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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 37 records · Page 2

Risk-informed Graded Approach for Reliability and Performance Assessment of Machine Learning and Artificial Intelligence for Advanced Condition Monitoring Techniques

With the shift away from time-based maintenance and toward condition-based maintenance, and to reduce overall maintenance costs, there has been an upsurge in the usage and development of advanced condition monitoring (ACM) techniques for real-time monitoring of nuclear power plant (NPP) components. ACM is particularly useful in the development of digital twins, which are designed to predict the failure or degradation of plant components. Successful implementation of ACM requires an assessment to inform the development of a risk-informed approach to evaluate the use of ACM to meet Nuclear Regulatory Committee (NRC) regulations for in-service testing (IST) programs. This includes the monitoring and diagnostics of reactor components and systems in current, new, and advanced reactors. A key component in ACM is the usage of machine learning (ML) and artificial intelligence (AI) algorithms that can employ real-time data from instrumentation and sensors to detect and predict reactor component degradations. Such predictive capabilities enable early detection of component degradation so as to help plant personnel plan and execute necessary maintenance. For successful implementation of ML/AI in ACM such that regulatory requirements are met, a risk-informed graded approach is needed to assess the reliability and performance of ML/AI for ACM. The American Society for Mechanical Engineers (ASME) developed their Operations and Maintenance (O&M) Code to provide guidance on safe, reliable O&M of NPPs. The IST section of the O&M Code specifically establishes requirements for IST and examination to gauge operational readiness of components in water-cooled NPPs. This paper presents a state-of-the-art review of how reliability and risk assessment can be integrated with ACM to assess component performance by non-nuclear industries. This is followed by different methodologies and approaches for conducting performance and reliability assessments so as to meet IST requirements for NPP components.

97 - MATHEMATICS AND COMPUTING↗

Risk-informed Graded Approach for Reliability and Performance Assessment for Advanced Condition Monitoring Techniques

With the shift away from time-based maintenance and toward condition-based maintenance, and to reduce overall maintenance costs, there has been an upsurge in the usage and development of advanced condition monitoring (ACM) techniques for real-time monitoring of nuclear power plant (NPP) components. ACM is particularly useful in the development of digital twins, which are designed to predict the failure or degradation of plant components. Successful implementation of ACM requires an assessment to inform the development of a risk-informed approach to evaluate the use of ACM to meet Nuclear Regulatory Committee (NRC) regulations for in-service testing (IST) programs. This includes the monitoring and diagnostics of reactor components and systems in current, new, and advanced reactors. A key component in ACM is the usage of machine learning (ML) and artificial intelligence (AI) algorithms that can employ real-time data from instrumentation and sensors to detect and predict reactor component degradations. Such predictive capabilities enable early detection of component degradation so as to help plant personnel plan and execute necessary maintenance. For successful implementation of ML/AI in ACM such that regulatory requirements are met, a risk-informed graded approach is needed to assess the reliability and performance of ML/AI for ACM. The American Society for Mechanical Engineers (ASME) developed their Operations and Maintenance (O&M) Code to provide guidance on safe, reliable O&M of NPPs. The IST section of the O&M Code specifically establishes requirements for IST and examination to gauge operational readiness of components in water-cooled NPPs. This paper presents a state-of-the-art review of how reliability and risk assessment can be integrated with ACM to assess component performance by non-nuclear industries. This is followed by different methodologies and approaches for conducting performance and reliability assessments so as to meet IST requirements for NPP components.

99 - GENERAL AND MISCELLANEOUS↗

26th International Symposium on Plant Lipids

The 2024 International Symposium on Plant Lipids (ISPL) successfully advanced scientific knowledge in plant lipid biology by presenting new discoveries in lipid metabolism, membrane structure and function, lipid signaling, and biotechnology. The symposium fostered professional development for early-career scientists through oral and poster presentation opportunities, lightning talks, and networking events. It promoted the exchange of new technologies, including advances in mass spectrometry, metabolic modeling, and synthetic biology, that will accelerate research across plant biology and related fields. ISPL also strengthened international collaborations, drawing 220 participants from 15 countries across four continents, and established a platform for ongoing scientific exchange and community-building within the global plant lipid research community.

