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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 325 records · Page 18

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DOE OSTI2020

A statistical model to predict ignition probability

Ignition capability is a critical design constraint for aeronautical gas turbines. However the current trend toward overall lean burn is detrimental to the engine ignition and relight and the ignition system must be adapted to ensure a fast and reliable light-round in all circumstances. As ignition is a stochastic phenomenon, the optimization of an ignition system requires to build ignition probability maps, which is difficult and costly with either experiment or numerical simulation as both require many tests. Here, this work proposes a model to predict the ignition probability map, knowing only flow statistics in non-reacting conditions, i.e., with only one test. The originality of the model is to construct statistics of the flame kernel trajectory, which are then combined with local flow indicators to evaluate the ignition probability at the considered sparking location. Application to a swirled burner operated in premixed, non-premixed and spray combustion modes illustrates the model concepts and demonstrates its ability to recover the experimental ignition map with good accuracy.

42 ENGINEERING↗

DOE OSTI2021

Highly selective ion separations based on counter-flow electromigration in nanoporous membranes

Highly selective ion separations are vital for recovering important salts, and membrane-based techniques may enable environmentally friendly ion separations that operate continuously. This study demonstrates that simply opposing convective flow with electromigration in track-etched membranes leads to remarkable selectivities among monovalent ions. Because the membrane-pore diameters are orders of magnitude larger than the ion diameters, advection moves all ions at the same velocity, whereas electrophoretic velocities are proportional to ion mobilities. Thus during counter-flow cation electromigration, less mobile cations have lower electromigration velocity components and pass through porous membranes more rapidly than more mobile cations. Using membranes with 400 nm pores, counter-flow electromigration gives Li + /K + selectivities of 100 and Li + /Na + selectivities around 30 in mixed-salt studies. In this work, numerical simulations based on the extended Nernst-Planck equation agree with trends in experimental data and highlight the importance of high Péclet numbers, high current-to-flow ratios, and uniform current distributions for achieving high selectivities. Importantly, experimental separations give high selectivities at 0.3 M ionic strength and low Li + /K + ratios, which suggest these methods may also work in brine solutions. Nevertheless, energy costs for such separations are high.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Integrated assessment model diagnostics: key indicators and model evolution

Integrated assessment models (IAMs) form a prime tool in informing climate mitigation strategies. Diagnostic indicators that allow to compare these models can help to describe and explain differences in model projections. This also increases transparency and comparability. Earlier, the IAM community has developed an approach to diagnose models (Kriegler et al., 2015). Here we build on this, by proposing a selected set of well-defined indicators as a community standard, similar to metrics used for other modeling communities such as climate models. These indicators are the relative abatement index (RAI), emission reduction type index (ERT), inertia timescale (IT), fossil fuel reduction (FFR), transformation index (TI) and cost per abatement value (CAV). We apply the approach to 17 IAMs, including both older version as well as their latest versions, as applied in the IPCC 6th Assessment Report (AR6). The study shows that the approach can be easily applied and allows for comparison of model versions in time. The indicators and their trends can often be explained in terms of model characteristics and changes. We show that together, the set of six indicators can provide an useful indication of the main traits of the model and can roughly indicate the general model behavior. The results also show that there is often a considerable spread across the models. Interestingly, the diagnostic values often change for different model versions, but there does not seem to be a distinct trend across the different models.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

Quantifying Energy Storage Density Utilization Trends in Redox Flow Battery Chemistries

The transition to new energy resources is driving the need for efficient energy storage. Redox flow batteries (RFBs) are a promising solution due to their flexible design and safer materials, particularly for long-duration storage applications. Despite these advantages, RFB technologies still have considerable room for growth in terms of utilizing all of their available energy storage density. Herein, we assess RFB energy storage density utilization trends for multiple chemistries by accounting for their unique thermodynamic limits, energy efficiencies, and charge capacity constraints. Of the RFBs chemistries analyzed, most still use less than 60% of their theoretical energy storage capacity. The conventional all-vanadium RFB was the closest to its thermodynamic limit available. Moreover, the volumetric footprint and electrolyte cost analyses demonstrate the real-world implications of these inefficiencies. This analysis further indicates that future studies would benefit from clearer reporting of two key quantities: discharge efficiency, which is more directly tied to practically recoverable energy density than round-trip energy efficiency, and state-of-charge or capacity-utilization limits, which govern access to theoretical storage capacity. More consistent reporting of these factors would improve the accuracy and comparability of energy storage utilization analyses across RFB chemistries.

battery energy storage↗

DOE OSTI2021

Economic and Environmental Assessment of Biological Conversions of Agile BioFoundry (ABF) Bio-Derived Chemicals

