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DOE OSTI2023

Development of a 300 MWe Utility Scale Oxy-Fuel sCO2 Turbine

A 300 MWe direct-fired supercritical carbon dioxide (sCO2) oxy-fuel turbine is being developed that will burn natural gas-fired, coal syngas and even hydrogen mixtures capable of 1,150ºC turbine inlet temperature at 300 bar. This design will significantly improve the state-of-the-art for thermal efficiency and results in a high-pressure stream of CO2 with 98%+ carbon capture, making the power plant near emission-free and more efficient than Natural Gas Combined Cycle (NGCC) plants with carbon capture. This power plant will be capable of burning coal through gasification and cleanup of the synthesis gas (syngas). sCO2 power cycles are a transformational technology for the energy industry, providing higher efficiency heat source energy conversion for conventional and alternative energy sources. This novel cycle significantly reduces capital costs because of smaller equipment footprints, design modularity, and allows for rapid cyclic load and source following to balance solar and wind energy power swings. Oxy-fuel sCO2 cycles take these advantages even further, utilizing higher firing temperatures, improved efficiency, and simpler carbon capture strategies. This turbine will require cooled turbine nozzles and blades as well as advanced thermal management systems to accommodate these high temperatures. The cooled blade heat transfer correlations required new test programs at higher Reynolds number than air-breathing gas turbines for impingement, serpentine, and pin-fin regions. Novel blade optimization was performed to maximize aerodynamic efficiency, while minimizing cooling flows. A turbine layout was generated utilizing individual combustor cans with cooled liners feeding into a 6-stage axial flow turbine with cooled stator nozzles and turbine blades. The case design and thermal management preliminary design will be described.

Moore, Jeffrey↗

NASA NTRS2019

The ILRS: Approaching 20 Years and Planning for the Future

The International Laser Ranging Service (ILRS) was established by the International Association of Geodesy (IAG) in 1998 to support programs in geodesy, geophysics, fundamental constants and lunar research, and to provide the International Earth Rotation Service with data products that are essential to the maintenance and improvement in the International Terrestrial Reference Frame (ITRF), the basis for metric measurements of changes in the Earth and Earth–Moon system. Other scientific products derived from laser ranging include precise geocentric positions and motions of ground stations, satellite orbits, components of Earth’s gravity field and their temporal variations, Earth Orientation Parameters, precise lunar ephemerides and information about the internal structure of the Moon. Laser ranging systems are already measuring the one-way distance to remote optical receivers in space and are performing very accurate time transfer between remote sites in the Earth and in Space. The ILRS works closely with the IAG’s Global Geodetic Observing System. The ILRS develops (1) the standards and specifications necessary for product consistency, and (2) the priorities and tracking strategies required to maximize network efficiency. The service collects, merges, analyzes, archives and distributes satellite and lunar laser ranging data to satisfy a variety of scientific, engineering, and operational needs and encourages the application of new technologies to enhance the quality, quantity, and cost effectiveness of its data products. The ILRS works with (1) new satellite missions in the design and building of retroreflector targets to maximize data quality and quantity, and (2) science programs to optimize scientific data yield. Since its inception, the ILRS has grown to include forty laser ranging stations distributed around the world. The ILRS stations track more than ninety satellites from low Earth orbit (LEO) to the geosynchronous orbit altitude as well as retroreflector arrays on the surface of the Moon. Applications have been expanded to include time transfer, asynchronous ranging for targets at extended ranges, free space quantum telecommunications, and the tracking of space debris. Laser ranging technology is moving to lower energy, higher repetition rates (kHz), single-photon-sensitive detectors, shorter pulse widths, shorter normal point intervals for faster data acquisition, and increased pass interleaving, automated to autonomous operation with remote access, and embedded software for real-time updates and decision making. An example of pass interleaving is presented for the Yarragadee station (see Fig. 4); tracking of LEO satellites is often accommodated during break in LEO and GNSS passes. New satellites arrays provide more compact targets and work continues on the development of lighter less expensive arrays for satellites and the moon. The service now provides operational ITRF products including daily/ weekly station positions and daily resolution Earth orientation products; the flow of weekly combination of satellite orbit files for LAGEOS/Etalon-1 and -2 has recently been established. New products are under testing through a pilot project on systematic error monitoring currently underway. The article will give an overview of activities underway within the service, paths forward presently envisioned, and current issues and challenges.

