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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Feasibility Assessment and Preliminary Design of a Low Cost, Modular Concrete, Suction Pile Support Structure and Heavy Lift Vessel Alternative (CRADA Final Report)

The project goal is to prove the feasibility and advance the development of a low-cost, modular concrete suction pile support structure and heavy lift vessel alternative for offshore wind deployment in the United States. These technology developments are critical to alleviating specific challenges faced by the United States market, including a limited number of Jones Act-compliant installation vessels and environmental restrictions associated with using conventional offshore wind foundations. The first phase of this project is a conceptual design and feasibility assessment of modular concrete substructure options for NREL’s 15 MW reference turbine.

17 WIND ENERGY↗
DOE OSTI2020

Thin Film Hydrogen Sensor Development, Testing and Integration Into Low Cost Wireless Sensing Systems (SBIR Phase 1 Final Report)

Element One, Inc. is reporting on the results of its DOE SBIR Phase I project for the development and testing of low-cost thin film hydrogen sensors and their subsequent integration into wireless sensing systems and networks. This work is based on Element One’s chemo-chromic sensing technology which indicates hydrogen presence (leaks) colorimetrically and electronically with no power required. The lack of required power makes them particularly suitable for passive Radio Frequency Identification Device (RFID) technology which can be deployed affordably and abundantly to detect leaks in hazardous environments. Element One built upon its experience with chemochromic materials that change color in the presence of hydrogen. Both thin films and pigments have been used, but thin films have the ability to change conductivity by more than three orders of magnitude making them ideal for resistive sensors. Prototype sensors were fabricated, tested and characterized. For the wireless component, Element One partnered with Esensor, Inc. to construct and test a wireless sensing network. The network was tested and validated at the National Renewable Energy Laboratory (NREL) in February and March. The tests involved exposing the wireless system to hydrogen gas concentrations of 1% and 5%. There were no significant problems encountered, and the system is ready for commercial development. The system demonstrated the viability of wireless hydrogen sensing networks for hydrogen leak detection and other applications.

08 HYDROGEN↗
DOE OSTI2020

A versatile and low-cost chip-to-world interface: enabling ICP-MS characterization of isotachophoretically separated lanthanides on a microfluidic device

Microfluidics offer novel and state-of-the-art pathways to process materials. Microfluidic systems drastically reduce timeframes and costs associated with traditional lab-scale efforts in the area of analytical sample preparations. The challenge arises in effectively connecting microfluidics to off-chip analysis tools to accurately characterize samples after treatment on-chip. Here, a fused silica microfluidic device (MFD) is connected to a fused-silica capillary in order to create a world-to-chip connection between the MFD and an inductively coupled plasma mass spectrometer (ICP-MS). Specifically, this is demonstrated by utilizing isotachophoresis (ITP) on a microfluidic chip to separate samples containing up to 14 lanthanides into elementally pure bands. The separated sample is successfully transferred across a 7 nL dead space at the microchip-capillary junction, such that separation resolution is maintained and even increased through the interface and into the ICP-MS, where the elemental composition of the separated sample is analysed. Lanthanide samples of varying composition are detected using ICP-MS, demonstrating this versatile and cost-effective approach that does not degrade the separation quality achieved on the MFD. This simple and inexpensive connection enables fast, low-cost sample preparation immediately prior to injection into an ICP-MS or other analytical instruments.

Lackey, Hope E.↗
DOE OSTI2022

An Integrated Flame Spray Process for Low Cost Production of Battery Materials for Lithium Ion Batteries and Beyond

