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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

Capacity Gain in Li-Ion Cells with Silicon-Containing Electrodes

Silicon-containing lithium-ion batteries can exhibit capacity gain early in life, which makes forecasting future cell behavior difficult. We have observed these anomalous trends even in conditions where known mechanisms, such as overhang equalization and excessive electrolyte oxidation, are unlikely to be significant. Here, we combine simulations and experiments to analyze four cases that can produce increased capacity in Si cells. Three of these pathways relate to “break-in” processes, where improved mass and charge transport can lead to increased access to active electrode domains and decreased cell impedance. The fourth case occurs at high levels of prelithiation, when the positive electrode (PE) is completely replenished with Li + at the end of cell discharge. We show that the commonality among these mechanisms is that the underlying transformations change the potentials experienced by electrodes at the end of half-cycles, increasing the Li + inventory available to the cell. A quantitative framework to describe these effects is presented, enabling these ideas to be extended to other battery systems.

25 ENERGY STORAGE↗

Surface Quantitative Precipitation Estimates (SQUIRE) of Snow Water Equivalent from the Surface Atmospheric Integrated Field Laboratory

The upper Colorado River basin is the primary source of water for 40 million people. With declining snowpack in the basin, forecasting hydrological budgets in the Southwest United States is more important than ever. However, due in part, to a lack of reliable observations of precipitation in complex terrain, hydrological models struggle to assess and forecast snowpack snow water equivalent (SWE) in the upper Colorado River basin (UCRB). Therefore, the need for more reliable SWE forecasts in the UCRB motivated the U.S. Department of Energy Atmospheric Radiation Measurement Facility’s Surface Atmospheric Integrated Field Laboratory (SAIL) that occurred from June 2021 to June 2023. During SAIL, the X-band precipitation radar from Colorado State University conducted volume scans sampling the precipitation properties over the UCRB. The ARM facility developed a gridded Surface Quantitative Precipitation Estimates (SQUIRE) product from the radar observations. To do this, various daily SWE estimates from radar using the radar reflectivity factor Z e and specific differential phase K dp were compared against ground-based precipitation gauges. SWE in precipitation calculated from Wolfe and Snider’s S–Z e estimator was in best agreement with the rain gauges for the days when SWE < 12 mm. For days with SWE > 12 mm, the WSR-88D Intermountain West relationship had the best agreement with the precipitation gauges. Airborne snow depth observations show that SQUIRE captures regions of orographic enhancement in the mountains to the west and northwest of the SAIL study area, indicating that the scientific community should focus on understanding and ultimately simulating orographic atmospheric precipitation processes to improve UCRB snowpack SWE assessment and forecasting.

Hydrology↗

Off-gas capture: a promising strategy for removal and recovery of toxic bioproducts in aerobic fermentation

In many bioprocesses, maximum achievable titers are limited below economically viable levels by toxic accumulation of the primary end-product. To combat end-product inhibition, a variety of in situ product removal technologies have been developed to selectively remove or partition toxic bioproducts, thereby prolonging fermentation and improving overall process efficiency. Use of an in situ organic overlay to partition toxic hydrophobic products is a commonly employed approach, but this technique occupies valuable space in the fermentor, imposes replacement costs for unrecovered solvent, and increases downstream separation due to formation of stable emulsions. In addition, for many volatile hydrophobic products produced under aerobic conditions—including medium-chain alcohols, esters, monoterpenes, and other aviation fuel precursors—a significant fraction of the product is volatilized to the fermentor off-gas and must be recovered separately to maximize product yield. To address these challenges, we explore the viability of leveraging existing aeration energy to fully strip and recover volatile products from the fermentor off-gas. We compare two strategies of in situ product removal—liquid–liquid extraction and direct recovery from fermentation off-gas—for the production and recovery of intermediates used to generate isoprene and DMCO (1,4-dimethylcyclooctane), a high-performance jet fuel. We evaluate product toxicity, solvent toxicity, solvent partitioning, and the impact of aeration and internal overlay configurations on product volatilization rates. We then optimize product recovery from fermentor off-gas via condensation in chilled solvent, achieving 84% capture efficiency. In addition to greatly simplifying downstream processing, relying on aeration for product volatilization in the absence of an internal overlay enables continuous removal of toxic fermentation products up to maximum isoprenol titers of 20.4 g/L, the highest reported to date.

