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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 OSTI2021

Data Driven Analysis for Modernization Program Management

NNSA is responsible for managing national nuclear security missions: ensuring a safe, secure, and reliable nuclear deterrent; supplying nuclear fuel to the Navy; and supporting the nation’s nuclear nonproliferation efforts. However, over half of NNSA’s facilities are more than 40 years old, and roughly one-third date back to the Manhattan Project. To execute its critical nuclear security missions, NNSA is making large investments to modernize its nuclear production capabilities. This ramp up represents NNSA’s largest modernization effort since the Cold War. Given the scale of these efforts, NNSA’s Office of Secondary Stage Production Modernization has implemented data driven techniques to prioritize investments and inform strategic decision making. NNSA, with support from its site managing contractors, has developed and implemented an integrated schedule and risk management system to address the issues and limitations with the traditional approach. The multi-year integrated schedules are key to identifying program linkages and managing large portfolios comprised of many different projects and efforts. In conjunction with the integrated schedule, a new program risk management system has also been developed and implemented, which manages program risks and opportunities, along with specific mitigation strategies to reduce or eliminate the risks per timelines that are tracked in the integrated schedule. This paper is supplemented with a follow-on presentation on effective management of program material and throughput modeling.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Unitary Thermal Energy Management for Propulsion Range Augmentation (UTEMPRA) (CRADA Final Report)

NREL will work with Delphi to develop technology that integrates the thermal management of electric drive vehicle sub-systems into a unified thermal system that reduces auxiliary loads and increases vehicle range. The ultimate goal is to create a cost-effective system which improves climate control efficiency through heat pump operation and waste heat recovery, while maintaining occupant thermal comfort and meeting powertrain thermal requirements. The technology will also aim to reduce the number of independent cooling systems required in electric drive vehicles.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Additive Manufacturing of Thermal Energy Storage Composites with Microencapsulated Phase Change Materials Supported in a Multi-Polymer Matrix

Advanced manufacturing techniques, such as additive manufacturing (AM), that can directly integrate phase change materials (PCMs) have garnered interest in recent years due to their potential for development of highly efficient thermal energy storage architectures. Complex, high surface area geometries embedded with PCMs that are only feasible with AM can improve thermal management with reduced material waste. Our work focuses on developing composite filaments with microencapsulated phase change materials (MEPCM) bound within a single or dual polymer matrix that can be processed through standard filament extruders and additively manufactured using off-the-shelf 3D printers. Polymer powders, rather than polymer pellets, were key to homogenously mixed filaments achieving high MEPCM loadings with no deterioration in thermal energy storage (TES) capability during extrusion. Composite filaments contain upwards of 60 wt% MEPCM and were printed without loss in feature resolution, print speed, or layer adhesion. Storage enthalpies of printed composites range from 100 - 130 kJ/kg, which were within 5% of the theoretical enthalpy based on weight fraction of MEPCM and maintained enthalpies within 1% over 500 thermal cycles. We can reliably manufacture low density, high surface area structures like 15% gyroid infill, along with dense, compact pucks at a 100% concentric infill. Prints were also scalable to a 900 cm3 honeycomb infill heat exchanger model that has an estimated energy storage capacity of 9 Wh.

3D printing↗
DOE OSTI2025

DEVELOPMENT OF AN INTEGRATED SECURITY AND SAFETY MONITORING SYSTEM FOR SPENT NUCLEAR FUEL AND HIGH-LEVEL WASTE TRANSPORTATION

