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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

High-burnup boiling water reactor steady-state operating conditions and fuel performance analysis

The primary operational costs for existing nuclear reactors are plant operation costs, maintenance costs, and fuel costs, all of which are influenced by the materials used and the design of the reactor core. Optimizing core design parameters—including burnup limits and enrichment levels—can lengthen cycles, reduce outages, reduce reload batch fractions and spent fuel storage requirements, and lower maintenance and operating expenses, thereby enhancing economic viability. Furthermore, developing higher-fidelity tools to simulate these parameters enables better identification of the available margin, improves overall plant safety, and improves the understanding a given plant’s responses to accident scenarios. Here, in the US, much of the research and development focus has traditionally been on pressurized water reactors (PWRs), but boiling water reactors (BWRs) comprise approximately one-third of the US reactor fleet. Modeling and simulation advances for BWRs and PWRs—particularly those achieved through the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program—are crucial to the long-term viability of the light–water reactor industry. A key research area of the high burnup and increased enriched fuel initiative is focused on addressing issues related to postulated loss-of-coolant accident (LOCA) scenarios. NEAMS has dedicated significant effort to enhancing tools to better support BWRs. A current focus is showcasing the BWR framework for high-burnup LOCA analysis. This high-fidelity steady-state analysis is a first step toward demonstrating a best-estimate, pin-by-pin high-burnup BWR LOCA analysis to assess full-core cladding rupture behavior for a representative BWR. The objective of this effort is to provide a modeling capability that will help elucidate and provide a best-estimate evaluation for cladding rupture susceptibility in BWRs. This modeling capability could then be used to prevent and/or mitigate cladding ruptures in postulated accident scenarios without penalizing operational parameters. Additionally, the results of this work will help identify strategies for finding additional margins or potentially limiting cladding ruptures through core design optimizations to enable more efficient core designs.

Capps, Nathan [Oak Ridge National Laboratory (ORNL↗

Joining Study for Formed Plate Heat Exchangers (CRADA Final Report)

Plate heat exchangers (PHEs) have been used in numerous industrial applications, such as HVAC systems, power generation, transportation and manufacturing. The performance of plate heat exchangers is frequently undermined by corrosion, fouling, and scaling. These phenomena not only diminish heat transfer efficiency but also lead to increased operational costs, maintenance demands, and reduced equipment lifespan. In this project, the team addressed the widespread challenges of corrosion, fouling, and scaling, and explored alternative material solutions. While commonly used materials like stainless steel and titanium offer notable benefits, they can still experience corrosion under certain operating conditions. The advancement of new materials and surface engineering technologies, such as advanced coating, ceramics, composites materials, and high entropy alloys are promising for can help solve these issues, enable longer lifetime and high performance of plate heat exchangers.

99 GENERAL AND MISCELLANEOUS↗

Joining Study for Formed Plate Heat Exchangers (Final Report)

Plate heat exchangers (PHEs) have been used in numerous industrial applications, such as HVAC systems, power generation, transportation and manufacturing. The performance of plate heat exchangers is frequently undermined by corrosion, fouling, and scaling. These phenomena not only diminish heat transfer efficiency but also lead to increased operational costs, maintenance demands, and reduced equipment lifespan. In this project, the team addressed the widespread challenges of corrosion, fouling, and scaling, and explored alternative material solutions. While commonly used materials like stainless steel and titanium offer notable benefits, they can still experience corrosion under certain operating conditions. The advancement of new materials and surface engineering technologies, such as advanced coating, ceramics, composites materials, and high entropy alloys are promising for can help solve these issues, enable longer lifetime and high performance of plate heat exchangers.

