Results for “technology maturity” — Page 44

NASA NTRS2011

NASA Technology Demonstrations Missions Program Overview

The National Aeronautics and Space Administration (NASA) Fiscal Year 2010 (FY10) budget introduced a new strategic plan that placed renewed emphasis on advanced missions beyond Earth orbit. This supports NASA s 2011 strategic goal to create innovative new space technologies for our exploration, science, and economic future. As a result of this focus on undertaking many and more complex missions, NASA placed its attention on a greater investment in technology development, and this shift resulted in the establishment of the Technology Demonstrations Missions (TDM) Program. The TDM Program, within the newly formed NASA Office of the Chief Technologist, supports NASA s grand challenges by providing a steady cadence of advanced space technology demonstrations (Figure 1), allowing the infusion of flexible path capabilities for future exploration. The TDM Program's goal is to mature crosscutting capabilities to flight readiness in support of multiple future space missions, including flight test projects where demonstration is needed before the capability can transition to direct mission The TDM Program has several unique criteria that set it apart from other NASA program offices. For instance, the TDM Office matures a small number of technologies that are of benefit to multiple customers to flight technology readiness level (TRL) 6 through relevant environment testing on a 3-year development schedule. These technologies must be crosscutting, which is defined as technology with potential to benefit multiple mission directorates, other government agencies, or the aerospace industry, and they must capture significant public interest and awareness. These projects will rely heavily on industry partner collaboration, and funding is capped for all elements of the flight test demonstration including planning, hardware development, software development, launch costs, ground operations, and post-test assessments. In order to inspire collaboration across government and industry, more than 70% of the TDM funds will be competitively awarded as a result of yearly calls for proposed flight demonstrators and selected based on possible payoff to NASA, technology maturity, customer interest, cost, and technical risk reduction. This paper will give an overview of the TDM Program s mission and organization, as well as its current status in delivering advanced space technologies that will enable more flexible and robust future missions. It also will provide several examples of missions that fit within these parameters and expected outcomes.

Turner, Susan↗

DOE OSTI2021

The rise of electric vehicles—2020 status and future expectations

Electric vehicles (EVs) are experiencing a rise in popularity over the past few years as the technology has matured and costs have declined, and support for clean transportation has promoted awareness, increased charging opportunities, and facilitated EV adoption. Suitably, a vast body of literature has been produced exploring various facets of EVs and their role in transportation and energy systems. This paper provides a timely and comprehensive review of scientific studies looking at various aspects of EVs, including: (a) an overview of the status of the light-duty-EV market and current projections for future adoption; (b) insights on market opportunities beyond light-duty EVs; (c) a review of cost and performance evolution for batteries, power electronics, and electric machines that are key components of EV success; (d) charging-infrastructure status with a focus on modeling and studies that are used to project charging-infrastructure requirements and the economics of public charging; (e) an overview of the impact of EV charging on power systems at multiple scales, ranging from bulk power systems to distribution networks; (f) insights into life-cycle cost and emissions studies focusing on EVs; and (g) future expectations and synergies between EVs and other emerging trends and technologies. The goal of this paper is to provide readers with a snapshot of the current state of the art and help navigate this vast literature by comparing studies critically and comprehensively and synthesizing general insights. This detailed review paints a positive picture for the future of EVs for on-road transportation, and the authors remain hopeful that remaining technology, regulatory, societal, behavioral, and business-model barriers can be addressed over time to support a transition toward cleaner, more efficient, and affordable transportation solutions for all.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

