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DOE OSTI2022

Hydrogen Storage for Load-Following and Clean Power: Duct-firing of Hydrogen to Improve the Capacity Factor of NGCC Plants (Final Report, Phase I Conceptual Study)

The 12-month Feasibility study in Phase I study was completed and confirmed the system is feasible and the proposed system is an improvement over alternate low carbon dispatchable power options. Our demonstration will include 54 MWh of hydrogen storage. CO 2 capture inherent to the CHG process can capture 90% of the CO 2 (with upgrades to >98%) in a commercial system (~300 MWth) for sequestration or other uses. The hydrogen will be utilized in a duct burner in a Heat Recovery Steam Generator (HRSG) integrated with the existing Southern Company fossil asset. Here, the firing rate of the duct burner is varied to let the plant respond to fluctuations of electrical load. However, H 2 production is relatively constant by storing H 2 , and revenues are improved by arbitrage between use of low-cost off-peak variable electricity generation or use of stored H 2 under peak demand. The study enabled the fidelity of the concept to be improved and allowed identification of the requirements for the system. Defining the individual system and component requirements was performed via system requirements review with the whole team. These requirements were then incorporated into/iterated with our Heat & Mass Balance models and process flow diagrams were generated to reflect the overall system. This information was then used to complete the TEA and show economic feasibility. Our system generates power at 17.4% lower cost than other low carbon approaches for the H 2 generation, H 2 compression and storage, carbon sequestration, and HRSG added electricity production for a large-scale duct-fired system. Our team recommends completing the Phase II Pre-FEED study for the proposed system as the next step for the project and its tasks will achieve the overall objective and be ready to launch the FEED. The Pre-FEED tasks include updating the requirements, Concept of Operations, plant scope/process description, component modeling, system modeling, performance estimates, emission estimates, block flow diagrams, fluid/process conditions (PFD), utility usage, and facility sizing/definition. The approach will be to complete these updates in a greater level of detail for the selected site. The approach for developing the EIV is to use the updated results, including model outputs, for carbon dioxide and waste streams.

03 NATURAL GAS↗

DOE OSTI2021

The JLab Eta Factory (JEF) experiment

The new experiment, JLab Eta Factory (JEF), in the experimental Hall D at Jefferson Lab will extend the physics potential of the GlueX detector beyond the main spectroscopy program and perform precision measurements of various ?(?)decays with emphasis on rare neutral modes. The physics program of the experiment spans from precision tests of low-energy QCD to search of gauge bosons in the mass range below 1 GeV coupling the SM sector to the dark sector. Photoproduction of highly boosted ?(?)mesons using a tagged photon beam, good detection of recoil proton and multi-photon final states will allow to suppress background and collect high-statistics data sample of ?mesons. All these provide many advantages over other ?(?)experiments. The JEF experiment requires to upgrade the inner part of the forward lead glass calorimeter of the GlueX detector with high-granularity, high-resolution lead tungstate PbWO4 scintillating crystals. The calorimeter insert is currently under construction at Jeffeson Lab. The detector will be ready to take data in 2024. An overview of the JEF project will be presented.

Somov, Alexander↗

DOE OSTI2019

Cool GTL - A New Biogas Conversion Process from GTI

GTI is currently developing the Cool GTL process, to convert biogas into jet fuel. Cool GTL can be used to convert any biogas stream or high CO2 content natural gas to high quality liquid fuels. In Cool GTL we convert high CO2 feeds to synthesis gas at a 2-2.4/1 H2/CO ratio using a novel CO2/steam reforming catalyst which has high stability. The 2.0-2.4/1 H2/CO synthesis gas ratio is always achieved, for a variety of levels of feed CO2 content, by adjusting the amount of water added according to the amount of CO2 in the feed. The reformer catalyst has been tested for 500 hours and shows no deactivation. The product from the reformer then goes directly to a low temperature bubbling fluid bed Fischer Tropsch reactor with an integrated finishing hydroisomerization reactor which makes hydrocarbon liquids from the synthesis gas, With this configuration no wax is produced. The fluid bed allows excellent temperature control. Cool GTL is under development but still requires longer integrated testing. Currently Cool GTL is being developed at GTI through DOE funding in the project “Cool GTL for the Production of Jet Fuel from Biogas”. In this DOE project, our goal is to make 100 gallons of high quality jet fuel. This project will also demonstrate Cool GTL catalyst and process stability through long term, 24 hour operation. Once the DOE project is complete, we believe the Cool GTL process will be ready for larger scale commercial deployment in multiple applications.

