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NASA NTRS1992

Combustion devices technology team - An overview and status of STME-related activities

The Consortium for CFD applications in propulsion technology has been formed at NASA/Marshall Space Flight Center. The combustion devices technology team is one of the three teams that constitute the Consortium. While generally aiming to advance combustion devices technology for rocket propulsion, the team's efforts for the last 1 and 1/2 years have been focused on issues relating to the Space Transportation Main Engine (STME) nozzle. The nozzle design uses hydrogen-rich turbine exhaust to cool the wall in a film/dump scheme. This method of cooling presents challenges and associated risks for the nozzle designers and the engine/vehicle integrators. Within the nozzle itself, a key concern is the ability to effectively and efficiently film cool the wall. From the National Launch System vehicle base standpoint, there are concerns with dumping combustible gases at the nozzle exit and their potential adverse effects on the base thermal environment. The Combustion Team has developed and is implementing plans to use validated CFD tools to aid in risk mitigation for both areas.

Tucker, P. K.↗

NASA NTRS1994

Slush Hydrogen Technology Program

A slush hydrogen (SH2) technology facility (STF) was designed, fabricated, and assembled by a contractor team of McDonnell Douglas Aerospace (MDA), Martin Marietta Aerospace Group (MMAG), and Air Products and Chemicals, Inc. (APCI). The STF consists of a slush generator which uses the freeze-thaw production process, a vacuum subsystem, a test tank which simulates the NASP vehicle, a triple point hydrogen receiver tank, a transfer subsystem, a sample bottle, a pressurization system, and a complete instrumentation and control subsystem. The STF was fabricated, checked-out, and made ready for testing under this contract. The actual SH2 testing was performed under the NASP consortium following NASP teaming. Pre-STF testing verified SH2 production methods, validated special SH2 instrumentation, and performed limited SH2 pressurization and expulsion tests which demonstrated the need for gaseous helium pre-pressurized of SH2 to control pressure collapse. The STF represents cutting-edge technology development by an effective Government-Industry team under very tight cost and schedule constraints.

Cady, Edwin C.↗

NASA NTRSDate not supplied

An Interim Set of TNT Curves for LOX/LNG Explosions

Space launch companies are actively developing, or in some cases have already developed, new vehicles that use large quantities of liquid oxygen (LOX) and liquid natural gas (LNG) propellants. This propellant mixture currently lacks sound/verified explosive safety standards for use in explosive siting and flight safety analysis. In the U.S., multiple government and commercial organizations have conducted limited testing, or are preparing to conduct tests, intended to provide a sound technical basis for LOX/LNG explosive standards applicable to space launch vehicle ground and flight operations. The limited testing and analysis conducted so far indicates the potential to produce extremely energetic explosions due to the miscibility of LOX/LNG (methane), a unique feature relative to previously used propellant mixtures such as hydrogen/oxygen or kerosene/oxygen. MOX is a homogenous mixture of methane and oxygen that is possible because of methane’s 100% miscibility in LOX. Preliminary testing by N2L, Inc. described in this paper shows that it is possible to form MOX with a variety of mixing methods, and that MOX is a sensitive high explosive capable of producing overpressures greater than comparable masses of C-4. The limited amount and quality of large-scale LOX/LNG explosive test data, and the potential formation of high-explosive MOX, create significant unknowns in the determination of hazard areas (cleared of the public) for ground operations (such as a static fire test) and flights of launch vehicles with LOX/LNG propellant. This paper will review the methods used by NASA to develop and validate the LOX/LH2 blast model using large-scale explosive test programs such as Project PYRO, the Hydrogen-Oxygen Vertical Impact (HOVI), and the Large-Scale Hydrogen-Oxygen Explosion (LSHOE) tests. This paper will describe how the same process was used to prepare an interim LOX/LNG blast model that applies to various LV failure scenarios and conservatively accounts for potential MOX formation. This paper also summarizes past and future testing and modeling efforts funded by a consortium of NASA, the US Federal Aviation Administration (FAA), and the US Space Force (USSF). These test programs should be concluded within the next 3 years and are intended to provide empirical data for model verification and validation.

