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DOE OSTI2024

Shear rate dependency on flowing granular biomass material

The commercialization of bioenergy has been significantly limited by various material handling issues due to the poor flowability of granular biomass materials. A good understanding of flow physics and robust constitutive models to predict flow behavior across multiple regimes are essential to address these issues. In this study, we investigated the multi-regime flow behavior of loblolly pine chips, a widely used bioenergy feedstock, through comprehensive inclined plane flow experiments and simulations. A quasi-static hypoplastic model and a cross-regime Drucker-Prager-µ(I) model were calibrated and validated against the physical experiments to investigate the quasi-static and dense flow behavior. The results show that for granular biomass, 1) plane flow (iso-thickness along the plane) exists within a smaller range of inclination while heap flow (varying thickness along the plane) exists within a broader range of inclination, as compared with conventional granular materials (e.g., glass beads); 2) the scaling law of granular biomass flowing on an inclined plane (Froude Number versus dimensionless thickness) forms a bi-linear trend with the turning point governed by the quasi-static and dense flow regimes; 3) the multi-regime DP-µ(I) model can capture the flow behavior in both regimes well at the cost of extra calibration. In conclusion, these findings advance the scientific understanding of the multi-regime flow behavior of granular biomass materials and shed light on formulating novel constitutive models to assist granular biomass handling in the bioenergy industry.

09 BIOMASS FUELS↗

DOE OSTI2022

Online Machine Learning for Accelerating Molecular Dynamics Modeling of Cells

We developed a biomechanics-informed online learning framework to learn the dynamics with ground truth generated with multiscale modeling simulation. It was built on Summit-like supercomputers, which were also used to benchmark and validate our framework on one physiologically significant modeling of deformable biological cells. We generalized the century-old equation of Jeffery orbits to a new equation of motion with additional parameters to account for the flow conditions and the cell deformability. Using simulation data at particle-based resolutions for flowing cells and the learned parameters from our framework, we validated the new equation by the motions, mostly rotations, of a human platelet in shear blood flow at various shear stresses and platelet deformability. Our online framework, which surrogates redundant computations in the conventional multiscale modeling by solutions of our learned equation, accelerates the conventional modeling by three orders of magnitude without visible loss of accuracy.

multiscale modeling↗

DOE OSTI2022

The nonlinear rheology of complex yield stress foods

Many foods have a yield stress that allows them to retain a desired shape at rest, but transition into a viscous fluid when being served or consumed. The determination of the yield stress of the food dictates how the foods are formed and packaged, how they are served, and how they are perceived when being eaten. Oscillatory shearing provides an ideal test protocol to map the rheology across a range of time and flow strength scales. We couple oscillatory shearing and an iterative recovery procedure to show that the yielding process is a continuous transition for two common yield stress foods. We show that unrecoverable processes from oscillatory tests are equivalent to the steady shear flow behavior. We show that this yielding behavior can be well approximated by a recently published model that treats yield stress materials as continuous viscoelastic fluids with a rate-dependent relaxation time and has parameters that can be obtained from the linear viscoelastic oscillatory frequency sweep and the steady shear flow curve.

Griebler, James J.↗

DOE OSTI2022

Do ambient shear and thermal stratification impact wind turbine tip-vortex breakdown?

Modern wind turbines experience uneven inflow conditions across the rotor, due to the ambient flow’s shear and thermal stratification. Such conditions alter the shape and length of turbine wakes and thus impact the loads and power generation of downstream turbines. To this end, understanding the spatial evolution of the individual wakes under different atmospheric conditions is key to controlling and optimising turbine arrays. With this numerical study we aim to obtain a better understanding of the fundamental physics governing the near-wake dynamics of wind turbines under shear and thermal stability, by examining their tip-vortex breakup mechanisms. Our approach considers scale-resolving simulations of a single turbine wake under a linear shear profile as well as the application of harmonic tip perturbations to trigger flow instabilities. For the subsequent analysis we use the proper orthogonal decomposition (POD) method to extract coherent structures from the flow, and we also calculate mean kinetic energy fluxes to quantify each coherent structure’s contribution to wake recovery. The wake’s helical spiral is found to hinder wake recovery for all studied ambient flow conditions, whereas the mutual inductance instability has positive MKE flux leading to an enhanced wake recovery. Finally, the ambient shear has the largest impact on the local MKE flux with respect to downstream location by changing the shape of the curve and location of extrema, whereas thermal stratification has only a minimal impact on the magnitude of the near-wake local MKE flux distribution.

