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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 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Biofuel production from palm oil deoxygenation using nickel-molybdenum on zirconia catalyst using glycerol as a hydrogen donor

The growing demand for renewable energy has generated interest in biofuels as alternatives to fossil fuels. Second-generation biofuels, derived from deoxygenating fats and oils, have garnered a higher level of interest from industry and academia due to their potential for direct replacement of diesel and jet fuels. Palm oil, mostly cultivated in Thailand and composed of C16 and C18 fatty acids, is a primary feedstock sought for biofuel production. Palm oil deoxygenation contains several pathways that may or may not require hydrogen gas. This study aimed to produce biofuels in different fuel ranges, such as gasoline, jet fuel, and diesel, through palm oil deoxygenation using glycerol as a hydrogen source. Glycerol, a low-value byproduct, was used as a hydrogen donor, whereas nickel-molybdenum-supported catalysts were chosen for their high efficiency in deoxygenation and cost-effectiveness. The study investigated the impact of reaction time, temperature, and catalyst activation method on palm oil deoxygenation. Catalyst characterization methods, including XRD, SEM, TEM, XPS, FTIR, TGA, and nitrogen-sorption, were employed to understand the role of catalysts’ activity during palm oil upgrading. Findings indicated that alkane hydrocarbons are the major components in liquid products. The presence of excess hydrogen in post reaction gaseous phase proves the hydrogen donation capability of glycerol. Increased reaction time and temperature facilitated the removal of oxygen from palm oil. Nickel-molybdenum on zirconia activated by sulfidation demonstrated higher stability than by reduction activation.

09 BIOMASS FUELS↗
DOE OSTI2023

Bottlebrush Polymers at Liquid Interfaces: Assembly Dynamics, Mechanical Properties, and All-Liquid Printed Constructs

Bottlebrush polymer surfactants (BPSs), formed by the interfacial interactions between bottlebrush polymers (BPs) with poly(acrylic acid) side chains dissolved in an aqueous phase and amine-functionalized ligands dissolved in the oil phase, assemble and bind strongly to the fluid-fluid interface. The ratio between N BB (backbone degree of polymerization) and N SC (side chain degree of polymerization) defines the initial assembly kinetics, interface packing efficiency, and stress relaxation. The equilibrium interfacial tension (γ) increases when N BB < N SC , but decreases when N BB $\gg$ N SC , correlating to a pronounced change in the effective shape of the BPs from being spherical to worm-like structures. The apparent surface coverage (ASC), i.e., the interfacial packing efficiency, decreases as N BB increases. The dripping-to-jetting transition of an injected polymer solution, as well as fluorescence recovery after photobleaching experiments, revealed faster initial assembly kinetics for BPs with higher N BB . Furhter, Euler buckling of BPS assemblies with different N BB values was used to characterize the stress relaxation behavior and bending modulus. The stress relaxation behavior was directly related to the ASC, reflecting the strong influence of macromolecular shape on packing efficiency. The bending modulus of BPSs decreases for N BB < N SC , but increased when N BB $\gg$ N SC , showing the effect of molecular architecture and multisite anchoring. All-liquid printed constructs with lower N BB BPs yielded more stable structured liquids, underscoring the importance of macromolecular packing efficiency at fluid interfaces. Overall, this work elucidates fundamental relationships between nanoscopic structures and macroscopic properties associated with various bottlebrush polymer architectures, which translate to the stabilization of all-fluidic printed constructs.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

A novel path to runaway electron mitigation via deuterium injection and current-driven MHD instability

