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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
NASA NTRS1992

Intelligent Processing Equipment Developments Within the Navy's Manufacturing Technology Centers of Excellence

The U.S. Navy has had an active Manufacturing Technology (MANTECH) Program aimed at developing advanced production processes and equipment since the late-1960's. During the past decade, however, the resources of the MANTECH program were concentrated in Centers of Excellence. Today, the Navy sponsors four manufacturing technology Centers of Excellence: the Automated Manufacturing Research Facility (AMRF); the Electronics Manufacturing Productivity Facility (EMPF); the National Center for Excellence in Metalworking Technology (NCEMT); and the Center of Excellence for Composites Manufacturing Technology (CECMT). This paper briefly describes each of the centers and summarizes typical Intelligent Equipment Processing (IEP) projects that were undertaken.

Nanzetta, Philip↗
NASA NTRS1974

Space processing applications payload equipment study. Volume 2A: Experiment requirements

An analysis of the space processing applications payload equipment was conducted. The primary objective was to perform a review and an update of the space processing activity research equipment requirements and specifications that were derived in the first study. The analysis is based on the six major experimental classes of: (1) biological applications, (2) chemical processes in fluids, (3) crystal growth, (4) glass technology, (5) metallurgical processes, and (6) physical processes in fluids. Tables of data are prepared to show the functional requirements for the areas of investigation.

Smith, A. G.↗
DOE OSTI2017

Direct Coal -to-Liquids (CTL) for Jet Fuel Using Biomass-Derived Solvents

Battelle has demonstrated a novel and potentially breakthrough technology for a direct coal-to-liquids (CTL) process for producing jet fuel using biomass-derived coal solvents (bio-solvents). The Battelle process offers a significant reduction in capital and operating costs and a substantial reduction in greenhouse gas (GHG) emissions, without requiring carbon capture and storage (CCS). The results of the project are the advancement of three steps of the hybrid coal/biomass-to-jet fuel process to the technology readiness level (TRL) of 5. The project objectives were achieved over two phases. In Phase 1, all three major process steps were explored and refined at bench-scale, including: (1) biomass conversion to high hydrogen-donor bio-solvent; (2) coal dissolution in biomass-derived bio-solvent, without requiring molecular H 2 , to produce a synthetic crude (syncrude); and (3) two-stage catalytic hydrotreating/hydrogenation of syncrude to jet fuel and other distillates. In Phase 2, all three subsystems of the CTL process were scaled up to a pre-pilot scale, and an economic analysis was carried out. A total of over 40 bio-solvents were identified and prepared. The most unique attribute of Battelle’s bio-solvents is their ability to provide much-needed hydrogen to liquefy coal and thus increase its hydrogen content so much that the resulting syncrude is liquid at room temperature. Based on the laboratory-scale testing with bituminous coals from Ohio and West Virginia, a total of 12 novel bio-solvent met the goal of greater than 80% coal solubility, with 8 bio-solvents being as good as or better than a well-known but expensive hydrogen-donor solvent, tetralin. The Battelle CTL process was then scaled up to 1 ton/day (1TPD) at a pre-pilot facility operated in Morgantown, WV. These tests were conducted, in part, to produce enough material for syncrude-upgrading testing. To convert the Battelle-CTL syncrude into a form suitable as a blending stock for jet turbine fuel, a two-step catalytic upgrading process was developed at laboratory scale and then demonstrated at pre-pilot scale facility in Pittsburg, PA. Several drums of distillate products were produced, which were then distilled into unblended (neat) synthetic jet fuel and diesel products for a detailed characterization. Based on a detailed characterization of the synthetic jet fuel, a 20% synthetic, 80% commercial jet fuel blend was prepared, which met all specifications. An analysis of the synthetic diesel product showed that it has the promise of being a drop-in fuel as super-low (less than 15 ppm)-sulfur diesel fuel. A detailed economic analysis showed that the Battelle liquefaction process is economical at between 1000 metric tons/day (MT/day) and 2000 MT/day. The unit capital cost for Battelle CTL process for making jet fuel is 50K USD/daily bbl compared to 151K USD/daily bbl for indirect CTL, based on 2011 dollars. The jet-fuel selling cost at the refinery, including a 12% capital cost factor (which included profit), for the Battelle CTL process is 61USD/bbl (1.45 USD/gallon). This is competitive with crude oil price of 48 USD/bbl. At the same time, the GHG emissions of 3.56 MT CO 2 /MT fuel were lower than the GHG emissions of 3.79 MT CO 2 /MTfuel for petroleum-based fuels and 7.77 MT CO 2 /MT fuel for indirect CTL. Thus, the use of bio-solvents completely eliminates the need for carbon capture in the case of Battelle CTL process. The superior economics and low GHG emissions for the Battelle CTL process has thus sparked worldwide interest and some potential commercialization opportunities are emerging.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2010

