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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 OSTI2023

The Energy Transition: Advanced Nuclear Needed but Address Climate Vulnerabilities Now

The term “Energy Transition” is an attempt to capture an elaborate set of activities related to the modernization and decarbonization of energy grids. Performed concurrently and often in an ad hoc manner across local, state, regional and national boundaries, it is bringing chaos to what should arguably be one of the most conservatively managed of all critical infrastructure sectors. What’s more, with climate change producing an increasing tempo of extreme events, confidence in the intended resilient and redundant structure of the electric grids is likely to ebb. Even without these climate induced stressors, the nation’s electric grid was built for an earlier century. In addition to a drive towards greater efficiency via digitization and a continuing price decline in distributed energy resources (DERs), one could argue that climate change concerns are the primary driver of the energy transition. Non-CO2 emitting generation sources like wind and solar have become an important part of the overall generation fleet, albeit ones that cannot be counted upon to provide dispatchable power. Current projections indicate deployment of even larger percentages of DERs in coming years. Until far better storage capabilities arrive, the variability of wind and solar, inconsistent performance of traditional thermal generation plants, and energy delivery failures associated with natural gas pipelines will reinforce mounting reliability concerns. This pertains to both electric transmission and distribution. The recent shuttering of nuclear power plants in Germany, Japan, the US and elsewhere are also putting more downward pressure on dispatchable generation. Russia’s attack on Ukraine has roiled energy markets worldwide and forced some countries to return to coal as a primary fuel. In view circumstances such as these, it is essential that significant changes be made to policies and planning criteria, and to the standards and code on which they are based. Given the accelerating pace of extreme weather events, this needs to occur as soon as possible.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

Simulink Modeling and Dynamic Study of Fixed-Speed, Variable-Speed, and Ternary Pumped Storage Hydropower

Pumped Storage Hydropower (PSH) is one of the most popular energy storage technologies in the world. It uses an upper reservoir to store water which can be later used during high-demand. In the United States, most of the energy storage capability actually corresponds to PSH. Moreover, PSH also brings multiple benefits to grid operation. This report presents the Simulink models of three common PSH technologies: Fixed-Speed (FS), Variable-Speed (VS), and Ternary (T)-PSH. These models are available to the general public on this GitHub repository, which contains the MATLAB model initialization files, the Simulink model files, and supplementary MATLAB code used to obtain the figures in this work. For each PSH model, an introductory description of the model components and other relevant functionalities are provided. For further information regarding the models and the initialization parameters, the reader is referred to the shared files in the repository. This report also presents the dynamic behavior of each model. The response of such models to a load event is analyzed and matched with each model's features. A custom IEEE 39 bus case is employed for the FS and T-PSH simulations, while the VS-PSH is simulated on a simplified three-bus test system due to the computational complexity of the model. For the T-PSH, the steady-state and the switching between several operating modes are also studied in this work.

13 HYDRO ENERGY↗
DOE OSTI2021

Thermodynamically Stable, Plasmonic Transition Metal Oxide Nanoparticle Solar Selective Absorbers towards 95% Optical-to-Thermal Conversion Efficiency at 750 °C