NASA NTRS2017

Development and Test of Robotically Assisted Extravehicular Activity Gloves

Over the past two years, the High Performance EVA Glove (HPEG) project under NASA's Space Technology Mission Directorate (STMD) funded an effort to develop an electromechanically-assisted space suit glove. The project was a collaboration between the Johnson Space Center's Software, Robotics, and Simulation Division and the Crew and Thermal Systems division. The project sought to combine finger actuator technology developed for Robonaut 2 with the softgoods from the ILC Phase VI EVA glove. The Space Suit RoboGlove (SSRG) uses a system of three linear actuators to pull synthetic tendons attached to the glove's fingers to augment flexion of the user's fingers. To detect the user's inputs, the system utilizes a combination of string potentiometers along the back of the fingers and force sensitive resistors integrated into the fingertips of the glove cover layer. This paper discusses the development process from initial concepts through two major phases of prototypes, and the results of initial human testing. Initial work on the project focused on creating a functioning proof of concept, designing the softgoods integration, and demonstrating augmented grip strength with the actuators. The second year of the project focused on upgrading the actuators, sensors, and software with the overall goal of creating a system that moves with the user's fingers in order to reduce fatigue associated with the operation of a pressurized glove system. This paper also discusses considerations for a flight system based on this prototype development and address where further work is required to mature the technology.

Rogers, Jonathan M.↗

NASA NTRS2020

The Evolution of Lidar Networks: A US Perspective

Atmospheric aerosols and clouds play an important role in climate by directly scattering and absorbing sunlight. Aerosol-cloud interactions modify the particle properties causing indirect effects, alter aerosol deposition and rainfall, and contribute substantially to the uncertainties in predicting climate effects. Aerosols also affect air quality and both constituents modulate boundary layer dynamics to a certain extent, in turn impacting aerosol transport and aerosol-cloud interactions. The spatiotemporal distribution of aerosol and cloud layers is thus important, and lidar remains the primary instrument for determining the vertical distribution of aerosols and thin clouds. Lidar still provides important information for opaque cloud layers by determining base heights. Combined lidar and radar data provide a comprehensive coverage of aerosol and cloud vertical distributions, and thus locations where and when they interact. Lidar data provide a means of constraining column aerosol loading observations (e.g. AOD) to vertical extents. In addition, lidar has proven effective at determining a proxy for boundary layer height by examining aerosol gradients and/or cloud base heights in lidar profiles. Polarized lidars provide additional information on particle shape, allowing estimates of cloud phase and separation of dust or smoke from sulfate and sea salt aerosols. Given the importance of lidar observations and a critical maturation in technology and retrieval techniques, several organizations began to build operational lidar networks around 2000. The European Aerosol Research Lidar Network (EARLINET) was started as a research focused network of advanced lidars across Europe. The Asian Dust Lidar Network (ADNET) was also developed as a regional network providing lidar profiles of dust and pollution across Eastern Asia. In the US, the NASA Micro Pulse Lidar Network (MPLNET) was created to provide global lidar profiling at key sites in the NASA Aerosol Robotic Network (AERONET). The Network for the Detection of Atmospheric Composition Change (NDACC) pre-dates these networks and many sites have lidar, but it is not strictly a lidar network and at the time focused less on the lower troposphere. Finally, there were already existing ceilometer networks operated by various meteorological agencies, but in particular here in the US the profile data has not been available. The ceilometer networks were used to provide only clouds base heights and estimates of PBL height. Thus, the distinguishing feature between lidar and ceilometer networks was historically the ability to actually provide profile information (in addition to differences in wavelength, and advanced retrievals such as the raman technique). As time progressed, each lidar network matured and developed more operational capabilities and data sets, coupled with viable data centers providing DAAC services and access to near-real-time (NRT) data. In 2008 under WMO guidance, the Global Atmospheric Watch (GAW) Aerosol Lidar Observation Network (GALION) was formed as a global network made up of the existing lidar networks. The goal was to share information, best practices, and develop frameworks and techniques for quality data. GALION grew to include several other regional lidar networks and this has led to a vast increase in quality lidar sites worldwide.

Welton, Ellsworth J.↗

NASA NTRS2013

Hypersonic Inflatable Aerodynamic Decelerator (HIAD) Technology Development Overview

