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DOE OSTI2022

Low Cost, High Volume, Carbon Fiber Precursor for Plasma Oxidation

Light weighting with carbon fiber is critical to improving the energy efficiency of wind turbines, airplanes, and automobiles, but the high cost of carbon fiber continues to limit market growth and applications. Half of this cost is in the raw materials. For the carbon fiber market to reach the next level of adoption, the cost of both the raw materials and conversion must be reduced. This project considered the combination of low-cost, textile-grade precursors combined with the increased efficiency of plasma oxidation to greatly reduce the cost of carbon fiber. The primary objective of this project was to make industrial-grade carbon fiber (550 ksi tensile strength, 35 Msi tensile modulus) from textile-grade PAN precursors, something that cannot be achieved with conventional oxidation and to date has not been achieved with any technology. To accomplish this, the project team iteratively optimized the process conditions in the plasma oxidation and carbonization stages to maximize the tensile properties of the resultant carbon fibers. This involved implementing experimental designs for both stages, whereby process conditions (e.g. temperature) were varied and correlated to fiber properties. Samples of oxidized PAN fibers (OPFs) were prepared using a small pilot-scale plasma oxidation oven at 4XTechnologies (4XT). The thermal, chemical, and physical properties of OPF samples were analyzed by the University of Tennessee (UTK) and Oak Ridge National Laboratory (ORNL). The OPF samples were then converted to carbon fiber by subsequent low- and high-temperature carbonization using a lab-scale furnace at ORNL. The resultant carbon fibers were tested for tensile strength also at ORNL, and the results were fed back into the experimental design. Of the hundreds of carbon fiber samples produced over the course of the project, the best sample had an average break strength of 479 ksi and modulus of 33 Msi. While the best tensile properties achieved fell short of the final project targets of 550 ksi for break strength and 35 Msi for modulus, the team demonstrated the potential to produce industrial-grade carbon fiber using textile-grade precursors. The best performing fiber samples had tensile properties that are 87% of the goal for tensile strength and 94% of the goal for tensile modulus. With additional optimization work, it is likely that the targets could be achieved, since only a fraction of the process parameter space was explored during this project. 4XT and its affiliate (4M) have already secured funding through private equity, and there is a CRADA (Cooperative Research and Development Agreement) project currently underway with the Carbon Fiber Technology Center (CFTF) at ORNL to continue this research. Additionally, while not an original goal of the project, the carbon fibers for most samples had diameters >8.5μm. This is considerably larger than commercially available carbon fiber products, which can impart unique properties to the composites (e.g. increased compressive strength) and decrease manufacturing costs even further. Moreover, these fibers were oxidized with plasma oxidation using residence times ranging <60mins, which would be considered fast for normal diameter fibers, but it is as much as 5x faster when factoring in the diameter of the fibers.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Chemical Looping Coal Gasification Sub-Pilot Unit Demonstration and Economic Assessment for IGCC applications (Final Report)

The Ohio State University (OSU) coal to syngas (CTS) technology is an advanced air separation process that can be applied for electricity production via an integrated gasification combined cycle (IGCC). The objective of the proposed project is to enable the OSU CLG technology for a commercially relevant demonstration by 2020. In order to accomplish this objective, small pilot scale demonstration of the CLG reactor system was performed. The small pilot test unit incorporates commercially scalable non-mechanical gas sealing and solids flow control components for extended operations of the integrated reactor system. A cumulative demonstration of greater than 100 hours was performed to confirm the reliability of the reactors (reducer and oxidizer) and non-mechanical devices in maintaining controlled solid circulation, gas sealing, and coal distribution in the reactor (reducer) as well as to confirm sustained syngas product performance. A comprehensive techno-economic analysis (TEA) of the OSU CLG process for IGCC application was conducted with the support of WorleyParsons, Ltd. (WP) and compared to the Department of Energy (DOE) baseline IGCC report. Using the data gained from the small pilot demonstration, a complete comprehensive techno-economic analysis (TEA) of the CLG process was conducted. The evaluation was used as basis to attract utilities and coal industries in Ohio. The project duration lasts 30 months (6 months of no cost extension). Ohio coal was used in the integrated CLG small pilot unit to convert to high hydrogen syngas. A demonstration of the integrated chemical looping reactor system at the 15 kW th scale accelerates technology commercialization in the near term. The 15 kWth demonstration addressed several major technology gaps, such as coal injection and distribution in the reducer, controllable solids circulation with the desired fuel to solids ratio, system pressure distribution for proper gas sealing, effects of contaminants and fuel/oxygen carrier residence time requirements. The fates of impurities, such as SO x and NO x was also investigated in unit demonstrations. WP conducted a comprehensive system TEA to optimize the OSU CLG process design for efficient electricity generation with greater than 90% CO 2 capture in IGCC applications. The conclusion of this project supports the further scale-up of the technology to a commercially applicable large pilot scale test unit for operation by 2020. More importantly, it benefits Ohio as it provides an economically competitive mean for power generation with carbon capture. Given the rise of natural gas usage and strict environmental regulations, the use of Ohio coal is expected to decrease and thus impact the coal economy in Ohio. The conclusion of this project provided way for Ohio coal to compete in the future and secure jobs in the energy sector.