This paper provides an overview of the progress to date, and discussion of the path forward, related to designing, fabricating, and testing an integrated security and safety monitoring system (ISSMS) for railcars used to transport spent nuclear fuel (SNF) and high-level radioactive waste (HLW) in the United States. The system will comply with the US Department of Energy’s (DOE) Order 460.2B “Departmental Materials Transportation Management” and the Association of American Railroads’ (AAR) standard S-2043 “Performance Specification for Trains Used to Carry High-level Radioactive Material” [1] developed specifically for railcars used to transport high-level radioactive material (HLRM). DOE is in the process of developing and testing an ISSMS that will satisfy both DOE requirements and AAR standards. DOE has already developed railcar designs for transportation of HLRM. In 2024, DOE’s Atlas railcar project completed the design, fabrication and testing of three railcar types: transportation cask-carrying, buffer, and security escort, resulting in AAR conditional approval to operate on freight rail networks in North America. DOE decided to combine the required security and safety systems into one system, and this combined system is the subject of the current effort. DOE is developing and proposes to implement the ISSMS for these railcars as part of the build out of the railcar fleet. DOE began planning for development of the ISSMS in February 2020. The project is divided into seven phases starting with conceptual design and continuing through production design, as shown in Figure 1. An earlier version of the system was tested as part of the Atlas railcar consist demonstration test run in 2023. This paper describes the design features and system testing using the Atlas project railcars, and laboratory testing completed to date. The paper will also describe the activities planned to support the DOE project to ship the High Burn-Up Research Cask (HBRC) in 2027.

Schultze, Michael [ORNL] (ORCID:0000000283205671)↗
DOE OSTI2026

Annual Summary Report (FY 2025) Performance Assessment for the Integrated Disposal Facility

The purpose of this Annual Summary Report (ASR) for fiscal year (FY) 2025 is to evaluate the continued adequacy of the Integrated Disposal Facility (IDF) Performance Assessment (PA) and Disposal Authorization Statement (DAS). This report consolidates relevant monitoring data, modeling analyses, and regulatory reviews to demonstrate a reasonable expectation that the PA objectives and performance measures will be met, as required under DOE O 435.1, Radioactive Waste Management. The ASR follows the guidance in DOE-STD-5002-2017, Disposal Authorization Statement and Tank Closure Documentation, which provides a framework for maintaining the validity of the DAS through periodic assessment of facility performance and compliance with waste disposal requirements.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Design of solvent-assisted plastics recycling: Integrated economics and environmental impacts analysis

In 2018, the United States generated over 35. 7 million tons of plastic waste, with only 8.4% being recycled and the other 91.6% incinerated or disposed of in a landfill. The continued growth of the polymer market has raised concerns over the end of life of plastics. Currently, the waste management system is faced with issues of inefficient sorting methods and low-efficiency recycling methods when it comes to plastics recycling. Mechanical recycling is the commonest recycling method but presents a lower-valued recycled material due to the material incompatibilities introduced via the inefficient sorting methods. Chemical recycling offers a promising alternative as it potentially allows for plastics to maintain their original properties. To that end, there is the need to investigate feasible chemical recycling methods to help mitigate the challenging problem posed by plastics at the end-of-life stage. This work proposes a conceptual solvent-assisted plastics recycling framework based on a superstructure optimization approach. This framework is evaluated using a representative case study to recover Polyethylene Terephthalate (PET). In this case study, it is found that polymer recovery is both economically and environmentally favorable when compared to traditional methods of disposal such as incineration.

Lehr, Austin L.↗
DOE OSTI2020

Special Analyses for the Hanford Integrated Disposal Facility Performance Assessment - 20102

In 2014, the Department of Energy (DOE) Office of River Protection and its contractors began to develop a performance assessment for the near-surface disposal of low-level and mixed low-level waste at the Hanford Site's Integrated Disposal Facility (IDF). The IDF is a doubly-lined landfill that was constructed between 2004 and 2006 to be the disposal facility for the vitrified low-activity waste that will be produced at the Waste Treatment and Immobilization Plant (WTP). IDF is also expected to receive solid secondary waste produced at the WTP and other solid wastes from site activities. The IDF has been in a preoperational state awaiting authorization from DOE and a RCRA permit modification from the State of Washington Department of Ecology to receive waste. Both the Disposal Authorization Statement and permit modification require a performance assessment demonstrating that the system of engineered and natural features will limit releases of radionuclides and hazardous chemicals from the IDF and be protective of human health and the environment. The simulated duration is 10,000 years. Based on the analyses presented in the 2017 Integrated Disposal Facility Performance Assessment, DOE issued a conditional Operating Disposal Authorization Statement for the IDF in June 2018. The long-term performance of the IDF to be protective of human health and the environment was evaluated under the requirements of DOE Order 435.1, Radioactive Waste Management. Computer simulations were performed to evaluate whether or not the IDF would comply with DOE requirements. In the time that has passed since the performance assessment was approved by DOE, new information has been discovered that had not been considered in the performance assessment. Since this new information has not been evaluated, the potential impact of the changes have not been taken into consideration in DoE's disposal authorization. DOE and its contractors follow a change control process to screen and, when necessary, evaluate new information that could potentially impact the conclusions of the completed performance assessment. This paper will describe the change control process and provide two examples of evaluations performed following the change control process. The first example evaluates a new waste form for liquid secondary waste that was not evaluated in the performance assessment. In the performance assessment, liquid secondary waste was assumed to be solidified with grout. A new recommendation to dispose of the liquid secondary waste after drying it to a powder was evaluated. The second example evaluates inventory implications from changes to the flow sheet that estimates the feed composition to the low-activity waste vitrification facility. The changes result in higher strontium concentrations in the vitrified waste stream. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

