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At least 91 records · Page 5

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NASA NTRS2007

Compact Fuel-Cell System Would Consume Neat Methanol

In a proposed direct methanol fuel-cell electric-power-generating system, the fuel cells would consume neat methanol, in contradistinction to the dilute aqueous methanol solutions consumed in prior direct methanol fuel-cell systems. The design concept of the proposed fuel-cell system takes advantage of (1) electro-osmotic drag and diffusion processes to manage the flows of hydrogen and water between the anode and the cathode and (2) evaporative cooling for regulating temperature. The design concept provides for supplying enough water to the anodes to enable the use of neat methanol while ensuring conservation of water for the whole fuel-cell system.

Narayanan, Sekharipuram↗

NASA NTRS2007

Photometric Calibration of Consumer Video Cameras

Equipment and techniques have been developed to implement a method of photometric calibration of consumer video cameras for imaging of objects that are sufficiently narrow or sufficiently distant to be optically equivalent to point or line sources. Heretofore, it has been difficult to calibrate consumer video cameras, especially in cases of image saturation, because they exhibit nonlinear responses with dynamic ranges much smaller than those of scientific-grade video cameras. The present method not only takes this difficulty in stride but also makes it possible to extend effective dynamic ranges to several powers of ten beyond saturation levels. The method will likely be primarily useful in astronomical photometry. There are also potential commercial applications in medical and industrial imaging of point or line sources in the presence of saturation.This development was prompted by the need to measure brightnesses of debris in amateur video images of the breakup of the Space Shuttle Columbia. The purpose of these measurements is to use the brightness values to estimate relative masses of debris objects. In most of the images, the brightness of the main body of Columbia was found to exceed the dynamic ranges of the cameras. A similar problem arose a few years ago in the analysis of video images of Leonid meteors. The present method is a refined version of the calibration method developed to solve the Leonid calibration problem. In this method, one performs an endto- end calibration of the entire imaging system, including not only the imaging optics and imaging photodetector array but also analog tape recording and playback equipment (if used) and any frame grabber or other analog-to-digital converter (if used). To automatically incorporate the effects of nonlinearity and any other distortions into the calibration, the calibration images are processed in precisely the same manner as are the images of meteors, space-shuttle debris, or other objects that one seeks to analyze. The light source used to generate the calibration images is an artificial variable star comprising a Newtonian collimator illuminated by a light source modulated by a rotating variable neutral- density filter. This source acts as a point source, the brightness of which varies at a known rate. A video camera to be calibrated is aimed at this source. Fixed neutral-density filters are inserted in or removed from the light path as needed to make the video image of the source appear to fluctuate between dark and saturated bright. The resulting video-image data are analyzed by use of custom software that determines the integrated signal in each video frame and determines the system response curve (measured output signal versus input brightness). These determinations constitute the calibration, which is thereafter used in automatic, frame-by-frame processing of the data from the video images to be analyzed.

Suggs, Robert↗

NASA NTRS2012

Compact, Lightweight Adsorber and Sabatier Reactor for CO2 Capture and Reduction for Consumable and Propellant Production

The utilization of CO2 to produce (or recycle) life support consumables, such as O2 and H2O, and to generate propellant fuels is an important aspect of NASA's concept for future, long duration planetary exploration. One potential approach is to capture and use CO2 from the Martian atmosphere to generate the consumables and propellant fuels. Precision Combustion, Inc. (PCI), with support from NASA, continues to develop its regenerable adsorber technology for capturing CO2 from gaseous atmospheres (for cabin atmosphere revitalization and in-situ resource utilization applications) and its Sabatier reactor for converting CO2 to methane and water. Both technologies are based on PCI's Microlith(R) substrates and have been demonstrated to reduce size, weight, and power consumption during CO2 capture and methanation process. For adsorber applications, the Microlith substrates offer a unique resistive heating capability that shows potential for short regeneration time and reduced power requirements compared to conventional systems. For the Sabatier applications, the combination of the Microlith substrates and durable catalyst coating permits efficient CO2 methanation that favors high reactant conversion, high selectivity, and durability. Results from performance testing at various operating conditions will be presented. An effort to optimize the Sabatier reactor and to develop a bench-top Sabatier Development Unit (SDU) will be discussed.

