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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Recent advances in CO 2 hydrogenation to value-added products — Current challenges and future directions

Climate change, global warming, fossil fuel depletion and rising fuel prices have created great incentives to seek alternative fuel production technologies. CO 2 transformation to value-added products using renewable H 2 has proven to be an emerging solution to enable this goal. In this regard, three different promising processes, namely methane, methanol and hydrocarbon synthesis via CO 2 hydrogenation are thoroughly discussed. In addition, the influential factors affecting process efficiencies such as catalyst design and mechanistic insight, operating conditions as well as reactor types are investigated, with key pathways that dictate catalyst activity and selectivity of the most promising materials described. Furthermore, a brief overview of the reactor configuration and its crucial role in the improving process viability is analyzed. Accordingly, fixed-bed, fluidized-bed, annular and spherical reactors along with H 2 O/H 2 perm-selective membrane reactors are disscussed for hydrocarbon production. In addition, different reactor configurations are compared to assess the best one that is adjustable depending on the reaction mechanism. In conclusion, a corrugated-wall dual-type membrane reactor is proposed as an emerging alternative for CO 2 hydrogenation to value-added products.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Massachusetts and New England Sustainable Aviation Fuel Study

The Massachusetts Port Authority established a project to assess feedstock availability to produce SAF near 10 New England airports. A techno-economic analysis was conducted to determine renewable fuels and SAF that could be produced from these feedstocks. The resource assessment found municipal solid waste, woody biomass, and food waste were most abundant. The techno-economic analysis found that potential fuel production varied widely based on location, feedstock, and technology production pathway ranging from 1 to 369 million gallons of gasoline equivalent per year. An assessment of infrastructure readiness to handle SAF was conducted. It was determined that SAF produced outside of New England should be blended in other regions with more capacity and flexibility and delivered to New England as Jet A is today. For SAF produced in New England, there are terminals that have existing infrastructure to receive, blend, and distribute SAF/Jet A blends.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2026

Massachusetts and New England SAF Study [Slides]

The Massachusetts Port Authority established a project to assess feedstock availability to produce SAF near 10 New England airports. A techno-economic analysis was conducted to determine renewable fuels and SAF that could be produced from these feedstocks. The resource assessment found municipal solid waste, woody biomass, and food waste were most abundant. The techno-economic analysis found that potential fuel production varied widely based on location, feedstock, and technology production pathway. An assessment of infrastructure readiness to handle SAF was conducted. It was determined that SAF produced outside of New England should be blended in other regions with more capacity and flexibility and delivered to New England as Jet A is today. For SAF produced in New England, there are terminals that have existing infrastructure to receive, blend, and distribute SAF/Jet A blends.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

Characteristics of U.S. Energy Production using Nuclear Fission

When considering potential energy production technologies for the future, a critical consideration centers on the question of “how green” the technology is. Here, the word “green” implies that the technology has a zero or minimal impact on the public and environment while still providing benefits by way of electricity, heat, and other products such as hydrogen and water. And, these potential impacts must be considered over the lifecycle of the technology deployment, from design, construction, operation, and disposition. Ideally, a green energy technology would be net-zero (i.e., having no to almost negligible contribution) on five key elements: 1. Greenhouse gas emissions, including carbon dioxide (CO 2 ), methane, nitrous oxide, and fluorinated gases such as ozone-depleting gases 2. Water consumption 3. Material resource consumption 4. Disposition of wastes 5. Public, flora, and fauna safety including deaths, health, and environmental impacts. Society would benefit from net-zero impacts of the five elements above while having low-cost energy. As society starts to replace fossil fuels in the energy mix, we need to consider the possible impacts of adopted technologies. We need a production approach that provides large quantities of energy while being safe, reliable, economical, and sustainable. In this report, we describe a variety of characteristics related to the five elements above to provide a fact-supported, science-based depiction of nuclear fission as an energy providing technology. By better understanding how fission power is nearly net-zero in the five elements above, we can position our thinking to align with the overarching goal to provide society with a low-impact energy source.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Degradation Mechanisms in Advanced MEAs for PEM Water Electrolyzers Fabricated by Reactive Spray Deposition Technology

