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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 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Demonstration and technoeconomic analysis of dodecanol production from acetate using metabolically engineered Escherichia coli

In a circular bioeconomy, the one-way conversion of petroleum to chemicals and CO 2 is replaced with processes that reduce CO 2 to energy carriers and useful materials that are returned to CO 2 upon combustion. A circular bioeconomy that relies on photosynthesis to generate sugars as the chief energy carrier and precursor to chemical building blocks has yet to overcome many recalcitrant aspects of plant-based photosynthesis, namely, high feedstock costs, arable land scarcity, food competition, and fertilizer overuse. Acetate is a potential sustainable energy carrier because it can be produced from CO 2 either electrocatalytically or by acetogens via the Wood-Ljungdahl pathway. Here, in this work, we conducted a metabolic engineering study of Escherichia coli 's ability to convert acetate into dodecanol as a model oleochemical product. We performed techno-economic and life cycle analyses to determine break-even points with alternative fossil fuel-based strategies and identified critical process performance parameters for supporting an industrial acetate-based bioprocess. These analyses showed that oleochemical yield is the primary driver of minimum oleochemical selling price and carbon intensity. Therefore, to increase yield on acetate, we deleted the aceBAK operon, which facilitates funneling of acetate into biomass instead of product. We performed additional strain engineering to increase flux towards dodecanol and increase acetate uptake. Finally, we demonstrated increased yield in controlled bioreactors, improving from 13% of the maximum theoretical yield to 37%. Rigorous uncertainty analyses assuming a range of market conditions and future technological performances resulted in 88% and 37% of simulated scenarios having lower carbon intensities than fossil fuel-based routes and lower minimum selling prices than the market price.

Acetate↗
NASA NTRS1995

The origin of the solar wind

The high speed solar wind, which is associated with coronal holes and unipolar interplanetary magnetic field, has now been observed in situ beyond 0.3 a.u. and at latitudes up to 80 degrees. Its important characteristics are that it is remarkably steady in terms of flow properties and composition and that the ions, especially minor species, are favored in terms of heating and acceleration. We have proposed that the high speed wind, with its associated coronal holes, forms the basic mode of solar wind flow. In contrast, the low speed wind is inherently non-stationary, filamentary and not in equilibrium with conditions at the coronal base. It is presumably the result of continual reconfigurations of the force-free magnetic field in the low-latitude closed corona which allow trapped plasma to drain away along transiently open flux tubes. Observations of high speed solar wind close to its source are hampered by the essential heterogeneity of the corona, even at sunspot minimum. In particular it is difficult to determine more than limits to the density, temperature and wave amplitude near the coronal base as a result of contamination from fore- and back-ground plasma. We interpret the observations as indicating that the high speed solar wind originates in the chromospheric network, covering only about 1% of the surface of the sun, where the magnetic field is complex and not unipolar. As a result of small-scale reconnection events in this 'furnace', Alfven waves are generated with a flat spectrum covering the approximate range 10 kHz to 10 Hz. The plasma is likely to be produced as a result of downwards thermal conduction and possibly photoionization at the top of the low density chromospheric interface to the furnace, thus controlling the mass flux in the wind. The immediate source of free (magnetic) energy is in the form of granule-sized loops which are continually carried into the network from the sides. The resulting wave spectrum is such that energy can be efficiently transferred to the ions within a few solar radii of the base of the corona, favoring heavy species and creating stable, fast solar wind.