Relativistic electron (RE) beams at high current density (low safety factor, qa) yet very low free-electron density accessed with D2 secondary injection in the DIII-D and JET tokamak are found to exhibit large-scale MHD instabilities that benignly terminate the RE beam. In JET, this technique has enabled termination of MA-level RE currents without measurable first-wall heating. This scenario thus offers an unexpected alternate pathway to achieve RE mitigation without collisional dissipation. Benign termination is explained by two synergistic effects. First, during the MHD-driven RE loss events both experiment and MHD orbit-loss modeling supports a significant increase in the wetted area of the RE loss. Second, as previously identified at JET and DIII-D, the fast kink loss timescale precludes RE beam regeneration and the resulting dangerous conversion of magnetic to RE kinetic energy. During the termination, the RE kinetic energy is lost to the wall, but the current fully transfers to the cold bulk thus enabling benign Ohmic dissipation of the magnetic energy on longer timescales via a conventional current quench. Hydrogenic (D2) secondary injection is found to be the only injected species that enables access to the benign termination. D2 injection: 1) facilitates access to low qa in existing devices (via reduced collisionality & resistivity), 2) minimizes the RE avalanche by ‘purging’ the high-Z atoms from the RE beam, 3) drives recombination of the background plasma, reducing the density and Alfven time, thus accelerating the MHD growth. Furthermore, this phenomenon is found to be accessible when crossing the low qa stability boundary with rising current, falling toroidal field, or contracting minor radius - the latter being the expected scenario for vertically unstable RE beams in ITER. While unexpected, this path scales favorably to fusion-grade tokamaks and offers a novel RE mitigation scenario in principle accessible with the day-one disruption mitigation system (DMS) of ITER.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Simulations of vertical displacement oscillatory modes and global Alfvén Eigenmodes in JET geometry

Vertical Displacement Oscillatory Modes (VDOM), with frequency in the Alfvén range, are natural modes of oscillation of magnetically confined laboratory plasmas with elongated cross-section. These axisymmetric modes arise from the interaction between the plasma current, which is in equilibrium with currents flowing in external coils, and perturbed currents induced on a nearby conducting wall. The restoring force exerted by these perturbed currents on the vertical motion of the plasma column leads to its oscillatory behavior. An analytic model for VDOM was proposed based on an idealized 'straight tokamak' equilibrium with uniform equilibrium current density. This article introduces the first numerical simulations of VDOM in a realistic JET tokamak configuration, using the extended-MHD code NIMROD and drawing comparisons with Global Alfvén Eigenmodes (GAE). The results show qualitative agreement with analytic predictions regarding mode frequency and radial structure, supporting the identification of VDOM as a fundamental oscillation mode in tokamak plasmas. VDOM and GAE are modeled in a representative JET discharge, where axisymmetric perturbations with toroidal mode number n = 0 driven unstable by fast ions were observed. The two modes are examined separately using a forced oscillator within the NIMROD code, which enables a comparison of their characteristics and helps identify the experimentally observed mode possibly as a GAE.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Simultaneous measurements of unstable and stable Alfvén eigenmodes in JET

Here, we report the novel experimental observation of both unstable and stable toroidicity-induced Alfvén eigenmodes (TAEs) measured simultaneously in a JET tokamak plasma. The three-ion-heating scheme (D-DNBI-3He) is employed to accelerate deuterons to MeV energies, thereby destabilizing TAEs with toroidal mode numbers n = 3–5, each decreasing in mode amplitude. At the same time, the Alfvén eigenmode active diagnostic resonantly excites a stable n = 6 TAE with total normalized damping rate –γ/ω 0 ≈ 1%–4%. Hybrid kinetic-MHD modeling with codes NOVA-K and MEGA both find eigenmodes with similar frequencies, mode structures, and radial locations as in experiment. NOVA-K demonstrates good agreement with the n = 3, 4, and 6 TAEs, matching the damping rate of the n = 6 mode within uncertainties and identifying radiative damping as the dominant contribution. Improved agreement is found with MEGA for all modes: the unstable n = 3–5 and stable n = 2, 6 modes, with the latter two stabilized by higher intrinsic damping and lower fast ion drive, respectively. While some discrepancies remain to be resolved, this unique validation effort gives us confidence in TAE stability predictions for future fusion devices.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Advanced Finite-Volume Numerics and Source Term Assumptions for Kernel and G-Equation Modelling of Propane/Air Flames