Glass Ceramic Waste Forms for Combined CS+LN+TM Fission Products Waste Streams

In this study, glass ceramics were explored as an alternative waste form for glass, the current baseline, to be used for immobilizing alkaline/alkaline earth + lanthanide (CS+LN) or CS+LN+transition metal (TM) fission-product waste streams generated by a uranium extraction (UREX+) aqueous separations type process. Results from past work on a glass waste form for the combined CS+LN waste streams showed that as waste loading increased, large fractions of crystalline phases precipitated upon slow cooling. The crystalline phases had no noticeable impact on the waste form performance by the 7-day product consistency test (PCT). These results point towards the development of a glass ceramic waste form for treating CS+LN or CS+LN+TM combined waste streams. Three main benefits for exploring glass ceramics are: • Glass ceramics offer increased solubility of troublesome components in crystalline phases as compared to glass, leading to increased waste loading; • The crystalline network formed in the glass ceramic results in higher heat tolerance than glass; and • These glass ceramics are designed to be processed by the same melter technology as the current baseline glass waste form. It will only require adding controlled canister cooling for crystallization into a glass ceramic waste form. Highly annealed waste form (essentially crack free) with up to 50X lower surface area than a typical High-Level Waste (HLW) glass canister. Lower surface area translates directly into increased durability. This was the first full year of exploring glass ceramics for the Option 1 and 2 combined waste stream options. This work has shown that dramatic increases in waste loading are achievable by designing a glass ceramic waste form as an alternative to glass. Table S1 shows the upper limits for heat, waste loading (based on solubility), and the decay time needed before treatment can occur for glass and glass ceramic waste forms. The improvements are significant for both combined waste stream options in terms of waste loading and/or decay time required before treatment. For Option 1, glass ceramics show an increase in waste loading of 15 mass % and reduction in decay time of 24 years. Decay times of ≈50 years or longer are close to the expected age of the fuel that will be reprocessed when the modified open or closed fuel cycle is expected to be put into action. Option 2 shows a 2x to 2.5x increase in waste loading with decay times of only 45 years. Note that for Option 2 glass, the required decay time before treatment is only 35 years because of the waste loading limits related to the solubility of MoO 3 in glass. If glass was evaluated for similar waste loadings as those achieved in Option 2 glass ceramics, the decay time would be significantly longer than 45 years. These glass ceramics are not optimized, but already they show the potential to dramatically reduce the amount of waste generated while still utilizing the proven processing technology used for glass production.

