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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 OSTI2025

Control Selection for the Neutralization Tank in the Aqueous Recovery System at the Savannah River Plutonium Processing Facility

The Aqueous Recovery System (ARS) at the Savannah River Plutonium Processing Facility (SRPPF) recovers and purifies plutonium (Pu) using aqueous chemistry techniques. The neutralization tanks in the ARS collect waste streams with various impurities and greatly reduced concentrations of Pu than are produced during aqueous processing. Criticality safety is primarily achieved in the ARS by using geometrically favorable process vessels. However, due to the geometry of neutralization tanks, each tank is administratively limited to no more than 450 g Pu, thus representing the transition from geometry to mass control. To ensure that this mass limit is not exceeded, an administrative control requires taking two samples of any solution to be sent to a neutralization tank. Normal operations are expected to result in less than 50 g Pu in a neutralization tank filled to its capacity of 250 L. Process upsets may cause an inadvertent transfer of up to 1000 g Pu to a neutralization tank, producing a system that is potentially not subcritical for all possible configurations of the tank. To ensure that a neutralization tank remains safety subcritical, passive engineered controls (e.g. changing tank geometry or adding fixed poisons), active engineered controls (e.g. interlocks), and administrative controls (e.g. soluble poisons and valve isolation) were considered and their viability evaluated. Ultimately, the team chose an administrative, dual-valve isolation strategy. This paper will thoroughly discuss the various control strategy options and why many of the options were not feasible for maintaining criticality safety.

Dressman, Phillip M. [Savannah River Nuclear Solut↗
DOE OSTI2025

Control Selection for the Neutralization Tank in the Aqueous Recovery System at the Savannah River Plutonium Processing Facility

The Aqueous Recovery System (ARS) at the Savannah River Plutonium Processing Facility (SRPPF) recovers and purifies plutonium (Pu) using aqueous chemistry techniques. The neutralization tanks in the ARS collect the waste streams, containing various impurities and greatly reduced concentrations of Pu, that are produced during aqueous processing. Criticality safety is primarily achieved in the ARS by using geometrically favorable process vessels. However, due to the geometry of neutralization tanks, each tank is administratively limited to no more than 450 g Pu, thus representing the transition from geometry to mass control. To ensure that this mass limit is not exceeded, an administrative control requires taking two samples of any solution to be sent to a neutralization tank. Normal operations are expected to result in less than 50 g Pu in a neutralization tank filled to its capacity of 250 L. Process upsets may cause an inadvertent transfer of up to 1000 g Pu to a neutralization tank, producing a system that is potentially not subcritical for all possible configurations of the tank. To ensure that a neutralization tank remains safety subcritical, passive engineered controls (e.g.changing tank geometry or adding fixed poisons), active engineered controls (e.g. interlocks), and administrative controls (e.g. soluble poisons and valve isolation) were considered and their viability evaluated. Ultimately, the team chose an administrative, dual-valve isolation strategy. This paper will thoroughly discuss the various control strategy options and why many of the options were not feasible for maintaining criticality safety.

Dressman, Phillip M. [Savannah River Nuclear Solut↗
DOE OSTI2024

IB3A Helium Recovery System

An evaluation of the Fermilab's helium cryogenics test facilities has identified a pressing need for a helium recovery system in the Technical Division's Industrial Building 3a (IB3A). The IB3A facility, which plays a crucial role in testing components for various research projects, including the High-Luminosity LHC Accelerator Upgrade and Mu2e, currently vents helium into the air. Implementing recovery practices is essential due to helium's non-renewable nature and the goal of sustaining the Fermilab's scientific operations long-term. This poster covers benefits helium recovery for Fermilab and highlights the most important aspects of current helium recovery effort.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2025

