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DOE OSTI2023

Predicting Deposition Rate and Closing the Loop on Aerosol Jet Printing with In‐Line Light Scattering Measurements

Aerosol jet printing is a compelling noncontact, digital manufacturing technology for flexible, hybrid, and conformal electronics, but batch‐to‐batch variability and process drift inhibit systematic study and translation to production environments. Emerging measurement techniques for the aerosol volume fraction, a key parameter governing deposition rate, have shown promise for real‐time response, including a recent demonstration of human‐in‐the‐loop control. By integrating improved light scattering measurements with custom software, a robust environment for real‐time monitoring is established and fully automated closed‐loop control over the deposition rate during printing is enabled. The physical basis for scattering measurements as a feedback source is examined and the quantitative insight this provides for ink development and fundamental process studies is highlighted. Three candidate process variables for closed‐loop control, namely the atomizer voltage, carrier gas flow rate, and print speed, are then evaluated. The atomizer voltage demonstrates the best extended duration validity because it addresses atomization variability directly, but carrier gas flow rate and print speed provide faster and more deterministic responses. This methodology is then demonstrated for electrical properties using a silver nanoparticle ink, maintaining 98% of printed patterns within 10% of the mean resistance value over 3 h of printing.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Anomaly Detection in Liquid Sodium Cold Trap Operation with Multisensory Data Fusion Using Long Short-Term Memory Autoencoder

Sodium-cooled fast reactors (SFR), which use high temperature fluid near ambient pressure as coolant, are one of the most promising types of GEN IV reactors. One of the unique challenges of SFR operation is purification of high temperature liquid sodium with a cold trap to prevent corrosion and obstructing small orifices. We have developed a deep learning long short-term memory (LSTM) autoencoder for continuous monitoring of a cold trap and detection of operational anomaly. Transient data were obtained from the Mechanisms Engineering Test Loop (METL) liquid sodium facility at Argonne National Laboratory. The cold trap purification at METL is monitored with 31 variables, which are sensors measuring fluid temperatures, pressures and flow rates, and controller signals. Loss-of-coolant type anomaly in the cold trap operation was generated by temporarily choking one of the blowers, which resulted in temperature and flow rate spikes. The input layer of the autoencoder consisted of all the variables involved in monitoring the cold trap. The LSTM autoencoder was trained on the data corresponding to cold trap startup and normal operation regime, with the loss function calculated as the mean absolute error (MAE). The loss during training was determined to follow log-normal density distribution. During monitoring, we investigated a performance of the LSTM autoencoder for different loss threshold values, set at a progressively increasing number of standard deviations from the mean. The anomaly signal in the data was gradually attenuated, while preserving the noise of the original time series, so that the signal-to-noise ratio (SNR) averaged across all sensors decreased below unity. Results demonstrate detection of anomalies with sensor-averaged SNR < 1.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2020

Impact of climate change on water availability and its propagation through the Western U.S. power grid

Climate impact assessment for power systems has tended to focus on the effects of water availability on generation without explicitly considering how these impacts propagate through the interconnected grid to affect generation in other locations. We investigate the impact of projected water availability on the operations of the contemporary Western U.S. power grid, focusing specifically on regional interdependencies. Hydrologic simulations derived from three GCMs (CCSM4, INMCM4 and GFDL-CM3) and two radiative scenarios (RCP4.5 and RCP8.5) are used to force a large-scale, distributed water management model (MOSART-WM), which translates water availability into power generation constraints at hydropower plants and water-dependent thermo-electric plants. Power system dynamics are evaluated using the production cost model PLEXOS. We find that the inter-regional connections across the Western U.S. electricity infrastructure are key in managing drastic variations in regional water availability. Net generation in the Northwest and Northern California is substantially sensitive to local water availability. Generation from the Desert Southwest emerges as a critical resource to compensate for variations in water availability in those regions. Climate change impacts on Northwestern water availability therefore drive future changes in other regions’ generation and regional power flows. The large inter-annual hydrological variability of Northern California exacerbates grid stress arising from long-term changes in water availability in the Northwest. While the regional power flow directions seem insensitive to long-term variations in water availability, the analysis highlights the need to consider other compounding regional factors such as changes in Southern California net load or changes in regional fuel prices.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Improving air leakage prediction of buildings using the fan pressurization method with the Weighted Line of Organic Correlation

