Search NASA⌕ Search

SEARCH · Search NASA

Results for “scalable production”

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

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

At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Simple and Scalable Process for Nanocellulose Production from Residues and Waste (CRADA Final Report)

This project successfully developed an innovative, cost-effective, and scalable method for converting low-cost agricultural waste feedstocks into nanocellulose—a sustainable material with wide-ranging industrial applications. It addressed the critical challenges of high production costs and limited global supply, which have hindered the widespread adoption of nanocellulose in industry. Through this work, significant advancements were made in optimizing resource use, improving process efficiency, and reducing costs. Notable achievements included a 50% reduction in water usage, 30% lower chemical consumption, and 20% energy savings, all while maintaining high-quality product standards. The technical feasibility of the process was further validated at a 10L scale in collaboration with the Advanced Biofuels and Bioproducts Development Unit (ABPDU), demonstrating scalability and replicability. Key challenges in reducing nanocellulose production costs were addressed by utilizing low-cost biomass feedstocks and implementing low-temperature conversion reactions, leading to lower capital and operating expenses. The project also mitigated financial risk by generating critical data on the feasibility, adaptability, and scalability of the conversion technology, paving the way for its commercial implementation. Public benefits include advancing the circular bioeconomy, reducing environmental impact, fostering job creation, and enabling a shift toward biobased materials as sustainable alternatives to fossil-based products. These outcomes align closely with national goals to reduce greenhouse gas emissions and promote sustainable technological innovation.

09 BIOMASS FUELS↗
DOE OSTI2024

Scalable electrified cementitious materials production and recycling

The production of Portland cement, the industry-standard cement, contributes ~8% of global CO 2 emissions through fossil-fuel heating and decomposition of limestone (the primary cement raw material). Decarbonization, e.g., via direct electrification, of this 200-year-old liming routine is extremely challenging at the industry scale. We propose a scalable electrochemical decarbonization approach to circumvent the limestone use by switching to carbon-free calcium silicates from abundant minerals and recycled concrete. Water electrolysis produces protons and hydroxides to drive a pH gradient that accelerates Ca 2+ ion leaching from calcium silicates and captures atmospheric CO 2 to form carbon-negative CaCO 3 , which serves as the feedstock for cement manufacturing or as the carbon-mineralized product for cement substitution with permanent carbon storage. Value-added co-products amorphous silica and green H 2 further enhance cement performance and supplant fossil fuels for net-zero transition, respectively. The products readily meet present-day regulatory standards and demands, and the approach readily synergizes with business-as-usual cement manufacturing and concrete construction, which are important for upscaling and structural safety, promising ready reception by the public and industries. Blended Portland cement produced through our approach with carbon-negative CaCO 3 and silica demonstrates enhanced resilience and achieves carbon neutrality or negativity when incorporating storage or circulation of CO 2 from cement plant flue gas, respectively. This low-cost, electrochemical cement production approach using abundant ubiquitous raw materials enables electrification, transition to clean fuel, and decarbonization at a gigaton scale.

36 MATERIALS SCIENCE↗
DOE OSTI2024

General synthesis of high-entropy single-atom nanocages for electrosynthesis of ammonia from nitrate

Given the growing emphasis on energy efficiency, environmental sustainability, and agricultural demand, there’s a pressing need for decentralized and scalable ammonia production. Converting nitrate ions electrochemically, which are commonly found in industrial wastewater and polluted groundwater, into ammonia offers a viable approach for both wastewater treatment and ammonia production yet limited by low producibility and scalability. Here we report a versatile and scalable solution-phase synthesis of high-entropy single-atom nanocages (HESA NCs) in which Fe and other five metals-Co, Cu, Zn, Cd, and In-are isolated via cyano-bridges and coordinated with C and N, respectively. Incorporating and isolating the five metals into the matrix of Fe resulted in Fe-C5 active sites with a minimized symmetry of lattice as well as facilitated water dissociation and thus hydrogenation process. As a result, the Fe-HESA NCs exhibited a high selectivity toward NH3 from the electrocatalytic reduction of nitrate with a Faradaic efficiency of 93.4% while maintaining a high yield rate of 81.4 m h -1 mg -1 .