Helium recovery system at IB3a

The increasing need for optimal and sustainable use of cryogenic resources to support Fermilab’s scientific mission has highlighted the necessity of improving the Laboratory’s helium management practices. An assessment of cryogenic test facilities identified the Technical Division’s Industrial Building 3a (IB3A) as a key site requiring upgrades to integrate a helium recovery system. The IB3A facility is essential for characterizing and testing superconductors, cables, and coils for various R&D projects, including the US High-Luminosity LHC Accelerator Upgrade Project (AUP), Mu2e, and other external collaborations. Currently, the facility relies on 500 L helium Dewars and vents the vaporized helium directly into the atmosphere, leading to significant helium loss. Given the non-renewable nature of helium, recovering and reusing this resource is critical for the sustainability of Fermilab’s operations. To address this challenge, a project has been initiated to connect IB3A to an existing helium purification station and refrigeration system located in another building via a dedicated pipeline pass over the roof of several buildings. This solution will enable the efficient capture of vented helium, its transfer to the purification station, and subsequent liquefaction for reuse in future operations. The project includes a detailed design phase, specifying the pipeline route, flow control mechanisms, and integration with the existing cryogenic infrastructure, followed by phased implementation and commissioning. By implementing this pipeline connection and upgrading IB3A, Fermilab aims to significantly reduce helium waste, lower operational costs, and align with its commitment to sustainability. This initiative provides a model for resource-efficient cryogenic operations and reinforces the Laboratory’s capacity to support its science mission for the long term.

Porwisiak, D. [Fermilab]↗
DOE OSTI2025

Control Selection for the Neutralization Tank in the Aqueous Recovery System at SRPPF

• Neutralization and solidification is the last step in the Aqueous Recovery Process • All waste streams are acidic and must be neutralized before being combined with grout in a solidification drum • The neutralization tank is a 250 L, 24” diameter, 45” high tank • The batch tank is a 125 L tank • The solidification drum is a 55-gallon drum, pre-filled with grout & a sacrificial mixing paddle • Normal mass in neutralization tank: 50 g Pu • Normal mass in batch tank or drum: 25 g Pu

Dressman, Phillip M. [Savannah River Nuclear Solut↗
DOE OSTI2024

Heat Recovery System for Domestic Dishwashers (Final Report)

The objectives of this project were to enable commercialization of a patent-pending technology for unprecedented dishwasher energy savings and non-energy consumer benefits. Specific objectives were to (1) provide customer-requested features of more thorough drying, (2) reduce kitchen humidity load (75% target reduction in water vapor released by the dishwasher), (3) introduce the lowest energy consumption domestic dishwasher on the market with 30% less energy consumption than that of the current best in market, and (4) maintain high cleaning performance.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Helium recovery system at IB3A

The growing demand for sustainable cryogenic operations at Fermilab has underscored the need to improve helium management, particularly at the Industrial Building 3A (IB3A) test facility. IB3A characterizes and tests superconductors, cables, and coils for projects such as the HL-LHC AUP and Mu2e, yet currently relies on 500 L Dewars whose boil-off is vented to atmosphere, wasting a critical, non-renewable resource and increasing the cost of testing. A project is therefore under way to link IB3A to an existing purification and liquefaction station in a neighboring building through a dedicated pipeline. Captured helium will be transferred, purified, reliquefied, and returned for reuse, cutting losses and operating costs. This paper details the first two project phases: "Design and Engineering" and "Procurement and Installation." The design phase finalizes pipeline specifications, establishes flow-control requirements, and resolves integration challenges with existing cryogenic infrastructure. The procurement and installation phase covers material sourcing, pipeline construction, and deployment of control and monitoring systems to assure reliable, efficient operation. Key technical hurdles-route optimization, pressure drop mitigation, and interface compatibility-are discussed alongside implemented solutions. Implementing the pipeline and upgrading IB3A will dramatically reduce helium consumption and therefore testing cost, strengthening Fermilab's capacity to support frontier science far into the future.

