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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Auto Indexer for Percussive Hammers Final Report

Geothermal energy has been underutilized in the U.S., primarily due to the high cost of drilling in the harsh environments encountered during the development of geothermal resources. Drilling depths can approach 5,000 m with temperatures reaching 170 C. In situ geothermal fluids are up to ten times more saline than seawater and highly corrosive, and hard rock formations often exceed 240 MPa compressive strength. This combination of extreme conditions pushes the limits of most conventional drilling equipment. Furthermore, enhanced geothermal systems are expected to reach depths of 10,000 m and temperatures more than 300 °C. To address these drilling challenges, Sandia developed a proof-of-concept tool called the auto indexer under an annual operating plan task funded by the Geothermal Technologies Program (GTP) of the U.S. Department of Energy Geothermal Technologies Office. The auto indexer is a relatively simple, elastomer-free motor that was shown previously to be compatible with pneumatic hammers in bench-top testing. Pneumatic hammers can improve penetration rates and potentially reduce drilling costs when deployed in appropriate conditions. The current effort, also funded by DOE GTP, increased the technology readiness level of the auto indexer, producing a scaled prototype for drilling larger diameter boreholes using pneumatic hammers. The results presented herein include design details, modeling and simulation results, and testing results, as well as background on percussive hammers and downhole rotation.

15 GEOTHERMAL ENERGY↗
DOE OSTI2022

Improving the accuracy of discretisations of the vector transport equation on the lowest-order quadrilateral Raviart-Thomas finite elements

Within finite element models of fluids, vector-valued fields such as velocity or momentum variables are commonly discretised using the Raviart-Thomas elements. However, when using the lowest-order quadrilateral Raviart-Thomas elements, standard finite element discretisations of the vector transport equation typically have a low order of spatial accuracy. This paper describes two schemes that improve the accuracy of transporting such vector-valued fields on two-dimensional curved manifolds. The first scheme that is presented reconstructs the transported field in a higher-order function space, where the transport equation is then solved. The second scheme applies a mixed finite element formulation to the vector transport equation, simultaneously solving for the transported field and its vorticity. In this work, an approach to stabilising this mixed vector-vorticity formulation is presented that uses a Streamline Upwind Petrov-Galerkin (SUPG) method. These schemes are then demonstrated, along with their accuracy properties, through some numerical tests. Two new test cases are used to assess the transport of vector-valued fields on curved manifolds, solving the vector transport equation in isolation. The improvement of the schemes is also shown through two standard test cases for rotating shallow-water models.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

W7-X and the sawtooth instability: towards realistic simulations of current-driven magnetic reconnection

Magnetic reconnection in W7-X is studied by means of global numerical simulations in a series of models of increasing complexity. The magnetic geometry ranges from that of a cylinder to the full three-dimensional field of W7-X, and the equations solved range from ideal magnetohydrodynamics (MHD) to gyrokinetics. We simulate plasmas from the first operation phase with electron cyclotron current drive (ECCD). These are characterized by an equilibrium magnetic field featuring an ECCD-distorted 'humped' profile of the rotational transform ι, with ι = 1 in two radial locations. Such plasmas generally show sawtooth activity, hence motivating the present study. We pay particular attention to the role of equilibrium current density gradients in the destabilization of reconnecting modes. When the equilibrium temperature and density gradients are artificially suppressed (to eliminate the pressure gradient drive), the perturbed electrostatic potential is radially localized between the locations at which ι = 1. This is shown with a purely collisionless gyrokinetic model, in cylindrical geometry. In the real toroidal geometry of W7-X, for a non-ideal MHD model including a uniform resistivity, electron inertia and (numerical) viscosity, the same qualitative behaviour is observed. In particular, even if a resonant (m, n) = (1, -1) perturbation is initialized, the most unstable mode is the (m, n) = (-4, 4), where m and n are the poloidal and toroidal mode numbers, respectively. Other modes are destabilized due to geometric coupling. The growth rate of this instability scales as η 1/3 , where η is the plasma resistivity, thus suggesting that ECCD drives ideal MHD stable W7-X plasmas towards non-ideal marginality. An ideal magnetohydrodynamic analysis confirms the result. A fluid-kinetic hybrid version of the EUTERPE code shows that gyrokinetic ions have a stabilizing effect on these modes. For W7-X relevant collisionalities, the growth rate scales linearly with the electron skin depth, d e . Implications of our results for sawtoothing W7-X operation are discussed.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Modeling active control of resistive wall mode with power saturation and sensor noise on HL-2M