09 BIOMASS FUELS↗

DOE OSTI2025

Reducing Mass of Steel Auto Bodies using Thin Advanced High Strength Steel with Carbon-Fiber Reinforced Epoxy

Diversitak, a company based in Detroit, MI, has developed a proprietary, low specific gravity, carbon fiber-reinforced epoxy (CFRE) under U.S. patent number 9,963,58832. Preliminary testing on this new material conducted in collaboration with ArcelorMittal Steel Company proved out the CFRE concept. A thin layer of this CFRE was applied to a stamped sheet of steel with residual stamping oils from a mill, in a time corresponding to automotive processing (e.g., ~15 seconds), and processed following automotive e-coat procedures (phosphating + 175–200°C heating), to complete the curing. No problems with adherence or performance were noted. While the CFRE does add weight to a thin gauge steel panel, it weighs much less than what is displaced by using thicker conventional mild steel gauges. The application of the coating showed a significant increased dent resistance, oil canning resistance, and part stiffness.This current two-year project was designed to mature this new technology to near manufacturing readiness to reduce the weight of a vehicle and lower the cost of weight reduction. The process involves the use of thinner gauge steels than are currently used. The collaborative development team included two industrial manufacturers: Diversitak and ArcelorMittal Steel Company; LightMAT; and two National Laboratories: Oak Ridge National Laboratory (ORNL) and Idaho National Laboratory (INL). The team developed a new manufacturing process to reduce the weight of a vehicle and lower the cost of weight reduction, as well as a better understanding of how to apply the coating so that it will perform to a high standard in-service. The team also performed an in-depth study to determine the long-term durability of the materials manufactured using this technology and well-known automotive industry standard tests.The overall process involved stiffening the thinner gauge steel by applying the CFRE on only one side. To accomplish this goal, the optimal reinforcement fiber length and fiber concentration was first determined. This was followed by measuring the coefficient of thermal expansion (CTE) in all three directions, so it could be fed into manufacturing models and methods for rapidly and inexpensively applying the coating. This was followed by panel level evaluations of the coating and steel combination, and then by full part demonstration of the technology on door panels. The final step was corrosion testing of the parts.ArcelorMittal characterized the advanced high strength steel (AHSS) (e.g., metallurgy-heat treatment for required AHSS properties as a function of the sheet thickness, state of internal stress) and quantified CFRE adhesion to the steel as a function of sheet preparation (e.g., rolling and stamping).ORNL optimized the fiber length, fiber concentration, and coating thickness for best vehicle function and performance at the least cost. Along with the suppliers, ORNL developed a durable CFRE application process (e.g., gun material, design, robotic dispensing process) and identified the adhesion stability of the CFRE during process holding. An approach to ensure that application/curing timing conforms to conventional assembly line speed and plant cycle times was determined. ORNL also determined the CTE of the material in all three directions and performed material scanning electron microscopy (SEM) analyses.INL characterized the corrosion properties of the steel panels coated with CFRE. The panels were investigated for corrosion resistance and stability as replacement materials used in automotive body panels to reduce mass. The coupons tested at INL were supplied by Diversitak after an optimized CFRE formulation was achieved in the already coated form for corrosion testing.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2026

Novel additive manufacturing for plasma facing materials ‐ creating a research pathway for minority students