Axford, W. I.↗
DOE OSTI2021

Remote Monitoring and Diagnostics of Pitch-Bearing Defects in an MW-Scale Wind Turbine Using Pitch Symmetrical-Component Analysis

Recently, multiple wind turbine failure databases have reviewed that the pitch system is one of the subassemblies with the highest failure rates and largest contributors to the overall downtime. Therefore, there has been an increasing interest to provide remote health monitoring for wind turbine pitch system. While most of the research articles are discussing pitch actuation system (hydraulic or electric actuator) faults only, there is very limited research on pitch-bearing-defect detection. This article provides a remote and hardware-free solution to monitor multiaxis pitch-bearing health condition called pitch symmetrical-component analysis. It leverages readily available low-resolution (100 Hz) electrical measurements, mechanical measurements, and control signals from the existing pitch control platform, and innovatively applies symmetrical-component analysis in multiphase ac system to multiaxis pitch control system and introduces multiaxis pitch-bearing degradation trending curves. This hardware-free solution can be directly applied to the existing wind turbines and successfully give the wind farm operator an early warning before multiaxis pitch bearing fails. It has been proved to be accurate, low cost, and has minimum impacts on turbine normal operation, and has been validated by field data from several North America MW-scale wind farms. This approach turns out to be the first hardware-free (no additional hardware needed) method to remotely monitor and diagnose multiaxis wind turbine pitch-bearing condition.

17 WIND ENERGY↗
DOE OSTI2026

Public Reference Data for Megawatt-Scale Hydrogen Electrolysis - NLR Historical Solar PV

The U.S. Department of Energy and National Laboratory of the Rockies (NLR) demonstrate hydrogen electrolysis from variable sources, hydrogen compression and storage, and hydrogen fuel cell power production using megawatt-scale equipment at NLR’s Flatirons Campus as part of the Advanced Research on Integrated Energy Systems (ARIES) research platform. This dataset represents part of that effort and is intended for academic, national laboratory, industrial, and other stakeholders to plan, design, and validate models of megawatt-scale hydrogen technologies and diverse energy infrastructure nationwide. These data provide a baseline for how existing hydrogen electrolysis technologies perform when coupled with various energy technologies. Future datasets will demonstrate how existing hydrogen fuel cell technologies can provide controllable, dispatchable, and variable power output for artificial intelligence data centers and other variable loads. This dataset entry describes the behavior of a 1.25-MW proton exchange membrane MC250 electrolyzer system, manufactured by Nel Hydrogen , [1] when fed historical data generated by the 430-kW, fixed-axis solar photovoltaic (PV) array located at NLR’s Flatirons Campus. (While the electrolyzer balance of plant supports up to 2.5 MW of electrolysis, NLR only has a single 1.25-MW electrolysis stack.) Solar PV power output data for the 2020 calendar year were categorized on a daily basis by total energy generation and standard deviation. Each day was then ranked by these metrics, and the 25th, 50th, and 100th percentiles were selected. The 75th percentile day did not exhibit sufficient variability to make for a valuable experiment. A similar process was used for the related historical wind dataset . [2] The historical days in 2020 that represented these percentiles are Dec. 19, March 29, and May 4, respectively. The entire solar day’s power profile was then fed through the MC250 electrolyzer. Due to its length, the 100th percentile day experiment was split into two parts, and the final 3 hours of the solar day were not captured. These final 3 hours contained no spikes or dips of interest and simply represented a slow decay of input solar power. Also, a single timestamp (13:13:47 on Jan. 14, 2026) was lost in the hydrogen system supervisory control and data acquisition. Finally, during the 25th percentile experiment (solar day Dec. 19, 2020) data recording was lost from 11:00:13 to 11:14:45. The roughly 15 minutes of the solar profile were rerun at the end of the experiment and spliced into this time slot during post-processing. The electrolysis system controls hydrogen production by varying direct current applied to the stack, from a maximum of 3,000 A to a minimum safe operation of 300 A, or 10%. Because the current–voltage characteristic changes as the stack ages and efficiency degrades, the actual minimum safe operating power changes over time. The historical solar profiles were translated from power (kilowatts) to current (amperes) using a curve fit with calibration data and sent to the electrolyzer power supply at 1-Hz frequency. For more details on the statistical analysis process, see the slide deck “Public Reference Data for Megawatt-Scale Hydrogen Electrolysis: NLR Historical Solar PV Analysis and Profile Generation” accessible with this data entry. These datasets report relevant hydrogen balance-of-plant and system data, all captured at 1 Hz, including hydrogen mass production measured with an Emerson Coriolis flow meter. Each .zip file represents a single solar PV electrolysis experiment and is formatted as: {technology}_{percentile}_{scaling factor} For instance, “solarPV-430kW_25_2x.zip” reports the experiment using the 25th percentile solar data from the historical 2020 solar PV dataset, scaled to 200%. Scaling factors were applied to the generated solar PV power output files to more closely match the 1.25-MW capacity of the electrolyzer. Each .zip folder contains the following files: A .csv file containing raw data. An .xlsx file explaining all the fields in the raw data. A .png plot showing the time series of hydrogen production, electrolysis power consumption, and solar power input. A PDF file detailing the historical solar data statistical analysis used to generate the solar profile. An experiment labeled “characterization_200.zip” demonstrates the MC250 electrolyzer steady-state response with 30-minute load steps for a total duration of 5 hours. Finally, a .csv file is provided with all experiments combined into one dataset labeled "combined_solarPV_experiments.csv". [1] nelhydrogen.com/product/mc-series-electrolyser . [2] data.nlr.gov/submissions/316 .