Generation 3 (Gen) concentrating solar power (CSP) systems requires a high operation temperature ≥750°C to increase the power-cycle efficiency towards ≥50%. However, such a high operation temperature poses a notable challenge to high temperature materials. On the receiver side, a critical challenge is the lack of solar selective absorbers that demonstrate both high optical-to-thermal energy conversion efficiency η therm approaching 95% and long-term thermal stability at >750°C in air. Existing solar absorbers either have limited η therm ≤89% or deteriorate significantly within 500 h at 750°C; some of these also require costly vacuum deposition for stringent thickness control. Therefore, it is highly desirable to simultaneously achieve η therm ~95% AND high thermal stability at 750°C for future generations of CSP receivers. This project has investigated and developed low-cost, highly scalable spray-coated transition metal oxide nanoparticle (NP) pigmented solar selective coatings on various types of Inconel alloy tube sections that are thermodynamically stable at 750-800°C in air, maintaining η therm >94.3%(93.2%) under a solar concentration ratio of C=1000 after 60 simulated day-night cycles at 750ºC (800ºC) (1 cycle=12 h at 750 or 800°C and 12h ramping down to 25°C). We have also coated up to 48 inches long receiver tubes for preliminary solar testing under Norwich Technology’s parabolic trough systems, demonstrating notably improved performance in solar heating compared to benchmark Pyromark 2500 coatings. Two key innovations have been developed in this project: (1) We achieved an unprecedented high thermal efficiency >94% by optimizing the d-band optical absorption spectra of transition metal ions, engineering their valences and stoichiometry; (2) We were able to maintain or even slightly increase the efficiency when operating at 750°C in air by engineering the interdiffusion of transition metal ions between the coating and the Inconel substrate to our advantage. Featuring high-temperature solar spectral selectivity and thermodynamic stability in air, as well as low-cost, highly scalable solution-chemical synthesis and spray coating techniques, this innovation in solar selective absorber technology alone accounts for nearly 40% of the targeted reduction in the levelized cost of electricity (LCOE) from the receiver, thermal energy storage, and operation & maintenance combined by 2030, as proposed by the U.S. Department of Energy. For a 110 MWe CSP power plant, this LCOE reduction from the solar selective coating alone transfers to ~$\$ $1.9 M increase in annual profit based on a sales price of 10¢/kWh (or an annual sale of $50 M/year). The high solar absorptance (~98%) NP pigment materials developed in this project are equally applicable to volumetric receivers either as a coating or as bigger ceramic microspheres after sintering, potentially benefiting Gen3 falling particle CSP technologies. All these contributions facilitate the larger scale deployment of CSP systems with energy storage capability to address the intermittency issue of solar energy towards dispatchable solar electricity, bridging the temporal gap between peak solar electricity production and peak electricity consumption. The collaboration with Norwich Technologies and Brayton Energy in this project will also facilitate the future commercialization of this new solar selective coating technology developed in this SIPS project.

14 SOLAR ENERGY↗
DOE OSTI2022

Deep Electrification Analysis: The Role of the U.S. Power Grid for Sustainable Transportation

This project attempts to quantify the size of electric generation for the entire nation to transition from a fossil fuel based transportation sector to a zero GHG emission-based energy source. The scope of this analysis is limited to decarbonizing the transportation sector, leaving the remaining sectors, such as power (for those that are still fossil based), industry, and building sectors, for later phases of study. The study year for this analysis is 2050, with expected escalation in transportation services and naturally occurring evolutions in the electric power sector and the entire economy. This analysis uses the projections of the Energy Information Administration’s (EIA’s) Annual Energy Outlook (AEO 2020) Reference Case for study year 2050 [EIA/AEO2020] as a base-case. The transportation sector is disaggregated by the following modes and classes: (1) on-road (divided into light-duty, medium-duty, heavy-duty vehicles), (2) aviation, (3) maritime, and (4) rail. The decarbonization case was based on only 2 pathways: (1) electrification of on-road transportation except for 30% of heavy-duty vehicles, and (2) power-to-liquid for the remaining transportation modes. The study estimated for 11 US regions what the additional wind and storage capacities requirements are to replace the fossil-based fuels with renewable wind capacity. Considered were the utilization of the existing idle capacity particularly during the load valley at night and any additional new generation capacity in EIA projections for the reference case. To balance the additional wind capacity required significant energy storage capabilities which were estimated in terms of power capacity (GW) and energy capacity (GWh). The paper further characterizes the energy requirements by a relation of power capacity to duration, allowing the analyst to gain insights into what the best technology portfolio might be to meet the new balancing or flexibility needs.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2024

Material Discovery and Design Principles of Perovskite Oxides for Reversible Solid Oxide Cells (R-SOC)

Reversible solid oxide cells (R-SOCs) are highly efficient devices for energy conversion and storage, capable of operating for both hydrogen utilization and production. In fuel cell mode, an R-SOC consumes hydrogen or natural gas to generate electricity, while in electrolysis mode, it produces hydrogen from steam. The discover of new materials with rapid oxygen surface exchange kinetics and enduring stability is crucial for the economically viable commercialization of R-SOCs. To facilitate this pursuit, we conducted extensive Density Functional Theory (DFT) calculations and developed Machine Learning (ML) models to predict critical catalytic properties essential for R-SOCs, such as oxygen surface exchange/diffusivity, and area-specific resistance (ASR). BaCoxFeyZrzO3-d(BFCZ)(x+y+z=1) emerged as a promising family of electrode materials with high activity and stability, validated through systematic experimental study. Moreover, a robust numerical multiphysics model was developed to optimize materials and microstructure parameters, providing the ability to predict the performance of functional R-SOCs.