01 COAL, LIGNITE, AND PEAT↗

NASA NTRS1992

An energy analysis of crack-initiation and arrest in epoxy

The objective of this work is to study fracture processes such as crack initiation and arrest in epoxy. A compact tension specimen with displacement-controlled loading is employed to observe multiple crack initiations and arrests. The energy release rate at crack initiation is significantly higher than that at crack arrest, as has been observed elsewhere. In this study, the difference between these energy release rates is found to depend on specimen size (scale effect), and is quantitatively related to the fracture surface morphology. The scale effect, similar to that in strength theory, is conventionally attributed to the statistics of defects which control the fracture process. Triangular shaped ripples, deltoids, are formed on the fracture surface of the epoxy during the slow sub-critical crack growth, prior to the smooth mirrorlike surface characteristic of fast cracks. The deltoids are complimentary on the two crack faces which excludes any inelastic deformation from consideration. The deltoids are analogous to the ripples created on a river surface downstream from a small obstacle. However, in spite of the expectation based on this analogy and the observed scale effect, there are no 'defects' at the apex of the deltoids detectable down to the 0.1 micron level. This suggests that the formation of deltoids during the slow process of subcritical crack growth is an intrinsic feature of the fracture process itself, triggered by inhomogeneity of material on a submicron scale. This inhomogeneity may be related to a fluctuation in the cross-link density of the epoxy.

Chudnovsky, A.↗

DOE OSTI2019

Graph dynamical networks for unsupervised learning of atomic scale dynamics in materials

Understanding the dynamical processes that govern the performance of functional materials is essential for the design of next generation materials to tackle global energy and environmental challenges. Many of these processes involve the dynamics of individual atoms or small molecules in condensed phases, e.g. lithium ions in electrolytes, water molecules in membranes, molten atoms at interfaces, etc., which are difficult to understand due to the complexity of local environments. In this work, we develop graph dynamical networks, an unsupervised learning approach for understanding atomic scale dynamics in arbitrary phases and environments from molecular dynamics simulations. We show that important dynamical information, which would be difficult to obtain otherwise, can be learned for various multi-component amorphous material systems. With the large amounts of molecular dynamics data generated every day in nearly every aspect of materials design, this approach provides a broadly applicable, automated tool to understand atomic scale dynamics in material systems.

36 MATERIALS SCIENCE↗

NASA NTRS1989

The formation of topological defects in phase transitions

It was argued, and fought through numerical work that the results of non-dynamical Monte Carlo computer simulations cannot be applied to describe the formation of topological defects when the correlation length at the Ginzburg temperature is significantly smaller than the horizon size. To test the current hypothesis that infinite strings at formation are essentially described by Brownian walks of size the correlation length at the Ginzburg temperature, fields at the Ginzburg temperature were equilibrated. Infinite structure do not exist in equilibrium for reasonable definitions of the Ginzburg temperature, and horizons must be included in a proper treatment. A phase transition, from small-scale to large-scale string or domain wall structure, is found to occur very close to the Ginzburg temperature, in agreement with recent work. The formation process of domain walls and global strings were investigated through the breaking of initially ordered states. To mimic conditions in the early Universe, cooling times are chosen so that horizons exist in the sample volume when topological structure formation occurs. The classical fields are evolved in real-time by the numerical solution of Langevin equations of motion on a three dimensional spatial lattice. The results indicate that it is possible for most of the string energy to be in small loops, rather than in long strings, at formation.