17 WIND ENERGY↗

DOE OSTI2020

Applying the Gyrokinetic Formulation of Magnetized Plasma Dynamics to Z-pinch plasmas

This project adapts and applies the gyrokinetic Eulerian code COGENT to an emerging area of highly-magnetized Z-pinch plasma systems. Simulation efforts for these plasmas currently use either magneto-hydrodynamic (MHD) fluid codes, which suffer from fidelity being restricted to narrow plasma conditions, or fully kinetic particle-in-cell (PIC) methods, which suffer from the run-time needed to resolve the very small spatial and temporal scales required for the plasma conditions. The progress with achieving detailed theoretical understanding of Z-pinch plasma systems can be greatly expedited using some combination of gyrokinetic and drift-ordered MHD models, developed in the tokamak community and implemented in the COGENT code. These formulations are applicable to a much larger parameter space than standard MHD models, while providing a substantial speed-up in run-time over fully kinetic codes. In particular, the gyrokinetic formalism is successfully applied to a flow-stabilized Z pinch (FSZP) system – a promising fusion concept where a sheared axial flow is used to provide stability against large-scale ideal-MHD modes. Results of gyrokinetic simulations with COGENT agree well with those from fully kinetic simulations, while requiring ~500x less run-time.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2020

Viscometric flow of dense granular materials under controlled pressure and shear stress

This study examines the flow of dense granular materials under external shear stress and pressure using discrete element method simulations. In this method, the material is allowed to strain along all periodic directions and adapt its solid volume fraction in response to an imbalance between the internal state of stress and the external applied stress. By systematically varying the external shear stress and pressure, the steady rheological response is simulated for: (1) rate-independent quasi-static flow; and (2) rate-dependent inertial flow. The simulated flow is viscometric with non-negligible first and second normal stress differences. While both normal stress differences are negative in inertial flows, the first normal stress difference switches from negative to slightly positive, and second normal stress difference tends to zero in quasi-static flows. The first normal stress difference emerges from a lack of coaxiality between a second-rank contact fabric tensor and strain rate tensor in the flow plane, while the second normal stress difference is linked to an excess of contacts in the shear plane compared with the vorticity direction. A general rheological model of second order (in terms of strain rate tensor) is proposed to describe the two types of flow, and the model is calibrated for various values of interparticle friction from simulations on nearly monodisperse spheres. The model incorporates normal stress differences in both regimes of flow and provides a complete viscometric description of steady dense granular flows.

42 ENGINEERING↗

DOE OSTI2022

A scalable compressible volume of fluid solver using a stratified flow model

Here, in this paper, a Volume of Fluid method which uses a Stratified Flow model for flux calculation is proposed to solve a compressible multiphase flow in a way that has high parallel efficiency. The solver is part of an open-source computing tool to study fuel entrainment and combustion in the application of paraffin-based hybrid rocket motors. This paper focuses on the compressible Volume of Fluid solver for the liquid and gaseous phases in this environment. This solver uses perfect gas and stiffened gas models for equation of state, with the ability to easily add other models as desired. Additionally a comparison of a Riemann solver versus an AUSM+up scheme is conducted, showing improvement with the later in the solution of multiphase flows. This solver successfully reproduces shock tube cases with the expected accuracy, as well as simulating two-dimensional shear and gravity-driven flows. Results also show that the code is able to utilize a Stratified Flow model to evaluate shear flow without the need for interface reconstruction or gradient calculations. Finally, it is shown that the solver has near-ideal scaling under strong scaling tests as well as good performance in static scaling, giving improved performance over current options and implying future advancement of high-performance computing efficiency for multiphase flow solvers.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Fiber orientation and porosity in large-format extrusion process: The role of processing parameters