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

Supply Chain Sustainability Analysis of Renewable Hydrocarbon Fuels via Hydrothermal Liquefaction, Combined Algal Processing, and Biochemical Conversion: Update of the 2022 State-of-Technology Cases

The Department of Energy's (DOE) Bioenergy Technologies Office (BETO) aims to develop and deploy technologies to transform renewable biomass resources into commercially viable, high-performance biofuels, bioproducts, and biopower through public and private partnerships. BETO and its national laboratory teams conduct in-depth techno-economic assessments (TEA) of biomass feedstock supply and logistics and conversion technologies to produce biofuels. There are two general types of TEAs: A design case outlines a target case (future projection) for a particular biofuel pathway. It informs R&D priorities by identifying areas in need of improvement, tracks sustainability impact of R&D, and provides goals and benchmarks against which technology progress is assessed. A state of technology (SOT) analysis assesses progress within and across relevant technology areas based on actual results at current experimental scales relative to technical targets and cost goals from design cases, and includes technical, economic, and environmental criteria as available. In addition to developing a TEA for a pathway of interest, BETO also performs a supply chain sustainability analysis (SCSA). The SCSA takes the life-cycle analysis approach that BETO has been supporting for over 20 years. It enables BETO to identify energy consumption, environmental, and sustainability issues that may be associated with biofuel production. Approaches to mitigating these issues can then be developed. Additionally, the SCSA allows for comparison of energy and environmental impacts across biofuel pathways in BETO's research and development portfolio. This technical report describes the SCSAs for the production of renewable hydrocarbon transportation fuels via a range of conversion technologies in the 2022 SOTs: (1) renewable hydrocarbon fuels via hydrothermal liquefaction (HTL) of wet sludge from a wastewater treatment plant; (2) renewable hydrocarbon fuels via biochemical conversion of herbaceous lignocellulosic biomass; (3) renewable hydrocarbon fuels via HTL of an algae/woody biomass blend; and (4) renewable hydrocarbon fuels via combined algae processing (CAP).

09 BIOMASS FUELS↗
DOE OSTI2026

Technology pathways for energy- and water-efficient controlled environment agriculture: A review of technologies, implementation pathways, and regional use cases

Controlled Environment Agriculture (CEA) offers high-yield, climate-resilient food production, but high energy and resource demands challenge its sustainability. This paper synthesizes technologies that can improve outcomes across six categories—energy, CO 2 utilization, building envelope, hardware, water, and process—plus colocation strategies. We evaluate 80 technologies and define ten implementation pathways bundling complementary technologies to reduce energy use, optimize water consumption, and minimize emissions. Regional application is demonstrated through five U.S. case studies spanning different climates. A logic framework guides pathway selection for case studies based on climate, infrastructure, and regulatory context, informing context-sensitive technology deployment. Results show energy intensity reductions of 3–55 %, ranging from energy management programs to comprehensive lighting retrofits; water savings of 20–40 % through closed-loop recirculation; and emissions reductions of 3–100 %, with strategic energy management achieving 3–5 % and renewable electricity paired with electrified heating achieving up to 100 %. Text mining revealed that energy, hardware, and process technologies account for 91 % of literature coverage. Water, building envelope, and CO 2 utilization remain underexplored, indicating priorities for future research. This integrative approach to technology assessment supports growers, developers, and policymakers in aligning CEA system design with local conditions, improving resource efficiency and addressing gaps in cross-domain technology coverage.

Controlled environment agriculture↗
DOE OSTI2011

Status and potential of atmospheric plasma processing of materials

This paper is a review of the current status and potential of atmospheric plasma technology for materials processing. The main focus is the recent developments in the area of dielectric barrier discharges with emphasis in the functionalization of polymers, deposition of organic and inorganic coatings, and plasma processing of biomaterials. A brief overview of both the equipment being used and the physicochemical reactions occurring in the gas phase is also presented. Atmospheric plasma technology offers major industrial, economic, and environmental advantages over other conventional processing methods. At the same time there is also tremendous potential for future research and applications involving both the industrial and academic world.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Develop a Simulation Framework for Understanding Physico-Chemical Processes and Optimization of CHZ' Plastic Thermolyze Technology (CRADA Final Report)