Liu, Jian↗
DOE OSTI2023

Interconnection and Interoperability Requirements of Hydrogen Assets to Enable Grid Integration

Traditionally, the inverters used for distributed energy resources (DERs) including solar, energy storage and hydrogen fuel cells are grid following assets. Grid following assets track real power and reactive power setpoints decided by either a local autonomous controller or a remote controller like a microgrid controller. In the past five years, multiple challenges have increased the need for grid forming inverters that can interface to a wide variety of energy resources. These grid forming inverters are becoming critical assets for power systems to enable the replacement of existing rotational machines and provide grid services such as grid resiliency services and black-start. Hydrogen assets (fuel cells) have the potential to successfully replace rotating machines and act as voltage and frequency master by leveraging the long-duration and seasonal energy storage capabilities of hydrogen technologies. This poster presents the progress made in budget period 1 of the proposed work. We will leverage an existing ARIES platform experimental setup to run power-hardware-in-the-loop and controller-hardware-in-the-loop experiments with grid forming fuel cell inverters to develop and document the standardization requirements.

electrolyzer↗
DOE OSTI2023

Expandable systems for space

Systems for insulating a space vehicle or space borne container from an external environment as well as cryogens from heat sources. Such systems also protect the vehicle from the high dynamic pressures, the high heat loads encountered in atmospheric flight, and provide storage capability that strongly limits, or effectively eliminates, cryogenic boil-off losses once in space. Such systems include an expandable structure having a plurality of contiguously adjacent expandable layers. The layers are connected by a plurality of tension connectors between successive layers. For launch and flight the layers can be restrained in a collapsed position. Whereupon exiting a free stream environment, the layers are expanded where they can lock into place or otherwise remain in an expanded state. The expansion creates separation between the layers with minimal conduction paths providing near theoretically perfect multi-layer insulation and extremely effective debris protection.

de Jong, Maxim↗
DOE OSTI2024

Maximizing Demand Flexibility with Buildings and FERC 2222

In 2020, the Federal Energy Regulatory Commission (FERC) approved a rule, Order 2222, that requires market operators to create pathways enabling distributed energy resource aggregators (DERAs) to compete in all regional organized wholesale electric markets. The goal is to encourage various forms of distributed energy resources (DERs) to participate in electricity markets in a way that would enhance competition, encourage innovation, and drive down costs for consumers. In this document, we briefly discuss how FERC Order 2222 affects the opportunities for participation in electricity markets for building owners and operators, the role of aggregators, and the involvement of buildings in the electricity market.

demand flexibility↗
DOE OSTI2026

Scientific computing

Our research generates a vast amount of data that scientists must gather, store, analyze and interpret. These activities require expertise and the right tools. Fermilab is home to one of the largest tape robotic systems available today, providing more than 800 petabytes of storage capability. The lab is growing the tape facilities to meet expected demands of over 1,000 petabytes of additional data per year by the end of the decade. Fermilab also has the technology and computing power to efficiently pr ocess these data to facilitate scientific discoveries. Our computation al experts work closely with experimenters and the scientific commu - nity at large to provide and facilitate the use of the cutting-edge computing tools necessary for these discoveries.

Fermilab, Fermilab↗
DOE OSTI2025

Measuring 3D Profilometry of SAVY-4000 Nuclear Material Storage Containers: Novacam TubeInspect Capabilities Report

The SAVY-4000 container series is a general-purpose interim storage container for nuclear materials, developed and maintained by Los Alamos National Laboratory (LANL). It is the first vented, general-use nuclear material container to be demonstrated as meeting the requirements outlined in DOE M 441.1-1, the Nuclear Material Packaging Manual. Due to the challenging radiation, thermal, and corrosive storage conditions that the SAVY containers must endure, continuous surveillance techniques are employed to ensure the containers meet all safety standards and specifications. These inspections are typically performed by human operators, who check for issues such as corrosion, O-ring deterioration, corrosion, filter integrity, and potential manufacturing defects. However, human inspections alone are not sufficient, and automated inspection technologies, such as the ATIS system, as well as other automated systems are also utilized. The MicroCam TubeInspect, developed by Novacam Technologies Inc., is designed to address the challenges of understanding how manufacturing variations in the SAVY-4000 container series may affect performance. It is a 3D profilometry measurement system that enables detailed analysis of surface features, including defects, surface roughness, and manufacturing variations. This advanced tool significantly enhances rapid surveillance techniques for both pristine and used containers. In this study, container properties such as surface roughness, thickness, and geometric attributes like circularity are measured for SAVY-4000 containers. Artificially corroded or dented containers are examined to demonstrate the MicroCam's ability to quantify defects. A sensitivity analysis is also conducted, comparing the MicroCam results to those obtained using more precise instruments such as confocal microscopy. This comparison aims to provide valuable insights into container quality, durability, and potential improvements in manufacturing processes.

