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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Conceptual range estimation for total cost of ownership of modular process‐intensified chemical plants

Abstract Chemical companies have used modularization to reduce capital costs and project timelines, putting capital to work faster and lowering the risk of entering new markets. Nevertheless, the impacts of using modularization along with advanced technologies, such as process intensification, have not yet been fully realized, often due to the uncertain business risks associated with their implementation. Therefore, new methods are needed for quantifying the impact of modular chemical process intensification (MCPI) on the capital and operating costs of chemical plants to help build a business case for this novel approach. This article presents a new conceptual range estimation technique for total cost of ownership that addresses the deficiencies of existing methods for quantifying MCPI impacts. The incorporation of percentage range estimates was employed to allow for adaptability across various cost and size scales. This work also begins to elucidate how chemical engineering and construction firms can benefit from MCPI and identifies barriers that inhibit MCPI applications in the chemical industry.

Alhamouri, Khaled I.↗
DOE OSTI2025

Assessment of NuScale SMR Steam Heat Augmentation for Chemical Plant Decarbonization

Nearly 50% of the total energy consumed by the industrial sector in the United States is used to produce process steam with natural gas and coal-fired boilers1 . This project conducts a technoeconomic assessment of a NuScale Small Modular Reactor (SMR) coupled with a chemical plant as an Integrated Energy System (IES) where nuclear produces steam and electric power to meet the requirements of a large chemical plant. In a 2020 study, ORNL evaluated the feasibility of using advanced SMRs, including the NuScale design, to supply energy to the Eastman Chemical Plant. However, since that report was published, NuScale received NRC approval for its uprated 77 MWe design with 56% more power and has also introduced a high-temperature, high pressure, steam heat-augmentation system, a key focus of the new study. The new study also benefits from revised capital costs, a 10-day refueling outage time, reduced plant staffing, higher capacity factors, and a site boundary Emergency Planning Zone methodology. The study consists of a techno-economic assessment of two possible energy sources (nuclear and natural gas) in a number of steam and power generation configurations (NuScale Power Modules (NPMs), boilers and combinations of both) to satisfy the steam and power demand with the most reliable and cost competitive system. A total of 2,947.3 klb/hr of steam and 72.5 MWe of electricity are required for the demonstration case. A range of scenarios and solutions are explored, from a 12-NPM plant (3,000 MWth)—with excess capacity and redundancy, capable of supplying a significant amount of extra power to the grid—to a 4-NPM (1,000 MWth) plant—supplemented with existing boilers or grid power for redundancy. The study uses historical steam and power data from a chemical plant and examines the sensitivity to natural gas and grid power cost variations. Scenarios with up to two times gas and electricity costs were considered. Profitability in a 60-year time horizon was analyzed, consistent with NuScale’s design life specification. A steady-state site integration and reliability analysis was performed, and trade-offs were identified.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2014

Plant chemical biology: are we meeting the promise?

As an early adopter of plant chemical genetics to the study of endomembrane trafficking, we have observed the growth of small molecule approaches. Within the field, we often describe the strengths of the approach in a broad, generic manner, such as the ability to address redundancy and lethality. But, we are now in a much better position to evaluate the demonstrated value of the approach based on examples. In this perspective, we offer an assessment of chemical genetics in plants and where its applications may be of particular utility from the perspective of the cell biologist. Beyond this, we suggest areas to be addressed to provide broader access and enhance the effectiveness of small molecule approaches in plant biology.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Low Carbon Intensity Formic Acid Chemical Synthesis from Direct Air Captured CO 2 Utilizing Chemical Plant Waste Heat - Final Technical Report

The primary objective of Low Carbon Intensity Formic Acid Chemical Synthesis from Direct Air Captured CO 2 Utilizing Chemical Plant Waste Heat (ChemFADAC) is to execute and complete a FEED study for an integrated direct air capture (DAC) and carbon conversion system (together, the DACUS system) co-located at a Nutrien nitric acid production facility in Kennewick, WA capable of capturing and converting a minimum of 5,000 MT/year net atmospheric CO 2 to low carbon intensity formic acid (FA) using industrial waste heat and renewable electricity. The goal will be achieved through the completion of four objectives using a collaborative approach with community stakeholders. Objective 1. Conduct a FEED study and Class 3 project cost estimate for the proposed DACUS system that maximizes use of thermal energy from the Nutrien KFO host site to produce low carbon intensity FA from atmospheric CO 2 . Objective 2. Perform a cradle-to-gate life-cycle analysis of the DACUS system to determine the environmental sustainability and carbon intensity (CI) of the proposed project and product from the results of the FEED study. Objective 3. Perform a business case analysis from results of the LCA, FEED study and cost estimate to justify investment to build the DACUS project at the Nutrien KFO site. Objective 4. Quantify how deployment of the proposed technology will promote and prepare a ready workforce for clean energy and manufacturing jobs and coordinate with community stakeholders to perform an environmental justice and a preliminary economic revitalization and job creation outcomes analysis.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Nuclear Technology Selection and Preliminary Integration at St. Charles and Carrollton Chemical Plants

