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At least 289 records · Page 16

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DOE OSTI2022

Efficient light harvesting and photon sensing via engineered cooperative effects

Abstract Efficient devices for light harvesting and photon sensing are fundamental building blocks of basic energy science and many essential technologies. Recent efforts have turned to biomimicry to design the next generation of light-capturing devices, partially fueled by an appreciation of the fantastic efficiency of the initial stages of natural photosynthetic systems at capturing photons. In such systems extended excitonic states are thought to play a fundamental functional role, inducing cooperative coherent effects, such as superabsorption of light and supertransfer of photoexcitations. Inspired by this observation, we design an artificial light-harvesting and photodetection device that maximally harnesses cooperative effects to enhance efficiency. The design relies on separating absorption and transfer processes (energetically and spatially) in order to overcome the fundamental obstacle to exploiting cooperative effects to enhance light capture: the enhanced emission processes that accompany superabsorption. This engineered separation of processes greatly improves the efficiency and the scalability of the system.

42 ENGINEERING↗

DOE OSTI2015

Predicting laser weld reliability with stochastic reduced-order models. Predicting laser weld reliability

Laser welds are prevalent in complex engineering systems and they frequently govern failure. The weld process often results in partial penetration of the base metals, leaving sharp crack-like features with a high degree of variability in the geometry and material properties of the welded structure. Furthermore, accurate finite element predictions of the structural reliability of components containing laser welds requires the analysis of a large number of finite element meshes with very fine spatial resolution, where each mesh has different geometry and/or material properties in the welded region to address variability. We found that traditional modeling approaches could not be efficiently employed. Consequently, a method is presented for constructing a surrogate model, based on stochastic reduced-order models, and is proposed to represent the laser welds within the component. Here, the uncertainty in weld microstructure and geometry is captured by calibrating plasticity parameters to experimental observations of necking as, because of the ductility of the welds, necking – and thus peak load – plays the pivotal role in structural failure. The proposed method is exercised for a simplified verification problem and compared with the traditional Monte Carlo simulation with rather remarkable results.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Soot Formation and Ignition Characteristics of Ethanol/Gasoline Blends in a Rapid Compression Machine

With the ever-increasing demand for sustainable energy, alcohol fuels have garnered interest for use in heavy duty engines. The significant infrastructure for ethanol production and blending of ethanol with gasoline make these fuels/fuel blends desirable candidates. However, development of heavy duty engine technology that is capable of burning alcohol fuels while retaining the advantages of traditional diesel combustion requires an improved understanding of the soot formation for these fuels under conditions relevant to mixing-controlled combustion. This work uses an extinction diagnostic to study the sooting tendency of ethanol and gasoline/ethanol blends ranging from E10 to E98 during ignition in a homogeneous environment. Experiments were conducted in a rapid compression machine (RCM) for compressed conditions of 20 ± 1 bar and an approximately constant temperature (± 10K) which was unique for each fuel. For a given soot volume fraction, a linear relationship was observed between ethanol content and the equivalence ratio in which that soot volume fraction was formed. Accounting for the oxygenated nature of ethanol, E85 and E98 fuels produced similar amounts of soot at a given Φ ox, , suggesting other factors outside of fuel oxygen content, such as fuel morphology, impact soot formation. Ignition delay data is reported for compressed pressures of 20 ± 1 bar and compressed temperatures ranging from 633 – 670 K for E10 and 771 – 789 K for E98. Varying pressures for E10 and E98 at conditions producing similar soot volume fractions demonstrated a linear dependence of soot formation on pressure, regardless of if the pressure considered was at top dead center or peak combustion pressure. Furthermore, the data gleaned from this work will be used to select soot models and chemical kinetic mechanisms for RCM simulations to ultimately model heavy duty engine technology with the studied fuels.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2026

Development of a coupled experimental–computational approach for engineering optimization of spout-fluidized bed particle coating systems

