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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

V31 Test Report

The V31 containment vessel was procured by the US Army Recovered Chemical Material Directorate (RCMD) as a third - generation EDS containment vessel. It is the fifth EDS vessel to be fabricated under Code Case 2564 of the 2019 ASME Boiler and Pressure Vessel Code, which provides rules for the design of impulsively loaded vessels. The explosive rating for the vessel, based on the code case, is twenty-four (24) pounds TNT - equivalent for up to 1092 detonations. This report documents the results of explosive tests that were performed on the vessel at Sandia National Laboratories in Albuquerque, New Mexico to qualify the vessel for field operations use. There were three design basis configurations for qualification testing. Qualification test (1) consisted of a simulated M55 rocket motor and warhead assembly of 24lbs of Composition C-4 (30 lb TNT equivalent). This test was considered the maximum load case, based on modeling and simulation methods performed by Sandia prior to the vessel design phase. Qualification test (2) consisted of a regular, right circular cylinder, unitary charge, located central to the vessel interior of 19.2 lb of Composition C-4 (24 lb TNT equivalent). Qualification test (3) consisted of a 12-pack of regular, right circular cylinders of 2 lb each, distributed evenly inside the vessel (totaling 19.2 lb of C-4, or 24 lb TNT equivalent). All vessel acceptance criteria were met.

42 ENGINEERING↗
DOE OSTI2023

V31 Test Report

The V31 containment vessel was procured by the US Army Recovered Chemical Materiel Directorate (RCMD) as a third-generation EDS containment vessel. It is the fifth EDS vessel to be fabricated under Code Case 2564 of the 2019 ASME Boiler and Pressure Vessel Code, which provides rules for the design of impulsively loaded vessels. The explosive rating for the vessel, based on the code case, is twenty-four (24) pounds TNT-equivalent for up to 1092 detonations. This report documents the results of explosive tests that were performed on the vessel at Sandia National Laboratories in Albuquerque, New Mexico to qualify the vessel for field operations use. There were three design basis configurations for qualification testing. Qualification test (1) consisted of a simulated M55 rocket motor and warhead assembly of 24lbs of Composition C-4 (30 lb TNT equivalent). This test was considered the maximum load case, based on modeling and simulation methods performed by Sandia prior to the vessel design phase. Qualification test (2) consisted of a regular, right circular cylinder, unitary charge, located central to the vessel interior of 19.2 lb of Composition C-4 (24 lb TNT equivalent). Qualification test (3) consisted of a 12-pack of regular, right circular cylinders of 2 lb each, distributed evenly inside the vessel (totaling 19.2 lb of C-4, or 24 lb TNT equivalent). All vessel acceptance criteria were met .

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

OpenFacadeControl: enabling integration of automated facades with other building systems

Automated facades are, for the most part, still considered as separate from other building systems throughout the design, installation, commissioning, operation, and maintenance cycle. This takes place despite the fact that their energy and comfort performance are deeply interlinked with the operation of lighting and HVAC systems. Over the last two decades, research has shown that there are significant advantages from operating facades as an integrated system with the rest of the building. Nevertheless, significant barriers prevent this type of integration becoming more common. One of them is the lack of a platform that is inexpensive to implement and that easily allows the practical implementation of integrated control algorithms across fenestration and other building systems, using a variety of communications protocols. This is particularly challenging when automated facades are installed in existing buildings, where interaction with legacy building systems that were installed over the past lifetime of the building can require a high degree of interoperability. OpenFacadeControl (OFC) is an open-source controls framework aimed at unified control of facades and other building systems, including the sharing of third-party sensor information. Through leveraging the Volttron controls platform, it allows the integration of systems and sensors that are manufactured by different companies and that use different communications protocols into an ensemble that functions as a single system. OFC is designed to enable integrated control algorithms of varying degrees of complexity, ranging from simple, heuristic controls to more sophisticated approaches like model-predictive control. Use of a research version to test advanced lighting and shading strategies in a full-scale experimental testbed has demonstrated the ease of deploying advanced control solutions using OpenFacadeControl. This paper presents the structure of OpenFacadeControl and a demonstration case showing the use of OFC in laboratory tests of advanced lighting and fenestration controls that coordinated motorized shades communicating via the BACnet building communications standard and lights communicating via internet-protocol-based application programming interface (API), based on the readings of a shared light level sensor communicating via a different API.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Why Wideband Gap Needs Techno-Economics