Nuclear energy is identified as a valuable candidate for decarbonizing industrial facilities as a non-emitting baseload energy source capable of dispatching energy as needed for an integrated facility. As industrial facilities are unique, analyzing what nuclear technology is the best candidate should be evaluated on a case-by-case basis. For two identified facilities of the Dow Chemical Company, an ideal mix of nuclear energy resources is calculated, and integration strategies are put forward. This research was funded through a Gateway for Accelerated Innovation in Nuclear (GAIN) Nuclear Energy Voucher, specifically seeking near-term engineering solutions for the technical issue of introducing nuclear generated energy into the Dow chemical facilities. The research is split into four main phases: background on reactors and chemical facilities, preliminary engineering analysis determining how reactor technologies may be integrated with specific facilities, site characterization and discrete hazards analysis, and finally an optimization of reactor-facility selection through the use of Framework for Optimization of ResourCes and Economics (FORCE) tools.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2014

Fuel-Flexible Combustion System for Refinery and Chemical Plant Process Heaters

This project culminated in the demonstration of a full-scale industrial burner which allows a broad range of “opportunity” gaseous fuels to be cost-effectively and efficiently utilized while generating minimal emissions of criteria air pollutants. The burner is capable of maintaining a stable flame when the fuel composition changes rapidly. This enhanced stability will contribute significantly to improving the safety and reliability of burner operation in manufacturing sites. Process heating in the refining and chemicals sectors is the primary application for this burner. The refining and chemical sectors account for more than 40% of total industrial natural gas use. Prior to the completion of this project, an enabling technology did not exist that would allow these energy-intensive industries to take full advantage of opportunity fuels and thereby reduce their natural gas consumption. Opportunity gaseous fuels include biogas (from animal and agricultural wastes, wastewater plants, and landfills) as well as syngas (from the gasification of biomass, municipal solid wastes, construction wastes, and refinery residuals). The primary challenge to using gaseous opportunity fuels is that their composition and combustion performance differ significantly from those of conventional fuels such as natural gas and refinery fuel gas. An effective fuel-flexible burner must accept fuels that range widely in quality and change in composition over time, often rapidly. In Phase 1 of this project, the team applied computational fluid dynamics analysis to optimize the prototype burner’s aerodynamic, combustion, heat transfer, and emissions performance. In Phase 2, full-scale testing and refinement of two prototype burners were conducted in test furnaces at Zeeco’s offices in Broken Arrow, OK. These tests demonstrated that the full range of conventional and opportunity fuels could be utilized by the project’s burner while achieving robust flame stability and very low levels of air pollutant emissions. In Phase 3, the team retrofitted three fuel-flexible burners into a fired heater at a Shell plant and demonstrated the project’s technology over a 6-month period. The project burners performed well during this period. They remain in commercial service at the Shell plant. Through this work, an improved understanding of flame stabilization mechanisms was gained. Also, methods for accommodating a wide range of fuel compositions were developed. This knowledge facilitated the commercialization of a new generation of burners that are suitable for the fuels of the future.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2015

