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DOE OSTI2024

Developing a predictive science of the biosphere requires the integration of scientific cultures

Increasing the speed of scientific progress is urgently needed to address the many challenges associated with the biosphere in the Anthropocene. Consequently, the critical question becomes: How can science most rapidly progress to address large, complex global problems? We suggest that the lag in the development of a more predictive science of the biosphere is not only because the biosphere is so much more complex, or because we do not have enough data, or are not doing enough experiments, but, in large part, because of unresolved tension between the three dominant scientific cultures that pervade the research community. We introduce and explain the concept of the three scientific cultures and present a novel analysis of their characteristics, supported by examples and a formal mathematical definition/representation of what this means and implies. The three cultures operate, to varying degrees, across all of science. However, within the biosciences, and in contrast to some of the other sciences, they remain relatively more separated, and their lack of integration has hindered their potential power and insight. Our solution to accelerating a broader, predictive science of the biosphere is to enhance integration of scientific cultures. The process of integration—Scientific Transculturalism—recognizes that the push for interdisciplinary research, in general, is just not enough. Unless these cultures of science are formally appreciated and their thinking iteratively integrated into scientific discovery and advancement, there will continue to be numerous significant challenges that will increasingly limit forecasting and prediction efforts.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

Coal to Carbon Fiber – A Novel Supercritical CO 2 Solvated Process

This project aims to demonstrate, independently, the three primary processes necessary to produce carbon fiber from coal feedstock material and assess the potential for those independent processes to integrate into a single, continuous process in order to provide significant cost reductions in the most costly steps of carbon fiber processing. The specific objective of the present research is to assess the technical feasibility for generation of quality carbon fiber pre-cursor materials from coal using a supercritical carbon dioxide (sCO 2 ) solvation process.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2024

Acceleration of Solvation Free Energy Calculation via Thermodynamic Integration Coupled with Gaussian Process Regression and Improved Gelman–Rubin Convergence Diagnostics

The determination of the solvation free energy of ions and molecules holds profound importance across a spectrum of applications spanning chemistry, biology, energy storage, and the environment. Molecular dynamics simulations are powerful tools for computing this critical parameter. Nevertheless, the accurate and efficient calculation of the solvation free energy becomes a formidable endeavor when dealing with complex systems characterized by potent Coulombic interactions and sluggish ion dynamics and, consequently, slow transition across various metastable states. Here, in the present study, we expose limitations stemming from the conventional calculation of the statistical inefficiency g in the thermodynamic integration method, a factor that can hinder the determination of convergence of the solvation free energy and its associated uncertainty. Instead, we propose a robust scheme based on Gelman–Rubin convergence diagnostics. We leverage this improved estimation of uncertainties to introduce an innovative accelerated thermodynamic integration method based on the Gaussian Process regression. This methodology is applied to the calculation of the solvation free energy of trivalent rare-earth elements immersed in ionic liquids, a scenario in which the aforementioned challenges render standard approaches ineffective. The proposed method proves to be effective in computing solvation free energy in situations where traditional thermodynamic integration methods fall short.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

How Can Construction Process Simulation Modeling Aid the Integration of Lean Principles in the Factory-Built Housing Industry?