08 HYDROGEN↗
NASA NTRS2016

Spiral Lamber's Problem with Generalized Logarithmic Spirals

Lambert’s problem subject to a continuous acceleration is solved using the family of generalized logarithmic spirals. Thanks to the existence of two first integrals related to the energy and angular momentum surprising analogies with the Keplerian case are found. A minimum-energy spiral transfer exists. Increasing the value of the constant of the generalized energy yields pairs of conjugate spiral trajectories. The properties of such spirals are strongly connected with the properties of conjugate Keplerian orbits. When the generalized constant of the energy reaches a critical value the two solutions degenerate into a pair of parabolic spirals, one of which connects the two vectors through infinity. From that point the spiral transfers become hyperbolic. Generalized logarithmic spirals admit closed-form solutions to all the required magnitudes including the time of flight, providing a deep insight into the dynamics of the problem. In addition, the maximum acceleration along the transfer is found analytically so the solutions that violate the design constraints on the maximum thrust acceleration can be rejected without any further computations. When the time of flight is fixed there is still a degree of freedom in the solution, related to a control parameter. Resonant transfers appear naturally thanks to the symmetry properties of the generalized logarithmic spirals. The problem of designing a low-thrust transfer between two bodies can be reduced to solving the corresponding spiral Lambert’s problem. In order to show the versatility of the method it is applied to the design of an asteroid tour and to explore launch opportunities to Mars.\

Roa, Javier↗
DOE OSTI2022

Sensitivity Study of Mini-Batch Size on a Long Short-Term Memory Network for In-situ Sensing of Core-to-shell Ratio of Microencapsulated Phase Change Materials

Microencapsulated phase change materials are being studied for applications for thermal energy storage in concentrated solar fields. During fabrication, the thickness of the encapsulation cannot be readily measured for real-time control. Therefore, a machine learning network, specifically a Long Short-Term Memory network, is being developed to estimate the ratio of the shell radius to core radius based on a one second temperature history. The mini-batch size determines how often the algorithm weights are updated during network training, and shuffle indicates whether the training data is shuffled during training. A general factorial design is used to analyze the effects of varying mini-batch size and shuffle, along with the core-to-shell ratio, on the RMSE of the response from the Long Short-Term Memory network. It was found that the network performed better for smaller core to shell ratios (less than 0.6) and had the lowest RMSE when the minibatch size was 128. The minimum RMSE found was 0.00501.

