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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 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Continuous condensed-phase ethanol conversion to higher alcohols: Experimental results and techno-economic analysis

The conversion of ethanol to n-butanol and higher alcohols is carried out in a continuous fixed bed reactor over a Ni/La 2 O 3 /γ-Al 2 O 3 catalyst at 210–250 °C and 100 bar. At these conditions, the reaction mixture is a condensed, near-critical phase that facilitates higher reaction rates than corresponding vapor phase reactions. Combined selectivity to n-butanol and C 6 + higher alcohols reached 74% at 41% ethanol conversion. A process concept is presented in which n-butanol and mixed C 6 + alcohols are produced as saleable products; ethanol is recycled to achieve nearly 100% overall conversion and minor byproducts are burned to provide process energy. A process design is conducted using Aspen Plus V8.4 process simulation software, and economic analyses are carried out for several cases of ethanol conversion and alcohol selectivities. Several additional cases involving permutations of the base process configuration are also examined in attempts to improve process economics. At n-butanol selectivities achieved experimentally, a facility producing 75 million kg n-butanol per year has a total capital cost of 38.1 million with a required n-butanol selling price of 1.55/kg to 1.60/kg for typical values of expected return on investment.

09 BIOMASS FUELS↗
DOE OSTI2024

Autonomous online optimization of a closed-circuit reverse osmosis system

As freshwater becomes increasingly scarce, many industrial and municipal water utilities look at premise-scale water treatment and reuse to meet water demand. Closed-circuit reverse osmosis (CCRO) has been proposed as a promising process design to do so. This sequencing batch process enables operation at higher brine salinity levels by means of a recycle flow. Optimal operation requires that the maximum salinity level at the membrane surface represents an optimal trade-off between brine disposal costs and energy efficiency. This maximum salinity level may change over time as the feed water composition changes and electricity markets fluctuate. In this article, we present the results of the experimental evaluation of an automatic technique for continuous online optimization, known as extremum seeking control. This technique has a long history in the process control community but has received little traction so far in the water industry. We modify this technique to enable its use for online optimization of CCRO, specifically to account for its sequential batch operation. We challenge the optimization schemes through several experimental tests and illustrate the advantages and drawbacks of extremum-seeking control.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Conceptual Fuel Element Design Candidates for Conversion of High Flux Isotope Reactor with Low-Enriched Uranium Silicide Dispersion Fuel

Engineering design studies are underway to assess the feasibility of converting the High Flux Isotope Reactor (HFIR) to operate with low-enriched uranium (LEU) silicide dispersion (U3Si2-Al) fuel. These studies are supported by the U.S. Department of Energy National Nuclear Security Administration’s Office of Material Management and Minimization. A systematic approach employing neutronic and thermal-hydraulic analyses have been performed with the ORNL Shift and HFIR Steady State Heat Transfer Code tools, respectively, to predict reactor performance and thermal safety margins for proposed LEU3Si2-Al fuel designs. The design process was initiated by generating an optimized design with fabrication features identified from previous studies that result in excellent performance and safety metrics. The approach continued by substituting a single fabrication feature anticipated to be difficult to manufacture with another feature expected to perform an analogous function to that of the removed feature. Four conceptual fuel element design candidates, with various fabrication features, for conversion of HFIR with 4.8 gU/cm3 LEU3Si2-Al fuel have been generated and shown to meet pre-defined performance and safety metrics. Results to date indicate that HFIR could convert with the subject fuel system and meet performance and safety requirements if, among other considerations, fabrication of the specific design features are demonstrated and qualification of the fuel is complete under HFIR-specific conditions.

Chandler, David↗
DOE OSTI2022

Power Converter Circuit Design Automation using Parallel Monte Carlo Tree Search

The tidal waves of modern electronic/electrical devices have led to increasing demands for ubiquitous application-specific power converters. A conventional manual design procedure of such power converters is computation- and labor-intensive, which involves selecting and connecting component devices, tuning component-wise parameters and control schemes, and iteratively evaluating and optimizing the design. To automate and speed up this design process, we propose an automatic framework that designs custom power converters from design specifications using Monte Carlo Tree Search. Specifically, the framework embraces the upper-confidence-bound-tree (UCT), a variant of Monte Carlo Tree Search, to automate topology space exploration with circuit design specification-encoded reward signals. Moreover, our UCT-based approach can exploit small offline data via the specially designed default policy and can run in parallel to accelerate topology space exploration. Further, it utilizes a hybrid circuit evaluation strategy to substantially reduce design evaluation costs. Empirically, we demonstrated that our framework could generate energy-efficient circuit topologies for various target voltage conversion ratios. Compared to existing automatic topology optimization strategies, the proposed method is much more computationally efficient --- the sequential version can generate topologies with the same quality while being up to 67% faster. Here, the parallelization schemes can further achieve high speedups compared to the sequential version.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2017

Design of an Airlift Bioreactor

An important consideration for the process design is cell immobilization-enabled flow-through operation. Large-scale biosorption relies on cells that are immobilized on a supporting substrate and used to 'attract' metal ions. Cell immobilization allows easy separation of the feed solution and REEs that are attached to the cell surface. It also allows continuous operation without the need of energy-intensive centrifugation or filtration. Lightweight, high surface area, low cost (~$200/m3) high-density polyethylene (HDPE) plastic disks are used as cell carriers for biofilm formation.