36 MATERIALS SCIENCE↗

Interparticle Characterization of Mechanical Biomass Particle-Particle and Particle-Wall Interactions

The biomass materials industry faces significant challenges in managing material variability and its impact on storage and handling systems. Physical properties such as moisture content, particle size, and density fluctuate considerably, leading to operational issues like bridging and ratholing that disrupt material flow. These variations create a complex cascade effect throughout the process chain, affecting transportation, storage, and conversion processes. The economic consequences of this variability manifest in increased operational costs, maintenance requirements, and system downtime. Environmental factors further complicate the situation, as weather conditions and seasonal availability influence material properties and system performance. Engineers employ specialized equipment design, material characterization protocols, and pre-processing steps like size reduction and homogenization to address these challenges. A critical knowledge gap exists between continuous-level constitutive models and particle-scale behavior. This project developed a novel device to quantify interparticle mechanics between biomass particles, measuring friction and adhesion forces between particles and wall materials. The research focused on corn stover and southern pine forest residue, creating a comprehensive database of particle interactions. This breakthrough enables direct application in particle-based computational modeling, advancing the field's understanding of biomass handling characteristics and supporting the development of more reliable and efficient storage and handling systems. The project's outcomes contribute significantly to understanding biomass's mechanical and flow characteristics, particularly how variability at the particle level affects larger-scale handling operations. This knowledge is crucial for engineering feedstock supply systems that consistently meet quality and cost specifications for various conversion processes. The innovative experimental setup developed through this research represents a significant advancement in biomass characterization methodology. Providing precise measurements of particle-level interactions establishes a foundation for more accurate predictive modeling of bulk material behavior. This enhanced understanding of fundamental particle mechanics enables engineers to anticipate better and address handling challenges before they manifest in full-scale operations. This research opens new avenues for optimizing biomass handling systems through data-driven design approaches. The comprehensive database of particle interactions serves as a valuable resource for future research and development efforts, potentially leading to more efficient and cost-effective biomass processing solutions. This advancement in particle-level mechanics could revolutionize how biomass handling systems are designed and operated, contributing to more sustainable and reliable renewable energy production.

09 BIOMASS FUELS↗

Levelized Cost of Electricity (LCOE) Content Model for Design of High Deflection Foils for MHK Applications

The LCOE Content Model provides data submitters with an easy and consistent means of uploading data that can be used to calculate the levelized cost of energy for MHK devices. These data are important to DOE and will be used to develop data products that provide quantitative information to guide and support programmatic decisions. Data will also be used to evaluate MHK products and determine costs and can help data users compare the combination of capital costs and operations and maintenance over time. The ultimate goal is to use these data to perform research and tailor programs to best benefit the industry.

16 TIDAL AND WAVE POWER↗

Performance and cost of fuel cells for urban air mobility

Several companies are developing enabling elements of urban air mobility (UAM) for air taxis, including prototypes of electric vertical take-off and landing (eVTOL) vehicles. These prototypes incorporate electric and hybrid powertrains for multi-rotor and tilt-rotor crafts. Many eVTOLS are using batteries for propulsion and charging them rapidly between the flights or swapping them for slow charging overnight. Rapid charging degrades the battery cycle life while swapping requires multiple batteries and charging stations. This study has conducted a technoeconomic evaluation of the eVTOL air taxis with alternate powertrains using hydrogen fuel cell systems being developed for light-duty and heavy-duty vehicles. We consider performance metrics such as fuel cell engine power, weight, and durability; hydrogen consumption and weight of storage system; and maximum take-off weight. The metrics for economic evaluation are capital cost, operating and maintenance cost, fuel cost, and the total cost of ownership (TCO). In this work, we compare the performance and TCO of battery, fuel cell and fuel cell – battery hybrid powertrains for multi-rotor and tilt-rotor crafts. We show that fuel cells are the only viable concept for powering multi-rotor eVTOLs on an urban scenario that requires 60-mile range, and hybrid fuel cells are superior to batteries as powertrains for tiltrotor eVTOLs

08 HYDROGEN↗

Cost and Efficiency Analysis for Hybrid AC/DC Distribution System Planning with PV and Battery

Distribution system planning is one of the main tasks for the electric utilities. Cost and energy efficiency are two main concerns in the distribution planning process. In this work, cost and efficiency analyses are conducted for the hybrid AC and DC distribution grids for the planning purposes. The IEEE 34-bus feeder has been applied for the case studies. The investment cost, operation and maintenance cost, replacement cost, etc., have been considered in the life cycle cost analysis. Power losses of both the AC and DC section are calculated with an open source simulation tool, the Open Distribution Simulator Software (OpenDSS). The proposed framework can be applied to quantitatively evaluate the cost and efficiency of hybrid AC and DC distribution grids and help comparing different planning options.

