Search NASA⌕ Search

SEARCH · Search NASA

Results for “operating envelopes”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Editors’ Choice—Flooded by Success: On the Role of Electrode Wettability in CO 2 Electrolyzers that Generate Liquid Products

Economic operation of carbon dioxide (CO 2 ) electrolyzers generating liquid products will likely require high reactant conversions and product concentrations, conditions anticipated to challenge existing gas diffusion electrodes (GDEs). Notably, electrode wettability will increase as lower surface tension products (e.g., formic acid, alcohols) are introduced into electrolyte streams, potentially leading to flooding. To understand the hydraulically stable operating envelopes in mixed aqueous-organic liquid domains, we connect intrinsic electrode wettability descriptors to operating parameters such as electrolyte flow rate and current. We first measure contact angles of water-organic product dilutions on polytetrafluoroethylene (PTFE) and graphite surfaces as planar analogues for GDE components. We then use material balances around the reactive gas-liquid-solid interface to calculate product mass fractions as functions of water sweep rate and current. Product composition maps visualize the extent to which changes in cell performance influence capillary pressure, a determinant of GDE saturation. Analyses suggest that formic acid mixtures pose little risk for GDE flooding across a wide range of conditions, but effluents containing <30% alcohol by mass may cause flooding. This study reveals opportunities to integrate microstructural features and oleophobic surface treatments into GDEs to repel aqueous-organic mixtures and expand the window of stable operating conditions.

25 ENERGY STORAGE↗
DOE OSTI2026

Artificial Intelligence-Driven Management of Sustainable Energy Resources: Visibility, Operation, and Control

The rapid global transition toward sustainable energy resources (SERs) is reshaping how modern power systems are observed, optimized, and controlled. While SERs have significantly advanced decarbonization, their weather dependence, variability, and inverter-dominated characteristics challenge traditional, centralized, and deterministic grid operation. At the same time, the proliferation of high-resolution data from inverters, smart meters, and sensors offers unprecedented visibility into system dynamics. Yet, it also exceeds the analytical capability of conventional model-based approaches. Artificial intelligence (AI) provides a new foundation for addressing these challenges by bridging physical laws with data-driven learning, enabling accurate state awareness, adaptive operation, and coordinated control across distributed assets. This article examines how AI transforms the management of SER-rich power systems along three critical dimensions: 1) enhancing visibility by inferring behind-the-meter (BTM) activities, assessing SER flexibility, and reconstructing system states from sparse or noisy measurements; 2) improving operation through AI-enhanced SER service provision, volt/var control (VVC), and dynamic operating envelopes (DOE) for efficiency and security; and 3) advancing control by embedding learning-based intelligence into inverter coordination, voltage and frequency regulation, and long-term dispatch. Together, these developments reveal how AI can convert the variability of SERs from an operational challenge into a source of flexibility, resilience, and intelligence, paving the way toward sustainable, adaptive, and self-optimizing power systems.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2026

Online and Offline Analytical Techniques to Quantify Chloride Salts

This report serves as the deliverable for Milestone- M3FT-26AN080502017: Summary of Accomplishments for Online and Offline Analytical Qualification of Chloride Fuel Salts. The qualification of chloride fuel salts is a critical challenge for the development and deployment of molten salt reactors (MSRs), requiring precise control and verification of chemical and isotopic composition to ensure predictable neutronics, manageable radiological behavior, and safe plant operation. Currently, there is no universally accepted standard for fuel salt qualification, particularly for chloride-based systems, which underscores the need for robust, science-based analytical methodologies. This report presents a comprehensive evaluation of both online and offline techniques for quantifying chloride fuel salts, including multielectrode array voltammetry, differential thermal analysis (DTA) probes, inert gas fusion (IGF) analyzers, and gamma spectrometry using the Mirion NAIS-2x2 NaI(Tl) detector. The integration of these methods enables real-time monitoring of actinide concentrations, redox state, and thermophysical properties, as well as high-precision measurement of impurities and isotopic composition. The acquisition of advanced instruments such as the Bruker Leonardo G6 for IGF and the Mirion NaI detector enhances analytical capabilities, supporting the establishment of operational envelopes and impurity thresholds. These approaches provide essential data for neutronic impact evaluation, feedstock documentation, and compliance with nuclear safety standards. The methodologies developed and validated in this report lay the groundwork for future standardized protocols, bridging the gap between laboratory research and commercial reactor operation, and advancing the safe and efficient deployment of chloride-fueled MSRs.

