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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 OSTI2022

Reliability-Informed Economic and Energy Evaluation for Bi-Level Design for Remanufacturing: A Case Study of Transmission and Hydraulic Manifold

Abstract Design for remanufacturing (DfRem) is one attractive strategy that encourages the reuse of a product and extends the product's life cycle. Traditional design processes often only consider product reliability at an early design stage. However, from the perspective of environmental sustainability, it is becoming increasingly important to evaluate the long-term economic and environmental impacts of design decisions during early-stage design. We propose a bi-level DfRem framework consisting of system-level reusability allocation and component-level design tradeoff analysis, considering reliability and product warranty policy. First, a system-level reusability allocation problem aims at a theoretical exploration of the design space where all the components comprising the system are allocated certain reuse rates to achieve target energy savings with minimum cost. Following the theoretical exploration at the system level, a component-level analysis looks at practical design options for each component and trades-off between the overall cost and energy consumption for multiple remanufacturing cycles. Both levels of the framework require modeling component reuse for multiple remanufacturing cycles, which we achieve by using a branched power-law model that provides probabilistic scenarios of reusing the component or replacing it with a new part. We demonstrate the utility of this framework with the case study of an infinitely variable transmission (IVT) used by some agricultural machines manufactured by John Deere and show snapshots of a prototype software tool that we developed for easy use by designers.

Engineering↗
DOE OSTI2024

Transactive Energy Practices Survey

For nearly two decades, the idea of using market-based approaches in field deployments that coordinate the flexible operation of electricity customer assets has occupied the efforts of transactive energy practitioners. While the purported benefits of this distributed decision-making approach encourage transactive energy designs have been well explored, the practical aspects of implementing such a system to address real-world problems are just beginning to emerge. This report surveyed 24 field-deployed programs and interviewed experts instrumental in these deployments. The results of the survey and interviews reveal the diversity of designs and applications. They highlight the technical promise of the approaches as well as challenges with system integration, sustainable business strategy, and regulatory policy obstacles. Insights from the survey offer considerations to direct future effort and investment.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

The potential of caproate (hexanoate) production using Clostridium kluyveri syntrophic cocultures with Clostridium acetobutylicum or Clostridium saccharolyticum

Caproate (hexanoate) and other medium-chain fatty acids are valuable platform chemicals produced by processes utilizing petroleum or plant oil. Clostridium kluyveri , growing on short chain alcohols (notably ethanol) and carboxylic acids (such as acetate) is noted for its ability to perform chain elongation to produce 4- to 8-carbon carboxylates. C. kluyveri has been studied in monoculture and coculture conditions, which lead to relatively modest carboxylate titers after long fermentation times. To assess the biosynthetic potential of C. kluyveri for caproate production from sugars through coculture fermentations, in the absence of monoculture data in the literature suitable for our coculture experiments, we first explored C. kluyveri monocultures. Some monocultures achieved caproate titers of 150 to over 200 mM in 40–50 h with a production rate of 7.9 mM/h. Based on that data, we then explored two novel, syntrophic coculture partners for producing caproate from sugars: Clostridium acetobutylicum and Clostridium saccharolyticum . Neither species has been cocultured with C. kluyveri before, and both demonstrate promising results. Our experiments of C. kluyveri monocultures and C. kluyveri — C. saccharolyticum cocultures demonstrate exceptionally high caproate titers (145–200 mM), fast production rates (3.25–8.1 mM/h), and short fermentation times (18–45 h). These results represent the most caproate produced by a C. kluyveri coculture in the shortest known fermentation time. We also explored the possibility of heterologous cell fusion between the coculture pairs similar to the results seen previously in our group with C. acetobutylicum and Clostridium ljungdahlii. Fusion events were observed only in the C. acetobutylicum — C. kluyveri coculture pair, and we offer an explanation for the lack of fusion between C. saccharolyticum and C. kluyveri . This work supports the promise of coculture biotechnology for sustainable production of caproate and other platform chemicals.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2024

Data from: Biomass yield, yield components and growing season phenotypic measurements of Miscanthus