New and existing factories that produce and deliver factory-built housing can benefit from construction process simulation modeling to explore the integration of Lean principles in their operations. Construction process simulation modeling provides digital or virtual recreations of the real-world factory environments to visualize, quantify, analyze, and optimize their underlying behavior, including factory productivity, material flow, labor dynamics, bottlenecks, and work scope. One of the key benefits of process simulation modeling is the ability to create and compare "what-if" scenarios, including integrating Lean principles such as reducing waste (for example, transportation, waiting), line balancing, and just-in-time concepts. In general, three process simulation methods are widely used: discrete event simulation (DES), agentbased modeling (ABM), and system dynamics (SD). Myriad process simulation software also is available, but depending on the industry, complexity of the system, and purposes of the simulation, some software might be more appropriate. Similar to how computer-aided design (CAD) software such as AutoCAD and Rhinoceros enable building design of modular or factory-built housing, process simulation modeling software such as jStrobe, ProModel, and AnyLogic can enable factory design of new and existing factories to deliver modular affordable housing at scale, as opposed to traditional site-built construction. Software with DES capabilities can help generate a process model that is a logical representation of resources and activities in a factory. Software with CAD-DES integration can leverage product-process data integration to help spatially visualize a DES model of the factory in the CAD environment. Software with multimethod simulation capabilities, widely used in the manufacturing industry, brings together DES, ABM, and SD in a single platform that allows visualization, quantification, analyses, and optimization at varying data fidelities. Near-real-time data from an existing factory can be directly plugged into multimethod simulation software so that the construction process simulation model is a near-accurate representation of the real-world factory conditions. This report provides insights into the use of simulation as an aid to integrate Lean concepts in factories, including guidelines for selecting the appropriate process simulation modeling method and software. These insights have been developed as part of ongoing process simulation modeling research, development, and demonstration projects at the U.S. Department of Housing and Urban Development, the U.S. Department of Energy, and the National Renewable Energy Laboratory focused on how process simulation models can enable better integration of resilience, energy efficiency, and low-carbon design strategies.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Achieving superior mechanical properties: Tailoring multicomponent microstructure in AISI 9254 spring steel through a two-stage Q&P process and nanoscale carbide integration

In the pursuit of lightweight, durable steel, we have successfully developed a multicomponent structure in AISI 9254 spring steel using a two-stage quenching and partitioning (Q&P) process. The primary objective of this process was to engineer an optimized microstructure consisting of nanobainite, martensite, and nano-carbides. Utilizing the insights gained from the results of advanced techniques such as X-ray diffraction (XRD), scanning electron microscopy (SEM), transmission electron microscopy (TEM), and atom probe tomography (APT) performed on the as-received AISI 9254 spring steel, we refined the quenching and partitioning (Q&P) path, leading to the successful establishment of a bainitic transformation for superior mechanical properties. Our tensile tests revealed a high yield strength (≈ 1600 ± 25 MPa) and ultimate tensile strength (≈ 1850 ± 50 MPa), along with considerable elongation (≈ 11.15 ± 0.25%). We also identified that pre-formed martensite lath defects and high silicon content play crucial roles during the Q&P process, preventing carbide coalescence and increasing strain-hardening capacity. Finally, this study demonstrates the potential of a Q&P process to generate high-strength, ductile steel for automotive and aerospace applications.

36 MATERIALS SCIENCE↗

DOE OSTI2021

BETO 2021 Peer Review - Biological Upgrading of Sugars (BUS) 2.3.2.105

The Biological Upgrading of Sugars (BUS) project directly targets the anaerobic conversion of lignocellulosic feedstocks into intermediate molecules readily upgradeable to fuel precursors. Recent efforts on the BUS project have a particular emphasis on the biological production of butyric acid, an intermediate that can be readily upgraded to sustainable aviation fuel, diesel blend-stocks, and high value chemicals. The BUS project approaches this direction through a combination of strain engineering, fermentation process engineering, development of novel separations technologies, and the design and build of pilot scale systems. Our ultimate project goal is to develop an integrated cost-effective process at pilot scale to achieve DOE's MYPP targets of $2.50/GGE. The major thrust of the BUS project over the last project cycle was on the development of integrated processes surrounding the anaerobic production of carboxylic acids using diverse Clostridium species. We developed and expanded genetic tools for several Clostridium species and rewired microbial metabolism in an attempt to maximize substrate utilization and flux towards butyric acid. We designed and built novel bioreactors with an in situ product recovery system enabling the biological production and recovery of highly purified acids. We leveraged this system to generate 100s of grams of acid from corn stover hydrolysate. In this presentation we highlight data surrounding our proposed process and accompanying results from technoeconomic and life-cycle analyses of our integrated process. Finally, we detail plans of our pilot scale reactor system that is in process and discuss our future routes towards achieving economically viable and sustainable diesel and jet blendstocks.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2023