Liquid Oxygen↗

NASA NTRSDate not supplied

An Interim Set of TNT Curves for LOX/LNG Explosions

Space launch companies are actively developing, or in some cases have already developed, new vehicles that use large quantities of liquid oxygen (LOX) and liquid natural gas (LNG) propellants. This propellant mixture currently lacks sound/verified LOX/LNG explosive safety standards for use in explosive siting and flight safety analysis. In the U.S., multiple government and commercial organizations have conducted limited testing, or are preparing to conduct tests, intended to provide a sound technical basis for explosive standards applicable to space launch vehicle ground and flight operations. The limited testing and analysis conducted so far indicates the potential to produce extremely energetic explosions due to the miscibility of LOX/LNG (methane), a unique feature relative to previously used propellant mixtures such as hydrogen/oxygen or kerosene/oxygen. MOX is a homogenous mixture of methane and oxygen that is possible because of methane’s 100% miscibility in LOX. Preliminary testing by N2L, Inc. described in this paper shows that it is possible to form MOX with a variety of mixing methods, and that MOX is a sensitive high explosive capable of producing overpressures greater than comparable masses of C-4. The limited amount and quality of large-scale LOX/LNG explosive test data, and the potential formation of high-explosive MOX, create significant unknowns in the determination of hazard areas (cleared of the public) for ground operations (such as a static fire test) and flights of launch vehicles with LOX/LNG propellant. This paper will review the methods used by NASA to develop and validate the LOX/LH2 blast model using large-scale explosive test programs such as Project PYRO, the Hydrogen-Oxygen Vertical Impact (HOVI), and the Large-Scale Hydrogen-Oxygen Explosion (LSHOE) tests. This paper will describe how the same process was used to prepare an interim LOX/LNG blast model that applies to various LV failure scenarios and conservatively accounts for potential MOX formation. This paper also summarizes past and future testing and modeling efforts funded by a consortium of NASA, the US Federal Aviation Administration (FAA), and the US Space Force (USSF). These test programs should be concluded within the next 3 years and are intended to provide empirical data for model verification and validation.

Liquid Oxygen↗

DOE OSTI2021

High Performance PEFC Electrode Structures

Raytheon Technologies Research Center (RTRC) in collaboration with Ion Power Inc. and the University of Arkansas at Little Rock and the FC-PAD consortium executed a project that: (1) developed comprehensive models of oxygen and proton transport in cathode catalyst layers that provided new insights about losses associated with reducing platinum loading to 0.1 mg/cm 2 , (2) designed, fabricated, characterized, and tested cells featuring carbon-supported catalyst layers with low platinum loadings that met efficiency and power density targets set forth by the Hydrogen and Fuel Cells Technology Office, and (3) designed, fabricated, characterized, and tested novel catalyst structures. The modeling efforts produced eight scientific publications that shared new descriptions of oxygen and proton transport in catalyst layers with the broader technical community. The key physical insights from the models are expressed in straightforward algebraic expressions, facilitating easy adoption by other researchers. The models developed during the project explain why resistance to oxygen transport is inversely proportional to interfacial area of platinum – an observation that eluded quantitative explanation for a decade. The models quantitatively predict polarization when measured morphological parameters and transport properties are input. Membrane-electrode assemblies made during the project met stated goals for current at high voltage and power density at rated voltage for transportation fuel cells at the end of budget period 2. High performance was achieved by developing a diffusion layer with low resistance to oxygen transport and a PtCo/C cathode catalyst layer capable of supporting rapid proton and oxygen transport. The project was subsequently directed to curtail experimental work and focus on modeling during budget period 3. Ion Power Inc. developed new expertise in fabricating catalyst layers containing platinum-cobalt catalysts, and processing very thin membranes. The University of Arkansas at Little Rock developed novel nanocolumnar self-supported thin film electrocatalysts that can be grown on carbon supports using a simple high pressure sputter deposition method. The nanocolumnar microstructure provides adequate surface-to-volume ratio for efficient platinum utilization, and the conformal platinum shell with larger crystal grain sizes covering the carbon support surface may eliminate durability issues associated with catalyst dissolution, agglomeration, and carbon corrosion.