In many countries, the fan pressurization method is the most frequently chosen approach for measuring the air leakage of houses. The measurements are usually performed at pressures that far exceed pressures to which buildings are exposed to under normal conditions. A fit of these tests to the power-law formulation allows an extrapolation to data points outside the measured pressure range. With the Ordinary Least Square (OLS) fitting method, the pressure exponent and flow coefficient can be determined. However, the measurement results are highly sensitive to uncertainties induced by external factors like changing wind conditions during the tests, which is neglected by OLS. This may lead to errors in the prediction of flows at lower pressures. The Weighted Line of Organic Correlation (WLOC) is an alternative approach and takes measurement uncertainty into account. In this paper, a statistical analysis of an extensive data set of pressurization measurements has been performed. Both regression techniques have been compared for almost 7500 fan pressurization measurements of six houses in 109 different house leak configurations. The variability in predicting pressure exponent and flow coefficient for both WLOC and OLS regression was analyzed using probability density functions. It was found that the Weighted Line of Organic Correlation significantly decreases the uncertainty in predicting pressure exponent, flow coefficient, and other low-pressure air leakage metrics compared to the Ordinary Least Square fitting. Here, the authors highly recommend the implementation of WLOC in current measurement standards and test equipment.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Phase-change valves and related methods

Valves may include an opening sized and shaped to permit a subject fluid to flow through the opening when the opening is unobstructed. A heat exchange element may be located proximate to the opening, the heat exchange element positioned and configured to induce a localized phase change in the subject fluid to form and unform a solid plug from the subject fluid around at least a portion of the heat exchange element. A heat transfer rate of the heat exchange element may be variable to control a rate of flow of the subject fluid through the valve by controlling a size of the solid plug from the subject fluid.

Sabharwall, Piyush↗

DOE OSTI2020

Effects of Atwood and Reynolds numbers on the evolution of buoyancy-driven homogeneous variable-density turbulence

The evolution of buoyancy-driven homogeneous variable-density turbulence (HVDT) at Atwood numbers up to 0.75 and large Reynolds numbers is studied by using high-resolution direct numerical simulations. To help understand the highly non-equilibrium nature of buoyancy-driven HVDT, the flow evolution is divided into four different regimes based on the behaviour of turbulent kinetic energy derivatives. The results show that each regime has a unique type of dependence on both Atwood and Reynolds numbers. It is found that the local statistics of the flow based on the flow composition are more sensitive to Atwood and Reynolds numbers compared to those based on the entire flow. It is also observed that, at higher Atwood numbers, different flow features reach their asymptotic Reynolds-number behaviour at different times. The energy spectrum defined based on the Favre fluctuations momentum has less large-scale contamination from viscous effects for variable-density flows with constant properties, compared to other forms used previously. The evolution of the energy spectrum highlights distinct dynamical features of the four flow regimes. Thus, the slope of the energy spectrum at intermediate to large scales evolves from -7/3 to -1 , as a function of the production-to-dissipation ratio. The classical Kolmogorov spectrum emerges at intermediate to high scales at the highest Reynolds numbers examined, after the turbulence starts to decay. Finally, the similarities and differences between buoyancy-driven HVDT and the more conventional stationary turbulence are discussed and new strategies and tools for analysis are proposed.

42 ENGINEERING↗

DOE OSTI2023

Understanding the compound flood risk along the coast of the contiguous United States

Abstract. Compound flooding is a type of flood event caused by multiple flood drivers. The associated risk has usually been assessed using statistics-based analyses or hydrodynamics-based numerical models. This study proposes a compound flood (CF) risk assessment (CFRA) framework for coastal regions in the contiguous United States (CONUS). In this framework, a large-scale river model is coupled with a global ocean reanalysis dataset to (a) evaluate the CF exposure related to the coastal backwater effects on river basins, and (b) generate spatially distributed data for analyzing the CF hazard using a bivariate statistical model of river discharge and storm surge. The two kinds of risk are also combined to achieve a holistic understanding of the continental-scale CF risk. The estimated CF risk shows remarkable inter- and intra-basin variabilities along the CONUS coast with more variabilities in the CF hazard over the US west and Gulf coastal basins. Different risk assessment methods present significantly different patterns in a few key regions such as the San Francisco Bay area, the lower Mississippi River, and Puget Sound. Our results highlight the need to weigh different CF risk measures and avoid using single statistics-based or hydrodynamics-based CFRAs. Uncertainty sources in these CFRAs include the use of gauge observations, which cannot account for the flow physics or resolve the spatial variability of risks, and underestimations of the flood extremes and the dependence of CF drivers in large-scale models, highlighting the importance of understanding the CF risks for developing a more robust CFRA.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Warming of the lower Columbia River , 1853 to 2018