Laser retroreflectors↗

DOE OSTI2020

Potential Impacts of High-Octane Fuel Introduction in a Naturally Aspirated, Port Fuel-Injected Legacy Vehicle

In recent years there has been an increased interest in raising the octane level of gasoline to enable higher compression ratios (CR) in spark-ignition engines to improve vehicle fuel efficiency. A number of studies have examined opportunities to increase efficiency in future vehicles, but potential impacts on the legacy fleet have not received as much attention. In this study, our effort focused on experimental studies on an engine using high-octane fuels without changing the engine’s CR. Spark timing was advanced until maximum torque was reached or knock was encountered for each engine condition, using each individual fuel to maximize engine efficiency. Knock-limited conditions occurred as the output brake mean effective pressure (BMEP) neared the maximum attainable output at a given engine speed. Increasing research octane numbers generally enabled knock-free operation under a greater number of operating conditions. Vehicle modeling using Autonomie was used to project vehicle energy use, fuel economy, and tailpipe CO 2 emissions for the Urban Dynamometer Driving Schedule (UDDS), the Highway Fuel Economy Test (HWFET), and the US06 cycle. Results show that decreases in energy consumption of up to 2% for a small SUV are possible through the use of a 97 RON fuel compared to a baseline using 91 RON fuel, provided that the formulation of the fuel does not cause unanticipated operational issues such as lower maximum BMEP. Greater improvements using high-octane fuels are possible if the CR is increased, but there is no opportunity to increase the CR in legacy vehicles. Thus, these vehicles realize an improvement from increased octane rating in accordance with their ability to spark advance to take advantage of a fuel with a higher octane rating. For the modeled vehicle, improvements of up to 2% in volumetric fuel economy may be possible through the use of a 97 RON fuel with the largest gains expected on the US06 cycle. Fuel economy impacts are strongly coupled to the heating value of the fuels in addition to changes in engine efficiency. Similarly, decreases in tailpipe CO 2 emissions are also achievable. However, simultaneous improvements in energy consumption, fuel economy, and tailpipe CO 2 emissions are not guaranteed and are dependent upon fuel formulation.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2024

Optimal operation of solid-oxide electrolysis cells considering long-term chemical degradation

Optimizing the performance of solid oxide electrolysis cells (SOECs) for long-term hydrogen (H 2 ) production at high temperatures is crucial, as prolonged operation leads to efficiency losses and shorter cell lifespans due to chemical degradation. Here, in this work, we adopt a quasi-steady state approach for dynamic optimization over extended operational periods to address the disparity in timescales between cell operation and degradation. Integrating a 2-D non-isothermal SOEC model with balance-of-plant (BOP) equipment, we explore three optimization objectives: minimizing terminal degradation, maximizing integral efficiency, and minimizing the levelized cost of H 2 (LCOH). Our dynamic optimization algorithm reduces LCOH by 9.5% and 16% compared to strategies focusing solely on terminal degradation and integral efficiency, respectively. For electricity prices of 0.03 $\$$/mWh and 0.3 $\$$ mWh optimal replacement schedules range from 5 to 2 years, depending on the operational mode. Furthermore, a flexible operational mode yields additional improvements in LCOH over traditional galvanostatic and potentiostatic modes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Piston geometry and stroke optimization for high efficiency propane spark ignition engines