59 BASIC BIOLOGICAL SCIENCES↗

Integrated Computational Materials and Mechanical Modeling for Additive Manufacturing of Alloys with Graded Structure Used in Fossil Fuel Power Plants

Wire-arc additive manufacturing (WAAM) has demonstrated its unique capability of producing large-size alloy components with a significantly reduced fabrication time and enhanced geometry design freedom. In this project, the team has developed an ICME (Integrated Computational Materials Engineering) modeling framework, which supports the WAAM of the AUSC (Advanced Ultra-Supercritical) power plant components. The manufacturing design has been applied to Inconel 740H, steel P91, as well as the dissimilar alloy components between steel P91 and Inconel 740H. The ICME model framework is developed by considering two types of modeling. First, mechanistic modeling has been applied to control the printing quality and understand the sequence of the dissimilar printing of the wall structure. The following models have been included in the developed ICME framework: finite element thermal model, grain structure model, residual stress simulation, crystal plasticity model, CALPHAD-based precipitation kinetic model, phase stability prediction, thermal expansion predictive model, and heuristic creep model. Secondary, a physics-based machine learning model has also been developed based on the ICME model structure. The machine learning model development is based on the ICME model prediction with calibration of the experiments. In addition, the WAAM has been utilized as a high-throughput experimental tool rapidly generating a gradient of alloy composition to facilitate experimental database generation for process-structure-property relationships. Such a database directly supported the ICME-enhanced machine learning, which further assisted in intermediate composition block design between P91 and 740H. A high-throughput screening study of the oxidation resistance has been performed based on such high-throughput experimentation. Based on the computational design, several dissimilar alloy manufacturing with post-heat treatment have been performed with a comprehensive evaluation of mechanical performance, including hardness mapping, yield strength, creep resistance. In this project, the single component of P91 and 740H processed by WAAM after heat treatment designed by ICME has demonstrated higher performance in yield strength and creep resistance than the wrought materials. The P91 sample prepared by WAAM with ICME-designed heat treatment performs better than P92 in creep resistance. The designed graded alloy printing with intermediate block shows a promising performance that exceeds the traditional welding. Moreover, the current research indicates the high need for location-specific design analysis with uncertainty quantification, an important topic that deserves more dedicated research. The achievement of this project demonstrated the promising future of WAAM in structural alloy manufacturing for energy power plant development. Successful printing requires synergetic efforts made by manufacturing, mechanical, and materials sciences.

20 FOSSIL-FUELED POWER PLANTS↗

Phosphoribosylpyrophosphate synthetase as a metabolic valve advances Methylobacterium/Methylorubrum phyllosphere colonization and plant growth

The proficiency of phyllosphere microbiomes in efficiently utilizing plant-provided nutrients is pivotal for their successful colonization of plants. The methylotrophic capabilities of Methylobacterium/Methylorubrum play a crucial role in this process. However, the precise mechanisms facilitating efficient colonization remain elusive. In the present study, we investigate the significance of methanol assimilation in shaping the success of mutualistic relationships between methylotrophs and plants. A set of strains originating from Methylorubrum extorquens AM1 are subjected to evolutionary pressures to thrive under low methanol conditions. A mutation in the phosphoribosylpyrophosphate synthetase gene is identified, which converts it into a metabolic valve. This valve redirects limited C1-carbon resources towards the synthesis of biomass by up-regulating a non-essential phosphoketolase pathway. These newly acquired bacterial traits demonstrate superior colonization capabilities, even at low abundance, leading to increased growth of inoculated plants. This function is prevalent in Methylobacterium/Methylorubrum strains. In summary, our findings offer insights that could guide the selection of Methylobacterium/Methylorubrum strains for advantageous agricultural applications.

59 BASIC BIOLOGICAL SCIENCES↗

Stellarators as a fast path to fusion

Herein this paper is focused on three points: (1) overcoming obstacles to tokamak power plants may require a configuration modification as large as that of a stellarator. (2) The demonstrated reliability of the computational design of stellarators should change fusion strategy. (3) Deployment of carbon-free energy sources is mandated by the thirty-year doubling of carbon dioxide emissions. Carbon-free energy options must be developed and fully deployed within a few doubling times. Unit size and cost of electricity are only relevant in comparison to alternative worldwide energy solutions. Intermittency, site specificity, waste management, and nuclear proliferation make fusion attractive as the basis for a carbon-free energy system compared to the alternatives. Nonetheless, fusion is not an option for deployment until a power plant has successfully operated. A critical element in a minimal time and risk program is the use of computational design as opposed to just extrapolation. Only the stellarator has an empirical demonstration of the reliable computational design through large changes in configuration properties and scale. The computational design of stellarators should proceed while the inventions necessary for a more tokamak-like power plant are sought. The cost of computational design is extremely small, but adequate time is required for the development of ideas that maximize attractiveness and minimize risk. Rapid power-plant construction without many intermediate steps may seem risky, but the price is small compared to the cost of trillions of dollars for each year's delay in addressing carbon-dioxide emissions.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Develop a Simulation Framework for Understanding Physico-Chemical Processes and Optimization of CHZ' Plastic Thermolyze Technology (CRADA Final Report)

