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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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At least 595 records · Page 33
All sourcesNASA NTRSDOE OSTI
NASA NTRS1980

Storage requirement definition study

A dish Stirling solar receiver (DSSR) and a heat pipe solar receiver with TES (HPSR) for a 25 kWe dish Stirling solar power system are described. The thermal performance and cost effectiveness of each are analyzed minute by minute over the equivalent of one year of solar insolation. Existing designs of these two systems were used as a basis for the study; TES concepts for the DSSR and alternative TES concepts for the HPSR are presented. Parametric performance and cost studies were performed to determine the operating and cost characteristics of these systems. Data are reported for systems (1) without TES and with varying amounts of TES, (2) with and without a fossil fuel combustor, (3) with varying solar to fossil power input, and (4) with different system control assumptions. The principal effects of TES duration, collector area, engine efficiency, and fuel cost sensitivity are indicated. Development needs for each of the systems are discussed and the need and nature of possible future TES solar modular experiments are presented and discussed.

Stacy, L. E.↗
DOE OSTI2023

An operando synchrotron study on the effect of wire melting state on solidification microstructures of Inconel 718 in wire-laser directed energy deposition

Directed energy deposition (DED) with a coaxial wire-laser configuration has gained significant attention in recent years for the production of large-scale metallic components because of its low directional dependence, fast deposition rate, high feedstock efficiency, and low manufacturing costs. This work studies the coaxial wire-laser DED process of Inconel 718 alloy under a stable deposition condition with a relatively low input volumetric energy density (55.5J/mm 3 ). Post characterization reveals a cluster of refined grains at the center-bottom region of the as-printed track. Operando high-energy synchrotron X-ray experiments and multi-physics modeling are applied innovatively to study the fundamental mechanism responsible for the formation of this microstructure. The X-ray diffraction experiment provides direct evidence, which is supported by the simulation, that the feeding wire can reach the melt pool bottom and release solid particles (primarily carbides) near the mushy zone owing to insufficient melting. Consequently, these sub-micron sized particles suppress the growth of large columnar grains and cause the formation of unique microstructural heterogeneity. In conclusion, this discovery offers new opportunities for tailoring the solidification microstructure by controlling the melting state of the feedstock wire in DED process, in addition to commonly known factors such as the thermal gradient and solidification velocity.

42 ENGINEERING↗
DOE OSTI2020

Modeling Photovoltaics Innovation and Deployment Dynamics

PV’s historically rapid cost reduction is exceptional among technologies. Further cost reductions could play a major role in increasing deployment in the future. To enable such cost reductions, new modeling frameworks are needed to understand the determinants of innovation in PV. In this project, we study the mechanisms driving PV module and system cost reductions, delving deeply into the specific technological innovations that have occurred in the past and the policies that encouraged them, and also opportunities for future cost reduction and widespread deployment. The project contributes new fundamental insight on the determinants of technological innovation by developing novel methods and insights that are generalizable and can therefore be applied to other technologies. The results will allow policy makers, engineers, and other stakeholders to better prioritize their efforts and investments in the future. The project is organized around four journal articles as described below. The first article [1] identifies ‘low-level’ (e.g. conversion efficiency improvement) and ‘high- level’ (e.g. R&D efforts) mechanisms of cost reduction in PV systems (Tasks 1-4). This work builds on a previous DOE grant, where we developed a framework for technological innovation leading to PV module cost reduction [2]. We advance a method to disentangle the contributions of physical (‘hardware’) and non-physical (‘soft technology’) changes. Our results uncover reasons behind the relatively slow evolution of soft technology and can inform new innovation approaches to these technologies. The second article [3] identifies specific engineering or institutional innovations that enabled the low-level mechanisms of cost reduction in PV module and balance-of-systems (BOS) (Tasks 5, 9, 10). We identify 85 innovations and connect them to the cost variables they affected. By developing an innovations typology, this study shows the differences between the types of innovations affecting PV modules and BOS components. Finally, by analyzing the industry origins of innovations, this study also finds that PV was well-positioned within an ecosystem of continuously advancing technologies. The third article [4] studies prospective cost reduction opportunities (Task 10). We explore how design approaches that emphasize standardization and automation, such as plug-and-play PV systems, can create cost reduction opportunities by reducing interactions and speeding up activities with high process costs. We show that this can lead to cost reduction in cost components with the most untapped opportunity for improvement such as installation labor, overhead, electrical BOS, and customer acquisition. The fourth article [5] analyzes how various policies supporting PV deployment and R&D contributed to PV’s cost improvement by enabling high-level mechanisms, specific innovations, and ultimately low-level mechanisms of cost reduction (Tasks 8, 13, 14). We investigate examples from different countries and connect these policies to quantifiable cost change mechanisms. Our study sheds light on the roles that different nations played over time, through a diverse set of policy approaches.

