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DOE OSTI2021

Techno-Economic Assessment for the Production of Hydrocarbon Fuels via Catalytic Upgrading of Furans

This technical report documents the techno-economic analysis (TEA) implications of a biochemical/catalytic pathway for the production of long-chain hydrocarbon fuels in support to the multi-lab Catalytic Upgrading of Biochemical Intermediates (CUBI) project within the Chemical Catalysis for Bioenergy Consortium (ChemCatBio). Two distinct conceptual biorefineries centered around the process encompassing sugar dehydration to furans, aldol condensation between furans and a ketone (methyl ethyl ketone [MEK]), and a final step of hydrotreating to obtain hydrocarbons in the C 14 -C 16 range are considered: an integrated plant that simultaneously produces both furans (furfural and HMF) and ketone (MEK via 2,3-butanediol [BDO]) from sugars and a dedicated facility focused on producing furans from corn stover hydrolysate and procuring the ketone externally. In either plant, the main coproducts are adipic acid (derived from lignin) and sodium sulfate. The results from the assessment are quite comparable to those reported in previous design case focused on biological conversion of sugars to fermentation intermediates with subsequent catalytic upgrading of those intermediates to hydrocarbon fuels, thus presenting another viable alternative pathway to achieve similar fuel cost targets through purely catalytic upgrading of sugars. Since this study considers long-term performance targets for the full pathway dedicated to sugar upgrading to fuels, the critical remaining research points needed to achieve future cost goals are also discussed. Finally, this report presents a single-point sensitivity analysis around selected parameters to identify the major cost drivers of the biorefineries and provides a qualitative discussion on additional opportunities for cost reduction within the proposed concepts, namely through adding value to furans, to coproducts that may be obtained following BDO dehydration, and to lignin through alternative pathways.

09 BIOMASS FUELS↗

DOE OSTI2022

Performance Testing of Software Upgrade for SRNL CPC Instrument at the Nuclear Material Laboratory, Office of Safeguards Analytical Services, International Atomic Energy Agency

This report summarizes the performance testing for the Software upgrade for the Savannah River National Laboratory (SRNL) Controlled Potential Coulometry (CPC) instrument. This upgrade is specifically to meet the needs of the Nuclear Material Laboratory, Office of Safeguards Analytical Services, International Atomic Energy Agency at Seibersdorf, Austria. The instrument hardware was upgraded in 2010, but the software continued to operate on a Windows platform using a High Tech Basic (HT Basic) application. HT Basic usage is declining. The IAEA requested an upgrade to the existing coulometer software to Laboratory Virtual Instrument Engineering Workbench (LabVIEW), an object-oriented programming language in wide use and one the NML staff is familiar with. The software was developed by SRNL Software Engineer, with assistance from Electrical Engineer and Scientist. Once developed, the new LabVIEW software was validated, tested with Iron (surrogate for plutonium) and plutonium. Once testing was completed, the software was installed at the International Atomic Energy Agency Nuclear Material Laboratory (IAEA NML) coulometer, and SRNL provided hands on training to NML staff on using the new software.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2023

Forward Pixel Detector for the Phase 2 Upgrade of CMS And Module Testing at UIC

High-Luminosity Large Hadron Collider (HL-LHC) upgrade aims to increase performance. In order to efficiently handle the larger particle flux and increased radiation, an upgrade is planned for the inner Tracker of the Compact Muon Solenoid (CMS) detector, which is located at the innermost part of the CMS. To efficiently reconstruct and track particles, the existing pixel tracker will be upgraded with novel sensors, readout chips, and front-end electronics designed to handle increased data rates. These improvements will allow the detector to track particles more precisely. In the United States, we are working on assembling new sensor modules to be inserted into disks, referred to as TFPX, for installation in the CMS detector for the HL-LHC era. We are currently testing the prototype of TFPX modules to ensure the upgrade is carried out in the best way possible. The University of Ilinois Chicago has been tasked with testing the final versions of the TFPX sensor modules before they are sent to CERN to be installed into the CMS detector. This work is supported by NSF.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2023

SPERLU Selective Process for Efficient Removal of Lignin and Upgrading (Final Technical Report)

