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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 OSTI2022

Comparison of Commercial, State-of-the-Art, Fossil-Based Hydrogen Production Technologies

Presentation describing NETL's public report entitled "Comparison of Commercial, State-of-the-Art, Fossil-Based Hydrogen Production Technologies" which features levelized cost of hydrogen (LCOH) and greenhouse gas emissions from six cases (3 reforming and 3 gasification technology cases) as well as CO2 capture. One case also features coal/biomass co-gasification that targeted net-zero emissions.

Stevens, Robert↗
DOE OSTI2022

Comparison of Commercial, State-of-the-Art, Fossil-Based Hydrogen Production Technologies

This presentation provides a deep dive overview of the NETL report publication "Comparison of Commercial, State-of-the-Art, Fossil-Based Hydrogen Production Technologies" released in April 2022. A summary of the study justification, objectives, and approach are presented along with a detailed overview of the major study phases and results.

Lewis, Eric↗
DOE OSTI2022

Developing a Coal to Products Technology Portfolio

At Ramaco Carbon we are working to bring into existence a new carbon economy with the mottos “coal is too valuable to burn” and “no molecule left behind.” Our research focus is using coal (carbon ore) as a feedstock for a variety of high-value carbon products. We have developed a process and manufacturing technology portfolio including carbon fiber, porous carbons, nano-structured carbons (bulk graphene), building products, monolayer graphene, and rare earth elements (REEs). A review of these product lines, the associated processes, and economics will provide insight into the value of carbon ore as a feedstock for high-value and specialty products. We will present our current progress in manufacturing and tailoring the properties of porous carbons and nano-structured carbon to enhance existing products and produce novel products. Included is a discussion of the properties of carbon fiber derived from direct liquefaction of sub-bituminous coal, and from pitches produced by pyrolysis and solvation by supercritical CO2. New processes for converting carbon ore into structural building materials and monolayer graphene and the evaluation of REE deposits in a Powder River Basin thermal coal reserve will also be described. The presentation will provide a review of our carbon ore to products technology portfolio and the economic advantages of using carbon ore as a feedstock for advanced carbon products and several associated end use applications.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Developing a Coal to Products Technology Portfolio

At Ramaco Carbon we are working to bring into existence a new carbon economy with the mottos “coal is too valuable to burn” and “no molecule left behind.” Our research focus is using coal (carbon ore) as a feedstock for a variety of high-value carbon products. We have developed a process and manufacturing technology portfolio including carbon fiber, porous carbons, nano-structured carbons (bulk graphene), building products, monolayer graphene, and rare earth elements (REEs). A review of these product lines, the associated processes, and economics will provide insight into the value of carbon ore as a feedstock for high-value and specialty products. We will present our current progress in manufacturing and tailoring the properties of porous carbons and nano-structured carbon to enhance existing products and produce novel products. Included is a discussion of the properties of carbon fiber derived from direct liquefaction of sub-bituminous coal, and from pitches produced by pyrolysis and solvation by supercritical CO2. New processes for converting carbon ore into structural building materials and monolayer graphene and the evaluation of REE deposits in a Powder River Basin thermal coal reserve will also be described. The presentation will provide a review of our carbon ore to products technology portfolio and the economic advantages of using carbon ore as a feedstock for advanced carbon products and several associated end use applications.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

Medium grain niobium SRF cavity production technology for science frontiers and accelerator applications

Herein we present the cost-effective production of superconducting radio frequency (SRF) cavities made of medium grain (MG) niobium (Nb) discs directly sliced from forged and annealed billet. This production method provides clean surface conditions and reliable mechanical characteristics with sub-millimeter average grain size resulting in stable SRF cavity production. We propose to apply this material to particle accelerator in the science and industrial applications. The science applications require high field gradients(≥ 30 MV/m) particularly in pulsed mode. The industrial applications require high $Q_0$ values with moderate gradients (~ 20 MV/m) in CW mode operation. This paper describes the MG Nb disc production recently demonstrated and discusses future prospects for application in advanced particle accelerators in the science and industrial applications.

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

Comparison of Commercial, State-of-the-Art, Fossil-Based Hydrogen Production Technologies

This report presents an independent assessment of the cost and performance of select hydrogen production plants utilizing fossil fuel resources as the primary feedstocks – specifically, natural gas (NG), steam methane reforming (SMR), NG autothermal reforming (ATR), coal gasification, and coal/biomass co-gasification – using a systematic, transparent technical and economic approach. Study cases were selected to reflect the capabilities of current, commercial technologies within plant configurations, and at scales, representative of next commercial offerings facing no fundamental research and development (R&D) obstacles. Additionally, several areas of R&D are identified as potential pathways for performance improvements and cost reductions.

08 HYDROGEN↗
DOE OSTI2021

Comparison of Commercial, State-of-the-Art, Fossil-Based Hydrogen Production Technologies

NETL's Strategic Systems Analysis & Engineering (SSAE) is developing a reference study for fossil-based, commercial scale hydrogen production with a levelized cost of hydrogen (2018 $/kg) as the figure of merit. Coal/biomass gasification as well as natural gas-based technology routes (steam-methane reforming & autothermal reforming) are featured as technologies to be assessed. The final report is expected to be completed in August, 2021 -- this presentation describes the study's design in more detail as well as reports on its progress.