Hodges, Hardy M.↗

DOE OSTI2018

Vitrification of Hanford Tank Waste 241-AP-105 in a Continuous Laboratory-Scale Melter

Low-activity waste (LAW) stored in underground tanks on the Hanford site in Washington State is planned to be filtered for solids removal and processed through ion exchange columns for cesium removal at the Low-Activity Waste Pretreatment System facility. These pretreatment steps will allow the waste to be transferred to the Hanford Tank Waste Treatment and Immobilization Plant LAW facility for immobilization into glass. The liquid waste will be combined with glass-forming chemicals (GFCs) to form a waste feed slurry that can be fed to electric melters for vitrification. The process of continuously converting the aqueous feed slurry into a melt is dynamic and includes multiple reactions, degassing, and dissolution processes that depend on heat from the melt below. In this conversion process, waste components are partitioned into one of two streams: glass and off-gas. Processing information and chemical information associated with these waste product streams has been requested by Washington River Protection Solutions for actual tank waste from tank 241-AP-105 (referred to as AP-105). To acquire this type of information, a small-scale melter system was desired that would not require high volumes of input waste or the large resource commitment of a full-scale melter system, while also providing dynamic information that would be difficult to determine from batch reactions in a crucible system. A continuous laboratory-scale melter (CLSM), has been designed to operate with a continuous feeding process, while periodically pouring glass product and collecting off-gas. The CLSM vessel has been sized to collect the relevant process and chemical information from obtainable volumes of AP-105 waste samples. Two CLSMs were constructed: one in a non-radioactive environment for processing waste simulants and another in a fume hood capable of handling radioactive material for processing actual Hanford tank waste. This dual-system setup allowed for comparison between simulated and real tank waste with essentially identical test equipment. AP-105 waste simulant was first tested in the non-radioactive CLSM to determine the processability and desired operating window for the actual tank waste. Rhenium (Re) was added to the simulant to act as a surrogate for technetium-99 ( 99 Tc), a key waste component found in the actual tank waste. The partitioning of Re into the glass and off-gas products during the continuous feeding of simulant was determined, which allowed the Re retention, the mass flow rate of Re out of the CLSM via the glass product with respect to the mass flow rate of Re into the CLSM via the feed slurry, to be calculated. Key processing results and the average Re retention, from the CLSM test run with AP-105 simulant feed slurry are shown in Table ES.1.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2024

Improving Stratocumulus Cloud Amounts in a 200‐m Resolution Multi‐Scale Modeling Framework Through Tuning of Its Interior Physics

Abstract High‐Resolution Multi‐scale Modeling Frameworks (HR)—global climate models that embed separate, convection‐resolving models with high enough resolution to resolve boundary layer eddies—have exciting potential for investigating low cloud feedback dynamics due to reduced parameterization and ability for multidecadal throughput on modern computing hardware. However low clouds in past HR have suffered a stubborn problem of over‐entrainment due to an uncontrolled source of mixing across the marine subtropical inversion manifesting as stratocumulus dim biases in present‐day climate, limiting their scientific utility. We report new results showing that this over‐entrainment can be partly offset by using hyperviscosity and cloud droplet sedimentation. Hyperviscosity damps small‐scale momentum fluctuations associated with the formulation of the momentum solver of the embedded large eddy simulation. By considering the sedimentation process adjacent to default one‐moment microphysics in HR, condensed phase particles can be removed from the entrainment zone, which further reduces entrainment efficiency. The result is an HR that can produce more low clouds with a higher liquid water path and a reduced stratocumulus dim bias. Associated improvements in the explicitly simulated sub‐cloud eddy spectrum are observed. We report these sensitivities in multi‐week tests and then explore their operational potential alongside microphysical retuning in decadal simulations at operational 1.5° exterior resolution. The result is a new HR having desired improvements in the baseline present‐day low cloud climatology, and a reduced global mean bias and root mean squared error of absorbed shortwave radiation. We suggest it should be promising for examining low cloud feedbacks with minimal approximation.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

On the halo-mass and radial scale dependence of the lensing is low effect

ABSTRACT The canonical Lambda cold dark matter (ΛCDM) cosmological model makes precise predictions for the clustering and lensing properties of galaxies. It has been shown that the lensing amplitude of galaxies in the Baryon Oscillation Spectroscopic Survey (BOSS) is lower than expected given their clustering properties. We present new measurements and modelling of galaxies in the BOSS LOWZ sample. We focus on the radial and stellar mass dependence of the lensing amplitude mismatch. We find an amplitude mismatch of around $35{{\ \rm per\ cent}}$ when assuming ΛCDM with Planck Cosmological Microwave Background (CMB) constraints. This offset is independent of halo mass and radial scale in the range Mhalo ∼ 1013.3−1013.9h−1 M⊙ and $r=0.1\!-\!60 \, h^{-1} \mathrm{Mpc}$ ($k \approx 0.05\!-\!20 \, h \, {\rm Mpc}^{-1}$). The observation that the offset is both mass and scale independent places important constraints on the degree to which astrophysical processes (baryonic effects, assembly bias) can fully explain the effect. This scale independence also suggests that the ‘lensing is low’ effect on small and large radial scales probably have the same physical origin. Resolutions based on new physics require a nearly uniform suppression, relative to ΛCDM predictions, of the amplitude of matter fluctuations on these scales. The possible causes of this are tightly constrained by measurements of the CMB and of the low-redshift expansion history.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2025