Polke, Amber↗
DOE OSTI2022

Use of Operating Agreements and Energy Storage to Reduce Photovoltaic Interconnection Costs: Technical and Economic Analysis

This report presents an analytical methodology to identify alternative options to manage interconnection costs and streamline interconnection timelines for distribution system-connected photovoltaic (PV) systems not co-located with load. Specifically, the report details the methodology and results of an analysis that: 1. Identifies potential grid violations that would be induced by a PV system requesting interconnection to a distribution circuit; 2. Identifies multiple technically viable options for mitigating the potential violations, including infrastructure upgrades, downsizing the PV system size, curtailment of PV, and addition of battery energy storage; 3. Defines the required technical operating parameters of the system in order to mitigate all potential violations (the "Operating Envelope"); 4. Compares the economics of each option, from the PV developer's perspective. The analysis supports the ongoing evolution of interconnection standards for combined PV and energy storage systems by providing a methodology to define allowable maximum export limits during each hour. The methodology presented could be used by utilities as part of the interconnection study process, to inform negotiations with DER developers and the drafting of mutually acceptable interconnection agreements. The resulting technical operating parameters could be included as part of the interconnection service agreement (ISA) between the system owner and the utility company. The companion report to this analysis, Gill et al. (2022), details the envisioned framework for the implementation of the technical operating parameters.

14 SOLAR ENERGY↗
DOE OSTI2022

FOULING MITIGATION FOR LASER IGNITERS IN NATURAL GAS ENGINES

Due to several recent developments in lasers and optics, laser igniters can now be designed to be (i) compact so as to have the same footprint as a standard spark plug, (ii) have low power draw, usually less than 50 Watts, and (iii) have vibration and temperature resistance at levels typical of reciprocating engines. Primary advantages of these laser igniters remain (i) extension of lean or dilution limits for ignition of combustible mixtures, and (ii) improved ignition at higher pressures. Recently, tests performed in a 350 kW six-cylinder stationary natural gas reciprocating engine retrofitted with these igniters showed an extension of the operational envelope to yield efficiency improvements of the order of 2.6% points while being compliant with the mandated emission regulations. Even though laser igniters offer promise, fouling of the final optical element that introduces the laser into the combustion chamber is of concern. After performing a thorough literature search, a test plan was devised to evaluate various fouling mitigation strategies. The final approach that was used is a combination of three strategies and helped sustain an optical transmissivity exceeding 98% even after 1500 h of continuous engine operation at 2400 rpm. Based on the observed trend in transmissivity, it now appears that laser igniters can last up to 6000 h of continuous engine operation in a stationary engine running at 1800 rpm.

spark ignited engines, laser ignition, natural gas↗
DOE OSTI2026

Optimization of the FRIB beam dump: a hybrid genetic algorithm and reinforcement learning approach

The operational envelope of high-power-density systems, such as particle accelerators and advanced nuclear energy systems, is critically constrained by the need to manage extreme thermal loads. To address this, we present a novel hybrid optimization framework combining a genetic algorithm (GA) with a soft actor-critic (SAC) deep reinforcement learning agent. This framework was applied to a practical high-heat-flux problem: redesigning the beam dump at the Facility for Rare Isotope Beams (FRIB) for a power upgrade from 20 kW to 50 kW. The resulting design, validated by three-dimensional conjugate heat transfer simulations, suppresses hazardous hot spots and yields a markedly more uniform temperature distribution. This provides a robust operating margin, increasing the average power-handling capability by 72% relative to the current design, demonstrating the framework’s potential to solve complex thermal management challenges in both accelerator technology and advanced nuclear systems.

Accelerator↗
DOE OSTI2025

Enhancing EnergyPlus capabilities to model dynamic building envelopes using python plugin

