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

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At least 91 records · Page 5

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DOE OSTI2019

Global optimization of multicomponent distillation configurations: Global minimization of total cost for multicomponent mixture separations

We introduce a global optimization framework for determining the minimum cost required to distill any ideal or near-ideal multicomponent mixture into its individual constituents using a sequence of columns. This new framework extends the Global Minimization Algorithm (GMA) previously introduced by Nallasivam et al. (2016); and we refer to the new framework as the Global Minimization Algorithm for Cost (GMAC). GMAC guarantees global optimality by formulating a nonlinear program (NLP) for each and every distillation configuration in the search space and solving it using global optimization solvers. In conclusion, the case study presented in this work not only demonstrates the need for developing such an algorithm, but also shows the flexibility and effectiveness of GMAC, which enables process engineers to design and retrofit energy efficient and cost-effective distillation configurations.

42 ENGINEERING↗

DOE OSTI2021

Cellular fluidics

The natural world provides many examples of multiphase transport and reaction processes that have been optimized by evolution. These phenomena take place at multiple length and time scales and typically include gas–liquid–solid interfaces and capillary phenomena in porous media. Many biological and living systems have evolved to optimize fluidic transport. However, living things are exceptionally complex and very difficult to replicate, and human-made microfluidic devices (which are typically planar and enclosed) are highly limited for multiphase process engineering. In this paper, we introduce the concept of cellular fluidics: a platform of unit-cell-based, three-dimensional structures—enabled by emerging 3D printing methods—for the deterministic control of multiphase flow, transport and reaction processes. We show that flow in these structures can be ‘programmed’ through architected design of cell type, size and relative density. We demonstrate gas–liquid transport processes such as transpiration and absorption, using evaporative cooling and CO 2 capture as examples. We design and demonstrate preferential liquid and gas transport pathways in three-dimensional cellular fluidic devices with capillary-driven and actively pumped liquid flow, and present examples of selective metallization of pre-programmed patterns. Our results show that the design and fabrication of architected cellular materials, coupled with analytical and numerical predictions of steady-state and dynamic behaviour of multiphase interfaces, provide deterministic control of fluidic transport in three dimensions. Cellular fluidics may transform the design space for spatial and temporal control of multiphase transport and reaction processes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Increased Fissile Loading Flowsheet Review

A request was made by H-Canyon Process Engineering to assess the impact of blending dissolved, neutralized Spent Nuclear Fuel (SNF) with future sludge batches and their impact on downstream processing facilities including the Concentration, Storage and Transfer Facilities (CSTF), the Salt Waste Processing Facility (SWPF), the Defense Waste Processing Facility (DWPF), Saltstone, and the Effluent Treatment Facility (ETF). The purpose of this change is to accelerate the deinventory of SNF which is currently stored in the L-Area Disassembly Basin. The addition of SNF increases the mass of fissiles in each future sludge batch, due to their high enrichment. This high enrichment has the potential to complicate the programs to eliminate criticality events in the downstream processing facilities and will increase the number of canisters produced by DWPF because of the SNF mass increase. A separate report addressed the impacts to glass. The review and subsequent calculations were based on average predicted compositions of Accelerated Basin Deinventory (ABD) slurry, average compositions for predicted future sludge batches, average past salt batches and average past recycle batches to predict the feeds that will be processed in SWPF, DWPF, Saltstone, the 2H evaporator and ETF. Each of the processes was evaluated for potential issues.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Increased Fissile Loading Flowsheet Review

A request was made by H-Canyon Process Engineering to assess the impact of blending dissolved, neutralized Spent Nuclear Fuel (SNF) with future sludge batches and their impact on downstream processing facilities. The purpose of this change is to accelerate the deinventory of SNF which is currently stored in the L-Area Disassembly Basin.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2022

Prototype HB650 Transportation Validation For The PIP-II Project

The PIP-II Project at Fermilab is centered around a superconducting 800 MeV proton linac to upgrade and modernize the Fermilab accelerator complex, allowing increased beam current to intensity frontier experiments such as LBNF-DUNE. PIP-II includes strong international collaborations, including the delivery of 12 cryomodules from European labs to FNAL (3 from STFC-UKRI in the UK and 9 from CEA in France). The transatlantic shipment of these completed modules is identifed as a serious risk for the project. To mitigate this risk, a rigorous and systematic process has been developed to design and validate a transport system, including specifcation, procedures, logistics, and realistic testing. This paper will detail the engineering process used to manage this effort across the collaboration and the results of the first major validation testing of the integrated shipping system prior to use with a cryomodule.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2025

Automatic building energy model development and debugging using large language models agentic workflow

