Search NASA⌕ Search

SEARCH · Search NASA

Results for “Industrial Engineering”

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.

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

At least 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Enhancing Operational Performance and Productivity Benefits in Breweries through Smart Manufacturing Technologies

This article uses case studies to demonstrate the potential of smart manufacturing (SM) and Internet of Things (IoT) technologies to enhance operational performance and productivity in industry. The analysis highlights benefits such as cost reduction, production flexibility, shorter product time-to-market, energy/water efficiency and environmental impact reduction, and increased productivity. To illustrate the effectiveness of SM and IoT approaches, the authors sought out manufacturers currently implementing or seeking to implement SM and IoT technologies. The authors identified beer brewing (NAICS Code 312120) as a rapidly expanding industry whose members appear eager to implement SM technologies to optimize production lines by revealing bottlenecks and identifying performance-reducing nodes. This article presents two case studies based on SM and IoT technologies in breweries. It briefly describes a systematic framework introduced elsewhere by the authors and uses it to assess the energy productivity and competitiveness of SM applications in breweries. This article addresses questions concerning the information and communications technology infrastructure needed to build smart breweries and how corporations simplify the installation and deployment of SM and IoT components. This article was originally published in the Proceedings of the 2019 ACEEE Summer Study on Energy Efficiency in Industry.

42 ENGINEERING↗
DOE OSTI2022

Tools Assessing Performance (FY2022 Quarter 4 Report)

We were finally successful in acquiring TTU’s 200-meter tower data for the duration of the Isolated Building Wake Experiment (IBWE). This data will provide an independent measurement of the undisturbed wind profile including heights far above those that are typical of meteorological sensor networks. These measurements will characterize the mean and turbulence throughout the atmospheric surface layer, which will be particularly useful for validation of highfidelity computational fluid dynamics models. This dataset can be shared freely among the TAP team but not outside of it as TTU sells this data to the wind power industry. The journal article overview has been submitted to LANL’s publication review and will be submitted to the Journal of Wind Engineering and Industrial Aerodynamics once the review is complete. We are nearing completion on another two articles. The first discusses analyses of the evolution of the measurements of mean wind speed along the centerline of the building as a function of atmospheric stability. Rather than using individual time steps, all of the wind speed measurements are normalized using the upwind measurement at 2 building heights (H) and filtered by wind direction and atmospheric stability. The second discusses the development of the diffusive wake model and uses the averaged profiles from the first article to validate the behavior of the model. The portion of the section below on the diffusive wake model discussing comparisons with the averaged profiles, will be included in the validation section of this paper.

17 WIND ENERGY↗
DOE OSTI2025

Attempting to Develop the World’s Most Cost-Effective Metal 3D Printing Technology Through Industrial Adoption of a High-Temperature Electro-Magnetic Nozzle for 3D Printing and Computer Numerical Control Integration

This project aimed to make a practical system capable of sustained metal deposition in air engineered with industrial integration and controls. The Al-Ce wire feedstock was tailored with appropriate deposition and solidification properties for direct reactive interface printing (DRIP), and the goal was to integrate onto a Hybrid Manufacturing Technologies system for producing test parts without a controlled environment.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Attempting to Develop the World’s Most Cost-Effective Metal 3D Printing Technology Through Industrial Adoption of a High-Temperature Electro-Magnetic Nozzle for 3D Printing and Computer Numerical Control Integration

This project aimed to make a practical system capable of sustained metal deposition in air engineered with industrial integration and controls. The Al-Ce wire feedstock was tailored with appropriate deposition and solidification properties for direct reactive interface printing (DRIP), and the goal was to integrate onto a Hybrid Manufacturing Technologies system for producing test parts without a controlled environment.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Regulatory Considerations for Nuclear Energy Applications of Digital Twin Technologies

