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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Comparative Study of Zinc Cold-Spray Coating and Pre-treatments for Magnesium Alloys

Magnesium (Mg) alloys are appealing for automotive lightweighting owing to their high specific strength. However, their susceptibility to corrosion in harsh environments remains a major challenge. Conventional industrial pre-treatment coatings, including zinc phosphate, chromate conversion, and non-chromate conversion, often exhibit discontinuities and microcracks, leading to localized corrosion near fasteners and parting lines. Here, this study investigates cold-sprayed zinc (Zn) coatings as a novel pre-treatment alternative for high-pressure die cast (HPDC) AZ91 Mg alloys, demonstrating significant improvements in wear and corrosion performance. Cold spray produces uniform and robust coatings, reducing wear rate by over 50% and reducing corrosion rate by over 99.3%, as measured by evolved hydrogen release, compared to traditional pre-treatments. Multimodal corrosion testing reveals that Zn cold-spray coatings form a protective layer during exposure, minimizing general and filiform corrosion, and exhibiting corrosion potential (E corr ) that is nobler by ~ 400 mV than the surfaces of both pre-treated and uncoated AZ91. Scalability of cold spray for selective application around multimaterial joints further strengthens their industrial viability. This work establishes Zn cold-spray coatings as highly effective pre-treatment solutions for the advancement of corrosion resistant Mg alloy components in automotive applications.

multimodal corrosion↗
DOE OSTI2025

Emerging Tools to Support DILI Assessment in Clinical Trials with Abnormal Baseline Serum Liver Tests or Pre-existing Liver Diseases

Abstract Based on the late Dr. Hyman Zimmerman’s observation that hepatocellular drug-induced liver injury (DILI) leading to jaundice carries a ≥ 10% fatality risk (coined as Hy’s law by others), evaluation of Drug-Induced Serious Hepatotoxicity (eDISH) continues to play a central role in the assessment of a study drug’s liability for acute hepatocellular DILI. The eDISH identifies drugs in clinical trials with DILI fatality (death or transplant) risk that may be unacceptable in a post-market setting. As a two-dimensional graph that plots peak total bilirubin (TB) versus peak serum aminotransferase levels for each patient during study drug or comparator treatment, eDISH identifies potential cases of acute, modest, and serious hepatocellular DILI for in-depth analysis of liver tests (LT) and clinical course so that the likelihood of causal association with the study drug can be determined. Unfortunately, the generalizable utility of this tool only pertains to trials enrolling patients with normal or near normal (NNN) baseline (BL) serum LTs. The eDISH does not necessarily apply to trials of patients with abnormal baseline (ABN-BL) LTs that often coincide with underlying liver disorders. Because drug development programs being reviewed by the FDA increasingly target liver disorders, we are often challenged to evaluate DILI risk in trials of patients with ABN-BL LTs. Also, the high background prevalence of metabolic dysfunction associated steatotic liver disease (MASLD) means patients with LTs above NNN may need to be enrolled in trials treating non-liver disorders to reflect the target population. Such study populations create challenges for industry and regulators because eDISH may not reliably categorize or identify potential cases of DILI for further analysis, as it so efficiently does in NNN-BL trials. We describe the main functionalities of eDISH in NNN-BL trials to understand what should be emulated by new tools or eDISH modifications. We then discuss non-eDISH–based plots that may be useful in ABN-BL trials.

Amirzadegan, Jasmine↗
DOE OSTI2025

Techno-economic analysis and life cycle analysis of renewable natural gas production from brewery wastewater via ex-situ methanation processes

As sustainability becomes increasingly critical, the brewing industry encounters challenges in managing high-organic-content wastewater, a promising renewable energy source. This study evaluates the economic feasibility and environmental impacts of converting brewery wastewater into renewable natural gas (RNG) through anaerobic digestion and biogas upgrading, with an emphasis on different hydrogen sources for biomethanation. Four scenarios were analyzed: Scenario 1 uses purchased hydrogen, while Scenarios 2–4 use renewable hydrogen from microbial electrolysis cells and water electrolyzers. Results show that capital investments for processing 139 MT/h of wastewater, yielding 208 m 3 /h of RNG, range from 10.6 M to 31.9M USD, with estimated minimum selling prices of RNG between 2.25 and 4.37 USD/m 3 . Life cycle greenhouse gas (GHG) emissions span from -21 to 32g CO 2 -equivalent per MJ of RNG. Further, this study presents key economic and environmental metrics for RNG production from brewery wastewater, offering insights to enhance sustainability in brewery wastewater management.

