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DOE OSTI2022

Reliability-Informed Economic and Energy Evaluation for Bi-Level Design for Remanufacturing: A Case Study of Transmission and Hydraulic Manifold

Abstract Design for remanufacturing (DfRem) is one attractive strategy that encourages the reuse of a product and extends the product's life cycle. Traditional design processes often only consider product reliability at an early design stage. However, from the perspective of environmental sustainability, it is becoming increasingly important to evaluate the long-term economic and environmental impacts of design decisions during early-stage design. We propose a bi-level DfRem framework consisting of system-level reusability allocation and component-level design tradeoff analysis, considering reliability and product warranty policy. First, a system-level reusability allocation problem aims at a theoretical exploration of the design space where all the components comprising the system are allocated certain reuse rates to achieve target energy savings with minimum cost. Following the theoretical exploration at the system level, a component-level analysis looks at practical design options for each component and trades-off between the overall cost and energy consumption for multiple remanufacturing cycles. Both levels of the framework require modeling component reuse for multiple remanufacturing cycles, which we achieve by using a branched power-law model that provides probabilistic scenarios of reusing the component or replacing it with a new part. We demonstrate the utility of this framework with the case study of an infinitely variable transmission (IVT) used by some agricultural machines manufactured by John Deere and show snapshots of a prototype software tool that we developed for easy use by designers.

Engineering↗

DOE OSTI2022

A Combined Computer Vision and Deep Learning Approach for Rapid Drone-Based Optical Characterization of Parabolic Troughs

Optical accuracy is a primary driver of parabolic trough concentrating solar power (CSP) plant performance, but can be damaged by wind loads, gravity, error during installation, and regular plant operation. Collecting and analyzing optical measurements over an entire operating parabolic trough plant is difficult, given the large scale of typical installations. Distant Observer, a software tool developed at the National Renewable Energy Laboratory, uses images of the absorber tube reflected in the collector mirror to measure both surface slope in the parabolic mirror and offset of the absorber tube from the ideal focal point. This technology has been adapted for fast data collection using low-cost commercial drones, but until recently still required substantial human labor to process large amounts of data. A new method leveraging advanced deep learning and computer vision tools can drastically reduce the time required to process images. This new method addresses the primary analysis bottleneck, identifying featureless, reflective mirror corner points to a high degree of accuracy. Recent work has shown promising results using computer vision methods. The combined deep learning and computer vision approach presented here proved highly effective and has the potential to further automate data collection and analysis, making the tool more robust. The method presented in this paper automatically identified 74.3% of mirror corners within 2 pixels of their manually marked counterparts and 91.9% within 3 pixels. This level of accuracy is sufficient for practical Distant Observer analysis within a target uncertainty. A commercial drone collected video of over 100 parabolic trough modules at an operating CSP plant to demonstrate the deep learning and computer vision method's usefulness in processing large amounts of data. These troughs were successfully analyzed using Distant Observer, paired with the new deep learning and computer vision algorithm, and can provide plant operators and trough designers with valuable insight about plant performance, operating strategies, and plant-wide optical error trends.