42 ENGINEERING↗
DOE OSTI2021

A Novel Framework for Optimizing Ramping Capability of Hybrid Energy Storage Systems

Hybrid Energy Storage System has been widely applied in aerospace, electric vehicle, and microgrid applications. The advantages are that they include complimentary technologies with both high power and energy capabilities. HESS have the potential to be useful to the bulk power systems, for example to increase the value of energy produced by variable generation resource through enabling participation in ancillary service markets. Actualizing the benefits of HESSs requires optimizing the combined ramping capability of aggregated HESS resources. To provide quality ancillary service, source of HESSs locating at multiple sites of variable generation resource must be optimally sized and cohesively controlled. Optimizing aggregated resources can be formulated as an optimization problem. Successfully solving this problem not only requires using effective solution methods but also depends on accurately and rapidly setting the necessary parameters in the problem formula. This article proposes a novel framework with double-layer structure to solve the optimization problem of aggregating ramping capability. Program developed on the upper layer focuses on solving the optimization of aggregating ramping capability among multiple HESSs and is compatible with most existing optimization algorithms. Program on lower layer of the framework targets at optimizing the local control of a single HESS based on a thorough analytics of HESS operation strategy presented in this article. Result of local optimization is also provided to upper layer program for updating the parameters in formula of optimization problem. Real time hardware-in-the-loop test is conducted to verify the performance of the optimization framework developed. The work presented is expected to provide guidance for implementing this framework in practical operation.

Luo, Yushen↗
DOE OSTI2024

FARM supervisory capabilities for thermal energy storage

The FARM (Feasible Actuator Range Modifier) module is a component of the RAVEN-based FORCE framework for the analysis of Integrated Energy Systems (IES). FARM aids HERON in the solution of the power dispatch problem by evaluating feasible set-point signals to be issued to the control systems of the different IES unit components. Set-points need to satisfy limits on both production variables (i.e., the variables to be optimized such as the electrical power, etc.) and process variables tied to the service life of equipment (e.g., steam flowrate, vessel pressure, turbine firing temperature, etc.). To enforce all these limits, a two-stage approach is adopted. First, the power dispatcher algorithm in HERON module estimates set-points that meet the constraints on the production variables, e.g., power levels and power ramp rate limits. These constraints are called explicit constraints. Then, if necessary, FARM adjusts these set-points to ensure the respect of the limits on the process variables of interest, given the knowledge of the system dynamics acquired through machine learning algorithms. These constraints are called implicit constraints. From this standpoint, FARM constitutes a bridge between the HERON power dispatcher that adopts a simplified description of the IES unit (low-resolution physics) and the HYBRID high-fidelity models (high-resolution physics). In this report, an overview of the major capabilities of the latest release of FARM is provided, along with a summary of the tool demonstration campaign conducted at the Dynamic Energy Technology and Integration Laboratory (DETAIL) facility. These results assess the performance of the control system architecture embedding FARM both as a Validator of the HERON power dispatcher and as a real time Supervisory control scheme. Additionally, the report outlines the areas that FARM might benefit from, along with proposed solutions.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2023