Building energy modeling (BEM) is a complex process that demands significant time and expertise, limiting its broader application in building design and operations. While Large Language Models (LLMs) agentic workflow have facilitated complex engineering processes, their application in BEM has not been specifically explored. This paper investigates the feasibility of automating BEM using LLM agentic workflow. Here, we developed a generic LLM-planning-based workflow that takes a building description as input and generates an error-free EnergyPlus building energy model. Our robust workflow includes four core agents: 1) Building Description Pre-Processing, 2) IDF Object Information Extraction, 3) Single IDF Object Generator Suite, and 4) IDF Debugging Agent. These agents divide the complex tasks into manageable sub-steps, enabling LLMs to generate accurate and reliable results at each stage. The case study demonstrates the successful translation of a building description into an error-free EnergyPlus model for the iUnit modular building at the National Renewable Energy Laboratory. The effectiveness of our workflow surpasses: 1) naive prompt engineering, 2) other LLM-based workflows, and 3) manual modeling, in terms of accuracy, reliability, and time efficiency. The paper concludes with a discussion on the interplay between foundational models and LLM agent planning design, advocating for the use of fine-tuned, specialized models to advance this field.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2023

Trophic interactions shape the spatial organization of medium-chain carboxylic acid producing granular biofilm communities

Abstract Granular biofilms producing medium-chain carboxylic acids (MCCA) from carbohydrate-rich industrial feedstocks harbor highly streamlined communities converting sugars to MCCA either directly or via lactic acid as intermediate. We investigated the spatial organization and growth activity patterns of MCCA producing granular biofilms grown on an industrial side stream to test (i) whether key functional guilds (lactic acid producing Olsenella and MCCA producing Oscillospiraceae) stratified in the biofilm based on substrate usage, and (ii) whether spatial patterns of growth activity shaped the unique, lenticular morphology of these biofilms. First, three novel isolates (one Olsenella and two Oscillospiraceae species) representing over half of the granular biofilm community were obtained and used to develop FISH probes, revealing that key functional guilds were not stratified. Instead, the outer 150–500 µm of the granular biofilm consisted of a well-mixed community of Olsenella and Oscillospiraceae, while deeper layers were made up of other bacteria with lower activities. Second, nanoSIMS analysis of 15N incorporation in biofilms grown in normal and lactic acid amended conditions suggested Oscillospiraceae switched from sugars to lactic acid as substrate. This suggests competitive-cooperative interactions may govern the spatial organization of these biofilms, and suggests that optimizing biofilm size may be a suitable process engineering strategy. Third, growth activities were similar in the polar and equatorial biofilm peripheries, leaving the mechanism behind the lenticular biofilm morphology unexplained. Physical processes (e.g., shear hydrodynamics, biofilm life cycles) may have contributed to lenticular biofilm development. Together, this study develops an ecological framework of MCCA-producing granular biofilms that informs bioprocess development.

09 BIOMASS FUELS↗

DOE OSTI2022

TRA Warm Waste Treatment Facility Process Controller Replacement

This poster details the work I did to replace the TRA Warm Waste Treatment System Process Controller. Additionally, my poster explains what Warm waste is, how the warm waste treatment system functions, and the next steps moving forward in the engineering process.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

Domain knowledge-informed, process-mapping AI graph for designing Fe-based alloys

<span style="font-family: Calibri, sans-serif; font-size: 12pt;">Continuous improvement in efficiency of a power plant relies on designing materials for use at increasingly higher temperature and/or pressure, for 100,000s hours of operation. Due to complexity, non-linearity and high-dimensionality of the problem, traditional Machine Learning (ML) approaches require unreasonably large datasets for the data-driven model development. Science-based material and process engineering complements hard data with, sometimes soft and intuitive, empirical domain knowledge. Artificial Intelligence (AI) was used in this study to incorporate such knowledge into computational graph architecture (process-mimicking artificial neuron design, causal layer and graph structures, ensemble modeling of latent states) and learning procedures (variable transformation, fuzzy physics pre-training and freezing of deep layers, virtual microstructure representation, and adversarial multi-objective optimization). The first alloys design pathways suggested by the AI tool (pyroMind) passed a preliminary engineering review on soundness and transparency.</span>

Romanov, Vyacheslav↗

DOE OSTI2022

The Energy in Modular (EMOD) Buildings Method: A Guide to Energy-Efficient Design for Industrialized Construction of Modular Buildings