Shannon, Rebecca↗
NASA NTRS1993

Incineration for resource recovery in a closed ecological life support system

A functional schematic, including mass and energy balance, of a solid waste processing system for a controlled ecological life support system (CELSS) was developed using Aspen Plus, a commercial computer simulation program. The primary processor in this system is an incinerator for oxidizing organic wastes. The major products derived from the incinerator are carbon dioxide and water, which can be recycled to a crop growth chamber (CGC) for food production. The majority of soluble inorganics are extracted or leached from the inedible biomass before they reach the incinerator, so that they can be returned directly to the CGC and reused as nutrients. The heat derived from combustion of organic compounds in the incinerator was used for phase-change water purification. The waste streams treated by the incinerator system conceptualized in this work are inedible biomass from a CGC, human urine (including urinal flush water) and feces, humidity condensate, shower water, and trash. It is estimated that the theoretical minimum surface area required for the radiator to reject the unusable heat output from this system would be 0.72 sq m/person at 298 K.

Upadhye, R. S.↗
DOE OSTI2020

Monitoring of Unvented Roofs with Fibrous Insulation, Diffusion Vents, and Interior Vapor Control in a Cold Climate

Unvented roof assemblies have been accepted in North American building codes since 2007; code-compliant construction calls for a minimum thickness of “air-impermeable insulation” (based on climate zone) to avoid cold-weather condensation and moisture risks. This is typically implemented with polyurethane spray foam insulation; however, negatives of this material include high first cost and possible adverse environmental impacts. Implementing unvented roofs in a moisture-safe manner with air-permeable fibrous fill insulations (e.g., fiberglass or cellulose) could potentially reduce the first cost of unvented roof designs, allowing for more widespread use. Building unvented roofs in a cost-effective, airtight, and moisture-safe manner opens up options for high-performance house designers and builders.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Defensive Islanding to Enhance the Resilience of Distribution Systems Against Cyber-Induced Failures

The extensive integration of communication, computation, and control technologies into cyber-physical power systems (CPPSs) has increased the vulnerabilities of CPPSs to cyberattacks. This calls for developing solutions that assess and reduce the impacts of cyber-induced failures on CPPSs. This paper proposes a defensive islanding strategy to isolate impacted parts of the CPPS and form self-sufficient islanded grids with an objective of minimum load curtailment. The defensive islanding aims to split a power system into smaller grids to improve its resilience against a potential extreme event. A clustering approach that leverages the hierarchical spectral clustering method is utilized for the optimal defensive islanding. The proposed approach captures the fragility behavior and loading conditions of power system components due to cyber-induced failures. A graphical-based coupling framework is used to map the impacts of cyber failures into operation of power system components. The proposed method is demonstrated on a modified 33-node distribution feeder system integrated with distributed energy resources. The amount of load curtailment and radiality constraints have been used to evaluate the performance of the proposed clustering strategies. The results show the capability of the proposed algorithm to create islands considering the cyber-induced failures for enhanced resilience.

cyber-induced failures↗
NASA NTRS1993

Dynamic tests on the NASA Langley CSI evolutionary model

A modal analysis study, representing one of the anticipated 'Cooperative Spacecraft Structural Dynamics Experiments on the NASA Langley CSI Evolutionary Model', was carried out as a sub-task under the NASA/DLR collaboration in dynamics and control of large space systems. The CSI evolutionary testbed (CEM) is designed for the development of Controls-Structures Interaction (CSI) technology to improve space science platform pointing. For orbiting space structures like large flexible trusses, new identification challenges arise due to their specific dynamic characteristics (low frequencies and high modal density) on the one hand, and the limited possibilities of exciting such structures and measuring their responses on orbit on the other. The main objective was to investigate the modal identification potential of several different types of forcing functions that could possibly be realized with on-board excitation equipment using a minimum number of exciter locations as well as response locations. These locations were defined in an analytical test prediction process used to study the implications of measuring and analyzing the responses thus produced. It turned out that broadband excitation is needed for a general modal survey, but if only certain modes are of particular interest, combinations of exponentially decaying sine functions provide favorable excitation conditions as they allow to concentrate the available energy on the modes being of special interest. From a practical point-of-view structural nonlinearities as well as noisy measurements make the analysis more difficult, especially in the low frequency range and when the modes are closely spaced.