Propane has unique properties and offers interesting characteristics for high-efficiency spark ignition engines. Its high volatility reduces or completely eliminates fuel-wall wetting and facilitates fuel air mixing. Furthermore, propane has a research octane number of 112 and a high octane sensitivity of 15. Finally, its laminar flame speed is on the same order as that of conventional gasoline, and it exhibits high dilution tolerance. Modern spark ignition internal combustion engines rely on fast combustion rates and high dilution to achieve high brake thermal efficiencies. To accomplish this, high stroke-to-bore ratios and high geometric compression ratios have been used in new engine designs. Therefore, propane’s relatively high laminar flame speeds, high knock resistance, and dilution tolerance make it an excellent candidate fuel for modern spark ignition engines. The objective of this work is to co-optimize the piston geometry and the engine stroke to maximize the efficiency of a spark-ignition engine fueled with propane. 3D computational fluid dynamics (CFD) simulations employing the extended coherent flamelet model were used to study the parametric effects of piston shape and stroke length. A piston geometry based on high performing pistons was parameterized using four controlling parameters. The piston geometry and engine stroke design space was explored using deterministic and quasi-random sampling techniques. In conclusion, a Gaussian process regression model was built using the simulation data to explain the results observed.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2017

Improving biomass pyrolysis economics by integrating vapor and liquid phase upgrading

Partial deoxygenation of bio-oil by catalytic fast pyrolysis with subsequent coupling and hydrotreating can lead to improved economics and will aid commercial deployment of pyrolytic conversion of biomass technologies. Biomass pyrolysis efficiently depolymerizes and deconstructs solid plant matter into carbonaceous molecules that, upon catalytic upgrading, can be used for fuels and chemicals. Upgrading strategies include catalytic deoxygenation of the vapors before they are condensed (in situ and ex situ catalytic fast pyrolysis), or hydrotreating following condensation of the bio-oil. In general, deoxygenation carbon efficiencies, one of the most important cost drivers, are typically higher for hydrotreating when compared to catalytic fast pyrolysis alone. However, using catalytic fast pyrolysis as the primary conversion step can benefit the entire process chain by: (1) reducing the reactivity of the bio-oil, thereby mitigating issues with aging and transport and eliminating need for multi-stage hydroprocessing configurations; (2) producing a bio-oil that can be fractionated through distillation, which could lead to more efficient use of hydrogen during hydrotreating and facilitate integration in existing petroleum refineries; and (3) allowing for the separation of the aqueous phase. In this perspective, we investigate in detail a combination of these approaches, where some oxygen is removed during catalytic fast pyrolysis and the remainder removed by downstream hydrotreating, accompanied by carbon–carbon coupling reactions in either the vapor or liquid phase to maximize carbon efficiency toward value-driven products (e.g. fuels or chemicals). The economic impact of partial deoxygenation by catalytic fast pyrolysis will be explored in the context of an integrated two-stage process. In conclusion, improving the overall pyrolysis-based biorefinery economics by inclusion of production of high-value co-products will be examined.

09 BIOMASS FUELS↗

DOE OSTI2021

A Component-Sizing Methodology for a Hybrid Electric Vehicle Using an Optimization Algorithm

Many leading companies in the automotive industry have been putting tremendous effort into developing new powertrains and technologies to make their products more energy efficient. Evaluating the fuel economy benefit of a new technology in specific powertrain systems is straightforward; and, in an early concept phase, obtaining a projection of energy efficiency benefits from new technologies is extremely useful. However, when carmakers consider new technology or powertrain configurations, they must deal with a trade-off problem involving factors such as energy efficiency and performance, because of the complexities of sizing a vehicle’s powertrain components, which directly affect its energy efficiency and dynamic performance. As powertrains of modern vehicles become more complicated, even more effort is required to design the size of each component. This study presents a component-sizing process based on the forward-looking vehicle simulator “Autonomie” and the optimization algorithm “POUNDERS”; the supervisory control strategy based on Pontryagin’s Minimum Principle (PMP) assures sufficient computational system efficiency. We tested the process by applying it to a single power-split hybrid electric vehicle to determine optimal values of gear ratios and each component size, where we defined the optimization problem as minimizing energy consumption when the vehicle’s dynamic performance is given as a performance constraint. The suggested sizing process will be helpful in determining optimal component sizes for vehicle powertrain to maximize fuel efficiency while dynamic performance is satisfied. Indeed, this process does not require the engineer’s intuition or rules based on heuristics required in the rule-based process.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2021

Isotropic etchback method of linewidth tailoring multilayer dielectric diffraction gratings for improvement of laser damage resistance and diffraction efficiency

A method of fabricating a multilayer dielectric (MLD) diffraction grating by providing a multilayer stack having a grating layer, and anisotropically etching the grating layer to form grating lines having an initial lineheight, an initial linewidth, and an initial grating duty cycle, that are greater than a target lineheight, a target linewidth, and a target grating duty cycle, respectively. An isotropic wet etch solution is then used to etch back the grating lines to the target lineheight, the target linewidth, and the target grating duty cycle so as to minimize electric field intensities and maximize diffraction efficiency for a given set of MLD illumination conditions.