The resistive wall mode (RWM) control on the HL-2M tokamak is simulated with the MARS-F code (Liu et al 2000 Phys. Plasmas 7 3681), aiming at quantifying control current and voltage requirements when more realistic issues are taken into account, i.e. the control power saturation and the sensor signal noise. The fluid model predicts a narrow stability region for the n = 1 RWM without magnetic feedback, in the 2D parameter space of the plasma pressure versus the toroidal flow speed. Magnetic feedback can fully stabilize the RWM on HL-2M. Without considering the voltage limitation and the sensor signal noise, it is found that plasma flow helps active control of the mode, by reducing the required critical feedback gain for both flux-to-current and flux-to-voltage control schemes. In the absence of the sensor signal noise, the lowest control voltage saturation level, below which the RWM control is lost, is found to roughly satisfy a linear relation to the plasma flow frequency, indicating that subsonic plasma flow is effective in relaxing the control power requirement for the RWM feedback stabilization. The presence of the sensor signal noise substantially modifies the feedback results. A statistical study finds that the sensor signal noise, with the standard deviation of 0.1 G on HL-2M, roughly doubles the required control voltage for successful mode control. The synergistic stabilization effect due to plasma flow is somewhat weakened by the presence of the sensor signal noise. At a given rotation, the tolerable voltage limit generally increases with increasing feedback gain due to the sensor signal noise.

Physics↗
DOE OSTI2024

Geometric and thermodynamic characterization of binary neutron star accretion discs

Accretion disks formed in binary neutron star mergers play a central role in many astrophysical processes of interest, including the launching of relativistic jets or the ejection of neutron-rich matter hosting heavy element nucleosynthesis. In this work we analyze in detail the properties of accretion disks from 44 ab initio binary neutron star merger simulations for a large set of nuclear equations of state, binary mass ratios, and remnant fates, with the aim of furnishing reliable initial conditions for disk simulations and a comprehensive characterization of their properties. We find that the disks have a significant thermal support, with an aspect ratio decreasing with the mass ratio of the binary from ~0.7 to 0.3. Even if the disk sample spans a broad range in mass and angular momentum, their ratio is independent from the equation of state and from the mass ratio. This can be traced back to the rotational profile of the disk, characterized by a constant specific angular momentum (as opposed to a Keplerian one) of 3 – 5×10 16 cm 2 s –1 . The profiles of the entropy per baryon and of the electron fraction depend on the mass ratio of the binary. For more symmetric binaries, they follow a sigmoidal distribution as a function of the rest mass density, for which we provide a detailed description and a fit. Furthermore, the disk properties discussed in this work can be used as a robust set of initial conditions for future long-term simulations of accretion disks from binary neutron star mergers, posing the basis for progress in the quantitative study of the outflow properties.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2022

Use of Multiple Tracer Gases to Quantify Vane Trailing Edge Flow Into Turbine Rim Seals

Abstract Overlapping features are commonly used as rim seals between stationary and rotating components in a turbine stage. These rim seals are used to prevent main gas path ingestion to the wheelspace cavity, which reduces the lifespan of critical engine components such as the turbine disk. In addition to the overlapping features, purge flow, diverted from the compressor, is injected into the rim cavity to act as an airflow sealing mechanism. Previous research identified that in addition to the purge flow in the rim cavity, cooling flow from the vane trailing edge (VTE) is ingested into the rim seal cavity carrying the potential to cool components in the wheelspace. These previous findings, however, were not able to distinctly separate purge from VTE cooling flows, which is the contribution of this paper based on uniquely using two different tracer gases. A one-stage test turbine operating at engine-relevant conditions and consisting of real engine hardware was used to validate and quantify the ingestion of the VTE flow by independently seeding the purge and VTE flows with two different tracer gases. Experimental results show the presence of VTE flow in the rim seal throughout all purge flowrates evaluated. Circumferential variation of VTE flow was also studied both experimentally and computationally using a computational fluid dynamics model. Results showed that ingested VTE flow can reduce the detrimental effect of hot gas ingestion particularly at higher purge flowrates.