Nearly half of the energy consumption in the United States is related to buildings, resulting in an urgent need to develop innovative technologies to improve building energy efficiency. Dynamic building envelopes, comprising switchable insulation and thermal energy storage materials, have been proposed recently as a promising solution to reduce buildings' heating and cooling loads by thermally coupling the indoor environment with the ambient environment when beneficial while decoupling them when outdoor conditions are not favorable. Although various related technologies are still underway, the whole-building energy modeling tools, like EnergyPlus, do not have the capability to simulate the transient and dynamic nature of dynamic envelope materials and components to accurately predict their impact on building energy use. The objective of this study is to formulate a method in EnergyPlus simulation engine to model multilayer envelopes, comprising dynamic building materials with variable thermophysical properties, and discuss the changes made to the program using a Python plugin. Furthermore, the thermal performance of the dynamic envelopes using the proposed method is compared and verified with the results from a well-established commercial code, COMSOL Multiphysics. A parametric assessment is also conducted to evaluate the energy efficiency benefits of dynamic envelopes in a single-family residential building, demonstrating total annual energy savings up to 11.6 %, when a dynamic envelope operates alone, and up to 18.2 % when it is combined with a thin layer of phase change material as a thermal storage medium. Finally, a United States wide energy efficiency assessment is presented to showcase the geographical spread of the energy savings. The method designed and implemented in this study provides the researchers with the ability to implement their dynamic insulation methods in EnergyPlus and evaluate the whole building energy impact.

25 ENERGY STORAGE↗
DOE OSTI2024

Design of Mini-Plate-1 Irradiation Test for Qualification of High-Density, Low-Enriched U-10Mo Monolithic Fuel

The United States High Performance Research Reactor project is tasked with fuel development and qualification leading to conversion of higher power research and test reactors in the US from high-enriched uranium (HEU) to low-enriched uranium (LEU) fuels. Here, this manuscript identifies the functional and operational design requirements of the first miniature test plate (mini-plate [MP]) irradiation campaign (MP-1) of commercially fabricated LEU U-10Mo monolithic plate-type fuel and is the precursor to a large parametric mini-plate test (MP-2) aimed at producing the data to support regulatory qualification of the LEU U-10Mo monolithic fuel. The manuscript (1) provides a general description of the selected U-10Mo LEU fuel and (2) defines the overall experiment design and functional requirements to accomplish the specific test objective of MP-1, which is to confirm that the commercially manufactured LEU U-10Mo monolithic fuel meets the established requirements of geometric stability, mechanical integrity and stable and predictable behavior. The fuel testing parameters are established by the need to bound performance behavior within the operational envelope of the reactors being converted.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Reactor and fuel cycle performance of light water reactor fuel with 235 U enrichments above 5%

Recent advances in nuclear fuel materials research, particularly on the topic of accident-tolerant fuels, have brought up potential opportunities for expanding the operating envelope of existing light water reactors. As many of the performance improvements offered by these technologies may be most fully realized by increasing fuel enrichment beyond the standard 5% limit, this paper examines the potential reactor performance and fuel cycle performance of low-enriched uranium oxide fueled light water reactors by generically considering pressurized water reactors with 235 U enrichment from 5 to 7%. Advanced cladding, including accident-tolerant cladding, has the potential to increase fuel burnup limits related to hydrogen in the cladding that coincide with those limits associated with end-of-life reactivity. Therefore, higher enrichment will be necessary in order to realize the higher fuel burnups. This work includes evaluation of the fuel cycle length, discharge burnup, reactivity coefficients, and fuel cycle performance, including radioactive waste and environmental impact metrics per unit energy generated. The analysis was performed using the evaluation metrics from the US Department of Energy Office of Nuclear Energy Fuel Cycle Evaluation and Screening Study. The reactor performance and safety analysis show that enrichments between 5 and 7% would have similar fuel temperature and moderator temperature coefficients. However, the soluble boron coefficient would decrease in magnitude, requiring more corrosive boric acid in the coolant or other methods of reactivity control during the fuel cycle. At these higher enrichments the maximum burnup at the rim of the fuel pellet would increase by almost a factor of two, which is expected to impact the formation of high-burnup structure in the fuel and the corresponding thermo-mechanical fuel properties. The fuel cycle performance assessment shows that increasing enrichment reduces the quantity of high-level waste disposed per unit energy generated, but it increases the natural resource requirements normalized to a gigawatt-electricity-per-year basis. Another impact is the slightly higher discharge burnup, resulting in somewhat different activity levels of the spent nuclear fuel and high-level waste radioactivity at 100 and 100,000 years after fuel discharge. The environmental impacts—including land use, water use, carbon emission, and radiological exposure—are of the same magnitude per unit energy generated. Finally, however, the impacts are distributed differently. Less than 5% enrichment has marginally more impact on the back-end of the fuel cycle, and greater than 5% enrichment has marginally more impact on the front-end of the fuel cycle. Ultimately, no neutronic or reactor safety hindrances to employing light water reactor fuel with enrichments greater than 5% are identified; given the achievable reactor performance benefits with advanced fuels, further practical exploration of increased enrichment fuel is recommended.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Pressure drop and heat transfer characteristics of nitrate salt and supercritical CO 2 in a diffusion-bonded heat exchanger