The successful flight of the Inflatable Reentry Vehicle Experiment (IRVE)-3 has further demonstrated the potential value of Hypersonic Inflatable Aerodynamic Decelerator (HIAD) technology. This technology development effort is funded by NASA's Space Technology Mission Directorate (STMD) Game Changing Development Program (GCDP). This paper provides an overview of a multi-year HIAD technology development effort, detailing the projects completed to date and the additional testing planned for the future. The effort was divided into three areas: Flexible Systems Development (FSD), Mission Advanced Entry Concepts (AEC), and Flight Validation. FSD consists of a Flexible Thermal Protection Systems (FTPS) element, which is investigating high temperature materials, coatings, and additives for use in the bladder, insulator, and heat shield layers; and an Inflatable Structures (IS) element which includes manufacture and testing (laboratory and wind tunnel) of inflatable structures and their associated structural elements. AEC consists of the Mission Applications element developing concepts (including payload interfaces) for missions at multiple destinations for the purpose of demonstrating the benefits and need for the HIAD technology as well as the Next Generation Subsystems element. Ground test development has been pursued in parallel with the Flight Validation IRVE-3 flight test. A larger scale (6m diameter) HIAD inflatable structure was constructed and aerodynamically tested in the National Full-scale Aerodynamics Complex (NFAC) 40ft by 80ft test section along with a duplicate of the IRVE-3 3m article. Both the 6m and 3m articles were tested with instrumented aerodynamic covers which incorporated an array of pressure taps to capture surface pressure distribution to validate Computational Fluid Dynamics (CFD) model predictions of surface pressure distribution. The 3m article also had a duplicate IRVE-3 Thermal Protection System (TPS) to test in addition to testing with the Aerocover configuration. Both the Aerocovers and the TPS were populated with high contrast targets so that photogrammetric solutions of the loaded surface could be created. These solutions both refined the aerodynamic shape for CFD modeling and provided a deformed shape to validate structural Finite Element Analysis (FEA) models. Extensive aerothermal testing has been performed on the TPS candidates. This testing has been conducted in several facilities across the country. The majority of the testing has been conducted in the Boeing Large Core Arc Tunnel (LCAT). HIAD is continuing to mature testing methodology in this facility and is developing new test sample fixtures and control methodologies to improve understanding and quality of the environments to which the samples are subjected. Additional testing has been and continues to be performed in the NASA LaRC 8ft High Temperature Tunnel, where samples up to 2ft by 2ft are being tested over representative underlying structures incorporating construction features such as sewn seams and through-thickness quilting. With the successful completion to the IRVE-3 flight demonstration, mission planning efforts are ramping up on the development of the HIAD Earth Atmospheric Reenty Test (HEART) which will demonstrate a relevant scale vehicle in relevant environments via a large-scale aeroshell (approximately 8.5m) entering at orbital velocity (approximately 7km/sec) with an entry mass on the order of 4MT. Also, the Build to Print (BTP) hardware built as a risk mitigation for the IRVE-3 project to have a "spare" ready to go in the event of a launch vehicle delivery failure is now available for an additional sub-orbital flight experiment. Mission planning is underway to define a mission that can utilize this existing hardware and help the HIAD project further mature this technology.

Hughes, Stephen J.↗

NASA NTRS2009

SMART Rotor Development and Wind-Tunnel Test

Boeing and a team from Air Force, NASA, Army, Massachusetts Institute of Technology, University of California at Los Angeles, and University of Maryland have successfully completed a wind-tunnel test of the smart material actuated rotor technology (SMART) rotor in the 40- by 80-foot wind-tunnel of the National Full-Scale Aerodynamic Complex at NASA Ames Research Center, figure 1. The SMART rotor is a full-scale, five-bladed bearingless MD 900 helicopter rotor modified with a piezoelectric-actuated trailing-edge flap on each blade. The development effort included design, fabrication, and component testing of the rotor blades, the trailing-edge flaps, the piezoelectric actuators, the switching power amplifiers, the actuator control system, and the data/power system. Development of the smart rotor culminated in a whirl-tower hover test which demonstrated the functionality, robustness, and required authority of the active flap system. The eleven-week wind tunnel test program evaluated the forward flight characteristics of the active-flap rotor, gathered data to validate state-of-the-art codes for rotor noise analysis, and quantified the effects of open- and closed-loop active-flap control on rotor loads, noise, and performance. The test demonstrated on-blade smart material control of flaps on a full-scale rotor for the first time in a wind tunnel. The effectiveness and the reliability of the flap actuation system were successfully demonstrated in more than 60 hours of wind-tunnel testing. The data acquired and lessons learned will be instrumental in maturing this technology and transitioning it into production. The development effort, test hardware, wind-tunnel test program, and test results will be presented in the full paper.

