS↗

Chromosome-level genome assembly and transcriptome of the green alga Chromochloris zofingiensis illuminates astaxanthin production

Microalgae have potential to help meet energy and food demands without exacerbating environmental problems. There is interest in the unicellular green alga Chromochloris zofingiensis, because it produces lipids for biofuels and a highly valuable carotenoid nutraceutical, astaxanthin. Here, to advance understanding of its biology and facilitate commercial development, we present a C. zofingiensis chromosome-level nuclear genome, organelle genomes, and transcriptome from diverse growth conditions. The assembly, derived from a combination of short- and long-read sequencing in conjunction with optical mapping, revealed a compact genome of ~58 Mbp distributed over 19 chromosomes containing 15,274 predicted protein-coding genes. The genome has uniform gene density over chromosomes, low repetitive sequence content (~6%), and a high fraction of protein-coding sequence (~39%) with relatively long coding exons and few coding introns. Functional annotation of gene models identified orthologous families for the majority (~73%) of genes. Synteny analysis uncovered localized but scrambled blocks of genes in putative orthologous relationships with other green algae. Two genes encoding beta-ketolase (BKT), the key enzyme synthesizing astaxanthin, were found in the genome, and both were up-regulated by high light. Isolation and molecular analysis of astaxanthin-deficient mutants showed that BKT1 is required for the production of astaxanthin. Moreover, the transcriptome under high light exposure revealed candidate genes that could be involved in critical yet missing steps of astaxanthin biosynthesis, including ABC transporters, cytochrome P450 enzymes, and an acyltransferase. Finally, the high-quality genome and transcriptome provide insight into the green algal lineage and carotenoid production.

60 APPLIED LIFE SCIENCES↗

Intermediate Temperature Solid Oxide Cell with a Barrier Layer Free Oxygen Electrode and Phase Inversion Derived Hydrogen Electrode

High-temperature solid oxide cells (SOCs) have fundamental advantages in efficiency and product rate over their low-temperature counterparts. However, the commercial development of SOCs is hindered by cost and reliability. To solve the issues, lowering the operating temperature of SOCs is deemed the best solution. Here we report on our effort toward intermediate temperature (IT) SOCs by developing a barrier layer free high-performance oxygen electrode and open structured hydrogen electrode. The results show that the new oxygen electrode provides reasonably good oxygen electrocatalytic activity at IT range for oxygen reduction and evolution reactions and the open structured hydrogen electrode provides low gas diffusion path for H 2 /H 2 O. However, at high electrolysis current density such as 1 A cm −2 and 650 °C, the present oxygen electrode delaminates after 200 h. The phase-inversion derived open structured hydrogen electrode helps gas diffusion but, in the meantime, reduces reactive sites. A proper balance of porosity and number of reactive sites is still needed for future hydrogen electrode development.

25 ENERGY STORAGE↗

Numerical investigation of a fueled pre-chamber spark-ignition natural gas engine

Pre-chamber spark-ignition (PCSI) is a leading advanced ignition concept for internal combustion engines with the potential to enable diesel-like efficiency in medium-duty/heavy-duty (MD/HD) natural gas (NG) engines. By leveraging distributed ignition sources from multiple turbulent jets, the PCSI technology can deliver extremely short combustion duration in ultra-lean mixtures and significantly improve the engine thermal efficiency. However, in the automotive industry there is a lack of adequate science base and predictive simulation tools required for commercial development of PCSI engines. Here, in this study, Reynolds-Average Navier-Stokes simulations are carried out to describe the combustion process in lean-burn NG engines, focusing on the combustion modeling approach. Two combustion models, multi-zone well-stirred reactor (MZ-WSR) and G-equation, are used to simulate the combustion process in an MD NG engine equipped with a fueled-PCSI system for four operating conditions close to the lean operating limit. A skeletal chemical mechanism and a laminar flame speed tabulation are used to compute the combustion accurately. Simulation results are compared with experimental data regarding measured cylinder pressure, heat release rate, and combustion duration. By dividing the PCSI combustion process into four distinct phases, the difference between the two models’ results for each phase is analyzed in detail. The MZ-WSR model overestimates the combustion duration for early flame kernel growth in the pre-chamber due to the lack of a specific formulation to take turbulence-chemistry interaction into account. Despite the prolonged combustion duration and low pressure built-up inside the pre-chamber, the model matches the combustion rate in the main-chamber. In contrast, the G-equation model delivers good agreements for the pre-chamber combustion and turbulent jet-driven combustion processes. However, the model starts to underestimate the combustion rate in the main-chamber, especially under ultra-lean mixture conditions. Finally, improvements are needed for both models to simulate the later combustion stage that occurred in the near-wall regions.

