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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Process-structure-property relationships for droplet-on-demand liquid-metal-jetted parts

Liquid metal jetting droplet-on-demand additive manufacturing is an attractive alternative to industry-standard, laser-based metal additive manufacturing techniques that use powder feedstocks and produce large heat affected zones. Liquid metal jetting provides a low feedstock footprint, minimal materials waste, less contamination and inclusions from feedstock, and is compatible with a large range of materials. However, little has been reported on the liquid metal jetting process-structure-property relationships that are crucial to understanding how to consistently print high quality metal parts. We investigate the effects of build plate temperature, infill pattern, and track raster rate on the macro- and microstructure, density, hardness, and tensile strength of metal parts created with our custom droplet-on-demand setup using pure tin feedstock as a surrogate for more relevant structural materials. We found that although the build plate temperature had the largest influence on the structure and properties, the infill pattern is an important factor for optimal structural integrity. It was observed that the track raster rate influenced track-to-track porosity and should be considered in toolpath development. Despite printing in ambient air, we could not identify oxide on the surface or in the bulk of the parts and saw no adverse effects on microstructure or tensile performance. The results and methods of this study will help guide future work in optimizing the liquid metal jetting process to reliably print parts using any liquid metal jetting system for a wide variety of metal feedstocks.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Technoeconomic Analysis of a Microwave-Assisted Novel Process That Converts Polypropylene Plastic Waste to Propylene

Propylene is an important petrochemical that is used in various industries, including the automobile and polymer sectors. Conventionally, propylene has been produced through fluid catalytic cracking, steam cracking, and propane dehydrogenation. In this project, a novel process to produce propylene from polypropylene plastic waste using a microwave reactor is introduced. Propylene production is simulated in Aspen Plus for both the conventional propane dehydrogenation process and the novel design, with heat integration applied to minimize utility demands and the conventional process serving as the base case for comparison. Finally, a tailored technoeconomic analysis is carried out for both simulated cases to estimate important economic indicators. Analysis of the results shows that the novel microwave-assisted process outperforms the conventional route for propylene production, achieving a single-pass conversion of almost 100%, compared with only 33.8% in the conventional plant. The Net Present Value of the novel plant is $\$1720.3$ MM, which is 3.5 times higher than the conventional process, while the Levelized Cost of Propylene is reduced by 40%. Capital and operating expenditure are also improved in the proposed scheme, with reductions of approximately $\$29$ MM and $\$222$ MM/yr, respectively. In addition to cost savings, this novel process also provides a convenient means to recycle waste polypropylene.

42 ENGINEERING↗
DOE OSTI2023

Thermo-Hydro-Mechanical Modeling of Brine Migration in a Heated Borehole Test in Bedded Salt

Abstract This research paper focuses on the thermo-hydro-mechanical (THM) modeling of brine migration in a heated borehole test conducted as part of the ongoing Brine Availability Test in Salt (BATS) at the Waste Isolation Pilot Plant (WIPP) in New Mexico. It is a component of the international collaboration project DECOVALEX-2023 (DEvelopment of COupled models and their VALidation against EXperiments), which aims to understand the THM processes governing brine flow in heated rock salt repositories through collaborative analysis by multiple research teams. Using the TOUGH–FLAC simulator, THM simulations were performed and compared with data from the BATS phase 1a. This experiment involved two identical horizontal-borehole arrays, one heated and one serving as a control, both equipped with sensor arrays. Analysis of measurements revealed water flow rate surges during heater power transitions, with the highest jump observed during cooling. Acoustic emission activity exhibited distinct patterns in response to heater power changes, suggesting that damage to rock salt is particularly pronounced during the cooling phase. The THM simulations successfully captured these phenomena, highlighting the significance of thermal effects, brine migration, and mechanical behavior in predicting brine availability in heated and damaged rock salt. Our modeling also revealed the critical interplay between heating and cooling-induced damage and its influence on flow properties, particularly affecting brine inflow estimation. Notably, we found that cooling-induced brine inflow spikes result from increased permeability due to tensile dilatancy. These findings have important implications for the development of robust containment strategies and enhance our understanding of the complex processes involved in repository performance.

