SEARCH · Search NASA

Results for “Complex industrial process”

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.

SourceResearch connectionFrom yearThrough year

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

At least 397 records · Page 22

All sources NASA NTRS DOE OSTI

DOE OSTI2025

Evaluating the carbon capture potential of industrial waste as a feedstock for enhanced weathering

Abstract Limiting anthropogenic global climate warming since the start of the industrial period to less than 2 °C will very likely require both deep and rapid reductions in anthropogenic greenhouse gas emissions and a range of approaches toward carbon dioxide removal (CDR). One prominent CDR approach is enhanced weathering (EW), in which crushed silicate rock is applied on land or in the open ocean to accelerate natural weathering processes that absorb carbon dioxide from Earth’s ocean–atmosphere system. However, in addition to a range of potential environmental, socioeconomic, and ethical issues associated with this pathway, bottlenecks in feedstock sourcing represent a key barrier for deployment of EW at scale. Here, we evaluate the potential of silicate wastes produced from industrial processes—such as steel slag and cement waste—as feedstocks for the EW process. An empirical model that links industrial alkaline waste production to gross domestic product at purchase power parity is developed to forecast waste production in the alternative futures described by the shared socioeconomic pathway (SSP) framework. By incorporating these results into an intermediate-complexity Earth system model, we also explore the impacts of EW using industrial waste on changes to global temperature, ocean pH, and ocean aragonite saturation state, while also quantifying overall CDR efficiency through the end of the century. We estimate a maximum cumulative end-of-century capture potential of ∼400 GtCO 2 for industrial waste, which could represent a significant fraction of the projected CDR requirement of many mitigation scenarios in the SSP framework. However, feedstock-dependent environmental impacts and the technoeconomics of feedstock redistribution may ultimately limit deployment scope.

Xu, Pengxiao (ORCID:0009000633724293)↗

DOE OSTI2026

Modeling and Calibration of Supplier Selection Problem in Freight Agent-Based Simulations

Freight transportation modeling often struggles with data limitations, especially in accurately representing complex supplier selection processes and their impact on network flows. This research addresses this critical gap by developing a large-scale, calibrated agent-based model for supplier selection, complemented by a probabilistic heuristic for international shipments. Our approach integrates trade relationships between industry sectors, transportation costs, and a supplier-rating model adapted from existing literature. The model’s core objective is to minimize the discrepancy between modeled and observed commodity flows while ensuring a close match to regional shipping distance distributions. Implemented and tested across four major U.S. metropolitan areas—Atlanta, Chicago, Dallas–Fort Worth, and Los Angeles—the model demonstrates high fidelity in replicating observed freight patterns. Key findings reveal consistent alignment with national shipping distance trends and highlight significant spatial variations in commodity trade assignments and demand across the study regions. This behaviorally informed and transport-sensitive framework is designed to approximate real-world decision making, providing a robust tool for policymakers and planners to evaluate targeted interventions, assess infrastructure investments, and enhance supply chain resilience in the face of disruptions.

Ismael, Abdelrahman (ORCID:0000000303712110)↗

DOE OSTI2019

Monitoring for Additive Manufacturing Technologies: Report on Progress, Achievements, and Limitations of Monitoring Techniques

The Transformational Challenge Reactor (TCR) program is leveraging additive manufacturing (AM) technologies to produce multiple nuclear components to be assembled into a fully functional microreactor core. AM was selected as the main manufacturing technology of choice for TCR because it has the potential to disrupt the nuclear industry on two fronts: (1) it enables the manufacturing of very complex geometries with optimized and tailored material properties for the intended use of the component, opening up new options for reactor designs, and (2) it allows for a better understanding of the manufacturing process through real-time in situ monitoring, data analytics, and artificial intelligence that can lead to a streamlined qualification and certification process. Within TCR, the development and deployment of a digital platform aims at addressing the latter opportunity. As part of this effort, the collection of pedigree data sets is vital, should these data be generated before, during, or after the manufacturing process. This report focuses on the collection of manufacturing process data using systems instrumentation and monitoring. It presents an inventory of the various monitoring modalities installed on the manufacturing systems by the machine manufacturer or specifically designed by our team to fill information gaps. It also provides details on other relevant data streams available and leverageable to evaluate the manufacturing process on all classes of AM systems investigated during the first year of this program. Through examples, the report gives an overview of the data collected and presents a path forward for the digital platform.

