Search NASA⌕ Search

SEARCH · Search NASA

Results for “Industry challenge”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 19 records

Challenges, Industry Practice, and Research Opportunities for Protection of IBR-Rich Systems

The objective of this technical report is to outline the challenges of protection design for power systems rich in inverter-based resources (IBRs), synthesize current industrial practices, review new approaches from recent literature, and explore future opportunities in protection. IBRs are experiencing widespread adoption across both transmission and distribution systems. When present in significant quantities, IBRs challenge the performance of many traditional protection functions. To address these issues, the industry has developed sophisticated protection schemes that involve advanced relaying techniques in highly engineered pilot projects. However, these schemes are expensive and time-consuming to develop, build, and test. Researchers have proposed a number of new approaches for protection in IBR-rich distribution systems. Despite their potential, these new approaches do not address some major shortcomings of industry approaches stemming from complexity, practical requirements, and reliability.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Electric Power Industry Challenges Due to Increasing Shares of Inverter-Based Resources in Power Systems

The large-scale integration of variable renewable energy technologies around the world is forcing electric power systems into an unprecedented transition. This paper reports on power grid modernization and reliability issues related to the planning and operation of power systems with high levels of variable renewable energy. The contents of this paper stem from recent qualitative research in the form of a summary of an industry survey. The technical feedback from the interviewed 37 industry experts helped us identify 12 key areas of potential concern, which are discussed throughout this paper.

power system operation↗

Integrating Renewable Energy in the Iron and Steel Industry: Challenges, Opportunities, and Enabling Approaches

Renewable energy can help mine operators with several challenges they face today, including energy costs, fossil fuel volatility, social license to operate, and meeting environmental, societal, and governance goals. However, the integration of wind, solar, storage, and other renewable technologies face several barriers that are generally not well understood. Many of these barriers will require further research, development, demonstration, and deployment before we see higher levels of renewables adoption in the mining industry. Thus, this poster highlights renewable opportunities, barriers, and enabling approaches.

energy demands↗

CTF: A modernized, production-level, thermal hydraulic solver for the solution of industry-relevant challenge problems in pressurized water reactors

CTF is a thermal hydraulic (T/H) subchannel tool that has been extensively developed over the past ten years as part of the Consortium for Advanced Simulation of Light Water Reactors (CASL) program. The code was selected early in the CASL program for support of high-impact challenge problems that were found to be relevant to the nuclear industry and its currently operating fleet of pressurized water reactors (PWRs), including issues such as departure from nucleate boiling (DNB), crud-induced power shifts (CIPSs), and reactivity-insertion accidents (RIAs). By incorporating CTF into the multiphysics Virtual Environment for Reactor Application (VERA) core simulator software developed by CASL, CTF has become the primary means of providing fluid and fuel thermal feedback, as well as T/H figure-of-merits (FOMs) in large-scale reactor simulations. With the goal of solving industry challenge problems, CASL placed great emphasis on developing high-quality, high-performance, validated software tools that offer higher fidelity than what is currently possible with current industry methods. In support of this effort, CTF was developed from a research tool into an nuclear quality assurance (NQA-1)–compliant, production-level software tool that is capable of addressing the stated challenge problems and goals of CASL. This work presents a review of the major technological achievements that were realized in developing CTF over the past decade of the CASL program and presents an overview of the code solution approach and closure models.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Transforming the Process Industries through Electrification: Challenges and Opportunities

For the more than 70 years, the process industries have provided essential fuels and materials for global growth. Increased manufacturing production comes with substantial environmental impact. Reducing environmental impact through process electrification, carbon capture, and other emerging technologies would require large changes throughout the process industries. We review opportunities and challenges related to electrification, focusing on technical, operational, and economic considerations. Here, we conclude that electrification could completely eliminate scope 1 CO 2 emissions, increase product quality, and reduce the equipment size and cost. On the other hand, it calls for a significant expansion of power generation capacity, as well as new paradigms for process design and operations.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Advanced High-Strength Steel - Basics and Applications in the Automotive Industry

