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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

Integrated Silicon Platform for Co-planar Design of Vertically Stacked 2.06 THz Mixer Module

The process for fabricating and utilizing the threedimensional Si stack receiver front-end is described in this paper. The capability to have exact dimensionality becomes essential as frequency scales due to the complexity arising in assembly and finer tolerances. Total process yields can be improved through Si fabrication by verifying achievement of specified tolerances lithographically and compatibility to rapid process changes and design fine-tuning. The integrated Si platform with the mounted device is shown in Figure 1. Signal I/O and alignment modalities enable lownoise measurements. Silicon micromachining provides the necessary accuracy for integration at the several THz regime. Particularly, processing and etch recipes have demonstrated smooth surfaces of < 1 μm surface roughness. In consideration is pre-compensating for minute offsets, matching mechanical strain on all interfaces, and including passive alignment verification in the design. As compared to metal blocks, computer numerical controlled (CNC) milling can produce slight burrs in the interfaces resulting in misalignment and resultant strain between two pieces of components. Furthermore, Si integration can make possible arrays of pixel transceivers through compact subsystems for the purpose of measuring multiple lines of spectral content simultaneously in space.

Mehdi, Imran↗

International Space Station (ISS) Payload Information Source

The International Space Station Payload Information Source CD is a joint effort of NASA and United Space Alliance. It is an introduction to the Space Station's capabilities, payload accommodations and the payload integration process. The CD is designed for use in conjunction with the station payloads website. The outline for the website includes fields of research, getting on board, international partners, about the ISS, basic accommodations, specialized facilities, payload integration, payload processing, payload operations, and reference documents.

Griswold, Tom↗

Implications of multiplane-multispeed balancing for future turbine engine design and cost

This paper describes several alternative approaches, provided by multiplane-multispeed balancing, to traditional gas turbine engine manufacture and assembly procedures. These alternatives, which range from addition of trim-balancing at the end of the traditional assembly process to modular design of the rotating system for assembly and balancing external to the engine, require attention by the engine designer as an integral part of the design process. Since multiplane-multispeed balancing may be incorporated at one or more of several points during manufacture-assembly, its deliberate use is expected to provide significant cost and performance (reduced vibration) benefits. Moreover, its availability provides the designer with a firm base from which he may advance, with reasonable assurance of success, into the flexible rotor dynamic regime.

Badgley, R. H.↗

Capabilities Development at the University of Texas at El Paso for Hydrogen Generation Research and Education

Gasification-based systems have recently received much attention due to their capability of converting wastes into useful fuels. The gasification of biomass, municipal solid waste (MSW), plastics, and other sustainable resources has shown promise in hydrogen production. When coupled to a CCU or CCS unit, these systems have the potential to achieve carbon neutrality or carbon-negative emissions. In addition, these systems have an edge over conventional incineration or landfill systems by reducing greenhouse gas emissions and recovering useful energy. However, the gasification of MSW and other wastes is still in its early stages. In particular, co-gasification of wastes with biomass has significant unknowns in optimizing the reaction kinetics, operability, design and performance improvements. Currently, Supercritical Water Gasifiers (SCWG) and Plasma Gasifiers are the major systems that are capable of producing high hydrogen amounts from Biomass and MSW, respectively. However, both systems have high capital and operating costs, adversely affecting efficiency and the hydrogen production cost. Additionally, due to lower temperatures, SCWGs are prone to tar formation and fouling in the heat exchangers. Hence, there is a need to look for alternative solutions for MSW and biomass gasifications, particularly in co-gasification. The current effort aims to develop a strategic plan to establish a sustainable gasification facility for hydrogen research at the University of Texas at El (UTEP). A major part of this effort involves an extensive literature survey to identify technological gaps and potential areas of interest. Several concepts were developed in accordance with the current demands from the literature survey. Based on the concepts, a center-wide capability assessment was conducted to measure the current capacity and feasibility of establishing hydrogen research. Afterward, a strategic research plan was developed, and a list of required resources was made for the expansion of hydrogen research at UTEP. In addition, successful partnerships with the local county and the city were developed to pursue hydrogen research. The strategic goal setting and planning of UTEP Aerospace Center resulted in securing $2.5 million in external support to expand the hydrogen research during the project performance period. In addition, during the project period, a course in Hydrogen Energy Systems was developed to expand the energy curriculum at the UTEP Aerospace and Mechanical Engineering Department. The course focused on hydrogen production, storage, supply and delivery and application. The cross-listed course was offered at both undergraduate and graduate levels during the Spring 2024 semester and had 27 enrolled students. Moreover, the students supported under this award were trained in gasification process modeling, CAD, CFD and FEA during the project period. The training enabled the students to move into new projects to support gasification design, integrated gasification combined cycle process plant analysis, gasifier structural and operational analysis, and digitally threading the systems.