Lau, Benton H.↗

DOE OSTI2021

Technology Advancement and Insertion into Operating Nuclear Facilities

Key challenges in the NNSA modernization effort are centered around the selection of new processing / production technologies to deploy in existing, operating, and oftentimes, aging nuclear facilities. New uranium processing technologies may offer significant improvements in worker and environmental safety, material control and accountability, and production efficiencies, but adaptation of these technologies into existing facilities presents unique (and usually, difficult) engineering solutions for each new technology. This presentation discusses approaches utilized at Y-12 to mature and demonstrate new processing and production technologies for deployment into nuclear facilities. The technology advancement lifecycle (from concept to deployment) of uranium electrorefining technologies will be reviewed, as a prototypical example, to describe steps and approaches utilized at Y-12 (and NNSA Sites) to (i) mature technologies and manufacturing strategies, (ii) establish testbed capabilities for full-scale process demonstrations, and (iii) reduce risks associated with operational disruptions when commissioning new uranium processing technologies.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

Technology Advancement and Insertion into Operating Nuclear Facilities

Key challenges in the NNSA modernization effort are centered around the selection of new processing / production technologies to deploy in existing, operating, and oftentimes, aging nuclear facilities. New uranium processing technologies may offer significant improvements in worker and environmental safety, material control and accountability, and production efficiencies, but adaptation of these technologies into existing facilities presents unique (and usually, difficult) engineering solutions for each new technology. This presentation discusses approaches utilized at Y-12 to mature and demonstrate new processing and production technologies for deployment into aging nuclear facilities. The technology advancement lifecycle (from concept to deployment) of uranium electrorefining technologies will be reviewed, as a prototypical example, to describe steps and approaches utilized at Y-12 (and NNSA Sites) to (i) mature technologies and manufacturing strategies, (ii) establish testbed capabilities for full-scale process demonstrations, and (iii) reduce risks associated with operational disruptions when commissioning new uranium processing technologies.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

NASA NTRSDate not supplied

BioSentinel: Mission Summary and Lessons Learned From the First Deep Space Biology CubeSat Mission

Launched on Artemis-1, BioSentinel carries a biology experiment into deep space for the first time in 50 years. A 6U CubeSat form factor was utilized for the spacecraft which included technologies newly developed or adapted for operations beyond Earth orbit. The spacecraft carries onboard budding yeast, Saccharomyces cerevisiae, as an analog to human cells to test the biological response to deep space radiation. This was the maiden deep-space voyage for many of the subsystems, and the first time to evaluate their performance in flight operation. Flying a CubeSat beyond LEO comes with unique challenges with respect to trajectory uncertainty and mission operations planning. The nominal plan was a lunar fly-by, followed by an insertion into Heliocentric orbit. However, some possible scenarios included lunar eclipses that could have severely impacted the power budget during that phase of the mission, while others could have resulted in a “Retrograde” hyperbola at swing-by resulting in the spacecraft traveling inward toward Earth or even towards a collision with the lunar surface. The commissioning phase of the mission was successful and completed a week ahead of schedule. It did not come without its exciting moments and challenges. First contact with the spacecraft uncovered that the vehicle was unexpectedly tumbling after deployment, a situation that needed to be corrected urgently. The mission operations team executed a contingency plan to stabilize the spacecraft, with just moments to spare before the battery ran out of power. The BioSensor payload onboard the spacecraft is a complex instrument that includes microfluidics, fluid systems, sensor control electronics, as well at the living yeast cells. BioSentinel also included a TimePix radiation sensor implemented by JSC’s RadWorks group. Dose and Linear Energy Transfer (LET) data is compared directly to the rate of DSB-and repair events measured by the S. cerevisiae cells. BioSentinel mature nanosatellite technologies included: deep space communications and navigation, autonomous attitude control and momentum management, and micro-propulsion systems, to provide an adaptable nanosatellite platform for deep space uses. This paper discusses the performance of the BioSentinel spacecraft through the mission phase, and includes lessons learned from challenges and anomalies. BioSentinel had many successes and will be a pathfinder for future deep space CubeSats and biology missions.