Stevens, Robert↗
DOE OSTI2023

Enhanced microbial production of protocatechuate from engineered sorghum using an integrated feedstock-to-product conversion technology

Building a stronger bioeconomy requires production capabilities that are largely generated through microbial genetic engineering. Plant feedstocks can additionally be genetically engineered to generate desirable feedstock traits and provide precursors for direct microbial conversion into desired products. The oleaginous yeast Rhodosporidium toruloides is a promising organism for this type of conversion as it can grow on a wide range of deconstructed biomass and consume a variety of carbon sources. Here, we leveraged R. toruloides native p-coumaric acid consumption pathway to accumulate protocatechuate (PCA) from 4-hydroxybenzoate (4HBA) released from a sorghum feedstock line genetically engineered to overproduce 4HBA. We did so by generating and evaluating an R. toruloides strain that accumulates PCA, RSΔ12623. We then show that at two scales a cholinium lysinate pretreatment with enzymatic saccharification successfully extracts 95% of the 4HBA from the engineered sorghum biomass while producing deconstructed lignin that can be more efficiently depolymerized in a subsequent thermochemical reaction. We also demonstrate that strain RSΔ12623 can convert more than 95% of 4HBA to PCA while consuming >95% of the glucose and >80% of the xylose present in sorghum hydrolysates. Finally, to evaluate the scalability of such fermentations, we conducted the conversion of 4HBA to PCA in a 2 L bioreactor under controlled conditions. Importantly, this work demonstrates the potential of purposefully producing aromatic precursors in planta that can be liberated during biomass deconstruction for direct microbial conversion to desirable bioproducts.

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

Multi-Objective Optimization of Uranium Target Assembly–3: A Comparison of Genetic and Traditional Methods

Commonly produced as a byproduct of uranium fission, 99 Mo is a key medical isotope that is in high demand in the United States. An international goal is to switch from medical isotope production technologies that require highly enriched uranium to medical isotope production technologies that require only low-enriched uranium. Niowave Inc. is contributing to this goal by developing an accelerator-driven subcritical assembly called the Uranium Target Assembly (UTA). This work compares the performance of Dakota’s Multi-Objective Genetic Algorithm (MOGA) against traditional sensitivity analysis in the neutronic optimization of the UTA-3 system. The design objectives are k-eigenvalue (k eff ) and natural uranium fission power, which are directly correlated with the amount of 99 Mo produced. Dakota:MOGA did not perform as well as human engineering ingenuity in optimization studies with high numbers of input parameters, such as fuel rod type selection and fuel rod placement. However, Dakota:MOGA did outperform traditional sensitivity analysis in optimization studies with fewer than 20 parameters and revealed the degree to which each parameter influences the optimal design space for k eff and natural uranium fission power (to a lesser extent). As the design model became more complex in the final stage of design, the computational resources required to calculate the design objective values in the Monte Carlo N-Particle transport code from selected input parameter combinations limited Dakota:MOGA’s performance, and, unfortunately, human intervention was required to discern the optimal design space. In conclusion, future work will attempt to reduce computational resource constraints by incorporating areduced-order neutronics model into the optimization cycle.

Accelerator-driven systems↗
DOE OSTI2025

STREAM: A technology planning and capacity expansion model for the industrial sector

The Strategic Technology Roadmapping and Energy, Environmental, and Economic Analysis Model—STREAM—is an optimization-based modeling tool and analysis framework to assist with strategic planning and technology investments of the industrial sector. This open-source framework is written in Julia using the JuMP package, which enables users to model future “pathways” for incumbent and future production technologies, costs, fuels and energy carriers, and energy and non-energy environmental impacts from industries as they transform in pursuit of a robust and competitive manufacturing sector. The model starts with an initial stock of industrial production technologies and assets at a facility level and then determines pathways that minimize cost, subject to an array of possible constraints on demand, market shares, environmental flows, and other exogenously specified operational considerations such as capacity utilization rates or regional energy costs. Key features of the framework include flexibility to model a wide range of industries and industrial technologies/processes at varying levels of granularity, ability to perform parametric sensitivity analyses, and ability to visualize model results using visualization objects.

capacity expansion↗
DOE OSTI2026

Operando X-Ray Diffraction During High Temperature Electrolysis

This work presents the design, development, and deployment of an operando X-ray diffraction (XRD) system for high-temperature electrolysis (HTE), enabling real-time characterization of solid oxide electrolysis cells (SOECs) under true operational conditions. The integration of an HTE test stand within a synchrotron radiation environment, mimicking the conditions of a laboratory setup, aims to enhance our understanding of the degradation processes affecting the performance and longevity of SOECs. Utilizing a custom furnace and a high precision motor stack assembly at the Stanford Synchrotron Radiation Lightsource (SSRL), the system revealed unparalleled insights into the structural evolution of SOEC components through various operational stages, including initial heat ramp, cell reduction, fuel ramp, and wet electrolysis. Initial results demonstrate the significant impact of the initial heating and cooling on secondary phase formation within the SOEC, highlighting the utility of operando XRD for developing more efficient and durable hydrogen production technologies.