For sustainable biomass production of Miscanthus × giganteus (hereafter miscanthus), understanding the impact of stand age and nitrogen (N) fertilization on biomass yield is crucial. This study investigated the effects of varying N fertilization rates (0, 56, 112, and 168 kg N ha-1) on yield components (tiller height, density, and weight) and their correlations with end-of-season biomass yield in miscanthus. We also explored end-of-season biomass yield prediction using in-season traits (canopy height, leaf area index (LAI), and leaf chlorophyll content (LCC)). The study was conducted at two sites in Illinois: a previously unfertilized 10-year-old miscanthus research stand at Urbana and a 16-year-old commercial stand at Pesotum with a history of annual 56N application. Results from 2018-2021 in Urbana and 2020-2021 in Pesotum showed increased biomass yields with N fertilization, varying by rate, year, and location. Biomass yield in Pesotum peaked at 56N, while in Urbana, it increased significantly at 112 kg N ha-1. Biomass yield was strongly correlated with tiller height and weight measured at Urbana across N rates. Morphological traits measured every 2-3 weeks during the 2020 and 2021 growing seasons showed that canopy height was the strongest single predictor of miscanthus biomass yield, followed by LCC. Mid-August to September measurements of these traits were the best predictors of biomass yield. Multiple regressions involving the canopy height and LCC further improved yield predictions. We conclude that while N enhances biomass yields of aging miscanthus, the optimum rate depends on the site, environmental conditions, and management.

Aging↗
DOE OSTI2020

Deep Isolation-Development of the Safety Case for Disposal of Radioactive Wastes in Horizontal Boreholes - 20028

Deep Isolation has developed a safe, secure, and permanent geological disposal method for high-level waste, including spent nuclear fuel as well as sealed sources and other highly radioactive materials. The method leverages well established directional drilling technology to create horizontal repositories deep underground. The combination of great depth (1-3 km) and the ability to precisely position repositories in a horizontal orientation provides access to geologic strata that are inaccessible for typical mined and deep vertical borehole repositories. A number of potential direct and indirect safety benefits accrue including:1) greater depth below regional freshwater aquifers; 2) increased flexibility and more geologic options for siting; 3) access to deep formations with persistent and sustained reducing conditions. In addition there are a number of safety elements related specifically to the horizontal repository geometry including: 1) passive direction of thermally driven fluid and radionuclide movement away from the vertical access hole and toward the 'dead end' portion of the repository; 2) mitigation of seismic hazards by orienting repositories parallel to local and regional fault structures. In this paper we explore and discuss some of the key technologic, geologic and hydrologic elements that support the deep horizontal borehole safety case. The stalemate seen across the globe on the disposal of spent nuclear fuel and high-level waste can be broken. Deep Isolation offers a novel option for safe, secure, and permanent deep geological disposal of nuclear waste that can be developed as centralized repositories or adapted to smaller regional or site-specific repositories located near waste sources. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2026

Physics basis for the reference flat-top plasma scenario in the ST–E1 fusion power plant

As part of the U.S. Department of Energy’s Milestone-Based Fusion Energy Development Program, Tokamak Energy has completed the pre-concept design of the ST–E1 fusion power plant. ST–E1 is envisaged to operate in two phases: a pilot plant phase, targeting sustained net power production of 300 - 500 MWe for a duration >1 hr, followed by a commercial power plant phase targeting steady-state operations and a normalised overnight capital cost of ⩽12 000 $\$$/kWe. The design process adopted was highly iterative, integrating all major plant systems and progressing in a phased fidelity approach. At the pre-conceptual stage, the emphasis has been on exploring the design space, identifying the main system-level trade-offs, and making the key decisions that define the overall plant concept, rather than optimising a single operating point. This paper, part of a focused collection detailing the ST–E1 pre-concept design, addresses the development of a series of reference flat-top plasma operating points for the pilot plant phase. A modelling workflow was established to develop and assess candidate plasma design points and explore key dependencies. The workflow includes integrated core plasma modelling, magnetohydrodynamic (MHD) stability assessment, equilibrium generation, scrape-off-layer and exhaust modelling, heating & current drive design and optimisation, and turbulent transport modelling. Using this framework, the impact of several key parameters on the flat-top operating space was investigated, including the density limit, core radiation fraction and divertor power loading, level of external heating and curent drive power and assumed pedestal characteristics. The MHD stability, controllability and micro-stability characteristics of these plasmas were also analysed. These investigations informed the definition of a set of fully non-inductive, flat-top reference operating points that satisfy the high-level ST–E1 mission, including a low and high density case, a case that is stable to resistive wall modes and a case with reduced divertor power loading.