Britten, Jerald A.↗

DOE OSTI2023

Aviation Mission Profile Performance Evaluation in a High Specific Power Surface Permanent Magnet Machine with Additively Manufactured Coils and Integrated Heat Pipes

The purpose of this paper is to accurately evaluate the performance and overall efficiency of an electrical machine driving a propeller (as a part of a hybrid or electric propulsion system) during the flight mission profile using electromagnetic-thermal simulations. The study focuses on a 250 kW, 5000 rpm, 1.25 kHz, 36/30 slot/pole surface permanent magnet (SPM) machine with additively manufactured (AM) hollow conductors and integrated heat pipes (HP). The machine drive parameters (frequency, and current) are tuned to maximize the efficiency for a given flight cycle, while providing the highest specific power (SP) during takeoff. Afterward using Multiphysics simulations, the transient thermal behavior of the machine is studied and temperature profile for different parts of the machine is extracted. Finally, steady-state temperatures during cruising are estimated and overall efficiency is re-evaluated.

additive manufacturing↗

DOE OSTI2018

Energy and Area Efficiency in Neuromorphic Computing for Resource Constrained Devices

Resource constrained devices are the building blocks of the internet of things (IoT) era. Since the idea behind IoT is to develop an interconnected environment where the devices are tiny enough to operate with limited resources, several control systems have been built to maintain low energy and area consumption while operating as IoT edge devices. Several researchers have begun work on implementing control systems built from resource constrained devices using machine learning. However, there are many ways such devices can achieve lower power consumption and area utilization while maximizing application efficiency. Spiky neuromorphic computing (SNC) is an emerging paradigm that can be leveraged in resource constrained devices for several emerging applications. While delivering the benefits of machine learning, SNC also helps minimize power consumption. For example, low energy memory devices (memristors) are often used to achieve low power operation and also help in reducing system area. In total, we anticipate SNC will provide computational efficiency approaching that of deep learning while using low power, resource constrained devices.

Chakma, Gangotree↗

DOE OSTI2022

Surrogate Hessian accelerated structural optimization for stochastic electronic structure theories

In this work, we present an efficient energy-based method for structural optimization with stochastic electronic structure theories, such as diffusion quantum Monte Carlo (DMC). This method is based on robust line-search energy minimization in reduced parameter space, exploiting approximate but accurate Hessian information from a surrogate theory, such as density functional theory. The surrogate theory is also used to characterize the potential energy surface, allowing for simple but reliable ways to maximize statistical efficiency while retaining controllable accuracy. We demonstrate the method by finding the minimum DMC energy structures of the selected flake-like aromatic molecules, such as benzene, coronene, and ovalene, represented by 2, 6, and 19 structural parameters, respectively. In each case, the energy minimum is found within two parallel line-search iterations. The method is near-optimal for a line-search technique and suitable for a broad range of applications. It is easily generalized to any electronic structure method where forces and stresses are still under active development and implementation, such as diffusion Monte Carlo, auxiliary-field Monte Carlo, and stochastic configuration interaction, as well as deterministic approaches such as the random-phase approximation. Accurate and efficient means of geometry optimization could shed light on a broad class of materials and molecules, showing high sensitivity of induced properties to structural variables.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2016