The wideband gap community when discussing projects antidotally refers to the cost of the technology, frequently noting the higher wideband gap upfront cost in comparison to the incumbent state of art. Other technologies such as photovoltaics have embraced techno-economics analysis (TEA) as a method of analytically articulating the impacts of research advancements on system performance and lifetime costs. Our TEA shows the potential impact of research advancements on Gallium Oxide (Ga2O3) and Silicon Carbide (SiC) wafer manufacturing cost, the impact on the levelized cost of electricity (LCOE) when using a SiC based solar inverter, and lastly how the high cost of devices (SiC in this case) can be offset by other system cuts, such as the footprint and cooling reductions in a 1MW variable frequency motor drive. The specific goal is to show analytically the lifetime cost and performance benefits of adopting wideband gap technology whether it is at the device level or it is cumulative benefit though a simplified balance of system.

14 SOLAR ENERGY↗
DOE OSTI2022

WBG-Enabled Current-Source Inverters for Integrated PM Motor Drives

This project takes advantage of the special capabilities of wide-bandgap (WBG) power semiconductor devices to develop innovative power electronics in the form of new current-source inverters (CSIs) that offer promising advantages over the dominant voltage-source inverter (VSI) topology. These CSIs, in turn, are extremely well-suited for integration into the housings of permanent magnet synchronous machines (PMSMs) to form integrated motor drives (IMDs). These new IMDs offer great promise for achieving major energy savings in a wide variety of applications that benefit from adjustable-speed control, including air conditioners, laundry appliances, industrial pumps/compressors, electric vehicles, and aerospace drives. WBG devices play a critical enabling role in these new IMDs because of their transformative features including much higher switching frequencies, lower losses, and compatibility with high operating temperatures. When incorporated into new CSI-based IMDs with PM machines, these WBG switches open the door to achieving major increases in power density, drive system efficiency, and fault tolerance, as well as substantial reductions in electromagnetic interference (EMI), manufacturing cost, and temperature-induced failures. The higher operating temperature capability of WBG devices compared to conventional silicon power devices is very appealing in IMD applications because the power electronics is mounted in close proximity to the motors which typically operate at temperatures well above the maximum limits of today’s silicon-based power electronics. This project has succeeded in designing, building, and testing multiple prototype versions of this CSI-IMD that have overcome many technical challenges in order to demonstrate the impressive performance improvements that can be achieved by the WBG-enabled CSI-IMD. The preliminary demo and bench-top versions of the current-source inverter developed during the first two years of the project were critical to laying the technical foundations for the 3 kW prototype CSI-IMD unit that was successfully built and tested during the third year. This prototype CSI-IMD unit was designed to fit within the housing envelope of the original permanent magnet (PM) synchronous machine in order to meet the demanding power density requirements that were set at the beginning of the project. All of the remaining performance objectives set for the prototype CSI-IMD unit including efficiency and electromagnetic interference (EMI) were also met. The last 18 months of the project were devoted to developing further enhancements of the WBG-enabled CSI-IMD technology that better prepare it for commercial production. More specifically, an upgraded version of the prototype CSI-IMD unit was developed that moved the power electronics into the same machine housing chamber as the motor, substantially raising the thermal demands on the power electronics. Tests with five different combinations of motor enclosure types and air cooling configurations were evaluated. Importantly, this work confirmed that the power electronics can deliver its full rated power and still operate well within its maximum temperature limits even for worst-case conditions when the housing is “totally-enclosed” without any openings for air to enter or exit the enclosure, and no blower/fan is provided to blow air over the outside surface of the enclosure. Reaching the full performance and energy-savings potential of this disruptive CSI-IMD motor drive technology is highly consistent with ARPA-E’s stated mission to “enhance the economic and energy security of the United States” while also supporting its commitment to “ensure that the U.S. maintains a technological lead in developing and deploying advanced energy technologies”. Follow-on projects are under way to explore the scalability of WBG-enabled CSI-IMD technology to 100 kW (peak) electric vehicle traction drives and fault-tolerant modular motor drives for future electrified aircraft propulsion applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Performance Evaluation of Three RTU Energy Efficiency Technologies