Engineering↗
DOE OSTI2021

Moiré nematic phase in twisted double bilayer graphene

Graphene moiré superlattices display electronic flat bands. At integer fillings of these flat bands, energy gaps due to strong electron-electron interactions are generally observed. However, the presence of other correlation-driven phases in twisted graphitic systems at non-integer fillings is unclear. Here, we report the existence of threefold rotational symmetry breaking in twisted double bilayer graphene. Using spectroscopic imaging over large and uniform areas to characterize the direction and degree of C 3 symmetry breaking, we find it to be prominent only at energies corresponding to the flat bands and nearly absent in the remote bands. We demonstrate that the magnitude of the rotational symmetry breaking does not depend on the degree of the heterostrain or the displacement field, being instead a manifestation of an interaction-driven electronic nematic phase. We show that the nematic phase is a primary order that arises from the normal metal state over a wide range of doping away from charge. Furthermore, our modelling suggests that the nematic instability is not associated with the local scale of the graphene lattice, but is an emergent phenomenon at the scale of the moiré lattice.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2020

The role of edge resonant magnetic perturbations in edge-localized-mode suppression and density pump-out in low-collisionality DIII-D plasmas

Two-fluid nonlinear MHD simulations using the TM1 code demonstrate that the formation of magnetic islands at the top and bottom of the H-mode pedestal, together with the strong screening of resonant fields in the gradient region of the pedestal, can account for ELM suppression and density pump-out by n = 2 resonant magnetic perturbations (RMPs) in low-collisionality DIII-D ITER similar shape (ISS) plasmas. Using experimentally relevant transport coefficients, neoclassical resistivity, electron collisionality, and RMP amplitudes, nonlinear MHD simulations reproduce the observed level of density reduction (density pump-out) in DIII-D due to the formation of narrow magnetic islands in the resistive foot of pedestal. For large amplitude RMPs ( B r / B t > 1 × 10 -4 ) simulations predict resonant field penetration and resulting in pressure reduction at the top of the pedestal, consistent with experimental observations at the onset of ELM suppression. The predicted reduction in the height and width of the pedestal by magnetic island enhanced collisional transport provides a quantitative mechanism for the stabilization of the peeling-ballooning mode (PBM). Importantly, these simulations predict strong screening of resonant fields in the steep gradient region of the pedestal due to strong E × B rotation and diamagnetic flows. Yet, if the plasma resistivity is made artificially larger (~ 10X) than neoclassical, the simulations predict magnetic stochasticity throughout the plasma edge and the collapse of the pedestal due to the reduction in the penetration threshold with increasing resistivity. A scaling relation for resonant field penetration at the pedestal top, using several hundred nonlinear simulations, reproduces the density and E × B rotation dependence of the ELM suppression threshold observed in DIII-D. Simulations using ITER model equilibria indicate that the penetration threshold at the top of the ITER pedestal will be lower than in DIII-D due to the anticipated lower perpendicular flow velocities in ITER, resulting in the weaker screening of resonant fields.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Activity-induced propulsion and separation of passive chiral particles in liquids

Recent literature shows that chiral particles driven by vorticity gradients of a base Newtonian liquid can separate only in nonlinear or nonstationary flows. Here, we show that a base Newtonian liquid endowed with rotational degrees of freedom, can give rise to chiral particle propulsion and separation even in the Stokes flow approximation. We consider active mechanisms generating spatially inhomogeneous vorticity in the base liquid in a channel such as a magnetic torque, a pressure gradient and a sliding wall. These mechanisms generate regions of spatially inhomogeneous vorticity maintained by the internal angular momentum, propelling the chiral particles according to their handedness. Similar conclusions can be reached when one of the channel walls is replaced by a free surface acted on by surface shear. This behavior is in contrast to the case of standard Newtonian liquids where chiral particle propulsion generated by vorticity gradients is not possible in Stokes flow. Furthermore, this effect can find applications in industry, biology and medicine.