Abstract Water temperature is a critical ecological indicator; however, few studies have statistically modeled century‐scale trends in riverine or estuarine water temperature, or their cause. Here, we recover, digitize, and analyze archival temperature measurements from the 1850s onward to investigate how and why water temperatures in the lower Columbia River are changing. To infill data gaps and explore changes, we develop regression models of daily historical Columbia River water temperature using time‐lagged river flow and air temperature as the independent variables. Models were developed for three time periods (mid‐19th, mid‐20th, and early 21st century), using archival and modern measurements (1854–1876; 1938–present). Daily and monthly averaged root‐mean‐square errors overall are 0.89°C and 0.77°C, respectively for the 1938–2018 period. Results suggest that annual averaged water temperature increased by 2.2°C ± 0.2°C since the 1850s, a rate of 1.3°C ± 0.1°C/century. Increased water temperatures are seasonally dependent. An increase of approximately 2.0°C ± 0.2°C/century occurs in the July–Dec time‐frame, while springtime trends are statistically insignificant. Rising temperatures change the probability of exceeding ecologically important thresholds; since the 1850s, the number of days with water temperatures over 20°C increased from ~5 to 60 per year, while the number below 2°C decreased from ~10 to 0 days/per year. Overall, the modern system is warmer, but exhibits less temperature variability. The reservoir system reduces sensitivity to short‐term atmospheric forcing. Statistical experiments within our modeling framework suggest that increased water temperature is driven by warming air temperatures (~29%), altered river flow (~14%), and water resources management (~57%).

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

A data-driven sensor placement approach for detecting voltage violations in distribution systems

Stochastic fluctuations in power injections from distributed energy resources (DERs) combined with load variability can cause constraint violations (e.g., exceeded voltage limits) in electric distribution systems. To monitor grid operations, sensors are placed to measure important quantities such as the voltage magnitudes. Here, in this paper, we consider a sensor placement problem which seeks to identify locations for installing sensors that can capture all possible violations of voltage magnitude limits. We formulate a bilevel optimization problem that minimizes the number of sensors and avoids false sensor alarms in the upper level while ensuring detection of any voltage violations in the lower level. This problem is challenging due to the nonlinearity of the power flow equations and the presence of binary variables. Accordingly, we employ recently developed conservative linear approximations of the power flow equations that overestimate or underestimate the voltage magnitudes. By replacing the nonlinear power flow equations with conservative linear approximations, we can ensure that the resulting sensor locations and thresholds are sufficient to identify any constraint violations. Additionally, we apply various problem reformulations to significantly improve computational tractability while simultaneously ensuring an appropriate placement of sensors. Lastly, we improve the quality of the results via an approximate gradient descent method that adjusts the sensor thresholds. We demonstrate the effectiveness of our proposed method for several test cases, including a system with multiple switching configurations.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2022

Methods and systems for fabricating high quality superconducting tapes

An MOCVD system fabricates high quality superconductor tapes with variable thicknesses. The MOCVD system can include a gas flow chamber between two parallel channels in a housing. A substrate tape is heated and then passed through the MOCVD housing such that the gas flow is perpendicular to the tape's surface. Precursors are injected into the gas flow for deposition on the substrate tape. In this way, superconductor tapes can be fabricated with variable thicknesses, uniform precursor deposition, and high critical current densities.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Methods and systems for fabricating high quality superconducting tapes

36 MATERIALS SCIENCE↗

DOE OSTI2024

Methods and systems for fabricating high quality superconducting tapes

Majkic, Goran↗

DOE OSTI2021

A Physics-Constrained Deep Learning Model for Simulating Multiphase Flow in 3D Heterogeneous Porous Media

Physics-based simulators for multiphase flow in porous media emulate nonlinear processes with coupled physics, and usually require extensive computational resources for software development, maintenance and simulation execution. As a result, a huge demand exists for fast modeling of coupled processes in a wide range of subsurface applications including geological sequestration, hydrocarbon recovery and geothermal energy extraction. In this work, an efficient physics-constrained deep learning model is developed for solving multiphase flow in 3-Dimensional (3D) heterogeneous porous media. The model fully leverages the spatial topology predictive capability of convolutional neural networks, specifically U-Net with successive contracting and expansive steps, and is coupled with an efficient continuity-based smoother to predict flow responses that need spatial continuity. Furthermore, the transient regions are penalized to steer the training process such that the model can accurately capture flow in these regions. The model takes inputs including properties of porous media, fluid properties and well controls, and predicts the temporal-spatial evolution of the state variables (pressure and saturation). While maintaining the continuity of fluid flow, the 3D spatial domain is decomposed into 2D images for reducing training cost, and the decomposition results in an increased number of training data samples and better training efficiency. Additionally, a surrogate model is separately constructed as a postprocessor to calculate well flow rate based on the predictions of state variables from the deep learning model. We use the example of CO 2 injection into saline aquifers, and apply the physics-constrained deep learning model that is trained from physics-based simulation data and emulates the physics process. The model performs prediction with a speedup of ~ 1400 times compared to physics-based simulations, and the average temporal errors of predicted pressure and saturation plumes are 0.27% and 0.099% respectively. Furthermore, water production rate is efficiently predicted by a surrogate model for well flow rate, with a mean error less than 5%. Therefore, with its unique scheme to cope with the fidelity in fluid flow in porous media, the physics-constrained deep learning model can become an efficient predictive model for computationally demanding inverse problems or other coupled processes.