Controlling fiber orientation and porosity in short-fiber thermoplastic composites is important for enhancing mechanical, electrical and thermal properties in large-format additive manufacturing. This study employs a factorial design of experiments (DoE) to assess the effects of nozzle diameter (5.08 mm–10.16 mm), temperature (230–250 °C), and extruder screw speed (150–280 rpm) on flow rate, shear rate, porosity, fiber orientation, fiber length and tensile strength in 20 % carbon fiber-filled acrylonitrile butadiene styrene. ANOVA results show that screw speed significantly impacts flow rate, while nozzle diameter and temperature have lesser effects. Shear rate increases with smaller nozzles and higher speeds. Porosity decreases from 5.58 % with a 10.16 mm nozzle to 3.11 % with a 5.08 mm nozzle at 150 rpm due to increased shear rates, which induce shear thinning, reducing viscosity and facilitating gas escape. Larger nozzles (10.16 mm) produce larger, more heterogeneous pores, while smaller nozzles (5.08 mm) yield smaller, uniform pores. Beads produced with the 5.08 mm nozzle exhibit longer fiber lengths due to reduced residence time, lower shear stress, and better alignment. Fiber orientation improves with smaller nozzles due to higher shear rates but decreases with higher screw speeds (280 rpm) due to shorter residence times. The highest fiber alignment (A xx ∼ 0.65) and low porosity (∼3%) were achieved with a 5.08 mm nozzle at 150 rpm, while equivalent additive manufacturing-compression molding samples exhibited better tensile strength (∼93 MPa) under these conditions. In conclusion, these findings emphasize the importance of optimizing processing parameters to enhance fiber alignment and reduce porosity for improved mechanical performance.

Design of experiments↗

DOE OSTI2021

Screening of resonant magnetic perturbation fields assuming various plasma flow models

A recently updated version of the MARS-F code [Y. Q. Liu et al., Phys. Plasmas 7, 3681 (2000); L. Li et al., Phys. Plasmas 25, 082512 (2018); and G. L. Xia et al., Nucl. Fusion 59, 126035 (2019)] is utilized to numerically investigate the plasma screening effect on the applied resonant magnetic perturbation (RMP) field, assuming various equilibrium flow models, including the toroidal flow, the parallel flow and their combinations, and poloidal and toroidal projections of the parallel flow. A parallel equilibrium flow with a uniform radial profile is found to have no effect on plasma screening of the RMP field. A sheared parallel flow, however, does change plasma screening. The poloidal projection of the parallel flow weakens plasma screening in the resistive-inertial regime. The effect on the favorable average curvature regime is found, however, to be non-monotonic. With the increasing flow speed, the poloidal projection first weakens Glasser-Green-Johnson (GGJ)-screening. Further increase in the flow speed results in enhanced GGJ-screening again. This non-monotonic behavior is related to the perturbed parallel shielding current, which appears also off the mode rational surface at fast flow due to additional resonances between the RMP perturbation and the sound wave continuum. These results indicate that flow induced plasma screening to the RMP field can have complicated characteristics, which, in turn, can have implications on the RMP field penetration into the plasma in experiments for controlling the edge localized modes.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

Grid resolution requirement for resolving rare and high intensity wall-shear stress events in direct numerical simulations

Turbulent signals are intermittent with large instantaneous fluctuations. Such large fluctuations lead to small Kolmogorov scales that are hard to resolve in numerical simulations [P. K. Yeung, K. R. Sreenivasan, and S. B. Pope, Effects of finite spatial and temporal resolution in direct numerical simulations of incompressible isotropic turbulence, Phys. Rev. Fluids 3, 064603 (2018)]. Here, the present paper follows the above basic logic, but instead of dissipation events in isotropic turbulence, we study wall-shear stress events in plane channel flow. Wall-shear stress fluctuations are increasingly more intermittent as the Reynolds number increases. Hence, one has to employ higher grid resolutions as the Reynolds number increases in order to resolve a given percentage of wall-shear stress events. The objective of this paper is to quantify effects of the grid resolutions on the rare and high intensity wall-shear stress events. We find that the standard grid resolution resolves about 99% of the wall-shear stress events at Re τ = 180. A slightly higher grid resolution has to be employed in order to resolve 99% of the wall-shear stress events at higher Reynolds numbers, and if the standard grid resolution is used for, e.g., a Re τ = 10000 channel flow, one resolves about 90%–95% wall-shear stress events.