This project was part of an effort by CLEAResult and ComEd to evaluate the energy saving potential of emerging technologies in the Chicago area. This project focused on evaluating emerging technologies related to rooftop units (RTUs). An RTU with a single-stage compressor and a constant-speed fan with an induction motor was selected as the baseline for technology comparison. Three retrofit strategies were investigated. The first two involved replacing the single-stage compressor of an RTU by either a two-stage or variable-speed compressor and adding a variable frequency drive (VFD) to the constant speed fan. The use of a multi-/variable-stage compressor improves the part-load efficiency of the compressor which will ultimately result in annual energy savings as well as peak demand shaving in some cases where the design capacity of the RTU is larger than the maximum cooling load of the building space that it is serving. The third technology was the use of a high rotor pole switched reluctance motor (SRM) as a replacement for the constant-speed supply fan. The SRM was applied in single-speed, two-stage and variable-speed compressor RTUs. SRM motors run via reluctance torque. Their stator poles are driven by direct current (DC) power and require an inverter as well as active control when using alternating current (AC) power. This inherent property results in high efficiency over a range of operating conditions. It also exhibits higher efficiency compared to variable frequency drives (VFDs) since its switching frequency is much slower (SCE, 2018).The three technologies investigated are summarized below: 1) Replacing the single-speed compressor with a two-stage compressor and adding a VFD to the supply fan. 2)Replacing the single-speed compressor with a variable-speed compressor and adding a VFD to the supply fan. 3) Replacing the constant-speed induction motor of the supply fan with a high rotor pole SRM. DOE’s building simulation platform EnergyPlus and its graphical user interface OpenStudio were used to evaluate the energy-saving potential of upgrading RTUs, by leveraging experimental data from previous research.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Thermal and electric multidomain dynamic model for integration of power grid distribution with behind-the-meter devices

As renewable energy sources like solar and wind power become more integrated into the grid, coordinated control of behind-the-meter devices is crucial for enhancing grid flexibility and reliability and for meeting cost targets, with standardized models being developed to support this transition. The increasing flexibility and uncertainty of integrated renewable energy grids, along with interactions between various subsystems, make traditional steady-state modeling insufficient to capture transient and dynamic behaviors. Current models (e.g., composite load and battery equivalent models) focus on thermodynamic or electrical characteristics but overlook critical electromechanical interactions. This limits the ability to share performance information for grid services and hampers fast dynamic simulations. In addition, motor stalling is usually triggered by a fault event and attributed to the characteristics of the mechanical torque of the motor, resulting in absorption of a large amount of reactive power during the stalling period. Further, this significant withdrawal of reactive power will deteriorate the dynamic voltage stability of power grids and cause delayed voltage recovery. Therefore, an in-depth modeling of the thermodynamics or mechanical torque is essential to study the impacts of the realistic torque characteristics of those behind-the-meter devices on power system voltage stability. This study developed a dynamic multidomain model for building HVAC systems, such as air-source heat pumps, to simulate their thermal and electrical responses to grid transients. The model can accurately predict power metrics with a mean absolute percentage error of 10%, by validating against with power system computer-aided design performance data. Case studies demonstrate the model capability of capturing the transient response to sudden voltage changes, rapid load fluctuations, and system shutdowns respectively. During a sudden voltage drop (30% for 0.1s), a fully loaded heat pump’s motor speed dropped, continued declining, and shut down after 3.6s, with severe power oscillations and a torque spike. A partially loaded unit experienced temporary oscillations but stabilized. Under higher building loads, compressor speed increased from 64% to 100%, with power and torque rising before stabilizing. In safety-triggered shutdowns, power decreased after minor fluctuations, and torque briefly spiked before dropping to zero.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