This project addresses two critical and intertwined challenges in fusion energy, namely the shortage of a broadly trained scientific workforce and the lack of scalable manufacturing solutions for plasma-facing components (PFCs). Through a collaboration among Florida International University (FIU), Miami Dade College (MDC), and Purdue University, the project established structured, reproducible educational and research pathways that recruit and advance students from institutions historically outside the fusion energy enterprise, building the human capital that this field urgently needs. The project integrates the complementary research strengths of FIU and Purdue to investigate flash sintering as a transformative processing route for tungsten-based PFCs. Unlike conventional sintering approaches, flash sintering offers rapid densification at significantly reduced thermal budgets, making it a compelling candidate for fabricating complex tungsten geometries that must withstand extreme plasma-facing environments. Systematic experimental and modeling efforts will elucidate the fundamental mechanisms governing microstructure evolution, grain boundary chemistry, and thermomechanical response during flash sintering — knowledge that is presently lacking but essential for translating this technology into reliable manufacturing practice. The convergence of workforce development and cutting-edge manufacturing research positions this project to deliver measurable, durable impact: a pipeline of fusion-ready researchers cultivated through expanded institutional partnerships, and a validated materials processing framework that accelerates domestic readiness for next-generation fusion reactor construction.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1974

SERT C project study

The SERT C (Space Electric Rocket Test - C) project study defines a spacecraft mission that would demonstrate the technology readiness of ion thruster systems for primary propulsion and station keeping applications. As a low cost precursor, SERT C develops the components and systems required for subsequent Solar Electric Propulsion (SEP) applications. The SERT C mission requirements and preliminary spacecraft and subsystem design are described.

Source record↗

NASA NTRS1978

The Aerospace Safety Advisory panel's report to Doctor Robert A. Frosch, 1977

Risks attendant to NASA's operations are identified for the following: mission operations; orbiter readiness for orbital flight tests; space shuttle main engine; avionics; thermal projection system; hazard assessment; human error. Past and future projects are assessed.

Source record↗

NASA NTRS2018

Polar Volatiles Exploration in Peary Crater Enabled by NASA's Kilopower Project

For more than 50 years, scientists have discussed the possibility of the existence of water ice and other frozen volatiles at the lunar poles [1]. However, it was not until the 1990s when the polar orbiting spacecraft Clementine and Lunar Prospector collected data supporting these hypotheses [2]. Subsequent missions, including the Lunar Reconnaissance Orbiter (LRO) mission [3], and the Lunar Crater Observation and Sensing Satellite (LCROSS) mission [4], provided further evidence that supports the existence of water ice deposits at the lunar poles. During NASA's Constellation Program, several areas at both lunar poles polar were included in 50 Regions of Interest (ROI) for intensive study by the Lunar Reconnaissance Orbiter Camera (LROC) [5]. These polar ROI focused on peaks and craters rims that received high amounts of solar illumination, assuming initial missions back to the lunar surface would utilize solar arrays to generate electricity. Recently, the successful demonstration of NASA's Kilopower Project at the National Nuclear Security Administration (NNSA) Nevada National Security Site makes it possible to consider lunar polar missions at locations other than highly illuminated regions. The Kilopower Project was initiated in 2015 to demonstrate subsystem-level technology readiness of a small space fission power system [6]. This abstract describes the science objectives and operations for a mission concept developed at NASA Glenn Research Center's COMPASS Concurrent Engineering Team for a 1-year exploration of Peary Crater focused on prospecting for lunar polar volatiles.

Gruener, J. E.↗

NASA NTRS2017

Parabolic Flight Testing of Aeroponic Plant Growth Systems and Super Omniphobic Surface Coatings

The purpose of this project is to gain valuable data from three separate experiments. One being an aeroponics watering system, another being a PONDS passive watering system, and the last a super omniphobic surface coating apparatus.There are two aeroponics watering systems that feed water and nutrients to "plant roots" inside of a contained box. The walls inside of the contained boxes have different surface textures and shapes but each contain the same nozzle and compressor set up as a control.There is one PONDS passive watering system that feeds water from a reservoir to a porous substrate utilizing wicking materials. There is one super omniphobic surface coating apparatus that feeds water into an apparatus allowing the water to make contact with three individual compartments in which glass beads with different coatings are carefully placed between two glass slides. The outcome will contribute to the advancement in self sustainment for space exploration. The status of the project when I started was to get the system built and ready for flight come November. My intended contributions are to assist with the build of the system.