Junaedi, Christian↗

NASA NTRSDate not supplied

Optimizing Consumable Gas Tank Usage while Maintaining Emergency Reserves Between Two Pressure Control Systems on Gateway

Two of NASA’s Lunar Space Station (Gateway) modules, the Habitation and Logistics Outpost (HALO) and International Habitat (IHAB) contain a pressure control system (PCS) that is used to supply Nitrogen (N2) and Oxygen (O2) to maintain a habitable environment within Gateway, with only one of the PCS active at any given time. To protect the crew during a contingency that is affecting pressure control and therefore gas consumables, Gateway is required to have sufficient amount of reserve consumable gas across the entire habitable Gateway stack of modules until the gas can be replenished by crew changing out a gas tank. This will occur in a non-contingency setting either on the current mission or on the next mission. To access the stack reserve Gateway features a Nitrogen Oxygen Transfer System (NOTS) between HALO and IHAB that allows each module’s PCS to access the gas tanks in the other module. The PCS designs are different between the two modules and lack interchangeable tanks so which module has active PCS must be accounted for in logistics planning. This paper describes the logistics resupply planning analysis used to determine the most efficient use of the tanks within each PCS, and a method for switching which module is active for PCS while maintaining the stack reserve that preserves enough gas to cover contingency cases.

Rachel Anne Sturtz↗

DOE OSTI2021

Microorganisms that co-consume glucose with non-glucose carbohydrates and methods of use

Microorganisms that co-consume glucose with non-glucose carbohydrates, such as xylose, and methods of using same. The microorganisms comprise modifications that reduce or ablate the activity of a phosphoenolpyruvate (PEP):carbohydrate phosphotransferase system (PTS) protein or modifications that reduce or ablate the activity of a phosphoglucose isomerase and a GntR. The PTS protein may be selected from an enzyme I (EI), an HPr, an FPr, and an enzyme IIGlc (EIIGlc). Additional modifications include reduction or ablation of the activity of a pyruvate formate lyase, a lactate dehydrogenase, and a fumarate reductase and inclusion of recombinant pyruvate decarboxylase and alcohol dehydrogenase genes. The microorganisms are particularly suited to co-consuming glucose and xylose in media containing these substrates and producing ethanol therefrom.

Reed, Jennifer L.↗

DOE OSTI2022

A Data Quality-Aware Framework to Reliably Forecast Photovoltaic Generation and Consumer Load for an Improved Resilience of Microgrids

Photovoltaic (PV) power and consumer load forecasting plays a critical role to ensure operational resilience of the electric grid. Most data-driven forecasting algorithms rely heavily on the continuous availability of good quality data for periodic training and validation. When deployed at the grid’s edge, prolonged disruptions to communications during extreme events degrade data quality. Factors such as missing observations, epistemic uncertainties, data drift, and concept drift are manifestations of data quality that impact the generalization of such field-deployed forecasting models. Currently, there exists no mechanism in the literature to dynamically switch between models under varying degrees of data quality as quantified by certain metrics for each factor highlighted above. This paper addresses this shortcoming by conceptually introducing a data qualityaware framework for reliable PV generation and consumer load forecasting. The framework’s design incorporates components of missing values, divergence tests, and continuous monitoring of generalization performance to detect changes in data quality caused by communications disruptions and trigger specific classes of forecasting models grouped under three use cases (UC1- UC3). As a first step towards validating this framework, real data collected from an actual field microgrid system is used to demonstrate the viability of the three use cases. Results show that the performance is the best in UC1 with an unadjusted R-square value of 0.954, followed by 0.939 for UC2 and 0.757 for UC3.

Sundararajan, Aditya↗

DOE OSTI2024

Utilization of Ultrasonication as a Method of Reducing Organic and Inorganic Contamination in Post‐Consumer Plastic Film Waste

Post-consumer plastic film waste often carries organic and inorganic contaminants that challenge recycling processes and affect the quality of recycled products. An effective contaminant removal procedure through washing such single-used plastic films (SUPFs) can address environmental and waste management concerns. This study compares the efficiency of different washing techniques in reducing SUPF contamination. To evaluate the efficacy of each washing technique, film samples collected from material recovery facilities are individually exposed to friction, ultrasonic-assisted, and a combination of both washes. Thermal analysis indicates that the polymers' melting temperature, crystallization temperature, and crystallinity remain unaffected by the washing methods, demonstrating method aptness. Confocal laser scanning microscope images show that washing results in a cleaner sample surface. 91% ash reduction during the combined wash treatment indicates a high method efficiency compared to the individual friction and ultrasonic wash procedures. This is further validated by reducing characteristic contaminant IR bands (3600–3000, 1750–1600, and 1100–1000 cm −1 ). Elements of concern such as Cd, Cr, Hg, and Pb in SUPFs after each washing technique applied conform with regulations (<100 ppm) for packaging products. This research shows the novel ultrasonic washing reduces more contamination than friction with shorter wash times and no surfactants.