A lab-scale 316/L stainless steel diffusion-bonded heat exchanger was examined within a coupled high-temperature test facility consisting of an atmospheric-pressure nitrate salt loop and a supercritical carbon dioxide (sCO 2 ) loop operating between 10 and 16 MPa. Pressure loss measurements collected for flow rates up to 0.55 kg/s of Solar Salt and up to 0.6 kg/s of carbon dioxide were used to generate friction factor correlations for the respective circular and semicircular zig-zag flow passages. Heat transfer measurements were also performed over a wide range of conditions to produce Nusselt correlations for the CO 2 and nitrate salt geometries. The Nusselt number is deduced from a heat transfer resistance network and overall conductance measurements collected across the operating envelope of the coupled sCO 2 – nitrate salt test facility. The CO 2 side correlation showed excellent agreement with existing correlations in the literature. Further, the salt side, having nearly circular channels with a different zig-zag angle and hydraulic diameter, yielded a new correlation applicable to the laminar flow regime. To examine the similitude of the friction correlations, pressure drop testing with water was performed on both sides of the component as well. Finally, results from non-destructive examination are discussed to provide insights regarding inspection methods and draining performance of high-temperature liquids in compact heat exchangers.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Integrated system to reduce emissions from natural gas-fired reciprocating engines

Natural gas-fired reciprocating engines (NGFRE), which are naturally aspirated are used in the oil and gas industry for the production, storage, processing, and transmission of natural gas extracted from wells. These stationary, lean-burn engines exhibit increased combustion instability and higher emissions of methane (CH 4 ) and Volatile Organic Compounds (VOCs) at lower loads, resulting in restrictions on the operational envelope of such engines. Here, in this paper, some of the emission reduction technologies for NGFREs are reviewed. Also, an experimental investigation of an integrated system to reduce emissions and improve the combustion performance of an NGFRE is presented. The integrated system consists of an air management package and integrated sensors including an amperometric NOx/O 2 sensor, exhaust temperature thermocouple, pressure transducers and vibration sensors. Experiments were carried out using natural gas and natural gas/propane blends at different load steps, and combustion performance, as well as emissions, were analyzed. For natural gas fuel, the results show that the standard deviation of peak pressure and indicated thermal efficiency (ITE) improved by 67.4 psi and 4.2% respectively, at 40% load. Similarly, CH 4 and Nitrogen Oxides (NOx) emissions reduced considerably by 84% and 63% respectively. However, CO emissions increased from 8 ppm to 152 ppm. At 60% load, the ITE improved by 3.8% and the CH 4 emissions were reduced by 68%. The reduction in VOCs emissions was 63% at 40% load and 69% at 60% load. The findings of this research provide evidence of the effectiveness of the integrated air management system in improving the sustainability of NGFREs. In general, this technology can be implemented on air-assisted combustion applications to improve combustion performance and, consequently, reduce emissions.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Design of a novel carbon/carbon composite microvascular solar receiver

Solar thermal power tower systems are the primary technology being proposed for solar electricity from thermal energy. Operational limits on these towers are often driven by mechanical properties under significant thermal loads, particularly at the receiver where incoming flux is converted to thermal energy. While the solar receiver’s efficiency is largely driven by its optical properties, thermomechanical stresses on the receiver limits the operational envelope. One pathway to higher efficiency is greater allowable solar fluxes on the receiver but novel materials are required. The present study uses computational fluid dynamics to describe a parametric design space for a microvascular carbon/carbon composite solar receiver as a new material option for high flux solar receivers. Simulations are conducted for different microvascular geometries considering the role of material properties and heat transfer fluids, for the impact on thermal efficiency, and allowable strain. Results show that microscale receiver modules made of the proposed carbon/carbon composite could achieve thermal efficiencies over 90% and full-scale receivers can achieve up to 85% thermal efficiency for the design explored considering realistic strain limits, flux levels, and material properties. These values are highly dependent on the heat transfer fluid pairing, the through plane thermal conductivity of the carbon/carbon composite, the path architecture of the microscale receiver, and the incident solar flux profiles.