A New Class of SiC Power MOSFETs with Record-Low Resistance

Silicon carbide (SiC) power transistors are used in the main traction inverter of electric vehicles (EVs). Tesla began installing SiC power MOSFETs in 2017, and has now produced 4.8 million EVs containing over 169 million SiC power MOSFETs. Looking ahead, the worldwide EV market is projected to exceed 50 million vehicles per year by 2030 (Reuters, Oct. 25, 2022). This will create a demand for over two billion SiC power MOSFETs per year. Our program aims to double the efficiency of today's commercial power MOSFETs. This will cut the number of MOSFETs per EV in half, reducing cost, simplifying assembly, decreasing weight, and increasing vehicle reliability through reduced parts count. Our approach is to apply innovative design and advanced processing to increase the density of current-controlling channels in SiC power MOSFET. We have developed two new MOSFET devices, each of which increases the channel density by a factor of six over today's best commercial MOSFETs. This required implementing new fabrication processes, creating new device designs, and integrating the processing steps and device designs into a manufacturable technology. In this project we have developed two innovative devices: (i) a novel three-dimensional structure, the "tri-gate MOSFET," and (ii) a deeply-scaled, fully self-aligned trench MOSFET, the "IMOSFET". Both products were experimentally demonstrated during this project and meet the program goals of increased efficiency relative to the current state-of-the art commercial products. In the process we have generated significant IP, with two US patents issued and three applications pending. We have also published three journal articles and given reports on this technology at seven international conferences. The success of this program has led to significant follow-on funding from industry. In May 2023 Purdue University signed a five-year R&D contract with GlobalFoundries to transfer our novel technology to commercial production. With headquarters in Malta, NY, Global Foundries is one of the largest pure-play silicon foundries in the world, with annual revenue of $\$$8.1B. Their SiC foundry will be built around the next-generation 200-mm diameter SiC wafers, which will double the number of die per wafer and reduce per-die production cost.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Turning a liability into an asset: creating liquid transportation fuels from CO2, natural gas, or RNG

GTI will be discussing our Cool GTL process, a new low cost versatile integrated modular process which can convert CO2, methane, ethane, and biogas, to gasoline jet and diesel with no wax intermediate product. We have tested Cool GTL at small scale and are beginning tests at larger 2 gallon/day scale for biogas conversion ( with DOE funding). Our ultimate goal is to have several commercial deployments of Cool GTL in a variety of applications running in 5 years. Most exciting is the fact that Cool GTL can totally eliminate Global Warming and produce all the worlds transportation fuel by conversion of the excess CO2 currently in the air to liquid transportation fuels, leading to a modern revolution in the way transportation fuels are produced.

09 BIOMASS FUELS↗

DOE OSTI2025

Immersive Scientific Visualization of Molten-Salt Reactor Waste Characteristics Using Virtual Reality

Immersive visualization is changing how we explore, communicate, and understand complex scientific systems. In nuclear energy, an area in which data are often multidimensional, time-dependent, and difficult to interpret, virtual reality (VR) represents a powerful and intuitive informational medium. This work introduces a VR-based platform that visualizes the post-shutdown behavior and waste management lifecycle of molten-salt reactors (MSRs), a next-generation reactor type with unique operational and safety characteristics. The platform, built in Unity, is streamed on the Meta Quest 3 headset. It transforms high-fidelity simulation data into an interactive, immersive experience. Users can explore time-dependent reactor characteristics such as nuclide decay, which is a key factor for evaluating reactor waste strategies. The datasets were generated using the MOOSE (Multiphysics Object-Oriented Simulation Environment) framework and then processed through ParaView scripting for smooth integration into Unity. From a visualization standpoint, the platform emphasizes spatial storytelling, temporal exploration, and user-centered interaction. Users can navigate 3D reactor geometries, slice through volumetric data, and manipulate time to observe how physical phenomena evolve. Real-scale rendering and embodied interaction make the experience feel tangible. The interface is designed to be accessible, even to those without nuclear or simulation expertise. This lowers the barrier for stakeholders, policymakers, and the general public, while still supporting expert analysis and collaborative decision-making. This work shows how immersive visualization can function as both a scientific tool and a communication interface. By integrating simulation, processing, and visualization into a cohesive workflow, we offer a scalable framework for immersive scientific storytelling. The modular design supports future extensions to other reactor types and lifecycle stages, from shutdown to long-term storage, making the platform adaptable for both research and outreach.