42 ENGINEERING↗

DOE OSTI2025

Let’s Stick Together: Interplay of Moisture, Particle Size, and Anatomical Fraction in the Flowability of Corn Stover Crumbles

Handling of agricultural waste biomass feedstocks (such as corn stover) is a persistent challenge in the production of biofuels and chemicals at integrated biorefineries. Inconsistent flowability and high feedstock variability creates equipment downtime and processing challenges. This work investigates the influence of anatomical fractionation and moisture content on the bulk solids handling behavior of corn stover crumbles. A combination of rotational shear testing, tribological measurements, and surface and sorption characterization techniques (inverse gas chromatography (IGC), dynamic vapor sorption (DVS), and electron microscopy) were used to evaluate the contributions of particle composition, size, and surface properties to flow behavior. Shear and frictional testing revealed that moisture content has the greatest effect on flowability, significantly increasing unconfined yield strength (ƒ c ) and reducing the flow function coefficient (F F C), regardless of anatomical fraction. While differences in surface energy were observed between fractions, particularly in polar contributions (γ AB ), these did not correspond to meaningful differences in flow behavior. Coarser 6 mm particles exhibited poorer flow performance than 4 mm crumbles, likely due to broader particle size distributions and increased particle interlocking. Taken together, these results suggest that anatomical fractionation provides minimal benefit from a bulk handling perspective. Moisture content and particle size heterogeneity dominate handling behavior, reinforcing the utility of unfractionated corn stover in processing environments. These insights can inform the design of more efficient and reliable feedstock processing systems for agricultural biomass in integrated biorefineries.

09 BIOMASS FUELS↗

DOE OSTI2026

Insights into mixing of non-isothermal multi-polymer melts for complex plastics recycling

Catalytic recycling or upcycling of plastics is often limited not by catalyst performance, but by transport, arising from highly viscous, non-Newtonian polymer melts. In this work, we develop a reactor-scale framework that integrates rheological measurements, constitutive modeling, computational fluid dynamics (CFD), and experiments to quantify mixing, heat transfer, and dispersion in surrogate hydrocarbon melts representing mixed plastics systems. Temperature- and shear rate-dependent viscosity of low-density polyethylene (LDPE) and high-density polyethylene (HDPE) is measured to create two surrogate polymers (PLD and PHD) that capture the dominant shear-thinning flow behavior while neglecting strong elastic effects, enabling tractable simulation of non-isothermal, polymer-melt mixing using a Carreau-Arrhenius generalized Newtonian framework. Three-dimensional CFD simulations are employed to evaluate impeller performance in PLD using mixing time, cavern volume, thermal uniformity, and interfacial area for regimes in which viscoelastic effects are not dominant. We show that magnetic stir bars commonly used in lab-scale studies produce large thermal gradients (~60 °C) and poor mixing, even under idealized power delivery and polymer flow conditions. In contrast, close-clearance anchor impellers achieve near-isothermal operation, reduce mixing times by up to 5×, and provide >90% active circulation volume. We further demonstrate that, at low pseudo-Deborah number (De*), motor power requirements can be predicted directly from shear rate-dependent rheology using the Carreau-Arrhenius framework, enabling rational selection of operating conditions. Extension to surrogate immiscible multi-polymer systems based on PLD and PHD shows that interfacial area is highly sensitive to operating conditions and impeller design, with coaxial anchor-turbine configurations enhancing dispersion by up to 4 × .

Close-clearance impellers↗

DOE OSTI2021

System and method for controlling metal oxide gel particle size

Metal oxide gel particles, may be prepared with a desired particle size, by preparing a low-temperature aqueous metal nitrate solution containing hexamethylene tetramine as a feed solution; and causing the feed solution to flow through a first tube and exit the first tube as a first stream at a first flow rate, so as to contact a high-temperature nonaqueous drive fluid. The drive fluid flows through a second tube at a second flow rate. Shear between the first stream and the drive fluid breaks the first stream into particles of the metal nitrate solution, and decomposition of hexamethylene tetramine converts metal nitrate solution particles into metal oxide gel particles. A metal oxide gel particle size is measured optically, using a sensor device directed at a flow of metal oxide gel particles within the stream of drive fluid. The sensor device measures transmission of light absorbed by either the metal oxide gel particles or the drive fluid, so that transmission of light through the drive fluid changes for a period of time as a metal oxide gel particle passes the optical sensor. If a measured particle size is not about equal to a desired particle size, the particle size may be corrected by adjusting a ratio of the first flow rate to a total flow rate, where the total flow rate is the sum of the first and second flow rates.