Here G-Equation models represent propagating flame fronts with an implicit two-dimensional surface representation (level-set). Level-set methods are fast, as transport source terms for the implicit surface can be solved with finite-volume operators on the finite-volume domain, without having to build the actual surface. However, they include approximations whose practical effects are not properly understood. In this study, we improved the numerics of the FRESCO CFD code’s G-Equation solver and developed a new method to simulate kernel growth using signed distance functions and the analytical sphere-mesh overlap. We analyzed their role for simulating propane/air flames, using three well-established constant-volume configurations: a one-dimensional, freely propagating laminar flame; a disc-shaped, constant-volume swirl combustor; and torch-jet flame development through an orifice from a two-chamber device. We tested the explicit (sub-cycled) vs. implicit formulation for the standard transport operators (advection, diffusion, compressibility). In addition to the accurate flame swept-volume method for chemistry and species source term, we developed a more accurate estimator for the burnt/unburnt split cell composition. Then, we developed a signed-distance-function (SDF) based method which provides a more stable reinitialization of the level-set field at every time-step. We found that simplifying assumptions common to several G-Equation implementations, for straightforward terms such as compressibility and advection, lead to large errors in predicting the propagation of even laminar flames, with deviations up to ~300% in simulated vs. formulated flame speed. Conversely, the enhanced numerics enabled through the SDF field reinitialization and improved chemistry source term improve simulation stability and smooth flame propagation even with significantly larger solver time-steps.

42 ENGINEERING↗
DOE OSTI2022

Fragmentation of faceted crystalline wires

The reduction of surface energy is a well-known driving force for the fragmentation of nanowires. Fragmentation can limit the service life of those small low-dimensional building blocks or can be controlled to induce beneficial shape changes. For isotropic surface energy, fragmentation is analogous to the classic Rayleigh-Plateau instability of liquid jets. However, commonly synthesized crystalline nanowires have strongly anisotropic surface energies and exhibit facets coinciding with cusps in the Wulff plot. Depending on growth orientation, different fragmentation behaviors have been seen in nanowires. Using phase-field simulations, we show that fragmentation of faceted nanowires with cubic crystal symmetry may occur by a finite-amplitude nonlinear instability, as opposed to a Rayleigh-Plateau-like linear instability, depending on nanowire growth orientation. Here, we carry out a weakly nonlinear analysis based on sharp interface theory to characterize the faceted nanowire shape corresponding to a surface-energy saddle point. The analysis predicts that the minimum amplitude of a periodic shape perturbation to trigger fragmentation increases with cusp strength but decreases inversely proportionally to the perturbation wavelength for long wavelengths, in good quantitative agreement with phase-field predictions. The results provide the theoretical foundation to predict nanowire stability as a function of length and surface energy in diverse applications.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Computational general relativistic force-free electrodynamics: I. Multi-coordinate implementation and testing

General relativistic force-free electrodynamics is one possible plasma-limit employed to analyze energetic outflows in which strong magnetic fields are dominant over all inertial phenomena. The amazing images of black hole (BH) shadows from the Galactic Center and the M87 galaxy provide a first direct glimpse into the physics of accretion flows in the most extreme environments of the universe. The efficient extraction of energy in the form of collimated outflows or jets from a rotating BH is directly linked to the topology of the surrounding magnetic field. We aim at providing a tool to numerically model the dynamics of such fields in magnetospheres around compact objects, such as BHs and neutron stars. To do so, we probe their role in the formation of high energy phenomena such as magnetar flares and the highly variable teraelectronvolt emission of some active galactic nuclei. In this work, we present numerical strategies capable of modeling fully dynamical force-free magnetospheres of compact astrophysical objects. Here, we provide implementation details and extensive testing of our implementation of general relativistic force-free electrodynamics in Cartesian and spherical coordinates using the infrastructure of the E INSTEIN T OOLKIT . The employed hyperbolic/parabolic cleaning of numerical errors with full general relativistic compatibility allows for fast advection of numerical errors in dynamical spacetimes. Such fast advection of divergence errors significantly improves the stability of the general relativistic force-free electrodynamics modeling of BH magnetospheres.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2022

Spray coating for washout tooling by binder jet additive manufacturing

We report washout tooling is a process in which a removable mold or fixture is disintegrated using a solvent. Binder Jet (BJ) additive manufacturing holds promise for creating customized washout molds from common materials. BJ-based washout tooling provides an advanced strategy in manufacturing fiber-reinforced composites (FRCs), especially for customized hollow FRCs. However, washout tools formed by BJ require an impermeable barrier between the porous tooling surface and the parts laid up on the surface to prevent the resin from infiltrating the tooling surface and bonding the tool to the FRC. The conventional method for preventing resin migration into the washout mold from the FRC is winding Teflon® tape over the entire surface, which is labor-intensive and very difficult to deploy for specific geometries. Here, we report the development of a polymer spray coating method to seal the tooling surface and prevent resin infiltration without affecting the washout properties needed for sacrificial tooling. Two water-soluble polymers, poly(sodium 4-styrenesulfonate) (PSS–Na) and poly(vinylsulfonic acid, sodium salt) (PVS–Na), were investigated for spray coating. PVS-Na maintained tighter geometric tolerances and provided excellent thermal stability with the onset of decomposition at 320 °C and glass transition temperature of 280 °C. Spray coating with PVS-Na streamlines the process of forming a protective layer for the washout molds by BJ, reduces migration of the resins from the FRC, and significantly improves the production efficiency of complex washout tools.

