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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 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 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↗
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.↗
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.↗
DOE OSTI2020

Bacteria Contribute to Plant Secondary Compound Degradation in a Generalist Herbivore System

Leaf-cutter ants are dominant neotropical herbivores capable of deriving energy from a wide range of plant substrates. The success of leaf-cutter ants is largely due to their external gut, composed of key microbial symbionts, specifically, the fungal mutualist L. gongylophorus and a consistent bacterial community. Both symbionts are known to have critical roles in extracting energy from plant material, yet comparatively little is known about their roles in the detoxification of plant secondary compounds. In this study, we assessed if the bacterial communities associated with leaf-cutter ant fungus gardens can degrade harmful plant chemicals. We identify plant secondary compound detoxification in leaf-cutter ant gardens as a process that depends on the degradative potential of both the bacterial community and L. gongylophorus . Our findings suggest that the fungus garden and its associated microbial community influence the generalist foraging abilities of the ants, underscoring the importance of microbial symbionts in plant substrate suitability for herbivores.

59 BASIC BIOLOGICAL SCIENCES↗
NASA NTRS1997

Pool Boiling Experiment Has Five Successful Flights

The Pool Boiling Experiment (PBE) is designed to improve understanding of the fundamental mechanisms that constitute nucleate pool boiling. Nucleate pool boiling is a process wherein a stagnant pool of liquid is in contact with a surface that can supply heat to the liquid. If the liquid absorbs enough heat, a vapor bubble can be formed. This process occurs when a pot of water boils. On Earth, gravity tends to remove the vapor bubble from the heating surface because it is dominated by buoyant convection. In the orbiting space shuttle, however, buoyant convection has much less of an effect because the forces of gravity are very small. The Pool Boiling Experiment was initiated to provide insight into this nucleate boiling process, which has many earthbound applications in steamgeneration power plants, petroleum plants, and other chemical plants. In addition, by using the test fluid R-113, the Pool Boiling Experiment can provide some basic understanding of the boiling behavior of cryogenic fluids without the large cost of an experiment using an actual cryogen.

Chiaramonte, Fran↗
DOE OSTI2020

Characterisation of Specimens from a Former Soviet Thorium Processing Facility to Support Site Remediation

The former Prydniprovski Chemical Plant (PChP) is a large ex-soviet nuclear materials processing site of roughly 260 hectares, located in central Ukraine. PcHP was in operation between 1948 and 1991 for the purposes of processing uranium and thorium ore into ore concentrate. During its operational lifetime, tens of millions of tonnes of radioactive waste was generated on the site. A consequence of these activities, coupled with the mismanagement of the resulting radioactive materials and by-products, is that approximately 45% of the southern part of the site has become radioactively contaminated. This area comprises some 100-200 buildings and structures, many of which are in a state of disrepair and dereliction. Around 20 of these buildings are heavily radioactively contaminated, with radiation levels from a few μSv/hr to a maximum of 4 mSv/hr reported. The European Commission is currently working with the Ukraine Ministry of Energy and Coal Use and the Nuclear Regulator to improve radiological safety and security at the site. In order for these remediation works to proceed, the site management needs to characterise the radioactive materials that are held there. As part of this activity, the team from the University of Bristol have undertaken a survey of one of the most heavily contaminated buildings, collecting a selection of in situ material samples. A suite of complimentary materials characterisation techniques (e.g. X-ray Fluorescence, Raman Spectroscopy, etc) have been deployed in order to determine the radionuclides and composition of the compounds present. Characterisation of these samples will allow the operators of the chemical plant to go forward with remediation works within the building.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2025

Unraveling Bacterial Adaptation Strategies in the Microbiome Shaped by the Chemical Environment of the Plant Rhizosphere

The rhizosphere is a dynamic environment where rhizodeposits that include primary and secondary metabolites and mucilage serve as nutrient sources for soil microorganisms, attracting them toward plant roots. However, understanding how these microbes specifically respond to plant root chemical signals has been hindered by the challenges of disentangling physical and chemical interactions between the microbes and plant roots. To address this, we implemented an innovative filter-based experimental setup on plant roots that creates a physical barrier while facilitating the exchange of chemical signals. The proteomic analysis of 10 Populus root-associated bacterial strains grown in the presence or absence of a plant in either individual or mixed community conditions provided detailed insights into the functional responses of these strains to the root chemical environment. Additionally, this approach allowed us to discern the impact of root exudates on overall community dynamics. In particular, metaproteomic analyses revealed that each of these 10 microbial members responds uniquely to the presence of the plant, with Bacillus and Pantoea exhibiting the most dramatic favorable impact. Proteomic examination revealed the details of metabolism fine-tuning, including processes such as chemotaxis and ATP-binding cassette transporter proteins. This study demonstrates the application of a filter-based experimental setup to study microbial responses to plant chemicals and sheds light on adaptation strategies employed by various bacterial strains for survival in the rhizosphere.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1996

Pool Boiling Experiment Has Successful Flights

The Pool Boiling Experiment (PBE) is designed to improve understanding of the fundamental mechanisms that constitute nucleate pool boiling. Nucleate pool boiling is a process wherein a stagnant pool of liquid is in contact with a surface that can supply heat to the liquid. If the liquid absorbs enough heat, a vapor bubble can be formed. This process occurs when a pot of water boils. On Earth, gravity tends to remove the vapor bubble from the heating surface because it is dominated by buoyant convection. In the orbiting space shuttle, however, buoyant convection has much less of an effect because the forces of gravity are very small. The Pool Boiling Experiment was initiated to provide insight into this nucleate boiling process, which has many Earthbound applications, such as steam-generation power plants, petroleum, and other chemical plants. Also, by using the test fluid R-113, the Pool Boiling Experiment can provide some basic understanding of the boiling behavior of cryogenic fluids without the large cost of an experiment using an actual cryogen.