Thermolyzer(TM) technology is a third-generation, multi-reactor, oxygen-free, low pressure, slow pyrolysis process. It has proven to be remarkably versatile in successfully processing all types of hydrocarbon waste. These include all seven types of plastics, tires, auto shredder residue, carpet, electronic waste, and composites. Working with the IACMI, Thermolyzer(TM) technology has recovered the glass and carbon fibers from wind turbine blades for reuse into new applications. Its primary output is a synthesis gas that is rich in H 2 , CH 4 , and small amounts of C 2-4 aliphatic hydrocarbons. Other components are CO and CO 2 . Three unique features set Thermolyzer(TM) apart from other pyrolysis systems: the syngas is clean enough to run in Siemens or Solar gas turbines or IC engines without fouling, clean, salable, byproducts are produced, and CO 2 emissions are lower than natural gas power plants. Research results have been obtained from an operating 7 ton/day facility. A 44 ton/day plant has successfully operated as noted above. The process works because it makes use of the recoverable embodied energy in the feedstock. Surprisingly, a pound of some plastics has the same recoverable energy content as a pound of gasoline. Thus, it is imperative to develop a process that economically converts scrap plastics (including ocean plastics) into energy and thereby conserve the non-renewable fossil fuels for future generations. The Thermolyzer(TM) technology can also be used to create liquid fuels like gasoline and diesel from hydrocarbon wastes. Because of the high hydrogen content of the synthesis gas, hydrogen can be recovered more inexpensively than the current solar or wind energy being used to electrolyze water. That hydrogen can be used for fuel cell powered vehicles or converted into ammonia for agriculture or as a hydrogen storage medium. Extension of this technology to other wastes such as tires, auto shredder residue or wood wastes would expand the circular economy.

36 MATERIALS SCIENCE↗
NASA NTRS1988

Maturity of the Bosch CO2 reduction technology for Space Station application

The Bosch process, which catalytically reduces CO2 with H2 to solid carbon and water, is a promising technique for the reduction of the CO2 removed from the Space Station atmosphere and the subsequent water formation for O2 recovery. A Bosch engineering subsystem prototype CO2 reduction unit was developed to demonstrate the feasibility of the Bosch process as a viable technology for Space Station application. A man-rated prototype unit is then described as part of the ECLSS Technology Demonstrator Program. The goal was to develop a Bosch subsystem that not only meets the performance requirements of two 60 person-day carbon cartridge capacities, but also satisfies inherent man-rated requirements such as offgassing characteristics, fail-safe operation, and ease of maintainability. It is concluded that the technology is at a state of maturity directly applicable to flight status for the NASA Space Station program.

Wagner, Robert C.↗
NASA NTRS1976

Selection of shuttle payload data processing drivers for the data system new technology study

An investigation of all payloads in the IBM disciplines and the selection of driver payloads within each discipline are described. The driver payloads were selected on the basis of their data processing requirements. These requirements are measured by a weighting scheme. The total requirements for each discipline are estimated by use of the technology payload model. The driver selection process which was both a payload by payload comparison and a comparison of expected groupings of payloads was examined.

Source record↗
NASA NTRS2016

NASA's Physics of the Cosmos and Cosmic Origins Technology Development Programs

The strategic astrophysics missions of the coming decades will help answer the questions "How did our universe begin and evolve?" and "How did galaxies, stars, and planets come to be?" Enabling these missions requires advances in key technologies far beyond the current state of the art. NASA's Physics of the Cosmos (PCOS) and Cosmic Origins (COR) Program Offices manage technology maturation projects funded through the Strategic Astrophysics Technology (SAT) program to accomplish such advances. The PCOS and COR Program Offices, residing at the NASA Goddard Space Flight Center (GSFC), were established in 2011, and serve as the implementation arm for the Astrophysics Division at NASA Headquarters. We present an overview of the Programs' technology development activities and the current technology investment portfolio of 23 technology advancements. We discuss the process for addressing community-provided technology gaps and Technology Management Board (TMB)-vetted prioritization and investment recommendations that inform the SAT program. The process improves the transparency and relevance of our technology investments, provides the community a voice in the process, and promotes targeted external technology investments by defining needs and identifying customers. The Programs' priorities are driven by strategic direction from the Astrophysics Division, which is informed by the National Research Council's (NRC) "New Worlds, New Horizons in Astronomy and Astrophysics" (NWNH) 2010 Decadal Survey report [1], the Astrophysics Implementation Plan (AIP) [2] as updated, and the Astrophysics Roadmap "Enduring Quests, Daring Visions" [3]. These priorities include technology development for missions to study dark energy, gravitational waves, X-ray and inflation probe science, and large far-infrared (IR) and ultraviolet (UV)/optical/IR telescopes to conduct imaging and spectroscopy studies. The SAT program is the Astrophysics Division's main investment method to mature technologies that will be identified by study teams set up to inform the 2020 Decadal Survey process on several large astrophysics mission concepts.