33 ADVANCED PROPULSION SYSTEMS↗

1:50 Scale Testing of Three Floating Wind Turbines at MARIN and Numerical Model Validation Against Test Data

The primary goal of the basin model test program discussed herein is to properly scale and accurately capture physical data of the rigid body motions, accelerations and loads for different floating wind turbine platform technologies. The intended use for this data is for performing comparisons with predictions from various aero-hydro-servo-elastic floating wind turbine simulators for calibration and validation. Of particular interest is validating the floating offshore wind turbine simulation capabilities of NREL’s FAST open-source simulation tool. Once the validation process is complete, coupled simulators such as FAST can be used with a much greater degree of confidence in design processes for commercial development of floating offshore wind turbines. The test program subsequently described in this report was performed at MARIN (Maritime Research Institute Netherlands) in Wageningen, the Netherlands. The models considered consisted of the horizontal axis, NREL 5 MW Reference Wind Turbine (Jonkman et al., 2009) with a flexible tower affixed atop three distinct platforms: a tension leg platform (TLP), a spar-buoy modeled after the OC3 Hywind (Jonkman, 2010) and a semi-submersible. The three generic platform designs were intended to cover the spectrum of currently investigated concepts, each based on proven floating offshore structure technology. The models were tested under Froude scale wind and wave loads. The high-quality wind environments, unique to these tests, were realized in the offshore basin via a novel wind machine which exhibits negligible swirl and low turbulence intensity in the flow field. Recorded data from the floating wind turbine models included rotor torque and position, tower top and base forces and moments, mooring line tensions, six-axis platform motions and accelerations at key locations on the nacelle, tower, and platform. A large number of tests were performed ranging from simple free-decay tests to complex operating conditions with irregular sea states and dynamic winds.

17 WIND ENERGY↗

Time-resolved chemical imaging based on stimulated TERS (Final Scientific-Technical Report-Phase-II-DE-SC0013172)

This is the Final Scientific/Technical Report for the DOE FastTrack SBIR Grant from Fiscal Year 2015. The report details the work pursued to scientifically demonstrate ultrahigh spatial resolution in ultrafast spectroscopy and commercially develop a product offering that provides the similar capability to other researchers. Chemical and electronic information associated with molecular-scale processes can be interrogated via optical spectroscopy. By utilizing two ultrafast lasers, one to “pump” and the other to “probe” with time delay between them, researchers are able to study various molecular and electronic dynamics with time resolution in femtosecond range. Due to the diffraction limit associated with these optical techniques, these techniques measure average behavior of ensemble of molecules since individual molecules are typically much smaller than the wavelengths of the lasers being utilized. This report presents the successful demonstration of ultrafast spectroscopy (temporal resolution of 150 femtosecond limited by the laser pulse width) of electronic recovery in carbon nanotubes, revealing different recovery dynamics for individual carbon nanotubes with spatial resolution of ~ 10 nm, more than 50X smaller than the wavelengths used to study them. The report also details the required instrumentation for such measurements and how it plans to offer a turnkey solution to the research community to provide such capability in a user-friendly and low maintenance package.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Computation of the Seismic Stability of Earth Retaining Structures Final Report CRADA No. TSB-954-94

The purpose of this CRADA project was to evaluate the seismic stability of block retaining wall systems. Retaining wall systems are used extensively in private and commercial developments. This study was designed to develop and demonstrate a computer modeling technology to be used to predict the seismic stability of any block wall system design. The nonlinear finite element computer programs developed at LLNL and employed in the Computational Earthquake Initiative were utilized in this small business CRADA to analyze the seismic stability of the block retaining walls. The unique capability of the LLNL programs to rigorously model frictional contact in a dynamic analysis problem were used in a computer simulation of the dynamic interaction the block waiVsoil systems under seismic excitation.

58 GEOSCIENCES↗