42 ENGINEERING↗
DOE OSTI2024

Evaluation of Thermal & Mechanical Properties of Additively Manufactured Monolithic SiC for Solar Receiver Applications

Increasing the operating temperatures of solar receivers is paramount to the efficiency of concentrated solar thermal (CST) and solar power (CSP) systems. Owing to its high temperature stability combined with excellent thermal and optical properties, SiC has been the material of choice for application in high-temperature solar receivers. State-of-the-art SiC volumetric concentrating solar air receivers such as the honeycomb design have successfully demonstrated in field exit air temperatures approaching 800oC. However, a successful application of CST systems for the decarbonization of heat reliant industrial sectors requires significant increases in the temperature capability of SiC receiver technology. Supported by an award from the Solar Technology Office (SETO), US Department of Energy (DOE), GE Research in collaboration with Heliogen Holdings Inc, is engaged in the development of an ultra-High Operating Temperature SiC-matrix Solar Thermal Air Receiver (HOTSSTAR) enabled by additive manufacturing. The program objective is to design and demonstrate a techno-economically viable SiC air receiver technology that can achieve exit air temperatures up to 1100oC for CST applications. We report and discuss the results of our testing and evaluation of thermal and mechanical properties of reaction-bonded SiC fabricated via binder jet printing to support the receiver component design, development, and analyses.

14 SOLAR ENERGY↗
DOE OSTI2020

W-ZrC composites prepared by reactive melt infiltration of Zr 2 Cu alloy into binder jet 3D printed WC preforms

W-ZrC composites were successfully prepared by reactive melt infiltration (RMI) of stoichiometric and excess amounts of Zr 2 Cu into sintered and un-sintered WC preforms made from binder jet 3D printing. The focus of this work was to study the conversion of reactant powders and liquid infiltrant with varying preform density and infiltrant amount by controlling the processing time to reach high conversion yield while understanding the phase composition, microstructure, and hardness. To investigate the effect of time, the reactive melt infiltration was conducted at 1400 °C for 2, 4 and 8 h in a furnace with 96% Ar - 4% H2 gas atmosphere. The increase in reaction time from 2 to 8 h increased the W and W 2 C phase contents and decreased the ZrC phase content when using sintered WC preforms. Samples prepared from un-sintered WC preforms exhibited improved reactive melt infiltration compared to sintered samples, and there was no detectable W 2 C phase and nearly full consumption of WC. Similar to sintered WC samples, the content of W and ZrC phases increased with the increase in time from 2 to 8 h. The interfaces and phases at reaction interfaces were investigated using electron diffraction analysis and S/TEM-EDS to understand material stability; the phases were identified and consistent with XRD analysis. Additionally, there was no Cu present at the interfaces. Increasing the amount of infiltrant led to better reactive melt infiltration. In general, the hardness increased with reaction time and the highest Vickers hardness was found in the W-ZrC sample formed from sintered WC reacted with excess Zr 2 Cu. Finally, this research addresses the critical comparison of sintering and RMI time and shows that by using un-sintered samples for 8 h we are able to achieve W-ZrC composites with fewer undesired phases.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Inkless, dry printing nanographene via in-Situ Coordinated laser ablation and sintering processes