BioSentinel↗

NASA NTRSDate not supplied

Biosentinel: Mission Summary and Lessons Learned From the First Deep Space Biology CubeSat Mission

Launched on Artemis-1, BioSentinel carries a biology experiment into deep space for the first time in 50 years. A 6U CubeSat form factor was utilized for the spacecraft which included technologies newly developed or adapted for operations beyond Earth orbit. The spacecraft carries onboard budding yeast, Saccharomyces cerevisiae, as an analog to human cells to test the biological response to deep space radiation. This was the maiden deep-space voyage for many of the subsystems, and the first time to evaluate their performance in flight operation. Flying a CubeSat beyond LEO comes with unique challenges with respect to trajectory uncertainty and mission operations planning. The nominal plan was a lunar fly-by, followed by an insertion into Heliocentric orbit. However, some possible scenarios included lunar eclipses that could have severely impacted the power budget during that phase of the mission, while others could have resulted in a “Retrograde” hyperbola at swing-by resulting in the spacecraft traveling inward toward Earth or even towards a collision with the lunar surface. The commissioning phase of the mission was successful and completed a week ahead of schedule. It did not come without its exciting moments and challenges. First contact with the spacecraft uncovered that the vehicle was unexpectedly tumbling after deployment, a situation that needed to be corrected urgently. The mission operations team executed a contingency plan to stabilize the spacecraft, with just moments to spare before the battery ran out of power. The BioSensor payload onboard the spacecraft is a complex instrument that includes microfluidics, fluid systems, sensor control electronics, as well at the living yeast cells. BioSentinel also included a TimePix radiation sensor implemented by JSC’s RadWorks group. Dose and Linear Energy Transfer (LET) data is compared directly to the rate of DSB-and repair events measured by the S. cerevisiae cells. BioSentinel mature nanosatellite technologies included: deep space communications and navigation, autonomous attitude control and momentum management, and micro-propulsion systems, to provide an adaptable nanosatellite platform for deep space uses. This paper discusses the performance of the BioSentinel spacecraft through the mission phase, and includes lessons learned from challenges and anomalies. BioSentinel had many successes and will be a pathfinder for future deep space CubeSats and biology missions.

BioSentinel↗

NASA NTRSDate not supplied

Biosentinel: The First Deep Space Biology CubeSat Mission- Mission Summary and Lessons Learned

Launched on Artemis-1, BioSentinel carries a biology experiment into deep space for the first time in 50 years. A 6U CubeSat form factor was utilized for the spacecraft which included technologies newly developed or adapted for operations beyond Earth orbit. The spacecraft carries onboard budding yeast, Saccharomyces cerevisiae, as an analog to human cells to test the biological response to deep space radiation. This was the maiden deep-space voyage for many of the subsystems, and the first time to evaluate their performance in flight operation. Flying a CubeSat beyond LEO comes with unique challenges with respect to trajectory uncertainty and mission operations planning. The nominal plan was a lunar fly-by, followed by an insertion into Heliocentric orbit. However, some possible scenarios included lunar eclipses that could have severely impacted the power budget during that phase of the mission, while others could have resulted in a “Retrograde” hyperbola at swing-by resulting in the spacecraft traveling inward toward Earth or even towards a collision with the lunar surface. The commissioning phase of the mission was successful and completed a week ahead of schedule. It did not come without its exciting moments and challenges. First contact with the spacecraft uncovered that the vehicle was unexpectedly tumbling after deployment, a situation that needed to be corrected urgently. The mission operations team executed a contingency plan to stabilize the spacecraft, with just moments to spare before the battery ran out of power. The BioSensor payload onboard the spacecraft is a complex instrument that includes microfluidics, fluid systems, sensor control electronics, as well at the living yeast cells. BioSentinel also included a TimePix radiation sensor implemented by JSC’s RadWorks group. Dose and Linear Energy Transfer (LET) data is compared directly to the rate of DSB-and repair events measured by the S. cerevisiae cells. BioSentinel mature nanosatellite technologies included: deep space communications and navigation, autonomous attitude control and momentum management, and micro-propulsion systems, to provide an adaptable nanosatellite platform for deep space uses. This paper discusses the performance of the BioSentinel spacecraft through the mission phase, and includes lessons learned from challenges and anomalies. BioSentinel had many successes and will be a pathfinder for future deep space CubeSats and biology missions.