42 ENGINEERING↗

DOE OSTI2019

Viability of Data Analytics to Ascertain Component Performance for Additive Manufacturing

The Transformational Challenge Reactor (TCR) program is leveraging additive manufacturing (AM) technologies to produce multiple nuclear components to be assembled into a fully functional microreactor core. AM was selected as the main manufacturing technology for TCR because it has the potential to disrupt the nuclear industry on two fronts: (1) it enables the manufacturing of very complex geometries with optimized and tailored material properties for the intended use of the component, opening up new options for reactor designs, and (2) it allows for a better understanding of the manufacturing process through real-time in situ monitoring, data analytics, and artificial intelligence, which can lead to a streamlined qualification and certification process. Within TCR, the development and deployment of a digital platform aims at addressing the latter opportunity. As part of this effort, the collection of pedigree datasets is vital, should these data be generated before, during or after the manufacturing process. This report focuses on the development of data analytics tools enabling qualitative assessment of the manufacturing processes to automate the identification of flaws in in situ monitoring imagery and to correlate those flaws to the resulting mechanical testing data. Through examples, the report gives an overview of the data collected and presents a path forward for the digital platform.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2023

Heat Exchanger Intensification Through Powder Processing and Enhanced Design (HIPPED)

High intensity, supercritical CO 2 heat exchangers capable of operating at temperatures between 800 and 1100 ˚C and pressures greater than 80 bar are considered a critical component for high efficiency power generation and a range of next-generation industrial processes. A novel heat exchanger concept was proposed in this project. The proposed concept involved a plate-type architecture with three-dimensional fins, called twisted s-shaped fins, that capitalize on additive manufacturing. Four manufacturing processes were studied to realize the complex envisioned design: press and sinter of metallic powders, directed energy deposition, laser powder bed fusion, and a novel powder bed process involving a photoreactive polymer called SEAM (scalable expeditious additive manufacturing), that later was developed at MSU. The team was able to manufacture subscale heat exchangers using laser powder bed fusion (LPBF) and SEAM. The team settled on using SEAM as a final manufacturing approach due to its very low cost. The SEAM-manufactured heat exchanger, however, when tested under pressure, exhibited leaks and the process still requires further development beyond the timeline of the project. To support the heat exchanger design and testing, the team developed a new high temperature flow loop allowing testing under high temperature and pressure. Computational modeling of the heat exchanger was also performed for the twisted s-shaped fins and the computations were validated with experimental data. The new twisted fins resulted in enhanced heat transfer and reduced pressure drop. To further minimize pressure drop in the plate heat exchanger, the team also developed a simplified model for flow maldistribution in the manifolds, providing a new tool for designers that eliminates the need for complex CFD calculations. A technoeconomic analysis was also developed to contrast SEAM with LPBF, this tool indicated that SEAM is several times less costly and offer significant promises as a rapid low cost additive manufacturing process for metallic systems.

30 DIRECT ENERGY CONVERSION↗

NASA NTRS2020

Strategic Deconfliction Performance: Results and Analysis from the NASA UTM Technical Capability Level 4 Demonstration

