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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

A methodology to develop multi-physics dynamic fuel cell system models validated with vehicle realistic drive cycle data

Fuel cell (FC) technology has been identified as a technically attractive solution to decarbonize the transportation sector, especially for heavy-duty vehicles. In this context, the industry and the scientific community are in need of advanced fuel cell systems (FCS) models that are able to replicate real -world operating conditions. Due to the scarcity of said models in the open literature, this study aimed to develop a comprehensive methodology to calibrate and validate multi -physics dynamic FCS models. Therefore, the key contribution of this paper is the detailed description of the calibration process for each component and the calibration order. The specific focus here was to accurately describe the behavior of the FC stack as well as the cathode, anode, and cooling circuits of the balance of plant. The model was calibrated with the aid of experimental data from a Toyota Mirai FC electric vehicle, which was predominantly retrieved from the vehicle's Controller Area Network (CAN) bus system thereby negating the need for major intrusion into the powertrain system. The validation process was deemed successful with the model being able to truthfully replicate the characteristics of the FC vehicle operated on the World-wide harmonized Light duty Test Cycle (WLTC) 3b and US06 driving cycle. The time -resolved physical parameters such as the cathode pressure, mass flow, or the FC stack temperature were captured with high fidelity, while the overall performance parameters such as the H2 consumption in the stack and the system, and the compressor energy consumption were predicted accurately with a deviation lower than 0.47%, 1.75% and 1.89% with respect to the experimental data, respectively.

Lopez-Juarez, Marcos↗
DOE OSTI2023

Investigating Combinations of Alkali Metal Oxides and Hydrogenation Catalysts for Reactive Capture of CO2 to Useful C1 Products

As the world endures environmental crises associated with climate change and the rise of atmospheric CO2 concentrations from anthropogenic CO2 emission, carbon capture and utilization (CCU) technologies are increasingly necessary. Reactive carbon capture (RCC) technologies, in which capture and conversion of CO2 occur in a single reactor, are more energetically and economically attractive by avoiding the need to purify, compress, and transport the captured CO2. To this end, dual function materials (DFMs) - composed of sorbents and catalysts co-dispersed on the same high surface area carrier - have been developed. The sorbent component allows for selective capture of CO2 from a gas stream and the catalyst component subsequently performs the in-situ conversion of the adsorbed CO2 upon introduction of a reactive gas (typically H2). The end product of the most established DFM, comprised of Ru and/or Ni with an alkaline sorbent, is methane via the CO2 methanation reaction. While renewable methane would be an excellent transition fuel, fossil methane is inexpensive (averaging $2.57/MMBTU in pre-pandemic 2019) and the economics of renewable methane utilization are noncompetitive. This requires the design and investigation of DFMs that enable CO2 capture and conversion to more valuable and more useful C1 products like CO or methanol (average price of methanol was $20.61/MMBTU in pre-pandemic 2019). These products can then be further upgraded to high energy density synthetic fuels, and related carbonaceous products, for more sustainable alternatives in industries that are difficult to decarbonize, specifically heavy duty vehicles and aviation. Herein, we report various sorbent + catalyst combinations to achieve the production of useful C1 products through reactive capture of CO2.

carbon capture↗
DOE OSTI2020

Rationale for reconsidering current regulations restricting use of hybrids in orange juice

Huanglongbing (HLB) is a disease that has devastated the Florida citrus industry, threatens the entire U.S. citrus industry, and globally is rapidly spreading. Florida’s citrus production is 90% sweet orange, which is quite sensitive to HLB. The heavy reliance on sweet orange for Florida citrus production makes the industry especially vulnerable to diseases that are damaging to this type of citrus. Furthermore, 90% of Florida oranges are used in producing orange juice that is defined by a federal regulation known as the “orange juice standard”, specifying that at least 90% of “orange juice” must be derived from Citrus sinensis. Genomic analyses definitively reveal that sweet orange is not a true species, but just one of many introgression hybrids of C. reticulata and C. maxima, with phenotypic diversity resulting from accumulated mutations in this single hybrid, the “sweet orange”. No other fruit industry is limited by law to such a narrow genetic base. Fortunately, there are new citrus hybrids displaying reduced sensitivity to HLB, and in some cases they produce juice, alone or in blends, that consumers would recognize as “orange juice”. Reconsidering current regulations on orange juice standards may permit use of such hybrids in “orange juice”, providing greater latitude for commercialization of these hybrids, leading to higher-quality orange juice and a more sustainable Florida orange juice industry.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Effects of carbonation on the retention of heavy metals in chemically activated BOF slag pastes