Troidl, H.↗
DOE OSTI2020

CY2019 Annual Closure Monitoring Report for Corrective Action Unit 98, Frenchman Flat, Underground Test Area, Nevada National Security Site, Nevada (January 2019–December 2019), Revision 1

Three types of monitoring are performed for CAU 98: water quality, water level, and institutional control. These are monitored to determine whether the URs remain protective of human health and the environment, and to ensure that the regulatory boundary objectives are being met. Monitoring data will be used in the future, once multiple years of data are available, to evaluate consistency with the groundwater flow and contaminant transport models because the contaminant boundaries calculated with the models are the primary basis of the UR boundaries. Six wells were sampled for water-quality monitoring in 2019. Contaminants of concern were detected only in the two source/plume wells already known to contain contamination as a result of a radionuclide migration experiment. Tritium concentrations in both of these wells, RNM-2S and UE-5n, remain above the Safe Drinking Water Act maximum contaminant level of 20,000 picocuries per liter but declined in 2019 as compared to measurements in 2018. All other contaminants of concern are below the minimum detection level plus analytical error. The water-level monitoring network includes 16 wells. Depth to water measured in 2019 is generally consistent with recent measurements for all wells. Many wells continue to exhibit a long-term downward trend in water level, though changes from 2018 to 2019 are minimal. The sharp 2016 decline in water level in Well ER-5-3-2 remains unexplained, with the lower level persisting through 2019. Rising water-level trends continue to be observed in Well ER-5-3 deep piezometer and former water supply Well WW-5A. Water supply Well WW-5B experienced a rise in water level as a result of an absence of pumping in the first part of the year (due to a mechanical problem), whereas water levels declined in WW-4 and WW-4A in response to greater pumping in 2019. Institutional control monitoring confirmed the URs are recorded in U.S. Department of Energy and U.S. Air Force land management systems, and that no activities within Frenchman Flat basin are occurring that could potentially affect the contaminant boundaries. Survey of groundwater resources in basins surrounding Frenchman Flat similarly identify no current or pending development that would indicate the need to increase monitoring activities or would otherwise cause concern for the closure decision. The URs continue to prevent exposure of the public, workers, and the environment to contaminants of concern by preventing use of potentially contaminated groundwater.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Operating Strategies for Dispatchable PEM Electrolyzers that Enable Low-Cost Hydrogen Production

Hydrogen is a pathway to enabling decarbonization across multiple economic sectors that cannot be directly decarbonized with electricity including heat for industrial operations, medium- and heavy-duty transportation applications, long-duration energy storage, and as a feedstock for chemical synthesis. Producing hydrogen at low costs and carbon footprint is likely essential to economically decarbonize these otherwise "hard to decarbonize" sectors. Low-temperature polymer electrolyte membrane (PEM) electrolysis produces hydrogen from water and electricity and is a rapidly developing pathway towards making hydrogen at the scales required for decarbonization applications. The levelized cost of electrolytic hydrogen is dependent on the capital cost, efficiency, and durability of the electrolyzer system as well as the price of electricity supplied to the electrolyzer and the annual utilization of the electrolyzer (capacity factor). Electricity price and capacity factor depend on the source of energy that the system uses and impact other economic factors. Electricity price and capacity factor and the connections between other aspects of hydrogen production via PEM electrolyzers are the focus of this work. PEM electrolyzers have conventionally been operated at high capacity factors using electricity purchased from utilities with a constant price throughout the year. To achieve lower effective electricity prices, recent work has investigated opportunities for electrolyzers to purchase electricity in wholesale markets, where the cost of electricity varies hourly. This option can lead to lower electricity costs when the electrolyzer is a controllable load that ramps up and down rapidly and turns on and off frequently. This configuration and operating strategy capitalizes on times of low wholesale electricity prices and results in lower hydrogen levelized costs than constant operation due to reduced electricity costs even though the reduced capacity factor increases the cost of recovering the capital investment. Cycling on and off frequently also has implications for electrolyzer durability. An electrolyzer configuration where it is directly connected to renewable generation such as wind or solar, only running when the generator is producing energy, has similar implications on operating strategy, hydrogen levelized cost, capacity factor, and durability. This work provides insight into the relationships between dispatchable electrolyzer operating strategies and the cost of producing hydrogen from these systems, outlining strategies and opportunities to minimize production costs while minimizing operations that are likely to negatively impact system durability and efficiency. We find strategies that minimize electrolyzer cycling and the resulting durability impacts while increasing the hydrogen levelized cost only slightly above the minimum. We also find opportunities for batteries to minimize the number of cycles in systems directly connected to renewable generation. These findings outline key opportunities for future electrolyzer deployments and the synergistic benefits between electrolyzers and increased deployment of renewable energy generation like wind and solar. They also inform research and development that is reducing electrolyzer capital cost while managing durability impacts.