The design of spout-fluidized bed (SFB) coating systems for nuclear particle fuels typically relies on trial-and-error processes, comprising iterative and time-consuming coating deposition experiments and post-deposition characterization. At an engineering scale, this approach to guided SFB system design is inefficient, highlighting the need for streamlined experimental methodologies which can correlate fluidization conditions to downstream coating outcomes. In this study, we combine time-resolved particle image velocimetry (PIV) with CFD–DEM simulations to benchmark hydrodynamic behavior in a 3D spout-fluidized bed. By exploiting easily accessible optical measurements of particle motion at the bed wall and within the spouting region, we obtain quantitative velocity fields that can be directly compared with model predictions of the occluded bed region, without resorting to complex imaging and characterization techniques such as X-ray or magnetic resonance tomography. Experimental benchmarking reveals strong agreement between CFD–DEM and PIV in the spout and annulus regions, while discrepancies near the wall highlight areas for future model development. Here, the proposed integrated experimental–numerical framework will enable a direct connection between measured variables and numerically predicted fluidization performance of dense, surrogate nuclear particle fuel feedstock such that experimental SFB component design can be rapidly evaluated, informing design decisions for nozzle geometry and operating conditions. Future work will extend this framework by correlating quantified fluidization metrics across nozzle geometries and operating conditions with the resulting coating morphology, microstructure, and uniformity. Establishing these correlations will enable predictive links between hydrodynamic performance and coating quality, providing a rational, scalable basis for optimizing SFB design prior to coating deposition.

CFD/DEM↗

DOE OSTI2023

W-4 W88 Systems Engineering Summer 2023 Project [Slides]

The purpose is to create a simple, streamlined process to produce reports on out of tolerance conditions with CMM data. The methods are to develop the code or process within MATLAB to import the data (import tool can be used) and to develop the code to be able to plot the data of interest. The end states are to use MATLAB to analyze CMM data from the PA and document the process for a user with some knowledge of MATLAB and an engineering background.

42 ENGINEERING↗

DOE OSTI2026

Design and Development of the Handling Frame Assembly Table for the National Ignition Facility Blast Shields

The Handling Frame Assembly Table is a custom designed piece of equipment developed to support the NIF Sustainment Project. The goal of the NIF Sustainment Project is to refurbish the National Ignition Facility (NIF), the world’s largest and most energetic laser, so it can continue advancing research in fusion energy, national security, and high energy density physics. A key aspect of this effort involves replacing all 1,728 blast shields on the NIF, which requires specialized equipment such as the Handling Frame Assembly Table to support the production of new blast shields. This project follows a systems engineering approach that guides the design sequence. This report documents the design process from initial concept through final design, including stakeholder analysis, requirements development, conceptual design, final design, and design validation. Future work will focus on building and commissioning the system.

42 ENGINEERING↗

DOE OSTI2016

Energy and emissions saving potential of additive manufacturing: the case of lightweight aircraft components

Additive manufacturing (AM) holds great potential for improving materials efficiency, reducing life-cycle impacts, and enabling greater engineering functionality compared to conventional manufacturing (CM), and AM has been increasingly adopted by aircraft component manufacturers for lightweight, cost-effective designs. This study estimates the net changes in life-cycle primary energy and greenhouse gas emissions associated with AM technologies for lightweight metallic aircraft components through the year 2050, to shed light on the environmental benefits of a shift from CM to AM processes in the U.S. aircraft industry. A systems modeling framework is presented, with integrates engineering criteria, life-cycle environmental data, aircraft fleet stock and fuel use models under different AM adoption scenarios. Estimated fleet-wide life-cycle primary energy savings at most reach 70-173 million GJ/year in 2050, with cumulative savings of 1.2–2.8 billion GJ. Associated cumulative GHG emission reductions were estimated at 92.1–215.0 million metric tons. In addition, thousands of tons of aluminum, titanium and nickel alloys could be potentially saved per year in 2050. The results indicate a significant role of AM technologies in helping society meet its long-term energy use and GHG emissions reduction goals, and highlight barriers and opportunities for AM adoption for the aircraft industry.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

A fast reduced model for a shell-and-tube based latent heat thermal energy storage heat exchanger and its application for cost optimal design by nonlinear programming

Numerical simulation of latent heat thermal energy storage (LHTES) systems plays a fundamental role in studying the physical process and guiding the engineering design. Discretization of the PDEs describing the nonlinear solidification/melting process of phase change materials (PCMs) leads to a large-scale complex dynamics system, where the system behavior depends on a set of parameters. In a design setting, repeated model evaluations are required over the set of parameters results in significant computational burden. In this paper, an explicit analytic solution was built for the propagation of the solidification front in a cylindrical coordinate. The analytic solution approach is further employed to develop a low computational reduced model (RM) as a module for a shell-and-tube based LHTES heat exchanger. The levelized Cost of Energy (LCOE) is used as a design metric and the RM model is used to apply system-level constraints in the nonlinear programming formulation that facilitates efficient global optimal design of the PCM properties, flow conditions and tube geometries. The use of LCOE as the design metric prevents over design of the heat transfer rate and also establishes a fair ground for evaluation of different thermal storage technologies and their integrated applications with other systems. Optimal results showed that a higher effectiveness results in a higher LCOE; the velocity of the HTF and the length of the channel are highly correlated with each other; both larger PCM latent energy and conductivity result in lower LCOE.