Printing carbon, such as graphene and other carbon structures, for flexible and printed electronics currently relies on either ink-based printing, laser-induced forward transfer (LIFT), or laser-induced graphitization (LIG) to convert carbon-rich precursor materials, such as polymers, to graphene-like carbon structures. Liquid inks contain toxic solvents, surfactants, and stabilizing additives that degrade electrical conductivity and require high-temperature post-processing. On the other hand, LIG is limited by the substrate. Here, this study introduces an additive manufacturing method for dry-printing carbon nanomaterials, ranging from amorphous carbon to crystalline graphene-like structures, on various substrates. The system utilizes laser ablation of a solid graphite target to create pure carbon nanoparticles in situ and on demand. An inert gas carries the nanoparticles onto the substrate, where they can be deposited either as amorphous structures or laser-sintered in real time to form various graphitic structures. The study of laser processing parameters, specifically fluence and pulse repetition frequency, revealed three unique regimes of nanostructure evolution that influence the morphological and electrical properties of these printed structures. Raman spectroscopy confirmed graphitization with a resistivity slightly higher than that of the bulk graphite target. The conductivity/resistivity could be tuned as a function of sintering laser power. Scanning transmission electron microscopy (STEM) revealed that turbostratic nanographene formed with an interlayer spacing of 0.40 nm. Despite ink-based printing methods, such as screen printing, inkjet printing (IJP), and aerosol jet printing (AJP), this eco-friendly and green manufacturing technique could eliminate toxic chemicals, reduce environmental impact, and enable single-step fabrication of carbon-based devices for applications in wearable sensors, energy storage, flexible electronics, and Internet of Things (IoT) devices.

Additive nanomanufacturing↗
DOE OSTI2021

Collaborative Research: Explosive reconnection in relativistic magnetically-dominated plasmas (Final Report)

Magnetic fields can be the dominant component of astrophysical plasmas, so that the magnetic energy density might exceed even the rest-mass energy density of matter. In this extreme (and largely unexplored) regime the magnetic field controls the overall plasma evolution, dissipation, and acceleration of non-thermal particles. This plasma regime, applicable to a variety of astrophysical sources - magnetars, pulsars and pulsar wind nebulae (PWNe), jets of Active Galactic Nuclei (AGNs) and Gamma-Ray Bursters (GRBs) - is dramatically different from laboratory plasmas, the magnetospheres of planets, and the interplanetary plasma. Relativistic astrophysical sources then provide an unique opportunity to study the fundamental plasma physics of magnetically-dominated plasmas; a novel and fast-evolving field of theoretical research which, by investigating energy conversion and particle energization processes in plasmas, is of vital importance to the Fusion Energy Sciences DoE program. Data coming from astrophysical high-energy missions, especially the Crab Nebula flares recently observed by the Fermi and AGILE satellites, suggest that the acceleration of non-thermal particles to the highest energies occurs in magnetic reconnection events - a major change of paradigm in high-energy astrophysics. Most importantly, observations demand that particle acceleration should proceed extremely fast (with accelerating electric field of the order of the magnetic field) and on macroscopic scales (much larger, e.g., than the microscopic plasma skin depth). We are conducting studies of the microphysics of magnetically-dominated plasmas focussing in particular on the highly dynamic regime of explosive reconnection and associated particle acceleration in relativistic plasmas. We are studying the stability and explosive plasma dynamics, particle acceleration and radiation production in a number of idealized plasma configurations that approximate relevant astrophysical sources (like the magnetic ABC structures and interacting flux tubes, as well as generalizations of analytical models of X-point collapse to relativistic plasmas). The well-studied case of the Crab Nebula is taken as a prototypical example for the application of the model. We are combining analytical studies of explosive magnetic dynamics and dissipation in relativistic plasmas with particle-in-cell (PIC) simulations and fluid simulations. The theoretical model, fluid and particle-in-cell simulations are cross-checked for agreement and convergence.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

SiC Receiver/Reactor by Additive Manufacturing for Concentrated Solar Thermocatalysis with Thermal Energy Storage (Final Technical Report - Public)