Basic Oxygen Furnace slag contains heavy metals, including vanadium, chromium and molybdenum. The leachability of these elements determines the industrial applicability of slag-based building products. This study investigates the post‑carbonation leaching of heavy metals from activated BOF slag pastes with the focus on the activator dosage and type (sodium and potassium citrate). Results reveal that the high degree of brownmillerite hydration boosts the leachability of heavy metals as its hydration product- hydrogarnet is less stable upon carbonation. With two leaching procedures, it is demonstrated that the carbonation resistance of pastes becomes the main attribute in preventing the leaching of heavy metals. It can be enhanced by optimising the activator dosage to facilitate the hydration of C{sub 2}S and consequent structural densification.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Viability of Vehicles Utilizing On-Board CO 2 Capture

Although battery electric and hydrogen fuel cell vehicles hold great promise for mitigating CO 2 emissions, there are still unaddressed sectors for electrified transport, e.g., the heavy-duty and long-range global shipping industry. In this Viewpoint, we examine the viability of CO 2 -neutral transportation using hydrocarbon or alcohol fuels, in which the CO 2 product is captured on-board the vehicle. This approach takes advantage of the unparalleled energy density of carbon-based fuels as needed for these energy-intensive applications. Here, a concept is developed considering the power technologies, infrastructure, and fuels required. Storage volume and mass requirements are calculated for a wide range of vehicle types and compared with those for other CO 2 -neutral options, namely hydrogen fuel cell and battery electric vehicles, and research and development needs to implement this technology are discussed.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2024

A US perspective on closing the carbon cycle to defossilize difficult-to-electrify segments of our economy

Electrification to reduce or eliminate greenhouse gas emissions is essential to mitigate climate change. However, a substantial portion of our manufacturing and transportation infrastructure will be difficult to electrify and/or will continue to use carbon as a key component, including areas in aviation, heavy-duty and marine transportation, and the chemical industry. In this Roadmap, we explore how multidisciplinary approaches will enable us to close the carbon cycle and create a circular economy by defossilizing these difficult-to-electrify areas and those that will continue to need carbon. Here, we discuss two approaches for this: developing carbon alternatives and improving our ability to reuse carbon, enabled by separations. Furthermore, we posit that co-design and use-driven fundamental science are essential to reach aggressive greenhouse gas reduction targets.

09 BIOMASS FUELS↗
DOE OSTI2020

Verification of Reactor Activation Modelling with Physical Characterization Data and the Impact on Long Term Assessments - 20303

Whiteshell Laboratories, located in Manitoba, Canada, provided research facilities for the Canadian nuclear industry since the early 1960's. The facility was centered on Whiteshell Reactor 1 (WR-1), an organically cooled, heavy water moderated nuclear reactor. WR-1 was safely shut down in 1985, defueled and drained, and has been in a safe Storage with Surveillance (Deferred Decommissioning) state until present day. In support of an Environmental Assessment for proposed in-situ disposal of WR-1, detailed characterization information regarding the reactor core components (calandria, calandria tubes, and pressure tubes) was necessary to provide confidence that the long-term impacts of the facility can be assessed adequately. A simplified estimate of the total activation of core components was completed in 1992 using conservative assumptions, expected reactor configuration and computer models built with WIMS-CRNL, ONEDANT and ORIGEN-S. Due to the simplification, and age of the work, there was considerable doubt that the modelled inventory estimate of the core components was sufficient to support long-term performance modeling of the planned in-situ decommissioning. Additional data would be required to provide this confidence. Several options were considered for characterizing the WR-1 core components, but it was decided to collect only a limited number of samples in an effort to validate the 1992 simplified estimate as bounding. The limited number of samples reduced risks to workers, both radiological and non-radiological, and significantly reduced the costs required to confidently define and bound the radiological inventory of activation products in the core. The results of the sampling were compared to the simplified activation estimation. There was good agreement between the modelled and sampled results, with all major contributors to total activity showing similar relative quantities. The samples were generally lower than predicted by the models, with few exceptions. Notable exceptions included Nb-94, which were higher in the sample results than the model. This was determined to be caused by the use of Niobium containing steel alloys in the stainless steel pressure tube that were not accounted for in the models. The comparison of results provided confidence that the original inventory estimates produced through the simplified model are conservative and bounding, and therefore suitable for use in the long-term assessment of in situ disposal of the WR-1 reactor. This paper provides details of the simplified computer model results, their comparison to results of the sampling, and the changes adopted in the assessment of the in-situ decommissioning of WR-1 as a result. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