Proton exchange membrane water electrolyzers (PEMWEs) have demonstrated enormous potential as the next generation hydrogen production technology. The main challenges that the state-of-the-art PEMWEs are currently facing are excessive cost and poor durability. Understanding the failure modes in PEMWEs is a key factor for improving their durability, lowering the precious metal loading, and hence cost reduction. Here, reactive spray deposition technology (RSDT) has been used to fabricate a membrane electrode assembly (MEA) with one order of magnitude lower Pt and Ir catalyst loadings (0.2–0.3 mg PGM cm –2 ) in comparison to the precious metal loadings in the stat-of-the-art commercial MEAs (2–3 mg PGM cm –2 ). As fabricated MEA with an active area of 86 cm 2 , has been tested for over 5000 h at steady-state conditions that are typical for an industrial hydrogen production system. Herein, we present and discuss the results from a comprehensive post-test analysis of the MEA of interest. The main degradation mechanisms, governing the performance loss in the RSDT fabricated MEA with ultra-low precious metal loadings, have been identified and discussed in detail. All failure modes are critically compared and the main degradation mechanism with the highest impact on the MEA performance loss among the others is identified.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Chapter 14: Chemical Recycling of Commodity Plastics

Global plastic production is at an all-time high and shows little signs of slowing down. Less than 10% of all plastic produced is recycled, with approximately 90% entering landfills, incinerators, and oceans. This has led to a rapid accumulation of single-use plastic waste across the planet. Mechanical recycling has been executed at the industrial level to manage plastic waste for decades. However, mechanically recycled plastic products are significantly limited by contamination and low performance. Chemical recycling technologies offer another pathway for achieving plastic circularity. This chapter highlights the current state-of-the-art chemical recycling technologies for plastic decomposition into monomers, fuels, or other petrochemical feedstocks. A brief description of recyclability of plastics and the waste sorting process is provided followed by a high-level overview of chemical recycling technologies. Products, key barriers, and limitations are also discussed as well as a brief overview of techno-economics.

chemical recycling↗
DOE OSTI2020

Advanced sorbents for modular oxygen production for REMS gasifiers

Under a DOE funded effort, Thermosolv LLC has been developing a sorbent-based oxygen production technology for gasification and oxy-combustion applications. The sorbents utilize oxygen-storage properties of certain perovskites to (1) selectively adsorb oxygen at moderate temperature from compressed air and (2) release the adsorbed oxygen into a vacuum or a sweep gas such as CO2 and/or steam. Through cyclic operations of multiple sorbent beds such a process can be made continuous. Pressure drop across the sorbent bed and other similar design considerations dictate that the sorbent be in the form of a high surface-area-to-volume pellet and yet still possess sufficient crush strength and integrity. Process efficiency is determined by the sorption and desorption kinetics and sorbent capacity. Typical process involves cycle times in the order of 100 seconds, a time too short to fully utilize the full volume of the sorbent and the sorption capacity of the sorbent pellets. As a part of this project, Thermosolv LLC undertook the development of oxygen sorbents as a high-surface area supported sorbent on a light-weight inert support to (1) reduce the cost, (2) increase the productivity, and (3) reduce the overall weight of the reactor. Using a previously developed perovskite (LSCF 1991) with its well-characterized performance, composite sorbent pellets each consisting of an inert core coated by a thin layer of the functional perovskite material were produced. Several low-density, inexpensive inert solids supports in the 1/8”-1/4” size were selected to keep the pressure drop across the sorbent bed in the acceptable range. A number of commercial technologies including spray coating, dip coating, incipient impregnation of porous substrate followed by thermal annealing at various temperatures and duration were employed and tested to produce robust composite supported sorbent pellets. A sense of optimum coating thickness was developed by testing sorbent pellets of various increasing diameter pellets. LSCF-1991extrudates ranging in size from 1/32” to 3/16” were tested in a TGA and in a fixed-bed pressure swing test set-up for sorption/desorption cycles of interest. The data show that for the operational conditions of interest the coating thickness for a supported sorbent pellet needs to be approximately 1/32” (about 0.8 mm). Subsequent work thereby concentrated on developing composite pellets of various substrates, shapes and sizes with coating layer of about this size range. Candidate support materials were chosen based on cost, inertness, mechanical strength, thermal expansion and chemical stability with sorbent material, and in a size range to give an acceptable pressure drop in fixed-bad reactor configurations. Coating application methods used for application of the sorbent onto the support included precipitation, spray coating and dip coating from sorbent slurries and sol gels. For all coated supports where we could successfully apply a uniform coating of desired thickness with an acceptable handling performance in terms of exfoliation, TGA-based cyclic sorption/desorption testing was performed to determine cycling capacity of oxygen. Among nearly twenty different support materials tested, best adhesion performance was obtained from stainless saddle supports. In the bench-scale fixed-bad tests stainless steel saddle support composite pellets with a coating thickness in the 0.6 mm or so range, the composite sorbent pellet performance approached up to 95% of that of the 2 mm parent material pellets. In a parallel approach to reducing the cost of the sorbent, alternate sorbent formulations replacing/reducing the amount of cobalt in the LSCF family were also investigated. Successful formulations that could match the performance of LSCF 1991 were identified based on TGA cyclic tests as LSCF 1919 and LSF 1910. In the range of operational envelop of cycle times and other relevant process operating conditions, the reduced Co formulations showed comparable performance in the bench-scale fixed-bad cyclic operations. As a part of this project, we also attempted substitution of La and Sr with Ca and Ba, and Co with Mn, Ni and Cu with little success, but the overall project goal of reducing sorbent cost in terms of raw material and manufacturing expenses was successful.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