14 SOLAR ENERGY↗
DOE OSTI2024

Hydrogen Production Cost with Anion Exchange Membrane Electrolysis

Rigorous stakeholder-vetted techno-economic analysis was performed to assess the cost of hydrogen (H 2 ) produced using state-of-the-art Anion Exchange Membrane (AEM) electrolysis. Projected high-volume, untaxed and unsubsidized levelized cost of hydrogen (LCOH)1 range from 2020 $\$$1.78 to $\$$3.68/kg H 2 depending on technology year, process design, and electrolyzer project scale, assuming an electricity price of $\$$0.03/kWh and a capacity factor of 97%. The total installed capital cost for an AEM electrolysis plant was estimated from bottom-up stack and process plant cost models. The stack cost model accounts for manufacturing equipment, equipment maintenance, material, tooling, cycle time, yield, labor, utilities and general overhead. The process plant cost model accounts for purchased equipment, installation costs, site preparation, and general overhead costs. For this study, the AEM electrolysis plant is assumed to be a stick-built, greenfield project developed by an engineering, procurement, and construction (EPC) firm with electrolysis stacks purchased directly from an electrolysis stack manufacturer. The price of the electrolysis stacks is based on a bottom-up cost assessment with business markup for the electrolysis company fabricator. Methods from the Hydrogen Analysis (H2A) production model, a peer-reviewed national laboratory-developed discounted cash flow (DCF) model, were used to calculate the production LCOH in 2020 $\$$/kg H 2 . The baseline electricity price case ($\$$0.03/kWh) corresponds to average wholesale electricity prices currently possible in U.S. markets with plentiful wind. Similar low-cost electricity pricing is possible from solar Power Purchase Agreements (PPA) although these prices are typically limited by renewable energy capacity factors.

08 HYDROGEN↗
NASA NTRS1979

Low-cost point-focus solar concentrator, phase 1

The results of the preliminary design study for the low cost point focus solar concentrator (LCPFSC) development program are presented. A summary description of the preliminary design is given. The design philosophy used to achieve a cost effective design for mass production is described. The concentrator meets all design requirements specified and is based on practical design solutions in every possible way.

Nelson, E. V.↗
DOE OSTI2024

Biofuel production from palm oil deoxygenation using nickel-molybdenum on zirconia catalyst using glycerol as a hydrogen donor