15 GEOTHERMAL ENERGY↗
DOE OSTI2013

Strategy Guideline: Compact Air Distribution Systems

This Strategy Guideline discusses the benefits and challenges of using a compact air distribution system to handle the reduced loads and reduced air volume needed to condition the space within an energy efficient home. Traditional systems sized by 'rule of thumb' (i.e., 1 ton of cooling per 400 ft 2 of floor space) that 'wash' the exterior walls with conditioned air from floor registers cannot provide appropriate air mixing and moisture removal in low-load homes. A compact air distribution system locates the HVAC equipment centrally with shorter ducts run to interior walls, and ceiling supply outlets throw the air toward the exterior walls along the ceiling plane; alternatively, high sidewall supply outlets throw the air toward the exterior walls. Potential drawbacks include resistance from installing contractors or code officials who are unfamiliar with compact air distribution systems, as well as a lack of availability of low-cost high sidewall or ceiling supply outlets to meet the low air volumes with good throw characteristics. The decision criteria for a compact air distribution system must be determined early in the whole-house design process, considering both supply and return air design. However, careful installation of a compact air distribution system can result in lower material costs from smaller equipment, shorter duct runs, and fewer outlets; increased installation efficiencies, including ease of fitting the system into conditioned space; lower loads on a better balanced HVAC system, and overall improved energy efficiency of the home.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2013

Strategy Guideline: Compact Air Distribution Systems

This guideline discusses the benefits and challenges of using a compact air distribution system to handle the reduced loads and reduced air volume needed to condition the space within an energy efficient home. The decision criteria for a compact air distribution system must be determined early in the whole-house design process, considering both supply and return air design. However, careful installation of a compact air distribution system can result in lower material costs from smaller equipment, shorter duct runs, and fewer outlets; increased installation efficiencies, including ease of fitting the system into conditioned space; lower loads on a better balanced HVAC system, and overall improved energy efficiency of the home.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Oxy-Combustion System Process Optimization

The overall objective of this work is to develop a new chemical absorbent-based, high pressure, CO 2 purification system to remove the residual oxygen that currently contaminates the recovered CO 2 , and to optimize the Pressurized Oxy-Combustion (POxC) process to minimize the Cost of Electricity (COE) generated in this advanced combustion process. TDA developed and validated the performance of the oxygen removal system for CO 2 purification. In collaboration with the Advanced Power & Energy Program (APEP) of University of California, Irvine (UCI), we optimized the POxC process, including thermal management, heat integration, and power cycle optimization using process design and modeling supported with Aspen Plus® process simulations. The techno-economic analysis results indicate that the pressurized oxycombustion coal power plant with Ion-transport membrane (ITM) air separation unit (ASU) (Case 2 – 30.55%) does not show an advantage over a cryogenic ASU (Case 1 – 31.24%) while TDA’s sorption-based ASU (Case 4 - 32.61%) shows a significant advantage over the cryogenic ASU (Case 1 – 331.24%). The specific plant costs show a wide range with a low of $2544/kW for Case 11C (TDA ASU, co-sequestering the SO x , and ultra-supercritical steam cycle) to a high of $2975/kW for Case 12A (cryogenic ASU and sCO 2 cycle). In general, the ITM ASU based cases have lower specific plant costs than the corresponding cryogenic ASU based cases while the TDA ASU based cases show the lowest specific plant costs. The main reason for lowering these costs is the higher overall plant thermal efficiency which decreases the plant cost on a $ per kW basis. Next comparing the cases with different power cycle working fluid conditions in terms of temperature and pressure while all utilizing steam, similar trends as the plant costs may be observed. However, with the supercritical CO 2 (sCO 2 ) cycle, the increase in thermal efficiency of the sCO 2 cycle was not able to offset its increase in plant cost making the plant costs higher than those of the corresponding steam cycle cases. The Cost of Electricity (COE) again shows similar trends as the specific plant costs. The COE for Case 11C at $110.1/MWh is also the lowest, but among all cases that do not co-sequester the SO x , Case 12C (TDA ASU and sCO 2 cycle) has the lowest COE at $\$$117.5/MWh while the highest is for Case 8A (cryogenic ASU and supercritical steam cycle) at $130.4/MWh.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2021