42 ENGINEERING↗
DOE OSTI2025

Laser Measurements and Modeling of Shock Tunnel Freestream Velocity and Multispecies Thermal Nonequilibrium

Coherent anti-Stokes Raman scattering (CARS) and nitric oxide molecular tagging velocimetry (NO-MTV) were used to characterize the freestream in Sandia’s Hypersonic Shock Tunnel (HST) using a burst-mode laser operated at 100 kHz. Experiments were performed at nominal freestream velocities of 3 and 4 km/s using both air and N 2 test gas. The CARS diagnostic provides nonequilibrium characterization of the flow by measuring vibrational and rotational temperatures of N 2 and O 2 , which are compared to NO temperatures from separate laser absorption experiments. Simultaneous, collinear freestream velocities were measured using NO MTV along with pitot pressure measurements. Furthermore, this extensive freestream dataset is compared to nonequilibrium CFD that is capable of modeling species-specific, vibrational temperatures throughout the nozzle expansion. Significant nonequilibrium between vibrational and rotational temperatures was measured at each flow condition. N 2 exhibits the most nonequilibrium, followed by O 2 and NO. The CFD model captures this trend, although it consistently overpredicts N 2 and O 2 vibrational temperatures. At 3 km/s, the modeled NO nonequilibrium is underpredicted, whereas it is overpredicted at 4 km/s. Good agreement is seen between CFD and the velocity and rotational temperature measurements. Experiments with water added to the test gas yielded no discernable difference in vibrational relaxation.

Aerodynamics↗
DOE OSTI2020

Identifying Characteristics of Wildfire Towers and Troughs

Wildfire behavior is dictated by the complex interaction of numerous physical phenomena including dynamic ambient and fire-induced winds, heat transfer, aerodynamic drag on the wind by the fuel and combustion. These phenomena create complex feedback effects between the fire and its surroundings. In this study, we aim to study the mechanisms by which buoyant flame dynamics along with vortical motions and instabilities control wildfire propagation. Specifically, this study employs a suite of simulations conducted with the physics-based coupled fire-atmosphere behavior model (FIRETEC). The simulations are initialized with a fire line and the fires are allowed to propagate on a grass bed, where the fuel heights and wind conditions are varied systematically. Flow variables are extracted to identify the characteristics of the alternating counter-rotational vortices, called towers and troughs, that drive convective heat transfer and fire spread. These vortices have previously been observed in wildfires and laboratory fires, and have also been observed to arise spontaneously in FIRETEC due to the fundamental physics incorporated in the model. However, these past observations have been qualitative in nature and no quantitative studies can be found in the literature which connected these coherent structures fundamental to fire behavior with the constitutive flow variables. To that end, a variety of state variables are examined in the context of these coherent structures under various wind profile and grass height conditions. Identification of various correlated signatures and fire-atmosphere feedbacks in simulations provides a hypothesis that can be tested in future observational or experimental efforts, potentially assisting experimental design, and can aid in the interpretation of data from in situ detectors.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Near-wake dynamics of a vertical-axis turbine

Cross-flow, or vertical-axis, turbines are a promising technology for capturing kinetic energy in wind or flowing water and their inherently unsteady fluid mechanics present unique opportunities for control optimization of individual rotors or arrays. To explore the potential for beneficial interactions between turbines in an array, as well as to characterize important cycle-to-cycle variations, coherent structures in the wake of a single two-bladed cross-flow turbine are examined using planar stereo particle image velocimetry in a water channel experiment. There are three main objectives in the present work. First, the mean wake structure of this high chord-to-radius ratio rotor is described, compared with previous studies, and a simple explanation for observed wake deflection is presented. Second, the unsteady flow is then analysed via the triple decomposition, with the periodic component extracted using a combination of traditional techniques and a novel implementation of the optimized dynamic mode decomposition. The latter method is shown to outperform conditional averaging and Fourier methods, as well as uncover frequencies suggesting a transition to bluff-body shedding in the far wake. Third, vorticity and finite-time Lyapunov exponents are then employed to further analyse the oscillatory wake component. Vortex streets on both sides of the wake are identified, and their formation mechanisms and effects on the mean flow are discussed. Strong axial (vertical) flow is observed in vortical structures shed on the retreating side of the rotor where the blades travel downstream. Time-resolved tracking of these vortices is performed, which demonstrates that vortex trajectories have significant rotation-to-rotation variation within one diameter downstream. This variability suggests it would be challenging to harness or avoid such structures at greater downstream distances.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2021