SDU7 Interior Liner Testing & Evaluation

The Saltstone Disposal Unit 7 (SDU7) project requested the Savannah River National Laboratory (SRNL), Materials Science & Engineering (MS&E) organization to evaluate an alternative bromobutyl liner and adhesives for potential use in SDU7 based on applicable ASTM testing standards. SRNL performed similar testing for the liner system used in SDU6. Bonded and non-bonded samples of the alternative liner (Blair Rubber Marflex™ RCHB60HT) were subjected to specific ASTM tests after immersion in two Saltstone leachate simulants, designated S1 and S2, for 1000 hours at 60 °C. Immersion exposures were performed at the Savannah River Ecology Laboratory (SREL). Post-immersion testing involved mechanical property and hardness testing of base material, lap-shear testing of bonded samples and rubber-to-concrete paver interrogation. The liner exhibited an approximate 40% drop in tensile strength and 25% drop in elongation at failure from baseline values after immersion, though final values are comparable to previous SDU6 liner values and are within liner manufacturer property ranges. Overall lap-shear strength behavior of the four adhesives showed a similar pattern, with short-term reduction and subsequent increase in peak load values. However, ranking of adhesives varied with the metric used for comparison. Two of the four adhesives tested (Normac 900 and REMA SC 4000) showed overall better behavior, collectively considering immersion performance, lap-shear data and bonded paver interrogation. Lap-shear samples bonded with the REMA adhesive showed the best combination of final retained bond strength, 6-week average bond strength and bond failure mode. Only one paver (REMA SC4000) was noted to have no defects after immersion. This document details the testing performed and provides conclusions and recommendations. The testing suggests that SDU liner performance is highly dependent upon seam integrity, which collectively depends on a combination of adhesive properties, installation workmanship and inspection/quality control.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

ISOCS-based Extended In Situ Gamma Spectrometry Services Tool SuperISOCS for Waste Measurements - 20275

Canberra's In Situ Object Counting System (ISOCS) is an established tool used for gamma spectrometry. It allows physical representation of complex geometries and mathematical calculation of the calibration function while avoiding the need for radioisotope standards. ISOCS provides a large range of templates to generate the geometry for most nuclear waste components in nuclear facilities. Nonetheless, there are some complex geometries where the accuracy attainable is limited by the conventional ISOCS templates. An ISOCS-based extended in-situ Gamma Spectrometry service tool has been developed, based on the so-called SuperISOCS (SISOCS) software. This tool was developed to generate the most complex geometries. The principle of geometry construction is based on the composition of 8 different primitive geometries. The primitive object is able to be cut and to change a part of an object. An object is able to overlap to another one to form a more complex object. These functions refine the modelled geometry compared to the real objects and decrease the measurement systematic error because they allow the mathematical model to represent the real-life geometry more faithfully through reducing the approximations and simplifications that need to be made The algorithm of SISOCS is the same as that of standard ISOCS. A set of calculations was done in comparison with MCNP efficiency calculation and SISOCS results. 80 different models were compared between SISOCS and MCNP, with added 30 cases compared between ISOCS and SISOCS. The average differences were less than 2%, for all energy's efficiency calculations. In this paper we illustrate the benefits that this new tool can provide, in terms of improved accuracy for complex realistic geometries, through simulation of some example scenarios. Furthermore, we demonstrate, through SISOCS modelling of the real object data test, the comparison between SISOCS to ISOCS calculations for the same geometry. This paper describes the added functions that are easily employed using SISOCS. Our results show the potential application and benefit of this technique for real waste assay projects and the way to integrate the tool into the waste assay systems. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