99 - GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

Finite-volume formalism for physical processes with an electroweak loop integral

This study investigates finite-volume effects in physical processes that involve the combination of long-range hadronic matrix elements with electroweak loop integrals. We adopt the approach of implementing the electroweak part as the infinite-volume version, which is denoted as the EW ∞ method in this work. A general approach is established for correcting finite-volume effects in cases where the hadronic intermediate states are dominated by either a single particle or two particles. For the single-particle case, this work derives the infinite volume reconstruction method from a new perspective. For the two-particle case, we provide the correction formulas for power-law finite-volume effects and unphysical terms with exponentially divergent time dependence. The finite-volume formalism developed in this study has broad applications, including the QED corrections in various processes and the two-photon exchange contribution in 𝐾 𝐿 → 𝜇 + ⁢𝜇 − or 𝜂 → 𝜇 + ⁢𝜇 − decays.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2018

The integrated impacts of natural processes and human activities on groundwater salinization in the coastal aquifers of Beihai, southern China

Salinization in coastal aquifers is usually related to both seawater intrusion and water–rock interaction. The results of chemical and isotopic methods were combined to identify the origin and processes of groundwater salinization in Daguansha area of Beihai, southern China. The concentrations of the major ions that dominate in seawater (Cl{sup −}, Na{sup +}, Ca{sup 2+}, Mg{sup 2+} and SO{sub 4}{sup 2–}), as well as the isotopic content and ratios ({sup 2}H, {sup 18}O, {sup 87}Sr/{sup 86}Sr and {sup 13}C), suggest that the salinization occurring in the aquifer of the coastal plain is related to seawater and that the prevailing hydrochemical processes are evaporation, mixing, dissolution and ion exchange. For the unconfined aquifer, groundwater salinization has occurred in an area that is significantly influenced by land-based sea farming. The integrated impacts of seawater intrusion from the Beibuwan Gulf and infiltration of seawater from the culture ponds are identified in the shallowest confined aquifer (I) in the middle of the area (site BBW2). Leakage from this polluted confined aquifer causes the salinization of groundwater in the underlying confined aquifer (II). At the coastal monitoring site (BBW3), confined aquifer I and lower confined aquifer II are heavily contaminated by seawater intrusion. The weak connectivity between the upper aquifers, and the seaward movement of freshwater, prevents saltwater from encroaching the deepest confined aquifer (III). A conceptual model is presented. Above all, understanding of the origin and processes of groundwater salinization will provide essential information for the planning and sustainable management of groundwater resources in this region.

58 GEOSCIENCES↗

DOE OSTI2024

Potential Integration Between Residual Biogenic Process Resources and Greener Hydrogen Production from Steam Reformers

Biomass conversion processes have varying efficiencies towards specific products like liquid fuels; process inefficiencies result in byproducts such as off-gases, heat, and solid residues such as char. The efficient use of these byproducts is key towards getting the maximum sustainability benefits from valuable biomass resources. For example, there are various utility product options that can utilize heat and off-gases from biomass pyrolysis processes; they include process heat and steam, hydrogen, fuel gas, and electricity. Further, there is potential for the use of the off-gases to supplement natural gas feed into steam reformers for hydrogen production. This presentation highlights results from previous analyses on tradeoffs based on utility byproduct choices (https://doi.org/10.1039/D3SE00745F); maximizing hydrogen production from off-gases is one potential winning strategy. This leads to the question regarding the utilization of these off-gases in existing steam reformers and the process impacts from feeding off-gases. Process modeling of a steam reformer system (https://doi.org/10.1002/adsu.20230021) quantifies those impacts and shows how much off-gas substitution is possible within the limits of an existing design with such an integration strategy.

biogenic gases↗

DOE OSTI2019

Integrated Two-Stage Alkaline-Oxidative Pretreatment of Hybrid Poplar. Part 1: Impact of Alkaline Pre-Extraction Conditions on Process Performance and Lignin Properties

