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DOE OSTI2021

Multifunctional Conjugated Ligand Engineering for Stable and Efficient Perovskite Solar Cells

Surface passivation is an effective way to boost the efficiency and stability of perovskite solar cells (PSCs). However, a key challenge faced by most of the passivation strategies is reducing the interface charge recombination without imposing energy barriers to charge extraction. Here, a novel multifunctional semiconducting organic ammonium cationic interface modifier inserted between the light-harvesting perovskite film and the hole-transporting layer is reported. It is shown that the conjugated cations can directly extract holes from perovskite efficiently, and simultaneously reduce interface non-radiative recombination. Together with improved energy level alignment and the stabilized interface in the device, a triple-cation mixed-halide medium-bandgap PSC with an excellent power conversion efficiency of 22.06% (improved from 19.94%) and suppressed ion migration and halide phase segregation, which lead to a long-term operational stability, is demonstrated. Finally, this strategy provides a new practical method of interface engineering in PSCs toward improved efficiency and stability.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Experimental study of the impact of scavenging efficiency on diesel combustion in an opposed-piston two-stroke engine

The opposed-piston two-stroke (OP2S) engine is a promising alternative powertrain technology that can offer thermal and brake efficiency improvements over conventional four-stroke engines. In recent years, many of the technical barriers of the OP2S engine architecture have been overcome. However, there is still a need for fundamental studies to provide insight into the scavenging and combustion processes of the OP2S engine to help design and operate the most efficient combustion systems using this engine architecture. This work aims to provide such insights by analyzing experimental data collected on a 3-cylinder, 4.9 L OP2S engine. Specifically, a scavenging efficiency sweep, an engine speed sweep with a constant scavenging efficiency, and an engine speed with a constant pressure differential across the engine were studied in detail. It was found that in diesel combustion, as the scavenging efficiency decreased, the increase in temperature of the hot, internal residuals resulted in a significant increase in heat transfer. Despite lowering pumping losses, this resulted in an overall decrease in brake efficiency. When the bulk thermodynamic conditions of two different scavenging efficiency cases (67% and 72%) were matched at port closing, the lower scavenging efficiency case still displayed a 0.7 percentage point penalty in net thermal efficiency and an increase in engine-out indicated specific emissions of NOx of 18% due to residual stratification in the cylinder. The results presented in this work show that the optimal breathing strategy in diesel combustion on an OP2S engine architecture is one that results in a slightly under-scavenged environment at port closing. However, the results did show potential system-level efficiency benefits of decreasing scavenging efficiency, meaning that alternative fuels and combustion strategies without the constraints of diesel combustion could achieve system-level efficiency gains by running significantly under-scavenged.

Engineering↗

DOE OSTI2022

Enhanced delivery of engineered Fe-Mn binary oxides in heterogeneous porous media for efficient arsenic stabilization

Heterogeneity in sediment and aquifer is universal, resulting in preferential flows of injected materials in the high permeability regions and forming flow by-passed zones in the low permeability regions during in-situ subsurface remediation. This adverse effect can considerably delay the completion of remedial operations and significantly increase the cost. Column experiments were designed and conducted to study the transport of starch- and starch-xanthan gum modified Fe-Mn binary oxide particles (SFM and SXFM) in saturated heterogeneous porous media and to reveal the particles’ arsenic (As) stabilization performance. Fine-in-Coarse (FIC) and Coarse-in-Fine (CIF) patterns of heterogeneous packings were set up in the columns. Testing results demonstrated that starch-xanthan gum dual treatment on Fe-Mn binary oxides successfully improved the particles’ migration capability in heterogeneous porous media and their distribution uniformity attributed to the profound shear thinning behavior of xanthan gum solution. The addition of xanthan gum to the system increased the viscosity and shear thinning property of SXFM suspension, making it a better candidate for delivery. Both SFM and SXFM stabilized As in heterogeneously packed sediment collected from a contaminated site, with SXFM showing better stabilization performance than SFM. The stabilization effects of SXFM were 90.7-97.0%, compared to 82.0-95.2% of SFM.

Yan, Xiulan↗

DOE OSTI2021

Fuel Property Effects on Knock Propensity and Thermal Efficiency in a Direct-Injection Spark-Ignition Engine

Engine knock remains one of the major barriers to further improvement in thermal efficiency of Direct-Injection Spark-Ignition (DISI) engines. While Research Octane Number and Motor Octane Number are often used as standard rating methods for knock resistance of fuels, the impacts of other fuel properties on knock propensity in modern engines such as heat of vaporization (HoV) and laminar flame speed (LFS) require better understanding in order to co-optimize fuels and engine designs to achieve higher thermal efficiency and lower CO2 emission. In the present study, computational fluid dynamics (CFD) is used to model a boosted DISI engine with a focus on knock prediction and fuel property effects. A level-set G-equation model is employed to capture turbulent premixed combustion, and is coupled with a transported Livengood-Wu (L-W) integral approach to predict autoignition in the unburnt region. A criterion associated with the L-W integral is developed to accurately predict knock onset and knock-limited spark-advance. This model is then applied to a sensitivity analysis of HoV and LFS on knock tendency and thermal efficiency. The pressure-temperature trajectory framework is applied and extended to study the fuel effects on auto-ignition process in the engine. An existing efficiency-based merit function, which is derived from experiments for boosted SI engines, is evaluated and improved based on the current CFD results.