25 ENERGY STORAGE↗

DOE OSTI2023

Multi-scale modeling of the electric field assisted sintering process

The electric field assisted sintering (EFAS) process involves tightly coupled physics that influence microstructural evolution in the particles being compacted. It is also an inherently multi-scale phenomenon, with the microstructure of the compact influencing the subsequent engineering-scale response of the sintering system. To improve understanding of how processing parameters influence microstructural evolution, we have developed a multi-scale modeling approach that couples a continuum-level model of the sintering system with a phase-field model for microstructural evolution of particles within the compact. The phase-field model couples the effect of chemical and electrical driving forces on microstructural evolution and includes the effect of charged defect segregation to surfaces and grain boundaries; this segregation leads to enhanced defect transport and heat generation at these interfaces in response to applied electric field. The effect of enhanced heat generation on particle neck growth and the influence of microstructural evolution on the engineering-scale model are demonstrated.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Multi-scale modeling of the electric field assisted sintering process

36 - MATERIALS SCIENCE↗

DOE OSTI2015

Engineering Options Assessment Report. Nitrate Salt Waste Stream Processing

This report examines and assesses the available systems and facilities considered for carrying out remediation activities on remediated nitrate salt (RNS) and unremediated nitrate salt (UNS) waste containers at Los Alamos National Laboratory (LANL). The assessment includes a review of the waste streams consisting of 60 RNS, 29 above-ground UNS, and 79 candidate below-ground UNS containers that may need remediation. The waste stream characteristics were examined along with the proposed treatment options identified in the Options Assessment Report . Two primary approaches were identified in the five candidate treatment options discussed in the Options Assessment Report: zeolite blending and cementation. Systems that could be used at LANL were examined for housing processing operations to remediate the RNS and UNS containers and for their viability to provide repackaging support for remaining LANL legacy waste.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2022

Advanced Ceramic Membranes/Modules for Ultra Efficient Hydrogen (H2) Production/Carbon Dioxide (CO2) Capture for Coal-Based Polygeneration Plants: Fabrication, Testing and CFD Modeling

Inorganic membrane-based systems are a promising technology for precombustion CO2 capture with simultaneous H2 production. State-of-the-art packages for high temperature and pressure service consist of multiple tube membrane bundles prepared in a "candle filter" configuration, in which the membrane tubes are open at one end and sealed at the other. This configuration is used for practical reasons, specifically the need to minimize problems due to thermal expansion mismatch between the ceramic tube bundle and the steel housing. However, the primary technical problem with the candle filter format for commercial-scale installations is the inability to purge the tube side (typically the permeate side), a feature that is crucial for high H2 recovery. In this study, the focus is to design and fabricate the first dual-end open full ceramic multiple tube membrane bundle that enables tube side (permeate) purge for gas separation applications. An additional key feature of this design is the simplified module layout, as the membrane bundles can be installed end-to-end with tube side (permeate) flow directly from one bundle to the next. This layout simplifies the membrane to housing seals and yields significant improvement in membrane packing density. Detailed focus areas in our studies include: (i) Materials development and preparation of the tube-to-tube sheet potting for the dual-ended bundle; (ii) the sealing and optimal module configuration design to minimize membrane stress upon module mounting; (iii) the demonstration, via the fabrication of CMS and Pd-alloy membranes supported on full-size, dual-ended ceramic support bundles, of the first example of a purgeable ceramic membrane and module; and (iv) development of a CFD model of the membrane module for calculation of feed flow distribution, and for use in scale-up, and capital cost estimating. The CFD model was validated using experimental data with the multi-tubular membrane system, employing He/N2 as a model gas mixture (surrogate for H2/CO2), and has been shown to be quite accurate. Employing the model, we are able to study the effects of operating pressure and temperature, feed and sweep gas flow rates, and the choice of membrane tube configuration on system performance.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2015

