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The project demonstrated how to “close the loop” on carbon fiber by integrating industrial carbon fiber scrap into new functional components in an automotive lightweighting application. The project serves as a validation of discontinuous recycled carbon fiber in a commercial context, while generating comprehensive material data throughout the production chain.
Wireless sensors and sensor networks is an emerging technology area with many applications within the aerospace industry. Integrated vehicle health monitoring (IVHM) of aerospace vehicles is needed to ensure the safety of the crew and the vehicle, yet often high costs, weight, size and other constraints prevent the incorporation of instrumentation onto spacecraft. This paper presents a few of the areas such as IVHM, where new wireless sensing technology is needed on both existing vehicles as well as future spacecraft. From ground tests to inflatable structures to the International Space Station, many applications could receive benefits from small, low power, wireless sensors. This paper also highlights some of the challenges that need to overcome when implementing wireless sensor networks for aerospace vehicles.
The Cryogenic Fluid In-situ Liquefaction for Landers (CryoFILL) activity has been investigating concepts for the liquefaction of cryogenic fluids produced on the surface of the Moon and Mars. Liquefaction testing of oxygen in a scaled lander tank using an integrated, industrial cryocooler system was completed. The testing covered the determination of the nominal performance operation of the system, constant liquefaction performance, and transient liquefaction performance. The goal of the testing was to demonstrate cryogenic liquefaction operational capabilities on the Lunar and Martian surfaces for landers and In Situ Resource Utilization. The testing met all key performance parameter threshold values including liquefaction rate (demonstrated 1.6 kg/hr compared to threshold of 1.1 kg/hr), number of variables as transient (goal of 3: liquefaction flow, environmental temperature, and cryocooler input power – all demonstrated), and number of fill levels (goal of 3: < 5%, 50%, and 90% - all demonstrated). Key testing results from oxygen liquefaction testing will be discussed including sensitivities provided by the analysis team.
Ensuring safe, reliable, cost-effective DER integration at scale requires holistic planning, broad stakeholder engagement, and should address key development areas such as standards adoption, equipment testing and certification, interoperability and cybersecurity, interconnection procedures, and advanced forecasting and DER management. Each of these areas currently represent significant challenges for utilities, regulators, OEMs, developers, and even consumers worldwide. India has already seen significant growth of DERs and has announced targets for substantial growth yet to come, with the potential for DERs to make up a non-negligible portion of the country's overall generation capacity. As such, it is of critical importance that Indian stakeholders consider the potential impacts of wide-spread adoption of DERs and take preemptive action related to the five development areas listed here, among others. India should consider strategies including the adoption of key DER standards related to interconnection, testing, and cybersecurity; enabling effective and secure communication channels for DER interoperability; testing and certifying DER equipment in accredited testing laboratories; building robust, streamlined interconnection procedures; and revamping legacy system planning structures to incorporate DERs in a holistic planning framework.
The goal of the DOE’s Industrial Assessment Center (IAC) program is twofold: first, to help US manufacturing competitiveness by providing assessments and recommendations for small and medium-sized enterprises (SMEs) on energy efficiency, productivity, sustainability and competitiveness – including measuring the impacts of these recommendations on reducing greenhouse gas emissions; and second, to address a growing shortage of engineering professionals with applied energy and manufacturing-related skills by training a diverse cross-section of engineering students through hands-on involvement in these assessments. IUPUI has an IAC, which was established in 2011, in the Department of Mechanical and Energy Engineering, Purdue School of Engineering and Technology, IUPUI. The IAC has won the awards twice. We have built the center that has the expertise and infrastructure for quality energy assessments to manufactures and commercial building owners and aligned our current research and teaching activities to the DOE’ training mission with programs to train the next generation of industrial energy efficiency experts, with theory and hands-on experience in conducting energy assessment for small and median manufacturing enterprises. We have made recommendations that have the potential to save about $20M annually. We also initiated research projects to meet DOE priorities, specifically in the areas of smart manufacturing and cybersecurity. On the energy assessment side, the Center has provided energy assessments to 144 qualified companies, primarily located in Indiana. On the training side, the center has trained students in various programs, such as the department’s Bachelor of Science (BS) programs in Mechanical Engineering (ME) and BS in Energy Engineering (EEN), both are ABET accredited engineering programs, as well as a graduate level Energy Management and Assessment certificate program. At the present, the center has trained 95 students, 43 or them received the DOE issued certificates. Research projects were developed within the center to advance energy efficiency related technologies, which provided excellent opportunities for our trainees. The center has also been building a professional network with utilities, Manufacturing Extension Partnership (MEP), government agencies, and manufacturing companies, to increase our client base and promote collaborations. The center received the 2019 Center of Excellence of the Year Award and three students received the “Outstanding Achievement in Energy Engineering by an IAC Student” awards in the past five years.