De-Risking Field Deployment of Power System Innovations Using Hardware-in-the-Loop Experiments

The last decade has seen needs for integrating new technologies in power system. Unlike other industries, field mis-operation of novel technologies in power system can create heavy economic losses. Thus, de-risking field deployment is critical. This webinar will provide background on technology readiness level introduced by the space industry and the use of these readiness levels in power industry to assess the maturity level of power system technologies. This webinar will discuss the different approaches used to de-risk field deployment of controller technologies and power hardware technologies. This webinar will also discuss the challenges and limitations of these de-risking approaches. Finally, the webinar will provide results from hardware-in-the-loop experiments performed at National Renewable Energy Laboratory.

controller hardware-in-the-loop↗
DOE OSTI2021

Bamboo Bio-composite Truck/Trailer Decking

Bamboo is one of the fastest growing plants in the world. Massively productive, bamboo will maintain that productivity with limited inputs and minimal management resulting in predictable volume and operating margins and with low overhead. The goal of this project was to develop a bamboo bio-composite trailer decking product that replaces apitong, is lighter weight, stronger and luminescent. The collaboration partners, Fontaine, Resource Fiber and IACMI, worked closely to develop the bamboo bio-composite decking to Fontaine Trailer’s (end-user) specifications. The various technological objectives were (a) To conduct a comprehensive Design of Experiments study for bamboo composites to understand the structure-property relationships for different resin composites and bamboo forms (strips, woven, bulk etc); (b) To establish the nail pull out characteristics of trailer deck geometry bamboo composite form. The nail pull out is a critical test in trailer decks; (c) To design, process and prototype select number of trailer decking planks for Fontaine evaluation; and (d) To conduct life cycle analysis to conduct energy calculations from the various conversion steps of the bamboo from crop to product. The project meets DOE/IACMI metrics of reduced embodied energy, lightweighting and lowering the cost of the end product. It also offers a green solution to a value-added application, i.e. trailer decking. The development goals and benefits of bamboo composite decking included: A. Decreased weight when compared to Apitong and Gen 1, thereby reducing operating costs and petroleum usage due to increased miles per gallon. B. Flexibility to allow camber design into trailers. C. Luminescence to increase safety during low light and dark conditions. D. Composite material to maximize use of bamboo bio-composites as substitute for petroleum-based composites. E. Embedded layer(s) of conditioned bamboo for added strength and stability. F. Improved safety over Apitong by temporary cargo indentation in planks for better stability. G. Cradle-to-cradle design so end-of-life becomes beginning-of-life for other products. Resource Fiber’s bamboo biocomposite trailer decking passed nail pullout tests as compared to apitong (incumbent), was lighter weight than apitong, and used less embodied energy particularly when bamboo is sourced domestically. The planks were optimized in the lab setting to the extent possible and successfully installed on the trailer at Fontaine for field testing. Despite the process not being fully optimized due to through-heat and tooling limitations within the budget constraints, the prototype decking withstood 400 cycles of reverse fatigue loading of a 107,000 lb Caterpillar 349F which was extreme conditions of field testing by Fontaine Trailer. Resource Fiber plans to outsource production of a next round of planks with a commercial pultrusion processor, then to do a re-test with Fontaine Trailers. Tooling specific to the part is required. Long-term commercial plans are to continue outsourcing production while supplying bamboo fiber and mats. Commercial markets include heavy haul trailers, military trailers, and decking for marine, industrial and residential use.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Anion-Exchange-Membrane Electrolysis with Alkali-Free Water Feed

Hydrogen is a green and sustainable energy vector that can facilitate the large-scale integration of intermittent renewable energy, renewable fuels for heavy transport, and deep decarbonization of hard-to-abate industries. Anion-exchange-membrane water electrolyzers (AEM-WEs) have several achieved or expected competitive advantages over other electrolysis technologies, including the use of precious metal-free electrocatalysts at both electrodes, fluorine-free hydrocarbon-based ionomeric membranes and bipolar plates based on inexpensive materials. Contrasting the analogous proton-exchange-membrane system (PEM-WE), where pure water is circulated (no support electrolyte), the current generation of AEM-WEs necessitates the circulation of a dilute aqueous alkaline electrolyte for reaching high energy efficiency and durability. For several reasons, including but not limited to lower cost of balance-of-plant, lower operating cost and improved device's lifetime, achieving high cell efficiency and performance using an alkali-free water feed is highly desirable. In this review, we develop and build a foundational understanding of AEM-WEs operating with pure water, as well as discuss the effects of operating with natural water feeds like seawater. After a discussion of the possible advantages of pure-water-fed AEM-WEs, we cover the thermodynamic and kinetic processes involved in AEM-WE, followed by a detailed review of materials and components and their integration in the device. We highlight the influence of electrolyte composition and alkali/electrolyte-free feed on the membrane-electrode assembly, ionomers, electrocatalysts, porous transport layer, bipolar plates and operating configuration. We provide evidence for how the pure water feed engenders several issues related to the degradation of device components and propose mitigation strategies.