DISI↗

DOE OSTI2020

SENSITIVITY ANALYSIS OF FUEL PHYSICAL PROPERTY EFFECTS ON SPARK IGNITION ENGINE PERFORMANCE

Alternative fuels are of interest to automakers and regulators due to their potential to reduce net greenhouse gas emissions from transportation sources. Alternative fuels also have fuel properties which may enable advanced combustion modes with higher engine thermal efficiencies. There has been previous work to identify the relationship between various fuel properties and engine performance, but most of this work has been experiments or simulations where the change in properties was obtained through changing the fuel composition, making isolating the effects of individual fuel properties difficult. In this study, numerical simulations have been used to investigate the effects of individual fuel physical properties such as viscosity or heat of vaporization (HoV) on engine performance. Simulations have been performed of two different engine platforms, the first an optical, single-cylinder research engine and the second a multi-cylinder production engine. Both engines are direct-injection spark-ignition engines with pent-roof heads and are designed for automotive applications. Each engine was run at a different operating condition, one stable and one knock-limited. Different base fuels provided a variety of simulated conditions. Up to six different fuel properties were varied as part of Global Sensitivity Analyses performed for each of the engines with multiple performance targets including thermal efficiency, combustion efficiency and combustion phasing. Results show trends that are largely consistent with previous experimental findings using multiple fuels. The engine thermal efficiency was primarily sensitive to the fuel's HoV, with other fuel physical properties having smaller effects. For optical engine results, the magnitude of the effect was greater in this study than expected based on previous experimental results were many fuel physical and chemical properties were varied simultaneously. However, for the multi-cylinder production engine, the relationship between thermal efficiency and HoV was slightly smaller.

engine simulation↗

DOE OSTI2026

Evaluating the efficiency of touch-spun scaffolds in producing dense cell cultures for tissue engineering applications

Developing efficient scaffolds for long-term cell cultivation remains a challenge in tissue engineering. Biomimetic approaches aim to create a three-dimensional (3D) extracellular matrix (ECM)-like fiber network with a tunable hierarchical structure to promote sufficient cell attachment, differentiation, and overall viability. Among the fiber fabrication methods documented in the literature, mechanical fiber drawing techniques, such as touch-spinning, have garnered significant research interest. This is due to the simplicity of the equipment, the ability to control fiber diameter and interfiber spacing at the nanoscale without the need for external fields, and the absence of specific requirements for material dielectric properties. Despite the advantages of mechanically drawn scaffolds in biomedical research, the methodologies for cell culturing and analysis for these materials have not been adequately addressed. In this study, we assess the potential of touch-spun scaffolds in promoting NIH/3T3-GFP fibroblast cell growth for tissue engineering applications. Polycaprolactone/polyethylene oxide (PCL/PEO)-based fiber arrays with a controlled interfiber spacing of 91.9 ± 25.0 μm (N = 50) were fabricated using a modified touch-spinning apparatus and then assembled into 2D and 3D scaffolds through additive manufacturing technology. A comparative cell analysis conducted for single- and multi-layered structures showed that the 3D touch-spun scaffolds support healthy growth of up to 6.5 million fibroblast cells within 21 days and offer enhanced cell viability compared to conventional 2D fiber scaffolds, as confirmed by the Presto Blue assay. Furthermore, the metabolic activity of fibroblasts on 3D scaffolds assessed by the MTT test is approximately four times higher than that of the positive control, making the 3D touch-spun materials ideal for long-term cell culture applications.

Peranidze, Kristina [University of Georgia, Athens↗

DOE OSTI2022

Doubling off-axis electron cyclotron current drive efficiency via velocity space engineering

For the first time, experiments on the DIII-D tokamak have demonstrated electron cyclotron current drive with more than double the conventional efficiency by tailoring the wave–particle interactions in velocity space using a novel ‘top launch’ geometry. Steering the EC waves to propagate nearly parallel to the resonance drives current more efficiently by (1) selective damping on electrons with higher parallel velocity v ||, and (2) longer absorption path to compensate for inherently weaker absorption at higher v ||. Experiments using a fixed-injection top launch system find an optimal velocity space interaction for maximum current drive efficiency at ρ ~ 0.5 where the ease of drawing out a high v || electron tail is balanced by sufficient absorption.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