RANGERS: Methodology Report on Design and Performance Assessment of Engineered Barrier Systems in a Salt Repository for HLW/SNF

Salt formations are one of the potential host rocks for the final disposal of high-level radioactive waste (HLW) in deep geological repositories, both in Germany and the United States. The safe isolation of radioactive waste in these repositories relies on a multi-barrier system, combining engineered and natural barriers. The natural barrier is provided by the salt rock itself, known for its self-sealing properties and long-term stability. The engineered barrier, on the other hand, comprises sealing components strategically placed within the repository to enhance its containment capabilities. In both Germany and the United States, long-term safety assessments require demonstrating the integrity of the natural barrier for a period of up to 1 million years. Concurrently, the engineered barrier system (EBS) must maintain its structural and functional integrity until the long-term sealing, such as the granular salt backfill material, has re-consolidated to its final low porosity and permeability. Based on extensive expertise and experience with engineered barriers in salt formations, BGE TECHNOLOGY GmbH and Sandia National Laboratories have partnered to develop a robust methodology for the integrity and performance assessment of EBS in HLW repositories through the RANGERS project. This collaborative effort aims to establish a unified approach to geotechnical engineering, repository design, integrity and performance evaluation of EBS in salt repositories.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2026

Quantitative 14 N NMR with Monte Carlo Uncertainty Analysis of Nitrate/Nitrite in Alkaline Nuclear Waste

While monitoring of nitrate and nitrite concentrations is important for managing corrosion in nuclear waste systems, existing analytical methods are hindered by turbidity, spectral interference, and delays from sample handling. Here, we demonstrate quantitative 14 N nuclear magnetic resonance (qNMR) spectroscopy as a direct, matrix-tolerant approach for nitrate and nitrite detection at natural abundance. Monte Carlo resampling was integrated into the workflow to quantify random error, establish precision–time tradeoffs, and separate noise-limited uncertainty from systematic bias arising from shimming, transmitter offset, or excitation pulse conditions. Quantification of nitrate and nitrite were validated in controlled alkaline matrix challenges and in 18-component Hanford-type simulants. These results establish 14 N qNMR as a practical, uncertainty-bounded tool for monitoring redox-active nitrogen species in chemically complex environments and provide a generalizable framework for quantitative analysis of quadrupolar nuclei.

Graham, Trent R. [Pacific Northwest National Labor↗
DOE OSTI2026

Revolutionizing thermal Management in Next-Generation AI data centers: Challenges and breakthrough innovations

Data centers (DCs) serve as critical infrastructure for powering the growth and evolution of AI. Next-generation AI DCs present unique challenges in thermal management driven by unprecedented computational demands. This paper provides a comprehensive summary of key stakeholder perspectives on technology gaps, infrastructure requirements, test bed needs, emerging opportunities, and preliminary solutions related to thermal management for AI DCs. It establishes six strategic pillars of thermal management for next generation AI DC: reliability, deployability, efficiency, resilience, measurability, and valorization. The discussion spans a range of critical topics, including advanced cooling technologies, thermal strategies for emerging modular and edge DCs, system-level optimization and control frameworks, infrastructure planning and grid integration designs, benchmarking approaches, and pathways for waste heat recovery and reuse. The proposed research, development, and demonstration efforts are aimed at accelerating the deployment of AI DCs while ensuring energy efficiency, reliability, safety, and regulatory compliance.