03 NATURAL GAS↗
DOE OSTI2022

Thermodynamic modeling of adsorption at the liquid-solid interface

Adsorptive separation techniques are significantly energy efficient in comparison to conventional thermal separation techniques such as distillation. Despite extensive research and development activities undertaken for mixed-gas adsorption, the use of adsorption techniques for the separation of multicomponent liquid mixtures is still limited. A major barrier is the lack of accurate adsorption thermodynamic models, which form the scientific foundation of process simulation of such systems, making the translation to industrial scale challenging. In this work, we have rigorously computed the surface excess of adsorption for six binary liquid mixtures on silica gel at 303 K using the frameworks of the generalized Langmuir isotherm (gL) and the adsorbed solution theory (AST). The six binary liquid mixtures were formed by the pair-wise combinations of four components: benzene, 1,2-dichloroethane, cyclohexane, and n-heptane. We have based our calculations by considering simultaneous equilibria of three phases: saturated vapor phase, bulk liquid phase, and adsorbed phase. Further, the composition of the corresponding saturated vapor phase was estimated by the Nonrandom Two-Liquid activity coefficient model and experimental vapor-liquid equilibria data. The activity coefficients of the adsorbed phase, the central issue of multicomponent adsorption thermodynamics, were calculated using the adsorption Nonrandom Two-Liquid activity coefficient model. Devoid of simplifying assumptions, gL and AST provide rigorous thermodynamic frameworks for adsorption equilibria of multicomponent liquid mixtures.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

On component isolation of conceptual advanced reactors

Implementation of component isolation in nuclear industry is challenging due to gaps in research and the lack of specific guidelines. In this study, parameters affecting component-level isolation of advanced reactor vessels are identified based on a representative numerical model with explicit consideration of nonlinear soil-structure interaction (SSI). The objective of this study is to evaluate the effectiveness of, and to identify potential limitations of using conventional friction pendulum and lead-rubber bearings to seismically isolate vessels. It is found that slender vessels or components are particularly vulnerable to rotational accelerations at the isolation interface, which are caused by rotation of the sub-structure and by excitation of higher modes in the horizontal direction of the seismically isolated system. Component isolation is found to be more effective for relatively stiffer vessels and at sites with stiff soil properties. Considering that conventional isolators are deficient in resisting axial tension, it is observed that the optimum location for supporting a component to achieve seismic isolation, is at a cross-sectional plane passing through the center of mass of the vessel. These findings are corroborated by numerous simulations of the response of seismically isolated reactor vessels at different nuclear sites subject to a variety of ground motions.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2026

Opportunities and challenges for the expansion of LFP battery supply chains

Global markets for energy storage are growing rapidly, with some applications transitioning from traditional LiNi x Mn y Co 1−x−y O 2 (NMC) toward LiFePO 4 (LFP) due to cost, safety, and performance advantages. Battery growth has seeded interest in critical material supplies such as high-purity lithium precursors. In contrast, challenges in securing high-purity iron and phosphorus, historically not considered critical materials, are often overlooked. Precursors must remain inexpensive to maintain LFP's current cost advantage, which leverages the low-cost (∼$\$100$ per t) FeSO 4 byproduct from titanium dioxide manufacturing and will not be available as LFP manufacturing expands. As an alternative, iron is mined primarily for steel manufacturing, for which the existing supply chain and beneficiation process is optimized. LFP batteries require small iron volumes compared to steel (0.11%), but profit margins associated with existing low-cost iron ores and high costs (∼$27 000 per t) associated with low volume high-purity iron oxides may limit interest in manufacturing small volumes of high-purity, specialized iron battery precursors. The complementary LFP precursor, phosphoric acid (H 3 PO 4 ), is primarily utilized in fertilizers. Of the current phosphate ore demand for fertilizers, 4–22.8% would be required to meet projected 2045 LFP H 3 PO 4 demand, suggesting significant supply chain planning is needed to achieve projected demand. If only higher-grade material is considered, demand jumps to 15–77% of current world production. While lithium precursor purity requirements have been evaluated (Li 2 CO 3 is commonly defined as ≥99.5%), “battery grade” iron and phosphorus precursors remain poorly defined, with no internationally accessible and widely adopted standard, further challenging expanding industry by creating manufacturing uncertainty and increasing potential costs.