Liquid Air Combined Cycle TM for Power and Storage

Liquid Air Combined Cycle (LACC) is a hybrid liquid air energy storage (LAES) system combining energy storage with a combustion turbine to enable large-scale, long-duration energy storage (LDES) while reducing fuel intensity compared to the current state-of-the-art. The LACC technical approach employs proven equipment (cryogenic refrigeration, storage, tanks, pumps, gas turbines, exhaust heat recovery equipment, and turbines) to limit technical risk to a novel organic Rankine cycle (ORC), which was evaluated during this project and found to be feasible. Moreover, LACC storage is safe and relatively compact, to facilitate siting close to loads and within metropolitan regions. The air storage medium is freely available and eliminates supply chain constraints. LACC uses cryogenic air as a storage medium and a gas turbine as the source of heat to drive the discharge process. LACC is distinguished from other LAES technologies by several factors. The charge and discharge processes are decoupled so that cryogenic liquid air is the only storage medium. Other systems also store the higher temperature thermal energy from the liquefaction process in an additional medium. Subsequently, LACC focuses on maximization of the discharge energy and power. LACC also permits the use of commercially available cryogenic refrigeration and storage technologies to increase competition. This project identified product requirements to support market entry and commercialization of the LACC in modular units of approximately 117 MW, each drawing liquid air from customary cryogenic storage tanks capable of storing 75 GWh of dispatchable energy, more than pumped storage hydro or compressed air energy storage technologies. An economic analysis identified the specific liquid air consumption (quantity of liquid air per unit of discharge energy) as a critical parameter. Minimizing the air consumption reduces the specific capital cost ($\$ $/kW) for charging and discharging equipment by reducing the size of piping and turbomachinery. Likewise, the specific cost of energy capacity ($\$ $/kWh) is reduced by increasing the energy deliverable from a given size tank. The cycle was analyzed to identify the optimal equipment selection and operating conditions, which in turn were combined with quotes and cost estimates to calculate the cost of energy from an LACC system. A substantial effort was focused on the ORC, which draws low-temperature heat from the gas turbine exhaust and condenses at low temperature using the cryogenic liquid air as a heat sink. Alternative turbomachinery arrangements were evaluated for feasibility and cost. A technology maturation plan lays out a low-risk approach to development of the novel ORC components and demonstration of LACC technology at pilot scale.

25 ENERGY STORAGE↗
DOE OSTI2024

Additive Manufacturing of Thermal Energy Storage Composites with Microencapsulated Phase Change Materials Supported in a Multi-Polymer Matrix

Advanced manufacturing techniques, such as additive manufacturing (AM), that can directly integrate phase change materials (PCMs) have garnered interest in recent years due to their potential for development of highly efficient thermal energy storage architectures. Complex, high surface area geometries embedded with PCMs that are only feasible with AM can improve thermal management with reduced material waste. Our work focuses on developing composite filaments with microencapsulated phase change materials (MEPCM) bound within a single or dual polymer matrix that can be processed through standard filament extruders and additively manufactured using off-the-shelf 3D printers. Polymer powders, rather than polymer pellets, were key to homogenously mixed filaments achieving high MEPCM loadings with no deterioration in thermal energy storage (TES) capability during extrusion. Composite filaments contain upwards of 60 wt% MEPCM and were printed without loss in feature resolution, print speed, or layer adhesion. Storage enthalpies of printed composites range from 100 - 130 kJ/kg, which were within 5% of the theoretical enthalpy based on weight fraction of MEPCM and maintained enthalpies within 1% over 500 thermal cycles. We can reliably manufacture low density, high surface area structures like 15% gyroid infill, along with dense, compact pucks at a 100% concentric infill. Prints were also scalable to a 900 cm3 honeycomb infill heat exchanger model that has an estimated energy storage capacity of 9 Wh.

3D printing↗
DOE OSTI2021

Project developer options to enhance the value of solar electricity as solar and storage penetrations increase

Increasing the penetration of photovoltaics (PV) reduces the marginal grid value of PV electricity. The declining grid value of PV with higher penetration could limit the technology's economic attractiveness and future demand. Various strategies have been proposed for preserving this value. Using a consistent framework, we analyze the net value (accounting for both cost and grid value) of more than ten strategies in the United States. Here, grid value is estimated from coincident wholesale power market prices and PV generation using observed historical prices or modeled future prices with up to 30% PV penetration. We find that established and emerging strategies designed to shift the timing of standalone PV generation at the expense of total generation—including orienting monofacial PV modules west or bifacial modules vertically—result in minor net-value benefits or penalties. Adding energy storage to such systems magnifies the net-value loss, because configurations that change the timing of PV production become redundant when the energy-shifting capabilities of storage are added. The largest net-value gains come from strategies that maximize generation (solar tracking plus oversized PV arrays) in conjunction with storage, especially at high PV penetrations. PV systems are long-lived assets. Our results suggest that efforts to promote generation-maximizing strategies today may yield increasing net-value benefits as PV and storage deployments continue to accelerate in the United States over the coming decades.