The growing demand for renewable energy has generated interest in biofuels as alternatives to fossil fuels. Second-generation biofuels, derived from deoxygenating fats and oils, have garnered a higher level of interest from industry and academia due to their potential for direct replacement of diesel and jet fuels. Palm oil, mostly cultivated in Thailand and composed of C16 and C18 fatty acids, is a primary feedstock sought for biofuel production. Palm oil deoxygenation contains several pathways that may or may not require hydrogen gas. This study aimed to produce biofuels in different fuel ranges, such as gasoline, jet fuel, and diesel, through palm oil deoxygenation using glycerol as a hydrogen source. Glycerol, a low-value byproduct, was used as a hydrogen donor, whereas nickel-molybdenum-supported catalysts were chosen for their high efficiency in deoxygenation and cost-effectiveness. The study investigated the impact of reaction time, temperature, and catalyst activation method on palm oil deoxygenation. Catalyst characterization methods, including XRD, SEM, TEM, XPS, FTIR, TGA, and nitrogen-sorption, were employed to understand the role of catalysts’ activity during palm oil upgrading. Findings indicated that alkane hydrocarbons are the major components in liquid products. The presence of excess hydrogen in post reaction gaseous phase proves the hydrogen donation capability of glycerol. Increased reaction time and temperature facilitated the removal of oxygen from palm oil. Nickel-molybdenum on zirconia activated by sulfidation demonstrated higher stability than by reduction activation.

09 BIOMASS FUELS↗
DOE OSTI2024

A Preliminary Feasibility Study on Multi-Cavity Cryomodule Integration for the Electron Ion Collider Energy Recover Linac Cooler

The Electron-Ion Collider (EIC) is a state-of-the-art accelerator designed for collisions between highly polarized electrons and ions. To achieve optimal luminosity, the ion beam is cooled using an electron beam sourced from an energy recovery linac (ERL). In the current ERL baseline design, one BNL type RF cavity is used per cryomodule, leading to spatial and cost challenges. This study examines the feasibility of using more compact PERLE (Powerful Energy Recovery Linac for Experiments) type cavities, which can house multiple cavities within a single cryomodule, by evaluating their Beam Breakup (BBU) instability performance. Higher Order Modes (HOM) parameters were obtained through frequency scaling, assuming constant quality factor Q_L, R/Q, and linearly scaling HOM frequencies. To predict the BBU threshold current and ensure accuracy, two different BBU tracking simulations are used for cross-verification. Although the reduced footprint of PERLE-type cavities is advantageous, maintaining sufficient damping of HOMs remains crucial. Finally, we compare the HOM damping efficiency of both cavity types and suggest a pathway forward.

Deitrick, K.↗
DOE OSTI2022

Potential Heating Energy and Cost Savings of Dual Fuel Heat Pump Controls as a Residential Building Equipment Retrofit in the U.S.

This study investigated the energy and cost savings potential by modeling a dual fuel heat pump system with its control for a residential building in (5A) cold climate in U.S. The simulation analysis showed that the application of the DFHP system and its control to the target building can save the heating energy by 42% over a gas furnace system (baseline system). Although the HP-only system can save more heating energy (i.e., 53%) over the baseline system than DFHP system does, the DFHP with its control demonstrated the higher cost savings when a time of use electricity rate was considered.

Yoon, Yeobeom↗
DOE OSTI2023

Development of sustainable low carbon Engineered Cementitious Composites with waste polyethylene fiber, sisal fiber and carbonation curing

Engineered cementitious composites (ECC) is an advanced fiber-reinforced cementitious composite with high tensile ductility. However, the binder and fiber system in ECC incur high economic and environmental cost. In this study, a low carbon ECC was developed by substituting virgin polyethylene fiber with waste polyethylene fiber (WPE) from waste marine fishing nets. Carbonation curing was applied to further reduce embodied carbon footprint via direct CO 2 mineralization. This research examined the low carbon ECC’s mechanical properties, including compressive strength and tensile strength and ductility. The CO 2 footprint and material costs of ECC were also investigated. The objective was to develop an ECC competitive to normal concrete economically and environmentally while maintain the unique ductile performance of ECC. Results suggest that carbonation-cured WPE reinforced ECC possesses 50% of the CO 2 footprint and 37% of the cost of traditional concrete. Meanwhile, this low carbon ECC maintains at least 4 MPa tensile strength and 6% tensile ductility. This research demonstrates the feasibility of developing construction materials with low environmental impact while maintaining high performance for civil infrastructure applications. As a result, the adoption of WPE in ECC provides a plausible pathway to recycle marine waste into the construction industry that urgently needs to be decarbonized.