Linneen, Nicholas N.↗

DOE OSTI2023

System and method for controlling metal oxide gel particle size

Linneen, Nicholas↗

DOE OSTI2022

Destabilization of binary mixing layer in supercritical conditions

Compressible mixing layer instabilities are of importance to a wide range of environmental and industrial applications. Past studies have focused on either ideal-gas or real-fluid thermodynamic regimes of single-species mixing layers. However, mixing layers of binary mixtures at supercritical conditions, commonly encountered in fuel injection systems, introduce additional complexities due to the added compositional degree-of-freedom. Moreover, the effect of strong variations in thermodynamic response functions across the Widom line on the binary mixing layer stability remains poorly understood. Thus, the objective of this study is to examine the coupling between the hydrodynamic instability and the real-fluid thermodynamics across the Widom line and its effects on the overall binary mixing layer dynamics. To this end, we develop a linear stability analysis of the full binary-species compressible transport equations coupled with the PC-SAFT equation of state. Analysis shows the existence of a novel instability mechanism that arises from juxtapositioning of the Widom-line transition and the hydrodynamic inflection point. This novel thermodynamically induced instability mechanism has the net effect of destabilizing the binary mixing layer at lowering supercritical conditions towards the critical pressure point. This is in contrast to previous stability analyses of supercritical single-species mixing layers, where increasing pressure destabilizes the flow due to its effect on reducing the density stratification. The discovered thermodynamically induced instability mechanism of binary mixing flows highlights the need for an extension of classical instability criteria to incorporate the effect of strong variations in the thermodynamic response functions across the Widom line on mixing layer instability.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2025

On Master-Length Scale Formulations for Stable Conditions in Turbulence Closure Models

Three formulations of the turbulence-length scales used in numerical modelling of atmospheric flows are compared. The comparison is made using the Mellor–Yamada–Nakanishi–Niino turbulence closure model within the stable boundary layer local similarity framework. With an appropriate choice of model constants, the model predictions are barely discernible and compare well with the empirical data obtained from the SHEBA campaign.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

Adiabatic behavior of an elliptical vortex in a time-dependent external strain flow

The adiabatic behavior of two-dimensional (2D) fluid vortices subject to slowly varying, time-dependent external strain flows is studied theoretically, and experimentally using magnetized non-neutral electron plasmas. Here the E × B drift dynamics of the electrons perpendicular to the magnetic field are analogous to the motion of fluid vorticity under the 2D Euler equations describing ideal fluids. A low-dimensional elliptical vortex patch model is used along with a WKB approximation to derive a formula for the breaking of an adiabatic invariant due to the changing external flow. The invariant is interpreted as the amplitude of a perturbative oscillation about a stable fixed point corresponding to a steady elliptical vortex. Smooth, hyperbolic tangent and piecewise linear ramp functions are considered for the external strain time dependence. Standard exponential breaking is observed in the former case, whereas the latter exhibits a power-law breaking curve with periodic modulation. It is found that a driving term in the equations of motion contributes the majority of the breaking whereas the frequency variation plays a weaker, but significant role. The experimental data agree closely with the theoretical model. The most significant deviation is due to inviscid damping behavior associated with the smooth edges of the experimental vortices, which tends to reduce the amplitude of the oscillation. Finally, the results are compared and contrasted with other related experimental, numerical, and theoretical work.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2020

Investigation of fouling mechanisms for diesel engine exhaust heat recovery

The effect of diesel engine exhaust fouling on heat and mass exchangers for waste heat recovery is investigated. Experiments are conducted for a range of operating conditions relevant to the use of the waste heat from a diesel engine for powering a 2.71 kW capacity absorption heat pump. Thermal resistances of fouling layers as well as their effects on pressure drop are determined, and the underlying mechanisms for deposition and removal are investigated. Fouling layer effects are most severe for the lowest coolant temperatures and 100% generator load. At these conditions, the fouling thermal resistance is approximately 70% of the total resistance, and the ratio of the steady-state pressure drop to the baseline pressure drop is 3.25. Flow induced shear is found to be the primary growth inhibiting mechanism at high exhaust velocities. Findings from this study can guide heat exchanger design for a variety of waste heat recovery systems.

04 OIL SHALES AND TAR SANDS↗