To meet the growing demand for bio-based chemicals and improve the profitability and efficiency of the emerging biorefinery industry, lignin is an abundant and attractive feedstock. Spero Renewables has developed a proprietary and patent-pending technology, the Selective Process for Efficient Removal of Lignin and Upgrading (SPERLU). The technology is a catalytic deconstruction and upgrading of lignin in lignocellulosic biomass or commercially available technical lignin to produce multi-functional phenol (MFP) products. The SPERLU process has been demonstrated and vetted on a lab scale to convert commercially available technical lignin to MFPs in yields of 60-90% (based on lignin). The MFP products can be separated and further upgraded through catalytic or biological means. Spero performed a detailed kinetic study of the SPERLU process and used the resulting kinetic data to design and construct a mini-pilot-scale reactor for routine production of hundreds of grams of MFP products. Spero’s lignin-based MFPs have been demonstrated for use as a drop-in replacement for bisphenol A (BPA) in the synthesis of thermoset polymers. Spero’s lignin-based thermoset polymers exhibit excellent mechanical properties and can be used in many applications. Additionally, a collaboration with the National Renewable Energy Lab (NREL) was used to evaluate the feasibility of upgrading SPERLU products through biological means into valuable chemicals. A comprehensive technoeconomic analysis (TEA) and Life-cycle analysis (LCA) have been completed and support the case for commercialization of the SPERLU technology. Through this project Spero has significantly de-risked the SPERLU technology and is actively planning larger scale pilot projects.

09 BIOMASS FUELS↗

DOE OSTI2023

Fermilab’s horizontal test stand upgrade overview and commissioning

Cryo-assemblies with the low-beta Nb3Sn quadrupoles for the High Luminosity LHC (HL-LHC) upgrade will be tested at Fermilab’s magnet test facility. Total of 10 cryo-assemblies will be delivered to CERN within the US HL-LHC Accelerator Upgrade Project (AUP). The horizontal test stand at Fermilab already has been used for testing the existing LHC inner-triplet quadrupoles, but the stand and corresponding electrical and cryogenic sub-systems were not operational more than a decade. In order to restore the test stand functions and meet the design and test requirements for the high luminosity LHC magnets, the existing horizontal test facility at Fermilab underwent a significant refurbishment of the cryogenic and mechanical components. Most of the upgrades were completed and verified during so called zero-magnet test by late 2020, and then final commissioning of the upgraded test stand was completed during the first cryo-assembly test in 2023. These tests verified all the cryo-mechanical installations, as well as the test stand operations, including controlled cooldown and operation at 1.9 K, the helium recovery capabilities, magnet protection and process controls.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2024

Risk-based System Upgrade Planning for AOT-IC Presentation [Slides]

The number of deployed systems and different HW/SW form factors makes it difficult to maintain a complete understanding of their health which leads to a reduced level of certainty when assessing risk and trying to prioritize system upgrade efforts. AOT-IC must constantly plan and execute system upgrade and replacement projects to ensure the longevity of the control system. There are many more projects needed than the group can realistically accomplish given schedule and resource constraints. The group must prioritize their upgrade projects to choose only the highest priority projects to execute each year. Currently plans upgrade and replacement projects based on alignment with mission needs, group vision, resource availability, and qualitative risk assessments based on SME estimates. The group maintains a risk register. This is useful as a tool for shaping strategic planning but currently lacks the quantitative data and process needed to generate accurate risk assessments.

43 PARTICLE ACCELERATORS↗

DOE OSTI2024

Options for Upgrading Low-Voltage Spot Network Protection to Increase DER Interconnection Capacity

Existing standards and policies for interconnecting distributed energy resources (DERs) into low voltage spot networks severely limits the amount of DER installed on those networks to avoid negative impacts on protection systems. This report investigates options for upgrading the protection systems of spot networks to allow for additional DER installations beyond the normal limits (i.e., no reverse power flows allowed onto the MV system). Eight potential upgrade options are discussed that span various methods for new network protector algorithms, hardware upgrades, and the addition of communication. Each method has tradeoffs in terms of accuracy of detecting faults, requirements to upgrade equipment in the spot networks, need for communication, and sensitivity to false trips—all of which are explored in this report.