Industrialized construction has immense potential to address the growing need globally to build and upgrade the building stock to be affordable, energy-efficient, and resilient. It can also help achieve the United States' goal of a 50% reduction in U.S. greenhouse gas (GHG) emissions by 2030. Despite this potential, and the ever-increasing push for electrification and decarbonization of households in the United States, industrialized construction has not yet been leveraged specifically to help address these challenges and accelerate the pathway to meet these goals. The National Renewable Energy Laboratory (NREL) aims to claim this missed opportunity by focusing on delivering affordable, grid-efficient net-zero energy (NZE) modular buildings for underserved communities to ensure an equitable transition to the future of clean energy, accelerate decarbonization of the built environment, and support the development of a high-productivity construction and energy efficiency workforce. The Energy in Modular (EMOD) method is our approach to designing, producing, and delivering affordable, net-zero energy, low-carbon, and healthier buildings at scale. The following energy efficiency strategies are part of the scope of this guide: envelope thermal control, envelope infiltration control, mechanical, electrical, and plumbing systems, smart controls, and solar plus storage. We draw synergies between design for manufacturing and assembly, process optimization, retrofit technologies, and digitization. Our goal is to influence the improvement and production of buildings to increase performance, enhance energy efficiency, and reduce GHG emissions. This guide documents the research and development efforts initiated by a set of design objectives to "modularize" a set of energy efficiency and low-carbon strategies into a housing unit while preserving and enhancing energy efficiency benefits and decarbonization pathways. This guide is intended to serve as a framework for housing developers, housing agencies, architects, energy experts, and process engineers or factory operator personnel who are critical to today's modular builder teams. This guide focuses on specific energy efficiency strategies, decarbonization pathways, and associated processes as part of NREL's research efforts. Stakeholders may substitute other means, methods, and technologies for the ones evaluated in this study.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2025

Artificial Intelligence and Digital Engineering as Enablers for System Engineering in the Energy Sector

Systems engineering is of utmost importance for the success of high-cost, high-complexity megaprojects, which are common in the energy sector. However, the traditional document-centric systems engineering approach tends to be labor-intensive and time-consuming, which has inhibited its full adoption despite proven metrics on its return on investment. However, with the modern approach of digital engineering and technological advancements in artificial intelligence (AI) technologies, the barriers to systems engineering adoption can finally be broken. This paper goes through the systems engineering V-model for lifecycle management and assesses the current state of implementation of digital engineering (especially, mod-el-based systems engineering, digital twins, and digital threads) and AI for each step. It was observed that a combination of digital engineering and AI is being used across different industries to accelerate and optimize systems engineering processes such as concept development, requirements management, architecture definition, system development, verification and validation, operations, and maintenance. Specifically in the energy sector, AI-augmented digital engineering has shown initial potential in accelerated development and deployment, performance optimization, anomaly detection, predictive maintenance, and configuration management. However, challenges remain in integrating DE and AI into an end-to-end system lifecycle management ecosystem safely and reliably. Addressing these challenges and continuously developing impactful tools will enable fast, efficient, and high-frequency deployment of power generation capabilities to keep up with the world’s energy demands and build energy security.

42 - ENGINEERING↗

DOE OSTI2025

Artificial Intelligence and Digital Engineering as Enablers for Systems Engineering in the Energy Sector

42 - ENGINEERING↗

DOE OSTI2020

Solar Engineering of Thermal Processes, Photovoltaics and Wind, Fifth Edition

The updated Fifth Edition of Solar Engineering of Thermal Processes, Photovoltaics and Wind contains the fundamentals of solar energy and explains how we get energy from the sun. The authors - noted experts on the topic - provide an introduction to the technologies that harvest, store, and deliver solar energy, such as photovoltaics, solar heaters, and cells. The book also explores the applications of solar technologies and shows how they are applied in various sectors of the marketplace.

14 SOLAR ENERGY↗

DOE OSTI2025

Material Needs and Measurement Challenges for Advanced Semiconductor Packaging: Understanding the Soft Side of Science

This Perspective builds upon insights from the National Institute of Standards and Technology (NIST)-organized workshop, “Materials and Metrology Needs for Advanced Semiconductor Packaging Strategies,” held at the 35th annual Electronics Packaging Symposium in Binghamton, NY, on September 5, 2024. It outlines critical challenges and opportunities related to polymer-based “soft” materials in advanced semiconductor packaging, with emphasis on polymer science, measurement science (metrology), and the strategic development of Research-Grade Test Materials (RGTMs). These efforts, led by the NIST CHIPS team, aim to advance the fundamental understanding of structure-property-processing relationships, promote standardized guidelines and innovative methods for material characterization, and accelerate the development, qualification, and adoption of next-generation packaging materials. The Perspective also distills key insights from the panel discussion with industry experts, emphasizing the need for close collaboration among materials scientists, process engineers, and metrology experts to enable a holistic strategy, further highlighting the importance of cross-sector partnerships among industry, academia, and government to address pressing challenges in packaging materials and processes.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2023