42 ENGINEERING↗

DOE OSTI2024

Catalytic conversion of post-consumer recycled high-density polyethylene oil over Zn-impregnated ZSM-5 catalysts

The catalytic conversion of post-consumer recycled high-density polyethylene (PCR-HDPE) pyrolysis oil was investigated using modified ZSM-5 zeolites, prepared under different conditions. The PCR-HDPE oil, obtained through pyrolysis at 500 °C followed by distillation at 165 °C, contained a naphtha fraction hydrocarbons suitable for catalytic upgrading. H/ZSM-5 converts PCR-HDPE naphtha fraction oil primarily into BTX, along with light paraffins and olefins. Introducing mesoporosity led to increased propylene yield at the expense of BTX. Zn impregnation onto H/ZSM-5 and H-meso/ZSM-5 enhanced BTX yield by up to 13 %. However, Zn-meso/ZSM-5 exhibited a lower BTX yield than Zn/ZSM-5 with the same Zn loadings, especially after additional steam treatment at 700 °C. Spent catalysts revealed no noticeable increase in metal contaminants such as calcium and aluminum that were present in the PCR-HDPE. Here, the Zn/ZSM-5 catalyst was stable for more than 50 h time on stream and showed promising potential for upgrading PCR-HDPE naphtha fraction oils.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Control of Weld Residual Stress in a Thin Steel Plate through Low Transformation Temperature Welding Consumables

Low transformation temperature welding (LTTW) consumables are characterized by a low martensite start temperature and a large fraction of martensite forming in the weld. It can efficiently reduce the tensile residual stress because the volume expansion associated with the martensitic transformation compensates for the thermal contraction during cooling. In this work, a LTTW wire, designated as EH200B, was created for the arc welding of advanced high-strength steel thin plates. In comparison to conventional ER70S-3 wires, this LTTW wire generated an opposite distortion pattern. Neutron diffraction measurements along the center thickness of the welded plates showed the maximum residual stress along the longitudinal direction (LD) in the weld region, and the heat-affected zone (HAZ) immediately adjacent to the weld region was reduced from ~330 MPa to below 240 MPa by using the LTTW wire. A finite element (FE) model was developed to predict the residual stress distributions of the plates welded under these two wires. The simulation results showed reasonable agreement with the volume-average neutron diffraction data. Compressive residual stress in the weld region using the LTTW wire was predicted by the FE method. Electron backscattered diffraction and x-ray diffraction measurements confirmed ~90% martensite was present in the LTTW weld. The fatigue life of DP980 steel lap joint panels using EH200B wire nearly doubled that of ER70S-3 wire. This improvement was attributed to the high strength and low LD residual stress in the weld and HAZ immediately adjacent to the weld.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Electric Vehicles for Consumers

More consumers are choosing electric vehicles (EVs) as new, competitively priced models with longer ranges hit the market. More public charging stations are also rapidly becoming available, and some offer quick charges to get drivers back on the road in minutes. New EVs are released all the time, with models designed to meet a wider variety of needs. To learn whether an EV is right for you, assess your driving requirements, available vehicles, and cost considerations. Easily compare costs and benefits of specific vehicles using the FuelEconomy.gov vehicle comparison tool.