We previously demonstrated that a two-stage pretreatment comprising of an alkaline pre-extraction followed by a Cu-catalyzed alkaline–oxidative treatment is effective at pretreating hardwoods under relatively mild reaction conditions. In this work, we focus on characterizing how biomass source and reaction conditions used during the alkaline pre-extraction impact the subsequent processing stages as well as lignin yields and properties. Specifically, three hybrid poplars were subjected to the first stage alkaline pre-extraction under various conditions including differences in time (15–300 min), temperature (95–155 °C), and alkali loadings (50–200 mg NaOH/g biomass), and the impact on total mass solubilization, lignin recovery, and lignin purity was determined. Empirical correlations were developed between reaction conditions and mass solubilization and lignin recovery during the pre-extraction stage. For select conditions, lignin properties were assessed and include β-O-4 content determined by 13C NMR, molecular mass distributions as determined by gel permeation chromatography, and susceptibility to depolymerization to aromatic monomers using thioacidolysis and formic acid catalyzed depolymerization. We found alkaline pre-extraction performed at higher temperatures generated lignins exhibiting lower contamination by polysaccharides, lower aromatic monomer yields from depolymerization, lower molar masses, and lower β-O-4 contents relative to the lower temperature pre-extractions. Lastly, the pre-extracted biomass from select conditions was assessed for its response to the subsequent Cu-catalyzed alkaline–oxidative treatment and enzymatic hydrolysis. It was demonstrated that minor differences in delignification during pre-extraction have quantifiable impacts on the subsequent efficacy of the second stage of pretreatment and enzymatic hydrolysis with improved lignin removal during the first pre-extraction stage resulting in improved hydrolysis yields.

09 BIOMASS FUELS↗

DOE OSTI2026

Improving anaerobic digestion of sewage sludge to renewable natural gas by the Advanced Pretreatment & Anaerobic Digestion technology (APAD): Pilot testing

Conventional anaerobic digestion (AD) of sewage sludge in wastewater treatment facilities suffers from low carbon conversion efficiency (CCE = 40%) and requires costly CO2 removal for injection of the produced CH4 into the natural gas grid. To address these limitations, we developed the Advanced Pretreatment and Anaerobic Digestion (APAD) process. This integrates Advanced Wet Oxidation & Steam Explosion (AWOEx) pretreatment of residual sludge after conventional AD, followed by biogas upgradation using a novel methanogenic strain, Methanothermobacter wolfeii BSEL, converting CO2 with H2 into CH4 or RNG (renewable natural gas). Pilot-scale results demonstrated that AWOEx pretreatment achieved a CCE of 62% for the residual sludge, 68% higher than the conventional AD process. The CH4 production was further increased by 79%. Subsequent biogas upgrading in a trickling bed reactor with H2 further enhanced total methane output by 100% and resulted in a final CO2 concentration of =3%. The integrated APAD process achieved a remarkable overall CCE of 83%, resulting in a 200% increase in RNG output when compared to conventional AD. Techno-economic analysis revealed that AWOEx pretreatment alone reduced sludge treatment costs from $494 to $253 per ton of dry solids. The complete APAD process incurred a higher cost of treatment of $530 per ton, driven by prices for bottled H2. The process did, however, show gains in energy recovery and decarbonization. Renewable H2, which may reduce in price in the near future, can positively improve the economics of biogas upgrading for the APAD process.

Life Cycle Assessment (LCA)↗

DOE OSTI2022

Recursive Gaussian Process over graphs for Integrating Multi-timescale Measurements in Low-Observable Distribution Systems

The transition to a smarter grid is empowered by enhanced sensor deployments and smart metering infrastructure in the distribution system. Measurements from these sensors and meters can be used for many applications, including distribution system state estimation (DSSE). However, these measurements are typically sampled at different rates and could be intermittent due to losses during the aggregation process. These multi timescale measurements should be reconciled in real-time to perform accurate grid monitoring. This paper tackles this problem by formulating a recursive multi-task Gaussian process (RGP-G) approach that sequentially aggregates sensor measurements. Specifically, we formulate a recursive multi-task GP with and without network connectivity information to reconcile the multi time-scale measurements in distribution systems. Here, the proposed framework is capable of aggregating the multi-time scale measurements batch-wise or in real-time. Following the aggregation of the multi time-scale measurements, the spatial states of the consistent time-series are estimated using matrix completion based DSSE approach. Simulation results on IEEE 37 and IEEE 123 bus test systems illustrate the efficiency of the proposed methods from the standpoint of both multi time-scale data aggregation and DSSE.