25 ENERGY STORAGE↗
DOE OSTI2024

Acceleration mechanisms of energetic ion debris in laser-driven tin plasma EUV sources

Laser-driven tin plasmas are driving new-generation nanolithography as sources of extreme ultraviolet (EUV) radiation centered at 13.5 nm. A major challenge facing industrial EUV source development is predicting energetic ion debris produced during the plasma expansion that may damage the sensitive EUV channeling multilayer optics. Gaining a detailed understanding of the plasma dynamics and ion acceleration mechanisms in these sources could provide critical insights for designing debris mitigation strategies in future high-power EUV sources. Here, we develop a fully kinetic model of tin-EUV sources using one-dimensional particle-in-cell simulations to study ion debris acceleration, which will be valuable for cross-validation of radiation-hydrodynamic simulations. An inverse-bremsstrahlung heating operator is used to model the interaction of a tin target with an Nd:YAG laser, and thermal conduction is included through a Monte Carlo Coulomb collision operator. While the large-scale evolution is in reasonable agreement with analogous hydrodynamic simulations, the significant timescale for collisional equilibration between electrons and ions allows for the development of prominent two-temperature features. A collimated flow of energetic ions is produced with a spectrum that is significantly enhanced at high energies compared to fluid simulations. The dominant acceleration mechanism is found to be a large-scale electric field supported mainly by the electron pressure gradient, which is enhanced in the kinetic simulations due to the increased electron temperature. We discuss the implications of these results for future modeling of tin-EUV sources and the development of debris mitigation schemes.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Numerical simulation of frost formation and heat transfer on fin-and-tube heat exchangers in turbulent cross-flow

Frost formation in fin-and-tube heat exchangers in turbulent cross-flow presents significant challenges in industrial refrigeration applications, affecting heat transfer efficiency and operational reliability. The purpose of this work is to investigate frost deposition and growth on a staggered bank of a fin-and-tube freezer coil under turbulent forced convection conditions. The focus here is on investigating conditions that closely replicate real-world scenarios in large walk-in industrial freezers. Using a direct numerical simulation approach, we examine the flow dynamics and thermal behaviour in the presence of frost, considering turbulent regimes characterized by a Reynolds number in the range 1050 ≤ R e D , avg ≤ 4800 , with the characteristic length being the outer diameter of the tube and the velocity being the bulk fluid velocity between the plates (fins). Computational fluid dynamics simulations are employed to resolve the interactions between turbulent airflow and the frost layer. Our approach incorporates a modified immersed boundary method and a slow-time acceleration technique to address the complex dynamic interface between the continuously evolving frost layer and the flowing air stream. Our findings indicate that frost forms more on the sides of the finned surfaces (plates) and less on the tubes themselves. This article is part of the theme issue ‘Heat and mass transfer in frost and ice’.

Science & Technology - Other Topics↗
DOE OSTI2025

Diffusion power spectra as a window into dynamic materials architecture

Chemical recycling of commodity and specialty polymers presents a multifaceted challenge for industrial societies. On one hand, macromolecular architectures must be engineered to yield durable products that, on the other hand, rapidly deconstruct to recyclable monomers under pre-determined conditions. Polymer deconstruction is a chemical process that requires deep understanding of molecular reactivity in heterogeneous media, where porous material architectures evolve in both space and time. To build this understanding, we develop herein experimental and analytical methods describing sets of diffusive eigenmodes that exist within time-varying, non-Euclidean boundary conditions, a situation commonly encountered in the reactive deconstruction of polymers where chain fragments splay, alter their local dynamics, and evolve in their confinement of reacting media. Diffusion power spectra, discerned experimentally by NMR, yield polymer and solvent frequency-domain velocity autocorrelation functions that are analyzed in the context of physical models for chemical reactions parameterized with fractal mathematics. The results connect local motion in polymers to chemical reactivity during acidolysis of circular elastomers.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Application of Ionic Liquids for the Recycling and Recovery of Technologically Critical and Valuable Metals