isoprene↗

Advancing attenuation estimation through integration of the Hessian in multiparameter viscoacoustic full-waveform inversion

Accurate seismic attenuation models of subsurface structures not only enhance subsequent migration processes by improving fidelity, resolution, and facilitating amplitude-compliant angle gather generation but also provide valuable constraints on subsurface physical properties. Leveraging full-wavefield information, multiparameter viscoacoustic full-waveform inversion ( Q-FWI) simultaneously estimates seismic velocity and attenuation ( Q) models. However, a major challenge in Q-FWI is the contamination of crosstalk artifacts, where inaccuracies in the velocity model are mistakenly mapped to the inverted attenuation model. While incorporating the Hessian is expected to mitigate these artifacts, the explicit implementation is prohibitively expensive due to its formidable computational cost. In this study, we formulate and develop a Q-FWI algorithm via the Newton-conjugate gradient (CG) framework, where the search direction at each iteration is determined through an internal CG loop. In particular, the Hessian is integrated into each CG step in a matrix-free fashion using the second-order adjoint-state method. We find through synthetic experiments that our Newton-CG Q-FWI significantly mitigates crosstalk artifacts compared with the limited-memory Broyden-Fletcher-Goldfarb-Shanno method and the CG method, albeit with a notable computational cost. In the discussion of several key implementation details, we also determine the significance of the approximate Gauss-Newton Hessian, the second-order adjoint-state method, and the two-stage inversion strategy.

Geochemistry & Geophysics↗

Microwave-Assisted Heating for Gasification

Compared to traditional heating, microwave-assisted heating enhances catalyst activity, selectivity and stability. These features are essential in gasification to improve the process outcome while mitigating the generation undesirable by-products such as char. To study the effect of microwaves on fluidized bed reactors, the electromagnetics module of COMSOL and MFiX are coupled using file input/output wherein external calls are made to COMSOL from MFiX. The particle bed heating rates and temperature distributions are investigateed in the case of a monodisperse bed of magnetite particles subjected to single mode transverse electric and magnetic fields in reacting and non-reacting conditions. The effect of inlet gas velocity on the heating rate of particle is also explored in this work.

Koneru, Rahul Babu↗

03.02.02.45: Energy Efficiency Improvement Approaches in Ice Related Processes

The primary objective of this project was to facilitate the dislocation of the interfacial ice layer by employing advanced materials and ultrasonic vibration to reduce ice adhesion strength. This work employed two technical approaches that were thoroughly investigated and previously reported. The effectiveness of these approaches, both individually and in combination, has been quantified, demonstrating notable energy savings. The projected payback period for these enhancements is approximately 2.2 years or less, contingent upon specific energy costs. Furthermore, these advancements hold significant promise for reducing carbon emissions across various equipment scales. This study particularly focused on the ultrasonic deicing technique for diverse structures, utilizing numerical simulations to evaluate performance and potential benefits.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Simulating Marine Stratocumulus Clouds using Lagrangian Superdroplet Method in ERF

This study investigates the simulation of marine stratocumulus (stratoCu) clouds – common in many offshore and coastal wind energy regions - using Lagrangian Superdroplet Method (SDM) implemented in Energy Research and Forecasting (ERF) model. Developed by the Wind Energy Technologies Office (WETO), ERF is a high-resolution atmospheric modeling tool that relies on traditional bulk microphysics schemes. Under an LLNL-led Laboratory Directed Research and Development (LDRD) project, SDM was integrated into ERF to improve cloud process fidelity by explicitly tracking individual “superdroplets”. This enables a realistic representation of the droplet size spectrum, cloud-atmosphere interactions, and potential feedbacks from wind plants on atmospheric flow and cloud structure.