Unmanned Aircraft System (UAS) Traffic Management (UTM) refers to the service-based, cooperative approach to the management of small UAS in the National Airspace System that is safe, scalable, and fair. UTM provides the means to manage the airspace in a complementary manner that does not burden the current air traffic control workforce or infrastructure but allows the Air Navigation Service Provider to maintain its regulatory and operational authority of the airspace. A key feature of UTM is the ability to provide operators the means to strategically deconflict operations from others in the airspace through the digital exchange of information via supporting services. Through this approach, the four-dimensional operation volumes that encompass the intent of operators in a given area are discoverable and can be used for airspace awareness as well as planning conflict free operations that account for and avoid other operations. In certain cases, it is also possible to negotiate volume intersections for shared airspace use without the need to re-plan. In the NASA UTM concept, strategic deconfliction is the first layer of three in the overall conflict management model. The three layers of the conflict management model, which follow the International Civil Aviation Organization’s scheme [ICAO 2005] are: strategic conflict management, separate provision, and collision avoidance. In UTM, the strategic layer mostly occurs prior to departure, but is applicable to en route operations with sufficient planning horizon. The initial requirements for a strategic deconfliction capability within UTM are defined in a NASA publication [Rios 2018]. Within the concept and implementation of service-provided strategic deconfliction is the notion of priority. It is understood that there are instances in which an operation requires a priority designation within the UTM system and special handling accordingly to provide situation awareness and facilitate appropriate responses from other airspace users. Examples of situations requiring priority designation include: when an operator declares an emergency due to problems with the vehicle or its immediate surroundings; operations that are in support of certain organizations (e.g., public safety and first responders); or special missions that also require priority use of airspace (e.g., emergency medical deliveries). UAS Volume Reservations (UVRs) also relate to the topic of priority in the sense that the airspace that the volume encompasses has a different status or classification in which unassociated operations must vacate if inside, or avoid if outside, through strategic deconfliction with the volume. Operations that are specially permitted to access the UVR area are typically assigned priority status given the nature of their mission and their associated credentials. The ability to perform strategic deconfliction, handle certain operations with a priority distinction, and establish UVRs that are communicated throughout the UTM system, is predicated on an architecture that has been established through an evolutionary process in response to close collaboration with stakeholders from government and industry. Another important and influential aspect of these capabilities and architecture is the live, distributed flight tests that have been conducted across the Technical Capability Levels (TCLs) that culminated with a set of complex tests performed as part of TCL4 [Rios 2020]. The TCL4 flight test involved two FAA-designated UAS test sites building teams to collaborate with NASA’s UTM Project on the execution of several detailed, small UAS scenarios in urban environments.

conflict management↗

DOE OSTI2014

Ligncellulosic feedstock supply systems with intermodal and overseas transportation

With growing demand for biomass from industrial uses and international trade, the logistic operations required to economically move the biomass from the field or forest to the end users have become increasingly complex. In addition to economics, understanding energy and GHG emissions is required to design cost effective, sustainable logistic process operations; in order to improve international supply chains it is also important to understate their interdependencies and related uncertainties. This article presents an approach to assess lignocellulosic feedstock supply systems at the operational level. For this purpose, the Biomass Logistic Model (BLM) has been linked with the Geographic Information Systems based Biomass Intermodal Transportation model (BIT-UU) and extended with inter-continental transport routes. Case studies of herbaceous and woody biomass, produced in the U.S. Midwest and U.S. Southeast, respectively, and shipped to Europe for conversion to Fischer-Tropsch (FT) diesel are included to demonstrate how intermodal transportation and, in particular, overseas shipping integrates with the bioenergy supply chains. For the cases demonstrated, biomass can be supplied at 99 € Mg-1 to 117 € Mg-1 (dry) and converted to FT-diesel at 19 € GJ-1 to 24 € GJ-1 depending on the feedstock type and location, intermediate (chips or pellets) and size of the FT-diesel production plant. With the flexibility to change the design of supply chains as well as input variables, many alternative supply chain cases can be assessed.

09 BIOMASS FUELS↗

DOE OSTI2025

Electrocatalytic CN Coupling: Advances in Urea Synthesis and Opportunities for Alternative Products

Urea is an essential fertilizer produced through the industrial synthesis of ammonia (NH 3 ) via the Haber–Bosch process, which contributes ≈1.2% of global annual CO 2 emissions. Electrocatalytic urea synthesis under ambient conditions via CN coupling from CO 2 and nitrogen species such as nitrate (NO 3 − ), nitrite (NO 2 − ), nitric oxide (NO), and nitrogen gas (N 2 ) has gained interest as a more sustainable route. However, challenges remain due to the unclear reaction pathways for urea formation, competing reactions, and the complexity of the resulting product matrix. This review highlights recent advances in catalyst design, urea quantification, and intermediate identification in the CN coupling reaction for electrocatalytic urea synthesis. Furthermore, this review explores future prospects for industrial CN coupling, considering potential nitrogen and carbon sources and examining alternative CN coupling products, such as amides and amines.