42 ENGINEERING↗
NASA NTRS2000

Beagle 2 and NASA's Mars 2003 Orbiter: A Unique Exobiology Opportunity with an Orbiter

With the exploration strategy for Mars undergoing reexamination, the opportunity exists for the incorporation of the 60 kg Beagle 2 lander, developed in the United Kingdom for inclusion on ESA's 2003 Mars Express mission, with NASA's Mars 2003 orbiter derived from the Mars Global Orbiter. The combination of Beagle 2 with a Mars orbiter would result in a unique mission which could obtain information on Mars' life, climate and resources both from orbit as well as on the surface of the planet. Beagle 2 has been developed in the LJK for ESA as a low-cost opportunity to study the exobiology of Mars and the spacecraft is in its final stages of manufacture. Only limited modifications to the Beagle 2 package would be required for inclusion on NASA's Mars 2003 orbiter. With the ESA Mars Express mission launch in 2003 and a potential NASA Mars orbiter in 2003, both Beagle 2 landers on Mars would offer a low-cost, decreased risk and increased science return opportunity for the exploration of Mars at two distinct geologically interesting sites.

Gibson, Everett K., Jr.↗
NASA NTRS1993

The effects of design details on cost and weight of fuselage structures

Crown panel design studies showing the relationship between panel size, cost, weight, and aircraft configuration are compared to aluminum design configurations. The effects of a stiffened sandwich design concept are also discussed. This paper summarizes the effect of a design cost model in assessing the cost and weight relationships for fuselage crown panel designs. Studies were performed using data from existing aircraft to assess the effects of different design variables on the cost and weight of transport fuselage crown panel design. Results show a strong influence of load levels, panel size, and material choices on the cost and weight of specific designs. A design tool being developed under the NASA ACT program is used in the study to assess these issues. The effects of panel configuration comparing postbuckled and buckle resistant stiffened laminated structure is compared to a stiffened sandwich concept. Results suggest some potential economy with stiffened sandwich designs for compression dominated structure with relatively high load levels.

Swanson, G. D.↗
NASA NTRSDate not supplied

Cost Breakeven Analysis of Lunar In-Situ Propellant Production for Human Missions to the Moon and Mars

NASA is preparing to return humans to the lunar surface as a first step to a human exploration campaign of Mars. Both a sustained lunar campaign and a campaign of missions to Mars will require tens to hundreds of tonnes of propellant. Although this propellant could be delivered from Earth, an alternative approach is to use the potentially vast quantities of lunar ice to enable in-situ propellant production on the lunar surface. This study evaluates the cost breakeven for using lunar-derived propellants, as opposed to those delivered from Earth, in support of an extended human exploration campaign with both a multi-year presence on the Moon as well as multiple crewed missions to Mars. In so doing, the value of lunar propellant production is considered in the context of future exploration priorities, addressing the question: over what range of human missions to the lunar surface and Mars does in-situ propellant production trade favorably with propellant delivery from Earth on the basis of cost? The results of this analysis show that the magnitude and duration of the lunar campaign, more so than the Mars campaign, drive the breakeven and that without long lifetime ISRU systems, with greater than 5 years of autonomous operation before replacement, the demand in cis-lunar space for a Mars campaign favors propellant delivery from Earth.