08 HYDROGEN↗

Integrating catalytic fractionation and microbial funneling to produce 2-pyrone-4,6-dicarboxylic acid and ethanol

Replacing biorefinery designs that use stepwise fractionation, depolymerization, and conversion processes with designed tandem process steps can greatly reduce a biorefinery's operating costs and environmental impact. Reductive Catalytic Fractionation (RCF) is a highly efficient lignin-first approach that combines biomass fractionation and lignin depolymerization to generate a hydrogenolysis oil and pulp. The oil is composed of a complex mixture of phenolic monomers, dimers, and oligomers. Intergrating this chemical deconstruction process with microbial funneling of phenolics can simplify the product mixture and make high-value products. We applied RCF to poplar biomass in a biomass-to-bioproduct processing chain in which the phenolics were funneled to 2-pyrone-4,6-dicarboxylic acid (PDC) by an engineered strain of Novosphingobium aromaticivorans DSM12444. The pulp was enzymatically digested and the glucose and xylose was funneled to ethanol by an engineered strain of Saccharomyces cerevisiae GLBRCY945. By combining biomass fractionation and lignin depolymerization we removed a costly processing step that directly translated into a 29% reduction in the minimum selling price of PDC. This work combines experimentation with process modeling of an integrated biorefinery design to show how utilizing tandem process steps can significantly reduce operating expenses and environmental impact of upgrading lignocellulosic biomass to a portfolio of high value products.

Sener, Canan [Great Lakes Bioenergy Research Cente↗

MICROREACTOR APPLICATIONS, RESEARCH, VALIDATION, AND EVALUATION (MARVEL) REACTOR ? STATUS, CONSTRUCTION, AND TESTING

The paper presents the current status of the Microreactor Applications, Research, Validation, and Evaluation (MARVEL) microreactor design, qualification testing, fabrication, and high-level construction schedule. An overview of initial criticality, low power physics testing, and start-up testing is included, as well as an overview of the envisioned processes in which end-users can engage the project for access to operational data or specific demonstrations. Designed by the Idaho National Laboratory (INL) under the auspices of the US Department of Energy’s Microreactor Program for construction and operation at the INL, MARVEL is a small, fully functional advanced reactor with UZrH fuel and thermal output of 85 kW. It offers a unique opportunity for scaled demonstrations that can dramatically accelerate the design, licensing, and deployment of commercial microreactors for power production or process heat applications. MARVEL’s objective is to build a small liquid-metal thermal reactor at the INL to demonstrate design and operating processes for microreactors, microgrid integration, and process heat applications. MARVEL finished 90%-final-design in September 2023 and completed an independent project assessment in early 2024. Fabrication of long-lead components and fuel, safety analysis review, and procurement for construction are underway. MARVEL assembly and construction will start in 2025 and fuel loading is expected in mid- 2027. Initial criticality will be performed in a dry condition in late 2027, followed by loading of NaK coolant and start-up testing. Approximately six months later, release for unrestricted operations will enable subsequent testing of microreactor characteristics, microgrid integration and select heat extraction applications.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

A Web Centric Architecture for Deploying Multi-Disciplinary Engineering Design Processes

There are continuous needs for engineering organizations to improve their design process. Current state of the art techniques use computational simulations to predict design performance, and optimize it through advanced design methods. These tools have been used mostly by individual engineers. This paper presents an architecture for achieving results at an organization level beyond individual level. The next set of gains in process improvement will come from improving the effective use of computers and software within a whole organization, not just for an individual. The architecture takes advantage of state of the art capabilities to produce a Web based system to carry engineering design into the future. To illustrate deployment of the architecture, a case study for implementing advanced multidisciplinary design optimization processes such as Bi-Level Integrated System Synthesis is discussed. Another example for rolling-out a design process for Design for Six Sigma is also described. Each example explains how an organization can effectively infuse engineering practice with new design methods and retain the knowledge over time.