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

Electric Vehicles for Consumers

charging↗

DOE OSTI2025

Repurposing Post-Consumer Polyethylene to Access Cross-Linked Polyethylene with Reprocessabilty, Recyclability, and Tunable Properties

Polyethylene (PE) is the most widely produced plastic but accumulation and resistance to degradation has significantly contributed to the plastic waste crisis. Upcycling has presented promising solutions to transform PE waste into value-added products. In this study, mixed post-consumer PE was successfully repurposed into reprocessable and chemically recyclable cross-linked polyethylene (XLPE). This process involved converting PE into telechelic oligomers, followed by repolymerization using a hybrid cross-linking system consisting of a dynamic cross-linker 2,4,6-triethoxy-1,3,5-triazine (TETA) and non-dynamic cross-linker tris(6-isocyanatohexyl)isocyanurate (Tri-HDI). In the resulting XLPE, TETA facilitated iterative reprocessing with minimal property degradation across cycles, whereas Tri-HDI helped preserve functional performance throughout service life. Compared to PE, XLPE exhibited enhanced mechanical properties, reduced creep deformation under application-relevant temperatures, and high temperature structural stability. Notably, copolymerizing PE oligomers with commercial macrodiols was employed to create composite XLPEs, enabling tuning material properties. After use, XLPE can be efficiently and selectively depolymerized under mild conditions, even when mixed with commercial insulator cables. This depolymerization allows for the recovery of the constituent building blocks, enabling purification and subsequent repolymerization for reuse. This approach demonstrates the potential of repurposing plastic waste into sustainable materials and fostering the development of a circular economy.

INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CHEMI↗

DOE OSTI2024

Evaluating consumer 3D printing nozzles as a low cost alternative for mesophase pitch-derived carbon fiber production

Synthetic fibers, such as Kevlar fibers, SiC fibers, and carbon fibers, are essential components for constructing high performance structures. Whether for engineering, sports, energy storage (batteries and supercapacitors), or aerospace applications, fiber microstructure plays a critical role in fiber properties and functionalities. However, studying fiber nozzle configurations and spinning parameters to achieve the desired microstructure remains challenging, costly, and time consuming. Here, mesophase pitch-derived fibers were used as an example to demonstrate that low cost, commercially available 3D printer nozzles can “print” fibers. Four different nozzles were used to “print” fibers and the effects of their features on fiber properties were observed and compared to other lab spun and commercial pitch- derived CF. A longer orifice length resulted in higher modulus fiber whereas a larger draw-down ratio yielded a stronger fiber. Furthermore, the findings provide a new opportunity for 3D printer hardware application and open up opportunities for developing low-cost fibers.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Aqueous buffer solution-induced crystallization competes with enzymatic depolymerization of pre-treated post-consumer poly (ethylene terephthalate) waste

In this paper, the complex relationship between kinetics and substrate morphology during enzymatic depolymerization of melt processed poly(ethylene terephthalate) (PET) is explored and the effects of competing transformations are analyzed. Extruded PET substrates from post-consumer recycled PET (RPET) bottles flakes subjected to enzymatic depolymerization are examined to reveal increases in crystallinity from ~10% post-extrusion to >30% after 3 days of depolymerization as well as increases in glass transition temperature (T g ) from ~66°C to > 80°C. Further investigation into this behavior shows that post-extrusion RPET substrates do not exhibit changes in crystallinity when subjected to dry annealing at 65°C in an oven over 7 days, but they do experience annealing in depolymerization buffer solution with no enzymes at 65°C within 3 days. This difference may be attributed to plasticization of PET in the presence of water, also known as solvent induced crystallization. The impact of this plasticized annealing behavior is demonstrated by subjecting RPET substrates to increasing enzyme-to-substrate loads. As enzyme load increases, overall conversion of substrates increases despite crystallinity also increasing to similar levels regardless of the initial enzyme loading. The competition between depolymerization and crystallization suggests that the rate at which PET substrates are depolymerized at the operational temperature is integral to achieving high conversion to monomeric product. This, in turn, also suggests that savings from lowered enzyme loadings may be more detrimental than helpful in pursuing the most cost-effective recycling systems.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Alloy selective optical sorting of mixed post-consumer aluminum scrap streams

Shredded post-consumer non-ferrous scrap stream, also known as Zorba, contains a mixture of cast and wrought aluminum pieces with very different compositions. Cast Al pieces, with their high Si, Cu and Fe content, are a major contaminant in wrought scrap fraction, which results in downcycling of the mixed cast + wrought scrap into non-structural cast Al alloys and parts. Here, in this paper, we introduce a chemical treatment method to color-code scrap aluminum pieces by alloy family and demonstrate low-cost optical sorting of cast from wrought pieces to upgrade the scrap stream. We utilized non-acidic chemical solutions that react with (i.e., etch) the scrap pieces to produce colors based on the Al alloy chemistry of a given piece. Cast pieces with high Si and Cu fractions turned black, whereas the much leaner wrought pieces remained unreacted. We showed > 95% sorting efficiency of mixed cast and wrought pieces using a repurposed low-cost optical sorter originally designed for food sorting. We also colored wrought Al pieces by alloy families, such as 5xxx and 6xxx, using a two-step chemical etching technique, which has the potential to create a circular supply chain in which wrought aluminum alloys are sorted from the mixed scrap stream and recycled back to high-value wrought products such as sheets, extrusions, and forgings with minimal contamination from cast scrap.