A novel green hydrogen production using water-energy nexus framework

The transformation of electrical energy to hydrogen via water electrolysis consumes considerable amount of fresh water and a productive use of nontraditional water sources enhances the reliability and resilience of energy and water systems. In this study, we have designed a solid oxide electrolysis cell (SOEC) system which is an evolving hydrogen production technology at high temperatures for water electrolysis. Here, the SOEC uses steam generated from flue gas as its feedstock and is fully integrated with numerous power production units, including coal and natural gas-fired power plants as its energy feedstock. While there is a hasten global shift away from fossil fuel, integrating its asset into this technology helps limit the risk and future losses of stranded assets and reduce the cost of investment in the new technologies. But high capital expenditures and doubt concerning the future cost and efficiency upgrade are obstacles to investing in water electrolysis. Such a detailed Levelized cost of hydrogen and techno-economic analysis is conducted to show the viability and environmental impacts of this novel technology. The results show SOEC efficiency of 97.4 % and 56.3 % as thermal-to-hydrogen efficiency of the system with a daily hydrogen production of 242,400 kg at $2.9–3.5/kg H 2 . The estimates show a positive gain prospect in this technology and techno-economic challenges.

08 HYDROGEN↗
DOE OSTI2024

Optimal Control of SOEC-Based Hydrogen Production Systems for Demand Response Using Deep Reinforcement Learning in Smart Grids

Solid oxide electrolysis cell (SOEC) hydrogen production technology can range in size from small, appliance-size equipment to large-scale, central production facilities that can be tied directly to renewable or non-greenhouse-gas-emitting forms of electricity production, making it an ideal resource for demand response (DR). The SOEC hydrogen production system is a complex integrated system that encompasses fluid dynamics, electrical dynamics, and electrochemical and thermal dynamics, all of which involve non-linearity and non-convexity. Proper control of the SOEC hydrogen production system is crucial to enable its participation in the DR program. Here, to overcome the difficulty of designing an explicit control law for such nonlinear systems with nonconvex optimization features in DR applications, deep reinforcement learning (DRL) is explored to achieve the optimal control of the SOEC system for DR participation. Specifically, a twin delayed deterministic policy gradient (TD3) control framework is applied to achieve optimal response performance during DR events by considering power tracking error and hydrogen production efficiency with a suitable reward function. Two case studies with grid connections for tracking different DR commands were investigated. The first case study involved operating conditions reaching the boundaries, while the second involved operating conditions within the boundaries. The results showed that the proposed DRL-based control for SOEC can track the DR signal in a timely manner while maintaining high energy efficiency.