electricity markets↗
DOE OSTI2023

Extended Low Load Boiler Operation to Improve Performance and Economics of an Existing Coal Fired Power Plant (Final Report)

The overall goal is to improve the performance and economics of existing coal fired power plants by extending low load boiler operation to lower loads than is currently achievable. The objective of this program is to develop and validate sensor hardware and analytical algorithms to lower plant operating expenses (OPEX) for the currently operating pulverized coal utility boiler fleet. Coal fired utility boilers are increasingly under grid dispatch pressure. In some cases, the coal fired cost of generation is noncompetitive with respect to natural gas generation and subsidized renewable sources. To remain profitable and remain fully compliant with existing environmental regulations, the installed coal fired fleet must find technologies which allow it to move into a more flexible cyclic load dispatch model. Today the installed coal fired utility fleet must be cost of generation competitive, fully emissions compliant, and responsive to the variability inherent in renewable energy generation sources. In the Phase I of the project, GE Steam Power, Inc. (GE) performed modeling of different operating scenarios for low load operation using an existing full plant dynamic model developed for a 660MW steam power plant. Sensors and analytic algorithms to enable a stable and steady coal supply for low load pulverizer operation were identified and tested at the Pulverizer Development Facility (PDF) at GE’s Clean Energy Center in Bloomfield, Connecticut. Sensors and analytic algorithms to enable stable combustion for low load operation were identified and tested at the 15 MWth Industrial Scale Burner facility (ISBF) at GE’s Clean Energy Center. A concept was developed to test the sensors and control algorithms, down selected after testing, at a full-scale coal fired power plant. A budget estimate was then developed, and the concept was implemented at an existing utility power plant. The specific objectives of the experimental work were to: • Identify and select sensors and analytic algorithms for monitoring coal pulverizer operation at lower loads to provide stable operation and appropriate coal fineness at lower coal throughput; Identify and select sensors and analytic algorithms for a Boiler Flame Stability Monitor to better balance air and fuel at each burner. This enables a reduction in a coal boiler’s safe low load power level while maintaining stable flame characteristics; Develop a concept in Phase I for low load operation of a full-scale power plant and develop a budget estimate for testing and execute the test plan at an existing plant in Phase II; Validate the capability of the extended low load boiler system to extend the minimum load operating point in a safe and reliable manner on an existing full-scale utility boiler. At the completion of this experimental study, GE has developed a set of sensors and analytic algorithms, down selected after testing, that have the potential to enable safe low load operation of a utility boiler. GE has also identified a host site for testing these identified sensors and analytic algorithms. GE has generated a full set of deliverables that provide sufficient information to proceed with the next step of testing at a host site. This includes a potential host site and budget estimate for concept testing at host site. In the Phase II of the project, a series of field tests were completed to validate the extended low load boiler operation, which consisted of detailed engineering, installation, commissioning, and testing the additional sensors and analytics for the coal-fired combustion system on an existing full-scale utility boiler. The optimization work has been supported by the host plant and endorsed by their engineering and operation staff.