Population growth has led to an increased demand for raw minerals and energy resources; however, their supply cannot easily be provided in the same proportions. Modern technologies contain materials that are becoming more finely intermixed because of the broadening palette of elements used, and this outcome creates certain limitations for recycling. The recovery and separation of individual elements, critical materials and valuable metals from complex systems requires complex energy-consuming solutions with many hazardous chemicals used. Significant pressure is brought to bear on the improvement of separation and recycling approaches by the need to balance sustainability, efficiency, and environmental impacts. Due to the increase in environmental consciousness in chemical research and industry, the challenge for a sustainable environment calls for clean procedures that avoid the use of harmful organic solvents. Ionic liquids, also known as molten salts and future solvents, are endowed with unique features that have already had a promising impact on cutting-edge science and technologies. This review aims to address the current challenges associated with the energy-efficient design, recovery, recycling, and separation of valuable metals employing ionic liquids.

36 MATERIALS SCIENCE↗
NASA NTRS2001

Gas-Phase Combustion Synthesis of Nonoxide Nanoparticles in Microgravity

Gas-phase combustion synthesis is a promising process for creating nanoparticles for the growing nanostructure materials industry. The challenges that must be addressed are controlling particle size, preventing hard agglomerates, maintaining purity, and, if nonoxides are synthesized, protecting the particles from oxidation and/or hydrolysis during post-processing. Sodium-halide Flame Encapsulation (SFE) is a unique methodology for producing nonoxide nanoparticles that addresses these challenges. This flame synthesis process incorporates sodium and metal-halide chemistry, resulting in nanoparticles that are encapsulated in salt during the early stages of their growth in the flame. Salt encapsulation has been shown to allow control of particle size and morphology, while serving as an effective protective coating for preserving the purity of the core particles. Metals and compounds that have been produced using this technology include Al, W, Ti, TiB2, AlN, and composites of W-Ti and Al-AlN. Oxygen content in SFE synthesized nano- AlN has been measured by neutron activation analysis to be as low as 0.54wt.%, as compared to over 5wt.% for unprotected AlN of comparable size. The overall objective of this work is to study the SFE process and nano-encapsulation so that they can be used to produce novel and superior materials. SFE experiments in microgravity allow the study of flame and particle dynamics without the influence of buoyancy forces. Spherical sodium-halide flames are produced in microgravity by ejecting the halide from a spherical porous burner into a quiescent atmosphere of sodium vapor and argon. Experiments are performed in the 2.2 sec Drop Tower at the NASA-Glenn Research Center. Numerical models of the flame and particle dynamics were developed and are compared with the experimental results.

Axelbaum, R. L.↗
NASA NTRS1995

Application of NASA's Advanced Life Support Technologies for Waste Treatment, Water Purification and Recycle, and Food Production in Polar Regions

NASA's advanced life support technologies are being combined with Arctic science and engineering knowledge to address the unique needs of the remote communities of Alaska through the Advanced Life Systems for Extreme Environments (ALSEE) project. ALSEE is a collaborative effort involving NASA, the State of Alaska, the University of Alaska, the North Slope Borough of Alaska, and the National Science Foundation (NSF). The focus is a major issue in the state of Alaska and other areas of the Circumpolar North, the health and welfare of its people, their lives and the subsistence lifestyle in remote communities, economic opportunity, and care for the environment. The project primarily provides treatment and reduction of waste, purification and recycling of water. and production of food. A testbed is being established to demonstrate the technologies which will enable safe, healthy, and autonomous function of remote communities and to establish the base for commercial development of the resulting technology into new industries. The challenge is to implement the technological capabilities in a manner compatible with the social and economic structures of the native communities, the state, and the commercial sector. Additional information is contained in the original extended abstract.

Bubenheim, David L.↗
NASA NTRS2003

Aerodynamics for Revolutionary Air Vehicles

Aeronautics research has seriously declined partly because of the perception that it is a mature science and only incremental improvements are possible. Recent aeronautics roadmapping activities at NASA Langley paint a different picture of the future. Breakthroughs are still felt to be possible if we expand the current design space of today's vehicles and optimize the airspace and vehicles as a system. The paper describes some of the challenges that the aircraft and airline industry face. These challenges include political, technical and environmental issues. Examples of the opportunities and technologies that could provide a different vision for the future are discussed.