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

A Fine-grained Asynchronous Bulk Synchronous parallelism model for PGAS applications

The Partitioned Global Address Space (PGAS) model is well suited for executing irregular applications on cluster-based systems, due to its efficient support for short, one-sided messages. Separately, the actor model has been gaining popularity as a productive asynchronous message-passing approach for distributed objects in enterprise and cloud computing platforms, typically implemented in languages such as Erlang, Scala or Rust. To the best of our knowledge, there has been no past work on using the actor model to deliver both productivity and scalability to irregular PGAS applications with large number of small messages. In this paper, we introduce a new programming system for PGAS applications, in which point-to-point remote operations can be expressed as fine-grained asynchronous actor messages. In our approach, the programmer does not need to worry about programming complexities related to message aggregation and termination detection. Our approach can be viewed as extending the classical Bulk Synchronous Parallelism model with fine-grained asynchronous communications within a phase or superstep. Here, we believe that our approach offers a desirable point in the productivity-performance space for PGAS applications, with more scalable performance and higher productivity relative to past approaches. Specifically, for seven irregular mini-applications from the Bale Kernels and three graph kernels executed using 2048 cores in the NERSC Cori system, our approach shows geometric mean performance improvements of ≥ 20X relative to standard PGAS versions (UPC and OpenSHMEM) while maintaining comparable productivity to those versions.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Predicting Low Toxicity and Scalable Solvent Systems for High–Speed Roll–to–Roll Perovskite Manufacturing

Printed lead-based perovskite photovoltaics (PV) have gained interest due to their potential to be manufactured with scalable roll-to-roll techniques. In industrial scale-up, toxicity of inks can constrain roll-to-roll manufacturing due to the added cost of managing toxic effluents. Due to solvent toxicity, few perovskite solution chemistries in published works are scalable to gigawatt production capacity at low cost. Herein, it is shown that for scalable PV production, the use of aprotic polar solvents should be avoided due to their overall toxicity. Compliance with worldwide worker safety regulations for solvent exposure limits could require additional air handling requirements for some solvents, which in turn would affect cost-effectiveness. It is shown that costs associated with handling of hazardous substances can be significant and estimate an added cost of ¢3.7/W for dimethylformamide (DMF)-based inks. To solve this problem, a new perovskite ink solvent system is developed that is composed entirely of ether and alcohol, which has an effective exposure limit 14× higher than DMF, making it suitable for industrial coating processes. Here, it is shown that the new ink solvent system is capable of fabricating high-efficiency perovskite solar cells processed in 1 min on a standard roll-to-roll system.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Efficient Screening of Bi–Metallic Electrocatalysts for Glycerol Valorization

Glycerol is a byproduct of biodiesel production and, as such, it is of limited economic value. By means of electrooxidation, glycerol can be used as a feedstock for scalable hydrogen production, in addition to conversion to value-added products. The development of novel and efficient catalytic electrode materials for the anodic side of the reaction is a key towards a hydrogen-based energy economy. In the present study, a computational screening protocol combining DFT, scaling relations, and microkinetic modeling allows for a rational selection of novel catalysts that can deliver efficient glycerol electrooxidation, low cost of production, and environmental sustainability. Activity and chemical selectivity towards hydrogen production on pure metal catalysts is discussed in terms of volcano-shaped plots. We find that the selectivity in the glycerol oxidation reaction is influenced by a different energy landscape when in the presence of water and best classified by a comparison of O—H and C—H bond-breaking barriers. In addition, we screened 3570 bi-metallic catalysts in the AB (L1 0 ) and A 3 B (L1 2 ) ordered structures for activity, stability, price, and toxicity. By filtering based on the criteria for toxicity, resistance to oxidation, miscibility, and price, we have identified 5 L1 0 structured catalysts (AgPd, AuPd, PtSb, CuPt, and AgPt) and 20 L1 2 catalysts (Ga 3 Ta, In 3 Ta, Ir 3 W, Ir 3 Mo, Cu 3 Pt, Ir 3 Ta, Ir 3 Re, Pd 3 Bi, Pd 3 Cu, Pd 3 W, Pd 3 Co, Pd 3 Sn, Pd 3 Mo, Pd 3 Ag, Pd 3 Ga, Pd 3 Ta, Au 3 Ru, Pd 3 In, Au 3 Ir, and Pd 3 Au) that are all predicted to show high activity. We also identify an additional 37 L1 0 and 92 L1 2 structured electrocatalysts with an anticipated medium-high activity.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Net-Zero Ethylene: On the Sustainability, Economics, and Scalability of Synthetic and Fossil Production Pathways