Thermolyzer(TM) technology is a third-generation, multi-reactor, oxygen-free, low pressure, slow pyrolysis process. It has proven to be remarkably versatile in successfully processing all types of hydrocarbon waste. These include all seven types of plastics, tires, auto shredder residue, carpet, electronic waste, and composites. Working with the IACMI, Thermolyzer(TM) technology has recovered the glass and carbon fibers from wind turbine blades for reuse into new applications. Its primary output is a synthesis gas that is rich in H 2 , CH 4 , and small amounts of C 2-4 aliphatic hydrocarbons. Other components are CO and CO 2 . Three unique features set Thermolyzer(TM) apart from other pyrolysis systems: the syngas is clean enough to run in Siemens or Solar gas turbines or IC engines without fouling, clean, salable, byproducts are produced, and CO 2 emissions are lower than natural gas power plants. Research results have been obtained from an operating 7 ton/day facility. A 44 ton/day plant has successfully operated as noted above. The process works because it makes use of the recoverable embodied energy in the feedstock. Surprisingly, a pound of some plastics has the same recoverable energy content as a pound of gasoline. Thus, it is imperative to develop a process that economically converts scrap plastics (including ocean plastics) into energy and thereby conserve the non-renewable fossil fuels for future generations. The Thermolyzer(TM) technology can also be used to create liquid fuels like gasoline and diesel from hydrocarbon wastes. Because of the high hydrogen content of the synthesis gas, hydrogen can be recovered more inexpensively than the current solar or wind energy being used to electrolyze water. That hydrogen can be used for fuel cell powered vehicles or converted into ammonia for agriculture or as a hydrogen storage medium. Extension of this technology to other wastes such as tires, auto shredder residue or wood wastes would expand the circular economy.

36 MATERIALS SCIENCE↗

Sludge Removal: Success and Partnership with T Plant - 20510

U.S. DOE contractor CH2M Hill Plateau Remediation Company (CHPRC) has safely and efficiently managed the removal of highly radioactive sludge from the 105-K West Reactor fuel storage basin (105- KW Basin) near the Columbia River. In mid-September 2019, sludge retrieval was completed after 21 storage containers were safely loaded with highly radioactive sludge and transported approximately 13 miles from the 105-KW Basin to T Plant, located in the 200 West Area on the Central Plateau of the Hanford Site. Sludge removal represents the last major source term reduction necessary before the K West Reactor and fuel storage basin can transition to closure activities in preparation for final deactivation and demolition. The technical complexity of the sludge retrieval process, coupled with the challenging physical and radiological characteristics of the waste, necessitated a methodical and deliberate approach using unique design and operational solutions to safely conduct the work. This challenge was further complicated by the need to plan and conduct the work in two separate facilities, each subject to the controls and requirements of its own nuclear facility safety basis. The project overcame these challenges through creating an integrated team that actively engaged, communicated and coordinated each phase of the project to ensure successful completion. This paper will cover how these key elements of the Sludge Removal Project led to its success: - Integrating project planning and management; - Lessons learned from design and construction; - Preparing for a successful campaign (lessons learned from testing and start-up); - Lessons learned from operating in two separate facilities, transporting sludge containers on the Hanford Site and ensuring compliance with a range of regulatory and safety basis requirements. The establishment of an integrated group spanning two facilities and multiple organizations created a team capable of overcoming the challenges necessary to successfully plan and execute the sludge retrieval mission. Sharing lessons learned from this successful project can enhance the ability of teams across the DOE complex to successfully plan and execute complex projects. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Enhancement of Carbon Capture Reactor Performance (Final Technical Report)