Development of an Efficient Conjugate Heat Transfer Modeling Framework to Optimize Mixing-Limited Combustion of Ethanol in a Diesel Engine

Mixing controlled combustion of alcohol fuels has been identified as a promising technology based on their low propensity for particulate and NOx production, but the higher heats of vaporization and auto-ignition temperatures of these fuels make their direct use in diesel engine architectures a challenge. To realize the potential of alcohol-fueled combustion, a computational fluid dynamics (CFD) modeling framework is developed, validated, and exercised to identify designs that maximize engine thermal efficiency. To evaluate the use of thermal barrier coatings (TBCs), a simplified one-dimensional (1D) conjugate heat transfer (CHT) modeling framework is employed. The addition of the 1D CHT model only increases the computational expense by 15% relative to traditional approaches, yet offers more accurate heat transfer predictions over constant temperature boundary conditions. The validated model is then used to explore a range of injector orientations and piston bowl geometries. Using a design of experiments (DoE) approach, several designs were identified that improved fuel-air mixing, shortened the combustion duration, and increased thermal efficiency. The most promising design was fabricated and tested in a Caterpillar 1Y3700 single-cylinder oil test engine (SCOTE). Engine testing confirmed the findings from the CFD simulations and found that the co-optimized injector and piston bowl design yielded over 2-percentage point increase in thermal efficiency at the same equivalence ratio (0.96) and over 6-percentage point increase at the same engine load (10.1 bar indicated mean effective pressure (IMEP)), while satisfying design constraints for peak pressure and maximum pressure rise rate.

Magnotti, Gina M.↗

DOE OSTI2021

Integrated Magnetics Design for a Three-Phase Differential-Mode Rectifier

Not Available

42 ENGINEERING↗

DOE OSTI2020

TAILORED BIOBLENDSTOCKS WITH LOW ENVIRONMENTAL IMPACT TO OPTIMIZE MCCI ENGINES

The overall objective of the project is to develop and demonstrate a microalgae bio-blendstock with greater than 60% greenhouse gas reduction potential relative to petroleum diesel, that can reduce sooting propensity, increase cetane number and improve engine thermal efficiency relative to a baseline diesel engine operating on conventional fuel. Specific objectives include: (1) development of a new framework for both LCA and TEA that explicitly considers temporal variation in productivity and the frequency of crop loss; (2) determination of how fuel compounds that can be produced from the algal biomass can be ‘bio-tailored’ based on the species composition and biological production process, and subsequent processing via HTL to biocrude, and upgrading of the biocrude; (3) execution of a feedback loop (algae production  biocrude refining  combustion optimization  feedback to refining stage), for optimization of fuels for MCCI combustion; (4) optimization of MCCI combustion and emissions performance, accounting first for the biological processes that dictate the chemical composition of biocrude oil, and second for the subsequent chemical processes that comprise mixing controlled compression ignition combustion; (6) simulation of MCCI engine combustion processes to demonstrate the incorporation of relevant fuel chemistry that captures the specific impacts of optimized algal fuels.

09 BIOMASS FUELS↗

DOE OSTI2023

Tailored Bioblendstocks With Low Environmental Impact To Optimize MCCI Engines

The prohect goal is to develop and demonstrate a microalgae bio-blendstock with greater than 60% greenhouse gas reduction potential relative to petroleum diesel, that can reduce sooting propensity, increase cetane number and improve engine thermal efficiency relative to a baseline diesel engine operating on conventional fuel.

09 BIOMASS FUELS↗

DOE OSTI2021

Tailored Bioblendstocks With Low Environmental Impact To Optimize MCCI Engines

This project seeks to overcome impediments to expansion of algae cultivation and conversion into fuels to displace petroleum and reduce greenhouse gas (GHG) emissions. The overall objective of the project is to develop and demonstrate a microalgae bio-blendstock with greater than 60% greenhouse gas reduction relative to petroleum diesel, reduce sooting propensity, increase cetane number, improve engine thermal efficiency relative to a baseline diesel engine operating on conventional fuel. These objectives are being accomplished by: Applying cultivation of algae polycultures to achieve robustness and productivity, Converting whole algae to bio-hydrocarbons via Hydrothermal Liquefaction (HTL) to make a biocrude and up-grading the biocrude via hydroprocessing to obtain tailored bioblendstocks for diesel fuel, Optimizing diesel (MCCI) combustion through blending model compounds into diesel fuel to represent the tailored bioblendstocks through experiments and numerical simulation.