Woyak, Scott↗

Key factors in designing a robust biorefinery feedstock preprocessing system

One essential prerequisite for achieving design throughput and product conversion yield of cellulosic biofuel in commercial operation is a robust biomass feedstock preprocessing system. Such a system will reliably and steadily supply consistent quality feedstock to the conversion reactor. Pioneer cellulosic biofuel plants have encountered many feedstock handling challenges which lead to lengthy startup and difficulties in meeting plant nameplate production rate. Most of the biomass material handling challenges are caused by: (1) variability in biomass properties especially for herbaceous materials such as corn stover, (2) inadequate integrated testing of equipment, (3) not using the appropriate equipment or equipment design for the job, (4) mismatching of equipment capacity and turn down ratio, (5) lack of integrated control for the whole feedstock preprocessing system, and (6) inadequate surge capacity. This presentation will discuss the feedstock preprocessing challenges, identify key areas from equipment design and operation to process integration requiring optimization or further development to achieve robust integrated biomass feedstock preprocessing systems.

09 BIOMASS FUELS↗

Human Engineering of Space Vehicle Displays and Controls

Proper attention to the integration of the human needs in the vehicle displays and controls design process creates a safe and productive environment for crew. Although this integration is critical for all phases of flight, for crew interfaces that are used during dynamic phases (e.g., ascent and entry), the integration is particularly important because of demanding environmental conditions. This panel addresses the process of how human engineering involvement ensures that human-system integration occurs early in the design and development process and continues throughout the lifecycle of a vehicle. This process includes the development of requirements and quantitative metrics to measure design success, research on fundamental design questions, human-in-the-loop evaluations, and iterative design. Processes and results from research on displays and controls; the creation and validation of usability, workload, and consistency metrics; and the design and evaluation of crew interfaces for NASA's Crew Exploration Vehicle are used as case studies.

Whitmore, Mihriban↗

Development of a Reference Governor-based Control Scheme for Integrated Energy Systems

The concept of an Integrated Energy System (IES) is meant to combine different energy technologies in synergistic ways to achieve a more secure and economical energy supply. The RAVEN-based HYBRID framework is used to find the optimal installed capacity and the optimal economical dispatch of each component of the IES. In practice what is achievable is limited by not only the inherent physical response characteristics of individual plant units but also by equipment operating limits. The inherent response characteristics are presently accounted for in the RAVEN-based HYBRID framework by dynamic models for plant units. The equipment operating limits, which are not yet addressed in HYBRID, are the subject of this report. These limits are set to achieve a design service life for a plant unit and are based on material degradation in the presence of mechanical fatigue induced by thermal cycling and by structure creep resulting from elevated temperature conditions. In general, the plant unit designer determines and specifies the allowable operating range of key process variables. It is then up to the integrated system design engineer to ensure those conditions are met. This can be accomplished through a combination of limiting the demand rates made on the plant unit and designing a control system that limits variations of key process variables. The typical control system design procedure, however, is not well suited for achieving this for complex dynamic systems such as encountered in integrated energy systems where multiple plant units must be simultaneously coordinated. This report describes how equipment operating limitations in an IES can be formally met through a control system design procedure know as the Reference Governor. The approach augments the existing controllers in a plant unit with an advance controller that modifies the issued setpoints so that selected process variables remain within limits. The design procedure is applied to the reference multi-unit system that has been the focus of Modeling and Simulation task in the Integrated Energy System program. Results describing application to the problem of limiting key process variables during operational transients for two of the plant units, the balance of plant and the gas turbine, are then presented. It is demonstrated that the Reference Governor method is an effective means for ensuring equipment operating constraints can be met in an IES. The software that implements the method has been made accessible to others on the Modeling and Simulation upload site.