Advanced IGCC/Hydrogen Gas Turbine Development

The objective of this program was to develop the technologies required for a fuel flexible (coal derived hydrogen or syngas) gas turbine for IGCC that met DOE turbine performance goals. The overall DOE Advanced Power System goal was to conduct the research and development (R&D) necessary to produce coal-based IGCC power systems with high efficiency, near-zero emissions, and competitive capital cost. To meet this goal, the DOE Fossil Energy Turbine Program had as an interim objective of 2 to 3 percentage points improvement in combined cycle (CC) efficiency. The final goal is 3 to 5 percentage points improvement in CC efficiency above the state of the art for CC turbines in IGCC applications at the time the program started. The efficiency goals were for NOx emissions of less than 2 ppm NOx (@15 % O2). As a result of the technologies developed under this program, the DOE goals were exceeded with a projected 8 point efficiency improvement. In addition, a new combustion technology was conceived of and developed to overcome the challenges of burning hydrogen and achieving the DOE’s NOx goal. This report also covers the developments under the ARRA-funded portion of the program that include gas turbine technology advancements for improvement in the efficiency, emissions, and cost performance of gas turbines for industrial applications with carbon capture and sequestration. Example applications could be cement plants, chemical plants, refineries, steel and aluminum plants, manufacturing facilities, etc. The DOE’s goal for more than 5 percentage point improvement in efficiency was met with cycle analyses performed for representative IGCC Steel Mill and IGCC Refinery applications. Technologies were developed in this program under the following areas: combustion, larger latter stage buckets, CMC and EBC, advanced materials and coatings, advanced configurations to reduce cooling, sealing and rotor purge flows, turbine aerodynamics, advanced sensors, advancements in first stage hot gas path components, and systems analyses to determine benefits of all previously mentioned technologies to a gas turbine system in an IGCC configuration. This project built on existing gas turbine technology and product developments, and developed and validated the necessary turbine related technologies and sub-systems needed to meet the DOE turbine program goals. The scope of the program did not cover the design and validation of a full-scale prototype machine with the technology advances from this program incorporated. In summary, the DOE goals were met with this program. While the commercial landscape has not resulted in a demand for IGCC gas turbines many of the technologies that were developed over the course of the program are benefiting the US by being applied to new higher efficiency natural gas fueled gas turbines.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Criticality Alarm Systems at the Idaho Chemical Processing Plant

The Idaho Chemical Processing Plant (ICPP) has a number of criticality alarm systems (CAS) in the various facilities. The complexity of the plant creates some unique CAS problems. A detailed review of the CAS has been made to determine the level of compliance with ANSI 8.3-1986. A major CAS upgrade project is currently in the design stage which will expand coverage and bring all CAS monitoring unshielded areas into full compliance with ANSI 8.3-1986. Because DOE Orders do not contain an exclusion that exempts the need for CAS coverage in shielded areas as provided in ANSI 8.3-1986, a future CAS upgrade project is in the planning stage which will also upgrade the CAS coverage in shielded portions of the plant.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

Manufacturing Supply Chain Development for Modular Solar-Thermochemical Conversion Platform - CRADA 387 (Final Report)

Modular chemical process intensification (MCPI) is an emerging field where chemical processing is performed using small-scale modular equipment instead of conventional large centralized chemical plants. Conventional chemical plants benefit from economies of scale that encourage scale-up to ever larger plants. A goal of MCPI is to develop technology that intensifies processing so that equipment can be dramatically smaller and integrated into modular systems. Scale-up occurs by adding more modules in parallel rather than making the equipment larger. A key concept is that equipment and modules can ultimately be cheaper by leveraging economies of mass production, analogous to the automotive industry, in manufacturing the equipment. This project made significant progress toward this outcome by meeting the RAPID institute metric to reduce equipment cost by 20% for each doubling in manufacturing volume. The MCPI application was thermochemical technology that is being commercialized by STARS Technology Corporation, one of the CRADA partners. The technology converts solar and renewable power to chemical energy to produce renewable hydrogen, fuels, and chemicals. The benefit to the public is reduction in greenhouse gases that are contributing to climate change. The project transitioned the steam methane reforming (SMR) reactor from conventional fabrication methods to additive manufacturing (AM) direct metal laser sintering (DMLS) process. This is projected to reduce the cost of making a reactor by 58% when producing 100 reactors per year. Innovations in the DMLS process produced a patented design that reduces reactor weight by 60%. Reductions in material costs and processing time extend the DMLS advantage to higher production volumes. The new design promises to be 38% cheaper than the conventional processes at 1000 units per year. The resulting 87% reduction in the steam methane reforming (SMR) module cost in scaling from current costs meets the RAPID metric. The project was successful in producing and testing the first ever additively manufactured SMR reactors. A reactor achieved over 82% efficiency in converting electric power to chemical energy, which is a world record for an inductively heated SMR. The project has contributed to the design and assembly of a first demonstration plant that is headed to a hydrogen bus filling station in Thousand Palms, CA.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2016