Additive Manufacturing Case Study Test Report

Sandia National Labs collaborated with Oak Ridge National Laboratory on a case study examining additive manufacturing opportunities for Geothermal applications. The study focused on designing components with improved performance characteristics that cannot be fabricated conventionally. A rotor for a downhole motor was chosen based on the potential for improving its rotational dynamics. Topology optimization was used as a design method to reduce the rotational inertia of the part while preserving sufficient rotational stiffness to transmit the torque required for the drilling application. The optimization resulted in a nearly 50% reduction in polar moment of inertia while maintaining other desired performance characteristics. The design developed using the topology optimization approach was fabricated using additive manufacturing and cannot be fabricated conventionally.

15 GEOTHERMAL ENERGY↗
DOE OSTI2021

Additive Manufacturing Case Study

Geothermal technologies include an extremely wide range of products required for well construction, completion, production, intervention and surface energy conversion activities. Many of these products are geometrically complex, require multi-step and highly specialized fabrication processes, and are expensive due to the low production numbers typically associated with the geothermal market. These challenges along with the high temperature demands of the geothermal environment have also hindered the adoption of many tools routinely used in the oil & gas industry.Recent advancements in Additive Manufacturing (AM) materials of construction, build volumes and part quality have transitioned the technology from primarily cosmetic prototyping applications to the point where AM can be used to make production parts, even for the most demanding applications. These improved AM capabilities along with the inherent ability of AM to produce complex parts and, in some cases, geometries that cannot be manufactured using conventional casting, machining and joining fabrication approaches motivate an exploration of its potential to positively impact geothermal well construction and operations technologies.Sandia National Labs collaborated with Oak Ridge National Laboratory on a case study examining additive manufacturing opportunities for Geothermal applications. The study focused on designing components with improved performance characteristics that cannot be fabricated conventionally. A rotor for a downhole motor was chosen based on the potential for improving its rotational dynamics. Topology optimization was used as a design method to reduce the rotational inertia of the part while preserving sufficient rotational stiffness to transmit the torque required for the drilling application. The optimization resulted in a nearly 50% reduction in polar moment of inertia while maintaining other desired performance characteristics. The design developed using the topology optimization approach was fabricated using additive manufacturing and cannot be fabricated conventionally. This paper will discuss the design approach, performance improvements and manufacturing methods used to produce the part.

Polsky, Yarom↗
DOE OSTI2026

New principles of self‐organization created through the interplay of DNA condensates, microtubules, and motors