Bias-hardened estimators of patchy screening profiles

Detecting anisotropic screening of the cosmic microwave background (CMB) holds the promise of revealing the distribution of gas in the Universe, characterizing the complex processes of galaxy formation and feedback, and studying the epoch of reionization. Estimators for inhomogeneous screening, including some recently proposed small-scale (stacked) estimators, are quadratic or higher order in the CMB temperature or polarization fields and are therefore subject to contamination from CMB lensing. We review the origin of this lensing bias and show that, when stacking on unWISE galaxies, the expected lensing bias dominates the signal if left unmitigated. Hardening techniques that null the lensing bias have been proposed for standard quadratic estimators, whereas only approximate methods have been proposed for stacked estimators. In conclusion, we review these techniques and apply the former to stacked estimators, presenting several strategies (including the optimal strategy) to null lensing contamination when stacking on any large-scale structure tracer.

Cosmic microwave background↗

NASA NTRS1986

Earth rotation as a proxy for interannual variability in atmospheric circulation, 1860-present

Modern atmospheric and geodetic data sets have demonstrated that changes in the axial component of the atmosphere's angular momentum and in the rotation rate of the solid earth are closely coupled on time scales of up to several years. The feasibility of using a historical record of the earth's rotation as a proxy for year-to-year changes in the zonal wind field over the globe is examined. The bulk of the earth rotation series acquired for this purpose is based on telescopic observations of the occultation of stars by the moon; semiannual values of changes in the length of day derived from these observations have acceptably small errors from about 1860 onwards. These values are filtered to remove decade-scale fluctuations, which are driven primarily by nonatmospheric processes, and the resulting proxy series is examined to see if it contains a signal associated with one of the major modes of interannual variability in the atmosphere, namely that due to the El Nino/Southern Oscillation (ENSO). According to tests of statistical significance, such a signal is present in the historical earth rotation series, in that the day is typically longer during the year following an ENSO oceanic warm event than otherwise. Therefore other signals of interannual variability in the proxy series are considered. In particular, it is inferred that noteworthy trends in atmospheric interannual variability have occurred over the last century; for example, the decade of the 1920s was marked by much larger year-to-year changes in the zonal circulation over the globe than that of the 1940s. Based on modern atmospheric data, it is suggested that most of these circulation changes have resulted from anomalies in the region between 30 deg N and 30 deg S.

Salstein, David A.↗

NASA NTRS1992

Flow enthalpy effects on scramjet mixing and combustion

The present analysis of the 3D characteristics of the mixing processes in a scramjet combustor gives attention to the streamwise, vorticity-driven macromixing, as well as shear-driven small-scale mixing, in both an unconfined Mach 6 airstream and a high-enthalpy (Mach-17) confined, Mach 6 airstream. The results obtained indicate that mixing is substantially lower for the high-enthalpy case. The effect of residence time on jet mixing is discussed in view of the production and decay of the axial vorticity, cross-flow velocities, and mean-flow velocities of these confined flows. The effective distance travelled by a fluid particle in the cross-flow, over the combustor length, is used to explain axial vorticity's contribution to mixing.

Riggins, D. W.↗

NASA NTRS2001

Automation of a N-S S and C Database Generation for the Harrier in Ground Effect

A method of automating the generation of a time-dependent, Navier-Stokes static stability and control database for the Harrier aircraft in ground effect is outlined. Reusable, lightweight components arc described which allow different facets of the computational fluid dynamic simulation process to utilize a consistent interface to a remote database. These components also allow changes and customizations to easily be facilitated into the solution process to enhance performance, without relying upon third-party support. An analysis of the multi-level parallel solver OVERFLOW-MLP is presented, and the results indicate that it is feasible to utilize large numbers of processors (= 100) even with a grid system with relatively small number of cells (= 10(exp 6)). A more detailed discussion of the simulation process, as well as refined data for the scaling of the OVERFLOW-MLP flow solver will be included in the full paper.