58 GEOSCIENCES↗
DOE OSTI2022

Machine Learning Guided Synthesis of Flash Graphene

Advances in nanoscience have enabled the synthesis of nanomaterials, such as graphene, from low-value or waste materials through flash Joule heating. Though this capability is promising, the complex and entangled variables that govern nanocrystal formation in the Joule heating process remain poorly understood. In this work, machine learning (ML) models are constructed to explore the factors that drive the transformation of amorphous carbon into graphene nanocrystals during flash Joule heating. An XGBoost regression model of crystallinity achieves an r 2 score of 0.8051 ± 0.054. Feature importance assays and decision trees extracted from these models reveal key considerations in the selection of starting materials and the role of stochastic current fluctuations in flash Joule heating synthesis. Furthermore, partial dependence analyses demonstrate the importance of charge and current density as predictors of crystallinity, implying a progression from reaction-limited to diffusion-limited kinetics as flash Joule heating parameters change. Finally, a practical application of the ML models is shown by using Bayesian meta-learning algorithms to automatically improve bulk crystallinity over many Joule heating reactions. Furthermore, these results illustrate the power of ML as a tool to analyze complex nanomanufacturing processes and enable the synthesis of 2D crystals with desirable properties by flash Joule heating.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2020

Flash Graphene from Plastic Waste

In this work, an approach to upcycling plastic waste (PW) products is presented. The method relies on flash Joule heating (FJH) to convert PW into flash graphene (FG). In addition to FG, the process results in the formation of carbon oligomers, hydrogen, and light hydrocarbons. In order to make high quality graphene, a sequential alternating current (AC) and direct current (DC) flash is used. Here, the FJH process requires no catalyst and works for PW mixtures, which makes the process suitable for handling landfill PW. The energy required to convert PW to FG is ~ 23 kJ/g or ~ $125 in electricity per ton of PW, potentially making this process economically attractive for scale-up. The FG was characterized by Raman spectroscopy and had a I 2D /I G peak ratio up to 6 with a low-intensity D band. Moreover, transmission electron microscopy and X-ray diffraction analysis show that the FG is turbostratic with an interlayer spacing of 3.45 Å. The large interlayer spacing will facilitate its dispersion in liquids and composites. Analysis of FG dispersions in 1% Pluronic aqueous solution shows that concentrations up to 1.2 mg/mL can be achieved. The carbon oligomers that distilled from the process were characterized by Fourier-transform infrared spectroscopy and have chemical structures similar to the starting PW. Initial analysis of gas phase products shows the formation of considerable amounts of hydrogen along with other light hydrocarbons. Since graphene is naturally occurring and it shows a low toxicity profile, this could be an environmentally beneficial method to upcycle PE.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Recycling of Printed Circuit Boards to Recover Critical Materials

The printed circuit board (PCB), a central component of most electronic devices, represents a significant fraction of the electronic product waste stream. The complex composition of PCBs, consisting of metals, polymers, and fiberglass, requires specialized recovery steps to reclaim valuable and critical materials and the safe disposal of brominated compounds. In this review paper, we describe the current state of critical material recovery and traditional recycling technologies and identify key obstacles to large-scale implementation. Metals present at high concentrations, such as copper, lead, and iron, are conventionally recovered from PCBs using hydrometallurgical, pyrometallurgical, or electrometallurgical processes. Hydrometallurgical methods achieve high selectivity through chemical leaching but pose significant challenges for effluent and reagent recovery. Pyrometallurgical methods facilitate rapid metal separation through smelting but require substantial energy and may release harmful gases. Electrometallurgical techniques produce high-purity metals but are constrained by pretreatment requirements and the consumption of energy. The non-metallic fraction of PCB waste is recycled using thermochemical conversion, microwave-aided heating, and direct recycling of epoxy–fiberglass composites, enabling material or energy recovery. The recovered polymer from direct recycling may have reduced mechanical strength and poor compatibility with new polymer matrices, and the resulting products from the thermal conversion suffer from incomplete conversion, degradation of quality, and residual contamination, as compared to synthetic polymers. Recent process developments have focused on extracting rare earth and supply-critical materials present at lower concentrations in the waste stream. The literature on existing and emerging approaches for recycling PCB wastes is reviewed to identify sustainable, economically viable, and environmentally responsible strategies for the recovery and reuse of critical materials from waste streams.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Vitrification Testing of HLW with High Phosphate