Digital twins (DTs) in complex industrial and engineering applications have potential benefits that include increased operational efficiencies, enhanced safety and reliability, improved security engineering, reduced errors, faster information sharing, and better predictions. The interest in DT technologies continues to grow, and many of these advanced technologies are expected to experience rapid and wide industry adoption in the near future. Some of the potential application areas for DTs in the nuclear industry are design, licensing, plant construction, training simulators, predictive operations and maintenance, autonomous operation and control, failure and degradation prediction, physical protection modeling and simulation, and safety and reliability analyses. The Office of Nuclear Regulatory Research at the U.S. Nuclear Regulatory Commission (NRC) has initiated a future-focused research project to assess the regulatory viability of DTs for nuclear power plants and other NRC-regulated activities, such as fuel cycle facilities and operations. This report explores the potential impact of DT technologies in nuclear applications on NRC-regulated activities of interest. This report describes a nuclear DT system and its capabilities for nuclear power plant applications, followed by identification and discussion of some regulated activities that merit special consideration and present opportunities in implementing DT-enabling technologies and capabilities.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2024

Improving the Concrete Crack Detection Process via a Hybrid Visual Transformer Algorithm

Inspections of concrete bridges across the United States represent a significant commitment of resources, given their biannual mandate for many structures. With a notable number of aging bridges, there is an imperative need to enhance the efficiency of these inspections. This study harnessed the power of computer vision to streamline the inspection process. Our experiment examined the efficacy of a state-of-the-art Visual Transformer (ViT) model combined with distinct image enhancement detector algorithms. We benchmarked against a deep learning Convolutional Neural Network (CNN) model. These models were applied to over 20,000 high-quality images from the Concrete Images for Classification dataset. Traditional crack detection methods often fall short due to their heavy reliance on time and resources. This research pioneers bridge inspection by integrating ViT with diverse image enhancement detectors, significantly improving concrete crack detection accuracy. Notably, a custom-built CNN achieves over 99% accuracy with substantially lower training time than ViT, making it an efficient solution for enhancing safety and resource conservation in infrastructure management. These advancements enhance safety by enabling reliable detection and timely maintenance, but they also align with Industry 4.0 objectives, automating manual inspections, reducing costs, and advancing technological integration in public infrastructure management.

42 ENGINEERING↗
DOE OSTI2021

Toward sustainable, cell-free biomanufacturing

Industrial biotechnology is an attractive approach to address the need for low-cost fuels and products from sustainable resources. Unfortunately, cells impose inherent limitations on the effective synthesis and release of target products. One key constraint is that cellular survival objectives often work against the production objectives of biochemical engineers. Additionally, industrial strains release CO2 and struggle to utilize sustainable, potentially profitable feedstocks. Cell-free biotechnology, which uses biological machinery harvested from cells, can address these challenges with advantages including: (i) shorter development times, (ii) higher volumetric production rates, and (iii) tolerance to otherwise toxic molecules. In this review, we highlight recent advances in cell-free technologies toward the production of non-protein products beyond lab-scale demonstrations and describe guiding principles for designing cell-free systems. Specifically, we discuss carbon and energy sources, reaction homeostasis, and scale-up. Expanding the scope of cell-free biomanufacturing practice could enable innovative approaches for the industrial production of green chemicals.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2025