14 SOLAR ENERGY↗
DOE OSTI2020

Improved lithium storage capacity and high rate capability of nitrogen-doped graphite-like electrode materials prepared from thermal pyrolysis of graphene quantum dots

Adopting a solid-phase microwave-assisted technique followed by thermal pyrolysis of N-functionalized graphene quantum dots, novel nitrogen-doped graphite-like (NGL) electrode materials were synthesized in this work and served as the anode for Li-ion batteries. The NGL anode demonstrated reversible capacity of 530 mAh g -1 at 0.1C, superior rate capability at high C rate operation (420 mAh g -1 at 5C), remarkable initial coulombic efficiency (>95.7%), and excellent cyclic stability along with high efficiency (>99.1%) during entire cycling. The NGL anode nanostructure enables improved lithium ion mobility and reversible Li + storage during cycling. The analysis of the Ragone plots revealed that the specific energy of NGL anode reaches to ca. 840 Wh kg -1 at the power density of 4200 W kg -1 . The diffusion coefficient of Li ions was measured as 1.69 × 10 -9 cm 2 s -1 for the NGL anode material, substantially improving over commonly used graphite electrodes (15–26 times higher Li + diffusivity). The high-rate cyclability as well as the cyclic stability of the NGL anodes were also confirmed via long-term cycling of full pouch cells assembled with ternary cathode and NGL anode. The robust design of the NGL anode materials introduced in this work, paves the way for designing next-generation lithium-ion batteries operating at ultra-high C rates.

25 ENERGY STORAGE↗
DOE OSTI2021

Modeling and Optimization Methods for Controlling and Sizing Grid-connected Energy Storage: A Review

Purpose of Review Energy storage is capable of providing a variety of services and solving a multitude of issues in today's rapidly evolving electric power grid. This paper reviews recent research on modeling and optimization methods for optimally controlling and sizing grid-connected battery energy storage systems (BESSs). Open issues and promising research directions are discussed. Recent Findings Recent studies on BESS dispatch, evaluation, and sizing focus on advanced modeling and optimization methods to maximize stacked value streams from multiple services. BESS models have been improved to better represent operational characteristics or capture degradation effects. Different solution methods and optimization techniques have been proposed to improve the benefits and cost-effectiveness of BESSs, using deterministic approaches prevalently but with impressive progress in capturing and addressing uncertainties. Summary Recent progress in BESS scheduling and sizing better supports planning and operational decision-making in different use cases, which is highly important to advance the deployment of BESSs. Additional research is required to properly model the trade-off between short-term benefits and service life with multiple degradation effects explicitly considered in the decision-making process. Advanced methods are to be developed for effectively determining optimal BESS sizes that maximize overall benefits within a varying lifetime considering diversified system, conditions as well as uncertainties at planning and operational stages.

Wu, Di↗
DOE OSTI2022

Melt-Spun PAN Precursor for Cost-Effective Carbon Fibers in High Pressure Compressed Gas Tankage

The objective of this program was to synthesize melt-spinnable polyacrylonitrile (PAN) precursor that will lead to carbon fiber 25% less expensive than carbon fiber produced from conventional PAN precursor when produced in large volumes. The carbon fiber produced from this precursor needs to achieve ≥ 700 ksi tensile strength with this cost reduction to replace the incumbent fiber. In this program, the technology for producing precursor and then converted carbon fiber (CF) capable of meeting the 700 ksi target was to be demonstrated at a small scale in tows, containing ≥ 100 filaments. If this program moved on to a “Phase 2”, the processes would be scaled up to produce and test Type IV compressed gas storage tanks capable of meeting the 700-bar ultimate targeted FOA performance level. Precursor fiber production typically contributes a large fraction (~50%) to finished CF manufactured cost. Presently, all high strength CFs are manufactured from solution spun PAN precursor, accomplished at low temperatures using large amounts of environmentally unfriendly solvents that impart major impact to line speed and costs involved with handling and reclaiming the solvents and associated “waste streams” required in spinning and extracting those solvents. PAN melt spinning was demonstrated by the company BASF in CF precursor production and used in production of some other acrylic fibers, but significant production challenges remain for meeting the established CF metrics. Melt spinning requires use of plasticizers to suppress the melt temperature of the predominantly PAN formulation to a point sufficiently below the temperature of significant cross-linking. Fortunately, BASF and this team’s earlier work had demonstrated acrylic formulations melt spun with combinations of plasticizing solvents at much lower solvent levels. This project team made significant progress in understanding technical issues and identifying formulation pathways in earlier work in this area where >250ksi strength was achieved. The goal of this program was to pursue a more comprehensive approach with a larger, more diverse team having greater equipment design and overall production capabilities to push rapidly beyond the science to resolve remaining “engineering” issues associated with establishing stable, continuous processes for precursor fiber leading to enhanced, cost-effective CF and composite tank production.

36 MATERIALS SCIENCE↗