Challenged to improve safety and fuel economy, automakers continually search for new materials to meet high standards. Several factors drive the material R&D and selection for automotive applications, including safety, fuel efficiency, environmentalism, manufacturability, durability, and quality. In the highly competitive automotive industry, cost is an extremely important factor in material selection. As the motivation to reduce the mass of vehicles continues to grow, automakers seek to maximize the efficiency of their materials selection. Materials in automotive applications are selected to minimize weight while meeting key criteria, including crash performance, stiffness, and forming requirements. Since the 1920s, steel has been the material of choice for automakers worldwide. The weight percentage of steel used in vehicles relative to other materials has grown from around 50% in the early 1980s to about 60% in 2010 for North American light vehicles. Today, steel makes up around 65% of an average automobile’s weight and is the backbone of the entire vehicle. On average, that is 900 kg of steel used per vehicle. To further enhance passenger safety, vehicle performance, and fuel efficiency, reducing the weight of vehicles has become one of the top priorities for the automotive industry. Advanced high-strength steels (AHSSs) are a new generation of steel grades that provide much higher strength and other advantageous properties than other materials while maintaining the high formability required for manufacturing. AHSSs help engineers meet requirements for safety, efficiency, emissions, manufacturability, durability, and quality at a low cost. The relevance of AHSSs is quickly increasing in the automotive industry, and AHSSs are the key material for vehicle mass reduction. Different types of AHSS help parts meet the varied performance demands in different areas of the vehicle, including both the crumple zone and passenger compartment.

36 MATERIALS SCIENCE↗

Opportunities and Challenges for Industrial Water Treatment and Reuse

As the impact of water scarcity in the United States (U.S.) continues to grow through the 21st century, it is critical to develop strategies to reduce water use and improve the security of water resources. One such strategy is to diversify the sources from which water is supplied. Industrial withdrawals represent the fourth largest category of U.S. water use, the majority of which is sourced from fresh surface and groundwater. In this study, we critically explore the potential of industrial wastewater to serve as an alternative water resource through direct treatment and reuse. We begin by reviewing the state of the art of water use, treatment, and reuse across six representative industries: food and beverages, primary metals, pulp and paper, petroleum refining, chemicals, and data centers and campuses, highlighting key challenges and opportunities toward the expansion of reuse. We then employ a technoeconomic assessment of water treatment processes to analyze the capital investment, operating and maintenance costs, levelized cost of water, and electricity consumption of three specific industrial plants as case studies to better understand where research can promote impactful innovation. Finally, drawing together the results of our literature review and technoeconomic analyses, we provide a broad outlook on the future of industrial water reuse and discuss strategies for its expansion.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Key insights from US Department of Energy Better Plants workforce development bootcamps (2022–2025)

This study examines the effectiveness of the US Department of Energy’s Better Plants Program Bootcamps, which are designed to enhance participants’ technical skills in improving energy efficiency and optimizing operations in manufacturing facilities. Through the analysis of survey data collected from 529 participants across 9 bootcamps, the research investigates the motivations, benefits, and demographic trends of attendees. The findings reveal that skill acquisition and improvement are primary drivers for participation, with key benefits including hands-on training on diagnostic equipment and software tools, networking opportunities, and access to technical resources. The analysis shows strong participation from sectors characterized by high energy consumption and employment, such as chemical and transportation equipment manufacturing. Over 50% of participants have job titles that include “EHS” or “Energy” showing their key roles in leading energy efficiency and energy management efforts in manufacturing. Furthermore, the analysis highlights the distribution of participants across managerial, engineering, and technical roles, revealing a higher representation of managers and engineers. This observation suggests a need for targeted outreach to engage technicians, equipment operators, maintenance staff, and floor workers to ensure comprehensive workforce development. The post-bootcamp survey showed that the participants highly valued the opportunities for peer learning and idea exchange, and the benefits they gained from them. This research contributes to the advancement of manufacturing education by demonstrating the efficacy of specialized training in addressing critical industry challenges and fostering a more competent and empowered workforce.

Energy efficiency↗

Transport Mediating Core–Shell Photocatalyst Architecture for Selective Alkane Oxidation

The high activation barrier of the C-H bond in methane, combined with the high propensity of methanol and other liquid oxygenates toward overoxidation to CO 2 , have historically posed significant scientific and industrial challenges to the selective and direct conversion of methane to energy-dense fuels and chemical feedstocks. Here, we report a unique core-shell nanostructured photocatalyst, silica encapsulated TiO 2 decorated with AuPd nanoparticles (TiO 2 @SiO 2 -AuPd), that prevents methanol overoxidation on its surface and possesses high selectivity and yield of oxygenates even at high UV intensity. This room-temperature approach achieves high selectivity for oxygenates (94.5%) with a total oxygenate yield of 15.4 mmol/g cat ·h at 9.65 bar total pressure of CH 4 and O 2 . The working principles of this core-shell photocatalyst were also systematically investigated. Finally, this design concept was further demonstrated to be generalizable for the selective oxidation of other alkanes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Unblocking a rigid purine MOF for kinetic separation of xylenes