Porwisiak, D. [Fermilab; Wroclaw Tech. U.]↗
DOE OSTI2025

Glass Furnace Decarbonization Technology Stack (Final Technical Report)

This report summarizes the objectives, approach, and outcomes of the Glass Furnace Decarbonization Technology Stack project undertaken by Owens-Brockway Glass Container Incorporated under award number DE-CD0000093. The project aimed to implement a pioneering combination of furnace technologies at the Zanesville, OH manufacturing site to reduce carbon intensity (CI) by 20–40% compared to baseline operations. The proposed Furnace Technology Stack included a Gas/Oxy-fuel system, OPTIMELT™ Heat Recovery System, raw material pre-heating, electric boosting, and forehearth electrification—designed to demonstrate commercial feasibility and drive industry-wide decarbonization.

42 ENGINEERING↗
DOE OSTI2025

Experimental investigation on heat transfer performance of drain water heat recovery heat exchangers

Water heating accounts for 18 % of residential energy consumption, and a substantial portion of this energy can be recovered through drain water heat recovery systems. Here, this paper investigates the heat transfer performance of drain water heat recovery heat exchangers. Two heat exchanger configurations were studied: vertical (gravity film exchanger) and horizontal. The heat recovery performance of the exchangers was quantified using sensible effectiveness and characteristic curves following the ε-NTU approach. Depending on the flow conditions, heat exchangers with a vertical configuration offered higher heat transfer effectiveness compared with the horizontal configuration under similar operating conditions. Furthermore, the results showed that properly designed and sized heat exchangers can effectively recover considerable amounts of waste heat from drains, depending on flow rates. Additionally, in the vertical heat exchanger configuration, low flow rates result in partially wet conditions, resulting in lower heat transfer effectiveness. Therefore, two distributor configurations are proposed to improve the heat transfer performance of vertically configured heat exchangers at low flow rates. The proposed distributor configurations and data presented in this paper will be useful in the design and development of drain water heat recovery systems in building applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

CO2 Enhanced Oil Recovery Evaluation System (CO2_E_EvSystem), Version 2025

The United States Department of Energy’s (DOE’s) Office of Fossil Energy and the National Energy Technology Laboratory (NETL) developed a suite of screening-level, techno-economic models/tools, known as the CO2_E_EvSystem, to evaluate technical aspects and costs of using carbon dioxide (CO2) enhanced oil recovery (EOR) to store CO2 and produce oil. CO2_E_EvSystem has three software components and several input and output files. The software components are CO2_E_EvTool, CO2_Prophet, and CO2_E_COM. Almost all computational work is performed by CO2_Prophet and CO2_E_COM, which are both Fortran programs. The primary role of CO2_E_EvTool is to manage input and output files for the two programs, run the two programs, allow multiple oilfields to be evaluated in a single run, and generate files that summarize the results for all the oilfields run. This version of the CO2_E_EvSystem includes a residual oil zone dataset from the San Andres formation, Permian Basin, to demonstrate the system and guide users on attributes needed for dataset inputs.

AS↗
DOE OSTI2024

Heat exchanger(s) for recovering water and/or heat energy from turbine engine combustion products

A turbine engine is provided that includes a fan section, a turbine engine core and a recovery system. The turbine engine core is configured to power the fan section. The turbine engine core includes a core compressor section, a core combustor section and a core turbine section. A centerline axis of the turbine engine core is offset from a centerline axis of the turbine engine. The recovery system includes an evaporator module and a condenser module. A core flowpath extends sequentially through the core compressor section, the core combustor section, the core turbine section, the evaporator module and the condenser module from an inlet into the core flowpath to an exhaust from the core flowpath.

Sobanski, Jon E.↗
DOE OSTI2024

Enabling Robust Compressor Operation Under Various sCO 2 Conditions at Compressor Inlet

The supercritical carbon dioxide (sCO 2 ) power cycle is one of the most investigated power conversion systems in last decade. The reason for this is its wide range of potential applications from fossil fuels (Natural gas), nuclear (Fusion, Fission), through concentrated solar power, energy storage system and waste heat recovery systems to power-to-x systems. The main advantage of the sCO 2 power cycle is very similar operation conditions, especially for the compressor, for all potential applications. Because of this the potential cost of the system can be reduced. However, the sCO 2 power cycle has still several issue that needs to address before commercial application. The current key issue is design of the primary compressor. The primary compressor is one of the key components in the sCO 2 power cycle; it operates with inlet conditions just above the critical point of CO 2 to maintain high fluid density and reduce power requirements.