Christopher A Jones↗
NASA NTRSDate not supplied

Cost Breakeven Analysis of Lunar In-Situ Propellant Production for Human Missions to the Moon and Mars

NASA is preparing to return humans to the lunar surface as a first step to a human exploration campaign of Mars. Both a sustained lunar campaign and a campaign of missions to Mars will require tens to hundreds of tonnes of propellant. Although this propellant could be delivered from Earth, an alternative approach is to use the potentially vast quantities of lunar ice to enable in-situ propellant production on the lunar surface. This study evaluates the cost breakeven for using lunar-derived propellants, as opposed to those delivered from Earth, in support of an extended human exploration campaign with both a multi-year presence on the Moon as well as multiple crewed missions to Mars. In so doing, the value of lunar propellant production is considered in the context of future exploration priorities, addressing the question: over what range of human missions to the lunar surface and Mars does in-situ propellant production trade favorably with propellant delivery from Earth on the basis of cost? The results of this analysis show that the magnitude and duration of the lunar campaign, more so than the Mars campaign, drive the breakeven and that without long lifetime ISRU systems, with greater than 5 years of autonomous operation before replacement, the demand in cis-lunar space for a Mars campaign favors propellant delivery from Earth.

Christopher A. Jones↗
DOE OSTI2023

Bi-Level Adaptive Storage Expansion Strategy for Microgrids Using Deep Reinforcement Learning

Battery energy storage (BES) is a versatile resource for the secure and economic operation of microgrids (MGs). Prevailing stochastic optimization-based approaches for BES expansion planning for MGs are computationally complicated. This work proposes a data-driven bi-level multi-period BES expansion planning framework to determine the siting, sizing, and timing of BES installations. The proposed planning framework unifies deep reinforcement learning (DRL) and linear programming, thereby decoupling the determinations for the integer and continuous decision variables in two time scales, respectively. In the upper level, a rainbow DRL agent with quantile regression is trained to provide dynamic planning policies to accommodate stochastic renewable energy resources (RESs), load, and battery price changes efficiently. Further, the lower level computes the optimal operation of MGs with frequency constraints to hedge the islanding contingency. The two levels communicate with one another by exchanging storage configuration and operating expenses in order to accomplish the shared goal of minimizing investment and operation costs. Comparative case studies on an MG are carried out to demonstrate the superiority of the proposed DRL-based solution to the mixed-integer linear programming counterpart on efficiency, scalability, and adaptability.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2026

A System-Level Cost Modeling Framework for Design for Remanufacturing: A Case Study of an Agricultural Machine Transmission

Remanufacturing offers significant environmental and economic benefits by restoring end-of-life products to as-new conditions. Although extensive research has been conducted on the topic, the adoption of remanufacturing practices remains limited across various industries. A primary barrier to broader implementation is the substantial upfront investment required, which necessitates reliable cost modeling to justify potential future savings. Most existing models treat components independently and ignore inter-component dependencies. We develop a probabilistic, system-level cost modeling framework that integrates reliability, reusability, and a dependency matrix to capture cascading effects across components over multiple life cycles. Our model identifies those critical components that maximize remanufacturing benefits across a product's many lives. A toy example and an industry case study (John Deere PowrQuad transmission subassembly) illustrate how design alternatives affect cumulative cost. Using a Monte Carlo simulation (MCS) to perform life cycle cost analysis on the system with different design changes, we show the normalized average cost savings after three remanufacturing cycles. Accounting for dependencies meaningfully alters cost projections and ignoring them underestimates accumulated cost by up to 20% in our examples. Furthermore, the results of our study confirm that accounting for component interdependencies is necessary to produce cost estimates that meet industry standards.

Life Cycle Analysis and Design↗
NASA NTRS2016

Cost-Benefit Analysis for the Advanced Near Net Shape Technology (ANNST) Method for Fabricating Stiffened Cylinders