54 ENVIRONMENTAL SCIENCES↗

Technologies for Enhanced Condensation in sCO 2 Power Cycles

The direct fired supercritical carbon dioxide power cycle has higher efficiency, compact machinery footprint, and is resilient under transient operation. It has been shown that improving the cycle main cooler significantly improves performance, including increased cycle efficiency, decreased cost of electricity and decreased cooler outlet temperatures. One way to improve this process is through enhanced condensation techniques and management of condensation fluid. This manuscript provides an overview of active and passive enhanced condensation technologies, with a focus on the passive approaches. compared to passive approaches, active approaches can have higher heat transfer enhancement, but the additional power and infrastructure can be problematic. The passive approaches identified include microfins (helical and herringbone), corrugated tubing, dimpled tubing and pin fins. After comparison it is found that the microfin geometry has the best performance characteristics followed by the additively manufactured pin fins. It is noted that current literature around additively manufactured enhancements is lacking, and investigation of conventional as well as novel geometries fabricated in this manner may be worth further investigation. Benchmark correlations for these geometries are identified and their limitations outlined. For further investigation, a matrix of test articles is presented for possible experimentation.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

From tides to seasons: How cyclic tidal drivers and plant physiology interact to affect carbon cycling at the terrestrial-estuarine boundary (Final technical report)

Coastal ecosystems are among the most biologically and biogeochemically active and diverse systems on Earth. Because they act as important linkages between terrestrial ecosystems and the open ocean, their incorporation in Earth system models (ESMs) is critical to predict coastal and global responses to environmental changes. However, they vary greatly in the magnitude of tides and the volume and timing of freshwater input from land, making it challenging to model the major biogeochemical reactions that control productivity and greenhouse gas emissions across coastal terrestrial aquatic interfaces (TAIs). Our overall objective was to improve mechanistic process understanding and modeling of tidal wetland hydro-biogeochemistry in coastal TAIs. We established a new flux tower site (Ameriflux US-PLo) in the oligohaline part of the Parker River to continuously monitor ecosystem-scale carbon fluxes under temporally varying salinity conditions. The site is co-located with long-term monitoring plots of the Plum Island Ecosystems LTER project. We installed wells and redox sensors in the marsh interior and creek bank, established biomass monitoring plots and deployed novel optode sensors in both locations. We used this data to parameterize plant-mediated transport in PFLOTRAN and tested the impact of soil heterogeneity on porewater constituents and gas fluxes. We collected observations of root oxygen release with a novel planar optode system in the field. Flux data collected during the measurement period encompasses a large variation in salinity ranging from drought to record precipitation years. We developed a method to extract functional relationships from the flux data using artificial neural networks, identifying salinity thresholds for CH 4 fluxes. Finally, we are using the coupled ELM-PFLOTRAN model to test the impact of antecedent hydrological conditions on the salinity-CH 4 flux relationship. This grant contributed to the professional development of one postdoc, three research assistants and one graduate student. The sensor data has been shared with external collaborators.

54 ENVIRONMENTAL SCIENCES↗

Bench-Scale Development of Promoted High-Capacity Structured Sorbents (Final Technical Report)

The project objective was to develop high-capacity structured sorbent capable of achieving low CO 2 removal from air. The sorbent framework consists of an amine-functionalized onto hydrophobic polymer backbone with an added promoter. The functionalized amine provides high CO 2 capacity and adsorption rates and the polymer backbone to reduce water uptake. For the sorbent development, multiple functionalized amines and promoters were assessed to select a candidate that achieved high CO 2 capacity, high adsorption rate, and high stability. A sorbent-coated filter design was selected as the structured sorbent, which provides high sorbent loading capacity and contains an electrically conductive nonwoven filter substrate that can be Joule-heated to provide efficient utilization of available electricity for sorbent regeneration. A commercial partner operated a pilot filter manufacturing line to produce the filter panels coated with the developed sorbent. A 1 kg CO 2 /day bench unit was designed and fabricated to test the structured filter sorbent. The key achievements from the structured sorbent development activity were demonstrating that existing filter industrial-scale processes can be used for manufacturing Susteon’s structured sorbent and completing a proof-of-concept demonstration of the commercially manufactured structured sorbent filters for CO 2 capture from air with direct, Joule-heated regeneration. A techno-economic assessment with sensitivity analysis was conducted on a 100,000 TPY facility with 85% operating capacity. Through sorbent optimization and process design improvements, it is estimated that the cost of capture was reduced from $\$$349/tCO 2 to $\$$241/tCO 2 . The TEA projects further reductions to $165/tCO 2 through enhancements in CO 2 adsorption rate and sorbent capacity and reducing manufacturing and scale up risks. A life cycle analysis was conducted on the same 100,000 TPY facility and confirmed that the facility’s electricity demand drives its greenhouse gas impact. It was determined that electricity supplied through the current grid mix would result in net-positive CO 2 emissions and that achieving net-negative emissions is only possible by powering the system with renewable electricity or fossil fuel sources equipped with carbon capture and sequestration.