Bioinspired design—which holds great promise for a new generation of materials that are robust to defects, scalable under green manufacture, environmentally responsive, and programmably reconfigurable—requires mastery over molecular self-organization. Yet, from its specific mechanisms to most general architectures, the principles governing self-organization remain poorly understood and not even fully enumerated. For living systems, one obvious architectural principle is the modular reuse of a few simple molecular components in myriad combinations to achieve more complex phenomena. For example, the mechanical tasks of a cell are driven by the nonequilibrium dynamics of cytoskeletal filaments and molecular motors—the same filaments and motors, reprogrammed by a variety of modulators, perform tasks ranging from cell movement to division. Similarly, many compartmentalization tasks are performed by liquid-like condensates of simple components, which act as membraneless organelles to localize particular molecules in space and time (e.g. for gene regulation or RNA processing). In a few cases, condensates combine and interact with the cytoskeleton to create still more complex phenomena, e.g. the nucleation of microtubule asters from the centrosome (a protein condensate) to form the mitotic spindle during cell division. Very little is known about the fundamental mechanisms of such filament-plus-condensate phenomena. Despite few examples, the landscape of behaviors that can be achieved through the combination of condensates, filaments, and motors appears vast. However, exploration has been hindered by a lack of systems that have sufficiently programmable and dynamically tunable interactions between component condensates, filaments, and motors. We proposed to combine programmable DNA condensates, filamentous microtubules, and light-controlled motors into self-organizing systems whose principles go beyond those that have been observed in nature. In one limit, our systems will use microtubules and motors to create the molecular analog of a network of roads, which will organize droplets of DNA condensates capable of carrying molecular cargo. DNA condensates coupled to motors will flow from one microtubule aster hub to another, with their direction and timing controlled by DNA circuits. In another limit, microtubules will swim through bulk DNA condensates and exhibit strong interactions with boundaries between different types of condensates. Microtubule swimmers will reflect, get trapped, or refract at boundaries, under a mechanical analog of the classical optical index of refraction. DNA condensates having different mechanical indexes of refraction will be used to construct the analog of optical lenses, so that microtubule swimmers can be manipulated like light—collimated, diffracted, focused, and sorted based on properties analogous to wavelength. These two limits define two new architectures, within which multiple new mechanistic principles for self-organization will be discovered and explored. To explore these architectures, the motor-based coupling between DNA condensates and filaments will be controlled in time and space through the use of opto-proteins that create reversible links between DNA condensates and motors upon illumination. For each principle of interest, patterns of light will create virtual experiments by defining patterns of activity where DNA condensates walk along filaments, or filaments swim through condensates, and patterns of inactivity which will serve either as controls, or as boundary conditions vital to create the desired phenomena. This research serves the goals of Basic Energy Sciences Biomolecular Material Program by elucidating the principles by which the emergent, nonequilibrium behavior of collections of DNA condensates, motors, and microtubules can be programmed by environmental light patterns to create complex motion and materials transport. Because DNA condensates can be readily coupled to virtually any high performance nanomaterial, from carbon nanotubes, to metal nanoparticles, to light harvesting systems, this work provides a path to the construction, self-maintenance and reconfiguration of materials relevant to the Department of Energy.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2024

A cell type-aware framework for nominating non-coding variants in Mendelian regulatory disorders

Abstract Unsolved Mendelian cases often lack obvious pathogenic coding variants, suggesting potential non-coding etiologies. Here, we present a single cell multi-omic framework integrating embryonic mouse chromatin accessibility, histone modification, and gene expression assays to discover cranial motor neuron (cMN)cis-regulatory elements and subsequently nominate candidate non-coding variants in the congenital cranial dysinnervation disorders (CCDDs), a set of Mendelian disorders altering cMN development. We generate single cell epigenomic profiles for ~86,000 cMNs and related cell types, identifying ~250,000 accessible regulatory elements with cognate gene predictions for ~145,000 putative enhancers. We evaluate enhancer activity for 59 elements using an in vivo transgenic assay and validate 44 (75%), demonstrating that single cell accessibility can be a strong predictor of enhancer activity. Applying our cMN atlas to 899 whole genome sequences from 270 genetically unsolved CCDD pedigrees, we achieve significant reduction in our variant search space and nominate candidate variants predicted to regulate known CCDD disease genesMAFB, PHOX2A, CHN1, andEBF3– as well as candidates in recurrently mutated enhancers through peak- and gene-centric allelic aggregation. This work delivers non-coding variant discoveries of relevance to CCDDs and a generalizable framework for nominating non-coding variants of potentially high functional impact in other Mendelian disorders.