14 SOLAR ENERGY↗
DOE OSTI2022

Design of an Additively Manufactured Recuperator With 800 °C Inlet Temperature for sCO2 Power Cycle Application

Abstract Recuperators with design temperatures at and above 800 °C can further increase the thermal efficiency of supercritical CO2 power cycles by enabling higher turbine exhaust temperatures. Mar-M247 is a well-suited nickel-based superalloy for high temperature service due to its high creep strength that prevents excessive material thickness being required for pressure containment. Additive manufacturing using a high-speed laser-directed energy deposition (L-DED) process presents a promising solution, with build trials demonstrating the ability to produce nonconventional flow channels for enhanced heat transfer. A design process is presented that includes aerothermal and mechanical evaluation to maximize performance within the constraints of the manufacturing process. A 2-D heat transfer network and pressure drop code allows prediction of flow distribution and its effect on overall thermal performance. Established literature correlations, along with CFD simulation, inform the prediction of heat transfer coefficients and friction factors for the flowpaths and enhancement features in the heat exchanger core. Mechanical evaluation using finite element analysis (FEA) modeling with the intent of the ASME Boiler & Pressure Vessel Code (BPVC) Section VIII, Div. 2 assesses the operational safety of the design. The detailed design features annular finned passages that take advantage of helical flow paths to distribute the flow from separated headers to shared heat transfer surfaces. Performance predictions for the recuperator at a 50 kW scale provide insights into the feasibility of the additively manufactured (AM) process to produce recuperators on a commercial scale that extend existing operating envelopes.

Engineering↗
DOE OSTI2023

Modeling Electrochemical and Rheological Characteristics of Suspension-Based Electrodes for Redox Flow Cells

Flowable suspension-based electrodes (FSEs) have gained attention in recent years, as the integration of solid materials into electrochemical flow cells can offer improved performance and flexible operation. However, under conditions that engender favorable electrochemical properties (e.g., high particle loading, high conductivity, high surface area), FSEs can exhibit non-Newtonian characteristics that impose large pumping losses and flow-dependent transport rates. These multifaceted trade-offs motivate the use of models to broadly explore scaling relationships and better understand design rules for electrochemical devices. To this end, we present a one-dimensional model, integrating porous electrode theory with FSE rheology as well as flow-dependent electron and mass transport under pressure-driven flow. We study FSE behavior as a function of material properties and operating conditions, identifying key dimensionless groups that describe the underlying physical processes. We assess flow cell performance by quantifying electrode polarization and relative pumping losses, establishing generalized property-performance relationships for FSEs. Importantly, we expound relevant operating regimes—based on a subset of dimensionless groups—that inform practical operating envelopes, ultimately helping to guide FSE and cell engineering for electrochemical systems.

25 ENERGY STORAGE↗
DOE OSTI2025

Mapping ammonia-diesel combustion on a single-cylinder 107 mm bore diesel engine retrofitted for ammonia port-fuel injection

Ammonia is garnering significant interest from the international maritime sector as an alternative fuel. It is attractive as a hydrogen carrier and as a fuel because it has a higher volumetric energy density compared with gaseous or liquid hydrogen, making it easier to store and transport without requiring high pressures or cryogenic storage. Ammonia has significant toxicity concerns, but safe handling procedures have already been established because it is one of the most widely produced chemicals worldwide for use as a fertilizer. Barriers to consuming NH 3 as a fuel in engines include (1) less favorable ignition energy and flame speed compared with conventional fuels; (2) emissions challenges, including potentially high NH 3 , NO X , and N 2 O emissions; and (3) fuel delivery and handling challenges. Although NH 3 has been used to fuel compression-ignition marine engines in limited demonstration projects, technical barriers still exist. The use of NH 3 as a fuel in smaller-bore, high-speed auxiliary engines for large vessels and for smaller inland and coastal marine applications remains unaddressed. This work investigates a late-injection diesel pilot ignition dual-fuel NH 3 strategy using a single-cylinder, high-speed Cummins four-stroke diesel engine platform with a 107 mm bore and 1.1 L displacement per cylinder. The engine was modified for port fuel injection of heated gaseous anhydrous NH 3 . The diesel fuel injection system and the combustion geometry were unmodified to represent a retrofit application, which would minimize additional hardware to maximize diesel fuel displacement with NH 3 . Furthermore, the results show the applicability of a late injection diesel pilot strategy to overcome the challenging fuel properties of NH 3 over the engine operating envelope. Mapping results focusing on emissions are presented, and comparisons are made to a conventional diesel combustion baseline.