Aluminum↗

DOE OSTI2026

Production of high-quality polyethylene (PE) films from post-consumer shrink wrap with solvent targeted recovery and precipitation (STRAP)

The solvent-targeted recovery and precipitation (STRAP™) process separates polymers from contaminants present in the feedstock. In this work, we demonstrate the recyclability of a post-consumer waste (PCW) shrink wrap that contains inks, adhesives, and paper using STRAP. We produced a clear rPE cast film from the PCR shrink wrap with no visual contamination from paper or inks. STRAP decreased the ash content from 0.96 wt% to 0.24 wt%. A techno-economic analysis (TEA) shows that a STRAP plant processing 50,000 metric tons annually of shrink wrap waste (purchased at $\$0.25$/kg) containing 85 wt% PE can achieve an IRR of 16.2% when selling rPE at $\$1.30$/kg, an IRR of 10.7% with an rPE price of $\$1.00$/kg, or an IRR of 3.79% with an rPE price of $\$0.70$/kg. Furthermore, the life cycle assessment (LCA) shows a 64% reduction in global warming potential (kg CO 2 equivalent) when compared to the production of virgin LDPE. As a result, this work shows how feedstocks with insoluble impurities can be recycled using STRAP on a large scale.

Radkevich, Elizaveta [University of Wisconsin-Madi↗

DOE OSTI2022

Regional economic potential for recycling consumer waste electronics in the United States

Waste electronics are a growing environmental concern but also contain materials of great economic value. If properly recycled, waste electronics could enhance the sustainability of vital metal supply chains by offsetting the increasing demand for virgin mining. However, rapid changes in the size and composition of electronics complicate their end-of-life management. Here we couple material flow and geospatial analyses on over 90 critical consumer electronic products and find that over 1 billion devices, representing up to 1.5 million tonnes of mass, could be discarded annually in the United States by 2033. Emerging electronics such as connected home, health and augmented/virtual reality devices have become the fastest-growing types in the waste stream. Here we highlight policy opportunities to develop various sustainable circularity strategies around metal supply chains by showing the potential to integrate waste electronics and virgin mining pathways in western US regions, while new infrastructure designed specifically for waste electronics treatment is favourable in the central and eastern United States. Furthermore, we show the importance of building national-level refining and tear-down databases to improve electronics end-of-life management in the next decade.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2022

Ultra-high SERS detection of consumable coloring agents using plasmonic gold nanostars with high aspect-ratio spikes

Solution-based SERS detection by using a portable Raman instrument has emerged as an important tool due to its simplicity, and flexibility for rapid and on-site screening of analyte molecules. However, this method has several shortcomings, including poor sensitivity especially for weak-affinity analyte molecules, where there is no close contact between the plasmonic metal surface and analyte molecule. Examples of weak-affinity molecules include pigment molecules that are commonly used as a consumable coloring agent, such as allura red (AR), and sunset yellow (SY). As high consumption of colorant agents has been shown to cause adverse effects on human health, there is a strong need to develop a simple and practical sensing system with high sensitivity for these agents. Here we present a novel, highly sensitive solution-based SERS detection method for AR, and SY by using CTAC capped gold nanostars (GNS) having different aspect ratios (GNS-2, GNS-4, and GNS-5) without utilizing any aggregating agents which can enhance SERS signal however it reduces batch to batch reproducibility. The influence of the aspect ratio of GNS on SERS properties was investigated. We have achieved a limit of detection (LOD) of AR and SY as low as 0.5 and 1 ppb, respectively by using GNS-5 with the advantages of minimal sample preparation by just mixing the analyte solution into a well plate containing GNS solution. In addition, excellent colloidal stability and reproducibility have further enhanced the applicability in real-world samples. Altogether, our results evidence that the solution-based SERS detection platform using high aspect-ratio GNS can be applied for practical application to detect pigment molecules in real samples with satisfactory results.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