Chemistry↗

DOE OSTI2024

Aliphatic Amines from Waste Polyolefins by Tandem Pyrolysis, Hydroformylation, and Reductive Amination

Pyrolysis of waste plastics can produce a product mixture with a high concentration of olefins (>50 wt%). The olefins, as building blocks in the petroleum industry, are potential precursors for valuable commodity chemicals with higher values (>$2000 per ton). In this work, we produce aldehydes by hydroformylation of the olefins present in pyrolysis oil from colored post-consumer recycled high-density polyethylene (PCR-HDPE). The obtained aldehydes in the oil are then converted into aliphatic amines via reductive amination with a Ru/C catalyst. The aminated oil was characterized by multiple analytical chemistry techniques including elemental analysis, nuclear magnetic resonance spectroscopy, high-resolution liquid chromatography-mass spectrometry, and gas chromatography-mass spectrometry with a Polyarc flame ionization detector. The concentration of metals in the PCR-HDPE and oil changes during the tandem processes, showing limited effects of these elements (e.g., Al, Ca, Fe, Mg, Ti, Zn) on hydroformylation and reductive amination. Additionally, we demonstrated that reductive amination of aldehydes with varied carbon numbers and branching properties can be achieved in the presence of a complex mixture, including paraffins and aromatics. The results indicate that waste plastics have the potential to serve as a renewable source for mono and di aliphatic amines, thereby diminishing reliance on fossil feedstocks as the current primary amine source.

aliphatic amines↗

DOE OSTI2024

Enabling the broader adoption of fusion simulation on complex geometry

This project addressed a key barrier to advanced fusion and nuclear simulation: the difficulty of performing high-fidelity Monte Carlo neutronics directly on complex, real-world CAD geometry. Traditional workflows require engineers to rebuild CAD models as simplified constructive solid geometry, a time-consuming and error-prone process that limits design iteration and broader adoption of simulation tools. The goal of this Phase I SBIR was to make CAD-based neutronics practical, accessible, and robust for industrial and research users. During the project, Coreform significantly enhanced the Direct Accelerated Geometry Monte Carlo (DAGMC) workflow and fully integrated it into Coreform Cubit as a first-class capability. Major achievements include optimized material assignment and surface meshing workflows, substantial performance improvements to geometry imprinting and preparation, native export of DAGMC models, and new visualization tools to support OpenMC source definition and lost-particle debugging. Coreform also expanded Cubit’s capabilities as a full OpenMC preprocessor, including the ability to convert OpenMC constructive solid geometry models back into CAD for visualization, multiphysics coupling, and debugging. In collaboration with Argonne National Laboratory, the project delivered comprehensive new DAGMC documentation and training materials, transforming DAGMC from a research-oriented tool into a production-ready workflow. Results were disseminated through tutorials, conference training, and multiple well-attended webinars demonstrating integrated CAD-based neutronics and multiphysics workflows. Overall, this project demonstrated that high-fidelity Monte Carlo simulations can be performed directly on complex CAD geometry, reducing setup time, improving usability, and enabling faster, more informed design decisions for fusion and nuclear energy systems.

42 ENGINEERING↗

DOE OSTI2026

Understanding the Thermal Physics and Metallurgy of Metal Big Area Additive Manufacturing

The research goal of this EPSCoR-DOE partnership is to mitigate defects in parts made using a new type of additive manufacturing (AM) process called metal Big Area Additive Manufacturing (m-BAAM). To realize this goal, the PIs will detect and correct defects in the part as it is being printed by combining fundamental knowledge of the thermal physics and metallurgy of m-BAAM with in-process sensor data. Developed at the DOE-funded Manufacturing Demonstration Facility at Oak Ridge National Laboratory, the m-BAAM process involves one or more robots working together to produce a part by fusing metal wire layer-by-layer using arc welding. The process can print large metal parts such as turbine blades, which is not possible using other AM processes. In addition, m-BAAM production rates are more than ten times faster than other AM processes while requiring one-tenth of the material cost. Despite their potential to become a critical force multiplier in the energy generation industry, m-BAAM parts may fail to print accurately due to retention of heat and uneven cooling. Overheating and anomalous cooling rates in turn can cause inconsistencies in the microstructure, leading to sudden failure when used in safety-critical applications. In other words, flaw formation in m-BAAM parts is governed by the thermal history – intensity and spatial distribution of heat inside the part during printing. The thermal history is a complex function of the part shape and process settings such as welding energy, path taken by the welding torch for deposition (tool path), wire feed rate, among others.