ST–E1↗
DOE OSTI2022

Safeguarding Commercial Breed and Burn Sodium-Cooled Fast Reactors

A new class of reactors is under development in the United States. These new reactor designs use fast neutron spectra and rely on fuel technology advancements to reach fleet-wide operating conditions where neither enrichment nor reprocessing fuel are required to sustain or grow the fleet. Achieving this level of operation requires nuclear fuel that can remain in the reactor environment for much longer than current limits. The transfer of irradiated fuel is also required as the initial fissile source for new and replacement reactors. This class of reactors is known as breed and burn reactors and can be deployed as a fleet whereby the transfer of fuel is used to power subsequent generations of reactors. The use of breed and burn reactors reduces, and potentially eliminates, the need for enrichment and reprocessing to sustain a reactor fleet. Currently, enrichment and reprocessing plants require extremely complicated safeguards implementation and offer States diversion pathways for indirect use material. By eliminating the need for these facilities, a nuclear power fleet based on the BREED AND BURN reactor concept has the potential to indirectly reduce the burden on IAEA safeguards. However, this complex dynamic system does pose new safeguards challenges that are explored further in this report.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Power Quality and Load Capacity Evaluations of an Electric Vehicle for Multi-Robot System Applications

This paper evaluates the capability of a fully electric pickup truck, using the Ford F-150 Lightning as an example, to provide power to the circuit of a multi-robot system. The case study was conducted on a simulated INL Autonomous Pit Exploration System (APES) designed for the inspection of nuclear waste tank pits. Through a series of controlled tests, the vehicle’s power delivery consistency, load-handling capability, and battery performance were assessed under various conditions. First of all, the load test demonstrated that the vehicle provided stable power with low distortion and no unexpected interruptions. Second, during the operational limit test, the 240V system sustained loads up to 7.4 kW before tripping, providing insights into its operational limits. Last but not least, during a simulated full-scale APES operation, the vehicle’s battery depleted by only 6% over an hour, indicating sufficient capacity for extended use while retaining reserve power for transportation needs. This study highlights the potential of electric vehicles as reliable power sources for field operations, contributing to the advancement of sustainable technologies by reducing reliance on traditional fossil fuel generators and promoting the integration of clean energy solutions in remote and challenging environments.

Electric vehicle↗
DOE OSTI2025

IEEE SusTech 2025 Presentation

This paper evaluates the capability of a fully electric pickup truck, using the Ford F-150 Lightning as an example, to provide power to the circuit of a multi-robot system. The case study was conducted on a simulated INL Autonomous Pit Exploration System (APES) designed for the inspection of nuclear waste tank pits. Through a series of controlled tests, the vehicle’s power delivery consistency, load-handling capability, and battery performance were assessed under various conditions. First of all, the load test demonstrated that the vehicle provided stable power with low distortion and no unexpected interruptions. Second, during the operational limit test, the 240V system sustained loads up to 7.4 kW before tripping, providing insights into its operational limits. Last but not least, during a simulated full-scale APES operation, the vehicle’s battery depleted by only 6\% over an hour, indicating sufficient capacity for extended use while retaining reserve power for transportation needs. This study highlights the potential of electric vehicles as reliable power sources for field operations, contributing to the advancement of sustainable technologies by reducing reliance on traditional fossil fuel generators and promoting the integration of clean energy solutions in remote and challenging environments.

42 - ENGINEERING↗
DOE OSTI2022

Translating advances in microbial bioproduction to sustainable biotechnology

Advances in synthetic biology have radically changed our ability to rewire microorganisms and significantly improved the scalable production of a vast array of drop-in biopolymers and biofuels. The success of a drop-in bioproduct is contingent on market competition with petrochemical analogues and weighted upon relative economic and environmental metrics. While the quantification of comparative trade-offs is critical for accurate process-level decision making, the translation of industrial ecology to synthetic biology is often ambiguous and assessment accuracy has proven challenging. In this review, we explore strategies for evaluating industrial biotechnology through life cycle and techno-economic assessment, then contextualize how recent developments in synthetic biology have improved process viability by expanding feedstock availability and the productivity of microbes. By juxtaposing biological and industrial constraints, we highlight major obstacles between the disparate disciplines that hinder accurate process evaluation. The convergence of these disciplines is crucial in shifting towards carbon neutrality and a circular bioeconomy.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2022

Perspective—Is Sustainable Electrowinning of Neodymium Metal Achievable?