BioSentinel↗

DOE OSTI2020

GaAsP/Si Tandem Solar Cells: Pathway to Low-Cost, High-Efficiency Photovoltaics

Si is the dominant PV technology, now and for the foreseeable future, due to its extensive manufacturing infrastructure, supply chain, feedstock availability, and highly optimized degree of fabrication processes, which altogether has produced an economic scenario where PV electricity generation is often cheaper than conventional fossil based generation. In many places, the overarching goal of grid parity has been achieved, but further improvement in performance-cost metrics are still needed to sustain the continued LCOE reductions needed to not only compete with conventional generation, but displace it on a global scale; a matter of critical importance if we stand any hope of slowing climate change. Nevertheless, single-junction Si PV is already nearing its physical limit, both in performance and cost, and is thus cannot meet these long-term goals alone. To this end, we are working on the development of monolithic III-V/Si tandem solar cells, which improve upon the performance of pure Si by providing enhanced utilization (reduced thermalization) of high-energy photons. This architecture nominally combines the substantial existing knowledge base, manufacturing infrastructure, and low cost of Si PV with the high efficiencies afforded by the well-established multijunction approach — the only proven way to break the single-junction limit. Although the metal-halide perovskite/Si tandem architecture has garnered substantial attention in recent years, serious questions regarding reliability and service lifetime remain, whereas III-V PV has a proven track record, including in the harsh concentrator and space environments. Additionally, there are multiple fabrication approaches to producing III-V/Si tandem cells, but we are focused on monolithic epitaxial integration as it is the most likely to yield the lowest ultimate LCOE in a fully mature, scaled technology. In this work we have produced multiple generations of GaAsP/Si tandem solar cells, demonstrating a more than 10% absolute AM1.5G efficiency improvement within the time frame of the project, including two verified world records. We have done this using industry-standard fabrication methods, showing that this platform can ultimately be manufactured at scale using existing or only slightly upgraded Si and III-V tooling. Our scientific and engineering advances across a range of fundamental and applied areas – III-V/Si heteroepitaxial integration, defect control in metamorphic III-V epitaxy, fundamental materials-oriented solar cell design and modeling methodology, and more – have created clear pathways for continued advances toward the goal of >30% AM1.5G cell efficiency (and >25% module) and will serve to inform the broader research community for well beyond this immediate application. Techno-economic modeling indicates that our approach can indeed meet SunShot/SETO LCOE targets, but as with any “post-Si” technology there are difficult, but not insurmountable barriers, requiring continued focused research and development efforts.

14 SOLAR ENERGY↗

DOE OSTI2022

High Yield, Economical and Environmentally Benign Production of Rare Earth Elements from Coal Ash (Phase II Final Summary Report)