Projections of the number of high level waste (HLW) canisters to be produced in the Hanford Tank Waste Treatment and Immobilization Plant (WTP) (e.g., [1]) are based upon the inventory of the tank wastes, the anticipated performance of the sludge treatment processes, and current understanding of the capability of the borosilicate glass waste form. The WTP HLW melter design, unlike earlier Department of Energy (DOE) melter designs, incorporates a glass bubbler system. The bubblers create active glass pool mixing and thereby improve heat and mass transfer and glass melting rate. The WTP HLW melters each have a glass surface area of 3.75 m 2 and depth of ~1.1 m. The two melters in the HLW facility together are designed to produce up to 7.5 MT of glass per day at 100% availability. Further increases in HLW waste processing rates can potentially be achieved by optimization of the feed and glass formulations, increasing the melter operating temperature above 1150⁰C, and by increasing the waste loading in the glass product. Increasing the waste loading also has the added benefit of decreasing the number of canisters for storage.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2026

M3SF-25LL010302052 - Radionuclide Interaction with Hydrothermally Altered Repository Materials

This progress report (Level 3 Milestone Number M3SF-25LL010302052) summarizes research conducted at Lawrence Livermore National Laboratory (LLNL) within the Crystalline Host Rock Properties & Processes - LLNL Number SF-25LL01030205. Observed changes in radionuclide sorption after bentonite/clay heating have implications for radionuclide diffusive transport through engineered barriers and must be considered when designing waste disposal repositories. Recent research performed at Los Alamos National Laboratory (LANL) has provided key insights regarding the hydrothermal alteration behavior of bentonite backfill in the presence of repository materials (steel, concrete, etc.). We are examining how this mineral alteration affects retardation behavior of a suite of radionuclides of interest to repository performance assessment. Sorption experiments and data analysis for 233 U were initiated in FY24 following earlier experiments performed on 243 Am, 90 Sr, 137 Cs. In FY25, we completed the 233 U study and initiated and completed a study of 237 Np sorption. Below, we summarize the results and potential impacts of hydrothermal alteration on radionuclide retardation and assess the importance of this process to radionuclide migration from a GHRDC. We also use statistical tools (i.e. PCA) to help us determine the major drivers in affecting changes in measured Kd values induced by hydrothermal alteration. These experiments also allow us to test the predictive ability of our component additivity approach to surface complexation and ion exchange. Our guiding hypothesis is that a robust surface complexation/ion exchange model and associated database can effectively predict changes in radionuclide sorption behavior resulting from the hydrothermal alteration of mineralogy in a repository near field. In November 2024 the paper “Selenium interaction with iron minerals: Quantitative comparison of sorption and coprecipitation impacts on mobility” was published in Applied Geochemistry. A short update of results to date is presented below. In FY25, we also actively supported the DITUSC project, which is part of the EURADII initiative, as associate partners. We are executing the Migration2025 conference and support associated the NEA-TDB and Thermochimie workshops that will provide critical international engagements and develop consensus and synergy in thermodynamics as it relates to supporting the US nuclear waste repository program.

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

In-situ X-ray and visual observation of foam morphology and behavior at the batch-melt interface during melting of simulated waste glass

We report to attain a basic understanding of the primary foam structure and behavior, which affects the heat and mass transfer and the efficiency of the glass melting process, we investigated the primary foam layer under the glass batch floating on molten glass. The primary foam affects mass transfer during batch melting, in turn affecting the melting process. The recently performed direct in-situ three-dimensional X-ray computed tomography of the batch melting in a laboratory-scale melter vessel allowed us to visualize the features of the reacting batch layer and the foam that develops at its bottom, though with an insufficient resolution of images. In this study, we obtained better temporal and spatial resolution using the two-dimensional X-ray radiography and visual observation of the structure and behavior of transient primary foam as it formed and decayed. As soon as the batch was charged onto the melt surface, foam bubbles began to evolve, grow, and coalesce, forming a primary foam layer, 5-10 mm thick, within tens of seconds. This foam layer was sustained by ongoing gas evolving reactions counterbalanced by bubble coalescence into cavities that moved sideways and escaped to the atmosphere. Eventually, the entire remaining batch turned into foam that gradually decayed at the melt surface. The decay rate agreed with literature observations of surface foam produced by secondary foaming.