The separation of xylene isomers still remains an industrially challenging task. Here, we synthesized and studied porous purine-based metal–organic frameworks (MOFs) for their potential in xylene separations. In particular, Zn(purine)I showed excellent para-xylene/ortho-xylene separation capability with a diffusion selectivity of 6 and high equilibrium adsorption selectivity as indicated by coadsorption experiments. This high selectivity is attributed to the shape and size of the channel aperture within the rigid framework of Zn(purine)I.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Securing Digital Energy Infrastructure: Procurement, Contracting, and Supply Chain Risk Management Guidance

Recognizing the scale of this industry challenge, the United States (U.S.) Department of Energy (DOE) Grid Deployment Office (GDO) and Cybersecurity Energy Security & Emergency Response office have launched a multi-year BESS supply chain security initiative to identify consequence-driven approaches to addressing BESS supply chain security and provide resources to support prioritization of supply chain security efforts associated with the procurement of BESS equipment and services. This guide is one element of the supporting resources to be provided and sets forth a framework and guidance for procurement bidding, selection, risk analysis, and agreements stakeholders can implement to mitigate cybersecurity risks across the entirety of battery system component ecosystem, including the interconnected software and hardware required for control and monitoring BESSs.

25 ENERGY STORAGE↗

High-Burnup BWR LOCA Burst Analysis Using High-Fidelity Multiphysics Simulations

The US nuclear industry is looking to improve on the operating economics of the current fleet of light-water reactors (LWRs). One way of achieving this is by operating fuel to higher burnup. In pressurized water reactors (PWRs), relaxing the current burnup limit will allow for cycle length extensions and power uprates; in boiling water reactors (BWRs) it may allow for improved fuel utilization and reduced feed assemblies, as well as more efficient power uprates and increased capacity factors that will support the Administration’s Executive Order to facilitate 5 GW of power uprates at existing nuclear facilities. However, one of the key limitations to operating fuel to higher burnup is the risk of fuel fragmentation, relocation, and dispersal (FFRD). Recognizing the high interest in extending burnup limits, the US Nuclear Regulatory Commission (NRC) has issued Draft Regulatory Guide DG-1434, which defines an approach that would be acceptable to the NRC for addressing FFRD risk. The approach defined will require better understanding of the phenomena leading to FFRD as well as best-estimate simulation methods to understand FFRD risk in high-burnup cores. The Nuclear Energy Advanced Modeling and Simulation program is supporting the FFRD industry challenge problem through development of state-of-the-art, high-fidelity modeling and simulation LWR analysis capabilities; namely, the BISON fuel performance code and the VERA core simulator software. These tools, along with the US NRC TRACE system analysis code, have been utilized for analysis of FFRD risk in both PWR and BWR cores in recent years. The work documented in this report addresses the lack of high-fidelity research for BWRs and builds on a previous activity where the framework has been applied to Cycles 16 through 18 of Limerick Unit 1, a BWR/4, with introduction of 8 high-burnup lead use assemblies (HBLUAs) that were representative of the 8 HBLUAs loaded into Limerick Unit 2 in 2021. VERA was used in this previous activity to model rod-by-rod depletion in these cycles, and its solution was used to initialize a TRACE simulation of a large-break loss-of-coolant accident (LBLOCA) at the end of Cycle 18. In the work documented in this report, the TRACE model was improved by refining the core mesh and utilizing a new feature that allows for capturing the full 3D VERA power distribution in the model. This allows for a more detailed solution for setting BISON boundary conditions. Furthermore, the solutions from VERA and TRACE were used to set up and perform BISON simulations of about 1,000 rods sampled from the core, including all burnup levels. Utilizing two cladding burst models, it was shown that no fuel rods were predicted to burst during the postulated LBLOCA transient. Additionally, a sensitivity study was performed by artificially increasing linear heat rate during the postulated LBLOCA to identify parameters that correlate with rod burst susceptibility. Burnup, fission gas release, and hoop strain were all found to be positively correlated with rod burst susceptibility. Small-break loss-of-coolant accident (SBLOCA) analyses were also performed; these analyses predicted cladding temperature increases that were bounded by the LBLOCA cladding temperatures for all small break sizes studied for this plant. However, future refinements to the plant response assumptions during the SBLOCA could impact the predicted cladding response. Finally, a benchmark study was performed between CTF and TRACE for LOCA conditions to better qualify CTF for BWR LOCA modeling.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Lawrence Livermore National Laboratory – Innovation and Partnerships Office (IPO): FY24 Technology Transfer Report (2025 Report V3)