This cost-benefit analysis assesses the benefits of the Advanced Near Net Shape Technology (ANNST) manufacturing process for fabricating integrally stiffened cylinders. These preliminary, rough order-of-magnitude results report a 46 to 58 percent reduction in production costs and a 7-percent reduction in weight over the conventional metallic manufacturing technique used in this study for comparison. Production cost savings of 35 to 58 percent were reported over the composite manufacturing technique used in this study for comparison; however, the ANNST concept was heavier. In this study, the predicted return on investment of equipment required for the ANNST method was ten cryogenic tank barrels when compared with conventional metallic manufacturing. The ANNST method was compared with the conventional multi-piece metallic construction and composite processes for fabricating integrally stiffened cylinders. A case study compared these three alternatives for manufacturing a cylinder of specified geometry, with particular focus placed on production costs and process complexity, with cost analyses performed by the analogy and parametric methods. Furthermore, a scalability study was conducted for three tank diameters to assess the highest potential payoff of the ANNST process for manufacture of large-diameter cryogenic tanks. The analytical hierarchy process (AHP) was subsequently used with a group of selected subject matter experts to assess the value of the various benefits achieved by the ANNST method for potential stakeholders. The AHP study results revealed that decreased final cylinder mass and quality assurance were the most valued benefits of cylinder manufacturing methods, therefore emphasizing the relevance of the benefits achieved with the ANNST process for future projects.

Stoner, Mary Cecilia↗
NASA NTRS1995

Marshall Space Flight Center solid waste characterization and recycling improvement study

The MSFC Facilities Office, which is responsible for disposing of all waste generated by MSFC, issued a delivery order to the University of Alabama in Huntsville (UAH) to characterize current MSFC waste streams and to evaluate their existing recycling program. The purpose of the study was to define the nature, quantity, and types of waste produced and to generate ideas for improving the present recycling program. Specifically, the following tasks were to be performed: Identify various surplus and waste materials--as identified by the Contracting Officer's Technical Representative (COTR)--by source, location, and type; Analyze MSFC's current methods for handling, storage, transport, and disposition of waste and surplussed materials; Determine the composition of various surplus and waste materials as to type and quantities from various sources and locations; Analyze different methods for the disposition of various surplus and waste materials, including quality, quantity, preparation, transport cost, and value; Study possible alternatives to current methods of handling, storage, transport, and disposition of surplus and waste materials to improve the quality and quantities recycled or sold and to reduce and minimize the quantities of surplus and waste material currently being disposed of or stored; Provide recommendations for source and centralized segregation and aggregation of materials for recycling and/or disposition; and The analysis could include identification and laboratory level evaluation of methods and/or equipment, including capital costs, operating costs, maintenance requirements, life cycle and return on investment for systems to support the waste reduction program mission.

Eley, Michael H.↗
DOE OSTI2025

Cost impact of hexose-to-pentose sugar ratios for biomanufacturing

Central to the long-term vision for biomanufacturing is the ability to deconstruct plant cell walls to sugars that microbes can convert to products. Aside from glucose, the most abundant sugar in biomass is xylose, a pentose sugar. Industrially relevant microbes have been engineered to co-ferment xylose and glucose. Most nth plant technoeconomic analyses (TEAs) assume similar consumption rates and product yields for both sugars, but in reality, xylose is consumed more slowly. Feedstocks can be selected, or engineered, to alter the glucan-to-xylan ratio (GXR) but no TEAs have quantified the impact of this strategy systematically. This study explores the cost impacts of varying the glucan-to-xylan ratio (GXR) from 1.9 to 6.7 for co-fermenting glucose and xylose to ethanol and bisabolene. The minimum selling prices (MSPs) for both products decrease as the GXR increases, with the largest reductions at shorter residence times. For instance, with an increase in GXR from 1.9 to 6.7, ethanol’s MSP drops by 16 %, 5 %, and 3 % at 24, 72, and 144 h, respectively, while bisabolene’s MSP declines by 23 %, 20 %, and 15 % at 24, 72, and 120 h. Particularly for early-stage commercialization, the results suggest that altering or selecting for feedstocks with higher GXR can minimize capital costs by reducing optimal residence times. Capital-constrained biorefineries operating with shorter residence times can justify paying up to 1.5X to 2X the price for feedstocks with a higher GXR, based on the expected improvements in their product yield and overall process economics.

Delayed xylose utilization↗