Active Magnetic Regenerative Liquefier

This final report for the DOE Project entitled Active Magnetic Regenerative Liquefier (AMRL) funded under Grant DE-FG36-08GO18064 to Heracles Energy Corporation d.b.a. Prometheus Energy (Heracles/Prometheus) describes an active magnetic regenerative refrigerator (AMRR) prototype designed and built during the period from July 2008 through May 2011. The primary goal of this project was to make significant technical advances toward highly efficient liquefaction of hydrogen. Conventional hydrogen liquefiers at any scale have a maximum FOM of ~0.35 due primarily to the intrinsic difficulty of rapid, efficient compression of either hydrogen or helium working gases. Numerical simulation modeling of high performance AMRL designs indicates certain designs have promise to increase thermodynamic efficiency from a FOM of ~0.35 toward ~0.5 to ~0.6. The technical approach was the use of solid magnetic working refrigerants cycled in and out of high magnetic fields to build an efficient active regenerative magnetic refrigeration module providing cooling power for AMRL. A single-stage reciprocating AMRR with a design temperature span from ~290 K to ~120 K was built and tested with dual magnetic regenerators moving in and out of the conductively-cooled superconducting magnet subsystem. The heat transfer fluid (helium) was coupled to the process stream (refrigeration/liquefaction load) via high performance heat exchangers. In order to maximize AMRR efficiency a helium bypass loop with adjustable flow was incorporated in the design because the thermal mass of magnetic refrigerants is higher in low magnetic field than in high magnetic field. Heracles/Prometheus designed experiments to measure AMRR performance under a variety of different operational parameters such as cycle frequency, magnetic field strength, heat transfer fluid flow rate, amount of bypass flow of the heat transfer fluid while measuring work input, temperature span, cooling capability as a function of cold temperature as a function of the amount of bypass flow of the heat transfer fluid. The operational AMRR prototype can be used to answer key questions such as the best recipe for multiple layers of different magnetic refrigerants in one or more integrated regenerators with varying amounts of bypass flow of the heat transfer fluid. Layered regenerators are necessary to span the AMRR range from 290 K to 120K. Our AMRR performance simulation model predicts that ~10-15 % of bypass flow should significantly improve the thermodynamic performance. Initial results obtained with regenerators made of gadolinium spheres were very encouraging; a temperature span of ~ 50 K (between 295K and 245 K) across both regenerators was achieved with zero bypass flow of the heat transfer fluid and with the magnetic field strength of ~4 T.

42 ENGINEERING↗

DOE OSTI2018

An efficient global optimization algorithm for maximizing the sum of two generalized Rayleigh quotients

Maximizing the sum of two generalized Rayleigh quotients (SRQ) can be reformulated as a one-dimensional optimization problem, where the function value evaluations are reduced to solving semi-definite programming (SDP) subproblems. In this paper, we first use the dual SDP subproblem to construct an explicit overestimation and then propose a branch-and-bound algorithm to globally solve (SRQ). Numerical results demonstrate that it is even more efficient than the recent SDP-based heuristic algorithm.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Sustainable aviation fuels from biomass and biowaste via bio- and chemo-catalytic conversion: Catalysis, process challenges, and opportunities

Sustainable aviation fuel (SAF) production from biomass and biowaste streams is an attractive option for decarbonizing the aviation sector, one of the most-difficult-to-electrify transportation sectors. Despite ongoing commercialization efforts using ASTM-certified pathways (e.g., lipid conversion, Fischer-Tropsch synthesis), production capacities are still inadequate due to limited feedstock supply and high production costs. New conversion technologies that utilize lignocellulosic feedstocks are needed to meet these challenges and satisfy the rapidly growing market. Combining bio- and chemo-catalytic approaches can leverage advantages from both methods, i.e., high product selectivity via biological conversion, and the capability to build C-C chains more efficiently via chemical catalysis. Herein, conversion routes, catalysis, and processes for such pathways are discussed, while key challenges and meaningful R&D opportunities are identified to guide future research activities in the space. Bio and chemo-catalytic conversion primarily utilize the carbohydrate fraction of lignocellulose, leaving lignin as a waste product. This makes lignin conversion to SAF critical in order to utilize whole biomass, thereby lowering overall production costs while maximizing carbon efficiencies. Thus, lignin valorization strategies are also reviewed herein with vital research areas identified, such as facile lignin depolymerization approaches, highly integrated conversion systems, novel process configurations, and catalysts for the selective cleavage of aryl C–O bonds. The potential efficiency improvements available via integrated conversion steps, such as combined biological and chemo-catalytic routes, along with the use of different parallel pathways, are identified as key to producing all components of a cost-effective, 100% SAF.