Sellers, William L., III↗
NASA NTRS2005

NASA's Radio Frequency Bolt Monitor: A Lifetime of Spinoffs

This story begins in the 1970s, when Dr. Joseph Heyman, a young scientist at NASA s Langley Research Center, was asked to support the investigation of a wind tunnel accident at a sister center. Although the work was outside of his physics background, it sparked a research focus that guided his lengthy NASA career and would earn him a slew of accolades, including NASA s highest award medals for Exceptional Leadership, Exceptional Achievement, and Exceptional Service; the coveted Silver Snoopy Astronaut Award for Space Shuttle Return to Flight; and the Arthur Fleming Award for being one of the Top Ten Federal Scientists in Government Service. He won 30 additional NASA awards, including the Agency s Invention of the Year and the Agency s highest award for technology transfer, and was the only person to ever win 4 R&D 100 Awards. Back in 1973, though, Heyman was a young civil servant with a background in physics who was asked to sit on an accident review panel. The panel met at Ames Research Center, in Moffet Field, California, and after considerable investigation, concluded that a high-pressure pebble heater used for heating gas had failed, due to improperly tightened bolts in a 1,000-pound gate valve control section. The accident showered the facility with incendiary ceramic spheres and nearly a ton of metal, but, luckily, caused no injuries. Heyman returned to Langley and began work on a solution. He developed an ultrasonic device that would measure bolt elongation, as opposed to torque, the factor typically measured in testing bolt preload or tension. Torque measurement can lead to load errors, with miscalculations as high as 80 percent that can be passed over during installation. Bolt stretch, however, is nearly always accurate to 1 percent or better. Within 1 month, he had an acoustic resonance solution that accurately determined bolt elongation. He assumed his work on this project had ended, but it was actually the start of nearly 15 years of work perfecting, improving, inventing, and modifying the "bolt monitor", all the while, filing numerous patents, presenting papers, and holding demonstrations as the technology matured. Industry engineers challenged Heyman s inventiveness, and reminded the physicist that most bolts are not perfect resonators, and that early devices required that the bolt have reasonably flat and parallel faces. The U.S. Geological Survey asked NASA for help in determining the load in mine roof bolts, which are 8- to 10-feet-long and rough cut. To solve that problem, Heyman modified the original device to operate at a lower frequency and to generate propagation modes that could be used to "lock" the instrument on a particular mode. Further work in this vein led to the development of the Pulsed Phase Locked Loop (P2L2) that worked on the mine bolts. The next set of problems involved high-strength bolts with head markings. For this solution, Heyman invented a modified P2L2 that tracked a specific phase point in the measurement wave. This class of instrumentation, well suited to measuring small changes in acoustic velocity, won the NASA "Invention of the Year" award in 1982. Other scientists and engineers have continued the evolution of this technology both inside NASA and outside of the Agency. Within NASA, the technology has been improved for medical applications, with a particular focus on intercranial pressure (ICP) monitoring.

Source record↗
NASA NTRS2011

Summary Report for National Aeronautics Space Administration (NASA) and Centro Para Prevencao da Poluicao (C3P) 2011 International Workshop on Environment and Alternative Energy

The C3P &. NASA International Workshop on Environment and Alternative Energy was held on November 15-18, 2011 at the European Space Agency (ESA)'s Research and Technology Centre (ESTEC) in Noordwijk, The Netherlands. The theme of the workshop was "Global Collaboration in Environmental and Alternative Energy Strategies". The workshop was held at ESTEC's conference center. More than 110 individuals from eleven countries attended the workshop. For the first time since the inception of NASA-C3P workshops, a full day was dedicated to a student session. Fifteen students from around the globe gave oral presentations along with poster displays relating to the latest technologies in environmental and alternative energy strategies. Judges from NASA, C3P and ESA awarded plaques to the top three students. In addition to the students, thirty eight U.S. and international subject matter experts presented on the following general environmental-related topics: (1) Hazardous materials management and substitution in support of space operations (2) Emerging renewable and alternative energy technologies (3) Sustainable development and redevelopment (4) Remediation technologies and strategies The workshop also included a panel discussion on the topic of the challenges of operating installations across borders. Throughout the workshop, attendees heard about the scope of environmental and energy challenges that industry and governments face. They heard about technologies for increasing energy efficiency and increasing use of renewable energy. They learned about ways companies and government agencies are using materials, processes, goods and services in a manner more respectful with the environment and in compliance with health and safety rules. The concept of partnerships and their inherent benefits was evidenced throughout the workshop. Partnering is a key aspect of sustainability because sustainable development is complicated. Through formal presentations and side discussions, attendees commented on the need for continued exploration of joint projects of mutual interest.