The direct use of solar thermal energy provides opportunities for low-cost heating sources for a variety of applications. Ultra-high temperatures around 1000°C are high value and highly useful for energy-demanding industries. Many materials cannot withstand these conditions. In the area of Sustainable Chemicals, further limitations on material stability exist. Combining state-of-the-art materials with new designs provides a promising pathway for harvesting solar thermal energy and performing high temperature chemical processes. However, conventional manufacturing limits the potential for design flexibility. In this project, Additive Manufacturing was combined with advanced materials and new chemical reactor designs. In addition, 24/7 energy is necessary for chemical processing, and designs for ultra-high temperature thermal storage were devised. Specifically, preliminary design of a novel solar thermal receiver was developed in this project and designed to work with thermocatalytic reactors for producing sustainable chemicals and fuels. An ultra-high temperature particle storage system and heat exchangers were proposed to transport ultra-hot air as thermal fluid for the system. On a broader scale, this system could be used to tap solar thermal energy for a centralized facility with capability of transferring that heat to various segments at a full range of temperatures to 1000°C. The project pushed the temperature boundaries past those in current use, and Additive Manufacturing was envisaged for fabricating the receiver to meet requirements of extreme environments. An extensive analysis of silicon carbide additive manufacturing was performed to compare the thermal and mechanical properties of complex geometries compared to conventional material and those manufactured via other methods. The Additive Manufacturing via Binder-Jet printing was optimized and characterized to provide high quality and reproducible components capable of withstanding the proposed extreme environments. The designs for the concentrating solar thermal cavity with ultra-hot air thermal fluid showed high performance in simulations, attributable to the complex optimized geometries of the 3D printed systems. The bright future of Additive Manufacturing with advanced materials developments should provide more options and even higher quality as the technology further develops. Current costs for Additive Manufacturing of advanced ceramics is relatively low, however post-processing of the materials for extreme environments is currently high. There is little industrial-scale infrastructure for these, but it is growing as niche applications become more mainstream. The results of the project can be translated into similar extreme environments for concentrating solar thermal energy as well as its integration with ultra-hot air thermal fluids. A number of industries that require ultra-high temperatures need to electrify or otherwise decarbonize for climate goals, and this project showed that theoretically there is a pathway to do so with direct concentrated solar thermal power.

10 SYNTHETIC FUELS↗
DOE OSTI2025

CMB-S4: Foreground-cleaning Pipeline Comparison for Measuring Primordial Gravitational Waves

We compare multiple foreground-cleaning pipelines for estimating the tensor-to-scalar ratio, r, using simulated maps of the planned CMB-S4 experiment within the context of the South Pole Deep Patch. To evaluate robustness, we analyze bias and uncertainty on r across various foreground suites using map-based simulations. The foreground-cleaning methods include: a parametric maximum likelihood approach applied to auto- and cross-power spectra between frequency maps; a map-based parametric maximum-likelihood method; and a harmonic-space internal linear combination using frequency maps. We summarize the conceptual basis of each method to highlight their similarities and differences. To better probe the impact of foreground residuals, we implement an iterative internal delensing step, leveraging a map-based pipeline to generate a lensing B-mode template from the large aperture telescope frequency maps. Our results show that the performance of the three approaches is comparable for simple and intermediate-complexity foregrounds, with σ(r) ranging from 3–5 ×10 −4 . However, biases at the 1σ–2σ level appear when analyzing more complex forms of foreground emission. By extending the baseline pipelines to marginalize over foreground residuals, we demonstrate that contamination can be reduced to within statistical uncertainties, albeit with a pipeline-dependent impact on σ(r), which translates to a detection significance between 2σ and 4σ for an input value of r = 0.003. These findings suggest varying levels of maturity among the tested pipelines, with the auto- and cross-spectra-based approach demonstrating the best stability and overall performance. Moreover, given the extremely low noise levels, mutual validation of independent foreground-cleaning pipelines is essential to ensure the robustness of any potential detection.

astronomy data analysis↗
DOE OSTI2024

Next Gen High Efficiency Boosted Engine Development

This work represents an advanced engineering research project partially funded by the U.S. Department of Energy (DOE). Ford Motor Company, FEV North America, and Oak Ridge National Laboratory collaborated to develop a next generation boosted spark ignited engine concept. The project goals, specified by the DOE, were 23% improved fuel economy and 15% reduced weight relative to a 2015 or newer light-duty vehicle. The fuel economy goal was achieved by designing an engine incorporating high geometric compression ratio, high dilution tolerance, low pumping work, and low friction. The increased tendency for knock with high compression ratio was addressed using early intake valve closing (EIVC), cooled exhaust gas recirculation (EGR), an active pre-chamber ignition system, and careful management of the fresh charge temperature. Engine weight reduction measures were implemented throughout the engine system making use of composite materials, advanced manufacturing techniques, and architectural choices. This report outlines the analytical, design, fabrication, and test work conducted for the duration of the project. The combustion system stability, EGR tolerance, and knock resistance were validated on a single cylinder engine. An inline six-cylinder engine was then designed targeting application in the Ford F150. Multi-cylinder engines were produced and tested achieving the target vehicle fuel economy improvement of 23% assessed using measured engine fuel consumption combined with a vehicle drive cycle simulation. Actions were identified and designs were demonstrated to achieve the 15% weight reduction target. This project included items covering a range of technology readiness levels. Some of the technologies explored are production ready, while others were investigated to understand the limitations for what can be achieved in a stoichiometric, gasoline-fueled, spark-ignited internal combustion engine.