The ethylene industry has contributed over 260 million tons of CO 2 annually, warranting a more sustainable approach. The conversion of CO 2 and H 2 O into ethylene is an appealing technology capable of decoupling chemical production from fossil fuels. However, the large energy demand from this process can potentially lead to adverse environmental impacts. Here, in this article, we critically analyze the economic viability, environmental impact, and scalability of the conversion of CO 2 to ethylene via electrochemical reduction (CO 2 R) and compare this with those of CO 2 -neutral fossil routes utilizing carbon capture and direct air capture. Ethylene derived from CO 2 may be economically competitive under optimistic conditions; however, its large energy requirements pose environmental and scalability challenges. Meeting forecast 2050 ethylene demand using CO 2 R would require half of all electricity produced globally today, and, if powered by solar PV, may have greater CO 2 emissions than current petrochemical ethylene production, negating the purpose of this technology. Using Carbon Capture and Storage and Direct Air Capture to decarbonize petrochemical pathways would require roughly an order of magnitude less energy but would have disproportionate health and climate impacts. Lastly, the analysis highlights the importance of low-carbon energy sources to ensure sustainable CO 2 R ethylene production.

CO2R↗
DOE OSTI2025

Atomic lift-off of epitaxial membranes for cooling-free infrared detection

Recent breakthroughs in ultrathin, single-crystalline, freestanding complex oxide systems have sparked industry interest in their potential for next-generation commercial devices. However, the mass production of these ultrathin complex oxide membranes has been hindered by the challenging requirement of inserting an artificial release layer between the epilayers and substrates. Here we introduce a technique that achieves atomic precision lift-off of ultrathin membranes without artificial release layers to facilitate the high-throughput production of scalable, ultrathin, freestanding perovskite systems. Leveraging both theoretical insights and empirical evidence, we have identified the pivotal role of lead in weakening the interface. This insight has led to the creation of a universal exfoliation strategy that enables the production of diverse ultrathin perovskite membranes less than 10 nm. Our pyroelectric membranes demonstrate a record-high pyroelectric coefficient of 1.76 × 10 −2 C m −2 K −1 , attributed to their exceptionally low thickness and freestanding nature. Moreover, this method offers an approach to manufacturing cooling-free detectors that can cover the full far-infrared spectrum, marking a notable advancement in detector technology.

nanoscale materials↗
DOE OSTI2020

All Electrospray Printing of Carbon–Based Cost–Effective Perovskite Solar Cells

With the power conversion efficiencies of PSCs exceeding 25%, the perovskite solar cells (PSCs) are closer to step into the initial industrialization. Prior to transferring from laboratory fabrication to industrial manufacturing, issues such as scalability, materials cost, and production line compatibility that significantly impact the manufacturing remain to be addressed. Here we report breakthroughs on all these fronts. Carbon-based PSCs with architecture FTO/electron transport layer/perovskite/carbon, that eliminate the need for the hole transport layer and noble metal electrode, provide ultra-low-cost configuration. This PSC architecture was manufactured using a scalable and industrially compatible electrospray (ES) technique, which enables continuous printing of all the cell layers. The ES deposited electron transport layer and perovskite layer exhibited properties comparable to that of the laboratory-scale spin coating method. The ES deposited carbon electrode layer exhibited superior conductivity and interfacial microstructure in comparison to films synthesized using the conventional doctor blading technique. As a result, the fully ES printed carbon-based PSCs showed a record 14.41% power conversion efficiency, rivaling the state-of-the-art hole transporter-free PSCs. Furthermore, these results will immediately have an impact on the scalable production of PSCs.