Greene, Brian↗
NASA NTRS2020

Urban Air Mobility (UAM) Working Groups

The NASA Aeronautics Research Mission Directorate (ARMD) is bringing together public, private, and academic organizations to collaborate with NASA in Urban Air Mobility (UAM) working groups. The primary purpose of the working groups is to accelerate the development of safe, high-volume UAM flight operations in the existing and anticipated future national airspace system. In coordination with the Grand Challenge series, industry developments and other ARMD efforts, these working groups will contribute to the enablement of UAM markets. Working group activities will seek to align the community on concepts to enable UAM, including communicating industry demonstrations and R&D priorities. The collaborative efforts will facilitate the identification of critical parameters and standards necessary to develop the framework and approach for safety, certification, airspace, aircraft concepts, technologies, and architectures. The realization of the UAM vision will be possible only though the efforts and contributions of multiple stakeholders, each possessing the necessary authority, expertise, and/or resources to fulfill a critical role in UAM's development, approval, and implementation. The applicable participants will become integral to the UAM working groups and will provide a platform for those stakeholders to collaborate and impact the overall ecosystem.

Kopardekar, Parimal H.↗
DOE OSTI2022

Findings on Subtask 3.1 - Bakken Rich Gas Enhanced Oil Recovery Project

Total in-place oil for the Bakken petroleum system (BPS) (which includes the Bakken and Three Forks Formations) has been estimated to be 600 billion barrels (bbl). However, BPS wells have decline rates as high as 85% over the first 3 years of their lives, and primary recovery factors typically range from 3% to 10% of original oil in place. Given the low initial recovery rates, even small incremental productivity improvements could dramatically increase technically recoverable oil in the BPS. One potential solution is enhanced oil recovery (EOR) using gas injection, such as carbon dioxide (CO2) or hydrocarbon (HC) gases. While commonly used in conventional reservoirs, CO2 EOR in unconventional tight oil reservoirs has been limited to pilot tests. EOR using rich gas (mixture of methane, ethane, and propane) has also been employed in numerous pilots in several unconventional plays and has recently been successfully applied in the Eagle Ford play. If successful, large-scale gas-based EOR in the BPS could dramatically increase oil productivity and recovery factors and extend the life of the play for decades. While CO2 may be a technically suitable working fluid for EOR in the BPS, supplies are limited and costs for using CO2 in EOR pilots are prohibitively high. Meanwhile, produced gas flaring has presented challenges for BPS operators in North Dakota. Analysis conducted by the North Dakota Pipeline Authority indicates that the current gas-gathering infrastructure in North Dakota is insufficient to accommodate all of the associated gas that is produced from the BPS. The geographically isolated location of North Dakota relative to large natural gas markets, combined with suppressed natural gas prices, has made it economically challenging for industry to invest capital in expanding gas-gathering infrastructure in the state. These circumstances led to a research program conducted by the Energy & Environmental Research Center (EERC) in partnership with Liberty Resources Management Company LLC (LR) to examine the potential to use rich gas injection for EOR and mitigate flaring. A rich gas EOR pilot test was designed and executed by LR at its Stomping Horse development area in Williams County, North Dakota. From July 2018 through May 2019, a total of 160 million standard cubic feet (MMscf) of rich produced gas was injected into the BPS using five different wells in a sequential injection strategy. LR’s Leon–Gohrick drill spacing unit (DSU) was used as the test site. Regulatory oversight was provided by the North Dakota Industrial Commission (NDIC). Technical support was provided by the EERC through a series of laboratory, modeling, and field-based activities, and additional post-pilot research activities incorporated learnings from the test, developed new laboratory data, improved fracture modeling methods, and developed machine learning and big data analytics. The results from the Stomping Horse rich gas EOR pilot activities indicate that developing an effective, economical EOR approach for the BPS will require more field tests. Another key lesson learned from the Stomping Horse tests is that detailed pre- and posttest data on reservoir conditions and fluids production are essential. Robust reservoir characterization provides information that is crucial to creating realistic geomodels and conducting valid dynamic simulations of potential EOR scenarios. A detailed understanding of the completions and production history of offset wells is also necessary for valid test result interpretations. This knowledge is essential to designing the operational parameters of injectivity tests and interpreting the results. A conformance control strategy is also essential to success. Laboratory-based examinations of rich