36 MATERIALS SCIENCE↗

DOE OSTI2015

Solving the Big Data (BD) Problem in Advanced Manufacturing (Subcategory for work done at Georgia Tech. Study Process and Design Factors for Additive Manufacturing Improvement)

3D printing originally known as additive manufacturing is a process of making 3 dimensional solid objects from a CAD file. This ground breaking technology is widely used for industrial and biomedical purposes such as building objects, tools, body parts and cosmetics. An important benefit of 3D printing is the cost reduction and manufacturing flexibility; complex parts are built at the fraction of the price. However, layer by layer printing of complex shapes adds error due to the surface roughness. Any such error results in poor quality products with inaccurate dimensions. The main purpose of this research is to measure the amount of printing errors for parts with different geometric shapes and to analyze them for finding optimal printing settings to minimize the error. We use a Design of Experiments framework, and focus on studying parts with cone and ellipsoid shapes. We found that the orientation and the shape of geometric shapes have significant effect on the printing error. From our analysis, we also determined the optimal orientation that gives the least printing error.

36 MATERIALS SCIENCE↗

NASA NTRS1999

Unlocking the Keys to Vortex/Flame Interactions in Turbulent Gas-Jet Diffusion Flames--Dynamic Behavior Explored on the Space Shuttle

Most combustion processes in industrial applications (e.g., furnaces and engines) and in nature (e.g., forest fires) are turbulent. A better understanding of turbulent combustion could lead to improved combustor design, with enhanced efficiency and reduced emissions. Despite its importance, turbulent combustion is poorly understood because of its complexity. The rapidly changing and random behavior of such flames currently prevents detailed analysis, whether experimentally or computationally. However, it is possible to learn about the fundamental behavior of turbulent flames by exploring the controlled interaction of steady laminar flames and artificially induced flow vortices. These interactions are an inherent part of turbulent flames, and understanding them is essential to the characterization of turbulent combustion. Well-controlled and defined experiments of vortex interaction with laminar flames are not possible in normal gravity because of the interference of buoyancy- (i.e., gravity) induced vortices. Therefore, a joint microgravity study was established by researchers from the Science and Technology Development Corp. and the NASA Lewis Research Center. The experimental study culminated in the conduct of the Turbulent Gas-Jet Diffusion Flames (TGDF) Experiment on the STS-87 space shuttle mission in November 1997. The fully automated hardware, shown in photo, was designed and built at Lewis. During the mission, the experiment was housed in a Get Away Special (GAS) canister in the cargo bay.

Stocker, Dennis P.↗

NASA NTRS2008

Discrete Element Modeling of Triboelectrically Charged Particles

Tribocharging of particles is common in many processes including fine powder handling and mixing, printer toner transport and dust extraction. In a lunar environment with its high vacuum and lack of water, electrostatic forces are an important factor to consider when designing and operating equipment. Dust mitigation and management is critical to safe and predictable performance of people and equipment. The extreme nature of lunar conditions makes it difficult and costly to carry out experiments on earth which are necessary to better understand how particles gather and transfer charge between each other and with equipment surfaces. DEM (Discrete Element Modeling) provides an excellent virtual laboratory for studying tribocharging of particles as well as for design of devices for dust mitigation and for other purposes related to handling and processing of lunar regolith. Theoretical and experimental work has been performed pursuant to incorporating screened Coulombic electrostatic forces into EDEM, a commercial DEM software package. The DEM software is used to model the trajectories of large numbers of particles for industrial particulate handling and processing applications and can be coupled with other solvers and numerical models to calculate particle interaction with surrounding media and force fields. While simple Coulombic force between two particles is well understood, its operation in an ensemble of particles is more complex. When the tribocharging of particles and surfaces due to frictional contact is also considered, it is necessary to consider longer range of interaction of particles in response to electrostatic charging. The standard DEM algorithm accounts for particle mechanical properties and inertia as a function of particle shape and mass. If fluid drag is neglected, then particle dynamics are governed by contact between particles, between particles and equipment surfaces and gravity forces. Consideration of particle charge and any tribocharging and electric field effects requires calculation of the forces due to these effects.

Hogue, Michael D.↗

NASA NTRS2018

Robust Exploration and Commercial Missions to the Moon Using Nuclear Thermal Rocket Propulsion and In Situ Propellants Derived from Lunar Polar Ice Deposits