42 ENGINEERING↗

PacWave South SeaRAY k2 Risk Registers

The SeaRAY is a deployable power system for maritime sensors, monitoring equipment, communications, unmanned underwater vehicles, and other similar payloads. This project is to design, deliver, and test a prototype low-power WEC that lowers the total cost of ownership and provides robust, new capabilities for customers in the maritime environment. Failure Modes, Effects, and Criticality Analysis (FMECA) is conducted to systematically identify all potential failure modes and their effects on the system, and to analyze the criticality of each risk based on the likelihood of the event and the severity of the impact. Actions may then be recommended to mitigate the criticality of a risk, either by reducing the likelihood of the risk or the severity of its impact. Risk assessment is executed iteratively as an integral part of the design process. By incorporating risk assessment early in the development cycle, mitigation of risk can be achieved cost effectively. The actions recommended to mitigate risk may be subsequently executed, and as the design progresses the risk assessment is reviewed and revised. Review of the risk assessment is integrated into structured design reviews, ensuring that critical risks are comprehended and that the Project will not progress to e.g. fabrication while intolerable risks remain. The risk assessment process results in the population and maintenance of Risk Registers (RRs). Each major system (and as needed, subsystem) will have a distinct RR. This allows each system or subsystem to be assessed individually, rendering the RRs to a manageable size for review.

16 TIDAL AND WAVE POWER↗

Cross Cutting Structural Design for Exploration Systems

The challenge of our new National Space Policy and NASA's Vision for Space Exploration (VSE) is keyed to the development of more effective space access and transportation systems. Optimizing in-space systems through innovative cross cutting structural designs that reduce mass, combine functional requirements and improve performance can significantly advance spacecraft designs to meet the ever growing demands of our new National Space Policy. Dependence on limited structural designs is no longer an option. We must create robust materials, forms, function and evolvable systems. We must advance national policy objectives in the design, development, test and operation of multi-billion dollar new generation crew capsules by enabling them to evolve in meeting the requirements of long duration missions to the moon and mars. This paper discusses several current issues and major design drivers for consideration in structural design of advanced spacecraft systems. Approaches to addressing these multifunctional requirements is presented as well as a discussion on utilizing Functional Analysis System Technique (FAST) in developing cross cutting structural designs for future spacecraft. It will be shown how easy it is to deploy such techniques in any conceptual architecture definition or ongoing preliminary design. As experts in merging mission, safety and life support requirements of the frail human existence into robust vehicle and habitat design, we will conquer the final frontier, harness new resources and develop life giving technologies for mankind through more innovative designs. The rocket equation tells us that a reduction in mass optimizes our propulsive results. Primary and secondary structural elements provide for the containment of gases, fluids and solids; translate and sustain loads/impacts; conduct/radiate thermal energy; shield from the harmful effects of radiation; provide for grounding/bonding of electrical power systems; compartmentalize operational functions; and provide physical interface with multiple systems. How can we redefine, combine, substitute, rearrange and otherwise modify our structural systems to reduce mass? New technologies will be needed to fill knowledge gaps and propagate new design methods. Such an integrated process is paramount in maintaining U.S. leadership and in executing our national policy goals. The cross cutting process can take many forms, but all forms will have a positive affect on the demanding design environment through initial radical thinking. The author will illustrate such cross cutting results achievable through a formal process called FAST. The FAST example will be used to show how a multifunctional structural system concept for long duration spacecraft might be generated.