36 MATERIALS SCIENCE↗
DOE OSTI2026

PERFORMANCE ANALYSIS OF AN ENGINEERING SCALE HYDROTHERMAL LIQUEFACTION SYSTEM

This work evaluates the Modular Hydrothermal Liquefaction System (MHTLS), an engineering-scale, integrated continuous HTL plant operated at the Pacific Northwest National Laboratory (PNNL), for converting realistic wet wastes into energy-dense biocrudes. The production campaigns discussed here processed algae, sewage sludges, lignocellulosic blends, Industrial food waste, and engineered food-waste slurries at 350?°C and around 200?bar, with nominal feed rates of ~12?L?h?¹. We report biocrude yields and composition, establish mass and elemental (C, N) balances, and quantify energy performance via heater duties, heat-exchanger behavior, and system-level efficiencies. Biocrudes contained 76–80?wt?% C (dry, ash-free) with HHVs of 38-41?MJ?kg?¹, substantially higher than feed materials HHVs of 16.6–26.1?MJ?kg?¹ and approaching petroleum fuels. Dry, ash-free biocrude yields of 32–53?wt?% corresponded to 43–71?wt?% carbon yields, with 18–40?wt?% of feed carbon routed to the aqueous phase. Thermal efficiencies were 50-65%, and total energy efficiencies, including reactor heat input, were 35-55%. A counter-current tube-in-tube heat exchanger delivered U values of 200–450?W?m?²?K?¹, with fouling-induced declines impacting heat recovery and heater duty. The analysis highlights three priorities for the process intensification of HTL: robust, fouling-resistant heat recovery, hydrodynamically suitable reactor and heat-exchanger designs, simplified and predictable solids management, and biocrude-water separation.

Biocrude production↗
DOE OSTI2020

Re-Envisioning RCx: Achieving Max Potential HVAC Controls Retrofits through Modernized BAS Hardware and Software

Most existing buildings have sub-optimal heating, ventilation, and air conditioning (HVAC) controls, resulting in wasted energy and occupant discomfort. Retro-commissioning (RCx) addresses many of these issues, but it is a lengthy and highly customized process. Limited capabilities of existing building automation system hardware restricts the scope of most RCx projects. Incentive programs consider building automation system (BAS) hardware retrofits to be high-capital investments and do not allow them in typical RCx programs. This paper describes work that the authors are leading to facilitate technical and market innovation in the BAS industry to unlock large savings in existing commercial buildings through deep retrofits of BAS hardware and software. California and New York research projects are demonstrating BAS retrofits leveraging the American Society of Heating, Refrigeration, and Air Conditioning Engineers’ (ASHRAE) new Guideline 36 high performance sequences of operation to achieve greater than 20 percent whole building energy savings, while saving costs and reducing risk through streamlined processes and standardization across BAS manufacturer product lines and across implementation practices. This paper describes market barriers that impede achieving deep savings from BAS retrofits in custom incentive and traditional RCx programs and presents a new maximum potential BAS retrofit model that addresses these barriers. The new model leverages the authors’ efforts in market enablement through open standards, BAS industry partnerships, and tools for cost-effective scaling that includes tools for project screening, savings calculations, and measurement and verification (M&V). This approach is widely applicable and will be ready for at-scale implementation within two years.