Low-Cost Sulfur Thermal Storage for Solar Industrial Process Heat Applications

Industrial process heat (IPH) is one of the largest energy demands in U.S., representing about 10% of all domestic energy consumption. Fuel costs to generate this industrial process heat are generally a top three cost for industry, a major component in American manufacturing competitiveness. Roughly 60% of US IPH demand (about 6,500 TBtu annually) falls in the medium-temperature range of 100–250 °C. While concentrated solar thermal (CST) technologies can provide a cost-effective source of heat in this temperature range, solar intermittency limits their adoption in industries that operate 24/7. Element 16 Technologies, Inc. developed a low-cost sulfur thermal energy storage (TES) technology to bridge this gap by capturing excess solar heat during the day and dispatching it reliably during non-solar hours. The core innovation is the use of sulfur, an abundant, industrial waste byproduct that costs ten times less than molten salt used in commercial TES systems. The overall goal of the project was to advance the design and development of molten sulfur TES to a manufacturing-relevant prototype stage for solar industrial process heat applications, while establishing and validating a realistic pathway to commercial success. Key tasks included corrosion and mechanical durability testing to identify cost-effective materials, design investigations using physics-based simulation tools, techno-economic evaluations of system lifetime costs, and pilot-scale testing for performance verification. Corrosion testing of steel alloys under cyclic molten sulfur conditions showed that austenitic stainless steels in the 300 series performed particularly well, with no structural degradation of welds or joints. Thermal cyclic testing of pilot sulfur TES units up to 1.5 MWh quantified charge/discharge rates, heat losses, round-trip efficiency and validated the system's capability to operate effectively under intermittent charging conditions. A techno-economic model, informed by sulfur TES performance model validated using pilot test data, showed that hybrid solar+sulfur TES+NG boiler systems are economically competitive with incumbent natural gas boilers for multiple locations in the southwest US. In summary, this project established molten sulfur TES as a technically viable pathway to improve economic competitiveness of American manufacturing by lowering the cost of solar industrial process heat.

14 SOLAR ENERGY↗
DOE OSTI2024

The Overlooked Potential of Sulfated Zirconia: Reexamining Solid Superacidity Toward the Controlled Depolymerization of Polyolefins

Closed-loop recycling via an efficient chemical process can help alleviate the global plastic waste crisis. However, conventional depolymerization methods for polyolefins, which compose more than 50% of plastics, demand high temperatures and pressures, employ precious noble metals, and yield complex mixtures of products limited to single-use fuels or oils. Superacidic sulfated zirconia (SZrO) with Hammet Acidity Functions (H 0 ) = -12 (i.e., stronger than 100% H 2 SO 4 ) is an industrially deployed heterogeneous catalyst capable of activating hydrocarbons under mild conditions and is shown to decompose polyolefins at ambient pressure and temperatures near 200 °C. Additionally, confinement of active sites in porous supports is known to radically increase selectivity, coking and sintering resistance, and acid site activity, presenting a possible approach to low-energy polyolefin depolymerization. However, a critical examination of the literature on SZrO led us to a surprising conclusion: despite 40 years of catalytic study, engineering, and industrial use, the surface chemistry of SZrO is poorly understood. Ostensibly spurred by SZrO's impressive catalytic activity, the application-driven study of SZrO has resulted in deleterious ambiguity in requisite synthetic conditions and insufficient characterization of acidity, porosity, and active site structure. Here, this ambiguity has produced significant knowledge gaps surrounding the synthesis, structure, and mechanisms of hydrocarbon activation for optimized SZrO, stunting the potential of this catalyst in olefin cracking and other industrially relevant reactions, such as isomerization, esterification, and alkylation. Toward mitigating these long extant issues, we herein identify and highlight these current shortcomings and knowledge gaps, propose explicit guidelines for characterization of and reporting on characterization of solid acidity, and discuss the potential of pore-confined superacids in the efficient and selective depolymerization of polyolefins.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Attacking the IEC-61131 Logic Engine in Programmable Logic Controllers in Industrial Control Systems