08 HYDROGEN↗
DOE OSTI2021

Chalkboard 2 - How to Make Clean Hydrogen

Clean hydrogen is a carbon-free energy carrier that can be produced from water and sustainable energy sources such as wind, solar, and nuclear. Therefore, clean hydrogen is one of the best ways to not only decarbonize the energy supply system, but also address the zero-emission challenges specific to large-carbon emitting industries that are difficult to separate from fossil fuels. To help achieve the Biden Administration's goal of a 100% clean energy economy and net-zero emissions by 2050, several tens of millions of metric tons of clean, low-cost hydrogen will be needed annually. The HydroGEN Advanced Water Splitting Materials (AWSM) Consortium was established in 2016 as part of the Energy Materials Network (EMN) under the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Hydrogen and Fuel Cell Technologies Office to enhance the performance, improve the durability, and reduce the cost of clean hydrogen production technologies, and it is helping to advance the H2@Scale vision.

08 HYDROGEN↗
DOE OSTI2022

Life-cycle greenhouse gas emissions reduction potential for corn ethanol refining in the USA

This study evaluates how low-carbon production technologies applicable to ethanol plants may reduce the life-cycle greenhouse gas emission (GHG) intensities of corn ethanol production in the USA. Results indicate that options focusing on incremental energy efficiency (e.g., combined heat and power) and yield improvements have a limited impact on GHG reductions. To achieve deep decarbonization (>50% GHG reduction compared to current corn ethanol production), a fuel switch from natural gas (NG) to alternative low-carbon fuels is needed. Replacing 50% of NG demand at ethanol plants with syngas from biomass through gasification or renewable natural gas from animal waste could achieve significant GHG reductions (11.7–23.5 g CO 2 e/MJ ethanol). Adding multiple technologies, including carbon capture and storage, to existing ethanol plants may further reduce GHG emissions to –18.4 g CO 2 e MJ –1 ethanol (including land-use change emissions), which is 120% lower than the carbon intensity of pure gasoline. These results could inform how the ethanol industry could move toward net-zero ethanol production.

09 BIOMASS FUELS↗
DOE OSTI2022

Thermodynamic Constraints on Electromicrobial Protein Production

Global consumption of protein is projected to double by the middle of the 21st century. However, protein production is one of the most energy intensive and environmentally damaging parts of the food supply system today. Electromicrobial production technologies that combine renewable electricity and CO 2 -fixing microbial metabolism could dramatically increase the energy efficiency of commodity chemical production. Here we present a molecular-scale model that sets an upper limit on the performance of any organism performing electromicrobial protein production. We show that engineered microbes that fix CO 2 and N 2 using reducing equivalents produced by H 2 -oxidation or extracellular electron uptake could produce amino acids with energy inputs as low as 64 MJ kg −1 , approximately one order of magnitude higher than any previous estimate of the efficiency of electromicrobial protein production. This work provides a roadmap for development of engineered microbes that could significantly expand access to proteins produced with a low environmental footprint.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2022

Overview of Integrated Pathway Analyses to Meet the Hydrogen Energy Earthshot Goal

This presentation was given at the 2022 Bulk Storage of Gaseous Hydrogen Workshop sponsored by the U.S. Department of Energy's (DOE) Hydrogen and Fuel Cell Technology Office (HFTO). The presentation topics cover the current status of an upcoming NETL publication titled "Comparison of Commercial, State-of-the-Art, Fossil-Based Hydrogen Production Technologies." The study will publicize plant performance, life cycle environmental performance, and the levelized cost of hydrogen (LCOH) production from six fossil-based pathways. The presentation provides preliminary results pending finalization of the study. In addition, the presentation provides an overview of NETL analysis efforts to support the DOE Hydrogen Shot targets.

Lewis, Eric↗
DOE OSTI2023

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↗
DOE OSTI2025

Sustainable aviation fuel from ethanol: Techno-economic analysis and life cycle analysis