58 GEOSCIENCES↗

DOE OSTI2020

Effect of Computational Schemes on Coupled Flow and Geo-Mechanical Modeling of CO 2 Leakage through a Compromised Well

Carbon capture, utilization, and storage (CCUS) describes a set of technically viable processes to separate carbon dioxide (CO 2 ) from industrial byproduct streams and inject it into deep geologic formations for long-term storage. Legacy wells located within the spatial domain of new injection and production activities represent potential pathways for fluids (i.e., CO 2 and aqueous phase) to leak through compromised components (e.g., through fractures or micro-annulus pathways). The finite element (FE) method is a well-established numerical approach to simulate the coupling between multi-phase fluid flow and solid phase deformation interactions that occur in a compromised well system. We assumed the spatial domain consists of a three-phases system: a solid, liquid, and gas phase. For flow in the two fluids phases, we considered two sets of primary variables: the first considering capillary pressure and gas pressure (PP) scheme, and the second considering liquid pressure and gas saturation (PS) scheme. Fluid phases were coupled with the solid phase using the full coupling (i.e., monolithic coupling) and iterative coupling (i.e., sequential coupling) approaches. The challenge of achieving numerical stability in the coupled formulation in heterogeneous media was addressed using the mass lumping and the upwinding techniques. Numerical results were compared with three benchmark problems to assess the performance of coupled FE solutions: 1D Terzaghi’s consolidation, Liakopoulos experiments, and the Kueper and Frind experiments. We found good agreement between our results and the three benchmark problems. For the Kueper and Frind test, the PP scheme successfully captured the observed experimental response of the non-aqueous phase infiltration, in contrast to the PS scheme. These exercises demonstrate the importance of fluid phase primary variable selection for heterogeneous porous media. We then applied the developed model to the hypothetical case of leakage along a compromised well representing a heterogeneous media. Considering the mass lumping and the upwinding techniques, both the monotonic and the sequential coupling provided identical results, but mass lumping was needed to avoid numerical instabilities in the sequential coupling. Additionally, in the monolithic coupling, the magnitude of primary variables in the coupled solution without mass lumping and the upwinding is higher, which is essential for the risk-based analyses.

deformation flow↗

DOE OSTI2022

Do Genetic Drift and Gene Flow Affect the Geographic Distribution of Female Plants in Gynodioecious Lobelia siphilitica?

Variation in population sex ratio is particularly pronounced in gynodioecious angiosperms. Extremely high female frequencies in gynodioecious populations cannot be readily explained by selective forces alone. To assess the contributions of drift and gene flow to extreme sex-ratio variation, we documented sex ratio and population size in 92 populations of Lobelia siphilitica across its range and genotyped plants using plastid and nuclear genetic markers. Similarity in spatial patterns of genetic and demographic variables may suggest that drift and/or gene flow have contributed to population sex-ratio variation in L. siphilitica. We found strong spatial structuring of extremely high female frequencies: populations with >50% female plants are restricted to the south–central portion of the range. However, we did not detect any spatial structuring in population size nor metrics of genetic diversity, suggesting that extreme variation in female frequency is not strongly affected by drift or gene flow. Extreme sex-ratio variation is frequently observed in gynodioecious plants, but its causes are difficult to identify. Further investigation into mechanisms that create or maintain the spatial structure of sex ratios in gynodioecious species will provide much needed insight.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Computational Algorithms for Unit Commitment with AC Power Flows (Final Report)