42 ENGINEERING↗

DOE OSTI2025

ALICE-USA Barrel Tracking Upgrade (Project Final Report)

The ALICE-USA Barrel Tracking Upgrade (BTU) project began in 2015 to participate in a major upgrade of the Time Projection Chamber (TPC) and the Inner Tracking System (ITS) of the ALICE Experiment at CERN in Geneva, Switzerland. This upgrade increased the maximum readout rate of the ALICE detector to accommodate the increased heavy ion interaction rates following Long Shutdown 2 of the Large Hadron Collider, and greatly improved the vertexing performance of the detector. The original scope was completed and reviewed in November 2019. The BTU project document BTU.19.v1 "ALICE Barrel Tracking Upgrade Project Closeout / Transition to Operations (2019)" from November 2019 describes the status in detail and is attached as Appendix 1 below. At that point, all delivery milestones had been met on time, all Key Performance Parameters (KPPs) of the project had been satisfied, and the project was under budget. Several subsequent No Cost Extensions (NCEs) supported integration and pre-commissioning of the BTU project deliverables at CERN, as well as study and assessment of performance with Pb-Pb collisions at 50 kHz. The BTU project was successfully completed on 30 September 2024.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRS1981

Upgraded demonstration vehicle task report

Vehicle/battery performance capabilities and interface problems that occurred when upgraded developmental batteries were integrated with upgraded versions of comercially available electric vehicles were investigated. Developmental batteries used included nickel zinc batteries, a nickel iron battery, and an improved lead acid battery. Testing of the electric vehicles and upgraded batteries was performed in the complete vehicle system environment to characterize performance and identify problems unique to the vehicle/battery system. Constant speed tests and driving schedule range tests were performed on a chassis dynamometer. The results from these tests of the upgraded batteries and vehicles were compared to performance capabilities for the same vehicles equipped with standard batteries.

Bryant, J.↗

NASA NTRS2004

Fuel Flexible Gas Turbine Combustor Flametube Facility Upgraded

In fiscal year 2003, test cell 23 of the Research Combustion Laboratory (RCL 23) at the NASA Glenn Research Center was upgraded with the addition of gaseous hydrogen as a working propellant and the addition of a 450-psig air-supply system. Test flexibility was further enhanced by upgrades to the facility control systems. RCL 23 can now test with gaseous hydrogen flow rates up to 0.05 lbm/sec and jet fuel flow rates up to 0.62 lbm/sec. Research airflow rates up to 3 lbm/sec are possible with the 450-psig supply system over a range of inlet temperatures. Nonvitiated, heated air is supplied from a shell and tube heat exchanger. The maximum nonvitiated facility air temperature is 1100 F at 1.5 lbm/sec. Research-section exhaust temperatures are limited to 3200 F because of material and cooling capacity limits. A variety of support systems are available depending on the research hardware configuration. Test section ignition can be provided via either a hydrogen air torch system or an electronic spark system. Emissions measurements are obtained with either pneumatically or electromechanically actuated gas sample probes, and the electromechanical system allows for radial measurements at a user-specified axial location for measurement of emissions profiles. Gas analysis data can be obtained for a variety of species, including carbon monoxide (CO), carbon dioxide (CO2), nitrogen oxides (NO and NOx), oxygen (O2), unburnt hydrocarbons, and unburnt hydrogen. Facility control is accomplished with a programmable logic control system. Facility operations have been upgraded to a system based on graphical user interface control screens. A data system is available for real-time acquisition and monitoring of both measurements in engineering units and performance calculations. The upgrades have made RCL 23 a highly flexible facility for research into low emissions gas turbine combustor concepts, and the flame tube configuration inherently allows for a variety of fuel nozzle configurations to be tested in a cost-effective manner. RCL 23 is poised to be a leading facility for developing modern low-emission fuel nozzles for use with jet fuel and alternative fuels.

Little, James E.↗

NASA NTRS2008

Floating Pressure Conversion and Equipment Upgrades of Two 3.5kw, 20k, Helium Refrigerators

Two helium refrigerators, each rated for 3.5KW at 20K, are used at NASA s Johnson Space Center (JSC) in Building No. 32 to provide cryo-pumping within two large thermal-vacuum chambers. These refrigerators were originally commissioned in 1996. Equipment refurbishment and upgrades to the controls of these refrigerators were recently completed. This paper describes some of the mechanical and control issues that necessitated the equipment refurbishment and controls change-over. It will describe the modifications and the new process control which allows the refrigerators to take advantage of the Ganni Cycle "floating pressure" control technology. The upgrades -- the controls philosophy change-over to the floating pressure control technology and the newly refurbished equipment -- have greatly improved the performance, stability, and efficiency of these two refrigerators. The upgrades have also given the operators more information and details about the operational status of the main components (compressors, expanders etc.) of the refrigerators at all operating conditions (i.e.: at various loads in the vacuum chambers). Capabilities, configuration, and performance data pre, and post, upgrading will be presented.