Semmes, Edmund B.↗

Advanced CO 2 Capture Technology for Low Rank Coal IGCC System

The overall objective of the project is to demonstrate the technical and economic viability of a new Integrated Gasification Combined Cycle (IGCC) power plant designed to efficiently process low rank coals. The plant uses an integrated CO 2 scrubber/Water Gas Shift (WGS) catalyst to capture over90 percent capture of the CO 2 emissions, while providing a significantly lower cost of electricity (COE) than a similar plant with conventional cold gas cleanup system based on Selexol TM technology and 90 percent carbon capture. TDA’s system uses a high temperature physical adsorbent capable of removing CO 2 above the dew point of the synthesis gas and a commercial WGS catalyst that can effectively convert CO in The overall objective of the project is to demonstrate the technical and economic viability of a new Integrated Gasification Combined Cycle (IGCC) power plant designed to efficiently process low rank coals. The plant uses an integrated CO 2 scrubber/Water Gas Shift (WGS) catalyst to capture over90 percent capture of the CO 2 emissions, while providing a significantly lower cost of electricity (COE) than a similar plant with conventional cold gas cleanup system based on Selexol TM technology and 90 percent carbon capture. TDA’s system uses a high temperature physical adsorbent capable of removing CO 2 above the dew point of the synthesis gas and a commercial WGS catalyst that can effectively convert CO in bituminous coal the net plant efficiency is about 2.4 percentage points higher than an Integrated Gasification Combined Cycle (IGCC) plant equipped with Selexol TM to capture CO 2 . We also previously completed two successful field demonstrations: one at the National Carbon Capture Center (Southern- Wilsonville, AL) in 2011, and a second demonstration in fall of 2012 at the Wabash River IGCC plant (Terra Haute, IN). In this project, we first optimized the sorbent to catalyst ratio used in the combined WGS and CO 2 capture process and confirmed the technical feasibility in bench-scale experiments. In these tests, we did not observe any CO breakthrough both during adsorption and desorption steps indicating that there is complete conversion of CO to CO 2 and H 2 . The overall CO conversions above 90 percent were observed. The sorbent achieved a total CO 2 loading of 7.82 percent wt. of which 5.68 percent is from conversion of CO into CO 2 . The results of the system analysis suggest that the TDA combined shift and high temperature PSA-based Warm Gas Clean-up technology can make a substantial improvement in the IGCC plant thermal performance for a plant designed to achieve near zero emissions (including greater than 90 percent carbon capture). The capital expenses are also expected to be lower than those of Selexol. The higher net plant efficiency and lower capital and operating costs result in substantial reduction in the COE for the IGCC plant equipped with the TDA combined shift and high temperature PSA-based carbon capture system.

01 COAL, LIGNITE, AND PEAT↗

Alternatives to MARVEL Power Conversion -- Comparison of Stirling Engine Thermal Efficiency and Design to Other Power Conversion Cycles

PRESENTATION for CONFERENCE PAPER: The Microreactor Applications, Research, Validation, and Evaluation (MARVEL) Reactor is a small liquid-metal thermal reactor that will be built at the Idaho National Laboratory to demonstrate design and operating processes for microreactors, microgrid integration, and process heat applications. Power conversion in the MARVEL design is provided by Stirling engines, which have disadvantages in nuclear environments. Compared to Stirling engine performance, some alternative power cycles can increase power production when coupled to a liquid-metal thermal reactor. In this paper, the thermal efficiency of MARVEL’s power production with Stirling engines is compared to the thermal efficiency of power production with MARVEL and alternative power cycles. Those cycles include a superheated Rankine cycle, open and closed Brayton cycles, and a supercritical carbon dioxide cycle. All cycles (except the Stirling engines) were modeled with an intermediate helium loop to meet MARVEL’s principal design criteria. All models are simple designs with conservative assumptions for consistent comparison. Detailed optimization will depend largely on reactor location and application, and the relative merit of each cycle is discussed for different environmental conditions. The study informs significant early decisions on power cycle design and economics for deployment of advanced microreactors as they move from theory and concept to execution.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Alternatives to MARVEL Power Conversion – Comparison of Stirling Engine Thermal Efficiency and Design to other Power Conversion Cycles