Paliaga, Gwelen↗
DOE OSTI2025

Coal-Waste-Enhanced Filaments for Additive Manufacturing of High-Temperature Plastics and Ceramic Composites

In the United States, coal waste from over a century of mining and burning coal for heat and electricity has accumulated as mountains of coal fly ash and bottom ash and acre-size ponds, coal fines and gob. These materials can be a problem for local communities and water systems. A cost-effective process to utilize high volumes of these coal wastes in a high-value product would be beneficial to those communities by reducing the amount of waste and providing jobs, manufacturing components, and materials from the waste. Many coal-to-products technologies (e.g., carbon fibers, graphene, carbon foam) rely on carefully choosing the starting material and then altering it chemically or thermally to make the products work. Due to the wide variability of composition and coal content in typical coal waste streams, many high-volume coal waste streams are likely to be unsuitable for use in those technologies. Semplastics’ technology has been shown to utilize most types of coal waste successfully without any pre-selection or pre-processing requirements other than a nominal particle-size reduction for wastes like bottom ash. This characteristic of Semplastics’ solution may enable the use of much larger volumes of a wider range of coal wastes than other coal-to-products technologies. In this project, Semplastics leveraged its unique experience with both coal waste (fly ash or coal combustion residuals), resin materials, and 3D printing to develop 3D printer filaments using common coal wastes – bituminous coal fines and fly ash – and researched the feasibility of using other forms of coal waste as fillers. Simple 3D-printed parts were successfully produced from the coal waste enhanced filaments, which were found to have improved strength and stiffness.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Power and energy capacity tradeoffs in an all-aqueous copper thermally regenerative ammonia battery

Thermally regenerative ammonia batteries (TRABs) can provide energy storage and produce electrical power from low-grade waste heat instead of electricity. The use of all-aqueous copper-based electrolytes has recently produced higher power densities than those achieved using previous TRAB approaches based on reversible metal deposition and dissolution processes, but further gains are possible in power and energy density. We investigated the limitations of power and energy density and how they are impacted by the electrolyte composition and discharge currents. By increasing the ammonia concentration from 1 to 5 M, the power density of the battery increased from 11.2 to 28.5 mW cm –2 , but the energy density decreased from 0.56 to 0.31 Wh L –1 . Increasing discharge current densities from 4 to 12.5 mA cm –2 increased the average power density during discharge from 2.4 to 5.9 mW cm –2 without appreciable losses in energy density. Increasing the copper concentration from 0.1 to 0.5 M increased both energy density to 2.15 Wh L –1 and energy efficiency to 2.2% but did not substantially impact the power density. Furthermore, these results represent the highest performance metrics achieved for a low-grade waste heat to electricity system.

25 ENERGY STORAGE↗
DOE OSTI2022

Nitinol Electroslag Remelting: Initial Slag Study

Nitinol’s unique shape memory and super-elastic properties make it attractive for many applications in biomedical, automotive, aerospace, industrial refrigeration, and waste heat reclamation industries. The fatigue performance is limited however, by non-metallic inclusions (NMI) formed during the traditional VIM/VAR or multi-VAR process. ESR is a potential alternative melt process and is commonly used to refine ingot chemistry and enhance the metallurgical structure of many superalloys and specialty steels, but no study on ESR of Nitinol has been reported to date. The key to establishing a successful ESR process is selecting a compatible slag. In this study, several different slag chemistries are evaluated for their compatibility with Nitinol. One slag chemistry is chosen, along with a control, to produce four Nitinol ESR ingots. Pursuit of a novel slag chemistry for adequate Nitinol refinement is discussed.

Fezi, Kyle↗
DOE OSTI2023

One System, Many Models: Designing a Surrogate Model for Sulfur Thermal Energy Storage: Preprint

Industrial process heating (IPH) relies primarily on thermal energy generated by fossil fuel combustion to produce, treat, and alter manufactured goods. Thermal energy storage (TES) helps reduce the carbon footprint of IPH systems by facilitating the utilization of renewable and waste heat sources. A promising new TES technology uses elemental sulfur as the heat-storage medium. The design of sulfur TES systems can be evaluated with the aid of computational fluid dynamics (CFD). However, the computational cost of such CFD efforts is prohibitive to comprehensive optimizations over design parameters. To reduce this computational cost, machine learning (ML) models can be developed to act as surrogates for CFD. In this paper, we describe the process of building and evaluating surrogate ML models for facilitating optimization of sulfur TES systems for IPH. To enforce the thermodynamic relationship between the two modeled quantities, we develop a hybrid model for sulfur temperature using both direct predictions of temperature and calculations of temperature from predictions of the heat transfer coefficient. The hybrid model enforces this constraint at the expense of the slightly reduced accuracy compared to two disjoint models. The overall high accuracy observed in our model evaluation demonstrates the usefulness of such surrogate modeling for studying TES systems. This work contributes to the field of TES surrogate modeling by offering a novel accurate hybrid approach to predicting simultaneously the heat transfer coefficient and temperature of the heat storage medium.