Electrodes↗
DOE OSTI2023

Key Considerations in Assessing the Safety and Performance of Camera-Based Mirror Systems

Camera-based mirror systems (CBMSs) are a relatively new technology in the automotive industry, and much of the United States’ medium- and heavy-duty commercial fleet has been reluctant to convert from standard glass, or “west coast”, mirrors to CBMSs. CBMSs have the potential to reduce the number of truck and passenger vehicle incidents, improving overall fleet safety. CBMSs also have the potential to improve operational efficiency by improving aerodynamics and reducing drag, resulting in better fuel economy, and improving maneuverability. Improvements in overall safety are also possible; the field of view for the driver is potentially 360° with the addition of trailer cameras, allowing for visibility of the rear of the trailer and the front of the truck. These potential improvements seem promising, but the literature on driver surveys clearly shows that there is reluctance to adopt this technology for many reasons. Additionally, more robust testing in the laboratory and in the field is necessary to determine whether CBMSs are adequate to replace standard mirrors on trucks. This analysis provides an overview of key research questions for CBMS testing based on the current literature on the topic (surveys, standards, and previous testing). The purpose of this analysis is to serve as guidance in developing further testing of CBMSs, especially testing involving human subjects.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2020

Management of Fissionable Equivalent Mass Materials at ORNL - 20146

The US DOE manages an inventory of materials that contains a range of long-lived radioactive isotopes that were produced from the 1960's through the 1980's by irradiating targets in production reactors to produce special heavy isotopes for US DOE programmatic use, scientific research, and industrial and medical applications. Since the production reactors and enrichment facilities that produced many of these materials have been shut down, they are considered unique materials that are not likely to be produced again. ORNL uses these materials in US DoE's center for production, storage, and distribution of TRU isotopes (plutonium through californium) and other related nuclear research programs. ORNL also operates the High Flux Isotope Reactor, which provides a high neutron source for production of isotopes for medical, industrial, and nuclear research programs. As a result, ORNL has an inventory of radioisotopes that are being managed for ongoing research programs and being held for reuse because they have potential intrinsic value to US DOE. An initiative is underway at ORNL to better manage these materials, particularly focusing on those with high fissionable equivalent mass that could impact the ability to perform ongoing or new research projects. This paper describes the actions ORNL is taking to manage these inventories, many of which consist of TRU materials, through reuse and disposal. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Evaluation of Safety Standards for Fuel System and Fuel Container Integrity of Alternative Fuel Vehicles

There are two Federal Motor Vehicle Safety Standards (FMVSS) in place that specify requirements for integrity of the fuel system and fuel container on compressed natural gas (CNG) fuel vehicles. These are FMVSS Nos. 303, “Fuel system integrity of compressed natural gas vehicles,” and FMVSS No. 304, “CNG fuel container integrity.” At this time, no FMVSS are defined for the fuel system and fuel container integrity of propane and liquefied natural gas (LNG) vehicles or fuel system integrity requirements for heavy-duty CNG vehicles on the road. However, there are voluntary industry design standards and best practices, as well as regulations defined in other countries. FMVSS No. 303 specifies requirements for the integrity of the CNG fuel system of light-duty vehicles and school buses, and FMVSS No. 304 specifies requirements for fuel container integrity on all CNG vehicles. FMVSS No. 304 applies to containers used for vehicle propulsion, whereas containers used to transport CNG and transportation of CNG containers are regulated by the DOT Pipeline and Hazardous Materials Safety Administration. FMVSS Nos. 303 and 304 are performance-based standards to consistently test and validate equipment and are not design restrictive. Despite the increasing number of natural gas and propane medium- and heavy-duty vehicles on the road, there are no FMVSS fuel system integrity requirements beyond light-duty and school buses for CNG vehicles and no FMVSS fuel system integrity requirements for propane vehicles. NHTSA is researching fuel system safety for medium- and heavy-duty natural gas and propane vehicles to update FMVSS Nos. 303 and 304. NHTSA is also researching current best practices and standards for high pressure fuel tanks in motor vehicles as they may apply to FMVSS No. 304.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2021