AC/DC hybrid system planning↗

User's Manual for the FE/NETL Onshore CO 2 EOR Cost Model, Version 1

This user's manual describes the conceptual and mathematical basis for the FE/NETL Onshore CO 2 EOR Cost Model (a Fortran program). The model performs a cash flow analysis to estimate the cost of implementing CO 2 EOR using supercritical CO 2 by incorporating oil field performance outputs for a pattern from the FE/NETL CO 2 Prophet Model (available on NETL's website along with its associated user's manuals under the Collection Name: FE/NETL CO 2 Prophet Model) and implementing patterns to develop an oil field for CO 2 EOR. The model calculates capital costs, operation and maintenance costs, and financing costs. The user’s manual also describes how to run the FE/NETL Onshore CO 2 EOR Cost Model, along with the model’s file structure, inputs and outputs. The FE/NETL Onshore CO 2 EOR Cost Model is available on NETL's website under the Collection Name: FE/NETL Onshore CO 2 EOR Cost Model.

54 ENVIRONMENTAL SCIENCES↗

Extraterrestrial processing and manufacturing of large space systems, volume 2, chapters 7-14 and appendices

Production and support equipment specifications are described for the space manufacturing facility (SMF). Defined production equipment includes electromagnetic pumps for liquid metal, metal alloying furnaces, die casters, electron beam welders and cutters, glass forming for structural elements, and rolling. A cost analysis is presented which includes the development, the aquisition of all SMF elements, initial operating cost, maintenance and logistics cost, cost of terrestrial materials, and transportation cost for each major element. Computer program listings and outputs are appended.

Miller, R. H.↗

Ozone Treatment For Cooling Towers

Report presents results of study of cooling tower in which water treated with ozone instead of usual chemical agents. Bacteria and scale reduced without pollution and at low cost. Operating and maintenance costs with treatment about 30 percent of those of treatment by other chemicals. Corrosion rates no greater than with other chemicals. Advantage of ozone, even though poisonous, quickly detected by smell in very low concentrations.

Blackwelder, Rick↗

Marshall Space Flight Center solid waste characterization and recycling improvement study

The MSFC Facilities Office, which is responsible for disposing of all waste generated by MSFC, issued a delivery order to the University of Alabama in Huntsville (UAH) to characterize current MSFC waste streams and to evaluate their existing recycling program. The purpose of the study was to define the nature, quantity, and types of waste produced and to generate ideas for improving the present recycling program. Specifically, the following tasks were to be performed: Identify various surplus and waste materials--as identified by the Contracting Officer's Technical Representative (COTR)--by source, location, and type; Analyze MSFC's current methods for handling, storage, transport, and disposition of waste and surplussed materials; Determine the composition of various surplus and waste materials as to type and quantities from various sources and locations; Analyze different methods for the disposition of various surplus and waste materials, including quality, quantity, preparation, transport cost, and value; Study possible alternatives to current methods of handling, storage, transport, and disposition of surplus and waste materials to improve the quality and quantities recycled or sold and to reduce and minimize the quantities of surplus and waste material currently being disposed of or stored; Provide recommendations for source and centralized segregation and aggregation of materials for recycling and/or disposition; and The analysis could include identification and laboratory level evaluation of methods and/or equipment, including capital costs, operating costs, maintenance requirements, life cycle and return on investment for systems to support the waste reduction program mission.