09 BIOMASS FUELS↗

DOE OSTI2026

Development of Digital Twin-Informed Predictive Maintenance for Critical Components in Advanced Reactors

Small modular reactors (SMRs) and microreactors, along with other advanced reactor (AR) technologies, are key to the future of nuclear energy. For these systems to achieve low operating costs, high reliability, and flexibility across applications, their operation and maintenance must be optimized. Digital twin (DT) technology is one of the technologies that enables real-time (or faster than real-time) monitoring and prognosis of critical components which are vital for operational efficiency, low costs, and enhanced safety of ARs, accelerating their deployment. DT technology provides dynamic virtual representation of physical assets by integrating real-time data, physics-based models, and advanced analytics, which is critical to optimizing the performance of the entire energy system throughout the life cycle. DTs empower engineers and operators to virtually explore different scenarios, configurations, and control strategies, allowing for the identification of optimal solutions that maximize reactor efficiency, safety, and economics.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1989

Numerically efficient algorithm for model development of high-order systems

A technique for estimating transfer functions in partial fraction expansion form from frequency response data for a high-order system is presented. The problem formulation avoids many of the numerical difficulties associated with high-order polynomials and has the advantage of having the option to fix the camping and frequency of a mode, if known, during the estimation process. The resulting transfer function(s) may be converted to Jordan-Form time domain equations directly. During the implementation of this technique, a frequency and amplitude normalizing window was developed that maximized the efficiency of the optimization algorithm. The combination of estimating the transfer function in factored form, the ability to fix preciously determined parameters and the effectiveness of the normalizing window led to a progressive approach to synthesizing transfer functions from frequency response data for high-order systems.

Parada, L. O.↗

NASA NTRS2005

Off-Design Performance Analysis of a Solid-Oxide Fuel Cell/Gas Turbine Hybrid for Auxiliary Aerospace Power

A solid-oxide fuel cell/gas turbine hybrid system for auxiliary aerospace power is analyzed using 0-D and 1-D system-level models. The system is designed to produce 440 kW of net electrical power, sized for a typical long-range 300-passenger civil airplane, at both sea level and cruise flight level (12,500 m). In addition, a part power level of 250 kW is analyzed at the cruise condition, a requirement of the operating power profile. The challenge of creating a balanced system for the three distinct conditions is presented, along with the compromises necessary for each case. A parametric analysis is described for the cruise part power operating point, in which the system efficiency is maximized by varying the air flow rate. The system is compared to an earlier version that was designed solely for cruise operation. The results show that it is necessary to size the turbomachinery, fuel cell, and heat exchangers at sea level full power rather than cruise full power. The resulting estimated mass of the system is 1912 kg, which is significantly higher than the original cruise design point mass, 1396 kg. The net thermal efficiencies with respect to the fuel LHV are calculated to be 42.4 percent at sea level full power, 72.6 percent at cruise full power, and 72.8 percent at cruise part power. The cruise conditions take advantage of pre-compressed air from the on-board Environmental Control System, which accounts for a portion of the unusually high thermal efficiency at those conditions. These results show that it is necessary to include several operating points in the overall assessment of an aircraft power system due to the variations throughout the operating profile.

Freeh, Joshua E.↗

NASA NTRS1993

Rotary blood pump

A rotary blood pump is presented. The pump includes a pump housing for receiving a flow straightener, a rotor mounted on rotor bearings and having an inducer portion and an impeller portion, and a diffuser. The entrance angle, outlet angle, axial, and radial clearances of the blades associated with the flow straightener, inducer portion, impeller portion, and diffuser are optimized to minimize hemolysis while maintaining pump efficiency. The rotor bearing includes a bearing chamber that is filled with crosslinked blood or other bio-compatible material. A back emf integrated circuit regulates rotor operation and a microcomputer may be used to control one or more back emf integrated circuits. A plurality of magnets are disposed in each of a plurality of impeller blades with a small air gap. A stator may be axially adjusted on the pump housing to absorb bearing load and maximize pump efficiency.

Bozeman, Richard J.↗