Weldon Spring, Missouri, Site Annual Report for Calendar Year 2015 June 2016

1.1 Purpose and Scope. This report summarizes the activities, compliance status, annual inspection, and environmental monitoring results from calendar year 2015 for the Weldon Spring, Missouri, Site. The U.S. Department of Energy (DOE) prepares this annual report as part of the site’s long-term surveillance and maintenance (LTS&M) activities, in accordance with the requirements of the Long-Term Surveillance and Maintenance Plan for the Weldon Spring, Missouri, Site (LTS&M Plan) (DOE 2008a) and the Federal Facility Agreement for the Weldon Spring Site (DOE 2006). The Weldon Spring site is a Comprehensive Environmental Response, Compensation, and Liability Act (CERCLA) site. 1.2 Site Description. The Weldon Spring site is located in St. Charles County, Missouri, about 30 miles west of St. Louis, Missouri (Figure 1). The site comprises two geographically distinct, DOE-owned properties: the former Weldon Spring Chemical Plant and Raffinate Pit sites (Chemical Plant) and the former Weldon Spring Quarry (Quarry). The former Chemical Plant is located about 2 miles southwest of the junction of Missouri State Route 94 and Interstate 64. The Quarry is about 4 miles southwest of the former Chemical Plant. Both sites are accessible from Missouri State Route 94. During the early 1940s, the Department of the Army acquired 17,232 acres of private land in St. Charles County for the construction of the Weldon Spring Ordnance Works facility. The former Ordnance Works site has since been divided into several contiguous areas under different ownership, as depicted in Figure 2. Current land use of the former Ordnance Works site includes the former Chemical Plant and Quarry, the U.S. Army Reserve Weldon Spring Training Area, the Missouri Department of Conservation (MDC), the Missouri Department of Natural Resources (MDNR) Division of State Parks (MDNR-Parks), Francis Howell High School, a St. Charles County highway maintenance (formerly Missouri Department of Transportation [MoDOT]) facility, the Public Water Supply District No. 2 water supply facility, the St. Charles County law enforcement training center, the village of Weldon Spring Heights, and a University of Missouri research park. The former Chemical Plant and Quarry areas total 228.16 acres. The Former Chemical Plant property occupies 219.50 acres, and the Quarry occupies 8.66 acres.

2015 Annual Report Weldon Spring↗
DOE OSTI2019

Dover Light & Power 10 MWe Coal Direct Chemical Looping Plant: Final Technical Report - Appendix A Environmental Information Volume

A 10 MWe coal direct chemical looping plant was designed for the City of Dover Municipal Power Plant. The system consisted of a moving bed reducer and circulating fluidized bed combustor. An iron-oxide oxygen carrier was used. The steam cycle included in bed surface in the combustor and conventional convection pass surface. A thorough environmental information volume was generated to support the installation of the system at the plant.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2019

Dover Light & Power 10 MWe Coal Direct Chemical Looping Plant - Topical Report - Appendix A Environmental Information Volume

An environmental information volume was generated to support the installation of a 10 MWe coal direct chemical looping power plant at the City of Dover's municipal power plant. The coal direct chemical looping process utilizes Ohio State University's iron oxide based oxygen carrier in a moving bed reducer coupled with a circulating fluidized bed combustor.

20 FOSSIL-FUELED POWER PLANTS↗
NASA NTRS2001

Automated Theorem Proving in High-Quality Software Design

The amount and complexity of software developed during the last few years has increased tremendously. In particular, programs are being used more and more in embedded systems (from car-brakes to plant-control). Many of these applications are safety-relevant, i.e. a malfunction of hardware or software can cause severe damage or loss. Tremendous risks are typically present in the area of aviation, (nuclear) power plants or (chemical) plant control. Here, even small problems can lead to thousands of casualties and huge financial losses. Large financial risks also exist when computer systems are used in the area of telecommunication (telephone, electronic commerce) or space exploration. Computer applications in this area are not only subject to safety considerations, but also security issues are important. All these systems must be designed and developed to guarantee high quality with respect to safety and security. Even in an industrial setting which is (or at least should be) aware of the high requirements in Software Engineering, many incidents occur. For example, the Warshaw Airbus crash, was caused by an incomplete requirements specification. Uncontrolled reuse of an Ariane 4 software module was the reason for the Ariane 5 disaster. Some recent incidents in the telecommunication area, like illegal "cloning" of smart-cards of D2GSM handies, or the extraction of (secret) passwords from German T-online users show that also in this area serious flaws can happen. Due to the inherent complexity of computer systems, most authors claim that only a rigorous application of formal methods in all stages of the software life cycle can ensure high quality of the software and lead to real safe and secure systems. In this paper, we will have a look, in how far automated theorem proving can contribute to a more widespread application of formal methods and their tools, and what automated theorem provers (ATPs) must provide in order to be useful.