08 HYDROGEN↗

DOE OSTI2026

Techno-economic analysis and life cycle assessment for the catalytic hydrogenolysis and hydrocracking of polyethylene

Catalytic hydrogenolysis and hydrocracking are promising technologies for the conversion of polyolefin waste into hydrocarbons. Here, to explore the economic and environmental viability of these approaches, we conducted techno-economic analysis and life cycle assessment of polyethylene hydrogenolysis and hydrocracking processes that produce fuel-range products or olefins, respectively. Relative to primary production, the minimum selling price (MSP) of alkanes for linear-chain naphtha was estimated to be 1.8-fold higher, whereas branched-chain naphtha and propylene were shown to be cost competitive. Environmental impacts showed similar trends across scenarios, with propylene production by hydrocracking exhibiting greenhouse gas emissions comparable with conventional propylene due to relatively low hydrogen demand and high yield. Together, these results suggest that innovations in catalysis and reaction engineering will be required to make viable products that are scale matched with today's plastics, such as light olefins for closed-loop recycling.

09 BIOMASS FUELS↗

DOE OSTI2022

Battery500 Consortium: Development of High Capacity Cathodes and Robust Solid Electrolytes

As the world have witnessed the tremendous development in portable electronic devices as well as electric vehicles, the current generation lithium-ion battery is unlikely to satisfy the bourgeon of market and the demand of the customers. A next generation battery, with cell energy density higher than 500 Wh kg -1 , needs to be developed to meet the growth of the industry. With its high theoretical capacity (3,860 mAh g -1 , or 2,061 mAh cm -3 ) and low electrochemical potential (–3.04 V versus the standard hydrogen electrode), lithium metal has been regarded as the ideal candidate for the next generation battery anode. In fact, Lithium metal anode is irreplaceable for Lithium-Sulfur chemistry. However, the continuous formation of inactive Li, which eventually leads the loss of reversible capacity of the cell, has prevented lithium metal to be used as anode in commercial rechargeable cells. The ultimate goal of the project is to propose a pathway to enable Li metal battery for stable cycling at 99.9% of Coulombic efficiency with energy density higher than 500 Wh kg -1 . A variety of advanced characterization tools, electrolyte systems, 3D current collectors and failure analysis methodologies have been developed throughout the project during the past 5 years. The UCSD effort is carried out by the groups of Ping Liu and Shirley Meng.

25 ENERGY STORAGE↗

DOE OSTI2023

BioHydrogen (BioH2) Consortium to Advance Fermentative H2 Production

The overall objective of this project is to develop a carbon-neutral, microbial dark fermentation technology to convert waste lignocellulosic biomass into H2 with a production cost less than $2/kg-H2 via strain engineering, bioprocess design for scale-up, and integrating fermentation with microbial electrolysis cell (MEC).

bioH2↗

DOE OSTI2024

BioHydrogen (BioH2) Consortium to Advance Fermentative H2 Production

bioH2↗

DOE OSTI2025

Durability of Pt-Alloy Catalyst for Heavy-Duty Polymer Electrolyte Fuel Cell Applications under Realistic Conditions

As an emerging technology, polymer electrolyte fuel cells (PEFCs) powered by clean hydrogen can be a great source of renewable power generation with flexible utilization because of high gravimetric energy density of hydrogen. To be used in real-life applications, PEFCs need to maintain their performance for long-term use under a wide range of conditions. Therefore, it's important to understand the degradation of the PEFC under protocols that are closely related to the catalyst lifetime. Alloying Pt with transitional metal improves catalyst activity. It is also crucial to understand Pt alloys degradation mechanisms to improve their durability. To study durability of Pt alloys, accelerated stress tests (ASTs) are performed on Pt-Co catalyst supported on two types of carbon. Two different AST protocols were being studied: Membrane Electrolyte Assembly (MEA) AST based on the protocol introduced by the Million Mile Fuel Cell Truck consortium in 2023 and Catalyst AST, adopted from the U.S. Department of Energy (DoE).