Design and Performance Analysis of a Highly Efficient Polychromatic Full Stokes Polarization Modulator for the CRISP Imaging Spectrometer

We present the design and performance of a polychromatic polarization modulator for the CRisp Imaging SpectroPolarimeter (CRISP) Fabry–Perot tunable narrow-band imaging spectropolarimer at the Swedish 1 m Solar Telescope (SST). We discuss the design process in depth, compare two possible modulator designs through a tolerance analysis, and investigate thermal sensitivity of the selected design. The trade-offs and procedures described in this paper are generally applicable in the development of broadband polarization modulators. The modulator was built and has been operational since 2015. Its measured performance is close to optimal between 500 and 900 nm, and differences between the design and as-built modulator are largely understood. We show some example data, and briefly review scientific work that used data from SST/CRISP and this modulator.

42 ENGINEERING↗
DOE OSTI2013

3S (Safeguards, Security, Safety) based pyroprocessing facility safety evaluation plan

The big advantage of pyroprocessing for the management of spent fuels against the conventional reprocessing technologies lies in its proliferation resistance since the pure plutonium cannot be separated from the spent fuel. The extracted materials can be directly used as metal fuel in a fast reactor, and pyroprocessing reduces drastically the volume and heat load of the spent fuel. KAERI has implemented the SBD (Safeguards-By-Design) concept in nuclear fuel cycle facilities. The goal of SBD is to integrate international safeguards into the entire facility design process since the very beginning of the design phase. This paper presents a safety evaluation plan using a conceptual design of a reference pyroprocessing facility, in which 3S (Safeguards, Security, Safety)-By-Design (3SBD) concept is integrated from early conceptual design phase. The purpose of this paper is to establish an advanced pyroprocessing hot cell facility design concept based on 3SBD for the successful realization of pyroprocessing technology with enhanced safety and proliferation resistance.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

General description of HTR-PM emergency power system - 18415

The paper will describe the design concept of the emergency power system utilized in the high temperature gas cooled reactor project (HTR-PM) which is currently under construction in Shandong, China. As a class 1E system which is related to the safety feature of the reactor, emergency power system is responsible for providing multiple reliable power sources for nuclear safety class loads. Therefore, the structure, power source deployment, operation, maintenance and alignment of the system should meet several standards and regulations. The paper will give a detailed description about the designing process of the system which include structure design, determination of primary device parameters, and some calculation results of device capacity such as emergency diesel engine, UPS et al. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

LOTO Training Flow Simulator Design

The LOTO Training Flow Simulator Design poster discusses the intended purpose of the simulator along with the steps taken in the design process. It highlights the two main systems designed in the primary flow loop and the bubbler system, along with a brief description of the flow calculations made to ensure the functionality of the system.

42 - ENGINEERING↗
DOE OSTI2023

Multi-objective Bayesian alloy design using multi-task Gaussian processes

In design applications, correlations among material properties (such as the tendency for stronger materials to be less ductile) are often neglected. This approach is echoed in multi-objective optimization techniques which treat each performance characteristic as an independent objective, aiming to optimize scalar functions and find optimal Pareto fronts. However, this overlooks the statistical relationships between performance characteristics inherent in a material system. To address this, we propose the use of Bayesian optimization, a highly efficient black-box optimization algorithm known for constructing Gaussian processes (GPs) – uncorrelated surrogates - to model objective functions. Rather than evaluating multiple GPs for each objective function separately, we argue for a shift towards jointly modeling these objective functions, considering their statistical correlations. This integrated approach utilizes naturally occurring relationships among material properties, providing additional information to enhance the performance of the design framework. This requires the replacement of multiple independent GPs with a single multi-task GP, employing a correlation matrix to construct a multi-task kernel function, wherein each task corresponds to a single objective function. Here, we anticipate this refined methodology will better leverage material correlations, improving design optimization results.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Cost of Using Laser Powder Bed Fusion to Fabricate a Molten Salt-to-Supercritial Carbon Dioxide Heat Exchanger for Concentrating Solar Power