The overall objective of this project was to develop an advanced manufacturing technology for Li-ion battery materials production at low cost and in a green chemical process using glycerol as solvent to replace water. It was aimed at developing a prototype pilot production line to reduce production cost by at least 25% to the baseline. During the course of this project, research was conducted to understand spray drying and combustion of eutectic solvent precursors of glycerol and metal salts (acetates) in the formation of mixed metal oxide powders. Reactor design and optimization were done to facilitate spray drying and combustion in powder formation and processing. Various cathode materials powders were produced, including lithium nickel-cobalt-manganese oxide (NCM) and lithium nickel-cobalt-aluminum oxide (NCA). These cathode materials powders were tested in half coin cells for their performances, with materials performances of 160 mAh/g for NCM111 and 200 mAh/g for NCA. NCA powders were also produced using a slurry spray-drying process and tested in full pouch cells. A pilot scale flame assisted spray drying reactor was constructed and demonstrated for its production rate exceeding the target of production rate of four metric tons per year. The work performed in this project has been documented in 9 peer reviewed journal publications, 8 conference presentations, and two IP disclosures/patent applications.

25 ENERGY STORAGE↗
DOE OSTI2022

Energy-effective and low-cost carbon capture from point-sources enabled by water-lean solvents

Aqueous amines, as the most mature carbon capture technology, are subject to high energy and cost penalties due to the large water content in their formulations. Emerging technologies are in demand to enable a transition to a low-carbon global economy. However, rigorous process modeling and techno-economic analyses are limited for emerging carbon capture technologies. Here, four CO 2 -Binding Organic Liquids (CO 2 BOLs), all water-lean solvents were presented as promising options towards energy-effective and low-cost carbon capture from point sources. Rigorous solvent property and process models were developed in Aspen Plus for a coal-fired power plant with CO 2 BOL-based carbon capture unit. Techno-economic analyses were conducted in 2018 US pricing basis. The results suggest that water-lean formulations can minimize water condensation and vaporization, leading to a 36% energy saving compared with aqueous amines. Indeed, these CO 2 BOLs can capture up to 97–99% CO 2 from coal fired plant. The estimated carbon capture cost is about $40/tonne CO 2 at 90–97% carbon capture rate, about 12–23% less expensive than the conventional aqueous amine technology. The comparison between these CO 2 BOLs showed that in addition to vapor liquid equilibrium and kinetics (key properties for aqueous solvents), viscosity, volatility, and hydrophobicity, also have strong impacts on the performance of water-lean solvents. The methods presented in this work can be used to evaluate other emerging carbon capture technologies, while the results linking costs and performance of carbon capture solvents with their properties. Additionally, this work identifies research directions and targets for further reductions in total costs of capture from either cost or energy perspectives for these leading water-lean solvents.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Na-FeCl2 Batteries: A Low-Cost Durable Na-FeCl2 Battery with Ultrahigh Rate Capability (Adv. Energy Mater. 10/2020)

In article 1903472, Guosheng Li and co-workers report an advanced high-rate Na-FeCl2 battery using low cost NaCl and crust-rich Fe as cathode materials. The fast-charging capability of the Na-FeCl2 battery, rooted in a fast Fe/Fe2+ redox reaction, rapid NaCl-Na6FeCl8-FeCl2 phase transitions, and quick Fe2+ lattice diffusion within FeCl2, revamps the understanding of Na-metal halide batteries.

Zhan, Xiaowen↗
DOE OSTI2021

Deactivation and Cathode-Healing™ to support the Low-Cost US Supply Chain

Lithium-ion recycling is challenged by cost and safety related to reactivity of lithium and electrolytes. OnTo’s deactivation eliminates flammability and residual reactivity enabling a roadmap for safe, low-cost end-of-life battery services essential to the industry. Deactivation coupled with Cathode-healing provides safety and efficiency in material recycling that can be applied all along the manufacturing value chain. Dr. Sloop will present recent developments in application and scale of these innovative technologies.