Source record↗
DOE OSTI2021

Economic risk analysis for the capture of a distributed energy resource using modular chemical process intensification

Recent advances in the chemical process industry have allowed for the intensification of reactors and unit operations, by enhancing heat and mass transfer or combining multiple unit operations. Process intensification can enable chemical plants to be constructed in a more compact, modular fashion, offering improvements over conventional on-site approaches to capital construction, operations and maintenance. This modular chemical process intensification (MCPI) offers several benefits over conventional stick-built (CSB) plant construction in terms of reduced footprint, reduced energy consumption, lower cost, less waste and improved safety and quality control. However, acceptance of MCPI over CSB construction practices within the chemical industry can be impeded by the uncertain risks associated with investing in new technology. Furthermore, the work here documents a case study during the development of a modular chemical plant for capturing distributed energy resources within chemical production. This MCPI approach to plant construction is contrasted with a CSB approach for producing the same chemical product. Data collection tools were developed, based on a literature review, and data was collected from the technology developer to understand the process technology. Sensitivity analysis was then conducted to analyze the business rationale for the application of MCPI over CSB across several market scenarios. It was found that MCPI would be better suited for capacities up to 150 000 metric tons per year, but that improvement in payback period was needed. Additionally, for MCPI approach to achieve acceptable payback periods, efforts are needed to reduce the cost of capital equipment and compress the schedule for ramping up modular production.

42 ENGINEERING↗
DOE OSTI2021

Hotter droughts alter resource allocation to chemical defenses in piñon pine

Abstract Heat and drought affect plant chemical defenses and thereby plant susceptibility to pests and pathogens. Monoterpenes are of particular importance for conifers as they play critical roles in defense against bark beetles. To date, work seeking to understand the impacts of heat and drought on monoterpenes has primarily focused on young potted seedlings, leaving it unclear how older age classes that are more vulnerable to bark beetles might respond to stress. Furthermore, we lack a clear picture of what carbon resources might be prioritized to support monoterpene synthesis under drought stress. To address this, we measured needle and woody tissue monoterpene concentrations and physiological variables simultaneously from mature piñon pines ( Pinus edulis ) from a unique temperature and drought manipulation field experiment. While heat had no effect on total monoterpene concentrations, trees under combined heat and drought stress exhibited ~ 85% and 35% increases in needle and woody tissue, respectively, over multiple years. Plant physiological variables like maximum photosynthesis each explained less than 10% of the variation in total monoterpenes for both tissue types while starch and glucose + fructose measured 1-month prior explained ~ 45% and 60% of the variation in woody tissue total monoterpene concentrations. Although total monoterpenes increased under combined stress, some key monoterpenes with known roles in bark beetle ecology decreased. These shifts may make trees more favorable for bark beetle attack rather than well defended, which one might conclude if only considering total monoterpene concentrations. Our results point to cumulative and synergistic effects of heat and drought that may reprioritize carbon allocation of specific non-structural carbohydrates toward defense.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2024

An Approach to Dynamic Human Reliability Analysis and Its Data Collection Framework

Human reliability analysis (HRA) is a method for evaluating human errors in a variety of complex systems such as nuclear power plants, military systems, aircraft, and chemical plants. Most HRA methods currently used by regulatory institutes or utilities are called static HRA and are carried out by simple worksheets or simple calculators. To date, there are many unsolved or intrinsic challenges in static HRA. For example, existing static HRA does not realistically model and evaluate human actions as they would be performed at actual systems. There is no method with HRA to objectively estimate the time required for human actions despite being essential to HRA processes. In addition, many HRA methods still rely on a dataset generated prior to the 1980s, from unrelated industry experience or simply from expert judgment. Accordingly, this study attempted to research how to overcome the challenges of existing HRA via dynamic risk assessment (a.k.a., simulation-based or computation-based risk assessment) techniques. First, this study developed a dynamic HRA method, named as PRocedure-based Investigation Method of EMRALD Risk Assessment – HRA (PRIMERA-HRA). The PRIMERA-HRA mainly concentrates on providing HRA analysts with specific guidelines on how to reasonably model human actions, assign human reliability data and evaluate output of simulation within a dynamic probabilistic risk assessment tool, called as Event Modeling Risk Assessment using Linked Diagrams (EMRALD). Second, this study also developed a module for performance shaping factors (i.e., the key concept in HRA quantification) applicable to dynamic HRA, then implemented it based on PRIMERA-HRA within the EMRALD tool. Third, this study developed an HRA data collection framework to support dynamic HRA, called as Simplified Human Error Experimental Program (SHEEP). Originally, the SHEEP study aimed to support static HRA and its data collection, but recently extended the scope to the new technologies such as dynamic HRA or HRA for advanced reactors. SHEEP focuses on the use of data collected from simplified simulators to complement—but not replace—data collection studies using full-scope simulators and actual operators. To date, many experiments were conducted under the SHEEP framework. Multiple analyses, such as human performance analysis, human error analysis, task complexity analysis, learning effect analysis and time distribution analysis, were also carried out using the collected data. Then, based on the major insights, an approach to inferring full-scope data based on simplified simulator data was proposed. The PRIMERA-HRA and SHEEP research are expected to evaluate human actions more realistically than existing static HRA, provide an opportunity to collect more HRA data with reasonable cost and labor, then contribute to enhance the quality of HRA.

99 - GENERAL AND MISCELLANEOUS↗