Energy distribution analysis in boosted HCCI-like / LTGC engines – Understanding the trade-offs to maximize the thermal efficiency

A detailed understanding of the various factors affecting the trends in gross-indicated thermal efficiency with changes in key operating parameters has been carried out, applied to a one-liter displacement single-cylinder boosted Low-Temperature Gasoline Combustion (LTGC) engine. This work systematically investigates how the supplied fuel energy splits into the following four energy pathways: gross-indicated thermal efficiency, combustion inefficiency, heat transfer and exhaust losses, and how this split changes with operating conditions. Additional analysis is performed to determine the influence of variations in the ratio of specific heat capacities (γ) and the effective expansion ratio, related to the combustion-phasing retard (CA50), on the energy split. Heat transfer and exhaust losses are computed using multiple standard cycle analysis techniques. Furthermore, the various methods are evaluated in order to validate the trends.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2013

In Situ Decommissioning (ISD) Concepts and Approaches for Excess Nuclear Facilities Decommissioning End State - 13367

The United States Department of Energy (DOE) currently has numerous radiologically contaminated excess nuclear facilities waiting decommissioning throughout the Complex. The traditional decommissioning end state is complete removal. This commonly involves demolishing the facility, often segregating various components and building materials and disposing of the highly contaminated, massive structures containing tons of highly contaminated equipment and piping in a (controlled and approved) landfill, at times hundreds of miles from the facility location. Traditional demolition is costly, and results in significant risks to workers, as well as risks and costs associated with transporting the materials to a disposal site. In situ decommissioning (ISD or entombment) is a viable alternative to demolition, offering comparable and potentially more protective protection of human health and the environment, but at a significantly reduced cost and worker risk. The Savannah River Site (SRS) has completed the initial ISD deployment for radiologically contaminated facilities. Two reactor (P and R Reactors) facilities were decommissioned in 2011 using the ISD approach through the American Recovery and Reinvestment Act. The SRS ISD approach resolved programmatic, regulatory and technical/engineering issues associated with avoiding the potential hazards and cost associated with generating and disposing of an estimated 124,300 metric tons (153,000 m{sup 3}) of contaminated debris per reactor. The DOE Environmental Management Office of Deactivation and Decommissioning and Facility Engineering, through the Savannah River National Laboratory, is currently investigating potential monitoring techniques and strategies to assess ISD effectiveness. As part of SRS's strategic planning, the site is seeking to leverage in situ decommissioning concepts, approaches and facilities to conduct research, design end states, and assist in regulatory interactions in broad national and international government and private industry decommissioning applications. SRS offers critical services based upon the SRS experience in decommissioning and reactor entombment technology (e.g., grout formulations for varying conditions, structural and material sciences). The SRS ISD approach follows a systems engineering framework to achieve a regulatory acceptable end state based on established protocols, attains the final end state with minimal long stewardship requirements, protects industrial workers, and protects groundwater and the environment. The ISD systems engineering framework addresses key areas of the remedial process planning, technology development and deployment, and assessment to attain the ultimate goal of natural resource stewardship and protecting the public. The development and deployment of the SRS ISD approach has established a path for ISD of other large nuclear facilities in the United States and around the globe as an acceptable remedial alternative for decommissioning nuclear facilities. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2013

Integrated System for Retrieval, Transportation and Consolidated Storage of Used Nuclear Fuel in the US - 13312

The current inventory of used nuclear fuel assemblies (UNFAs) from commercial reactor operations in the United States totals approximately 65,000 metric tons or approximately 232,000 UNFAs primarily stored at the 104 operational reactors in the US and a small number of decommissioned reactors. This inventory is growing at a rate of roughly 2,000 to 2,400 metric tons each year, (Approx. 7,000 UNFAs) as a result of ongoing commercial reactor operations. Assuming an average of 10 metric tons per storage/transportation casks, this inventory of commercial UNFAs represents about 6,500 casks with an additional of about 220 casks every year. In January 2010, the Blue Ribbon Commission (BRC) [1] was directed to conduct a comprehensive review of policies for managing the back end of the nuclear fuel cycle and recommend a new plan. The BRC issued their final recommendations in January 2012. One of the main recommendations is for the United States to proceed promptly to develop one or more consolidated storage facilities (CSF) as part of an integrated, comprehensive plan for safely managing the back end of the nuclear fuel cycle. Based on its extensive experience in storage and transportation cask design, analysis, licensing, fabrication, and operations including transportation logistics, Transnuclear, Inc. (TN), an AREVA Subsidiary within the Logistics Business Unit, is engineering an integrated system that will address the complete process of commercial UNFA management. The system will deal with UNFAs in their current storage mode in various configurations, the preparation including handling and additional packaging where required and transportation of UNFAs to a CSF site, and subsequent storage, operation and maintenance at the CSF with eventual transportation to a future repository or recycling site. It is essential to proceed by steps to ensure that the system will be the most efficient and serve at best its purpose by defining: the problem to be resolved, the criteria to evaluate the solutions, and the alternative solutions. The complexity of the project is increasing with time (more fuel assemblies, new storage systems, deteriorating logistics infrastructure at some sites, etc.) but with the uncertainty on the final disposal path, flexibility and simplicity will be critical. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2024