Murman, Scott M.↗

NASA NTRS2015

Don Quixote Pond: A Small Scale Model of Weathering and Salt Accumulation

The formation of Don Quixote Pond in the North Fork of Wright Valley, Antarctica, is a model for unique terrestrial calcium, chlorine, and sulfate weathering, accumulation, and distribution processes. The formation of Don Quixote Pond by simple shallow and deep groundwater contrasts more complex models for Don Juan Pond in the South Fork of Wright Valley. Our study intends to understand the formation of Don Quixote Pond as unique terrestrial processes and as a model for Ca, C1, and S weathering and distribution on Mars.

Englert, P.↗

NASA NTRS2018

Initial Approach to Collect Small Unmanned Aircraft System Off-Nominal Operational Situations Data

NASA is developing the Unmanned Aircraft System Traffic Management research platform to safely integrate small unmanned aircraft operations in large-scale at low-altitudes. As a part of this effort, small unmanned aircraft system off-nominal operational situations data collection process has been developed to take lessons learned and to reinforce operational compliance. In this paper, descriptions of variables used for digital data collection and an online report form for collection of observational data from the operators (contextual data) are provided. They are used to collect off-nominal data from the Unmanned Aircraft System Traffic Management National Campaign in 2017. The digital data show that 2 out of 118 campaign operations (1.7%) encountered loss of navigation. Since the campaign aircraft used Global Positioning System for navigation, it is likely that unobstructed view of the sky at the campaign locations contributed to this small number. Also, 4 out of 47 operations (8.5%) encountered loss of communications. A relatively short distance between ground control system and aircraft, ranging from 2300 feet to 4200 feet, likely contributed to this small number. There was no data to identify the loss of communications condition, aircraft received signal strength, for the remaining 71 operations suggesting that some operators may not be monitoring unmanned aircraft communications system performance or monitoring it with different parameters. For the contextual data, due to the low number of total reports during the campaign, no significant trends emerged. This is an initial attempt to collect contextual data from small unmanned aircraft operators about off-nominal situations, and changes will be made to the future data collection to improve the amount and quality of the information.

unmanned aviation systems traffic management (UTM)↗

NASA NTRS2018

Initial Approach to Collect Small Unmanned Aircraft System Off-Nominal Operational Situations Data

Jung, Jaewoo↗

NASA NTRS2014

Bioelectrochemical Systems for the Treatment of Wastewater and Methane Production

Long-term spaceflight will require technology that is self-sustaining, while minimizing volume and mass. Bioelectrochemical systems (BES) have the ability to recover valuable resources, process waste, and generate a small amount of electrical current, via microorganisms, while satisfying the above criteria. We are currently working on small scale BES reactors that will generate electricity from the breakdown of urine and utilize the electrical current to catalyze synthesis of products including water and methane.

water recovery↗

NASA NTRS1993

Design and test of a small two stage counter-rotating turbine for rocket engine application

The aerodynamic design and rig test evaluation of a small counter-rotating turbine system is described. The technology represented by this turbine is being developed for application in an advanced upper stage rocket engine turbopump. This engine will employ an oxygen/hydrogen expander cycle and achieve high performance through efficient combustion, high combustion pressure, and high area ratio exhaust nozzle expansion. Engine performance goals require that the turbopump drive turbines achieve high efficiency at low gas flow rates. The low flow rates result in very small airfoil diameter, height and chord. The high efficiency and small size requirements present a challenging turbine design problem. The unconventional approach employed to meet this challenge is described, along with the detailed design process and resulting airfoil configurations. The method and results of full scale aerodynamic performance evaluation testing of both one and two stage configurations, as well as operation without the secondary stage stator are presented. The overall results of this effort illustrate that advanced aerodynamic design tools and hardware fabrication techniques have provided improved capability to produce small high performance turbines for advanced rocket engines.

Huber, F. W.↗

NASA NTRS1983

Axial-compressor flow distortion with water ingestion

The objective of the investigation is as follows: to establish relations between the steady state mean flow distortion generated during water ingestion into an axial-flow compressor and (a) characteristic length and time scales pertaining to (1) the centrifugal action and (2) the heat and mass transfer processes and (b) aerodynamic parameters based on blade geometry, aspect ratio and blade loading. Analytical and experimental results are presented for a small compressor to illustrate the extent of the distortion introduced as a function of (1) the operating speed and (2) the mass-based water content in the ingested mixture. Methods of scaling the effects in compressors of different sizes are discussed.

Tsuchiya, T.↗