Ship engines↗
DOE OSTI2025

Micromechanical Properties of the SiC and Pyrolytic Carbon Layers in Tristructural-Isotropic Coated Particles

Tristructural isotropic (TRISO) coated particle fuel was initially developed for high temperature gas cooled reactors (HTGR) and has been proposed for several other advanced reactor concepts. The design of TRISO particles focuses on preventing the release of fission products in normal and off-normal reactor conditions. The particle design features an actinide bearing fuel kernel that is surrounded by three pyrolytic carbon (PyC) layers and a silicon carbide layer (SiC). The mechanical stability of the particle and fission product retention for both metallic and gaseous fission products depend on the SiC layer. Post irradiation examination (PIE) of TRISO fuel from the first two US DOE Advanced Gas Reactor Fuel Development and Qualification Program irradiation campaigns, AGR-1 and AGR-2, had identified a low rate of particles exhibiting cracking in the SiC layer that did not propagate across the SiC layer. While cracking in the SiC is rare for test conditions and particles associated with the AGR program, understanding the stress state and mechanical properties of the SiC and PyC layers related to particle architecture can aid predicting thermomechanical response of TRISO fuel under the prescribed operation envelope and beyond as well as aiding in the development of similar fuel concepts for other advanced reactors. The presented investigation shows the relationship of the mechanical properties and mechanical response (e.g., understanding crack propagation) of the SiC and PyC layers relative to position within the particle. Testing was conducted on the inner and outer PyC layers of TRISO particles to quantify differences in mechanical behavior.

Montoya, Katherine [ORNL] (ORCID:0000000326955086)↗
DOE OSTI2021

Phosgene Neutralization Chemistry for the Explosive Destruction System (EDS)

This report summarizes activities at Sandia National Laboratories as part of the Explosive Destruction System (EDS) Phase 3 (P3) System design. An exploration of chemical neutralization strategies of phosgene was conducted for safe disposal of recovered mortars and M79 1000 lb. bombs filled with carbonyl dichloride "phosgene" or "CG agent" (molecular formula = COCl 2 ). The incumbent strategy utilized aqueous sodium hydroxide was found to be the worst-case scenario, producing enough CO 2 gas that would cause an unacceptable pressure and temperature spike. Several chemical neutralization strategies were evaluated based on criteria set by the operating envelope of the P3 design. In the end, it was determined that a pure solution of N-methyl ethanolamine (MeEA) or 90% monoethanolamine (MEA)(aqueous) provided the best balance reaction profile, cost, and safety.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Low-cost Retrofit Kit for Integral Reciprocating Compressors (IRCs) to Reduce Emissions and Enhance Efficiency

Methane emissions from natural gas engines within the oil and gas industry pose a significant environmental challenge, contributing approximately 34.1 MMTCO2 eq to the total of 239 MMTCO2 eq of methane emissions in 2021, according to the EPA report. In response to this pressing issue, a collaborative effort involving the University of Oklahoma and key industry partners—WAGO Automation, Mid Continental Rental, Elipsa, and Perscient—has resulted in the development of a retrofit kit designed to reduce emissions from integral reciprocating compressors (IRCs), which are integrated compressors and engines. The retrofit kit developed comprises an Air Management System (AMS), Integrated Sensors, and a Cloud-Connected Control Unit with Graphical User Interface (GUI)/Human-Machine Interface (HMI). This solution enhances operational efficiency, reduces emissions, and expands the operational envelope of IRCs in the natural gas industry. The project successfully completed all tasks, including the installation of a full-size IRC at a designated site in Oklahoma, the development of an optimized AMS, integration of sensors, and implementation of a data acquisition system. Significant achievements include a notable reduction in CH 4 emissions, up to 84% at specific loads, and the successful deployment of the retrofit kit in diverse field conditions. The system's capabilities were enhanced through the creation of a feedback control algorithm for the AMS using a correlation matrix illustrating relationships between engine parameters, and the design of a predictive and preventive maintenance platform. The project concluded with the deployment of the entire retrofit kit to another location, confirming its effectiveness in reducing emissions and enhancing IRC performance. The comprehensive solution offers valuable benefits for IRCs, making them invaluable assets in the natural gas industry.

03 NATURAL GAS↗