Bio-derived chemicals are an essential part of the growing bioeconomy. They possess the potential to boost a new domestic bioproduct industry, improve the sustainability of integrated biomanufacturing, and reduce U.S. dependence on fossil energy. The Agile BioFoundry (ABF) consortium, a Department of Energy (DOE)-sponsored collaboration, is investigating biobased pathways to produce advantaged products including advanced biofuels, fuel intermediates, and bioproducts. ABF is integrating advanced computational tools for biological engineering, process design and data analysis, and economic/sustainability modeling tools into a comprehensive and dynamic platform for biomanufacturing of microbes and using them to produce key metabolic intermediates or beachhead molecules which may be derivatized into several distinct bioproducts of industrial interest. In this presentation, we first discuss a methodology to select a single exemplar product molecule to represent each beachhead pathway based on similarities with other end-molecule options (yields/titers/rates, fermentation operation mode, oxygen requirements, general separations challenges, etc.), in order to maintain a reasonable number of cases for rigorous process simulation. We then use techno-economic analysis (TEA) and life-cycle analysis (LCA) to highlight sensitivities and trends around economic performance and environmental footprint, reflecting examples for two selected ABF technology pathways to bio-derived chemicals: 1) adipic acid production via muconic acid fermentation from mixed sugars with Pseudomonas putida and 2) cineole via geranyl diphosphate with Rhodosporidium toruloides. We present multi-variable scan plots highlighting key drivers on costs and greenhouse gas emissions in order to identify the parameter space in which each pathway could ultimately achieve economic and environmental sustainability meeting or exceeding commodity product benchmarks, thus prioritizing future R&D focus areas.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2021

Valorisation of technical lignin in rigid polyurethane foam: A critical evaluation on trends, guidelines and future perspectives

Lignin is one of the most abundant aromatic natural polymers. Produced as a by-product from the biomass refinery industries, lignin remains largely underutilised in high-value industrial applications. The incorporation of lignin in rigid polyurethane foam (RPUF) has been the focus of much research, due to its potential to replace fossil fuel-based components of RPUF. However, the overall sustainability of RPUF depends on numerous factors including processability, cost-effectiveness, and retention of performance throughout the service life. To date, the incorporation of lignin has been explored either as filler particles (through direct incorporation) or as a blendable liquid polyol introduced after chemical modifications (such as oxyalkylation, functionalisation, or depolymerisation). However, the production of lignin incorporated foam with high performance through cost-effective processing is still an ongoing challenge. Herein, this review critically appraises the progress on the effective incorporation of lignin in RPUF. Firstly, this review briefly covers the essential raw materials, formulation, important properties, and sustainability aspects of RPUF for industrial applications. Secondly, it provides insights on the key parameters of lignin of relevance to incorporation into RPUF. Thirdly, it benchmarks the reported studies on incorporation of lignin in RPUF systems by evaluating their important properties and proposes potential strategies for addressing the key challenges in the incorporation of lignin in RPUF. By bridging the gaps that exist in the literature on the utilisation of lignin in RPUF this account will serve as a resource for both beginners and professionals in the polyurethane and biorefinery industries towards the successful development of lignin incorporated RPUF for industrial applications

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Insights from high-fidelity modeling of industrial rotary bell atomization

The global automotive industry sprayed over 2.6 billion liters of paint in 2018, much of which through electrostatic rotary bell atomization, a highly complex process involving the fluid mechanics of rapidly rotating thin films tearing apart into micrometer-thin filaments and droplets. Coating operations account for 65% of the energy usage in a typical automotive assembly plant, representing 10,000s of gigawatt-hours each year in the United States alone. Optimization of these processes would allow for improved robustness, reduced material waste, increased throughput, and significantly reduced energy usage. Here, we introduce a high-fidelity mathematical and algorithmic framework to analyze rotary bell atomization dynamics at industrially relevant conditions. Our approach couples laboratory experiment with the development of robust non-Newtonian fluid models; devises high-order accurate numerical methods to compute the coupled bell, paint, and gas dynamics; and efficiently exploits high-performance supercomputing architectures. These advances have yielded insight into key dynamics, including i) parametric trends in film, sheeting, and filament characteristics as a function of fluid rheology, delivery rates, and bell speed; ii) the impact of nonuniform film thicknesses on atomization performance; and iii) an understanding of spray composition via primary and secondary atomization. These findings result in coating design principles that are poised to improve energy- and cost-efficiency in a wide array of industrial and manufacturing settings.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2021