25 ENERGY STORAGE↗
DOE OSTI2023

A low-cost and realistic noisy light system for studying photosynthesis

Unlike the light conditions commonly used to grow photosynthetic organisms in the research laboratory, the light intensity in real environments is dynamic. A simple and low-cost system is described in which a commercial dimmable LED panel is controlled to simulate a sinusoidal function representing daylight hours and overlaid with stochastic shading events. The output closely resembles light intensity measurements on Earth’s surface on partly cloudy days or in lower levels of plant canopies. Here, this tool may be useful to researchers studying photosynthetic acclimation responses.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2023

Demonstration of low-density, high-performance operation of sustained spheromaks and favorable scalability toward compact, low-cost fusion power plants (Final Scientific/Technical Report)

This project worked to advance the technical viability of a novel method for efficiently sustaining stable, high-performance spheromak plasma configurations to serve as the basis of compact, low-cost fusion power plants. In particular, our group worked to improve the method of Steady Inductive Helicity Injection (SIHI) with Imposed-Dynamo Current Drive (IDCD) for spheromak plasma sustainment. Prior to this project demonstrations of this plasma sustainment technology have achieved plasma performance consistent with entry milestone 3 of the BETHE FOA. Research and development (R&D) activities for this project were focused on increasing plasma performance toward a level consistent with exit milestone 4. To do this the PI and his group worked to increase the performance of sustained spheromaks produced in an existing experimental prototype (HIT-SIU) while improving confidence in projections to and design of future, higher performance devices through three primary R&D activities: 1) Improved control over the density of plasma in the device throughout a discharge to provide a pathway for demonstration of spheromaks Ohmically heating to the Mercier beta limit via: a. Fueling the device directly with plasma through the installation of pre-ionized source on the injectors b. Optimization of electrical current waveforms in the driver circuits to enable low-density plasma formation with a lower fueling rate 2) Computational demonstration of a validated, realistic injector circuit coupled to a dynamic plasma model capable of use as a design tool for SIHI drivers and associated circuits for new experimental design points on the pathway to commercial reactors. The improvements in plasma performance achieved during research activity 1), and the computational projections performed in research activity 2) increased the technological readiness level (TRL) of this fusion energy concept toward a level sufficient to attract early-stage private investment and/or other forms of follow-on investment to pursue required R&D activities required for the eventual fusion power plants based on this novel technical approach.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Opportunities for Utilization of Low-Cost Algae Resources: Techno-Economic Analysis Screening for Near-Term Deployment (Parts 1 and 2)

This report presents a comprehensive techno-economic analysis (TEA) for the production, collection, or procurement of several low-cost algae resources that may otherwise be considered "waste" biomass materials today, as well as the utilization of these materials through exemplary conversion processes to produce renewable fuels and chemicals. In contrast to conventional TEA models attributed to large-scale algae "farming" approaches, which may be able to produce substantially more biomass and thus fuels/products at a national scale in the future, this assessment focuses on understanding opportunities and costs for such "waste" algal biomass resources as may be available at considerably lower cost today. Economics for base case assumptions and a range of sensitivity scenarios are presented, employing conversion technologies that are simple and well understood, and thus may be deployed at smaller community scale in the near term, as a means to support and expand a nascent algae industry on the way to employing a larger commercial algae farm approach for commodity-scale production. Specifically, three algal biomass resources are considered in this assessment, as may be sourced from (1) municipal wastewater treatment (WWT) utilizing algae in place of more conventional technologies for nitrogen/phosphorus removal, (2) collection and removal of harmful algal bloom (HAB) biomass as proliferates in certain inland water bodies, and (3) procurement of residual biomass following commercial lipid extraction (EXT) operations performed at smaller scale by industry today focused on higher-value nutraceutical applications. These three resources are evaluated through two conversion pathways: (1) combined algal biomass processing (CAP) through a simple/low-complexity configuration, and (2) anaerobic digestion (AD). The CAP pathway produces liquid fuels and chemical coproducts (polymer for off-site upgrading to bioplastics), whereas the AD pathway produces biogas (specifically renewable natural gas [RNG]) and crop fertilizer coproducts. To streamline the discussion, this report is broken into two sections: Part 1 focuses on WWT-derived biomass, and Part 2 on HAB and EXT biomass.