In industrial control systems (ICS), programmable logic controllers (PLCs) directly monitor and control a physical process such as nuclear power plants, gas pipelines, and water treatment. They are equipped with a control logic written in IEC-61131 languages (e.g., ladder logic and structured text) that defines how a PLC should control a physical process. A PLC's control logic is a usual target of a cyberattack to sabotage a physical process. For instance, Stuxnet targets a control logic of a Siemens S7-300 PLC to damage a nuclear facility's centrifuges. The existing attacks in the literature generally focus only on injecting malicious control logic into a PLC. This paper presents a new dimension of control logic attacks that target the control logic engine (responsible for running a control logic) of a PLC. It demonstrates that a cyberattack can disable the control logic engine successfully by exploiting inherent PLC features such as program mode and starting/stopping engine. We develop two novel case studies on control logic engine attacks by employing the MITRE ATT\&CK knowledge base on the real-world PLCs used in industry settings, i.e., 1) Schweitzer Engineering Laboratory (SEL)'s Real-Time Automation Controller (SEL-3505 RTAC) equipped with security features such as encrypted traffic and device-level access control, and 2) traditional PLCs, i.e., Schneider Electric's Modicon M221, Allen-Bradley's MicroLogix 1400 and 1100 that do not have security features. The case studies present the internals of the logic engine attacks and facilitate the ICS research community and industry to understand the attack vectors on the control logic engine. We evaluate the effectiveness of the control engine attacks on a power substation, a 4-floor elevator, and a conveyor belt to demonstrate their real-world impact of halting a physical process.

Ali qasim, Syed↗
DOE OSTI2025

Investigation of heat pump technologies for high-temperature applications above 250 °C

This paper examines heat pump (HP) technologies to achieve heat supply temperatures above 250 °C, referred to as ultra-high-temperature heat pump (UHTHP). UHTHP, as a low-carbon heat delivery and heat augmentation technology, can offer an alternative to traditional combustion heating for decarbonizing high-temperature industrial processes. However, the heat supply temperature of over 250 °C surpasses the temperature range typically covered in the high-temperature HP literature and existing capabilities of commercial HP systems. This paper reviews HP technologies with the potential to evolve into UHTHP. Additionally, UHTHP studies in the literature are analyzed to compare the pros, cons, and technical potentials of various HPs using different thermodynamic cycles and fluids. Furthermore, we then pinpoint the technical gaps and challenges that have hindered widespread adoption of UHTHP in industry, explore potential improvements and solutions, and discuss the feasibility. Current efforts aim to lay the ground for future research, development, and commercial deployment for UHTHP.

32 - ENERGY CONSERVATION, CONSUMPTION, AND UTILIZA↗
DOE OSTI2022

University of Miami Industrial Assessment Center (Final Scientific/Technical Report)

The University of Miami Industrial Assessment Center (MIIAC) is located at the Department of Industrial & Systems Engineering in the College of Engineering at University of Miami. The Center has conducted 402 energy assessments with estimated Total Energy Savings over $\$57.3$ million, Total Non- Energy Cost Savings of $\$23.7$ million, and Total Energy Saving as a 26% of Energy Costs of $\$311$ million. A total of 6.01 TBtu of energy savings were recommended as a result of energy efficiency measures resulting in $\$81$ million in cost savings.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Methanol mixing−controlled compression ignition enabled via homogeneous charge compression ignition of dimethyl ether through catalytic decomposition of methanol

Methanol is a potentially attractive fuel for marine and off−road engines owing to its availability at bunkering and global distribution locations. Although methanol is well−distributed worldwide, its fuel chemistry and ignition properties make it poorly suited as a direct drop−in replacement for diesel fuel in compression−ignition engines. However, industrial processes are regularly used to convert methanol, via catalytic dehydration, to dimethyl ether (DME) over nonprecious metal catalysts. This chemical conversion can occur at relatively low pressures, temperatures, and catalyst space velocities, highlighting a potential opportunity to generate DME via onboard catalytic dehydration of methanol. DME’s fuel kinetic and ignition properties for compression ignition are much more favorable than those of methanol or even diesel fuel, but DME is more challenging than diesel fuel or methanol to pump, store, and deliver through conventional diesel fueling injection hardware. Thus, a potential opportunity exists to use the ignition and kinetic properties of DME, with the transportation and delivery advantages of methanol, in a methanol−fueled mixing−controlled compression−ignition engine. The present work explores performance, combustion behavior, and emissions reduction opportunities for methanol mixing−controlled combustion, enabled by a HCCI of DME that represents a small fraction of the total fuel energy that can be generated onboard via catalytic dehydration of methanol.