01 COAL, LIGNITE, AND PEAT↗
NASA NTRS2018

Imaging X-Ray Polarimetry Explorer Mission Attitude Determination and Control Concept

The goal of the Imaging X-Ray Polarimetry Explorer (IXPE) Mission is to expand understanding of high-energy astrophysical processes and sources, in support of NASA's first science objective in Astrophysics: "Discover how the universe works." X-ray polarimetry is the focus of the IXPE science mission. Polarimetry uniquely probes physical anisotropies-ordered magnetic fields, aspheric matter distributions, or general relativistic coupling to black-hole spin-that are not otherwise measurable. The IXPE Observatory consists of Spacecraft and Payload modules. The Payload includes three polarization sensitive, X-ray detector units (DU), each paired with its corresponding grazing incidence mirror module assemblies (MMA). A deployable boom provides the correct separation (focal length) between the DUs and MMAs. These Payload elements are supported by the IXPE Spacecraft. A star tracker is mounted directly with the deployed Payload to minimize alignment errors between the star tracker line of sight (LoS) and Payload LoS. Stringent pointing requirements coupled with a flexible structure and a non-collocated attitude sensor-actuator configuration requires a thorough analysis of control-structure interactions. A non-minimum phase notch filter supports robust control loop stability margins. This paper summarizes the IXPE mission science objectives and Observatory concepts, and then it describes IXPE attitude determination and control implementation. IXPE LoS pointing accuracy, control loop stability, and angular momentum management are discussed.

Attitude Determination and Contro↗
NASA NTRS2021

A Study of Particle Size Metrics Using Non-Spherical Feedstock for Metal Additive Manufacturing

The goal of this work was to determine which standard particle size metric derived from optical analysis most closely approximates the sieved weight percent of irregularly shaped powder intended to be used for directed energy deposition. In this investigation, equivalent circle diameter, maximum diameter, minimum diameter, and perimeter are used as metrics to “virtually sieve” the particles in samples of irregularly shaped powder into the following particle size bins: <45 µm, 45 µm - 150 µm, and >150 µm. The percentage in the 45 µm - 150 µm bin is then compared to the weight percent of the powder mechanically sieved into this size range. The absolute difference between the virtually sieved percentage and the mechanically sieved percentage was assessed for 81 samples of mechanically-generated stainless steel 316L powder all produced under different processing conditions in an oscillation ball mill. This difference was found to be on average, the least with the minimum diameter assessed as an area percentage, followed by the equivalent diameter assessed as an area percentage, and then the maximum diameter assessed as a percentage of the total number of particles ranked third. These findings may be used by powder production process engineers and quality assurance personnel to assist in process control as more diverse additive manufacturing feedstocks become utilized.

Marcus Jackson↗
DOE OSTI2023

Design, Optimization, and Validation of GaN-Based DAB Converter for Active Cell Balancing in BTMS Applications: Preprint

This paper focuses on the design of a bidirectional dual active bridge (DAB) DC/DC converter that utilizes Gallium Nitride (GaN) switches as active components. In the existing literature, MOSFET-based DAB for active cell balancing is available, but GaN-based DAB converter for active cell balancing is still new. The proposed modular isolated GaN-based DAB converter is designed as an individual module of active cell balancing for behind-the-meter storage (BTMS) applications, targeting high-power charging stations. Modular isolated converters are connected to each cell (low voltage bus), and each cell is connected in series to build up a battery module. According to the reference current command of supervisory control, each DAB converter can transfer power back and forth through the high voltage (HV) bus to balance the State of Charge (SoC) between the cells. Each module DAB converter is designed at a 50W power rating. Switch power and transformer losses are analyzed for different switching frequencies, showing the optimum switching frequency for minimum losses. Furthermore, the procedure to select the required gate driver and the PCB layout optimization are discussed. Finally, the DAB performance analysis of GaNbased DAB and Si-based DAB is provided for a battery module operating with a LiFeMnPO4 prismatic cell with 3.2V 20Ah rated values.