computer vision↗

DOE OSTI2023

Enhancement of operational Flexibility of Power Plants Using IN740

Headers are crucial components within diverse industries, especially in the energy sector, as they enable the efficient transfer of fluids. The selection of materials for headers is determined by their specific applications; for example, Grade 91 and Grade 92 steels are commonly utilized. In our research, we recommend the adoption of INCONEL alloy 740 due to its exceptional robustness and heat-resistant characteristics. One critical parameter in header systems is the heat transfer coefficient, which directly influences the efficiency of heat exchange processes and can thereby impact the structural integrity of the headers. This coefficient is closely linked with factors such as the Nusselt number, which is influenced by fluid flow characteristics and thermal properties. The flow direction within headers, whether unidirectional or multidirectional—significantly affects the overall dynamics of heat transfer. This research focuses on exploring the behavior of headers, a specific pipeline system component, using ANSYS simulation software. The study aims to predict heat transfer and mechanical behavior within headers under various conditions through steady-state and transient simulations (parts 1 and 2 of the report). Key parameters such as heat transfer coefficient, velocity, and temperature are examined with the goal of optimizing header design. Part 3 of the report addresses the critical yet underexplored relationship between pressure drop and heat transfer coefficients in the transient flow regime within headers, specifically focusing on smooth horizontal circular tubes. Limited experimental work has been conducted in this area, prompting the need for comprehensive analysis. By leveraging machine learning techniques, this research aims to establish a correlation between pressure drop and heat transfer across various flow conditions, including laminar, transient, quasi-turbulent, and turbulent regimes. The data utilized for this analysis were meticulously gathered from existing literature, capturing simultaneous measurements of pressure drops and heat transfer. Part 4: In the context of power plants, header pipes are essential components that significantly influence system performance by facilitating the collection and distribution of steam. This report highlights the critical role of header pipes in enhancing reliability, efficiency, and overall power plant performance. A key aspect of this investigation is shape optimization, which aims to maximize performance while minimizing material usage. By focusing on shape optimization, this research contributes to improved efficiency and a reduced environmental footprint for power plant installations. The methodology developed in this study emphasizes optimizing header shapes to decrease reliance on expensive alloy materials and lower maintenance costs. Furthermore, a case study was conducted using a header from an operational power plant to validate the proposed optimization techniques. Finally, part 5 addresses the challenges associated with flexible operations in boiler systems, the study outlines several strategies for enhancing the durability and reliability of steam headers. Key approaches include material selection, which involves utilizing advanced materials with superior high-temperature properties and enhanced fatigue resistance to extend the lifespan of steam headers. Design modifications are also recommended, focusing on implementing changes that mitigate thermal stress and cyclic loading to reduce the likelihood of failures under varying operating conditions. Additionally, the study emphasizes the importance of regular inspection and monitoring by establishing rigorous protocols to detect early signs of damage, allowing for timely maintenance and minimizing the risks of catastrophic failures. Furthermore, operational guidelines are developed to minimize the frequency and severity of thermal transients, ensuring stable and efficient operations. Collectively, these strategies provide a robust framework for overcoming the unique challenges posed by flexible operation in boiler systems, ultimately contributing to improved reliability and performance in power plant operations. Through this comprehensive approach, the study not only enhances the understanding of pressure drop and heat transfer relationships but also promotes advancements in design and operation that will benefit the entire power generation industry.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2025

Benchmark Tracking System for Performance Monitoring

Benchmarking is essential for high-performance software development, particularly for monitoring performance across code iterations. This project focused on enhancing the benchmarking process for Lamellar, an asynchronous runtime for High-Performance Computing (HPC) systems developed at Pacific Northwest National Laboratory. Prior to this work, benchmark results were difficult to track and compare across code versions, presenting significant challenges in identifying performance regressions and long-term trends. The primary objective was to establish a systematic, reproducible approach for measuring performance and detecting regressions following code commits. Our methodology involved three key components: standardizing benchmark outputs, implementing data versioning, and developing analysis tools. We standardized the benchmark output format to JSON Line records containing specific fields (execution time, hardware specifications, and environmental variables). To address data management challenges, we evaluated several options and eventually chose a git repository dedicated to benchmark data. We developed a suite of Python tools that processed benchmark results, enriched them with metadata, and facilitated search in the repository. The resulting system enables more efficient filtering and comparison of performance metrics across commit histories, hardware configurations, and benchmark variants through a unified query interface. Our implementation reduces computational overhead by first checking for existing results through configuration matching before initiating new benchmark runs, thereby conserving resources. The system has been validated by Lamellar developers. It organizes results by benchmark type and build configurations for efficient retrieval. Future developments include a planned Large Language Model interface for predicting benchmark performance, incorporating the criterion package for statistical analysis, which will enable automated detection of statistically significant performance changes, and integration with continuous integration pipelines. Despite these enhancements being reserved for future work, this project has successfully provided the Lamellar development team with a framework for maintaining consistent performance standards and identifying optimization opportunities across workloads and hardware environments.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

Real-time 3D analysis during electron tomography using tomviz

The demand for high-throughput electron tomography is rapidly increasing in biological and material sciences. However, this 3D imaging technique is computationally bottlenecked by alignment and reconstruction which runs from hours to days. We demonstrate real-time tomography with dynamic 3D tomographic visualization to enable rapid interpretation of specimen structure immediately as data is collected on an electron microscope. Using geometrically complex chiral nanoparticles, we show volumetric interpretation can begin in less than 10 minutes and a high-quality tomogram is available within 30 minutes. Real-time tomography is integrated into tomviz, an open-source and cross-platform 3D data analysis tool that contains intuitive graphical user interfaces (GUI), to enable any scientist to characterize biological and material structure in 3D.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Genetic algorithm-based geometry calibration for dynamic compression x-ray diffraction experiments

An important component of dynamic compression x-ray diffraction (XRD) experiment analysis is geometry calibration: proper data interpretation requires knowledge of the precise detector position and orientation and, if the experiment involves a single-crystal sample, knowledge of the lattice orientation. The determination of these parameters in the arbitrary three-dimensional (3D) scattering geometries often present in dynamic compression facilities is challenging, as the associated optimization problem can be highly nonlinear, nonsmooth, and discontinuous. We present a genetic algorithm-based approach for performing dynamic compression XRD calibrations that overcomes these obstacles. We provide details regarding the image processing, algorithm implementation, and open-source software deployment and demonstrate the capability of the approach to calibrate the detector and crystal parameters in 3D geometries. Notably, we demonstrate the solver’s capacity to find the crystal orientation without a priori rotation constraints.