14 SOLAR ENERGY↗
DOE OSTI2026

Solventless, Ambient-Pressure Production of Bio-Based Lactones Over Earth-Abundant, Mixed Metal Oxide Catalysts for Circular Polyesters

Transitioning to a circular plastics economy will require use of renewable feedstocks, energy-efficient processes, and closed-loop recyclable polymers, such as polyesters. A key challenge lies in sustainably sourcing monomers used to make recyclable polyesters. This work presents a catalytic platform utilizing earth-abundant Cu(x)Ca(1-x)O mixed metal oxides for the oxidative dehydrocyclization of bio-based diols to lactones, which are advantaged for energy-efficient ring-opening polymerization. Operating below 200 degrees C, at ambient pressure, and without solvent, the process uses air as the sole oxidant, achieving high yields of lactones across a broad substrate scope of C4-8 diols in the liquid phase. The oxidative dehydrocyclization reaction is thermodynamically downhill due to water formation and energy-efficient compared to incumbent, non-redox pathways utilized in fossil carbon-based industrial processes for lactone production. Mechanistic studies reveal facile redox cycling of Cu2+-O(Ca2+)-Cu2+ interfacial sites unique to the developed catalyst. Techno-economic analysis and life cycle assessment estimate 40% lower energy demand and 15% lower GHG intensity per mass of butyrolactone produced compared to the fossil carbon-based route. Liquid-phase oxidative dehydrocyclization offers a promising approach for scalable lactone production from renewable, bio-based diols to enable circular polyesters.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Life-cycle environmental impacts of single-junction and tandem perovskite PVs: a critical review and future perspectives

For new technologies, such as perovskite solar cells (PSC), life cycle analysis (LCA) offers a fundamental framework for examining potential environmental, energy and health impacts and mitigation options before large-scale commercialization and for guiding improvements in development and production that further reduce their environmental footprint. However, credible LCA studies require actual process-based material, energy and emissions data, which may not exist before the technologies are commercially produced. Thus, the perovskite LCA literature is based on linear extrapolations of laboratory data. In this paper we critically reviewed the PSC LCA literature, explain the reasoning for a wide divergence of results, and determined which data apply to scalable industrial production, materials and processes. Our investigation probed into the formulation of each layer of a PSC device, and its potential for industrial scale fabrication. We found that electricity use is the main contributor to reported LCA results, explaining the large difference, ranging from 7.78 kWh to 1,460 kWh/m –2 , among various studies. Subsequently, we identified and discuss methodological errors in some of these estimates. In terms of life-cycle toxicity most of the reviewed LCA studies do not attribute any major overall toxicity impact to the presence of lead in the PSC devices. We also reviewed and critiqued studies describing “worst-case” scenarios of accidental release of lead into the environment, and, in spite of statements in those studies, we found them to be inconclusive. Lastly, we discussed end-of-life (EoL) management options for resource recovery and for minimizing environmental impacts.

14 SOLAR ENERGY↗
DOE OSTI2023

Signal Processing Based Method for Real-Time Anomaly Detection in High-Performance Computing

Performance anomalies can manifest as irregular execution times or abnormal execution events for many reasons, including network congestion and resource contention. Detecting such anomalies in real-time by analyzing the details of performance traces at scale is impractical due to the sheer volume of data High-Performance Computing (HPC) applications produce. In this paper, we propose formulating HPC performance anomaly detection as a signal-processing problem where anomalies can be treated as noise. We evaluate our proposed method in comparison with two other commonly used anomaly detection techniques of varying complexity based on their detection accuracy and scalability. Since real-time in-situ anomaly detection at a large scale requires lightweight methods that can handle a large volume of streaming data, we find that our proposed method provides the best trade-off. We then implement the proposed method in Chimbuko, the first online, distributed, and scalable workflow-level performance trace analysis framework. We compare our proposed signal-based anomaly detection algorithm with two other methods using a function of their accuracy, F1 score, and detection overhead. Our experiments demonstrate that our proposed approach achieves a 99% improvement for the benchmark datasets and a 93% improvement with Chimbuko traces.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2026

Machine-Learning-Driven Discovery of Water Splitting BaFe 2 O 4 and Human-in-the-Loop Improvement via Al-Substitution for Increased Thermal Stability