Sustainable aviation fuel (SAF) is crucial for improving energy security, enhancing domestic production, and reducing carbon emissions in the aviation sector. Among various SAF production technologies, the ethanol-to-jet (ETJ) pathway is a promising option due to its economic viability and technological maturity. This study integrates a techno-economic analysis (TEA) and a life cycle analysis (LCA) to evaluate emissions reduction strategies for SAF production via the ETJ pathway, considering use of ethanol derived from both corn grain and corn stover. Conventional corn grain-derived ETJ fuel reduces greenhouse gas (GHG) emissions by 22 % compared to fossil jet fuel, with potential reductions of 26 %–96 % when incorporating renewable energy sources, with a 6 %–32 % increase in the minimum fuel selling price (MFSP). Corn stover-derived ETJ achieves a 77 % GHG reduction but with higher MFSPs compared to corn grain ETJ. Carbon capture and storage (CCS without considering the cost for piping and sequestration, only compression) reduces the emissions of corn grain-derived ETJ by up to 32 gCO 2 e/MJ and enables negative emissions for corn stover-derived ETJ, with MFSP increases ranging from 1 % to 22 %. While carbon capture and utilization (CCU) increase ethanol yield by 47 %, it raises MFSPs by 54 % due to high electricity demand. Sustainable farming practices provide only limited carbon intensity (CI) reductions individually but do offer cumulative benefits when combined. These findings highlight the trade-offs between cost and environmental impact, providing insights to optimize SAF production strategies and support aviation sector goals for emissions reduction.

09 BIOMASS FUELS↗
DOE OSTI2021

Coal and Carbon Management Guidebook: Coal-to-Hydrogen Opportunities and Challenges

Key elements of this report include coal-to-hydrogen production in the context of the U.S. hydrogen market; the state of various hydrogen production technologies; present and forecasted demand for hydrogen in energy, transportation, and industrial sectors; an overview of environmental, economic, and infrastructure challenges to greater coal-to-hydrogen production; and information on the U.S. Department of Energy (DOE) programs and priorities for coal-to-hydrogen research and development.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2026

Photonuclear cross sections for the 197 Au ⁢(𝛾, 𝑝⁢𝑛)⁢ 195⁢𝑚 Pt reaction near threshold

Platinum radioisotopes are of growing interest for targeted cancer therapy and diagnostic imaging because their decay delivers highly localized radiation doses in tissue, herewith enabling precise DNA damage through Auger-electron emission. Developing production technologies that provide platinum isotopes with high specific activity is essential in radioisotope therapy. Photonuclear reactions on stable nuclei offer a viable accelerator-based route for isotope production when supported by reliable cross-section data. We report photonuclear cross-section measurements for the 197 Au(γ, pn) 195m Pt reaction at incident γ-ray energies of 27, 29, and 31 MeV using the activation method. The measurements were performed by irradiating a stack of concentric-ring gold targets with a quasi-monoenergetic γ-ray beam provided by the High Intensity Gamma-ray Source (HI γS). The induced 195m Pt activity was quantified using off-line γ-ray spectroscopy. These data provide the first experimental constraints on the 197 Au(γ, pn) 195m Pt cross section in the near-threshold region. Furthermore, the comparison of the measured excitation function to PHITS and TALYS calculations indicates that the reaction becomes measurable only near 30 MeV and that substantially higher bremsstrahlung end-point energies are required for practically meaningful production.

190 ≤ A ≤ 219↗
DOE OSTI2023

Dynamic Modeling of a Solar-To-Hydrogen Flexible High Temperature Steam Electrolysis Plant

Sustainble hydrogen production for use as a renewable combustible fuel and clean chemical feedstock is an important objective as the world moves towards a renewable energy future. High temperature steam electrolysis is a promising hydrogen production technology due to its reduced electric input that is offset by heat input into steam generation and steam superheating. An option to provide this heat is to use concentrating solar thermal technology that can sustainably provide heat input while renewable electricity is used for the electrolysis reaction. In this work, a solar-to-hydrogen high temperature steam electrolysis plant is designed and dynamically modeled, showing continuous hydrogen production by utilizing supplemental heating and efficient recuperative heating from the electrolysis product streams. Through this design, over 90% of the required heat input for the process can by met by a combination of solar and recuperative heat. Additionally, the plant can flexibility operate by ramping down hydrogen production and through flexible heat integration, which intelligently integrates solar heat based on solar conditions. Smooth operation with flexible hydrogen production is demonstrated which decreases electrical input during on-peak grid times and also decreases the total supplemental heat load over the course of a day from 26.1% to 24.5%. In addition, by using flexible heat integration, the plant can increase its solar heat usage by 4.1% relative to a base case. Both options for flexibility show efficient use of solar thermal energy to sustainably and continuously produce hydrogen.

Immonen, Jake (ORCID:0000000341231625)↗