Brown, Nathan P. [Sandia National Laboratories (SN↗

DOE OSTI2021

NMSBA: Continuous Application Benchmarking & Analysis – CABA

The CABA project is a test of a new tool, Survey,developed by Trenza to be used not only for benchmarking or profiling programs but also to allow incorporation of the information provided by Survey to be utilized in a CI, continuous integration,tool such as GitLab CI.Survey is foremost a means of assessing code performance in terms of time and operations which for computer programmers is known as benchmarking.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2021

Mechanistic Source Term Considerations for Advanced Non-LWRs (Revision 1)

This report is a functional review of the radionuclide containment strategies of fluoride-salt-cooled high temperature reactor (FHR), molten salt reactor (MSR) and high temperature gas reactor (HTGR) systems. This analysis serves as a starting point for further, more in-depth analyses geared towards identifying phenomenological gaps that still exist, hindering the creation of a mechanistic source term for these reactor types. As background information to this review, an overview of how a mechanistic source term is created and used for consequence assessment necessary for licensing is provided. How a mechanistic source term is used within the Licensing Modernization Project (LMP) is also provided. Lastly, the characteristics of non-LWR mechanistic source terms are examined. This report does not assess the viability of any software system for use with advanced reactor designs, but instead covers system function requirements. Future work within the Nuclear Energy Advanced Modeling and Simulations (NEAMS) program will address such gaps. This document is an update of SAND 2020-6730. An additional chapter is included as well as edits to original content.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2021

Companion Assisted Software Based Remote Attestation in SCADA Networks

Critical infrastructure such as power generation and water distribution systems have become a priority target in cyber warfare because of their recent computerization and introduction to the internet. As a result, Supervisory Control and Data Acquisition (SCADA) system security has become a hot topic in academic and industrial research. Among these topics, Remote Attestation is a security method intended to detect the presence of fileless malware in remote devices as they continue to operate. This allows for the detection of malware in the absence of long-term storage artifacts before symptoms of compromise begin to appear. In general, a trusted device (the verifier) makes a request for evidence of innocence from the untrusted device (the prover). In software-based schemes, the verifier can then measure the delay between its request and the prover’s response. If this delay is greater than the known computational time of the evidence gathering algorithm performed by the prover, then evidence may have been forged. Multi-hop networks often introduce too much network jitter to allow accurate measurement of prover response time, which limits the effectiveness of software based Remote Attestation in a real-world setting. In this work, we introduce a companion device that the verifier can trust to perform a subset of attestation, thereby removing any network jitter. This device is a Field Programmable Gate Array (FPGA) that is physically connected to the prover. We provide a communication protocol between the verifier, prover, and companion. To evaluate our scheme, we simulate it in a common SCADA network environment under normal and heavy traffic loads. Our simulations are performed in the discrete event network simulator NS-3, and we perform statistical analysis over our results to show that our scheme allows for tight timing constraints to be placed on the prover such that the verifier can more easily determine the validity of the evidence that it receives.

Johnson, William A.↗

DOE OSTI2022

QGLab v0.0.1

A software program for experimenting with holographic teleportation protocol on quantum computers. The code implements the protocol that was proposed in https://arxiv.org/abs/1911.06314. The code is an end-to-end software solution that facilitates conducting the holographic teleportation experiments on state-of-the-art and emergent generations of QPUs supported by the Qiskit and tket SDKs. The code bundles all stages of an experiment as a single configurable workflow allowing faster development and experimentation cycles. Features: 1. Easy switching between Qiskit and tket quantum compilers. 2. Semi-automatic facilities for finding optimal compilation solutions beyond what Qiskit and tket provide by default. 3. Experiment resolution scaling (based on automatic jobs' batching). 4. Automatic experiment scaling over qubits. 5. Automatic readout error mitigation. 6. Automatic reproducibility analysis. 7. Standalone error-mitigation tools (randomized compiling, mitigation with estimation circuits, zero-noise extrapolation)