active cell balancing↗
DOE OSTI2024

Seasonal Cost-Benefit Analysis of Automated Distribution Feeder Upgrades with Advanced Mitigation Technologies

The increasing deployment of distributed solar photovoltaics (DPV) to meet clean energy goals can trigger adverse grid operation issues, such as voltage excursions and the violation of thermal loading constraints of the power delivery elements (e.g., lines and transformers) on the evolving electricity infrastructure. Such integration issues would require distribution upgrades with associated costs to mitigate them and to maintain reliable and resilient grid operating conditions. Traditional distribution network upgrade approaches use a specific single snapshot analysis that is overly conservative. This study considers a multi-time point analysis to capture both moderate (probable bounds) and extreme grid operating conditions using time points such as minimum load with minimum photovoltaics (PV), maximum load with maximum PV, maximum load with minimum PV, and minimum load with maximum PV. Further, this study investigates seasonal variation impacts and associated distribution upgrade costs for a spring season case (March, representing a low load and high PV scenario) and a summer case (July, representing a high load and high PV scenario). Such seasonal analysis will allow system operators to characterize upgrade requirements and associated costs across various periods. Because the spatial distribution of DPV can impact upgrade and associated costs, this study investigates three common DPV deployment scenarios - randomly deployed, close to the substation, and far from the substation - at different penetration levels. Apart from spatial distribution impacts, this project evaluates the techno-economic impacts of the nodal photovoltaic penetration factor (NPPF) for generating the various DPV deployment scenarios at increasing penetration levels. This project investigates the impact of varying nodal PV-to-load ratios using conservative and extreme NPPF values of 3 and 10, respectively. This study investigates the deployment of traditional infrastructure upgrade strategies, such as installing new voltage regulating equipment, transformers and lines replacements, and the activation of advanced inverter functionality (e.g., autonomous volt/VAR) in expanding PV hosting capacity. Existing DPV systems are assumed to operate with the legacy unity power factor, and we considered the possibility of retrofitting such systems with the activation of volt/VAR control as integration standards and regulations continue to evolve to allow such functions. The cost-benefit analysis metrics used in study include distribution upgrade costs, average cost per watt of the upgrade cost, average marginal cost per watt of the upgrade cost, and power losses.

14 SOLAR ENERGY↗
DOE OSTI2022

Transmission-distribution long-term volt-var planning considering reactive power support capability of distributed PV

High penetration of grid-edge, inverter-based photovoltaic (PV) can cause significant voltage fluctuations not only at the distribution but also at the sub-transmission levels due to PV output intermittency. Traditional reactive power planning approaches do not consider intermittency, nor the possibility of coordinating the control of existing and future volt-ampere reactive resources. This paper proposes a reactive power planning tool for sub-transmission systems to mitigate voltage violations and fluctuations caused by high PV penetration and intermittency with a minimum investment cost. The planning tool coordinates with an optimization-based volt-var operational tool for: a) modeling the coordination of all existing var assets in both sub-transmission and distribution systems to reduce the need of new equipment, and b)selecting a set of scenarios with voltage violations, derived from PV intermittency c) testing the final investment decision. The tool obtains an investment need for each intermittency scenario with a proposed optimal power-flow framework with efficient techniques to handle a high number of discrete variables. Two options are provided for final planning decision: i) a conservative direct combination of investment need solutions and ii) a machine learning-based selection of representative investment needs at most time steps. The final investment decision options are verified using a realistic large-scale sub-transmission system and 5-minute PV and load data. The results show a significant voltage performance improvement with a lower investment cost for additional var equipment compared to conventional approaches.

14 SOLAR ENERGY↗