09 BIOMASS FUELS↗
DOE OSTI2025

Low-Cost Sulfur Thermal Storage for Solar Industrial Process Heat Applications

Industrial process heat (IPH) is one of the largest energy demands in U.S., representing about 10% of all domestic energy consumption. Fuel costs to generate this industrial process heat are generally a top three cost for industry, a major component in American manufacturing competitiveness. Roughly 60% of US IPH demand (about 6,500 TBtu annually) falls in the medium-temperature range of 100–250 °C. While concentrated solar thermal (CST) technologies can provide a cost-effective source of heat in this temperature range, solar intermittency limits their adoption in industries that operate 24/7. Element 16 Technologies, Inc. developed a low-cost sulfur thermal energy storage (TES) technology to bridge this gap by capturing excess solar heat during the day and dispatching it reliably during non-solar hours. The core innovation is the use of sulfur, an abundant, industrial waste byproduct that costs ten times less than molten salt used in commercial TES systems. The overall goal of the project was to advance the design and development of molten sulfur TES to a manufacturing-relevant prototype stage for solar industrial process heat applications, while establishing and validating a realistic pathway to commercial success. Key tasks included corrosion and mechanical durability testing to identify cost-effective materials, design investigations using physics-based simulation tools, techno-economic evaluations of system lifetime costs, and pilot-scale testing for performance verification. Corrosion testing of steel alloys under cyclic molten sulfur conditions showed that austenitic stainless steels in the 300 series performed particularly well, with no structural degradation of welds or joints. Thermal cyclic testing of pilot sulfur TES units up to 1.5 MWh quantified charge/discharge rates, heat losses, round-trip efficiency and validated the system's capability to operate effectively under intermittent charging conditions. A techno-economic model, informed by sulfur TES performance model validated using pilot test data, showed that hybrid solar+sulfur TES+NG boiler systems are economically competitive with incumbent natural gas boilers for multiple locations in the southwest US. In summary, this project established molten sulfur TES as a technically viable pathway to improve economic competitiveness of American manufacturing by lowering the cost of solar industrial process heat.