09 BIOMASS FUELS↗

DOE OSTI2020

Tailored Bioblendstocks with Low Environmental Impact to Optimize MCCI Engines

09 BIOMASS FUELS↗

DOE OSTI2023

Tailored Bioblendstocks with Low Environmental Impact to Optimize MCCI Engines (Final Technical Report)

09 BIOMASS FUELS↗

DOE OSTI2021

Process for retrofitting an industrial gas turbine engine for increased power and efficiency

A process for retrofitting an industrial gas turbine engine of a power plant where an old industrial engine with a high spool has a new low spool with a low pressure turbine that drives a low pressure compressor using exhaust gas from the high pressure turbine, and where the new low pressure compressor delivers compressed air through a new compressed air line to the high pressure compressor through a new inlet added to the high pressure compressor. The old electric generator is replaced with a new generator having around twice the electrical power production. One or more stages of vanes and blades are removed from the high pressure compressor to optimally match a pressure ratio split. Closed loop cooling of one or more new stages of vanes and blades in the high pressure turbine is added and the spent cooling air is discharged into the combustor.

Jones, Russell B.↗

DOE OSTI2023

High-throughput genetic engineering of nonmodel and undomesticated bacteria via iterative site-specific genome integration

Efficient genome engineering is critical to understand and use microbial functions. Despite recent development of tools such as CRISPR-Cas gene editing, efficient integration of exogenous DNA with well-characterized functions remains limited to model bacteria. Here, we describe serine recombinase–assisted genome engineering, or SAGE, an easy-to-use, highly efficient, and extensible technology that enables selection marker–free, site-specific genome integration of up to 10 DNA constructs, often with efficiency on par with or superior to replicating plasmids. SAGE uses no replicating plasmids and thus lacks the host range limitations of other genome engineering technologies. We demonstrate the value of SAGE by characterizing genome integration efficiency in five bacteria that span multiple taxonomy groups and biotechnology applications and by identifying more than 95 heterologous promoters in each host with consistent transcription across environmental and genetic contexts. We anticipate that SAGE will rapidly expand the number of industrial and environmental bacteria compatible with high-throughput genetics and synthetic biology.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2022

Effects of a CFD-improved dimple stepped-lip piston on thermal efficiency and emissions in a medium-duty diesel engine

Diesel piston-bowl shape is a key design parameter that affects spray-wall interactions and turbulent flow development, and in turn affects the engine’s thermal efficiency and emissions. It is hypothesized that thermal efficiency can be improved by enhancing squish-region vortices as they are hypothesized to promote fuel-air mixing, leading to faster heat-release rates. However, the strength and longevity of these vortices decrease with advanced injection timings for typical stepped-lip (SL) piston geometries. Dimple stepped-lip (DSL) pistons enhance vortex formation at early injection timings. Previous engine experiments with such a bowl show 1.4% thermal efficiency gains over an SL piston. However, soot was increased dramatically [SAE 2022-01-0400]. In a previous study, a new DSL bowl was designed using non-combusting computational fluid dynamic simulations. This improved DSL bowl is predicted to promote stronger, more rotationally energetic vortices than the baseline DSL piston: it employs shallower, narrower, and steeper-curved dimples that are placed further out into the squish region. In the current experimental study, this improved bowl is tested in a medium-duty diesel engine and compared against the SL piston over an injection timing sweep at low-load and part-load operating conditions. No substantial thermal efficiency gains are achieved at the early injection timing with the improved DSL design, but soot emissions are lowered by 45% relative to the production SL piston, likely due to improved air utilization and soot oxidation. However, these benefits are lost at late injection timings, where the DSL piston renders a lower thermal efficiency than that of the SL piston. Energy balance analyses show higher wall heat transfer with the DSL piston than with the SL piston despite a 1.3% reduction in the piston surface area. Vortex enhancement may not necessarily lead to improved efficiency as more energetic squish-region vortices can lead to higher convective heat transfer losses.

42 ENGINEERING↗

DOE OSTI2021

Electrochemically Engineered, Highly Energy-Efficient Conversion of Ethane to Ethylene and Hydrogen below 550 °C in a Protonic Ceramic Electrochemical Cell

Ethylene is one of the largest building blocks in the petrochemical industry, mainly produced by steam cracking of ethane derived from naphtha or shale gas at high temperatures (>800 °C). Despite its technical maturity and economic competitiveness, the thermal steam cracking of ethane is highly energy-intensive. In this work, an electrochemically engineered direct conversion process of ethane to produce hydrogen and ethylene using a planar protonic ceramic membrane reactor with a bi-functional three-dimensional catalytic electrode is reported, with a single-pass ethane conversion of 40% and ethylene yield of 26.7% at 550 °C. Compared with the industrial ethane steam cracking, this method saves process energy input by 45.1% and improves process energy efficiency by 50.6%, based on comprehensive process simulation using Aspen Plus software. Further, steam electrolysis treatment under the solid oxide electrolysis cell mode can regenerate the system’s catalytic performance and significantly alleviate catalytic degradation by 74%, demonstrating high techno-economic viability.

bi-functional electrode↗