Blockey, Jamie Lynn↗

NASA NTRS2019

Thermal Protection System Technology Maturation and Sustainment in Support of In-situ Science Missions: HEEET and PICA

Among the challenges faced by the Entry Descent and Landing (EDL) community have been: the lack of a matured forebody heatshield thermal protection system (TPS) capable of meeting the demanding entry environments for the high priority in-situ science missions identified in the decadal survey at Venus, Saturn and the Ice Giants, and the continued sustainment of thermal protection systems/materials. In response to the identified shortfall in TPS technologies capable of extreme entry environments NASA's Space Technology Mission Directorate (STMD) and Science Mission Directorate (SMD) initiated the Heatshield for Extreme Entry Environment Technology (HEEET) project which has matured a 3D-Woven TPS to Technology Readiness Level 6 and which is ready for infusion into these high priority missions. During the development of HEEET long term sustainability was a key consideration. However existing TPS also continue to face sustainability issues. Phenolic Impregnated Carbon Ablator (PICA) has been/is being utilized by many SMD Missions (Stardust, Mars Science Laboratory, OSIRIS-Rex, Mars 2020, Dragonfly) and is under consideration for others including Mars Sample Return, so maintaining PICA for the long term is a priority for NASA. This presentation will discuss raw material sustainability challenges faced by PICA and the efforts by NASA to work with Fiber Materials Inc (FMI) to resolve these challenges with a more sustainable supply chain. In addition, NASA is working with FMI to increase the manufacturing scale for single piece PICA heatshields and to expand the aerothermal performance envelop maturing PICA for larger sized heatshield and more aggressive entry environments. This presentation will also identify challenges and limitations with these systems, particularly around understanding failure modes in these materials and systems and how understanding these may allow use of these systems in environments that are difficult to achieve in ground based testing.

Heatshield for Extreme Entry Environment Technolog↗

NASA NTRS2019

Thermal Protection System Technology Maturation and Sustainment in Support of In Situ Science Missions: HEEET and PICA

Challenges faced by the Entry Descent and Landing (EDL) community include the lack of a matured forebody heatshield thermal protection system (TPS) capable of meeting the demanding entry environments for the high priority in-situ science missions identified in the decadal survey at Venus, Saturn and the Ice Giants, and the continued sustainment of thermal protection systems/materials. In response to the identified shortfall in TPS technologies capable of extreme entry environments NASA's Space Technology Mission Directorate (STMD) and Science Mission Directorate (SMD) initiated the Heatshield for Extreme Entry Environment Technology (HEEET) project which has matured a 3D-Woven TPS to Technology Readiness Level 6 and which is ready for infusion into these high priority missions. During the development of HEEET long term sustainability was a key consideration. However existing TPS also continue to face sustainability issues. Phenolic Impregnated Carbon Ablator (PICA) has been/is being utilized by many SMD Missions (Stardust, Mars Science Laboratory, OSIRIS-Rex, Mars 2020, Dragonfly) and is under consideration for others including Mars Sample Return, so maintaining PICA for the long term is a priority for NASA. This presentation will discuss raw material sustainability challenges faced by PICA and the efforts by NASA to work with Fiber Materials Inc (FMI) to resolve these challenges with a more sustainable supply chain. In addition, NASA is working with FMI to increase the manufacturing scale for single piece PICA heatshields and to expand the aerothermal performance envelop maturing PICA for larger sized heatshield and more aggressive entry environments. This presentation will also identify challenges and limitations with these systems, particularly around understanding failure modes in these materials and systems and how understanding these may allow use of these systems in environments that are difficult to achieve in ground based testing

Phenolic Impregnated Carbon Ablator (PICA)↗

NASA NTRSDate not supplied

ImageLabler: Labeling and Managing Image Data for Machine Learning in the Earth Sciences