computational fluid dynamics↗
DOE OSTI2026

Induction Melter Processing Alternatives for High Level Radioactive Wastes – 26198

This work investigates the potential to vitrify nuclear fuel directly, as well as the vitrification potential associated with experimental dissolver solutions. Greater understanding of the exothermicity is needed to quantify processing risk, especially with respect to potential phase changes and associated explosion hazards present in some systems. Thermal analysis was carried out on various simulants to elucidate the exothermic reaction potential from solid metal dissolution in glass and from the drying of alternative process dissolver solutions. Results from experimental testing of simulants to demonstrate vitrification potential and compatibility indicate that alternative dissolver flowsheets suppress the heat released during processing and that common silicate- and phosphate- based glass systems are potential candidates for direct vitrification. Direct vitrification (conversion) of fuel simulants was assessed using laboratory scale glass melts to obtain qualitative information on dissolution rates and waste loadings. Initial tests were successful to dissolve and incorporate metal directly into glass, although the kinetics and limits of dissolution and incorporation into glass are not fully understood.

Amoroso, Jake [Savannah River National Laboratory ↗
DOE OSTI2024

Hydrocoals from waste biomass via catalytic hydrothermal carbonization processing

This study investigates how operating conditions (temperature and residence time) and benzoyl chloride impact hydrochar production from almond shells through hydrothermal carbonization. Carbon content rises while volatile matter decreases with increasing temperature, yielding a hydrochar with an estimated heating value of 28 MJ/kg. Elevated temperatures lower the O/C and H/C atomic ratios of hydrochars. Even at the lowest temperature under scrutiny, catalytic experiments using benzoyl chloride enhance carbonization and fuel ratio across all temperatures. Hydrochars produced through catalytic runs demonstrate elevated fuel ratios relative to those generated through noncatalytic runs, despite operating under the same conditions. These insights reveal the capacity of benzoyl chloride as a catalyst to improve hydrochar properties, suggesting its utility for advancing both the efficiency and effectiveness of hydrothermal carbonization processes.

09 BIOMASS FUELS↗
DOE OSTI2020

Temperature response and brine availability to heated boreholes in bedded salt

Abstract There is a growing need for disposal of high‐level nuclear waste. To reduce uncertainty associated with brine availability to repository excavations in salt formations, a collaboration between Sandia, Los Alamos, and Lawrence Berkeley National Laboratories is performing a series of borehole‐scale coupled process tests. Here, we report on the first round of the Brine Availability Test in Salt (BATS) project, a “shakedown” experiment called Phase 1s. Experimental testing included placing a resistive heater, a 260‐W radiative heater, and a 750‐W radiative heater within previously drilled horizontal boreholes at the Waste Isolation Pilot Plant (WIPP) while monitoring temperature and water inflow. The experiments successfully achieved the targeted temperature of 120 °C when using the 750‐W radiative heater. Simulations using FEHM (Finite Element Heat and Mass transfer code) and TOUGH‐FLAC (Transport Of Unsaturated Groundwater and Heat–Fast Lagrangian Analysis of Continua) were able to accurately predict the coupled thermo–hydro–mechanical–chemical response of salt, matching the observed temperature and brine production. Due to the extremely low permeability of salt, these systems take many years to reach steady state when perturbed by mining activities. Long‐term numerical simulations are used to develop the initial pressure and saturation conditions. The inclusion of a damaged rock zone with higher permeability around the borehole also affects the saturation and pressure distributions and plays an important role in dissipating the potential for thermal pressurization. Knowledge gained from this round of experimentation and simulation will be used to conduct the next BATS project experiment in new boreholes at WIPP.

58 GEOSCIENCES↗