SPIE paper↗
DOE OSTI2025

Regulatory Sandboxes and Other Processes to Expedite Utility Adoption of Advanced Grid Technologies

Advanced grid technologies are increasingly important to enable electric transmission and distribution systems to meet growing demands. However, traditional regulatory processes typically lag technological advancements. Regulatory sandboxes, which provide a structured environment for testing new technologies and business approaches under modified rules to increase the speed of adoption, aim to bridge the gap between grid needs and opportunities to deliver solutions at scale. This report examines the role of regulatory sandboxes in promoting utility innovation, highlights examples of successful sandbox mechanisms, and provides emerging best practices for designing and implementing regulatory sandboxes.

24 POWER TRANSMISSION AND DISTRIBUTION↗
NASA NTRS1980

Industrial storage applications overview

The implementation of a technology demonstration for the food processing industry, development and technology demonstrations for selected near-term, in-plant applications and advanced industrial applications of thermal energy storage are overviewed.

Duscha, R. A.↗
NASA NTRS1982

Membrane separation technology in the 1980s

The current status of membrane technology is assessed and industrial processes in which membrane technology could effect energy savings or other advantages are identified. The extension of current trends is recommended; i.e., the development of ultrathin and highly permselective membranes, the use of specific carriers to enhance permselectivity and permit 'uphill' diffusion, and the improvement of separation efficiency. Membranes are predicted to be important in biotechnology and in the production of solar energy. Guidelines indicating where and how to look for opportunities where evolving membrane technology might fit are provided.

Lonsdale, H. K.↗
DOE OSTI2012

High Magnetic Field Processing - A Heat-Free Heat Treating Method

The High and Thermal Magnetic Processing/Electro-magnetic Acoustic Transducer (HTMP/EMAT) technology has been shown to be an enabling disruptive materials processing technology, that can achieve significant improvements in microstructure and consequently material performance beyond that achievable through conventional processing, and will lead to the next generation of advanced performance structural and functional materials. HTMP exposure increased the reaction kinetics enabling refinement of microstructural features such as finer martensite lath size, and finer, more copious, homogeneous dispersions of strengthening carbides leading to combined strength and toughness improvements in bainitic steels. When induction heating is applied in a high magnetic field environment, the induction heating coil is configured so that high intensity acoustic/ultrasonic treatment occurs naturally. The configuration results in a highly effective electromagnetic acoustical transducer (EMAT).

Electron Microscopy↗
DOE OSTI2019

Catalytic Upgrading of Thermochemical Intermediates to Hydrocarbons (Final Report)