Update on Parallel Process Execution in the Next Generation System Analysis Model (NGSAM)

As of the end of 2022, it is estimated that over 90,000 metric tons of heavy metal (MTHM) of spent nuclear fuel (SNF) were stored at various commercial nuclear power reactor sites (both operating and shutdown) across the United States [1]. The Office of Storage and Transportation within the U.S. Department of Energy’s Office of Nuclear Energy is planning for the transportation, storage, and eventual disposal of SNF and high-level radioactive waste (HLW). To aid in this effort and inform decision-makers about the backend of the spent fuel cycle, systems analysis tools capable of analyzing the various options with respect to SNF and HLW management are being used as well as continuously improved to meet the evolving needs of the program. System analysts typically use these tools to vary underlying assumptions (shipping rates, available facilities, start dates, interim storage capacity, etc.) and study the associated system implications such as timing for clearing sites of SNF, various cost elements, transportation infrastructure acquisition needs, etc.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2026

Design and Development of the Handling Frame Assembly Table for the National Ignition Facility Blast Shields

42 ENGINEERING↗

DOE OSTI2022

Use of Systems Engineering in Repurposing Coal-Fired Power Plants with Malta Pumped Thermal Energy Storage System

he electric sector across North America is facing a transition. Both economics and policy decisions have pointed towards a broad retirement of fossil assets across markets. Owners are facing the problem of how to evolve the base of the electric sector from fossil asset to greener alternative. Coal-fired power plants built the modern electricity grid. Their rotating machinery are the beating heart of the grid, providing essential resiliency and reliability services. Power plant retirements are disruptive to plant workforces and cause outsized impacts on surrounding communities. The transition from thermal power plants that use rotating machinery to generate electricity (e.g., coal- and gas-fired plants) to variable, inverter-based generation (e.g., solar and wind) is affecting the reliability of the electric grid. Grid operators and national regulators have issued warnings about known and anticipated risk. In 2021, Malta Inc. was awarded a Department of Energy (DOE) grant to study how to integrate a Malta 100MW Pumped Heat Energy Storage (PHES) system with a retiring coal-fired power plant to meet emissions requirements, retain plant workforces, preserve communities, and maintain grid reliability. This presentation provides a summary of this study, focusing on how systems engineering approach was used to arrive at a proposed design concept that met multiple objectives and requirements. There will be three main parts for this presentation. The first part of the presentation will focus on how different systems engineering was applied for this work. In particular, the following areas: stakeholder engagement, site selection process, developing requirements and use cases for the integrated system, defining the system and its boundary, coming up with different system architecture/option, performing a techno-economic analysis to compare the different options and down selection of the preferred option, will be discusses. For these areas, discussion on the decisions on how much breadth and depth to go into each area will be provided. These discussions provide good insights into how to apply systems engineering. The second part of the presentation will provide a deeper dive into the two recommended integration options that repurpose coal-fired power plants with Malta PHES system. The comparison of the two options and general guidance of how to choose an option will be provided. This is particularly useful for utilities who are facing coal-plant retirements. The two options will be compared based on its performance (such as power output, efficiency), complexity, and cost. The social impact on local communities of the two options will also be discussed. The final part of the presentation will discuss the impact that this work has had, including Malta Inc. being invited to the White House to discuss progress and outcomes of this work with the Interagency Working Group on Coal and Power Plant Communities and Economic Revitalization. In summary, this presentation aims to provide a showcase of how sy

25 ENERGY STORAGE↗