25 ENERGY STORAGE↗

DOE OSTI2025

Catalytic closed-loop recycling of polyethylene-like materials produced by acceptorless dehydrogenative polymerization of bio-derived diols

Petroleum-derived polyolefins exhibit diverse properties and are the most important and largest volume class of plastics. However, polyolefins are difficult to efficiently recycle or break down and are now a persistent global contaminant. Broadly replacing polyolefins with bio-derived and degradable polyethylene-like materials is an important yet challenging endeavour towards sustainable plastics. Here, in this study, we report a solution for circular bio-based polyethylene-like materials synthesized by acceptorless dehydrogenative polymerization from linear and branched diols and their catalytic closed-loop recycling. The polymerization and depolymerization processes utilize earth-abundant manganese complexes as catalysts. These materials exhibit a wide range of mechanical properties, encompassing thermoplastics to plastomers to elastomers. The branched diols, produced through a thiol-ene click reaction, can be polymerized to plastics with significantly enhanced tensile properties, toughness and adhesive properties. These materials could be depolymerized back to monomers through hydrogenation and were separatable with a monomer recovery of up to 99%, unaffected by the presence of dyes and additives. Overall, this system establishes a route to more sustainable plastics.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Midwest Nuclear-based Net-Zero Carbon Steelmaking Demonstration

Globally, the iron and steel industry accounts for around a quarter of GHG emissions from the manufacturing sector , which is about 7% of the 33 gigatonnes (Gt) of global CO 2 emissions . Thus, globally, the steel industry is a 2-3 Gt CO 2 per year emissions challenge. The steel industry is important to the U.S. economy with output equal to $0.5 trillion and domestic production capacity is critical to national defense, infrastructure, energy production, and transportation. President Biden’s executive order on climate identifies actions and policies to put the Nation on a path to achieve net-zero carbon emissions, economy-wide, by no later than 2050. To achieve this, deep carbon reductions in the power, transportation, buildings and capital-intensive industrial manufacturing segments such as steel, cement and chemicals need to be addressed. In its recent “Accelerating Decarbonization of the U.S. Energy System” report , the National Academy of Sciences (NAS) stated that, “while technology exists to decarbonize all parts of the energy system, some sectors remain at precommercial or first-of-a-kind demonstration stages and require significant improvement in cost and performance to become commercially viable.” The NAS goes on to state that these hard to decarbonize sectors include “aviation, shipping, and industrial subsectors such as steel, cement, and chemicals manufacturing .” The Administration has proposed a timeline to decarbonize energy, transportation and then industry and manufacturing. From a life-cycle approach, decarbonizing steel and other large industrial inputs are necessary to decarbonize transformations in energy and transportation. DOE’s TRI-Lab Consortium’s Integrated Energy Systems (IES) program is a collaboration amongst DOE’s three applied energy laboratories: the National Energy Technology Laboratory; National Renewable Energy Laboratory and Idaho National Laboratory. The IES approach looks at more tightly integrating low-carbon nuclear energy, renewable electricity, energy storage, load/demand balancing, and biomass (including plastics and other wastes) with one or more industrial processes that utilize heat and/or power from these clean and waste energy sources to produce a low-carbon commodity-scale product.

08 HYDROGEN↗

DOE OSTI2026

Alkylidene functionalization produces highly recyclable and scalable polyhydroxyalkanoates

Recyclable polymers that can be produced at scale and readily tuned within the same polymer framework for specific properties are important to achieving a circular materials economy. To this end, synthetic poly(3-hydroxyalkanoate)s (PHAs) have emerged as high-performance, chemically recyclable variants of biological PHAs, but their difficult monomer syntheses and suboptimal recycling efficiencies pose challenges for large-scale deployment. In this study, we investigated a β-isopropylidene PHA, i-PHA, for which the lactone monomer can be synthesized by existing industrial methods from biomass-derived isobutyric acid. The alkylidene substituent prevents decarboxylative degradation typically observed during PHA depolymerization, enabling near-quantitative chemical recycling to monomer. Controlled hydrogenation of the β-isopropylidene side group produces PHAs with diverse performance metrics that are competitive with a range of commodity polymers, spanning strong fibers to ductile thermoplastics to superglue epoxy resins.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Thermophilic Chassis-Enabled High-Throughput Selection of a Thermostable Fluorogenic Reporter