Global Market Analysis of Microreactors

Microreactors are smaller and simplified versions of nuclear power plants using current generation and advanced nuclear technology designs. The purpose of this report is to assesses the unique capabilities of microreactors and assess potential deployment in specific global markets in the 2030-2050 timeframe, with consideration for regulatory limits. The methods include developing unique microreactor deployment indicators and matching use cases to define future profile markets. Top-down and bottom-up analysis techniques were used to evaluate emerging market trends, derive a range of possible demands, and rank potential markets in 63 countries including current nuclear users and newcomer countries. Deployment is considered from regulatory and planning perspectives. Results indicate significant potential for global deployment of microreactors, but also significant challenges in achieving the technical capacities, meeting regulatory requirements and international accords, achieving competitive costs, and for gaining public acceptance. Profile microreactor markets were identified that include isolated operations, distributed energy, resilient urban applications, marine propulsion, and disaster relief. Market demands could be strong in Western Europe and possibly even the U.S., but particularly strong across Asia and Eastern Europe in isolated operations and distributed energy applications. Build rates in the hundreds of units by 2040 and thousands by 2050 would be needed to attain market penetration at scale.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2024

Winter 2024 Solar Industry Update

Each quarter, the National Renewable Energy Laboratory (NREL) conducts the Quarterly Solar Industry Update, a presentation of technical trends within the solar industry. Each presentation focuses on global and U.S. supply and demand, module and system price, investment trends and business models, and updates on U.S. government programs supporting the solar industry.

14 SOLAR ENERGY↗

DOE OSTI2024

Spring 2024 Solar Industry Update

Each quarter, the National Renewable Energy Laboratory (NREL) conducts the Quarterly Solar Industry Update, a presentation of technical trends within the solar industry Each presentation focuses on global and U.S. supply and demand, module and system price, investment trends and business models, and updates on U.S. government programs supporting the solar industry.

14 SOLAR ENERGY↗

DOE OSTI2020

Climate change impacts on wind power generation

Wind energy is a virtually carbon-free and pollution-free electricity source, with global wind resources greatly exceeding electricity demand. Accordingly, the installed capacity of wind turbines grew at an annualized rate of >20% from 2000 to 2019 and is projected to increase by a further 50% by the end of 2023. Here, in this Review, we describe the factors that dictate the wind resource magnitude and variability and illustrate the tools and techniques that are being used to make projections of wind resources and wind turbine operating conditions. Natural variability due to the action of internal climate modes appears to dominate over global-warming-induced non-stationarity over most areas with large wind energy installations or potential. However, there is evidence for increased wind energy resources by the end of the current century in northern Europe and the US Southern Great Plains. New technology trends are changing the sensitivity of wind energy to global climate non-stationarity and, thus, present new challenges and opportunities for innovative research. The evolution of climate modelling to increasingly address mesoscale processes is providing improved projections of both wind resources and wind turbine operating conditions, and will contribute to continued reductions in the levelized cost of energy from wind power generation.

17 WIND ENERGY↗

DOE OSTI2022

Hybrid Hydraulic-Electric Architecture (HHEA) for Mobile Machines (Final Report)

Traditionally, off-road mobile machines such as excavators and wheel loaders are primarily powered by hydraulics, and throttling valves are used to control their work circuits. In recent years, two general trends are towards more energy efficient systems and electrification. With electrification, both efficiency and control performance can be improved by the elimination of throttling losses and the use of high-bandwidth inverter control. Electrification is generally accomplished with Electro-hydraulic actuators (EHA) but they are limited to lower powered systems due to the high cost of electric machines capable of high power or high torque. This project proposes a new system architecture for off-road vehicles - Hybrid Hydraulic Electric Architecture (HHEA) to improve efficiency and control performance without requiring large electric machines. The widely applicable architecture combines hydraulic power and electric power in such a way that the majority of power is provided hydraulically while electric drives are used to modulate this power. In particular, HHEA utilizes multiple common pressure rails to transmit the majority of power and small electric machines to modulate the power. The energy-saving potential of the the HHEA has been validated for the work circuits of a variety of mobile machines, from small 5-ton excavators to medium sized 20-ton excavators and wheel loaders, and representative duty cycles to reduce energy input by 50-80% compared to the commercial state-of-art load-sensing systems. In addition, the corner power requirements of the electrical machines can be downsized by 85% compared to the EHA approach. Various tradeoff studies have also been conducted, including sensitivities to individual components performances, controllers, accumulator sizes, and variations of the system architecture etc. A control strategy has been developed to maintain or exceed the motion control precision compared to current systems. The motion control strategy consists of a nominal controller, based on a passivity-based backstepping design, and a transition controller, based on least-norn feedforward design. The nominal controller is used in between common pressure rail switches whereas the transition controller compensates for any disturbance that common pressure rail switchings inflict on the system. The control strategy has been experimentally validated on both a medium pressure (200bar) hardware-in-the-loop (HIL) testbed and a high pressure (300+bar) HIL testbed. An efficient and power-dense integrated electric-hydraulic machine consisting of an axial flux electric machine and a radial hydrostatic piston hydraulic machine has been designed, constructed and tested. The machine has an active material power density of 6.1kW/kg, a rated speed of 12500 RPM, and a design efficiency of 85%. This is among the highest power density electric machines using conventional materials. While the integrated machine was designed for modulating the hydraulic power within the HHEA, it can also be used in other applications.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Summer 2024: Solar Industry Update [Slides]