Schumann, Johann↗
NASA NTRS1978

High performance, high density hydrocarbon fuels

The fuels were selected from 77 original candidates on the basis of estimated merit index and cost effectiveness. The ten candidates consisted of 3 pure compounds, 4 chemical plant streams and 3 refinery streams. Critical physical and chemical properties of the candidate fuels were measured including heat of combustion, density, and viscosity as a function of temperature, freezing points, vapor pressure, boiling point, thermal stability. The best all around candidate was found to be a chemical plant olefin stream rich in dicyclopentadiene. This material has a high merit index and is available at low cost. Possible problem areas were identified as low temperature flow properties and thermal stability. An economic analysis was carried out to determine the production costs of top candidates. The chemical plant and refinery streams were all less than 44 cent/kg while the pure compounds were greater than 44 cent/kg. A literature survey was conducted on the state of the art of advanced hydrocarbon fuel technology as applied to high energy propellents. Several areas for additional research were identified.

Frankenfeld, J. W.↗
NASA NTRS1999

Low-Power Temperature-Swing Adsorption for Mars Atmosphere Acquisition

The promise of ISRU-based mission architectures for Mars surface exploration will begin to be realized during the next decade as robotic spacecraft sent to Mars carry components and whole chemical plants for producing propellants from the planet's atmosphere. These chemical plants will need to perform three primary operations: acquisition of atmospheric carbon dioxide, reactions to transform the gas into oxygen and possibly fuel, and storage of the products. This presentation focuses on development of technologies at NASA Ames Research Center for the first of these operations, carbon dioxide acquisition. The carbon dioxide acquisition component for a propellant production plant has several general, top level requirements. It has a stringent requirement for minimal power consumption; a critical need for long-term reliability over the period of time the chemical plant must operate (say, 500 days); a production rate requirement for carbon dioxide; and a state point requirement (particularly pressure) for the CO2 produced. The first two requirements help determine the best technological approach, while the latter two generally define the characteristics (e.g., size and power consumption) of the device. Mass and volume must be minimized, as usual.

Finn, J. E.↗
DOE OSTI2016

Special Analysis for the Disposal of the Idaho National Laboratory Idaho Chemical Processing Plant Low-Level Waste Stream at the Area 5 Radioactive Waste Management Site, Nevada National Security Site, Nye County, Nevada

This special analysis (SA) evaluates whether the Idaho National Laboratory (INL) Idaho Chemical Processing Plant (ICPP) Low-Level waste stream is suitable for disposal by shallow land burial at the Area 5 Radioactive Waste Management Site on the Nevada National Security Site (NNSS). The INL ICPP Low-Level waste stream consists of debris and solidified liquids. The INL ICPP Low-Level waste stream requires an SA to resolve two unreviewed disposal questions (UDQs). The first UDQ addresses whether it is acceptable to dispose of radium-226 (226Ra) at an activity concentration that exceeds the NNSS Waste Acceptance Criteria (WAC) Action Level. The second UDQ evaluates the acceptability of disposing of five long-lived radionuclides without WAC action levels. Long-lived radionuclides without action levels are radionuclides not evaluated in the performance assessment.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS1999

Low-Power Temperature-Swing Adsorption for Mars Atmosphere Acquisition

The promise of In-Situ Resource Utilization (ISRU)-based mission architectures for Mars surface exploration will begin to be realized during the next decade as robotic spacecraft sent to Mars carry components and whole chemical plants for producing propellants from the planet's atmosphere. These chemical plants will need to perform three primary operations: acquisition of atmospheric carbon dioxide, reactions to transform the gas into oxygen and possibly fuel, and storage of the products. This presentation focuses on development of technologies at NASA Ames Research Center for the first of these operations, carbon dioxide acquisition.

Finn, J. E.↗