Fly ash stored in landfills and ponds across the United States is an attractive, abundant domestic resource for the cost-effective recovery of rare earth elements (REE) and other critical minerals (CM). Physical Sciences Inc. (PSI) and its team members, Winner Water Services (WWS) and University of Kentucky/Center for Applied Energy Research (UK/CAER) successfully executed a multiphase program that developed technologies and their implementation in a pilot plant. We demonstrated plant operations for cost-effective and environmentally-friendly production of rare earth element oxide (REO) concentrates, and the critical minerals scandium and aluminum (in the forms of salts or oxide products), from coal ash. We also constructed and demonstrated a research-scale (0.5 kg/day) micropilot facility to validate the key physical and chemical processing operations, predict yields, and troubleshoot process bottlenecks. The project team then designed, constructed and operated two decoupled pilot plants: (1) an operational pilot plant for physical separation processes with capacity of 0.4 metric tons per day (tpd), where we optimized processes to produce selected ash fractions as the feedstock for chemical processing and as valuable byproducts such as cenospheres, magnetic ash, and secondary fuel carbon, and (2) an operational pilot plant for chemical ash processing with a capacity of 0.5 tpd that developed optimized processes for the production of: (a) REO concentrates, (b) critical minerals (Sc, Al), and (c) beneficiated ash as a valuable byproduct suitable for cement applications. In Phase I, the project team (with Equinox Chemicals in place of WWS) developed and demonstrated the feasibility of the physical and chemical separation processes, developed the design of a pilot plant, and began the development of a preliminary techno-economic model. In the baseline (initial) Phase II program, the project team developed and demonstrated the above pilot scale plant, producing salable REE concentrates, including Y and Sc (REYSc), plus commercially viable byproducts, using environmentally safe and high-yield physical and chemical enrichment processes. The team successfully demonstrated chemical pilot design, construction, shakedown, and operations of the plant. We produced the Phase II deliverable REYSc concentrate ((50 g of >60 wt.% purity REYSc salts on elemental basis), generated the feed for the Phase II follow-on program, identified processing challenges for future optimizations, and refined the techno-economic model. In the Phase II follow-on program, the project team: (1) developed and demonstrated processes to increase the REE amount by 3X (content basis) and convert the Phase II REE salt mixture to an oxide mixture, (2) produced/delivered >38 g of REO mixture with >85 wt.% purity (elemental basis); (3) developed processes to recover critical minerals scandium and aluminum from intermediate streams; (4) produced/delivered > 1 g of scandium salt mixture with >85 wt. % purity (elemental basis); (5) produced/delivered > 100 g of aluminum oxide type material with >70% wt. purity (elemental basis); and (6) updated the techno-economic model from the baseline Phase II program to assess CAPEX and OPEX of a commercial operation. This program has developed extensive databases on process chemistry, unit operations, plant engineering, and techno-economics that will enable further scale-up toward commercial plant design. Specific future developments will be focused on achieving dramatic savings in energy, reagent usage, and operating costs. The combined results will contribute significantly for maturing the technologies of REE recovery from coal byproducts and promote the establishment of domestic REE and CM supply chains.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2023

Feasibility of Pulsed Current Technology for Removing Bulk Carbon from TRISO-based Fuels

The work described in this report has evaluated the technical feasibility of maturing the pulsed current technology and its full-scale application to processing TRISO used nuclear fuel. No insurmountable technological or safety barriers were identified to successfully maturing the technology to the fourth TRL, which was considered appropriate for a DOE-NE program. The authors recommend DOE-NE’s Nuclear Fuel Cycle and Supply Chain Office should pursue the technology on that basis. In the immediate future, the authors recommend DOE-NE’s Nuclear Fuel Cycle and Supply Chain Office should acquire non-radioactive surrogate and natural uranium TRISO compacts and pebbles as they become available from commercial vendors. These surrogates could then be used to mature the pulsed current technology.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

High-Throughput Statistical Interrogation of Mechanical Properties with Build Plate Location and Powder Reuse in AlSi10Mg

Abstract Additive manufacturing (AM) allows agile, rapid manufacturing of geometrically complex components that would otherwise be impossible through traditional manufacturing methods. With this maturing manufacturing technology comes the need to adopt testing methods that are commensurate with the speed of additive manufacturing and take advantage of its geometric flexibility. High-throughput tensile testing (HTT) is a technique that allows a large number of tensile bars to be tested in a short amount of time. In the present study, HTT is used to evaluate AM AlSi10Mg produced using powder bed fusion with a Renishaw AM250 machine. Three parameters were varied in this study: (1) powder reuse history, (2) location on the build plate, and (3) size of the tensile specimen. For all parameter combinations, at least 22 specimens were tested; in several cases, over 40 were tested. This large dataset, consisting of over 500 tensile tests, permits Weibull statistical analysis and provides sufficient fidelity to isolate subtle trends that would have likely been missed in smaller, traditional datasets. The observed trends are rationalized in terms of the role of porosity and surface crust on mechanical response.