Splitter, Derek [ORNL] (ORCID:0000000174044047)↗
DOE OSTI2026

Multi-objective Decisions on Integrated Energy Systems Planning and Operation for Industrial Combined Heat and Power Supply

Unlike the power sector—which can transmit electricity over long distances via established grids—the industrial sector poses a unique challenge due to its geographically concentrated large-scale heat processes. Enhancing energy security in such industrial parks provides a dual benefit: reduced exposure to volatile fossil fuel prices and improved economic viability, largely driven by economies of scale in energy supply and distribution. This study presents a comprehensive technoeconomic analysis of a nuclear energy hub, employing a mechanism-focused approach to evaluate uncertainties in operational strategies and capacity optimization. Load profiles from three major energy intesive industries—chemical, refinery, and steelmaking—are examined, each presenting unique challenges and opportunities for nuclear energy integration. We adopt a multi-objective optimization framework, converting multiple objectives into a single objective function through the e-constraint method. The findings highlight clear trade-offs between system conditions and varying levels of energy independence. Overall, this analysis is granular enough to address industry-specific concerns yet sufficiently generalizable to provide actionable insights into the feasibility of nuclear-based clean heat solutions for the industrial sector.

25 - ENERGY STORAGE↗
DOE OSTI2026

CONTROL AND DATA ACQUISITION IN A CYBER-PHYSICAL MIDSTREAM TESTBED

This thesis presents the development of a laboratory-scale cyber–physical midstream pipeline testbed designed to address this gap and support research in industrial control systems security. The platform integrates pumps, valves, sensors, programmable logic controllers (PLCs), and a human–machine interface (HMI) to emulate the monitoring and control architecture of real pipeline operations. The physical process is implemented as a closed-loop liquid circulation system designed to replicate flow behavior characteristic of midstream pipeline infrastructure. The testbed enables real-time data acquisition of key process variables, including flow rate and pressure facilitating the generation of datasets representative of normal pipeline operation. A threat model encompassing common ICS attack vectors was developed, including sensor spoofing, command injection, false data injection, denial-of-service attacks, and relay manipulation. Multiple attack scenarios were implemented and evaluated to demonstrate how cyber intrusions targeting sensors, actuators, networks, and software propagate into measurable physical consequences in pipeline flow and pressure. The developed platform serves as a practical, cost-effective environment for experimentation, education, and future cybersecurity research in midstream pipeline systems.

42 ENGINEERING↗
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 OSTI2026

A unifying equation for fermentation sustainability across the titer-rate-yield landscape

Industrial fermentation is central to the sustainable production of fuels and chemicals, yet commercial viability of emerging technologies hinges on improving fermentation titer, rate, and yield (TRY). How these metrics shape system cost remains difficult to generalize due to complex interactions among feedstocks, fermentation, separations, catalytic upgrading, waste management, and facility design. Here, we systematically map theoretical fermentation performance spaces (formed by all potential TRY combinations) for 32 representative biomanufacturing facilities—spanning distinct choices for feedstocks, fermentation regimes and products, separations, and catalytic upgrading—by simulating and evaluating them (via techno-economic analysis, TEA) under uncertainty (600,000 Monte Carlo simulations) and across TRY combinations (7500 TRY combinations for each of 32 configurations). Across this wide design and thermodynamic simulation space, we find the relationship between fermentation TRY and system cost is captured by a simple, generalizable mathematical equation (R 2 of 0.992 − 1.000 across our simulations; 0.954 − 1.000 when validated against prior studies that used different tools). We use this equation to elucidate key drivers that shape cost sensitivity to fermentation performance, generating widely applicable insights. By demonstrating a unifying relationship governs the impact of fermentation on biomanufacturing economics, this work establishes a foundation for agile, holistically predictive, resource-efficient strategies to prioritize fermentation research and development needs and accelerate commercialization of emerging biomanufacturing technologies.

applied mathematics↗