14 SOLAR ENERGY↗
DOE OSTI2024

Trust-Based Detection and Mitigation of Cyber Attacks in Distributed Cooperative Control of Islanded AC Microgrids

In this study, we address the challenge of detecting and mitigating cyber attacks in the distributed cooperative control of islanded AC microgrids, with a particular focus on detecting False Data Injection Attacks (FDIAs), a significant threat to the Smart Grid (SG). The SG integrates traditional power systems with communication networks, creating a complex system with numerous vulnerable links, making it a prime target for cyber attacks. These attacks can lead to the disclosure of private data, control network failures, and even blackouts. Unlike machine learning-based approaches that require extensive datasets and mathematical models dependent on accurate system modeling, our method is free from such dependencies. To enhance the microgrid’s resilience against these threats, we propose a resilient control algorithm by introducing a novel trustworthiness parameter into the traditional cooperative control algorithm. Our method evaluates the trustworthiness of distributed energy resources (DERs) based on their voltage measurements and exchanged information, using Kullback-Leibler (KL) divergence to dynamically adjust control actions. We validated our approach through simulations on both the IEEE-34 bus feeder system with eight DERs and a larger microgrid with twenty-two DERs. The results demonstrated a detection accuracy of around 100%, with millisecond range mitigation time, ensuring rapid system recovery. Additionally, our method improved system stability by up to almost 100% under attack scenarios, showcasing its effectiveness in promptly detecting attacks and maintaining system resilience. These findings highlight the potential of our approach to enhance the security and stability of microgrid systems in the face of cyber threats.

Computer Science↗
DOE OSTI2025

Propulsion System Hybridization and Electrification and Energy Recovery of the Hydraulic System for a Diesel-Powered Off-Road Carry/Lift Machine Final Technical Report (FTR)

Historically, heavy-duty off-road equipment has prioritized performance, reliability, and cost, with limited emphasis on efficiency. While increasing carbon dioxide (CO 2 ) regulations have driven a focused effort for efficiency in on-road vehicles, off-road machines have remained largely overlooked, leaving significant opportunities for efficiency improvements and emissions reductions. To address this overlooked industry, Michigan Technological University’s Advanced Power Systems Research Center (APS LABS) worked with Pettibone to determine a unique electrified architecture for Pettibone’s heavy-duty off-road material handler, the Cary-Lift 204i, with a goal of 20% fuel savings. The base Cary-Lift uses a diesel engine with no electrification.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Data about data – when, why and how metadata can support the digital plant

A structured approach for recording data quality and contextual information about how and why a signal exists – i.e. metadata – is central to interpret and use sensor data correctly. This is becoming increasingly important with the global trend with data-driven applications such as digital twins and AI-models. But a structured metadata collection and organization of sensor data is not routine in most plants, which can result in lost information and missed opportunities to make use of the investments made in the data collection. Therefore, the IWA task group on Metadata Collection and Organization in wastewater resource recovery systems (MetaCO) was initiated in 2020 and recently delivered the IWA scientific and technical report number 31. The report gives and in-depth description about metadata in water resources recovery facilities (WRRFs) and is available as open access at IWA publishing. The report is the outcome of the collaboration between more than 80 water professionals with the intention to serve WRRF data users with a guide on how to structure and make use of metadata throughout the data pipeline in order to maximize the value of sensor data.