A lot of activity in catalytic pyrolysis and hydroprocessing occurred in the past 10-15 years with notable successes and failures; however, very little technical information is available in the open literature from pilot-scale studies such as those performed in this project. Besides, the next step along the technology commercialization pathway is to scale-up the catalytic biomass pyrolysis process, integrate this technology with a hydroprocessing unit, and demonstrate the long-term operation and performance of the integrated process; notably, these were achieved in this project. RTI International has developed a single-step catalytic biomass pyrolysis process to produce a hydrocarbon-rich bio-crude intermediate. This bio-crude is more thermally stable and has lower oxygen content than conventional biomass fast pyrolysis oil, so it can be effectively and efficiently upgraded with traditional hydroprocessing technology to produce gasoline and diesel. Our partner, Haldor Topsøe, has developed a strategy for hydroprocessing bio-crude intermediates based on extensive catalyst and process development in support of converting vegetable oils and waste greases into high-quality diesel fuel. The goal of the originally proposed project was to demonstrate an advanced biofuels technology that integrates a catalytic biomass pyrolysis step and a hydroprocessing step to produce infrastructure-compatible biofuels. The specific technical goals of this project were 1) to optimize the catalytic biomass pyrolysis process to achieve high degree of deoxygenation, while maximizing the bio-crude production, 2) improve bio-crude thermal stability, 3) evaluate the impact of bio-crude quality in the hydroprocessing step, 4) minimize hydrogen demand of the integrated process, and 5) maximize biofuels yields. This project showed that it is technically feasible to use non-zeolitic solid acid catalyst to consistently generate bio-crude with 20% oxygen content and that these liquids can be effectively hydrotreated into low oxygen fuel blendstocks. The reproducibility of the small-scale pyrolysis yields at the 1 tonne/day scale is an achievement worth noting and the effect of pyrolysis temperature on biocrude yields and quality was investigated at the pilot scale. Additionally, advanced analytical techniques were used to analyze bio-crude to investigate the effect of process conditions and feedstock on the concentration and speciation of oxygen-containing compounds. Insights into the impact of oxygen content and oxygen speciation on bio-crdue upgrading were also sought. Clearly, more successful upgrading correlated with bio-crudes with lower oxygen content. This was most evident when partially upgraded bio-crude with 55-90% less oxygen compared to the starting bio-crude was blended with straight run diesel and hydrotreated without any noticeable increase in pressure drop across the reactor or any measurable loss of hydrodenitrification (HDN) activity. Minimizing hydrogen demand while maximizing biofuels yield are the desired outcomes for the integrated process. In summary, several technical challenges remain before catalytic biomass pyrolysis becomes a commercial reality, most notably bio-crude yields and quality still need to be improved. The integrated catalytic biomass pyrolysis hydroprocessing scheme being developed produces intermediates that can be refined for use as drop-in hydrocarbon replacement fuels. From a technology perspective, this advanced biofuel technology produces liquid transportation fuels that can leverage capital expenditures in the existing petroleum refining and distribution infrastructure. From a business perspective, this technology does not face potential market limitations as other nonhydrocarbon biofuels caused by oxygenated blending limitations and fuel certification for light-duty vehicle applications.

09 BIOMASS FUELS↗
NASA NTRS1994

Influence of technology on magnetic tape storage device characteristics

There are available today many data storage devices that serve the diverse application requirements of the consumer, professional entertainment, and computer data processing industries. Storage technologies include semiconductors, several varieties of optical disk, optical tape, magnetic disk, and many varieties of magnetic tape. In some cases, devices are developed with specific characteristics to meet specification requirements. In other cases, an existing storage device is modified and adapted to a different application. For magnetic tape storage devices, examples of the former case are 3480/3490 and QIC device types developed for the high end and low end segments of the data processing industry respectively, VHS, Beta, and 8 mm formats developed for consumer video applications, and D-1, D-2, D-3 formats developed for professional video applications. Examples of modified and adapted devices include 4 mm, 8 mm, 12.7 mm and 19 mm computer data storage devices derived from consumer and professional audio and video applications. With the conversion of the consumer and professional entertainment industries from analog to digital storage and signal processing, there have been increasing references to the 'convergence' of the computer data processing and entertainment industry technologies. There has yet to be seen, however, any evidence of convergence of data storage device types. There are several reasons for this. The diversity of application requirements results in varying degrees of importance for each of the tape storage characteristics.

Gniewek, John J.↗