14 SOLAR ENERGY↗

DOE OSTI2020

Nonlinear Photovoltaic Degradation Rates: Modeling and Comparison Against Conventional Methods

Although common practice for estimating photovoltaic (PV) degradation rate (RD) assumes a linear behavior, field data have shown that degradation rates are frequently nonlinear. This article presents a new methodology to detect and calculate nonlinear RD based on PV performance time-series from nine different systems over an eight-year period. Prior to performing the analysis and in order to adjust model parameters to reflect actual PV operation, synthetic datasets were utilized for calibration purposes. A change-point analysis is then applied to detect changes in the slopes of PV trends, which are extracted from constructed performance ratio (PR) time-series. Once the number and location of change points is found, the ordinary least squares method is applied to the different segments to compute the corresponding rates. The obtained results verified that the extracted trends from the PR time-series may not always be linear and therefore, “nonconventional” models need to be applied. All thin-film technologies demonstrated nonlinear behavior whereas nonlinearity detected in the crystalline silicon systems is thought to be due to a maintenance event. A comparative analysis between the new methodology and other conventional methods demonstrated levelized cost of energy differences of up to 6.14%, highlighting the importance of considering nonlinear degradation behavior

14 SOLAR ENERGY↗

DOE OSTI2025

Advancing Manufacturing Water Resilience: Addressing Risks through New Approaches and Technologies

Water is indispensable in manufacturing operations, and many manufacturers operate on the assumption that water of sufficient quality and quantity will be available whenever and wherever needed. As such, the importance of water to this sector has been overlooked, despite its critical importance for operations and meeting production demands, due to perceived sufficient availability and low cost of water to manufacturers. However, the situation is changing as water-related risks are markedly increasing due to aging infrastructure, changing climate, and resource extraction, which alter global and regional water cycles and characteristics. These changes are occurring against a backdrop of intensifying competition from other sectors for scarce and/or unevenly distributed water resources and changing trends in water needs. Section 1 of this report explores those risks in the U.S. context, while the remaining sections detail the work needed to advance the resilience of manufacturing water supplies to these changing risks by filling critical data gaps, re-evaluating the value of water to manufacturers, and advancing opportunities for novel technologies and analyses. The intended audience for this report is broad, including manufacturers, decision makers, researchers, and policymakers.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Advancing Manufacturing Water Resilience: Addressing Risks through New Approaches and Technologies

36 MATERIALS SCIENCE↗

DOE OSTI2023

Operation and Process Control Development for a Pilot-Scale Leaching and Solvent Extraction Circuit Recovering Rare Earth Elements From Coal-Based Sources

The US Department of Energy in 2010 has identified several rare earth elements as critical materials to enable clean technologies. As part of ongoing research in REEs (rare earth elements) recovery from coal sources, the University of Kentucky has designed, developed and is demonstrating a ¼ ton/hour pilot-scale processing plant to produce high-grade REEs from coal sources. Due to the need to control critical variables (e.g. pH, tank level, etc.), process control is required. To ensure adequate process control, a study was conducted on leaching and solvent extraction control to evaluate the potential of achieving low-cost REE recovery in addition to developing a process control PLC system. The overall operational design and utilization of Six Sigma methodologies is discussed. Further, the application of the controls design, both procedural and electronic for the control of process variables such as pH is discussed. Variations in output parameters were quantified as a function of time. Data trends show that the mean process variable was maintained within prescribed limits. Future work for the utilization of data analysis and integration for data-based decision-making will be discussed.

coal, rare earth elements, pilot plant, automation↗

DOE OSTI2021

A two-equation soot-in-flamelet modeling approach applied under Spray A conditions

Soot production (including formation and oxidation) is studied in the transient, high-pressure and turbulent n-dodecane Spray A flames from the Engine Combustion Network (ECN) using computational fluid dynamics (CFD) simulations. A two-equation soot-in-flamelet modeling approach is applied within the framework of the Unsteady Flamelet Progress Variable (UFPV) model and results are validated against experimental data. Equations for soot mass fraction and soot number density derived in the mixture fraction space are solved in the context of detailed flamelet calculations. Source terms for the different steps in the soot chemistry are tabulated and incorporated in the flamelet manifold. For the reference condition, the modeling approach based on the tabulated flamelet manifold reduces the computational cost of a CFD calculation by approximately 40 times compared to a non-tabulated well-mixed (WM) modeling approach. The soot-in-flamelet approach is then extended to study the effect of ambient oxygen concentration, ambient mixture composition and ambient temperature on soot production. Results show that the modeling approach is able to capture the experimental trends for the soot volume fraction (SVF) with good quantitative agreement, especially in the soot ramp-up region.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