Alferes, Janelcy [VITO, Belgium]↗
DOE OSTI2025

On Stability and Electrochemical Performance of 316 Stainless Steel in Wastewater: Implications for Resource Recovery

Electrochemical nutrient recovery systems rely on stable electrode materials capable of operating in chemically complex wastewater environments. We investigated corrosion resistance and interfacial electrochemical behavior of 316 stainless steel (SS316) in a synthetic wastewater matrix representative of centrate streams, a key knowledge gap in electrochemical phosphorus recovery. A comprehensive suite of electrochemical techniques (chronoamperometry, cyclic voltammetry, potentiodynamic polarization, and electrochemical impedance spectroscopy (EIS)) and surface characterization methods (scanning electron microscopy, X-ray diffraction) were employed. Results revealed that wastewater containing typical ionic constituents (such as PO 4 3- , NH 4 + , and divalent cations) exhibited enhanced cathodic activity and the formation of a more stable, protective surface film on SS316 that mitigated chloride-induced corrosion. In contrast, SS316 in the NaCl solution showed significant susceptibility to passive layer breakdown and localized corrosion. Time-resolved EIS further confirmed improved interfacial stability and restricted charge transfer in WW over time, in stark contrast to the progressive passive layer degradation in NaCl. Surface analyses corroborated these findings, showing limited surface attack in WW compared to distinct localized corrosion features in NaCl. These findings indicate that competing ionic species in WW effectively mitigate chloride aggressiveness, enhance SS316 stability, and demonstrate improved electrode longevity and reliability for sustainable wastewater-based electrochemical phosphorus recovery applications.

36 MATERIALS SCIENCE↗
DOE OSTI2024

The Roles of Oil–Water Interfaces in Forming Ultrasmall CaSO 4 Nanoparticles

In natural and engineered environmental systems, calcium sulfate (CaSO 4 ) nucleation commonly occurs at dynamic liquid–liquid interfaces. Although CaSO 4 is one of the most common minerals in oil spills and oil–water separation, the mechanisms driving its nucleation at these liquid–liquid interfaces remain poorly understood. Here, in this study, using in situ small-angle X-ray scattering (SAXS), we examined CaSO 4 nucleation at oil–water interfaces and found that within 60 minutes of reaction, short rod-shaped nanoparticles (with a radius of gyration (R g ) of 17.2 ± 2.7 nm and a length of 38.2 ± 5.8 nm) had formed preferentially at the interfaces. Wide-angle X-ray scattering (WAXS) analysis identified these nanoparticles as gypsum (CaSO 4 ·2H 2 O). In addition, spherial nanoparticles measuring 4.1 nm in diameter were observed at oil–water interfaces, where surface-enhanced Raman spectroscopy (SERS) revealed an elevated pH compared to the bulk solution. The negatively charged oil–water interfaces preferentially adsorb calcium ions, collectively promoting CaSO 4 formation there. CaSO 4 particle formation at the oil–water interface follows a nonclassical nucleation (N-CNT) pathway by forming ultrasmall amorphous spherical particles which then aggregate to form intermediate nanoparticles, subsequently growing into nanorod-shaped gypsum. These findings of this study provide insights into mineral scaling during membrane separation and can inform more efficient oil transport in energy recovery systems.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Production and Purification of Terbium-155 Using Natural Gadolinium Targets

Terbium-155 (t 1/2 = 5.32 days) is one of four medically relevant radioisotopes of terbium. It is of interest to the field as a suitable diagnostic counterpart for therapeutic radiolanthanides, as its decay scheme includes γ-rays that are suitable for single photon emission computed tomography (SPECT) imaging. Additionally, 155 Tb has an Auger electron (AE) yield that is viable for AE therapy. There are several direct and indirect production routes that can produce 155 Tb. Two possible direct routes include proton irradiation on gadolinium targets via 155 Gd(p,n) 155 Tb and 156 Gd(p,2n) 155 Tb. The 155 Gd(p,n) 155 Tb reaction is accessible at incident proton beam energies of ∼10 MeV, whereas the 156 Gd(p,2n) 155 Tb nuclear reaction requires ∼18 MeV. This study aims to investigate the production of 155 Tb from natGd through the nat Gd(p,x) nuclear reaction, wherein both (p,n) and (p,2n) reactions were leveraged, and the purification using a three-column ion chromatography method. Using this system, recoveries of radioterbium of up to 97% were achieved in addition to high recoveries of the Gd target material, illustrating the suitability of this technique for enriched targets.

36 MATERIALS SCIENCE↗