While machine learning techniques for image classification have been around for a long time, storing and managing the vast number of images required as training data is still a problem for scientists. This is especially true for the field of Earth science, where only recently have experts begun using machine learning techniques for image-based phenomena classification. Image Labeler, a fast and scalable cloud-based tagging platform for Earth science images, seeks to improve upon existing methods of managing images and associated metadata, such as maintaining categorized folders of images on a local machine, a process that can be cumbersome and difficult to scale. The platform facilitates rapid development of image-based Earth science phenomena training datasets by allowing scientists to upload their existing imagery as well as extract new samples from open satellite imagery services made available through NASA’s Global Imagery Browse Service (GIBS). Image Labeler also supports GeoTIFF data, with capabilities such as displaying GeoTIFFs on an interactive map, drawing shapefiles over them, and tagging them with additional metadata. This allows scientists to perform spatiotemporal subsetting with geographic information and develop training data more quickly. Built using modern web technologies, Image Labeler includes additional capabilities such as team collaboration for large-scale image tagging projects. Users can download their data in a machine-learning-ready format, allowing scientists to spend time on experimentation rather than on the collection of training data. In this presentation, we demonstrate how Image Labeler seeks to become a one-stop image data management solution for machine learning applications in Earth science.

Ashish Acharya↗

NASA NTRSDate not supplied

Development of Stirling Convertors for Radioisotope and Fission Power Systems

NASA has been developing free-piston Stirling-cycle power convertors over the past 22 years for use in nuclear power systems that would provide electricity for space science missions to dark, dusty, or distant destinations where solar power is not practical. These nuclear power systems would generate heat from either the radioactive decay of isotopes or fission nuclear reactors. That heat would be converted to usable electricity using highly efficient Stirling convertors for a wide range of power needs needing 10s of watts to 50 kWe. NASA’s Radioisotope Power Systems (RPS) Program is maturing advanced thermoelectric and dynamic conversion technologies that would increase the system efficiency beyond what is currently possible using heritage systems to enable a larger number of robotic missions or higher power missions to solar system bodies of interest. The Dynamic Radioisotope Power Systems (DRPS) Project has matured prototype Stirling convertors to sufficiently increase the technology readiness level for infusion into flight development. Flexure and gas-bearing free-piston Stirling convertors were developed under contract by commercial partners and delivered to enable government evaluation. Gas-bearing designs have met performance and robustness requirements and were selected for flight development. This paper provides the status of SRSC test campaign and maturity level.

Dynamic↗

NASA NTRSDate not supplied

Polar Resources Ice Mining Experiment-1 (PRIME-1) NASA’s First Polar Drilling and Volatiles Detection Mission

The US Administration announced in 2019 that NASA would return to the Moon where it would seek to establish a sustainable lunar presence. In Situ Resource Utilization (ISRU) is needed to sustain and grow hu-man surface exploration and it is therefore a vital part of ensuring this bold endeavor. ISRU requires ground-truth on physical, mineral, and volatile characteristics of the resources. Water, a key and game-changing resource, exists in the polar regions of the Moon. Learning to harvest and use this resource first requires understanding where the resource is abundantly located and on what scales. Harvested water, which is usable for life support and fuel, must be identified, quantified, and assessed for its mining feasibility. The project goal for PRIME-1 is to develop a flight-ready instrumentation package that can assess the volatiles at a polar lunar landing location. PRIME-1 is the combination of two instruments; Mass Spectrometer observing lunar operations (MSolo) and The Regolith and Ice Drill for Exploring New Terrain (TRIDENT). TRIDENT is an 1-meter augering drill capable of bringing incremental lunar regolith samples to the surface for volatile analysis. MSolo is a modified, commercial-off-the-shelf (COTS) mass spectrometer capable of qualifying and quantifying atomic species in the 1-100 amu range, including isotopic differentiation. These two lunar flight instruments operating together make up the PRIME-1 instrument suite. PRIME-1 intends to fly on and operate from a static lunar lander acquired by the NASA Commercial Lunar Payload Services (CLPS) acquisition process. The PRIME-1 payload suite was selected to fly on Intuitive Machines Nova-C lander, and is currently targeting a late Fall 2023 landing attempt.