14 SOLAR ENERGY↗
DOE OSTI2022

6.26 Low Cost Basalt Fiber for Automotive Applications

Vehicle lightweighting is an essential component to the automotive industry to improve fuel economy of internal combustion engine (ICE) vehicles to meet ever improving emission standards and to improve the range of electric vehicles (EV). Composite materials offer high specific modulus and specific strength, which makes them appealing for these light weighting efforts. Sheet molding compounds (SMC) are particularly interesting from an automotive perspective because of the relatively low cost and high volume of producing SMC parts. Traditionally, composite materials for automotive application are glass fiber reinforced because of the attractive price - performance ratio, but basalt fibers are a cost and recycling competitive reinforcement alternative in this market. The aim of this project was to examine the feasibility of utilizing basalt fiber for automotive applications. More specifically, an effort was made to examine different fiber sizings on basalt fiber combined with vinyl-ester (VE) resin, and their performance as part of an SMC process. In addition to offering vehicle lightweighting with fiber reinforced polymer composites, basalt fiber is a fully recyclable material and thus supports the IACMI technical goal of: Demonstrate that the technology is capable at a sufficient scale for >80% recyclability or reuse of fiber reinforced polymer composites in five years into useful components with projected cost and quality at commercial scale competitive with virgin materials on a pathway to 95% recyclability or reuse starting in ten years. Three different fiber sizings were applied to a continuous roving of basalt fiber and compared to a traditional Electrical/Chemical Resistance (E-CR) glass fiber that is typically used in these types of applications. Fiber tows were examined for Loss on Ignition percentage (LOI%), Tex, and tow strength. Some sizings clearly outperformed others, and the ability to process these fibers on a pilot scale SMC line was demonstrated. A test plan for the manufacturing and mechanical testing of SMC panels was developed. This work continues outside the time frame allocated for this project. When this work is completed, it will be added to this report and posted as Appendix C. Glass fiber reinforced SMC materials have already proven feasible as a light weighting method for traditionally steel parts like the Volkswagen (VW) Atlas lift-gate (Figure 1); this project team is seeking the feasibility of basalt fiber as a drop-in replacement for glass fiber reinforced SMC. Sizing development for basalt fibers has proven that the mechanical properties are better than E-glass and closer to S-glass, which makes it an interesting material for SMC applications. Better mechanical properties translate to less material needed to achieve load case requirement for target applications. The business case has already been demonstrated for 100,000 parts per year of glass fiber reinforced SMC Atlas lift-gates compared to traditional steel manufacturing processes. Reduced overhead and assembly costs are offset by glass fiber SMC higher cost per kg beyond 100,000 parts per year, which is still a relatively low volume for the automotive industry. For basalt fiber reinforced SMC to become feasible for automotive applications, the price-performance ratio has to be precisely determined. Based on the mechanical performance it is possible to establish a range of applications and technical solutions in which the potential of basalt SMC can be utilized, while the price of the material can be used to compile the business case for such applications. Based on these business cases and the sustainability indicators, glass fiber reinforcement (or other) materials can be directly substituted. Volkswagen’s commitment to reducing carbon emissions cannot be understated. Basalt fiber shows promise of reducing the carbon footprint in SMC materials, especially if sizing optimizations can be made with thermoplastic based SMC. To fully realize the value of basalt fiber reinforced materials, a lifecycle cost analysis should be performed on basalt’s production and recycling, and then compared against E-glass. From this assessment, a true judgement can be made on the commercialization potential of this material. Figure 1. Example of Fiber Reinforced Polymer Composite Liftgate As a conclusion, we can state that Mafic basalt fiber is not a direct replacement for E-glass or E-CR glass based on price, but should be considered a technical solution when E-glass does not provide adequate performance in a composite design and S-glass, aramid and carbon fibers are too costly. Mafic basalt fiber can be placed on the high-performance fiber spectrum next to S-glass for performance but at one third the price. It should be considered for more technically challenging structural designs wherein the performance can demonstrate 20-25% performance enhancement over E-glass to elicit more strength or a weight reduction. Both Michelman and Mafic produce thermoplastic sizings which, in combination with Nylon and polypropylene resin and fibers, can further advance high speed composite implementations while maintaining an eco-friendly manufacturing process.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Metal-Supported Ceria Electrolyte-based SOFC Stack for Scalable, Low-Cost, High-Efficiency and Robust Stationary Power Systems (Final Report)

This is the end of project report for the DOE Project DE-FE-0027844 “Metal-Supported Ceria Electrolyte-based SOFC Stack for Scalable, Low-Cost, High-Efficiency and Robust Stationary Power Systems”. The objectives of the project were to develop several technologies required for the mass adoption of Solid Oxide Fuel Cell systems for medium to large power generation applications. The key achievements of this project were: 1) Development of fuel cells with complete internal fuel reforming capability. 2) Fuel cell power scale up with production of cells with larger active areas. 3) Assembly of an integrated 5 kW modular stack platform capable of installation into medium to large power systems. 4) Demonstration of a 10 kW Fuel Cell Power System utilizing the integrated 5 kW modular stack platform. 5) Cost modelling to show system cost of $1,500/kW are achievable at production volumes. 6) Development of cathode air poison getters for reduced degradation and extended fuel cell life. 7) Assessment of fuel poison on anode degradation, particularly poisons frequently produced from the process of gasification of coal. The Cummins led Voice of Customer (VOC) work identified several significant markets for natural gas powered fuel cell systems, where the end customer is interested in reducing energy consumption and emissions, or increasing reliability of electrical supply. Data centers and truck Auxiliary Power Units (APU) were highlighted as 2 key future markets for fuel cell systems.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2024

Perovskite/Perovskite Tandem Photoelectrodes for Low-Cost Unassisted Photoelectrochemical Water Splitting