42 ENGINEERING↗
DOE OSTI2024

Co-hydrotreatment of Bio-oil and Waste Cooking Oil to Produce Transportation Fuels

This paper reports the co-hydrotreatment of the heavy bio-oil fraction with waste cooking oil (WCO) using NiMo/γ-Al 2 O 3 catalyst, followed by the distillation of resulting deoxygenated oil and the characterization of resulting fuel cuts. The heavy BTG bio-oil fraction was obtained by removing the very reactive light-oxygenated compounds via rotary evaporation, subsequently mixed with 1-butanol. The resulting oil was blended with WCO and subjected to a two-step co-hydrotreatment process. The first step, called “stabilization,” is aimed at saturating highly reactive hydrogen-deficient compounds. The second step, called “deoxygenation,” aimed to remove bio-oil oxygen, primarily as H 2 O. This study examined the impact of varying bio-oil concentrations (0, 10, 20, 30, 40 wt.% of WCO) on the upgraded oil's yield, composition, and fuel properties. The resulting hydrotreated oil was distilled into gasoline-range, kerosene-range, and diesel-range hydrocarbons at <150 °C, 150 to 250 °C, and 250 to 350 °C, respectively. The yield of the hydrotreated oil indicates that as the bio-oil concentration increases, the amounts of coke (0.7 to 2.4 %) and water (2 to 10 wt. %) increase while the organic layer yields decrease (80 to 63 %). The coke yield was comparable to the coke yield obtained when co-processing the pyrolytic lignin fraction. This suggests that coke is formed from both the sugar oligomers and the lignin-derived oligomers. The UV-fluorescence analysis on the hydrotreated oil shows that more polycondensed and conjugated ring compounds formed as the bio-oil concentration is increased. These compounds are precursors of coke. FTIR results showed that most raw materials were converted to biofuels after the hydrotreatment. To achieve less than 1 wt. % of coke yield, blends with up to 20 wt. % pyrolysis oil should be used. An increase in bio-oil concentration leads to a slight increase in gasoline yield and a decrease in kerosene and diesel yields. The identified carbon species found in the fuel cuts include n-paraffin, iso-paraffin, cycloparaffin, and aromatics. Further, the jet fuel cut (kerosene) was characterized by density, surface tension, and viscosity. Our product conforms to the standard specifications for sustainable aviation fuels (Jet A-1). Further research is suggested to fine-tune the operating parameters for achieving reduced coke yield and enhanced kerosene yield.

09 BIOMASS FUELS↗
DOE OSTI2020

Results from the Alfvén Eigenmode Active Diagnostic during the 2019-2020 JET deuterium campaign

This paper presents results of extensive analysis of mode excitation observed during the operation of the Alfvén Eigenmode Active Diagnostic (AEAD) in the JET tokamak during the 2019-2020 deuterium campaign. Here, six of eight toroidally spaced antennas, each with independent power and phasing, were successful in actively exciting stable MHD modes in 479 plasmas. In total, magnetic resonances were detected with up to fourteen fast magnetic probes. In this work, we present the calculations of resonant frequencies $f_0$, damping rates γ < 0, and toroidal mode numbers $\textit{n}$, spanning the parameter ranges $f_0$ ≈ 30–250 kHz, –γ ≈ 0–13 kHz, and $\vert n \vert \leq {30}$. In general, good agreement is seen between the resonant and the calculated toroidal Alfvén Eigenmode frequencies, and between the toroidal mode numbers applied by the AEAD and estimated of the excited resonances. We note several trends in the database: the probability of resonance detection decreases with plasma current and external heating power; the normalized damping rate increases with edge safety factor but decreases with external heating. These results provide key information to prepare future experimental campaigns and to better understand the physics of excitation and damping of Alfvén Eigenmodes in the presence of alpha particles during the upcoming DT campaign, thereby extrapolating with confidence to future tokamaks.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