Rare–earth metals such as neodymium are central to numerous technologically important applications such as electrified transportation, renewable energy harvesting, and magnetic data storage. Presently, neodymium metal is produced via electrolysis of Nd 2 O 3 –containing NdF 3 –LiF molten salts at high temperatures. However, this conventional electrolytic route has several drawbacks including emissions of greenhouse gases such as CO 2 and perfluorocarbons, which are harmful to the environment. In this perspective, an alternate concept based on electrolysis of NdCl 3 –containing chloride–based molten salts is explored and its potential advantages are discussed. Notably, NdCl 3 can be obtained via direct non–carbothermic chlorination of Nd 2 O 3 , supported by thermodynamic calculations and experimental evidence from literature. The chloride–based molten salt electrolysis route also offers the possibility of incorporating a non–consumable or dimensionally stable anode leading to reduced electrical energy consumption, stable cell operation and ease of process scalability.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Reversed magnetic shear scenario development in NSTX-U using TRANSP

Abstract Understanding and control of electron thermal transport is a critical point of research in magnetic fusion experiments. Previous experiments have shown that operation with reversed magnetic shear (RMS) can suppress electron thermal transport, resulting in the generation of internal transport barriers (ITBs), with the location of the ITB correlated with the location of minimum magnetic shear. The recent upgrades to NSTX—increased magnetic field up to 1 T, increased plasma current up to 2 MA, 2nd neutral beam—present an increased operating space in which to explore electron thermal transport in RMS plasmas. Utilizing TRANSP, we have developed operating scenarios by which to generate RMS in NSTX-U. The results suggest that RMS in NSTX-U can be generated through fast current ramp and early beam injection into a large plasma volume. This is very similar to the procedure that was followed in both TFTR and NSTX to generate RMS. Sustainment of RMS, disregarding non-( q min = 1) MHD events, requires maintaining a large plasma volume, and increasing the core T e , either via increased plasma current and/or adding heating power. Using this procedure, RMS was sustained for ∼1 s, with q min > 1 for that period.

Galante, M. E. (ORCID:0009000098149425)↗
DOE OSTI2025

Charting the state of GEMs in microalgae: progress, challenges, and innovations

Genome-scale metabolic models (GEMs) provide a systems-level framework for understanding and engineering microalgal metabolism. This review explores the evolution of GEMs in microalgae, highlighting advances in light modeling, automation, and multi-omics integration. Special emphasis is placed on Chlamydomonas reinhardtii as a model species. Limitations of current models, particularly for microalgae, are discussed, alongside promising developments in dynamic modeling and machine learning. Together, these innovations chart a path toward more predictive, adaptable GEMs that can accelerate biotechnological applications of microalgae in sustainable production systems.

Plant Sciences↗
DOE OSTI2026

Recent progress in atomic-scale controlled plasma processing

Atomic-scale control in plasma processing is becoming increasingly critical for fabricating of advanced semiconductor devices, particularly as the industry shifts toward three-dimensional (3D) architectures and high-aspect-ratio (HAR) structures. This review presents a comprehensive overview of recent developments in atomic-scale controlled plasma processes, organized along two key directions: the hierarchical structure of plasma–surface interactions and the generational evolution of atomic layer processing (ALP) technologies. We examined the gas phase, where molecular design enables selective generation of ions and radicals; the boundary layer, where transport phenomena govern species delivery into nanoscale features, and the surface, where temperature-dependent reactions and cyclic processing determine etching selectivity and precision. Building on this foundation, we outline five generations of ALP—from thermal atomic layer deposition to transport-aware, temporally and structurally decoupled processes—highlighting the increasing sophistication of process control. The review further explores the transition from empirical recipe development to science-based, data-driven methodologies. By integrating quantum-chemical modeling, advanced diagnostics, and machine learning, we demonstrated how predictive models can link plasma species composition to process outcomes, enabling autonomous and adaptive control strategies. Finally, this review discusses the broader societal implications of plasma process innovation through the E4 quartet: energy and resource efficiency, environmental sustainability, evolutionary advancement, and educational promotion. These principles guide the development of sustainable and intelligent atomic-scale manufacturing technologies that are not only technically advanced but also socially responsible.