gas interactions with reservoir fluids and rocks were conducted, with an emphasis on determining the ability to mobilize oil in the tight reservoir rocks and shales of the BPS. Injection fluid composition was shown to have a positive impact on reducing reservoir oil minimum miscibility pressure (MMP), reducing interfacial tension (IFT), and altering wettability. IFT and contact angle measurements demonstrated that wettability can be altered in the presence of rich gas, suggesting the potential to improve oil recovery. Iterative modeling of surface infrastructure and reservoir performance using data generated by the various project activities was conducted. A geologic model of the Stomping Horse area was built; history-matched oil, gas, and water production was used in simulations of various EOR scenarios. Early programmatic modeling results were used to support LR’s design and operation of the EOR pilot and to provide insight regarding optimization of future commercial-scale BPS EOR design and operations. Post-pilot modeling focused on alternative methods of understanding complex fracture networks and accelerating simulation time. These led to improved simulation run times and provide excellent history-matching results. Several of these iterative models were used as the bases for developing algorithms into machine learning and big data analytics. History matching in reservoir simulation is time-consuming and computer processing-intensive. Machine learning algorithms were created, and an automated history-matching tool was developed. A large set of synthetic reservoir simulations were created to generate well responses (oil, gas, and water production, well bottomhole pressure [BHP], and tracer or propane breakthrough) for a set of EOR operating parameters that included offset well status (open or closed), injectate (rich gas or propane), injection rate, and injection well BHP. A user interface was developed to provide real-time visualization. Machine learning-based models were developed to provide rapid forecasting of well performance given a set of user-defined EOR operating parameters. These predictive models allow the user to modify the offset well status, injection rate, and injection well BHP and rapidly forecast future production performance. The combination of real-time visualization tools with real-time forecasting tools provides a framework for real-time control—operational changes that the EOR site operator can enact (e.g., changing gas injection rates) to affect the observed performance and potentially improve the EOR outcome. There is great reason to be optimistic about the future of EOR in the Bakken. The results of the laboratory studies suggest significant potential for high rates of oil mobilization using produced field gas injection under the right conditions. The results of the lab studies, combined with rigorous statistical analysis of well production data and associated modeling efforts, confirm the notion that fluid mobility within the reservoir is controlled by fractures. As more knowledge is gained about the nature and distribution of fracture networks in the Bakken, the industry will be in a better position to predict and, ultimately, influence fluid mobility. New field tests are necessary to develop a more complete understanding of those conditions. Thoughtful and creatively engineered field tests within a well-characterized geologic setting will yield the fundamental knowledge needed to take Bakken oil production to the next level. This subtask was cofunded through the EERC–U.S. Department of Energy Joint Program on Research and Development for Fossil Energy-Related Resources Cooperative Agreement No. DE-FE0024233. Nonfederal funding was provided by the North Dakota Industrial Commission’s Oil and Gas Research Program and Computer Modelling Group.

04 OIL SHALES AND TAR SANDS↗
DOE OSTI2022

Multi-Kernel Adaptive Support Vector Machine for Scalable Predictive Maintenance

Application of data-driven solutions across an industry is challenging, since the data are often stored locally, and increasing privacy and security concerns restrict access to the data. In addition, it is highly unlikely that all potential data patterns are captured in a single data source. Because it is highly unlikely that all potential data patterns are captured in a single data source, machine learning (ML) models developed from a single source cannot be robust enough. An alternative is to train the ML model at each source and develop a distributed knowledge discovery and aggregation approach to build global knowledge. In this paper, we develop and demonstrate a distributed ML model, federated transfer learning (FTL), using a multi-kernel-based adaptive support vector machine (MK-A-SVM). For federated learning (FL), the multi-kernel (MK) approach enables feature-specific model aggregation under data heterogeneity; whereas for transfer learning (TL) the adaptive model enables utilization of an aggregated model from a different task. The proposed approach is validated using nuclear power plant (NPP) vertical motor-driven pump data to predict the health condition of vertical motor-driven pumps as an anomaly detection. The efficiency of the proposed approach is also quantified and compared with neural network.

42 ENGINEERING↗