The nuclear thermal rocket (NTR) has frequently been identified as a key space asset required for the human exploration of Mars. This proven technology can also provide the affordable “access through cislunar space” necessary for commercial development and sustained human presence on the Moon. It is a demonstrated technology capable of generating both high thrust and high specific impulse (I(sub sp) ~900 s)— twice that of today’s best chemical rockets. Nuclear lunar transfer vehicles—consisting of a propulsion stage using three ~16.5-klb(sub f) small nuclear rocket engines (SNREs), an in-line propellant tank, plus the payload—can enable a variety of reusable lunar missions. These include cargo delivery and crewed lunar landing missions. Even weeklong “tourism” missions carrying passengers into lunar orbit for a day of sightseeing and picture taking are possible. The NTR can play an important role in the next phase of lunar exploration and development by providing a robust in-space lunar transportation system (LTS) that can allow initial outposts to evolve into settlements supported by a variety of commercial activities such as in situ propellant production used to supply strategically located propellant depots and transportation nodes. The processing of lunar polar ice (LPI) deposits (estimated to be ~2 billion metric tons) for propellant production—specifically liquid oxygen (LO(sub 2)) and hydrogen (LH(sub 2))—can significantly reduce the launch mass requirements from Earth and can enable reusable, surface-based lunar landing vehicles (LLVs) using LO(sub 2)/LH(sub 2) chemical rocket engines. Afterwards, LO(sub 2)/LH(sub 2) propellant depots can be established in lunar polar and equatorial orbits to supply the LTS. At this point a modified version of the conventional NTR called the LO(sub 2)-augmented NTR, or LANTR, would be introduced into the LTS, allowing bipropellant operation and leveraging the mission benefits of refueling with lunar-derived propellants (LDPs) for Earth return. The bipropellant LANTR engine utilizes the large divergent section of its nozzle as an “afterburner” into which oxygen is injected and supersonically combusted with nuclear preheated hydrogen emerging from the engine’s choked sonic throat—essentially “scramjet propulsion in reverse.” By varying the oxygen-to-hydrogen mixture ratio, LANTR engines can operate over a range of thrust and I(sub sp) values while the reactor core power level remains relatively constant. A LANTR-based LTS offers unique mission capabilities including short transit time crewed cargo transports. Even a “commuter” shuttle service may be possible, allowing “one-way” trip times to and from the Moon on the order of 36 hr or less. If only 1% of the postulated trapped water ice were available for use in lunar orbit, such a supply could support routine commuter flights to the Moon for many thousands of years. This report outlines an evolving LTS architecture that uses propellants derived from LPI and examines a variety of mission types and transfer vehicle designs along with their operating characteristics and increasing demands on LDP production as mission complexity and velocity change ΔV requirements increase. A comparison of the LDP production and mining requirements using LPI and volcanic glass to produce lunar-derived liquid oxygen (LUNOX) via the hydrogen reduction process is included, and the synergy with an evolving helium-3 mining industry is also discussed.

Borowski, Stanley K.↗

NASA NTRSDate not supplied

Transcribing Air Traffic Control System Command Center Planning Telecons Using Cloud-Based Automatic Speech Recognition

This paper addresses the challenge of using Automatic Speech Recognition (ASR) technology to transcribe regular teleconferences that happen between FAA Air Traffic Control System Command Center (ATCSCC) planners, stakeholders and air users. These planning teleconferences (aka telecons or planning webinars) are an integral part of managing air traffic in the U.S. National Airspace System (NAS). In particular, the meetings facilitate the creation and modification of various traffic management initiatives (TMIs), that are used to regulate the flow of air traffic. This is typically a human intensive process, requiring specialists to listen to the entire meeting audio (10-20 minutes duration) and inferring the state of the NAS (e.g., weather phenomenon) that was discussed. It would be advantageous to have digital transcripts of the audio and have useful information (e.g., related to TMIs) automatically extracted from the transcripts. In this regard, we are exploring the adoption of state-of-the-art speech to text and Natural Language Processing (NLP) tools that will achieve our objective of digitizing the webinar audio. Unfortunately, the highly technical phraseology present in the audio and limited data availability for model building make ASR difficult. To overcome this challenge, we have taken the critical first step in creating a human transcription dataset from ~20 hours of speech in the ATCSCC audio with the help of subject matter experts. A novelty of our work is the creation of a ground truth transcription dataset for ATCSCC teleconference webinars, which is particularly important for Aviation domain-specific NLP tasks. Using Microsoft Speech Studio, a cloud-based ASR platform, we have fine-tuned the English pre-trained ASR models (available in speech studio) and achieved an average word error rate (WER) of 6.81%. The baseline ASR also provides a digital version of each planning webinar, making it accessible and text-searchable for future references. Additionally, the transcriptions can serve as a bridge between raw audio data and a range of text-based NLP tasks, such as named entity recognition (NER) and intent classification, potentially enhancing the digital footprint of the webinars and other connected data sources. Our work has several potential applications. Firstly, the transcriptions can be analyzed to understand the complex decision process of creating, implementing and modifying TMIs and may also contribute to TMI prediction services. Secondly, our dataset and model can be used to develop more accurate ASR systems for aviation-specific language, which can bring about digital communication in the aviation industry (and aid current “voice only” communications, which are inherently error-prone). Lastly, the transcriptions themselves can be used as a valuable resource for training other NLP models.