36 MATERIALS SCIENCE↗

Beam Non-Uniformity Characterization at the SpinQuest and DarkQuest Experiments

The SpinQuest experiment, including upgrades to SpinQuest designed to increase sensitivity to dark sector searches (commonly known as DarkQuest), utilizes the high-intensity 120 GeV proton beam delivered by the Fermilab Accelerator Complex to probe the inner structure of nucleons and search for new physics beyond the Standard Model. The SpinQuest beam is extracted from the Main Injector synchrotron at Fermilab in what is known as a slow spill . The slow spill involves a complex non-linear half-integer extraction method, which results in non-uniform beam behavior. SpinQuest observes spikes of very high intensity beam which can saturate detectors and reduce trigger efficiency, significantly impacting the experiment's sensitivity. In this project we address this challenge by developing an analysis framework to characterize the beam delivered to SpinQuest. By discovering trends within each spill and by comparing thousands of spills, we can better inform the Accelerator Division and improve the slow spill extraction. We have also begun a collaboration with the Accelerator Division in order to simulate the slow spill and improve the magnet ramp process controls which will improve the uniformity of the beam. These improvements will directly enhance the physics reach of SpinQuest/DarkQuest, increasing their sensitivity to key measurements such as the Sivers function and searches for new physics.

Dolen, James William [Purdue U., Calumet] (ORCID:0↗

Sustainable Ethylene via Chemical Looping – Oxidative Dehydrogenation

This Phase I final report evaluates chemical looping–oxidative dehydrogenation as a lower-energy and cost-competitive alternative to conventional ethane steam cracking for ethylene production. The project combined catalyst development and experimental testing with process modeling, techno-economic analysis, and life-cycle assessment. Results indicate that the proposed process could improve olefin production, reduce energy use, and lower production costs, particularly when integrated with carbon capture and renewable electricity. The report also identifies remaining technical, environmental, and safety considerations and presents a technology maturation plan focused on longer-term catalyst evaluation and advancement toward pilot-scale demonstration.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Development of large-scale, 3D Printed high temperature ceramic material

Through this collaborative effort, a new 3D printing platform for ceramics called laser-induced slip casting (LIS) was explored and developed for improving the processing and manufacture of silicon carbide (SiC), a high temperature ceramic material. This method prints layers of ceramic slips/slurries with subsequent selective-laser heating to dry each layer to build a 3D structure. The completed and dried part is then sintered. This manufacturing process is inherently lower cost than alternative ceramic printing methods such as binder jet technology or stereolithography when it comes to the feedstock material but is more expensive than robocasting or direct ink writing. However, it has the potential to make more controlled parts with less defects compared to robocasting. The largest cost is the heating source for the printer. With this technique, there is potential to make large ceramic parts in a near-net shape. Further, there is no known commercial manufacturing of 3D printed ceramics that creates a large range of different high-density ceramics at large scale. The goals and outcomes for the development of the new printing technology were: 1) assessing the technology with alumina by characterizing coupons, 2) printing and sintering of silicon carbide (SiC), and 3) characterization and properties testing of materials printed and a scale-up of SiC part(s). Through this collaborative project, it was sought to provide the best solution to achieving highly dense and near-net shaped ceramic parts at large scale and reduced cost. The goal was to produce high density sintered materials for applications in defense, energy generating systems, armor, and wear parts using 3D printing methods. Variables including powder particle sizes, dispersant molecular weights (MWs), binders, printing parameters, and post processing were explored as well as the characterization of the physical properties (add specifics here).