Shapoval, Illya↗

DOE OSTI2024

AMReX and pyAMReX: Looking beyond the exascale computing project

AMReX is a software framework for the development of block-structured mesh applications with adaptive mesh refinement (AMR). AMReX was initially developed and supported by the AMReX Co-Design Center as part of the U.S. DOE Exascale Computing Project (ECP), and is continuing to grow post-ECP. In addition to adding new functionality and performance improvements to the core AMReX framework, we have also developed a Python binding, pyAMReX, that provides a bridge between AMReX-based application codes and the data science ecosystem. pyAMReX provides zero-copy application GPU data access for AI/ML, in situ analysis and application coupling, and enables rapid, massively parallel prototyping. In this paper we review the overall functionality of AMReX and pyAMReX, focusing on new developments, new functionality, and optimizations of key operations. We also summarize capabilities of ECP projects that used AMReX and provide an overview of new, non-ECP applications.

Myers, Andrew↗

DOE OSTI2025

Demonstrating Advanced Sensors for In-Situ Monitoring Towards Qualification of Nuclear Relevant Components

The U.S. Department of Energy’s Office of Nuclear Energy Advanced Materials and Manufacturing Technologies (AMMT) program is pursuing qualification of laser powder bed fusion (LPBF) components for nuclear applications. A major focus of this effort is the use of in situ process monitoring and machine learning–based tools to establish real-time quality assurance. The primary objective of this report is to identify and evaluate the most relevant in situ sensor systems for LPBF, and to document the deployment of these systems across platforms critical to the AMMT program. This work demonstrates how in situ monitoring can detect process anomalies, track geometry-dependent flaws, and identify limiting combinations of processing parameters—particularly those related to energy density and complex geometries (e.g., overhanging structures). To support this goal, a diverse suite of sensor modalities was evaluated across LPBF platforms, including visible and near-infrared (NIR) imaging, fringe projection profilometry, long-wavelength infrared (LWIR) thermography, and high-speed photodiode/pyrometry systems. These sensor streams were integrated with Peregrine, a machine-agnostic software platform that, among other capabilities, can generate real-time process anomaly classification. This report documents sensor deployments on multiple AMMT flagship platforms, including the Concept Laser M2 and Renishaw AM400/AM250 systems. Calibration builds with complex, flaw-prone geometries such as unsupported overhangs, stepped features, and thin walls, were used to evaluate how well Peregrine and its associated sensors could detect process anomalies and other instabilities under varied energy densities. It will be shown how Peregrine reliably identifies common process anomalies such as recoater streaking, superelevation, etc., and can be used in post-build analysis for anomaly spatial distributions throughout the build height to better understand the impact of geometry and processing parameter choice on the build. This work demonstrates measurable progress toward the vision that components can be born-qualified by establishing a real-time monitoring framework, identifying limiting process conditions, and laying the foundation for sensor fusion–enabled prediction pipelines that are scalable across platforms and applicable to nuclear-relevant components.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

GradientGraph

Under this SBIR Phase II, Reservoir Labs has developed G2 Analytics, a new technology that allows network operators to analyze bottleneck and flow performance with high precision. G2 delivers a new analytical approach and framework to resolve a variety of key problems found in modern communication networks, including: traffic engineering, routing, flow scheduling, network design, capacity planning, resiliency analysis, network slicing, or service level agreement (SLA) management, among others. G2 leverages the bottleneck structure of congestion-controlled communication networks, a recent mathematical discovery by the Reservoir team [RL19b, RL20a, RL20b, RL21a]. Bottleneck structures reveal how perturbations on flows and links propagate through the network, providing an analytical framework to measure (qualitatively and quantitatively) the ripple effects induced as they traverse the network. Leveraging the mathematics of bottleneck structures, Reservoir Labs is developing the G2 technology to provide network operators with a framework to design, optimize and troubleshoot network performance. This delivery includes the G2 software stack.

Yellamraju, Sruthi↗

DOE OSTI2024

Transient Stability Analysis of Direct Droop-Controlled Grid-Forming Inverter with Current Clipping as Current Limiting Control

This paper investigates the transient stability of the direct droop-controlled grid-forming (GFM) inverter which employs the current clipping-based approach for overcurrent limitation. An equivalent circuit model of the direct-droop GFM inverter with current clipping is developed for this purpose. It is shown that during overcurrent conditions, the GFM inverter with current clipping acts as a voltage source with a virtual resistance behind the inverter filters. To compute the parameters of this virtual resistance an analytical expression is given in the paper. Then utilizing the developed circuit, a criteria to exit current limiting during post-fault conditions is given. The developed analytical approaches are then validated through electromagnetic transient (EMT) simulation results in PSCAD software and finally concluding remarks are drawn.