The United States produced more than 66.2 billion Liters of biofuel, primarily in the form of corn ethanol (61 billion Liters) and soybean biodiesel (6 billion Liters), for the transportation industry in 2017. No work currently exists that evaluates both the economic and environmental outcomes of this industry with adequate geospatial resolution and national scope. In this study, a model framework is constructed to perform Techno-Economic Analysis and Life Cycle Assessment using high-resolution input datasets to provide a granular estimation of corn ethanol and soybean biodiesel sustainability performance in most counties in the United States in 2017 (the most recent year for which data is available). Results show a total life cycle, greenhouse gas emission volume of 99.5 million Mg CO 2-eq produced in 2017 by these two biofuels (94.8 million Mg from corn ethanol, and 4.7 million Mg from soybean biodiesel), excluding indirect land use change emissions. Further, this volume corresponds to a combined carbon intensity of 65.3 gCO 2-eq /MJ, which is a greenhouse gas improvement compared to petroleum-based gasoline (the carbon intensity of conventional gasoline is 93.0 gCO 2-eq /MJ). However, these biofuels are produced at an additional economic cost ($1.8 billion over the displaced gas/diesel). Additionally, these biofuels generate unfavorable impacts in other environmental categories when compared to petroleum-based fuels, particularly in areas of water, land, and nitrogen intensity. This work enables stakeholders to assess the specific value of biofuels as a means of emission reduction and determine if the attained improvements are worth the associated opportunity costs.
This paper presents past and current work in dealing with indirect industry and NASA costs when providing cost estimation or analysis for NASA projects and programs. Indirect costs, when defined as those costs in a project removed from the actual hardware or software hands-on labor; makes up most of the costs of today's complex large scale NASA space/industry projects. This appears to be the case across phases from research into development into production and into the operation of the system. Space transportation is the case of interest here. Modeling and cost estimation as a process rather than a product will be emphasized. Analysis as a series of belief systems in play among decision makers and decision factors will also be emphasized to provide context.
This is part 3 of the conference proceedings on rotorcraft technology. This volume is divided into areas on systems integration, research aircraft, and industry. Representative titles from each area are: system analysis in rotorcraft design, the past decade; rotorcraft flight research with emphasis on rotor systems; and an overview of key technology thrusts at Bell Helicopter Textron.
• Industries requiring high structural integrity, including automotive, aerospace, and construction, place considerable significance on weld quality classification. • The inspection normally involves human expertise through predefined quality metrics that are subjective, error-prone, and time-intensive • The challenge to classification model development is the scarcity of labeled data and imbalanced distributions in the data that are labeled. • This work develops a new hybrid methodology that achieves clustering using KMeans++ together with supervised classification to overcome these challenges. • The ensemble-based classifiers were identified as optimal, with accuracy enhancements of up to 8% using the pseudo-labeled dataset. • The work provides practical insight into feature engineering and machine learning integration in industrial quality assurance applications.
To decarbonize their industrial facilities, The Dow Chemical Company has collaborated with Idaho National Laboratory (INL) to study the integration of nuclear power with an industrial chemical facility. Using Holistic Energy and Resource Optimization Network developed at INL for optimizing and analyzing integrated energy systems, a nuclear microreactor system was sized and evaluated for dynamic dispatch to Dow Silicones Corporation’s Carrollton, KY (USA) site for iloxane production. It was found that a 180 MW th system (12 × 15MW th ) with 75.1 MWh th of thermal energy storage could provide heat and power to the chemical facilities. In the process, this would reduce electricity imports by 99.9 % and reduce the Scope 1 and 2 emissions of the site by 292,100 tonnes CO 2 /yr (98.8 %). The primary novelty of this work is a first of a kind design and optimization of a microreactor powered integrated energy system to provide heat and power to a chemical plant using real plant data. This analysis will pave the way for future studies using dispatchable clean energy sources to reduce carbon emissions and commodity industries’ reliance on fossil fuels.