Wang, Pengtao [ORNL] (ORCID:0000000214713429)↗
DOE OSTI2022

Achieving superior carbon transfer efficiency and pH control using membrane carbonation with a wide range of CO 2 contents for the coccolithophore Emiliania huxleyi

The economic viability of microalgal-derived products relies on rapid CO 2 transfer in a cost-effective manner. Many industrial gas streams contain concentrated CO 2 that, if converted to useful products, would lower greenhouse gas emissions and valorize the wasted CO 2 . Membrane carbonation (MC) uses non-porous hollow-fiber gas-transfer membranes to deliver CO 2 without bubble formation, which makes it possible to achieve a high carbon-transfer efficiency (CTE). However, inert gasses in the industrial streams (e.g., N 2 , O 2 , and H 2 O) can significantly lower the CO 2 -delivery rate. The means to overcome the buildup of inert gases in the membrane lumen is to manage the distal end of the membranes to sweep out inert gases while not wasting significant CO 2 . A MC-venting strategy was evaluated for CO 2 inputs from 5% to 100%. Abiotic tests using a restricted exit flow could achieve >95% CTE abiotic for industrial CO 2 streams. When integrated with semi-continuous cultivation of a marine coccolithophore, Emiliania huxleyi , CO 2 delivery and venting were on-demand based on a pH set points and pH-actuated feed and venting valves. MC using the venting strategy achieved 100% CTE biotic when delivering 100% and 50% CO 2 , which was better than 50% CTE biotic obtained from pH-controlled sparging of 100% CO 2 -sparging. E. huxleyi consistently fixed ~80% of the delivered CO 2 into biomass, and the remaining ~20% to calcite coccoliths. Finally, the compact size of MC modules, stable pH control, and no shear forces from bubble agitation during the CO 2 delivery made MC an ideal match for cultivation of coccolithophores, which are sensitive to shear forces and pH fluctuations.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

The role of international collaboration in the United States geologic disposal research program

Abstract. More than a decade ago, the United States disposal program discontinued all research activities focused on the unsaturated fractured tuff formation at Yucca Mountain as the geologic disposal site for spent fuel and high-level radioactive waste. A new research and development (R&D) program was initiated to provide a sound technical basis for alternative disposal options across clay, crystalline, and salt rocks. The goals of this broad program were (and still are) to (1) increase confidence in the robustness of generic disposal concepts, (2) develop the science and engineering tools needed to support disposal concept implementation, and (3) conduct R&D on the direct disposal of existing dual-purpose (storage and transportation) canisters. Recognizing the benefits of international collaboration toward the common goal of safely and efficiently managing the back end of the nuclear fuel cycle, the program emphasized international cooperation as an effective strategy for sharing information and knowledge. In a multi-laboratory effort coordinated by Lawrence Berkeley National Laboratory, the United States Department of Energy (DOE) program established formal and informal cooperation partnerships with several international initiatives and institutions and developed a number of collaborative R&D activities in important research areas, such as engineered barrier integrity, near-field perturbations, radionuclide transport, performance assessment, and methods for characterization and monitoring of engineered and natural barriers. This presentation gives an overview of these R&D activities, with a specific focus on activities that improve our current understanding of the coupled thermal–hydrological–mechanical–chemical (THMC) processes occurring in engineered and natural barriers. We start with a brief review of selected international collaboration initiatives and then describe a few specific collaboration projects. We focus specifically on such studies that use experimental data sets provided by international research cooperation for joint modeling work to increase confidence in performance-relevant predictions of coupled processes. Overall, the focus on international collaboration has allowed deep engagement of US researchers with the international waste management R&D community in terms of best practices, new scientific advances, state-of-the-art simulation tools, new monitoring and performance confirmation approaches, and lessons learned. The joint R&D with international researchers, worldwide sharing of knowledge and experience, and access to relevant data and experiments from a variety of host rocks have helped our researchers to significantly improve their understanding of the current technical basis for disposal in a range of potential host rock environments. International collaboration also provides ample opportunity for training and educating junior staff that are well suited to move the United States disposal research program forward into the next decades, a promising avenue for developing a next-generation workforce of disposal scientists.