Fuel Stratification Influence on NO x Emission in a Premixed Axial Reacting Jet-in-Crossflow at High Pressure

Three reacting jet-in-crossflow (JiC) methane/air flames were numerically investigated in a lean axially staged combustor at a pressure of five atmospheres. A detailed chemistry Star-CCM+ computational fluid dynamics (CFD) model was used with 53 species considered and the result of turbulence-governed finite-rate modeling was validated with in-house experimental data. An optically accessible test section features three side windows, allowing local flow and flame analysis with particle image velocimetry (PIV) and CH* chemiluminescence as well as pressure, temperature, and species exit measurements. The research objective was to predict and verify NO x formation of the premixed 12.7 mm axial jet. Three headend temperature levels were investigated along with three premixed jets at lean (φ Jet = 0.75), near-stoichiometric (φ Jet = 1.07), and rich (φ Jet = 1.78) axial fuel line equivalence ratio. Based on the matching exit emission concentration, global emission benefits were investigated by adjustment of the fuel stratification. The perfectly premixed methane/air flames of this study were shown to ignite at the lee-side of the jet. For the elevated headend temperature level T = 1800 K, the flame extended beyond the windward jet trajectory and caused high axial NO production. For industry application, a firing temperature of 1920 K was achieved with a NO x optimized fuel split of 25%, combining a lean headend (φ Headend = 0.61) with a rich (φ Jet = 1.78) jet equivalence ratio. As a result, this operating point allowed minimization of the combustor residence time at temperatures above 1700 K as well as combustion in a compact flame at the jet lee-side along the counter rotating vortex pair.

03 NATURAL GAS↗
DOE OSTI2023

CFD Data on a Vertical Axis Wave Turbine

In this study January to July, 2023, different variations of the original geometry of a vertical-axis wave turbine (VAWT) were generated and evaluated for hydrodynamic power efficiency using computational fluid dynamics (CFD). The key geometrical parameters considered in this parametric study included the chord length of the rotor blades and the horizontal semi-axis length. The immersion depth of the rotor was also examined as a key deployment parameter for the wave turbine. The CFD simulation results revealed that a medium chord length of the blade (i.e., the same as that of the baseline design) and a shorter horizontal semi-axis for the guide curve of the blade than that of the baseline design resulted in higher hydrodynamic power to extract. With the most efficient turbine rotor geometry identified in this study, a deployment depth that could assure full submergence of the rotor in waves but as close to the free surface as possible led to a higher hydrodynamic power. These findings revealed a pathway for the improvement of the wave turbine energy efficiency.

16 TIDAL AND WAVE POWER↗
DOE OSTI2021

Non-Diffusive Volume Advection with A High Order Interface Reconstruction Method

We show that non-diffusive volume advection in two-dimensions is achieved with several benchmark problems using a newly developed high-order volume of fluids (VOF) interface reconstruction method. (1) A new VOF interface reconstruction method using circular/corner facets (linear facets are a degenerate case of arcs). We create a circular interface facet in each mixed zone by matching neighbor volume with a hybrid Newton’s-bisection method and the local solution is final. In the general case, the new VOF interface reconstruction has 3rd order accuracy and can be easily made seamless. The new method addresses intrinsic issues with Young’s method such as gaps between interface facets in the case of a curved interface, and inability to define curvature nor identify corners. (2) A non-diffusive volume advection scheme. In an ALE advection step, a well-defined interface can be carried over through a Lagrange step and used to compute volume distribution into a relaxed mesh. Then, an interface reconstruction step is performed to redefine the interface in the relaxed mesh. We must point out that the interface carried over is also a solution of interface reconstruction because all the volume fractions in the relaxed mesh are naturally matched. We provide an interface tracking method compatible with our reconstruction scheme, where it is granted to use the prior info as an initial guess to capture sub-mesh resolution features. As a result, we are able to treat multiple facets inside a single mixed cell and obtain highly accurate, non-diffusive solution for advection problems with rather coarse meshes. We show our solutions for two-dimensional incompressible flows with two materials with a) the X + O diagonal translation; b) the Zalesak rotational test; and c) the single vortex spiral test.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Quenched lattice fluctuations in optically driven SrTiO3