Homan, Jonathan↗

NASA NTRS2004

Space Shuttle Upgrades Advanced Hydraulic Power System

Three Auxiliary Power Units (APU) on the Space Shuttle Orbiter each provide 145 hp shaft power to a hydraulic pump which outputs 3000 psi hydraulic fluid to 41 hydraulic actuators. A hydrazine fuel powered APU utilized throughout the Shuttle program has undergone many improvements, but concerns remain with flight safety, operational cost, critical failure modes, and hydrazine related hazards. The advanced hydraulic power system (AHPS), also known as the electric APU, is being evaluated as an upgrade to replace the hydrazine APU. The AHPS replaces the high-speed turbine and hydrazine fuel supply system with a battery power supply and electric motor/pump that converts 300 volt electrical power to 3000 psi hydraulic power. AHPS upgrade benefits include elimination of toxic hydrazine propellant to improve flight safety, reduction in hazardous ground processing operations, and improved reliability. Development of this upgrade provides many interesting challenges and includes development of four hardware elements that comprise the AHPS system: Battery - The battery provides a high voltage supply of power using lithium ion cells. This is a large battery that must provide 28 kilowatt hours of energy over 99 minutes of operation at 300 volts with a peak power of 130 kilowatts for three seconds. High Voltage Power Distribution and Control (PD&C) - The PD&C distributes electric power from the battery to the EHDU. This 300 volt system includes wiring and components necessary to distribute power and provide fault current protection. Electro-Hydraulic Drive Unit (EHDU) - The EHDU converts electric input power to hydraulic output power. The EHDU must provide over 90 kilowatts of stable, output hydraulic power at 3000 psi with high efficiency and rapid response time. Cooling System - The cooling system provides thermal control of the Orbiter hydraulic fluid and EHDU electronic components. Symposium presentation will provide an overview of the AHPS upgrade, descriptions of the four hardware elements, and a summary of development results to date.

Source record↗

NASA NTRS2012

Upgrades at the NASA Langley Research Center National Transonic Facility

Several projects have been completed or are nearing completion at the NASA Langley Research Center (LaRC) National Transonic Facility (NTF). The addition of a Model Flow-Control/Propulsion Simulation test capability to the NTF provides a unique, transonic, high-Reynolds number test capability that is well suited for research in propulsion airframe integration studies, circulation control high-lift concepts, powered lift, and cruise separation flow control. A 1992 vintage Facility Automation System (FAS) that performs the control functions for tunnel pressure, temperature, Mach number, model position, safety interlock and supervisory controls was replaced using current, commercially available components. This FAS upgrade also involved a design study for the replacement of the facility Mach measurement system and the development of a software-based simulation model of NTF processes and control systems. The FAS upgrades were validated by a post upgrade verification wind tunnel test. The data acquisition system (DAS) upgrade project involves the design, purchase, build, integration, installation and verification of a new DAS by replacing several early 1990's vintage computer systems with state of the art hardware/software. This paper provides an update on the progress made in these efforts. See reference 1.

Paryz, Roman W.↗

NASA NTRS2004

A Study to Compare the Failure Rates of Current Space Shuttle Ground Support Equipment with the New Pathfinder Equipment and Investigate the Effect that the Proposed GSE Infrastructure Upgrade Might Have to Reduce GSE Infrastructure Failures

The purposes of this study are to compare the current Space Shuttle Ground Support Equipment (GSE) infrastructure with the proposed GSE infrastructure upgrade modification. The methodology will include analyzing the first prototype installation equipment at Launch PAD B called the "Pathfinder". This study will begin by comparing the failure rate of the current components associated with the "Hardware interface module (HIM)" at the Kennedy Space Center to the failure rate of the neW Pathfinder components. Quantitative data will be gathered specifically on HIM components and the PAD B Hypergolic Fuel facility and Hypergolic Oxidizer facility areas which has the upgraded pathfinder equipment installed. The proposed upgrades include utilizing industrial controlled modules, software, and a fiber optic network. The results of this study provide evidence that there is a significant difference in the failure rates of the two studied infrastructure equipment components. There is also evidence that the support staff for each infrastructure system is not equal. A recommendation to continue with future upgrades is based on a significant reduction of failures in the new' installed ground system components.