Successful integration of metallic lithium anodes into secondary batteries could enhance energy density and enable new forms of electrified transportation. However, the outlook for widespread lithium metal adoption in energy storage devices remains mixed. This comes in part from existing gaps in our understanding of the relationships connecting the initial state of lithium, its evolution with cycling, and end-of-life state. It remains important to develop standardized protocols for material and cell characterization, cycling performance, safety, and recycling procedures for lithium metal-based batteries. In February 2023 a cohort of scientists and engineers from academia, national laboratories, and industry gathered to converge on a list of critical challenges and action items to provide better understanding of lithium metal evolution and to enhance academic, governmental, and industrial partnerships to address these challenges. Here, we highlight the major discussion topics revolving around the manufacturing of lithium metal, its related metrology and integration into battery form factors, and best practices testing its electrochemical performance relevant to automotive applications. We introduce a power-controlled discharge testing protocol for research and development cells, in alignment between major automotive stakeholders, that may reveal lithium metal battery dynamics closer to practical driving behavior.
Nuclear power in the United States has been used traditionally to provide baseload electric power to the grid. Advancements in nuclear power to create smaller and safer reactors have renewed interest in nuclear as a source of both heat and electricity for a variety of applications. There is great interest in coupling nuclear reactors with industrial applications because nuclear power is a low carbon energy source that can be utilized for process heating, hydrogen generation, on-site electricity demand, and more. Idaho National Laboratory is developing guidelines to identify and assist industrial heat and electricity decarbonization by integrating with nuclear power plants (NPPs) to provide clean, abundant, and dispatchable energy. Considerations include specific industrial hazards which impact NPP siting, heat transport requirements and associated technologies, and implementation feasibility based on site-specific demand profiles. To assess integration feasibility, facility process models are developed based on real data obtained from a survey of baseline requirements and process information from industrial facilities in the United States. An assessment of safety and siting requirements is also performed to determine how nuclear industrial pairings could meet licensing requirements for NPPs. In addition, site characterization of an industrial plant is essential to determining the feasibility and suitable integration methods for each industry. Characterization includes facility distance from the nearest population center, site size, rail or water transport availability, and proximity to undeveloped land. These characteristics are important to determine reactor- or industry-side design requirements for safe, efficient operation. The siting and technical data assessment will reveal opportunities for single-use nuclear integration and co-location opportunities for industries to share benefits from a single reactor. In addition to existing facilities, this “energy-park” style cooperation could include new construction like data centers which can cost-share energy investments or provide a stable demand-and-revenue stream to the investor. Deliverables will contain a library of documents and models to guide various industries toward understanding nuclear technologies based on their users’ needs. This paper is a summary of the current project status, and provides insights on suitable pairings for specific industries and reactor technologies
Industry studies were undertaken to establish the technology base for an advanced engine for Orbital Transfer Vehicles for mid-1990s IOC. This paper presents the results of a study conducted by General Dynamics Convair Division, under contract to Aerojet TechSystems Company for NASA-LeRC, to define requirements, interface conditions, and operational design criteria for new LO2/LH2 propulsion systems applicable to future Orbit Transfer Vehicles, and to assess the impacts of space basing, man rating, and low-g transfer on propulsion system design requirements. The primary study emphasis was to determine what the OTV engine thrust level should be, how many engines are required on the OTV, and how the OTV engine should be designed. This was accomplished by evaluating planned OTV missions and concepts to determine the requirements for the OTV propulsion system, conducting tradeoffs and comparisons to optimize OTV capability, and evaluating reliability and maintenance to determine the recommended OTV engine design for future development.