Lawrence Livermore National Laboratory’s (LLNL) Innovation and Partnerships Office (IPO) is the focal point for Laboratory engagement with industry. Organizations partner with LLNL to unlock the commercial viability of breakthrough technologies invented at the Laboratory and collaborate to mature them in order to solve complex industry challenges. LLNL technology transfer connects cutting-edge science with real-world applications, empowering businesses to thrive while advancing the nation’s technological edge. We do this by identifying new economic opportunities, protecting LLNL intellectual property (IP) and transferring it to the private sector through licensing and partnerships

42 ENGINEERING↗

Solvent recovery from solvent-fine coal slurries by filtration and steam stripping

Dewatering of fine coal is a significant industrial challenge with economic and environmental implications. Due to the lack of suitable dewatering technologies, fine coal particles are often discarded to waste impoundments, leading to substantial loss of valuable natural resources while creating environmental problems. The hydrophobic-hydrophilic separation (HHS) process is a unique solution to this problem. In this process, a recyclable solvent is used to simultaneously remove inorganic impurities (ash) and water from a run-of-mine fine coal slurry. A small amount of recyclable oil (or solvent) is added to a fine coal slurry so that the solvent can spontaneously displace the water from the surface of coal particles. The spent solvent is subsequently recovered and recycled in a closed loop. Here, we report the results obtained using two different solvents, i.e., pentane and hexane, to de-ash and dewater ultrafine coal and recover the spent solvent by filtration, followed by steam stripping. Most of the spent solvent can be recovered during the filtration step at 20 psig N₂ and at a 60 s filtration time. The residual solvent left in the cake was then recovered using steam under different conditions. The results showed that the residual solvent concentration could be reduced to <1,400 ppm after 10 s of steam stripping at 150°C and 15 psig.

01 COAL, LIGNITE, AND PEAT↗

NREL's Advanced Distribution Management System (ADMS) Test Bed

NREL's advanced distribution management system (ADMS) test bed is a vendor-neutral resource for evaluating existing and future ADMS functionalities in a realistic laboratory setting. The test bed uses Opal-RT's ePHASORsim and eMEGAsim products interfaced with an OpenDSS power system simulation through the HELICS cosimulation platform developed by multiple DOE laboratories; and with power and controller hardware. NREL will present an overview of the test bed and the technologies included within it, and also some examples of how the test bed has been used to address industry challenges.

24 POWER TRANSMISSION AND DISTRIBUTION↗

BISON Capability, Validation and Demonstration for Reactivity-Initiated Accidents

Reactivity Initiated Accidents (RIA) are design basis accidents that could have adverse impacts on the core coolability. In the unlikely event that sufficient reactivity is inserted into the reactor core by the ejected/dropped control rod, prompt energy deposition into the fuel can occur, which when sufficiently high can lead to fuel rod failure or, at large energy deposition levels, expulsion of UO2 fragments or molten UO2 material from the fuel rod. This results in a release of fission product and fuel into the coolant and has the potential to compromise core coolability and threatening the pressure boundary of the primary coolant system. The design basis RIA is one of the industry challenging problems that the CASL aimed to address; the CASL RIA Challenge Problem Charter [1] states, ?The Pressurized Water Reactor (PWR) Rod Ejection Accident (REA) and Boiling Water Reactor (BWR) Control Rod Drop Accident (CRDA) are postulated accidents with consequences that are important to nuclear safety (fuel rod integrity and core coolability). Currently each reload core design must be analyzed to meet regulatory acceptance criteria. The goal of CASLs ModSim capability for RIA is to model the event at a higher fidelity, with validation to existing tests, to better model the transient neutronics and the progression of the fuel and cladding thermal-mechanical behavior. These improved analytical capabilities can be used to better inform reload core design, limits on fuel assembly discharge burnup, restrictions on placement of fuel in the reactor, control rod insertion limits, operating margin, and performance sensitivities.? In support of that charter, BISON, the fuel performance code has been used to demonstrate the simulation of thermal-mechanical behavior of LWR fuels during a reactivity-initiated accident. The combination of mechanical, thermal, and thermal-hydraulic phenomena all present during an RIA makes a multi-physics code such as BISON a valuable tool for modeling these scenarios. This paper will highlight many of the activities associated with BISON relevant to reactivity-initiated accident capability development and validation efforts. These efforts have been performed under both CASL and the Nuclear Energy Advanced Modeling and Simulation (NEAMS) programs.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