Mohiuddin, Sheik Mohammad↗

DOE OSTI2024

A numerical study of process complexity in permafrost dominated regions

Numerical modeling of permafrost dynamics requires adequate representation of atmospheric and surface processes, a reasonable parameter estimation strategy, and site-specific model development. The three main research objectives of the study are: (i) to propose a novel methodology that determines the required level of surface process complexity of permafrost models by conducting parameter sensitivity and calibration, (ii) to design and compare three numerical models of increasing surface process complexity, and (iii) to calibrate and validate the numerical models at the Yakou catchment on the Qinghai-Tibet Plateau as an exemplary study site. The calibration was carried out by coupling the Advanced Terrestrial Simulator (numerical model) and PEST (calibration tool). Simulation results showed that (i) A simple numerical model that considers only subsurface processes can simulate active layer development with the same accuracy as other more complex models that include surface processes. (ii) Peat and mineral soil layer permeability, Van Genuchten alpha, and porosity are highly sensitive. (iii) Liquid precipitation aids in increasing the rate of permafrost degradation. (iv) Deposition of snow insulated the subsurface during the thaw initiation period. We have developed and released an integrated code that couples the numerical software ATS to the calibration software PEST. The numerical model can be further used to determine the impacts of climate change on permafrost degradation.

Calibration↗

DOE OSTI2023

A decision support tool for e-waste recycling operations using the hen-and-chicks bio-inspired optimization metaheuristic

E-waste from end-of-life electrical and electronic devices is one of the fastest growing waste streams from households and businesses. E-waste recycling yields environmental sustainability and economic benefits. Due to continuous changes in e-waste types and compositions, recycling businesses face challenges to optimize their operational configuration to achieve better economic and environmental performance. To help e-waste recyclers mitigate this problem, we have developed a modular decision support tool called the Comprehensive Manufacturing Assessment Tool (CMAT) that can simulate both e-waste recycling operations and economics. This tool can give valuable insights regarding the profitability of the entire operation and different e-waste types. In addition, a new bio-inspired metaheuristic optimization algorithm, hen-and-chicks optimization (HACO), was developed to assign manpower to different workstations to maximize operational efficiencies. According to the results of our case study, laptops, desktops, and computer peripherals are the three electronic waste products that produce the most profit. Our examination of the sensitivity of material prices shows that the price of steel has the most significant influence on total profit, because it is the most widely used material in the majority of electronic devices. We have released the decision support tool as open-source software under a general public license. It could be customized for other recycling industries beyond e-waste to achieve business sustainability by making their operations more efficient.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

COVID-19, An Exercise in Data Governance at Sandia National Laboratories

In April of 2020, Sandia National Laboratories had an urgent need to identify and manage the data that could be used to create mobile applications, models, reports, and visualizations to assist management in safely bringing the workforce onsite during the COVID-19 pandemic. Multiple divisions volunteered to design and build software solutions; meanwhile, requests for new data sources, including duplicate requests, were inundating Information Technology (IT) and data owners. The Enterprise Data Governance Team was assigned to resolve obtaining and accessing new sources of data in an accelerated timeframe. Through successful collaboration with multiple stakeholders and domain owners across Sandia, the Enterprise Data Governance Team rapidly developed a centralized data strategy and solution for use in safeguarding the Sandia workforce during the COVID-19 pandemic. This foundation enabled teams to successfully develop solutions, including reports for executives and management as well as the data for modeling and scientific analysis.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗

DOE OSTI2021

Thermochemical Modeling in Molten Fluoride Salts for Radionuclide Speciation

An important aspect of the licensing process for nuclear reactors is providing a reasonable assurance of safety to the general public. This includes modeling potential radionuclide releases from the reactor during normal operations and accident scenarios, which is known as the reactor’s source term. A new class of advanced (non-LWR) reactors are being developed which use molten salts as the coolant fluid. Because the molten salt coolant represents a credited barrier for radionuclide transport between the fuel and the environment, a necessary aspect of mechanistic source term (MST) analysis for the KP-FHR is modeling the thermochemistry of molten salts. Provided here is a review of the theory of the thermodynamic principles governing multicomponent phase equilibria, the background of molten salt thermochemistry research, and a summary of the thermochemical data relevant to the KP-FHR coolant salt, Li 2 BeF 4 , commonly referred to as “FLiBe”. A review of literature is followed by a brief introduction to methods that can be used to model the thermochemical behavior of molten salt mixtures. The methodology outlined is based on the use of a commercial thermodynamic modeling software called FactSage, which is one of only a few available softwares based on the modified quasichemical model(MQM), which is the recommended solution model for molten salts.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

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