MSolo↗

NASA NTRS2023

Development of Stirling Convertors for Radioisotope and Fission Power Systems

Dynamic↗

NASA NTRSDate not supplied

Polar Resources Ice Mining Experiment-1 (PRIME-1) NASA’s First Polar Drilling and Volatiles Detection Mission

MSolo↗

DOE OSTI2018

Making Progress toward Net Zero Sites in the Army Reserve through Analysis of Multiple Scenarios

The U.S. Army Reserve (USAR) prioritized achieving net zero as part of its Sustainability Program in 2013, and developed a pilot that investigated net zero energy, water, and waste at 10 sites. Pilot sites were selected based on mission requirements for energy and water resilience and the likelihood of achieving the technical and economic thresholds for net zero. USAR owns and operates hundreds of sites that typically consist of between 2 and 10 buildings. The pilot sites were intentionally dispersed across the U.S. and its territories to provide a range of geographic characteristics where the net zero potential could be analyzed and solutions could be developed. For the Army, changes to operations must support the mission and enhance readiness, which includes increasing efficiency and resiliency. To facilitate alignment of project prioritization with different goals and site-specific needs, a net zero roadmap outlined three scenarios for project implementation: (1) cost-effective measures, (2) net zero measures, and (3) recommended measures. Each scenario included the same measures for some sites, while others had three different outcomes. USAR has used these roadmaps to plan and execute projects and move toward net zero at multiple sites since 2014, with the primary focus on the cost-effective and recommended scenarios. As conditions and costs change, additional measures required to achieve net zero are considered. This paper describes the methodology deployed for analyzing net zero for the USAR and discusses the benefits of working toward net zero under three distinct scenarios.

Net Zero↗

DOE OSTI2024

Fabrication and Testing of DOE Standard Canister Closure Leak Test Assembly

DOE manages over 300 types of spent nuclear fuel (SNF), many of which are located at the Idaho National Laboratory (INL) site. Managing this large variety of SNF for storage, transportation, and disposal poses a challenge to DOE. The Idaho Cleanup Project and INL are collaborating on the DOE SNF Road-Ready Demonstration (“Road-Ready Demonstration”), which will develop and demonstrate the designs, technology, processes, and regulatory framework for packaging DOE-managed SNF for “road-ready dry storage.” Road-ready dry storage is an SNF management concept in which SNF is packaged into dry, sealed canisters that are then placed in onsite storage in anticipation of later transport and disposition. The forward-looking goal of the Road-Ready Demonstration is to establish the foundation for a large-scale road-ready dry storage program at the INL site. In support of establishing a large-scale road-ready dry storage program at the INL site, the Road-Ready Demonstration will first package Fort St. Vrain SNF currently in dry storage at INL into several DOE Standard Canisters (DOESCs). These DOESCs will in turn be loaded into another containment similar to commercial multi-purpose canisters. This multi-purpose canister will then be compatible with a transportation or storage system, such as a storage cask for interim storage or transportation package for offsite transport. These DOESCs will remain sealed over the course of their storage, transportation, and applicable disposal functions. The closure process for the DOESC will include fuel and basket loading, welding, inspection, leak testing, and, if needed, repair. As a follow-up to previous discussions on the design of the DOE Closure Leak Test Assembly (LTA), this report describes recent fabrication and testing efforts performed at INL. DOESCs are sealed by two sequential gas tungsten arc welds, both of which are performed by remotely operated and semiautomatic welding systems. The first weld is a circumferential pipe weld that completes the assembly of the canister body and lid assembly. The second and final closure weld attaches the vent plug to the vent socket via a butt joint. After the second weld is performed, the welds are helium leak tested using an evacuated envelope technique. The LTA was designed for both remote and manual operation. This report describes the fabrication and performance testing associated with the evacuated envelope technique. INL staff designed, fabricated, and tested the LTA at INL facilities. This testing included establishing technique and system sensitivities in accordance with ASME and American National Standards Institute N14.5 requirements. Forthcoming work will cover such areas as design optimization, process and personnel qualification, and implementation in Road-Ready Demonstration operations.

42 ENGINEERING↗