Thermochemical hydrogen (TCH) production offers a promising method for converting thermal energy into hydrogen fuel through heat-driven redox cycles of metal oxides. Here, in this work a defect graph neural network (dGNN) was used to predict oxygen vacancy formation energies ΔH V O combined with Materials Project predictions of oxygen chemical potential stability to screen candidate oxides via high-throughput database analysis. BaFe 2 O 4 was identified as a promising material for experimental validation based on its predicted ΔH V O , oxygen chemical potential stability range, and potential for tunable substitutions to improve thermal properties. Experimental validation using thermogravimetric analysis (TGA), stagnation flow reactor (SFR), X-ray diffraction (XRD), and electron microscopy confirmed positive water-splitting behavior but also revealed limitations in thermal stability under aggressive reduction conditions. To address this, a human-in-the-loop modification strategy was employed introducing Al substitution in BaFe 2–x Al x O 4 ; this modification improves thermal stability, alters the crystal structure and enhances overall performance. These results demonstrate a combined computational and experimental workflow in which machine learning accelerates identification of promising candidates, while targeted experimental design enables optimization of functional performance. This approach advances the development of robust, cost-effective TCH materials and highlights the importance of integrating data-driven discovery with human-guided materials design in paving the way for scalable hydrogen production technologies.

organic↗
DOE OSTI2026

From Pyrolysis Oil to Advanced Biographite Anode: Unravelling Biocoke Structural Evolution and Delayed Coking Effects

Catalytic graphitization of biomass-derived carbon offers a promising route to produce biographite as a sustainable alternative to petroleum-based synthetic graphite for lithium-ion battery (LIB) anodes. This study investigates the physicochemical properties of biocokes produced from pyrolysis oil at carbonization temperatures ranging from 150 degrees C to 500 degrees C. Using an iron (Fe) catalyst, graphitization was performed at 1500 degrees C, significantly lower than the ~3000 degrees C required for conventional synthetic graphite. The effects of introducing an intermediate-temperature hold (400 degrees C-600 degrees C) prior to graphitization were evaluated, simulating a "delayed coking" process to enable the coproduction of sustainable aviation fuels (SAFs). Chemical structure evolution during biocoke formation was analyzed, and proposed mechanisms are presented. Biographites produced via the delayed coking pathway exhibited high crystallinity and excellent electrochemical performance in both half-cell and full-cell LIB configurations. The full cells exhibited an initial discharge capacity close to the theoretical capacity of the NMC622 cathode (175 mAh/g at 4.2 V), and high capacity retention (~88%) after 150 cycles. Notably, the graphitic and electrochemical properties remained stable across the range of intermediate hold temperatures. These findings provide a foundation for optimizing temperature parameters in delayed coking systems to enable scalable, integrated production of biographite and SAFs from pyrolysis oil.

09 BIOMASS FUELS↗
DOE OSTI2025

Chemical Vapor Transformation of Lithium Metal: Mechanism and Enhanced Stability

Constructing a stable solid electrolyte interface (SEI) with high productivity and scalability is essential for the practical application of thin Li metal anodes. Here, in this work, we report a chemical vapor transformation (CVT) strategy in which Li metal is exposed to trimethylaluminum (TMA), inducing a rapid and spontaneous surface reaction that forms a robust, multilayered SEI. In situ quartz crystal microbalance (QCM) and quadrupole mass spectrometry (QMS), combined with ex situ X-ray photoelectron spectroscopy (XPS), UV Raman spectroscopy, and density functional theory (DFT) calculations, reveal that TMA removes the native passivation layer, reacts with Li metal, and drives a coupled bulk-surface transformation involving Li–Al interdiffusion. The resulting SEI exhibits a chemically graded structure consisting of an inner Li–Al alloy and an outer amorphous carbon layer formed via demethylation and ligand-exchange pathways. This modified surface exhibits significantly enhanced stability compared to that of bare Li in electrochemical cycling using liquid and solid-state electrolytes. This work unveils a unique surface-mediated bulk transformation mechanism for lithium metal and establishes CVT as a scalable and fundamentally distinct approach for the interfacial engineering of reactive metals.

Li metal↗