Expanding the Knock/Emissions/Misfire Limits for the Realization of Ultra-Low Emissions, High Efficiency Heavy Duty Natural Gas Engines

The Vehicle Technologies Office funds early-stage, high-risk research to develop technology upon which industry can implement innovative transportation energy technologies that increase efficiency, decrease cost, and expand use of domestic energy sources, such as natural gas (NG). To improve the viability of medium and heavy-duty vehicles the natural gas engine efficiency must be closer to that of diesel. This work addresses fundamental limitations to achieve diesel-like efficiencies in heavy duty on-road natural gas engines. The primary goal of this research is to achieve diesel-like efficiencies in heavy duty on-road NG engines, focusing on the Cummins 15 liter engine platform (baseline diesel efficiency of 44% at peak torque). That goal has been achieved, though more work is needed to facilitate practical implementation of the developed technologies.

03 NATURAL GAS↗
DOE OSTI2025

Refining Control, Charging, and Battery Chemistry for CO 2 e Savings in Heavy-Duty Off-Road Plug-In Series Hybrid

With current and future regulations continuing to drive reductions in carbon dioxide equivalent (CO 2 e) emissions in the on-road industry, the off-road industry is also likely to be regulated for fuel and CO 2 e savings. This work focuses on converting a heavy-duty off-road material handler from a conventional diesel powertrain to a plug-in series hybrid, achieving a 49% fuel reduction and 29% CO 2 e reduction via simulation. Control strategies were refined for energy savings, including a regenerative braking strategy to increase regenerative braking and a load-following hydraulic strategy to decrease electrical energy consumption. The load-following hydraulic control shuts off the hydraulic electric machine when it is not needed—an approach not previously seen in a load-sensing, pressure-compensated system. Furthermore, these strategies achieved a 24.1% fuel savings, resulting in total savings of 61% in fuel and 41% in CO 2 e in the plug-in series compared to the conventional machine. Beyond control strategies, this study evaluated battery chemistry and charging strategy refinements for total cost of ownership (TCO) and lifetime CO 2 e. LFP batteries emerged as the most cost-effective and least emitting due to their longer lifespan, which reduced replacement frequency. Charging comparisons showed that Level 2 charging (L2C) typically resulted in lower TCO but higher lifetime CO 2 e than DC fast charging (DCFC). DCFC costs were heavily influenced by local demand charges, and DCFC emissions were heavily influenced by local grid emissions.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Materials (FR 2023 Annual Progress Report)

This document summarizes the progress of VTO Materials R&D projects supported during the fiscal year 2023. The Propulsion Materials portfolio is closely aligned with other VTO subprograms to identify critical materials needs for next-generation high-efficiency powertrains for both heavy- and light-duty vehicles. The Lightweight Materials portfolio works closely with industry through the U.S. DRIVE Partnership to understand light-duty vehicle structural weight-reduction goals and identify technical challenges that prevent the deployment of lightweight materials.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Magnetic fly-ash geopolymer for heavy metal removal in aqueous solutions

Novel magnetic geopolymers were manufactured by synthesizing magnetic Fe 3 O 4 particles on the surface of prepared geopolymer (Method 1) or by incorporating pre-synthesized magnetic Fe 3 O 4 particles into the geopolymer during the manufacture of the geopolymer (Method 2). This study evaluated the effect of the incorporated magnetic Fe 3 O 4 on the geopolymer magnetic, physical, and adsorption properties and its separation in aqueous solutions. Based on several preliminary measurements on the synthesized magnetic geopolymers, Method 2 was found to be a better method for producing magnetic geopolymer. Magnetic geopolymer synthesized by Method 2 exhibited ferromagnetic properties comparable to that of magnetic Fe 3 O 4 , with a saturation magnetization of 8 emu·g −1 and an intrinsic coercivity of 265 Oe. The magnetic geopolymer was efficiently separated from an aqueous solution within 2 min using a 0.48-T magnetic field. In addition, the magnetic geopolymer has a maximum copper adsorption capacity of 111.1 mg·g −1 , which was similar to the non-magnetic reference geopolymer indicating that the addition of magnetic Fe 3 O 4 did not compromise the geopolymer adsorption capacity. The magnetic geopolymer is a promising material with good adsorption and separation properties that can be used for heavy metals removal and recovery in wastewater and metals separation in industrial processes.

fly ash↗