The Microreactor Applications, Research, Validation, and Evaluation (MARVEL) Reactor is a small liquid-metal thermal reactor that will be built at the Idaho National Laboratory to demonstrate design and operating processes for microreactors, microgrid integration, and process heat applications. Power conversion in the MARVEL design is provided by Stirling engines, which have disadvantages in nuclear environments. Compared to Stirling engine performance, some alternative power cycles can increase power production when coupled to a liquid-metal thermal reactor In this paper, the thermal efficiency of MARVEL’s power production with Stirling engines is compared to the thermal efficiency of power production with MARVEL and alternative power cycles. Those cycles include a superheated Rankine cycle, open and closed Brayton cycles, and a supercritical carbon dioxide cycle. All cycles (except the Stirling engines) were modeled with an intermediate helium loop to meet MARVEL’s principal design criteria. All models are simple designs with conservative assumptions for consistent comparison. Detailed optimization will depend largely on reactor location and application, and the relative merit of each cycle is discussed for different environmental conditions. The study informs significant early decisions on power cycle design and economic

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Application of State Analysis and Goal-Based Operations to a MER Mission Scenario

State Analysis is a model-based systems engineering methodology employing a rigorous discovery process which articulates operations concepts and operability needs as an integrated part of system design. The process produces requirements on system and software design in the form of explicit models which describe the behavior of states and the relationships among them. By applying State Analysis to an actual MER flight mission scenario, this study addresses the specific real world challenges of complex space operations and explores technologies that can be brought to bear on future missions. The paper describes the tools currently used on a daily basis for MER operations planning and provides an in-depth description of the planning process, in the context of a Martian day's worth of rover engineering activities, resource modeling, flight rules, science observations, and more. It then describes how State Analysis allows for the specification of a corresponding goal-based sequence that accomplishes the same objectives, with several important additional benefits.

mission planning↗

Development of Human System Integration at NASA

Human Systems Integration seeks to design systems around the capabilities and limitations of the humans which use and interact with the system, ensuring greater efficiency of use, reduced error rates, and less rework in the design, manufacturing and operational deployment of hardware and software. One of the primary goals of HSI is to get the human factors practitioner involved early in the design process. In doing so, the aim is to reduce future budget costs and resources in redesign and training. By the preliminary design phase of a project nearly 80% of the total cost of the project is locked in. Potential design changes recommended by evaluations past this point will have little effect due to lack of funding or a huge cost in terms of resources to make changes. Three key concepts define an effective HSI program. First, systems are comprised of hardware, software, and the human, all of which operate within an environment. Too often, engineers and developers fail to consider the human capacity or requirements as part of the system. This leads to poor task allocation within the system. To promote ideal task allocation, it is critical that the human element be considered early in system development. Poor design, or designs that do not adequately consider the human component, could negatively affect physical or mental performance, as well as, social behavior. Second, successful HSI depends upon integration and collaboration of all the domains that represent acquisition efforts. Too often, these domains exist as independent disciplines due to the location of expertise within the service structure. Proper implementation of HSI through participation would help to integrate these domains and disciplines to leverage and apply their interdependencies to attain an optimal design. Via this process domain interests can be integrated to perform effective HSI through trade-offs and collaboration. This provides a common basis upon which to make knowledgeable decisions. Finally, HSI must be considered early in the requirements development phase of system design and acquisition. This will provide the best opportunity to maximize return on investment (ROI) and system performance. HSI requirements must be developed in conjunction with capability ]based requirements generation through functional. HSI requirements will drive HSI metrics and embed HSI issues within the system design. After a system is designed, implementation of HSI oversights can be very expensive. An HSI program should be included as an integral part of a total system approach to vehicle and habitat development. This would include, but not limited to, workstation design, D&C development, volumetric analysis, training, operations, and human -robotic interaction. HSI is a necessary process for Human Space Flight programs to meet the Agency Human ]System standards and thus mitigate human risks to acceptable levels. NASA has been involved in HSI planning, procedures development, process, and implementation for many years, and has been building several internal and publicly accessible products to facilitate HSI fs inclusion in the NASA Systems Engineering Lifecycle. Some of these products include: NASA STD 3001 Volumes 1 and 2, Human Integration Design Handbook, NASA HSI Implementation Plan, NASA HSI Implementation Plan Templates, NASA HSI Implementation Handbook, and a 2 ]hour short course on HSI delivered as part of the NASA Space and Life Sciences Directorate Academy. These products have been created leveraging industry best practices and lessons learned from other Federal Government agencies.

Whitmore, Mihriban↗