Significant challenges are still present in post-combustion CO 2 capture and new technologies and advanced components are needed to significantly advance the deployment of CO 2 capture for natural gas combined cycle (NGCC) plants. Critical elements of CO 2 capture that still need to be addressed include how to increase CO 2 mass transfer in the absorber column with liquid to gas ratios of <1.2, while reducing the size of the absorber column to reduce capital costs. Research involving chemical mechanism with design, synthesis, and assembly of materials with targeted functionally were combined with advanced additive manufacturing techniques towards development of enhanced CO 2 capture reactors that can lead to safe, reliable, and low-cost carbon capture technologies. The objective of the project was to develop and test novel carbon capture materials and reactor components that contribute to increased CO 2 mass transfer through increased turbulent gas-liquid interface and improved solvent wetting within the absorber. A technoeconomic analysis (TEA) was completed showing how the proposed technology decreases capital costs by reducing the size of the absorber column and the amount of packing required for high CO 2 capture rates. A technology maturation plan (TMP) was also developed to describe the current technology readiness levels (TRL) and outline additional research and development (R&D) needed to further develop these advanced components for NGCC CO 2 capture plants. The successful completion of this project has shown a pathway to reduce the absorber size and associated construction costs of post-combustion NGCC CO 2 capture systems at 97% capture and promote the utilization of abundant natural gas for production of reliable electricity.

20 FOSSIL-FUELED POWER PLANTS↗

Pollution to products: recycling of ‘above ground’ carbon by gas fermentation

Climate crisis and rapid population growth are posing some of the most pressing challenges to mankind and have intensified the need for the deployment of carbon recycling and carbon capture and utilization (CCU) technologies. Gas fermentation offers a solution using carbon-fixing chemolithoautotrophic microorganisms. After a decade of scale up, the technology has recently been commercialized with the first plant operating successfully since 2018 and additional units under construction. Gas fermentation offers unique feedstock and product flexibility when compared to other available gas-to-liquid technologies. Advancements in process technology and synthetic biology enable a broad range of feedstocks including emissions from industry or syngas generated from any biomass resource to be converted into a wide range of molecules realizing a circular economy.

09 BIOMASS FUELS↗

Molecular and biochemical characterization of rice developed through conventional integration of nDart1-0 transposon gene

Mutations, the genetic variations in genomic sequences, play an important role in molecular biology and biotechnology. During DNA replication or meiosis, one of the mutations is transposons or jumping genes. An indigenous transposon nDart1-0 was successfully introduced into local indica cultivar Basmati-370 from transposon-tagged line viz., GR-7895 (japonica genotype) through conventional breeding technique, successive backcrossing. Plants from segregating populationsshowed variegated phenotypes were tagged as BM-37 mutants. Blast analysis of the sequence data revealed that the GTP-binding protein, located on the BAC clone OJ1781_H11 of chromosome 5, contained an insertion of DNA transposon nDart1-0. The nDart1-0 has “A” at position 254 bp, whereas nDart1 homologs have “G”, which efficiently distinguishes nDart1-0 from its homologs. The histological analysis revealed that the chloroplast of mesophyll cells in BM-37 was disrupted with reduction in size of starch granules and higher number of osmophillic plastoglobuli, which resulted in decreased chlorophyll contents and carotenoids, gas exchange parameters (Pn, g, E, Ci), and reduced expression level of genes associated with chlorophyll biosynthesis, photosynthesis and chloroplast development. Along with the rise of GTP protein, the salicylic acid (SA) and gibberellic acid (GA) and antioxidant contents(SOD) and MDA levels significantly enhanced, while, the cytokinins (CK), ascorbate peroxidase (APX), catalase (CAT), total flavanoid contents (TFC) and total phenolic contents (TPC) significantly reduced in BM-37 mutant plants as compared with WT plants. These results support the notion that GTP-binding proteins influence the process underlying chloroplast formation. Therefore, it is anticipated that to combat biotic or abiotic stress conditions, the nDart1-0 tagged mutant (BM-37) of Basmati-370 would be beneficial.

60 APPLIED LIFE SCIENCES↗

Aridity and forest age mediate landscape scale patterns of tropical forest resistance to cyclonic storms