To realize the full potential of biomanufacturing, the breadth of industrial microbes used to consume diverse feedstock and generate bioproducts needs to expand. As such, portable tools are required that can be used by multiple hosts for straightforward genomic manipulation and precise gene expression. Here, we demonstrate the co-utilization of two synthetic biology tools to achieve these goals: cis-repressors (CRs) and serine recombinase-assisted genome engineering (SAGE). CRs are small, noncoding RNAs that are placed upstream of the target gene to modulate bacterial translation rates at varying, discrete levels. SAGE uses site-specific serine recombinases to catalyze highly efficient, unidirectional insertion of DNA into the chromosome of diverse organisms. We used SAGE to integrate a suite of CRs into the industrially relevant hosts Pseudomonas putida, Corynebacterium glutamicum, and Cupriavidus necator. Using a fluorescent reporter as a readout of CR functionality, we found that CR performance across these backgrounds was similar—providing a range of translational repression up to 100-fold. Overall, these results demonstrate the high portability of CRs across bacterial genetic backgrounds, which ideally can be used in future microbial engineering efforts pertinent to biomanufacturing.
National Energy Technology Laboratory (NETL) provides system-level process, cost, and market analyses on solid oxide cell (SOC) based technologies. Specifically, techno-economic analyses (TEA), market assessments, and other technology evaluations serve to guide the U.S. Department of Energy (DOE) Office of Fossil Energy and Carbon Management (FECM) Reversible Solid Oxide Fuel Cell (R-SOFC) Program technology goals and objectives. These studies are key to describing how the technologies contribute to improving domestic energy infrastructure in a clean, efficient manner. This effort seeks to elucidate the potential integration opportunities between reversible SOCs and industrial systems which would aid in SOC commercialization and deployment. These preliminary screening-level results show what opportunities exist for power generating SOFCs, hydrogen producing SOECs, and point-source carbon capture. Improvements can be seen through changes in cost of electricity, cost of hydrogen, and cost of carbon capture.
This roadmap defines potential industrial scale integrated energy systems (IES) and identifies key technology gaps to achieving commercial deployment of such systems. IES under consideration could include multiple energy generation resources and energy use paths, with a focus on low-emission technologies, such as nuclear and renewable generators. Together these technologies provide affordable, reliable, and resilient energy while simultaneously reducing environmental emission of CO 2 and greenhouse gases (GHGs). System design and optimization would consider both technical performance and economic viability within various deployment markets.
NREL’s Industrialized Construction Innovation Team has developed an ambitious plan to accelerate the integration of energy efficiency (EE) strategies with Industrialized Construction (IC). The United States (U.S.) construction industry is beginning to use IC methods to build multifamily apartment buildings to address affordability and labor shortages. Apart from reducing cost of construction and delivery times, the IC method of permanent modular construction has the potential to facilitate the integration of a wide range of EE strategies and advanced controls into such buildings. While there may be unintended EE benefits to IC such as a tighter envelope due to higher construction quality, the process has not been leveraged specifically to enhance EE. NREL aims to claim this missed opportunity and integrate IC benefits with EE as well as advanced controls, distributed energy resources, and grid-friendly design strategies. The paper proposes an ‘IC Assessment Framework’ to achieve affordable zero-energy modular multifamily buildings. Through the selection criteria of Design for Manufacturing and Assembly, the framework aims to distill a broad range of proven EE strategies for site-built into a set of strategies that qualify as easy to integrate for off-site. The output is a Factory Information Model (FIM) that represents a process-based digital twin to enable advanced time-and-motion study, plugs into open source building energy modeling platform (EnergyPlus), and serves as a vital tool facilitating wider adoption of EE integration. Conclusively, the paper delineates next steps for upcoming pilots with NREL’s IC partners towards developing a transformational pathway for our Clean Energy Future.
The Center for Computational Structures Technology (CST) is intended to serve as a focal point for the diverse CST research activities. The CST activities include the use of numerical simulation and artificial intelligence methods in modeling, analysis, sensitivity studies, and optimization of flight-vehicle structures. The Center is located at NASA Langley and is an integral part of the School of Engineering and Applied Science of the University of Virginia. The key elements of the Center are: (1) conducting innovative research on advanced topics of CST; (2) acting as pathfinder by demonstrating to the research community what can be done (high-potential, high-risk research); (3) strong collaboration with NASA scientists and researchers from universities and other government laboratories; and (4) rapid dissemination of CST to industry, through integration of industrial personnel into the ongoing research efforts.