In this project, we aim to address the challenges of achieving efficient and cost-effective unassisted photoelectrochemical water splitting using perovskite/perovskite tandem photoelectrodes. We utilized the following unique approaches to advance our innovation. (1) We developed stable and efficient low-E g (1.2 – 1.4 eV) perovskites as the bottom electrodes. We demonstrated approaches to improve the photovoltaic performance and photothermal stability of low-E g Sn-Pb iodide perovskite solar cells. (2) We developed a low-temperature synthesis route to fabricate wide-E g (>1.8 eV) perovskite top electrodes. By combining theoretical and experimental investigation, we found methods to reduce the formation of defects and dislocations in the wide-E g mixed halide perovskites and suppress halide segregation. (3) We developed a robust metal oxide-based interconnecting layer to integrate two perovskite layers into tandem photoelectrodes. Our monolithically integrated tandem devices feature a high V OC of more than 2 V and a high J SC of more than 15 mA/cm 2 . We showed the new design of the tandem photoelectrodes that is critical to the stable operation of tandem photoelectrodes for unassisted PV/PEC water splitting. (4) We demonstrated a water-impermeable barrier of carbon paste/epoxy/metal foil composite, which can prevent photocorrosion and water ingress of perovskite active layers. This surface protection enabled the operation of perovskite photoelectrodes in water and significantly enhanced the long-term stability of our tandem devices. (5) We conducted standardized PEC characterization in collaboration with NREL and reported accurate determination of solar-to-hydrogen conversion efficiencies of perovskite/perovskite tandem photoelectrodes. At the end of the project, we demonstrated perovskite/perovskite tandem photoelectrodes with STH efficiencies of up to 18% and less than 20% efficiency loss after continuous operation for more than 500 hours in water. Our results demonstrate the potential to develop a low-cost, durable, and efficient water-splitting system that meets the DOE 2026 and 2031 cost targets for hydrogen production.

08 HYDROGEN↗
DOE OSTI2023

Stabilizing magnesium plating by a low-cost inorganic surface membrane for high-voltage and high-power Mg batteries

Mg batteries with halide-free electrolytes suffer from poor stability of the Mg metal anode due to electrolyte decomposition. Here, we report a low-cost zeolite membrane supported on Mg to address this challenge. It vastly reduces the population (hence decomposition) of free diglyme at the Mg/electrolyte interface, while allowing facile transport of Mg 2+ cations through the membrane. We demonstrate dendrite-free Mg plating/stripping performance in a magnesium tetrakis(hexafluoroisopropyloxy)borate/diglyme electrolyte with a 750-fold extended lifetime (over 6,000 h) and a high coulombic efficiency of ~98%. The prototype Mo 3 S 4 cathode paired with the protected Mg anode shows 91% capacity retention over 200 cycles. Importantly, this membrane protects soluble species in a high-voltage organic polymer cathode from being reduced at the anode via shuttling, achieving a full cell with a 3.5 V cutoff voltage. This results in a high specific energy density of 320 Wh kg –1 and a power density of 1,320 W kg –1 based on cathode mass.

25 ENERGY STORAGE↗
DOE OSTI2021

Technology Development for Modular, Low-Cost, High-Temperature Recuperators for Supercritical CO 2 Power Cycles (Final Report)

The program’s focus was to evaluate, advance, and demonstrate recuperator design concepts, materials, and fabrication methods that facilitate the commercial availability of compact and low-cost recuperators. Emphasis was placed on recompression closed Brayton cycles having a turbine inlet temperature exceeding 700°C and differential pressures on the order of 200 bar and were scalable to accommodate plant sizes from 10 to 1,000 MWe. The primary objectives of the first budget period, which included conceptual design, preliminary development, and prototype fabrication and testing, were accomplished. A new recuperator design concept, stacked-sheet heat exchanger (SSHX), was realized during the project. The design was taken from paper to hardware and successfully tested. The SSHX prototype recuperator met or exceeded program thermal, hydraulic and performance/cost metrics goals. The first budget period was extended to retire risk in scaling the recuperator from the kWt to MWt thermal capacity scale. The fabrication and design requirements for the budget period one extension were met. Delays associated with the Covid-19 pandemic prevented the fabrication and testing of the industrial scale prototype.

14 SOLAR ENERGY↗