Abstract Cyclonic storms, or hurricanes, are expected to intensify as ocean heat energy rises due to climate change. Ecological theory suggests that tropical forest resistance to hurricanes should increase with forest age and wood density. However, most data on hurricane effects on tropical forests come from a limited number of well‐studied long‐term monitoring sites, restricting our capacity to evaluate the resistance of tropical forests to hurricanes across broad environmental gradients. In this study, we assessed whether forest age and aridity mediate the effects of hurricanes Irma and Maria in Puerto Rico, Vieques and Culebra islands. We leveraged functional trait data for 410 tree species, remotely sensed measurements of canopy height and cover, along with data on forest stand characteristics of 180 of 338 forest monitoring plots, each covering an area of 0.067 ha. The plots represent a broad mean annual precipitation (MAP) gradient from 701 to 4598 mm and a complex mosaic of forest age from 5 to around 85 years since deforestation. Hurricanes resulted in a 25% increase in basal area mortality rates, a 45% decrease in canopy height and a 21% reduction in canopy cover. These effects intensified with forest age, even after considering proximity to the hurricane path. The links between forest age and hurricane disturbances were likely due the prevalence of tall canopies. Tall forest canopies were strongly linked with low community‐weighted wood density (WD). These characteristics were on average more common in moist and wet forests (MAP >1250 mm). Conversely, dry forests were dominated by short species with high wood density (WD > 0.6 g cm −3 ) and did not show significant increases in basal area mortality rates after the hurricanes. Synthesis . Our findings show that selection towards drought‐tolerant traits across aridity gradients, such as short stature and dense wood, enhances resistance to hurricanes. However, forest age modulated responses to hurricanes, with older forests being less resistant across the islands. This evidence highlights the importance of considering the intricate links between ecological succession and plant function when forecasting tropical forests’ responses to increasingly strong hurricanes.

Vargas G., German↗

Development of Spouting Bed Reactor for Reduction of Hematite to Magnetite (Final Report)

This project was designed to leverage both past and current technology development efforts and utilize the expertise of the National Energy Technology Laboratory (NETL) in a collaborative effort with SIOX for the development of a spouting bed reactor to produce magnetite from very fine hematite waste. More specifically, the effort involved the conversion of a steel manufacturing byproduct, iron oxide hematite (Fe 2 O 3 ), and reduces it chemically into a salable magnetite product applicable to a number of markets. SIOX previously operated a magnetite batch production facility based on a rotary kiln reactor process. Unfortunately, that process was both costly and inefficient, making it difficult to achieve desired economies, purity, and throughput levels. NETL’s technology, developed in this work, replaced the batch inefficient rotary kiln with a continuous spouting bed reactor capable of producing synthetic magnetite products. In the project, NETL was to develop the spouting bed for the SIOX application and SIOX was to construct and operate a fully integrated pilot scale demonstration plant. NETL successfully completed its tasks, but SIOX due to financial issues was not able to complete their tasks. They have chosen not to participate in this final report so for their tasks a short summary of NETL’s knowledge of their efforts is included.

36 MATERIALS SCIENCE↗

Demonstration of In Situ Down Blending During ZIRCEX Process

The Material Recovery Pilot Plant has successfully demonstrated in situ down-blending of HEU fuel to support INL’s commitment to HALEU production technologies. Depleted uranium pellets, along with an HEU fuel piece were placed in the hydrochlorinator and subsequently declad and oxidized. UOx product was recovered, analyzed, and demonstrated to have reduced enrichment within the targeted range of 20 – 30 % U-235. This first attempt at in situ down-blending will be followed by continued process refinement over the remaining fuel operations at MRPP.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

One-Step Regeneration of Hairy Roots to Induce High Tanshinone Plants in Salvia miltiorrhiza

Salvia miltiorrhiza is a traditional Chinese medicinal plant of Labiatae, which has been widely utilized to treat a variety of cardiovascular and cerebrovascular diseases. However, due to the long growth cycle, low content of active ingredients, and serious quality deterioration of S. miltiorrhiza , the use of biotechnology to improve S. miltiorrhiza to meet the growing demand for clinical applications has become a research hotspot. In this study, a novel one-step hairy root regeneration method was developed, which could rapidly obtain hairy roots and regenerated plants with high tanshinone content. By optimizing the parameters of Agrobacterium rhizogenes transformation in S. miltiorrhiza , it was finally established that the explants were infected in Ar.qual (OD 600 = 0.6) for 10 min, co-cultured for 3 days, and then screened on the screening medium containing 7.5 mg/l hygromycin, the maximum transformation frequency can reach 73.85%. GFP and PCR detection yielded a total of 9 positive transgenic hairy root lines and 11 positive transgenic regenerated plants. SmGGPPS1 was successfully overexpressed in positive transgenic regenerated plants, according to the results of qRT-PCR. The content of tanshinone IIA and cryptotanshinone were dramatically enhanced in transgenic regenerated plants and hairy roots by Ultra Performance Liquid Chromatography analysis. Based on the Agrobacterium-mediated transformation of S. miltiorrhiza , this study developed a new method for regenerating plants with transgenic hairy roots. This method provides a foundation for the breeding of S. miltiorrhiza and the sustainable development of medicinal plant resources, as well as provides a useful reference for the application of other species.