Advances in manufacturing technologies and materials are crucial to the commercial deployment of energy technologies. We present the case of concentrating solar power (CSP) with molten salt (MS) thermal storage, where low-cost, high-efficiency heat exchangers (HXs) are needed to achieve cost competitiveness. Here, the materials required to tolerate the extreme operating conditions in CSP systems make it difficult or infeasible to produce them using conventional manufacturing processes. Although it is technically possible to produce HXs with adequate performance using additive manufacturing, specifically laser powder bed fusion (LPBF), here we assess whether doing so is cost-effective. We describe a process-based cost model (PBCM) to estimate the cost of fabricating a MS-to-supercritical carbon dioxide HX using LPBF. The PBCM is designed to identify modifications to designs, process choices, and manufacturing innovations that have the greatest effect on manufacturing cost. Our PBCM identified HX design and LPBF process modifications that reduced projected HX cost from $\$750$ per kilo-Watt thermal (kW-th) ($\$8$ /cm 3 ) to $\$350$ /kW-th ($\$6/$ cm 3 ) using currently available LPBF technology, and down to $\$220$ /kW-th ($\$4$ /cm 3 ) with improvements in LPBF technology that are likely to be achieved in the near term. The PBCM also informed a redesign of the HX design that reduced projected costs to $\$140$ –160/kW-th ($\$3$ /cm 3 ).

36 MATERIALS SCIENCE↗
DOE OSTI2014

Development of a lab-scale, high-resolution, tube-generated X-ray computed-tomography system for three-dimensional (3D) materials characterization

The design and construction of a modular high resolution X-ray computed tomography (XCT) system is highlighted in this paper. The design approach is detailed for meeting a specified set of instrument performance goals tailored towards experimental versatility and high resolution imaging. The XCT tool is unique in the detector and X-ray source design configuration, enabling control in the balance between detection efficiency and spatial resolution. The system package is also unique: The sample manipulation approach implemented enables a wide gamut of in situ experimentation to analyze structure evolution under applied stimulus, by optimizing scan conditions through a high degree of controllability. The component selection and design process is detailed: Incorporated components are specified, custom designs are shared, and the approach for their integration into a fully functional XCT scanner is provided. Custom designs discussed include the dual-target X-ray source cradle which maintains position and trajectory of the beam between the two X-ray target configurations with respect to a scintillator mounting and positioning assembly and the imaging sensor, as well as a novel large-format X-ray detector with enhanced adaptability. The instrument is discussed from an operational point of view, including the details of data acquisition and processing implemented for 3D imaging via micro-CT. The performance of the instrument is demonstrated on a silica-glass particle/hydroxyl-terminated-polybutadiene (HTPB) matrix binder PBX simulant. Post-scan data processing, specifically segmentation of the sample's relevant microstructure from the 3D reconstruction, is provided to demonstrate the utility of the instrument. - Highlights: • Custom built X-ray tomography system for microstructural characterization • Detector design for maximizing polychromatic X-ray detection efficiency • X-ray design offered for maximizing X-ray flux with respect to imaging resolution • Novel lab-scale XCT data acquisition and data processing methods • 3D characterization of glass-bead mock plastic-bonded-explosive stimulant.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Small Modular Reactor and Microreactor Security-by-Design Lessons Learned: Integrated PPS Designs

U.S. nuclear power facilities face increasing challenges in meeting dynamic security requirements caused by evolving and expanding threats while keeping costs reasonable to make nuclear energy competitive. The past approach has often included implementing security features after a facility has been designed and without attention to optimization, which can lead to cost overruns. Incorporating security into the design process can provide robust, cost-effective, and sufficient physical protection systems. The purpose of this report is to capture lessons learned by the Advanced Reactor Safeguards and Security (ARSS) program that may be beneficial for other advanced and small modular reactor (SMR) vendors to use when developing security systems and postures. This report will capture relevant information that can be used in the security-by-design (SeBD) process for SMR and microreactor vendors.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2011

Gearbox Reliability Collaborative (GRC) Description and Loading

This document describes simulated turbine load cases in accordance to the IEC 61400-1 Ed.3 standard, which is representative of the typical wind turbine design process. The information presented herein is intended to provide a broad understanding of the gearbox reliability collaborative 750kW drivetrain and turbine configuration. In addition, fatigue and ultimate strength drivetrain loadsresulting from simulations are presented. This information provides the bases for the analytical work of the gearbox reliability collaborative effort.

17 WIND ENERGY↗
DOE OSTI2020

LBNF CMGC Delivery Method: ICE Process

The Construction Manager/General Contractor (CM/GC) delivery method is intended to benefit the design process, value engineering, risk mitigation, and schedule optimization while promoting construction and design innovation. This delivery method is particularly suited for complex projects that require significant consideration of contractor means and methods. Fermilab’s Far Site Conventional Facilities proceeded with a CM/GC delivery method to account for the unique conditions of excavating over 300,000 cubic yards of rock in tunnels and caverns that will be constructed approximately 5000-ft deep in the repurposed Homestake Mine in Lead, SD. The experiences of the Independent Cost Estimating (ICE) process are presented.

Pelletier, Douglas↗