Thermostable proteins show increased shelf life and performance at elevated temperatures and under harsh conditions, resulting in lower costs for various industrial and biotechnological applications. However, due to a limited understanding of the relationship between stability and function, protein stabilization remains primarily a trial-and-error approach. Therefore, building a combinatorial library of mutations predicted to improve stability, followed by experimental testing, represents a markedly improved methodology. However, the lack of high-throughput approaches to screen even a moderately sized library presents a major bottleneck in the field. Here, in this study, we use a thermophile, Parageobacillus thermoglucosidasius (Ptherm) to rapidly screen combinatorial libraries consisting of rationally designed thermostabilizing mutations (∼10 3 –10 4 ) of a mesophilic fluorescent reporter, Y-FAST. On a Petri dish, microbial growth at an elevated temperature and exposure to fluorogen yielded several colonies of Ptherm that showed distinct fluorescence at 55 and 68 °C in our two sequentially generated libraries using Rosetta and ProteinMPNN, respectively. The Y-FAST variants isolated from fluorescent colonies were brighter than Y-FAST and showed higher resistance to thermal and chemical denaturation. AlphaFold-predicted structures and MD simulations revealed stability-enhancing salt bridges and hydrogen bond networks in the isolated FAST variants. The moderately thermostable FAST (tsFAST) and hyperstable FAST (hsFAST) were then demonstrated as translation reporters for protein expression and folding at elevated temperatures, such as 55 and 68 °C. Our approach of combinatorial library generation and high-throughput screening in a thermophilic chassis could, in principle, be extended to other proteins fused to these translation reporters. Furthermore, the hsFAST protein is small─half the size of the green fluorescent protein─and does not require oxygen for maturation, making it ideal for engineering extremophilic anaerobes for biosensing and bioconversion.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2026

A Circular and Tacticity‐Independent Crystalline Mono‐Substituted Nylon‐6 Platform: Unexpected Large Positional Effects on Crystallizability and Performance

Seeking recyclable, more sustainable alternatives to nylon 6 has drawn much attention, but achieving its variants with both crystallinity and enhanced recyclability still remains a challenge. Here, by utilizing bio-derivable mono-substituted racemic lactam monomers, we reveal surprisingly large effects of methyl substitution positions on the nylon-6 backbone on crystallizability, thermomechanical performance, and recyclability of the resulting atactic nylon-6 variants. While γ-methyl substitution gives an amorphous nylon, all other four methyl-substitution positions (α, β, δ, and ε) afford, unexpectedly, crystalline nylons with melting temperatures ranging from 145°C to 200°C and tunable mechanical performance from being stiff and strong (α, ε) to ductile (β, δ). Investigations reveal that the crystallinity of atactic nylons arises independently of stereoregularity, which is driven by the amide backbone with robust hydrogen-bonding interactions and countered by the chain flexibility regulated by the substitution position. These nylons can be chemically recycled back to their parent monomers with high isolated yields up to 92%, enabling a circular, tacticity-independent crystalline nylon platform.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Balmer emission measurements in JET-ILW hydrogen, deuterium, tritium and deuterium-tritium low-confinement mode plasmas

Measurements of Balmer-alpha (B-α) and Balmer-gamma (B-γ), where B = H, D, or T isotopes of hydrogen, emission across the low-field side (LFS) divertor in JET ITER-like Wall (ILW), low-confinement mode (L-mode) plasma indicate that the divertor plasma was more strongly detached in deuterium, tritium and deuterium–tritium than in hydrogen plasmas. These measurements are consistent with the lower degree of detachment in hydrogen versus tritium plasmas inferred from Langmuir probes (Groth et al., 2023). The ratio of B-γ to B-α is a suitable indicator of high density/low temperature conditions because B-α emission is dominated by electron impact excitation with a small electron–ion recombination component regardless of electron temperature and density (for conditions in tokamak plasmas) whilst for B-γ the recombination component increases and the excitation component decreases as the electron temperature decreases and the electron density increases. Within the uncertainty of the measurements, the electron density at the low-field side separatrix and the power crossing the separatrix are similar to permit these comparisons. The B-©/B-α ratio is well correlated with the onset of detachment as measured by Langmuir probes (McCracken et al., 1998; Groth et al., 2023). The ratios of B-γ and B-α varied between 0.005 and 0.035 for low-recycling, high-recycling and partially detached conditions, and were 60–70 % higher in partially detached hydrogen than in tritium plasmas. In contrast, the difference between deuterium, tritium and 40–60 % deuterium–tritium is within 10 % and thus within the uncertainties of the measurements. Profiles of the B-α and B-γ emission was measured with two filtered CCDs connected to the visible lost light leg of JET’s mirror link spectroscopy system (Meigs et al., 2010; Lomanowski et al., 2014). Spatially (radial) narrower B-α profiles were measured with increasing isotope mass, while similarly broadened B-γ profiles were measured.