Birkholzer, Jens T.↗
DOE OSTI2020

Bio-Restore Workshop Summary Report

This report summarizes the results of a Bioenergy Technologies Office-sponsored public workshop held at Argonne National Laboratory on September 25–26, 2019. The purpose of the Bio-Restore Workshop was to bring together experts to discuss the current state of the technology and to identify data and R&D relevant to the bio-restore concept. Specific topics included using dedicated energy crops and other biomass sources to provide environmental benefits, implementing algae technologies (e.g., wastewater treatment, direct bloom harvest, turf scrubbers, macroalgae), quantifying and valorizing ecosystem services, developing low-cost sensors and data management systems, and integrating “bio-restore biomass” with supply chain needs. For the purposes of the workshop, the term “bio-restore biomass” refers to terrestrial and algal biomass that provides environmental benefits when produced or harvested. For terrestrial biomass, this primarily includes energy crops (herbaceous and woody), other cellulosic biomass, and waste biomass. For algal biomass, this includes wastewater treatment algal biomass, algal blooms, algal turf scrubbers/attached growth systems, and macroalgae. Types of biomass not of interest to the workshop discussions include oilseed crops, crops generally grown for food or feed, and algae grown in artificial light conditions or other energy-intensive cultivation designs.

09 BIOMASS FUELS↗
DOE OSTI2020

FY2020 Rotating Bed Reactor for Iodine Removal from WTP Melter Effluent to Support DFLAW Start-Up

In Performance Assessment (PA) of the Hanford Integrated Disposal Facility (IDF), 129 I is a significant contributor to the risk. The 2017 IDF PA accounted for 0.22% of the total 129 I inventory in Hanford tank waste as residing in the solidified liquid waste from the Effluent Treatment Facility (ETF). However, recent estimates suggest that higher percentages of the iodine processed at the Hanford Waste Treatment and Immobilization Plant (WTP) may be present in the liquid waste routed to the Liquid Effluent Retention Facility (LERF) for eventual treatment at the ETF. In addition, a recent integrated melter test performed at the Vitreous State Laboratory (VSL) at The Catholic University of America (CUA) showed the possibility that a significant fraction (>50%) of the total iodine in the melter feed could be present in the aqueous waste stream destined for the ETF. This stream represents a combination of the Effluent Management Facility (EMF) evaporator overhead condensate and the liquid waste from the WTP off-gas caustic scrubber. Higher levels of 129 I in this stream could affect the LERF and ETF Hazard Categorizations as well as the acceptability of the solidified ETF liquid secondary waste brine for disposal at the IDF. Accordingly, there is a need to investigate and develop potential methods and processes to mitigate this risk. Washington River Protection Solutions, LLC (WRPS) tasked Atkins and VSL to perform development and testing work to evaluate potential methods for removal of iodine species from the waste stream routed to the LERF. In particular, the testing investigated the use of an Atkins-SpinIonic™ Rotating Bed Reactor (RBR) system as a potential alternative to conventional column-based ion exchange or absorption processes. The present report provides results obtained from testing with an RBR system for the removal of iodine from simulants of the projected WTP waste stream that discharges to the LERF.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Improving the Concrete Crack Detection Process via a Hybrid Visual Transformer Algorithm

Inspections of concrete bridges across the United States represent a significant commitment of resources, given their biannual mandate for many structures. With a notable number of aging bridges, there is an imperative need to enhance the efficiency of these inspections. This study harnessed the power of computer vision to streamline the inspection process. Our experiment examined the efficacy of a state-of-the-art Visual Transformer (ViT) model combined with distinct image enhancement detector algorithms. We benchmarked against a deep learning Convolutional Neural Network (CNN) model. These models were applied to over 20,000 high-quality images from the Concrete Images for Classification dataset. Traditional crack detection methods often fall short due to their heavy reliance on time and resources. This research pioneers bridge inspection by integrating ViT with diverse image enhancement detectors, significantly improving concrete crack detection accuracy. Notably, a custom-built CNN achieves over 99% accuracy with substantially lower training time than ViT, making it an efficient solution for enhancing safety and resource conservation in infrastructure management. These advancements enhance safety by enabling reliable detection and timely maintenance, but they also align with Industry 4.0 objectives, automating manual inspections, reducing costs, and advancing technological integration in public infrastructure management.