Su, Yuekai↗

Expansion of high-latitude deciduous forests driven by interactions between climate warming and fire: Modeling Archive

This Modeling Archive is in support of an NGEE Arctic publication. More information in the related references. The dataset is a model (ecosys) output used in a study that examined the potential future shifts in high-latitude vegetation types (PFTs) driven by changes in 21st century climate and fire. The study highlights the importance of mechanistically representing differences in plant functional traits on current and possible 21st century trajectories of Alaskan PFTs. This dataset package includes 13 files in pdf, csv, and nc formats.The Next-Generation Ecosystem Experiments: Arctic (NGEE Arctic), was a research effort to reduce uncertainty in Earth System Models by developing a predictive understanding of carbon-rich Arctic ecosystems and feedbacks to climate. NGEE Arctic was supported by the Department of Energy's Office of Biological and Environmental Research.The NGEE Arctic project had two field research sites: 1) located within the Arctic polygonal tundra coastal region on the Barrow Environmental Observatory (BEO) and the North Slope near Utqiagvik (Barrow), Alaska and 2) multiple areas on the discontinuous permafrost region of the Seward Peninsula north of Nome, Alaska.Through observations, experiments, and synthesis with existing datasets, NGEE Arctic provided an enhanced knowledge base for multi-scale modeling and contributed to improved process representation at global pan-Arctic scales within the Department of Energy's Earth system Model (the Energy Exascale Earth System Model, or E3SM), and specifically within the E3SM Land Model component (ELM).

54 ENVIRONMENTAL SCIENCES↗

Advanced Models and Fast Simulation Algorithms for MARS Plants

With the successful commercialization of modular multilevel converters (MMC) and rapid increase in photovoltaic (PV) penetration and energy storage systems (ESS), one of the research areas being explored dynamically is integration of PV systems and ESS systems to MMCs. On this front, an integrated development of PV plants, ESS, and alternating- and direct-current (ac/dc) systems through Multi-Port Autonomous Reconfigurable Solar (MARS) plant is proposed and being researched upon. However, simulation of MARS systems on traditional existing software takes very long time (order of days) due to the presence of a large number of states and non-linear devices. Therefore, development of fast high fidelity models is of paramount importance to test the hardware design, control design and planning of power system expansions. In this context, two research objectives are addressed in this paper: firstly, an ultra fast single- or multi- CPU simulation algorithm to simulate the MARS system based on state-space models, hybrid discretization algorithm with a relaxation technique that reduces the imposed computational burden and a multi-rate method is presented. Secondly, a reduced order model of MARS is also presented. Both the developed techniques are validated with respect to reference PSCAD/EMTDC model.

Marthi, Phani Ratna Vanamali↗

Towards the scale-up production of cellulose nanocomposites using melt processing: A critical review on structure-processing-property relationships

Cellulose nanomaterials (CNMs) naturally exist in plant biomass. The success of extraction of CNMs opened up a new era of using plant biomass for innovative industrial applications. Because CNMs are abundant, renewable, biodegradable, transparent, light weight and low in cost, they are ideal materials for large volume applications such as packaging, automotive, building and infrastructure. In many potential application areas, CNM-enable products appear in a composite form, mostly polymer composites. Additionally, the industrial-scale manufacturing of CNM/thermoplastic composites remains as a set of unsolved problems for academia and industry. A prime challenge in applications is the nanoscale dispersion of CNMs in thermoplastic matrices during melt processing. Both bench-scale and pilot-scale studies have been conducted to solve the dispersion issue of CNMs. In this article, research related to the dispersion of CNMs in thermoplastic matrices during melt processing were critically reviewed. All research papers were classified into three groups: chemically-aided dispersion, physically-aided dispersion and mechanically-aided dispersion. Numerous factors affect the CNM dispersion and the mechanical performance of its nanocomposites. There are material-related factors, including CNM types and forms, polymer matrices, surface modification, coupling agents, etc. Furthermore, extrusion processing parameters also play a significant role, covering screw rotation speed, extrusion barrel temperature settings and screw design. In addition, the material-related factors interact with the processing-related factors. Understanding all factors and their interactions are important for moving CNM nanocomposites research a step further towards industrial-relevant production, which is the final ambitious goal of this manuscript.

42 ENGINEERING↗