Kennedy, Barbara J.↗

NASA NTRS2013

Estimation of Airline Benefits from Avionics Upgrade under Preferential Merge Re-sequence Scheduling

Modernization of the airline fleet avionics is essential to fully enable future technologies and procedures for increasing national airspace system capacity. However in the current national airspace system, system-wide benefits gained by avionics upgrade are not fully directed to aircraft/airlines that upgrade, resulting in slow fleet modernization rate. Preferential merge re-sequence scheduling is a best-equipped-best-served concept designed to incentivize avionics upgrade among airlines by allowing aircraft with new avionics (high-equipped) to be re-sequenced ahead of aircraft without the upgrades (low-equipped) at enroute merge waypoints. The goal of this study is to investigate the potential benefits gained or lost by airlines under a high or low-equipped fleet scenario if preferential merge resequence scheduling is implemented.

air traffic management↗

NASA NTRS2014

Upgrading Custom Simulink Library Components for Use in Newer Versions of Matlab

The Spaceport Command and Control System (SCCS) at Kennedy Space Center (KSC) is a control system for monitoring and launching manned launch vehicles. Simulations of ground support equipment (GSE) and the launch vehicle systems are required throughout the life cycle of SCCS to test software, hardware, and procedures to train the launch team. The simulations of the GSE at the launch site in conjunction with off-line processing locations are developed using Simulink, a piece of Commercial Off-The-Shelf (COTS) software. The simulations that are built are then converted into code and ran in a simulation engine called Trick, a Government off-the-shelf (GOTS) piece of software developed by NASA. In the world of hardware and software, it is not uncommon to see the products that are utilized be upgraded and patched or eventually fade away into an obsolete status. In the case of SCCS simulation software, Matlab, a MathWorks product, has released a number of stable versions of Simulink since the deployment of the software on the Development Work Stations in the Linux environment (DWLs). The upgraded versions of Simulink has introduced a number of new tools and resources that, if utilized fully and correctly, will save time and resources during the overall development of the GSE simulation and its correlating documentation. Unfortunately, simply importing the already built simulations into the new Matlab environment will not suffice as it will produce results that may not be expected as they were in the version that is currently being utilized. Thus, an upgrade execution plan was developed and executed to fully upgrade the simulation environment to one of the latest versions of Matlab.

Matlab Simulation↗

NASA NTRS2015

Improved Discrete Ordinate Solutions in the Presence of an Anisotropically Reflecting Lower Boundary: Upgrades of the DISORT Computational Tool

A successor version 3 of DISORT (DISORT3) is presented with important upgrades that improve the accuracy, efficiency, and stability of the algorithm. Compared with version 2 (DISORT2 released in 2000) these upgrades include (a) a redesigned BRDF computation that improves both speed and accuracy, (b) a revised treatment of the single scattering correction, and (c) additional efficiency and stability upgrades for beam sources. In DISORT3 the BRDF computation is improved in the following three ways: (i) the Fourier decomposition is prepared "off-line", thus avoiding the repeated internal computations done in DISORT2; (ii) a large enough number of terms in the Fourier expansion of the BRDF is employed to guarantee accurate values of the expansion coefficients (default is 200 instead of 50 in DISORT2); (iii) in the post processing step the reflection of the direct attenuated beam from the lower boundary is included resulting in a more accurate single scattering correction. These improvements in the treatment of the BRDF have led to improved accuracy and a several-fold increase in speed. In addition, the stability of beam sources has been improved by removing a singularity occurring when the cosine of the incident beam angle is too close to the reciprocal of any of the eigenvalues. The efficiency for beam sources has been further improved from reducing by a factor of 2 (compared to DISORT2) the dimension of the linear system of equations that must be solved to obtain the particular solutions, and by replacing the LINPAK routines used in DISORT2 by LAPACK 3.5 in DISORT3. These beam source stability and efficiency upgrades bring enhanced stability and an additional 5-7% improvement in speed. Numerical results are provided to demonstrate and quantify the improvements in accuracy and efficiency of DISORT3 compared to DISORT2.

Lin, Z.↗

NASA NTRS2019

Upgrades to the International Space Station Urine Processor Assembly

The ISS Urine Processor Assembly (UPA) began operations in November 2008. Though the UPA has successfully generated distillate from crew urine, several modifications and upgrades have been implemented to improve overall system performance throughout the years. Current and future upgrades to the UPA will continue to focus on improved system performance and reliability, focusing primarily on the Distillation Assembly and upgrades to the UPA vacuum pump. Work towards a flight demonstration experiment of a vacuum pump utilizing scroll pump technologies has also continued forward. The following paper discusses progress on these various concepts, including the implementation of a more reliable drive belt, improved methods for managing condensate in the stationary bowl of the Distillation Assembly, installation of improved centrifuge bearings, implementation of a liquid level sensor, and upgrades to the UPA vacuum pump.

Williamson, Jill P.↗