Ishikawa, Kenji [Nagoya Univ. (Japan)] (ORCID:0000↗
DOE OSTI2020

A Community Energy Operations and Planning System: Concept, Use cases, Metrics, and Benefits

Community and city leaders are interested in achieving sustainability goals, providing resilient energy infrastructure, and improving economic competitiveness. Community-level data acquisition and analysis can provide energy and associated benefits that are not possible at the single building level. However, there is a lack of organizational structure, common semantic data models, interoperable systems, and methods to support data-driven decision-making for community-scale energy supply and demand systems. We explored the need and opportunity for a Community Energy Operations and Planning System (Community EOPS), a potential data exchange platform. We conducted “customer discovery” interviews, and reviewed literature, public tools, and technology platforms to identify key energy data “users” and use cases in communities. The key users of the Community EOPS could be developers of mixed-use districts, corporate, defense and university campus energy managers, and city managers of cities that own their energy utility. The value could be for community planning and reporting (for energy data-integrated land use planning and community infrastructure investments in microgrids, storage, district heating and cooling), energy efficiency (leveraging optimizations for community scale energy supply and demand), flexible load management (grid-edge load management to offset, shift, and flatten loads for multiple buildings and EV fleets), cost savings and revenue generation (participating in grid services), and social benefits such as energy resilience, equity, and awareness. We developed a conceptual Community EOPS architecture with recommendations for streamlined and prioritized data acquisition, sharing, and integration driven by prioritized use cases, common metrics, and actionable visualizations that can provide value to a community’s users.

Singh, Reshma↗
DOE OSTI2026

Polyketide synthase-based controlled synthesis of polycyclopropanated fuel molecules

Reducing carbon emissions from aviation and long-distance transportation sectors requires the development of sustainable biofuels with suitable energy density, freezing point, and other physical properties. We previously demonstrated biological production of high energy polycyclopropanated fatty acids (POP-FAs, class I) using an iterative polyketide synthase (iPKS) pathway in a Streptomyces host. Here, we used a computational model of fuel properties to identify chain length and cyclopropanation control as critical steps to engineer this iPKS for biofuel applications. We next explored the natural diversity of POP biosynthesis by investigating homologous pathways. Then, by in vivo gene exchange, we determined cyclopropanase (CP) catalysis to be key for POP-FA engineering. Leveraging both natural and engineered pathway product diversity, we demonstrate targeted production of improved POP-FAs, namely shortened POP-FAs with predicted superior freezing point properties for aviation, as well as fully cyclopropane-saturated POP-FAs which should have superior energy-density. These precise and controllable modifications to POP-FA structure open the door for bioproduction of designer POP fuels.

Yin, Kevin↗
DOE OSTI2024

Assembly of CMS Endcap MIP Timing Detector Module at FNAL

The High-Luminosity LHC (HL-LHC) will enable a more detailed exploration of new phenomena thanks to an anticipated increase in collisions where pileup is expected to reach approximately 200 simultaneous interactions. Many CMS systems will be significantly upgraded to prepare for this new era, including the MIP Timing Detector (MTD) project. The MTD is designed to mitigate the effect of pileup and is set to provide a timestamp accurate to 30 ~ 40 picoseconds for every event, ensuring sustained detector performance at HL-LHC. The MTD is divided into two sections, Barrel Timing Layer (BTL) and Endcap Timing Layer (ETL) which utilize different sensor and ASIC technologies due to the difference in active surfaces, irradiation conditions, and installation schedules. The ETL, composed of two double-sided disks, employs the Low Gain Avalanche Detector (LGAD) sensor and the Endcap Timing Readout Chip (ETROC). More than 8,000 modules, each consisting of four LGAD sensors and ETROCs are required for the ETL detector. These modules will be assembled using an automated robotic gantry that guarantees precise placement at a level of 10 micrometers. In addition, the full assembly of ETL modules includes film application with the jig, wire-bonding, encapsulation with the automated dispensing robot for protecting the wire-bonding, and film curing with a vacuum oven. This talk reports on the successfully completed throughput test with mockup components using the gantry and the successful assembly of real functional modules for beam tests at CERN and FNAL, including the first official ETL module.

Apresyan, Artur↗