Abstract Crystal lattice fluctuations, which are known to influence phase transitions of quantum materials in equilibrium, are also expected to determine the dynamics of light-induced phase changes. However, they have only rarely been explored in these dynamical settings. Here we study the time evolution of lattice fluctuations in the quantum paraelectric SrTiO 3 , in which mid-infrared drives have been shown to induce a metastable ferroelectric state. Crucial in these physics is the competition between polar instabilities and antiferrodistortive rotations, which in equilibrium frustrate the formation of long-range ferroelectricity. We make use of high-intensity mid-infrared optical pulses to resonantly drive the Ti–O-stretching mode at 17 THz, and we measure the resulting change in lattice fluctuations using time-resolved X-ray diffuse scattering at a free-electron laser. After a prompt increase, we observe a long-lived quench in R-point antiferrodistortive lattice fluctuations. Their enhancement and reduction are theoretically explained by considering the fourth-order nonlinear phononic interactions to the driven optical phonon and third-order coupling to lattice strain, respectively. These observations provide a number of testable hypotheses for the physics of light-induced ferroelectricity.

36 MATERIALS SCIENCE↗
DOE OSTI2020

An in situ shearing x-ray measurement system for exploring structures and dynamics at the solid–liquid interface

Revealing interfacial structure and dynamics has been one of the essential thematic topics in material science and condensed matter physics. Synchrotron-based x-ray scattering techniques can deliver unique and insightful probing of interfacial structures and dynamics, in particular, in reflection geometries with higher surface and interfacial sensitivity than transmission geometries. We demonstrate the design and implementation of an in situ shearing x-ray measurement system, equipped with both inline parallel-plate and cone-and-plate shearing setups and operated at the advanced photon source at Argonne National Laboratory, to investigate the structures and dynamics of end-tethered polymers at the solid-liquid interface. With a precise lifting motor, a micrometer-scale gap can be produced by aligning two surfaces of a rotating upper shaft and a lower sample substrate. A torsional shear flow forms in the gap and applies tangential shear forces on the sample surface. The technical combination with nanoscale rheology and the utilization of in situ x-ray scattering allow us to gain fundamental insights into the complex dynamics in soft interfaces under shearing. In this work, we demonstrate the technical scope and experimental capability of the in situ shearing x-ray system through the measurements of charged polymers at both flat and curved interfaces upon shearing. Furthermore, through the in situ shearing x-ray scattering experiments integrated with theoretical simulations, we aim to develop a detailed understanding of the short-range molecular structure and mesoscale ionic aggregate morphology, as well as ion transport and dynamics in soft interfaces, thereby providing fundamental insight into a long-standing challenge in ionic polymer brushes with a significant technological impact.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Filament Extension Atomization for High Solids Loading in Energy Efficient Spray Drying Systems

We demonstrate that we could scale FEA to reach outputs needed by industrial production, while increasing solids loading of the sprayed product by at least 30% and maintaining equal or better spray powder. After testing a wide range of products, in collaboration with industry partners we decided on our primary spray products of dry whey and WPC-80, two common materials processed and sold by US manufacturers with different parameters. We sprayed these with FEA at solids loadings of 70% for dry whey and 45% for WPC-80 with a spray output with particle sizes similar to industrial particles sizes and reduced variation in particle size. We simultaneously scaled up FEA first with a multi-nip with 6 nips surrounding a central roller with parallel axis of rotation and eventually with a tapered design that solved problems we encountered with our initial design. We were able to achieve output from a single array from our first design of up to 4.7 liters per minute (L/min) and from an array of our second multi-nip of 8 L/min exceeding expectations. This demonstrates that FEA technology can indeed be scaled up to meet the needs of industrial production. More arrays can be added as necessary to meet a wide range of spray dryer designs. We also tested FEA to create dried powders from a small scale (10 L/hour of water removal) spray dryer. Though we were not able to produce large quantities of powder from FEA due to challenges in integration, the powder we produced was higher quality and produced from higher solids loading materials. From our technoeconomic analysis we for a typically sized spray dryer, we estimate a 27% cost reduction and 41% energy and carbon reduction for WPC-80 and a 39-57% cost reduction and 52-76% energy reduction for sweet dry whey (depending on the exact product).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