42 ENGINEERING↗
DOE OSTI2022

Development and Demonstration of a Fuel-Efficient, Class 8 Tractor & Trailer Engine System (SuperTruck II)

Navistar presents the SuperTruck II (ST II) Final Report to the Unites States Department of Energy (US DOE), which covers the five Budget Periods (BPs) from 10-1-2016 through 6-30-2022. For ST II, Navistar built on the achievements of the SuperTruck I (ST I) Program as a catalyst to continue critical research, design and development, testing, and operations to reach the ambitious goals of the ST II project. This approach allowed Navistar to continue contributing to the essential needs of our nation for safe, efficient, and cost-effective delivery of goods and services, as we reduced negative environmental effects and improved operational productivity. This document contains information specified in DOE F 4600.2, Final Scientific/Technical Report DOE F 241.3, B. SCIENTIFIC/TECHNICAL REPORTS, explaining how we met and exceeded program requirements. Throughout this Final Report, Navistar extracted information from documents prepared during the project that represent our management, design and development, building, and testing efforts to meet and exceed SuperTruck II project goals. Navistar followed Plan requirements to achieve / exceed Project Objectives: a) >100% improvement in vehicle freight efficiency (FE) (on ton-MPG basis) relative to 2009 baseline with stretch goal of 140% improvement [actual: 170%); b) >55% engine brake thermal efficiency (BTE) demonstrated in operational engine at a 65-mph cruise point on a dynamometer – ≥31% increase from 2009 baseline [actual: 55.20% of combined BTE) ; and c) development and implementation of commercially cost effective technologies (in terms of a simple payback). Technology selection / development path focused on developing technologies applicable for production within 3-year approach, while ensuring technology readiness and cost of ownership for end users. The Program was organized into five budget periods: Requirements / Technology Assessment and Initial Hardware Testing; Technology Development and Concept Readiness Demonstration; Technology Finalization and Validation Tractor / Trailer Fabrication, Integration and Commissioning Demonstration; and Fuel Economy (FE) and Brake Thermal Efficiency (BTE) and Program Completion. Leadership was provided by DOE, with tasks performed by laboratories (Argonne National Laboratory, Lawrence Livermore National Laboratory); partners at Bosch, TPI, Dana, and J.B. Hunt; , and support from University of Michigan and Clemson University. Navistar lead this team with Principal Investigator / Contracting Officer; Project Manager (PM); Vehicle, Engine, and Aftertreatment Engineers; Finance Manager, Technical Program Leads, and Legal/IP; and other key personnel. Work also included personnel in risk management; funding / budget / finance. Work involved analysis, development, testing, and down selection of individual/system engine, aftertreatment, and vehicle technologies, with integration of selected technologies into a prototype vehicle for demonstration of fuel-efficiency gain. Work also included component/integrated system level development of truck and trailer aerodynamics, base engine efficiency, advanced aftertreatment, combustion efficiency, waste heat recovery, hybrid powertrain, reduced rolling resistance, weight reduction, idle reduction, and driver feedback. As ST II progressed, Navistar performed computer-based modeling / simulations of technologies focused on the primary operational areas: Engine, Aftertreatment, and Vehicle. During the ST II Program, the COVID Virus outbreak unexpectedly challenged by the effects of, which affected staffing, scheduling, design, supplies, availability of materials, production procedures, and testing. The DOE responded by extending the program by three quarters to ensure that project tasks were completed for this vital project. Focus continued on analyzing, developing, testing, and down selecting individual-/system-level engine and vehicle technologies for integration of the final selected technologies into a prototype vehicle that would demonstrate fuel-efficiency gains made possible through these technologies. This included component/integrated system-level development of truck and trailer aerodynamics, base engine efficiency, advanced aftertreatment, combustion efficiency, waste heat recovery, solar power, distributed and intelligent vehicle power, hybrid powertrain, reduced rolling resistance, weight reduction, idle reduction, and driver feedback. Throughout the program, function, reliability, and performance at all levels were ensured through testing. Proof of this approach was demonstrated in multiple, on-road demonstrations: Scenario A (Flatland) Fuel Economy, Scenario B (Hilly) Fuel Economy, and City Cycle Tests. Other benefits derived from ST II included new/improved products, publications, patents, and next-step capabilities related to electric/hydrogen vehicles and autonomous driving.

Zukouski, Russ↗