Balmer↗

DOE OSTI2026

Leaf Wax Hydrogen Isotopes Reflect Storm Track Position Over Western North America

Proxy records of past climates have yielded powerful insights into regional hydroclimate dynamics. Novel insights may be gained by reconstructing spatiotemporal changes in precipitation isotopologues in past climate states that cannot be gleaned from individual site‐level studies. In this paper, we ask whether latitudinal gradients in the stable hydrogen isotopic composition of precipitation, as inferred from sedimentary leaf wax biomarkers, reflect aspects of large‐scale climate conditions in western North America (WNA). Modern coretop samples from offshore WNA show that leaf wax hydrogen isotopes broadly track the hydrogen isotopic composition of rainfall between 20 and 40N, but with an offset corresponding to a relatively constant “apparent fractionation” value. Poleward of 40N, the leaf wax signal may be complicated by fluvial transport of leaf waxes from the continental interior. Leaf wax‐inferred precipitation hydrogen isotopes show a shift to more negative values between 30 and 40N. We use modern observational data to show that this latitudinal range marks a major transition between the subtropical arid zone and the location of the midlatitude storm tracks over the northeast Pacific. Nudged water isotope‐enabled models capture the location of the arid to mesic climate transition with fidelity. This modern data set suggests that reconstructions of the latitudinal gradient of precipitation hydrogen isotopes can constrain the sensitivity of the storm tracks to shifts in climatic boundary conditions in past climate states. This approach can yield novel insights into past, present, and future hydroclimate variability in this arid region.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

TCO Analysis Approach and Regional Analysis of dWPT for Class 8 Tractors

Dynamic Wireless Power Transfer (dWPT) is a method by which battery electric vehicles (BEVs) can charge their battery while traveling on the road without the need for a physical conductive connection to the power source. dWPT has been proposed as a strategy to enable a reduction in vehicle battery capacity and associated mass and cost. In this slide deck presented at the EVs@Scale Consortium - Wireless Power Transfer Pillar Deep-Dive Meeting on November 11th, 2023, NREL provides results from an evaluation of dWPT using data from Class 8 tractors driving in the Atlanta Metro Area. NREL selected data for archetypal days representing local, regional, and long-haul trips, defined according to trip length, that included travel on primary roadways. EVI-InMotion (Electric Vehicle Infrastructure - InMotion), a systems planning and optimization tool developed at NREL, was used to evaluate dWPT performance assuming dWPT charging on 120 road segments for a total roadway lane distance of 2,365 miles. The EVI-InMotion results and representative day drive cycles were analyzed with NREL's T3CO (Transportation Technology Total Cost of Ownership) tool to estimate the total cost of ownership (TCO) for scenarios comprising two model years - 2030 and 2040 - and two technology progress cases. TCO was calculated for diesel, fuel cell electric, BEVs with batteries sized assuming no dWPT capabilities, and 200kWh BEVs with dWPT installed. This analysis finds that en-route stationary charging frequency and downtime when not on electrified roadways are the main contributors to TCO for the dWPT vehicles and that these vehicles can achieve cost parity with FCEVs at low electricity costs. Based on the scenario assumptions used here, low electricity costs would further help the cost parity with diesel vehicles in regional and long-haul cases due to stationary fueling downtime. This presentation also concludes that key factors affecting the parity potential of dWPT-capable vehicles include more extensive dWPT road coverage, higher en-route charging power, less expensive power batteries, and higher hydrogen or diesel fuel costs.

ADVANCED PROPULSION SYSTEMS,ENERGY PLANNING, POLIC↗