Carroll, Jay D. (ORCID:0000000258184709)↗

DOE OSTI2022

Nth-plant scenario for forest resources and short rotation woody crops: Biorefineries and depots in the contiguous US

Estimating the US potential of woody material is of vital importance to ensure cost-effective supply logistics and develop a sustainable bioenergy and bioproducts industry. We analyzed a mature conversion technology for woody resources for the contiguous US that takes advantage of economies of scale: the nth-plant. Here, we developed a database to quantify the total accessible woody biomass within a distributed network of preprocessing depots and biorefineries considering both quality specifications for conversion and a target cost to compete with fossil fuels. We considered two categories of woody biomass: 1) forest residues from trees, tops and limbs produced from conventional thinning and timber harvesting operations as well as non-timber tree removal; and 2) short rotation woody crops such as poplar, willow, pine, and eucalyptus. A mixed integer linear programming model was developed to analyze scenarios with woody feedstock blends at variable biomass ash contents and cost targets at the biorefinery. When considering a target cost of 85.51 dollars/dry ton (2016$) at the biorefinery, the maximum accessible biomass from forest residues in 2040 remained constant at 106 million dry tons regardless of ash targets. Including short rotation woody crops as part of the blend increased the total accessible biomass to 153 and 195 million dry tons at ash targets of 1% and 1.75%, respectively. We concluded from our analysis that woody resources could address about 55% of EPA’s (Environmental Protection Agency) target of 16 billion gallons of cellulosic biofuel.

09 BIOMASS FUELS↗

DOE OSTI2024

Nth-plant scenario for blended pellets of Miscanthus, Switchgrass, and Corn Stover using multi-modal transportation: Biorefineries and depots in the contiguous U.S.

The sustainability of the biofuel industry depends on the development of a mature conversion technology on a national level that can take advantage of the economies of scale: the nth-plant. Here, this study addresses the logistic challenge of mobilizing national cellulosic feedstock supplies for a sustainable bioenergy industry. A Mixed Integer Linear Programming (MILP) model was developed and updated to deliver on-spec biomass that considers both a desired quantity and quality at the biorefinery. Our supply chain analysis includes multi-modal transport (truck and rail), varying depot and biorefinery sizes, and feedstock blends of corn stover (harvested by either a two- or three-pass method), switchgrass, and miscanthus. The following US states: Illinois, Kansas, Missouri, North Carolina, Oklahoma, Georgia, and Texas were identified as key locations for producing accessible miscanthus. Based on our most optimistic scenario, using trucks as the only transportation mode in 2040 with a cost target of $\$$79/dt, corn stover, switchgrass, and miscanthus could help meet 48% of the EPA target, 173 million dry tons that translate into 7.8 billion GGE. The addition of rail transportation for biomass delivery to biorefineries could help meet 79% of the EPA target, 283 million dry tons that translate into 12.7 billion GGE.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2022

Influence of design and operating parameters for additively manufactured intensified packing devices on CO 2 -Absorption column cooling and capture efficiency

Solvent-based CO 2 absorption is technologically a matured CO 2 capture pathway but suffers from: high regeneration energy demand, and solvent temperature rise and decreased capture efficiency caused by the heat of reaction. While research has focused on developing non-aqueous and low-aqueous solvents for decreasing the regeneration energy, the temperature bulge due to exothermic absorption is typically dealt with by cooling the solvent with an external inter-stage heat-exchanger. This approach may increase the overall process footprint, as well as capital and operating costs. Here, the current study explores a process intensification approach by incorporating inside the column an additively manufactured intensified packing device that consists of corrugated plates and internal coolant channels. The corrugated plates provide surface area for mass transfer between gas and liquid, while cooling fluid inside the internal channels removes heat from the exothermic reactive system. Two different intensified devices with specific surface areas of 266 m 2 /m 3 and 359 m 2 /m 3 were designed, manufactured, and tested inside a 2.06-m long and 0.203-m diameter column packed with commercial Mellapak 250Y packing. The device with a lower surface area showed up to 27 % reduction in cooling performance. A steady-state heat transfer model provides good agreement with the experimental column temperature and intra-stage heat removal data. Although a decrease in heat transfer performance was observed for the device with lower surface area, CO 2 capture experiments performed with simulated flue gas and low-aqueous solvent demonstrated that both intensified devices lead to a similar improvement of 12 % in capture efficiency. This study provides an understanding on simplifying the intensified packing device geometry and decreasing the device fabrication cost by 25 % without compromising with the CO 2 absorption performance of the packed column.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