42 ENGINEERING↗

DOE OSTI2020

Techno-economic analysis of cathode material production using flame-assisted spray pyrolysis

The cost of cathode materials contributes approximately 32.7% of the total cell construction cost of lithium-ion batteries, significantly affecting the price of battery packs. To reduce the cathode material manufacturing cost, a flame-assisted spray pyrolysis (FSP) method has been developed to utilize a sustainable solvent of glycerol to manufacture the LiNi 1/3 Mn 1/3 Co 1/3 O 2 (NMC333) cathode materials. The purpose of this study is to evaluate the minimum cathode material selling price (MCSP) of the FSP processes compared with a traditional carbonate co-precipitation pathway. Results show that the MCSP of the FSP is $\$$19.1/kg that is 17% lower than the traditional carbonate co-precipitation pathway as a result of lower fixed operating cost and variable overhead. Sensitivity analysis shows that when the new process is integrated with in-situ sintering and processing, the MCSP can be as low as $\$$15.6/kg. When all the material prices are decreased by 20%, the FSP process can synthesize NMC333 at a price of $\$$2.3/kg lower. According to the simulation result, LiNi 0·8 Mn 0·1 Co 0·1 O 2 (NMC811) has the best potential to meet the U.S. Department of Energy battery price target of $\$$125/kWh, demonstrating that the FSP process is an attractive manufacturing technology for NMC cathode powder material production.

25 ENERGY STORAGE↗

DOE OSTI2021

Characterizing Self-Assembled Monolayer Breakdown in Area-Selective Atomic Layer Deposition

In order to enable area-selective atomic layer deposition (AS-ALD), self-assembled monolayers (SAMs) have been used as the surface inhibitor to block a variety of ALD processes. The integrity of the SAM throughout the ALD process is critical to AS-ALD. Despite the demonstrated effectiveness of inhibition by SAMs, nucleation during ALD eventually occurs on SAM-protected surfaces, but its impact on SAM structures is still not fully understood. In this study, we chose the octadecyltrichlorosilane (ODTS) SAM as a model system to investigate the evolution of crystallinity and structure of SAMs before and after ALD. The breakdown behavior of SAMs when exposed to ZnO and Al 2 O 3 ALD was systematically studied by combining synchrotron X-ray techniques and electron microscopy. We show that the crystallinity and structure of ODTS SAMs grown on Si substrates remain intact until a significant amount of material deposition takes place. In addition, the undesired ALD materials that grow on ODTS SAMs present contrasting morphologies: dispersed nanoparticles for ZnO while relatively continuous film for Al 2 O 3 . Lastly, substrate dependency was explored by comparing a Si substrate to single-crystal sapphire. Similar results in the evolution of SAM crystallinity and formation of ALD nuclei on top of SAM are observed in the ODTS–sapphire system. This study provides an in-depth view of the influence of ALD processes on the SAM structure and the nucleation behavior of ALD on SAM-protected surfaces.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Non-equilibrium signal integration in hydrogels

Abstract Materials that perform complex chemical signal processing are ubiquitous in living systems. Their synthetic analogs would transform developments in biomedicine, catalysis, and many other areas. By drawing inspiration from biological signaling dynamics, we show how simple hydrogels have a previously untapped capacity for non-equilibrium chemical signal processing and integration. Using a common polyacrylic acid hydrogel, with divalent cations and acid as representative stimuli, we demonstrate the emergence of non-monotonic osmosis-driven spikes and waves of expansion/contraction, as well as traveling color waves. These distinct responses emerge from different combinations of rates and sequences of arriving stimuli. A non-equilibrium continuum theory we developed quantitatively captures the non-monotonic osmosis-driven deformation waves and determines the onset of their emergence in terms of the input parameters. These results suggest that simple hydrogels, already built into numerous systems, have a much larger sensing space than currently employed.

36 MATERIALS SCIENCE↗