Stephen S. B. Clarke↗

DOE OSTI2022

Standard Analytical Methods for Pyrolysis Bio-Oils

There has been significant recent interest in the production of renewable fuels and chemicals from biomass and waste feedstocks. Pyrolysis pathways produce a liquid bio-oil product, which must be processed further, or upgraded, to yield fuel or chemical products. Bio-oils are very complex and often unstable samples, and research and development on upgrading processes needs reliable analytical information. In particular, chemical characterization techniques are needed to quantify both functional groups and individual compounds present in bio-oils. Reliable analytics are also needed to enable the bioenergy industry, as industrial facilities often have different analytical needs and capabilities than research facilities. In this presentation, we will discuss the development of a suite of standard analytical methods for pyrolysis bio-oils. Analytical methods to be discussed include: Determination of Carbon, Hydrogen, Nitrogen, and Oxygen in bio-oils; Accelerated Aging of Fast Pyrolysis Bio-oil using Carbonyl Titration; Determination of Water Content in Bio-oils by Volumetric Karl Fischer Titration; Determination of Carbon Functional Groups; Elemental Analysis of Bio-oils by Inductively Coupled Plasma Optical Emission Spectroscopy (ICP-OES) - Na, K, Mg, Ca, S, P, and Fe; Determination of Phenolic Groups in Bio-oils using Revised Folin-Ciocalteu Methods: Single Cuvette and Plate Reader; Corrosivity of Bio-oils: Screening Test using Metal Leaching; Determination of Biogenic Content by 14C Measurement using Liquid Scintillation Counter. These new analytical methods are publicly available as Laboratory Analytical Procedures (https://www.nrel.gov/bioenergy/bio-oil-analysis.html), along with previously developed standard methods: GC-MS, Acid Titration, Carbonyl Titration, and 31P NMR. Additionally, the development of diffusion ordered NMR for characterization of bio-oil molecular weight will be discussed. Collectively, this suite of analytical methods represents the most comprehensive set of standard methods available for pyrolysis bio-oils. These standard methods are commonly used by the bioenergy community, and provide reliable information that enables research, scaleup, and industrial processing of biomass to produce renewable fuels and chemicals.

analytical↗

DOE OSTI2023

Heat Exchanger Design for Waste Heat Recovery using Additive Manufacturing

With anticipated increases in global energy use and their associated emissions, there are many efforts to improve the emissions and efficiency of many industrial processes through waste heat recovery (WHR). To maximize improvements, the heat exchangers in WHR power cycles must be designed and optimized for a given heat source. Meanwhile, additive manufacturing (AM) is a single part manufacturing technique that provides the opportunity to develop unique and complex heat exchanger designs. Consequently, this work centers on the modeling, design, optimization, and testing of AM shell and tube heat exchangers for WHR. Specifically, a modified one-dimensional (1+1-D) and three-dimensional (3-D) heat exchanger models were developed and validated, with the 1+1-D model serving as the basis for design optimization. After modifications to the design to allow for AM, heat exchanger geometry optimizations were completed, targeting increased effectiveness across a range of physical parameters. Of the designs considered, nine were additively manufactured using Ti5553, and then tested using an external heat source and working fluid. Experimentally, the nineteen-tube, zero-baffle heat exchanger displayed the best overall performance, with the effects of dimensional accuracy, surface roughness, and baffles in the other designs also indicated. Next, the experimental results were used as inputs for the 1+1-D model. Although the original model was able to predict fluid outlet temperatures within 5% differences, larger variations in the heat exchanger performance parameters, temperature differences, and pressure drop necessitated optimizing the pressure drop and heat transfer calculations within the model. Thus, the resulting improved model was able to predict the heat transfer rates, heat source temperature difference, and effectiveness within 15% differences, while showing improvements in the pressure drops and working fluid temperature differences. The improved model serves as the foundation for future work to improve the design and performance of AM heat exchangers.

Spickler, Bailey Ann↗