Eley, Michael H.↗

Modular Rocket Engine Control Software (MRECS)

The Modular Rocket Engine Control Software (MRECS) Program is a technology demonstration effort designed to advance the state-of-the-art in launch vehicle propulsion systems. Its emphasis is on developing and demonstrating a modular software architecture for advanced engine control systems that will result in lower software maintenance (operations) costs. It effectively accommodates software requirement changes that occur due to hardware technology upgrades and engine development testing. Ground rules directed by MSFC were to optimize modularity and implement the software in the Ada programming language. MRECS system software and the software development environment utilize Commercial-Off-the-Shelf (COTS) products. This paper presents the objectives, benefits, and status of the program. The software architecture, design, and development environment are described. MRECS tasks are defined and timing relationships given. Major accomplishments are listed. MRECS offers benefits to a wide variety of advanced technology programs in the areas of modular software architecture, reuse software, and reduced software reverification time related to software changes. MRECS was recently modified to support a Space Shuttle Main Engine (SSME) hot-fire test. Cold Flow and Flight Readiness Testing were completed before the test was cancelled. Currently, the program is focused on supporting NASA MSFC in accomplishing development testing of the Fastrac Engine, part of NASA's Low Cost Technologies (LCT) Program. MRECS will be used for all engine development testing.

Tarrant, C.↗

Modular Rocket Engine Control Software (MRECS)

The Modular Rocket Engine Control Software (MRECS) Program is a technology demonstration effort designed to advance the state-of-the-art in launch vehicle propulsion systems. Its emphasis is on developing and demonstrating a modular software architecture for a generic, advanced engine control system that will result in lower software maintenance (operations) costs. It effectively accommodates software requirements changes that occur due to hardware. technology upgrades and engine development testing. Ground rules directed by MSFC were to optimize modularity and implement the software in the Ada programming language. MRECS system software and the software development environment utilize Commercial-Off-the-Shelf (COTS) products. This paper presents the objectives and benefits of the program. The software architecture, design, and development environment are described. MRECS tasks are defined and timing relationships given. Major accomplishment are listed. MRECS offers benefits to a wide variety of advanced technology programs in the areas of modular software, architecture, reuse software, and reduced software reverification time related to software changes. Currently, the program is focused on supporting MSFC in accomplishing a Space Shuttle Main Engine (SSME) hot-fire test at Stennis Space Center and the Low Cost Boost Technology (LCBT) Program.

Tarrant, Charlie↗

Telescience Resource Kit

The Telescience Resource Kit (TReK) is a PC based ground control system. It can be used by a single individual or in a group environment to monitor and control spacecraft systems and payloads. Capabilities include data receipt, data processing, data storage, data management, and data transmission. Commercial-Off-The-Shelf (COTS) hardware and software have been employed to reduce development costs, operations and maintenance costs, and to effectively take advantage of new commercial products as they become available. The TReK system is currently being used to monitor and control payloads aboard the International Space Station. It is located at sites around the world.

Schneider, Michelle↗

Thermal Insulation Strips Conserve Energy

Launching the space shuttle involves an interesting paradox: While the temperatures inside the shuttle s main engines climb higher than 6,000 F hot enough to boil iron for fuel, the engines use liquid hydrogen, the second coldest liquid on Earth after liquid helium. Maintained below 20 K (-423 F), the liquid hydrogen is contained in the shuttle s rust-colored external tank. The external tank also contains liquid oxygen (kept below a somewhat less chilly 90 K or -297 F) that combines with the hydrogen to create an explosive mixture that along with the shuttle s two, powdered aluminum-fueled solid rocket boosters allows the shuttle to escape Earth s gravity. The cryogenic temperatures of the main engines liquid fuel can cause ice, frost, or liquefied air to build up on the external tank and other parts of the numerous launch fueling systems, posing a possible debris risk when the ice breaks off during launch and causing difficulties in the transfer and control of these cryogenic liquid propellants. Keeping the fuel at the necessary ultra-cold temperatures while minimizing ice buildup and other safety hazards, as well as reducing the operational maintenance costs, has required NASA to explore innovative ways for providing superior thermal insulation systems. To address the challenge, the Agency turned to an insulating technology so effective that, even though it is mostly air, a thin sheet can prevent a blowtorch from igniting a match. Aerogels were invented in 1931 and demonstrate properties that make them the most extraordinary insulating materials known; a 1-inch-thick piece of aerogel provides the same insulation as layering 15 panes of glass with air pockets in between. Derived from silica, aluminum oxide, or carbon gels using a supercritical drying process - resulting in a composition of almost 99-percent air - aerogels are the world s lightest solid (among 15 other titles they hold in the Guinness World Records), can float indefinitely on water if treated to be hydrophobic, and can withstand extremely hot temperatures (from 1,100 F to 3,000 F depending on the type of aerogel) down to cryogenic levels, making this "frozen smoke" ideal for use in space. Because of its low weight and ability to withstand temperature extremes, an aerogel was even used as the space-based catcher s mitt to trap comet particles and space dust for NASA s Stardust mission, launched in 1999. All of this remarkable technology s characteristics were ideal for NASA s purposes except one: The aerogels were extremely brittle. Through a long-term partnership between Kennedy Space Center and Aspen Aerogels Inc., of Northborough, Massachusetts, researchers developed a flexible, durable form of aerogel that NASA has since used as cryogenic insulation for space shuttle launch systems. Through Aspen Aerogels, the technology has made oil pipeline insulation, extreme weather clothing, and infrared shielding for combat helicopters.