Modelling the Liquid Waste Operation at the Savannah River Site

Modeling Successes Dounreay – Site Closure Optimization and Risk Reduction Re-structuring and streamlining a complex project plan to achieve site decommissioning in reduced time and at reduced cost, through automated task prioritization. Idaho AMWTP – Multi-stream Optimization Speeding up a complex facility with many process lines, by utilizing all of the process lines more efficiently and reducing overall plant downtime, by coordinating repairs and shutdowns. AWE –Waste Repackaging and Relocation Relocating schedule for waste material from an old storage facility to a new purpose-built one, safely, and in a timely fashion that removed the need to reassure the safety of the old facility. Sellafield – Effluent, Sludge and HAW Treatment Improving a wide range of chemical engineered processes including aqueous effluent treatment, chemically-reactive sludge management and waste vitrification processing. Strategic Petroleum Reserve – Cavern Management Linking chemistry models of petroleum prediction, through engineering cavern management to financial modeling of gasoline sales to benefit US government

Jung, Andrew W.↗

DOE OSTI2025

Using Best Basis Inventory Data to Direct Strategies for Real-Time Monitoring of Hanford High Level Waste

The proposed Direct Feed High Level Waste (DFHLW) approach for processing high-level tank waste at Hanford is intended to reduce processing time by bypassing the Pretreatment Facility and transferring waste directly from the tank farm to the WTP HLW vitrification facility. This processing strategy could reduce or eliminate the washing and leaching steps that would have occurred in the Pretreatment facility. Operation of the vitrification facility is subject to chemical and radiological limits protecting safety (e.g. Waste Acceptance Criteria, or WACs) and process quality (e.g. Process Control Limits, or PCLs). Without washing and leaching, there is a greater risk of exceeding the WACs and PCLs. Hanford process engineers have devised blending strategies based on known chemical and radiological composition, volumes, and solids loadings of individual layers within each waste tank. These blending campaigns succeed in predicting a processing strategy that does not exceed the WACs and PCLs. However, the calculations do not ascribe uncertainties to the tank analysis data, quantities of material taken from the tanks to make the blend, or potential for mixing of layers within tanks. In order to confirm that a process strategy is working, it would be advantageous to have inline or at-line analytical instrumentation installed in the processing facilities that deliver measurement results in real time.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

Current Developments of Carbon Capture Storage and/or Utilization–Looking for Net-Zero Emissions Defined in the Paris Agreement

An essential line of worldwide research towards a sustainable energy future is the materials and processes for carbon dioxide capture and storage. Energy from fossil fuels combustion always generates carbon dioxide, leading to a considerable environmental concern with the values of CO2 produced in the world. The increase in emissions leads to a significant challenge in reducing the quantity of this gas in the atmosphere. Many research areas are involved solving this problem, such as process engineering, materials science, chemistry, waste management, and politics and public engagement. To decrease this problem, green and efficient solutions have been extensively studied, such as Carbon Capture Utilization and Storage (CCUS) processes. In 2015, the Paris Agreement was established, wherein the global temperature increase limit of 1.5 °C above pre-industrial levels was defined as maximum. To achieve this goal, a global balance between anthropogenic emissions and capture of greenhouse gases in the second half of the 21st century is imperative, i.e., net-zero emissions. Several projects and strategies have been implemented in the existing systems and facilities for greenhouse gas reduction, and new processes have been studied. This review starts with the current data of CO2 emissions to understand the need for drastic reduction. After that, the study reviews the recent progress of CCUS facilities and the implementation of climate-positive solutions, such as Bioenergy with Carbon Capture and Storage and Direct Air Capture. Future changes in industrial processes are also discussed.

Regufe, Maria João (ORCID:0000000327748302)↗

DOE OSTI2021

Optimal Header Design for Diffusion Bonded Heat Exchangers

Microchannel heat exchangers have seen increasing adoption in many high-pressure applications in recent decades but are subject to particulate fouling from the relatively small channel size compared to traditional designs. Typical cleaning methods require process shutdown, heat exchanger removal, cleaning, then reassembly. The objective of this project was to refine and transfer technology to enable header design improvements for Cleaning-in-Place (CIP), allowing for reduced/negligible process interruption for the cleaning process. The technology transfer was from Sandia National Laboratories (Sandia) to Vacuum Process Engineering, Inc. (VPE). This primary purpose of CIP was developed while considering channel flow uniformity and heat exchanger cost. The project phases were to 1) capture and define potential improvement options, 2) evaluate options with both simulation and experiments, and 3) transfer design knowledge to the industry partner. These efforts resulted in improved header designs from the first known focused effort in this area. The improved designs will help the entire microchannel heat exchanger field that has applications in supercritical CO 2 power cycles, hydrogen (fuel cell) vehicle fueling, liquified natural gas processing, and more.

42 ENGINEERING↗