Security-constrained unit commitment (SCUC) is a key component in power system operations. When AC power flow constraints are considered in the SCUC model (AC-SCUC), the problem becomes extremely difficult due to its discrete and non-convex nature, as described in “Grid Optimization Competition Challenge 3 Problem Formulation (GOCC)”. There are four main challenges: (i) Discrete decisions regarding unit online/offline status and start-up/shut-down procedures for every single unit. The number of discrete decision variables increases considerably when a system integrates multiple generators; (ii) Configuration-based combined-cycle formulations, and multi-commodity models that include ramping products, spin/non-spin products, and regulation up/down products. The combined-cycle units introduce additional discrete decision variables and auxiliary service products further complicate the model by connecting multi-commodity products’ continuous and discrete variables; (iii) SCUC models with AC power flow constraints are far more complex due to massive bilinear terms in the large-scale nonlinear power balance equations. The nonlinear power balance equations are further complicated by the discrete step control variables of shunts; (iv) N − 1 contingency analysis. The size of the model increases linearly with the number of contingencies considered, greatly increasing the size of the optimization model. Accordingly, there is an emergent need to develop a robust algorithm capable of deriving a high-quality solution in a short time and passing through contingency tests simultaneously. In this project, we explore innovative techniques to address this challenging problem by integrating advanced polyhedral theory, approximation methods, relaxation strategies, decomposition techniques, and parallel computing. Each technique approaches the problem from a different perspective, leveraging its specific strengths to tackle distinct challenges. Each individual method has demonstrated its effectiveness in the PI’s previous research. Their integration is expected to significantly reduce the computational time required to solve the proposed complex problem. Successful completion of this project has the potential to transform the industry by enhancing optimization solvers capable of handling large-scale day-ahead energy market clearing models within strict time constraints, while incorporating AC power flow constraints. This advancement will lead to reduced overall generation costs and, consequently, increased social welfare.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2025

Thermal Characterization and Exhumation of Northwest San Juan Basin Area, NM

The San Juan Basin (SJB), located in southwestern Colorado northwestern New Mexico, containing Paleozoic through middle Cenozoic strata, formed as a partitioned basin approximately 80 Ma in response to the Laramide orogeny. The SJB is a commercially mature, petroleum-producing basin, and currently being explored for CCUS and geothermal resources. Modern heat flow within the SJB is spatially variable with higher geothermal gradients in its northern and eastern portions. The temporal history of the basin thermal history is essential for understanding capacity for carbon storage and geothermal exploration. We present thermochronometric analyses of two surface and two subsurface samples to constrain spatial-temporal thermal evolution of the northwestern San Juan Basin. Apatite (U-Th)/He thermochronometric analyses were conducted on Cliff House and Kirtland Formation outcrops and subsurface samples of the Ojo Alamo and Pictured Cliffs Formations from a DOE funded, CCUS project pilot-well. In addition, vitrinite reflectance data and 1D basin modelling constrain possible time-temperature pathways of the samples in an area where no previous studies have constrained the uplift/exhumation of the Hogback Monocline using thermochronometry. Modeling suggests that elevated subsurface temperatures developed simultaneously with regional late Oligiocene volcanism in the San Juan Volcanic field and timing of maximum burial in the SJB. Late Miocene to Pliocene cooling/exhumation through the apatite (U-Th)/He partial retention zone support stratigraphic evidence of the Colorado Plateau uplift, possibly regional epeirogenic uplift driven by mantle processes.

02 PETROLEUM↗

DOE OSTI2021

Prediction of Detonation-Induced Disturbances Propagating Upstream into Inlets of Rotating Detonation Combustors

Disturbances caused by the detonation wave in a rotating detonation combustor (RDC) propagate upstream through the inlet, and can potentially affect and couple to upstream components, such as turbomachinery or isolators. These disturbances can potentially also affect the operation of the RDC itself. By drawing from the analogy of a detonation wave bounded by an inert gas, the pressure disturbances observed upstream of the inlet are explained as the consequence of the passage of an upstream propagating oblique shock. In this study, the pressure rise in the plenum from the oblique shock is measured in an axial air inlet RDC. The speed of the upstream propagating wave is estimated to be moderately above the acoustic speed of the oxidizer in the plenum. The wave propagates into the plenum despite local regions of choking in the inlet. It is estimated that the time it takes a fluid particle to transit from the plenum to the detonation channel through the inlet is much larger than the rotational time of the detonation wave. This implies that a fluid particle experiences multiple shocks prior to entering the detonation channel. The oblique shock propagating upstream through the inlet area change is modeled by leveraging an analogy with a quasi-1D shock wave moving in a variable area duct with mean (incoming) flow. Due to flow expansion along the area change, fluid particles are found to experience stronger shocks in the inlet than in the plenum, thereby creating different thermodynamic states within the fill region as the oxidizer emerges from the inlet.

Feleo, Alexander↗