Source record↗

Need for Cost Optimization of Space Life Support Systems

As the nation plans manned missions that go far beyond Earth orbit to Mars, there is an urgent need for a robust, disciplined systems engineering methodology that can identify an optimized Environmental Control and Life Support (ECLSS) architecture for long duration deep space missions. But unlike the previously used Equivalent System Mass (ESM), the method must be inclusive of all driving parameters and emphasize the economic analysis of life support system design. The key parameter for this analysis is Life Cycle Cost (LCC). LCC takes into account the cost for development and qualification of the system, launch costs, operational costs, maintenance costs and all other relevant and associated costs. Additionally, an effective methodology must consider system technical performance, safety, reliability, maintainability, crew time, and other factors that could affect the overall merit of the life support system.

Costs↗

Machine-Learning Enabled Evaluation of Probability of Piping Degradation In Secondary Systems of Nuclear Power Plants

The transition to condition-based, risk-informed automated maintenance will contribute to a significant reduction of operations and maintenance costs that account for the majority of nuclear power generation costs. Furthermore, of the operations and maintenance costs in U.S. plants, approximately 80% are labor costs. To address the issue of rising operating costs and economic viability, technologies used to perform online monitoring of piping and other secondary system structural components in commercial nuclear power plants (NPPs) are under evaluation. These online monitoring systems have the potential to identify when a more detailed inspection is needed using real time measurements, rather than at a pre-determined inspection interval thus reducing the maintenance cost. This paper describes distributed high-temperature stable fiber sensors fabricated in optical fibers through a roll-to-roll laser direct writing process using femtosecond lasers. Using phase-sensitive optical time domain reflectometry, distributed acoustic and vibration sensors can be developed and deployed to critical components and systems in NPPs to perform active measurements with spatial resolution down to 0.5-meter throughout the piping systems. Complex acoustic and vibration signatures harnessed by distributed sensors are registered and analyzed by artificial intelligence algorithms for degradation detection and flaw identification. Piping elbows with machined-in flaws were instrumented with fiber sensors. High-spatial-resolution data were used to develop and validate machine learning algorithms, including both linear and nonlinear regression, and classification. Additionally, classification and sensor analysis were also performed for data analysis. The paper concludes with recommendations and future work on applications of machine learning enabled high-resolution fiber sensors for piping degradation monitoring in current or future NPPs.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

An Overview of the Design and Optimized Operation of Vanadium Redox Flow Batteries for Durations in the Range of 4–24 Hours

An extensive review of modeling approaches used to simulate vanadium redox flow battery (VRFB) performance is conducted in this study. Material development is reviewed, and opportunities for additional development identified. Various crossover mechanisms for the vanadium species are reviewed, and their effects on its state of charge and its state of health assessed. A stack design focusing on flow fields and an electrode design tailored to various flow fields are reviewed. An operational strategy that takes these parameters into account is reviewed for various operating envelopes, chosen based on end user preference in terms of minimizing capital cost or operation and maintenance cost. This work provides a framework for the design and operation of a VRFB for various grid services.

25 ENERGY STORAGE↗