36 MATERIALS SCIENCE↗

Mechanical and Tribological Performance of Additively Manufactured Nanocrystalline Aluminum via Cryomilling and Cold Spray

In this study, nanocrystalline (NC) aluminum (Al) and magnesium (Mg)-doped Al bulk components were fabricated using a hybrid manufacturing process that combines cryomilling and high-pressure cold spray (HPCS) additive deposition techniques. Yttria-stabilized zirconia (YSZ) was also added during the HPCS process to improve deposition efficiency and build-up thickness via peening. The evolution of morphology, crystallite size, and elemental composition of both cryomilled powders and cold-sprayed (CS’ed) components was systematically characterized using X-ray Diffraction (XRD), Scanning Electron Microscopy (SEM), and Transmission Electron Microscopy (TEM). Mechanical characterization was performed using Vickers microhardness and uniaxial tensile testing, while the tribological behavior was assessed using sliding wear tests under dry/lubricated conditions. XRD analysis revealed that increased cryomilling duration led to significant crystallite refinement, which directly correlated with enhanced hardness and strength. This mechanical strengthening was accompanied by an increase in coefficient of friction (COF) and lower wear rates. The results also showed that the Mg-doped Al exhibited superior hardness, tensile strength, and tribological performance compared to pure Al. The study further explores the underlying mechanisms responsible for these enhancements, highlighting the potential of solute-assisted grain boundary stabilization in tailoring high-performance NC Al alloys.

36 MATERIALS SCIENCE↗

Cellulose Nanofibrils Dewatered with Poly(Lactic Acid) for Improved Bio-Polymer Nanocomposite Processing

Cellulose nanofibrils (CNFs) have theoretically ideal properties for bio-based composite applications; however, the incorporation of these materials into polymers is made challenging by the strong binding of water to CNFs and the irreversible agglomeration of CNFs during drying. Previous methods used “contact dewatering”, wherein the addition of wood flour (WF) to CNFs facilitated the mechanical removal of water from the system via cold pressing, which showed potential in producing dried CNF fibrils attached to wood fibers for biocomposite applications. In this work, the viability of contact dewatering with poly(lactic) acid (PLA) powder for PLA/CNF composites was evaluated. The energy efficiency of dewatering, preservation of nanoscale CNF morphology, and mechanical properties were examined by mixing wet CNFs with pulverized PLA at various loading levels, pressing water out of the system, and compression molding and shear mixing composites for testing. The most impressive results from this dewatering method were the preservation of micron-to-nanoscale fibers with high aspect ratios in PLA-CNF composites; increased strength and modulus of 1.7% and 4.2%, respectively, compared to neat PLA; equivalent or better properties than spray-dried nanocellulose at similar loading levels; and an 11-194x reduction in drying energy compared to spray-drying CNFs.

Chemistry↗

Bio-Based Polyurethane Materials: Technical, Environmental, and Economic Insights

Polyurethane (PU) is widely used due to its attractive properties, but the shift to a low-carbon economy necessitates alternative, renewable feedstocks for its production. This review examines the synthesis, properties, and sustainability of bio-based PU materials, focusing on renewable resources such as lignin, vegetable oils, and polysaccharides. It discusses recent advances in bio-based polyols, their incorporation into PU formulations, and the use of bio-fillers like chitin and nanocellulose to improve mechanical, thermal, and biocompatibility properties. Despite promising material performance, challenges related to large-scale production, economic feasibility, and recycling technologies are highlighted. The paper also reviews life cycle assessment (LCA) studies, revealing the complex and context-dependent environmental benefits of bio-based PU materials. These studies indicate that while bio-based PU materials generally reduce greenhouse gas emissions and non-renewable energy use, their environmental performance varies depending on feedstock and formulation. The paper identifies key areas for future research, including improving biorefinery processes, optimizing crosslinker performance, and advancing recycling methods to unlock the full environmental and economic potential of bio-based PU in commercial applications.

Jayalath, Piumi↗

Energy Efficiency Improvement Approaches in Ice Related Processes

Application and development of energy efficient techniques to separate ice from different surfaces and substrates is of significant value in the context of building equipment performance. A hybrid approach to help dislocate the ice layer using advanced materials and ultrasonic vibration to lower ice adhesion strength was investigated. Application of advanced polymer materials in lowering the adhesion strength of ice was confirmed where the measured strength was lowered by 50-70% depending on the material and geometry. Additionally, utilization of induced ultrasonic vibration in further lowering the ice harvesting energy was confirmed on multiple materials and geometries. Durability of the coating enhancement was also confirmed in a thermal cycling test under realistic operating conditions. Integration of these technical approaches was implemented and validated in commercial ice makers showing energy consumption reduction by ~ 15% to 30% depending on the technical enhancement.

Cheekatamarla, Praveen↗