08 HYDROGEN↗
DOE OSTI2026

SAF: a promising approach to meet growing jet fuel demand

SAF provides a promising approach to aid the rising jet fuel demand from increased travel around the world and reduce the lifecycle emissions from the aviation sector. Although the feasibility of SAF pathways has been demonstrated through economic and environmental metrics quantification, the models used to quantify these variables have a high degree of variability in terms of accuracy and thereby reliability. To understand how to adopt and commercialize SAF, we need to harmonize these process models and assess metrics and technical limitations related to their production technologies. We find the production cost of SAF using hydro processed fatty acids and esters (HEFA), Fischer-Tropsch (FT), and alcohol-to-jet (ATJ) to be $\$$3-$\$$6/gallon gasoline equivalent (gge) and life cycle emissions to be lower than Jet A, except for ATJ using corn grain (≤25%). HEFA utilizing oil feedstocks has the lowest production cost (~$\$$2.9/gge) and highest jet yield (>150 gge/dry ton), while FT has the largest emission reduction (94%) compared to fossil jet. A unique contribution of this study is a comparative analysis of metrics related to SAF processes across technical, economic, and sustainability aspects. A cross-comparison of these metrics shows HEFA using fats, oils, and grease have the most favorable ratings, while HEFA using algae and ATJ using corn stover have more neutral and unfavorable ratings, respectively. These ratings can be improved by implementing the right combination of practical and technological advancements.

09 BIOMASS FUELS↗
DOE OSTI2021

Technology Advancement and Insertion into Operating Nuclear Facilities

Key challenges in the NNSA modernization effort are centered around the selection of new processing / production technologies to deploy in existing, operating, and oftentimes, aging nuclear facilities. New uranium processing technologies may offer significant improvements in worker and environmental safety, material control and accountability, and production efficiencies, but adaptation of these technologies into existing facilities presents unique (and usually, difficult) engineering solutions for each new technology. This presentation discusses approaches utilized at Y-12 to mature and demonstrate new processing and production technologies for deployment into nuclear facilities. The technology advancement lifecycle (from concept to deployment) of uranium electrorefining technologies will be reviewed, as a prototypical example, to describe steps and approaches utilized at Y-12 (and NNSA Sites) to (i) mature technologies and manufacturing strategies, (ii) establish testbed capabilities for full-scale process demonstrations, and (iii) reduce risks associated with operational disruptions when commissioning new uranium processing technologies.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Technology Advancement and Insertion into Operating Nuclear Facilities

Key challenges in the NNSA modernization effort are centered around the selection of new processing / production technologies to deploy in existing, operating, and oftentimes, aging nuclear facilities. New uranium processing technologies may offer significant improvements in worker and environmental safety, material control and accountability, and production efficiencies, but adaptation of these technologies into existing facilities presents unique (and usually, difficult) engineering solutions for each new technology. This presentation discusses approaches utilized at Y-12 to mature and demonstrate new processing and production technologies for deployment into aging nuclear facilities. The technology advancement lifecycle (from concept to deployment) of uranium electrorefining technologies will be reviewed, as a prototypical example, to describe steps and approaches utilized at Y-12 (and NNSA Sites) to (i) mature technologies and manufacturing strategies, (ii) establish testbed capabilities for full-scale process demonstrations, and (iii) reduce risks associated with operational disruptions when commissioning new uranium processing technologies.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2025

Coal-Waste-Enhanced Filaments for Additive Manufacturing of High-Temperature Plastics and Ceramic Composites

In the United States, coal waste from over a century of mining and burning coal for heat and electricity has accumulated as mountains of coal fly ash and bottom ash and acre-size ponds, coal fines and gob. These materials can be a problem for local communities and water systems. A cost-effective process to utilize high volumes of these coal wastes in a high-value product would be beneficial to those communities by reducing the amount of waste and providing jobs, manufacturing components, and materials from the waste. Many coal-to-products technologies (e.g., carbon fibers, graphene, carbon foam) rely on carefully choosing the starting material and then altering it chemically or thermally to make the products work. Due to the wide variability of composition and coal content in typical coal waste streams, many high-volume coal waste streams are likely to be unsuitable for use in those technologies. Semplastics’ technology has been shown to utilize most types of coal waste successfully without any pre-selection or pre-processing requirements other than a nominal particle-size reduction for wastes like bottom ash. This characteristic of Semplastics’ solution may enable the use of much larger volumes of a wider range of coal wastes than other coal-to-products technologies. In this project, Semplastics leveraged its unique experience with both coal waste (fly ash or coal combustion residuals), resin materials, and 3D printing to develop 3D printer filaments using common coal wastes – bituminous coal fines and fly ash – and researched the feasibility of using other forms of coal waste as fillers. Simple 3D-printed parts were successfully produced from the coal waste enhanced filaments, which were found to have improved strength and stiffness.

01 COAL, LIGNITE, AND PEAT↗