Science & Technology - Other Topics↗
DOE OSTI2022

MAGNETICALLY SUSPENDED CANNED ROTOR PUMPS FOR THE INTEGRAL MOLTEN SALT REACTOR

This project developed a molten salt pump design for small modular reactors, concentrated solar, and Gen IV nuclear reactors with a magnetically levitated rotor that can operate at temperatures of up to 700 °C. This eliminates the need for rotating seals and roller element bearings which require maintenance and are prone to failure. The pump design is also more compact than existing molten salt pump designs which require long shafts to thermally isolate the electric motor. The aims of the project are to: 1) design and test the molten salt pump, 2) develop and test a high temperature position sensor needed for magnetic bearing control, and 3) develop and test high temperature coil fabrication methods for electric motor and magnetic bearing fabrication. To develop the high temperature coils, conductor materials were analyzed for oxidation, diffusion, cladding, and resistivity. Of the candidate conductor materials that met the requirements, silver was chosen. The long-term impact of radiation on silver resistivity was analyzed by developing a model of a generic molten salt fast reactor to model the conductor irradiation in worst case scenarios. The analysis showed that increased resistivity due to transmutation of silver decreases exponentially with the reactor reflector thickness. Different electrical insulation materials were tested and the final high temperature coils developed were able to withstand conductor to ground voltages up to 1800 V before insulation breakdown. Magnetic bearings require high-precision high-speed measurements of the rotor position to operate. Current commercial position sensors can only operate up to 550 °C so a novel position sensor was developed that can operate up to 800 °C. These sensors were also designed to measure the position of the metallic rotor through a thin metallic corrosion barrier that protects that coils, insulation, and magnetic cores so that the salt containment barrier does not have any penetrations. The high-temperature sensor was tested and had comparable performance to commercially available inductive position sensors. The sensor design and signal processing has led to several invention disclosures. The magnetically levitated molten salt pump design was completed and analyzed. The chloride salt test loop at Oak Ridge National Laboratory was chosen to test the pump and the pump hydraulics and power were designed for the test loop flow and pressure requirements. Classes of motor designs that do not utilize permanent magnetic were considered for the high-temperature motor. After extensive analysis of their performance, a synchronous reluctance motor was chosen for the pump. The design was refined and analyzed to optimize performance. The magnetic bearings were designed to meet the force and frequency requirements necessary to levitate the rotor and reject disturbances from rotor imbalance, motor forces, and hydraulic forces. Compliant mounts for the position sensors were designed that would not damage the ceramic sensor components and maintain sensor alignment over a wide temperature range. A thermal hydraulic analysis of the molten salt coolant flow used to cool the rotor and stator was performed to ensure that the maximum temperature in the rotor and stator will not exceed 725 °C. The corrosion barrier and casing were designed to maintain the salt fluid boundary by using compliant features to absorb large expansion mismatches due to different coefficients of thermal expansion (CTE). Finally, the salt drain and fill systems were designed along with the pump support structure, integration with the test loop, and thermal insulation and heating. Corrosion barrier fabrication experiments were performed to assess using laser cladding to apply a sub-millimeter corrosion barrier to the surface of a Fe-Co-V magnetic core material. The cladding method showed minimal mixing between materials at their interface and withstood temperature cycling without damage to the cladding. The technology commercialization is focused on the high-temperature position sensors and there has been significant interest from the nuclear industry in utilizing these sensors along with some interest from the aerospace industry. The project also led to a research collaboration with a fusion energy industrial partner to study barriers to scaling the pump design from the kW size to the MW size. This research collaboration will also study methods to create high-temperature coils that have conductor to ground breakdown voltages above 5 kV. The successful development of high-temperature electromagnetic coils and high-temperature position sensors greatly increases the temperature limits for electromagnetic devices that don’t rely on permanent magnets. This includes electric motors, magnetic bearings, linear actuators, rotary position and velocity sensing, actuated valves, and generators to name a few. This will fill a current need in molten salt reactors, concentrated solar, and fusion energy for these critical peripheral devices needed for practical reactor designs that do not currently have commercial solutions.

Hines, J Wesley↗
DOE OSTI2025

Evaluating Chemical Kinetics Predictions for Propane Using 3-D and 0-D Models in a Boosted Spark-Ignited Engine

Propane has been shown to be a promising alternative fuel to reduce emissions while simultaneously achieving high efficiencies in medium- and heavy-duty engines. These high-power density applications require boosted engines which, combined with high compression ratio, can lead to auto-ignition and knock. While three-dimensional (3-D) computational fluid dynamics (CFD) models are often used for resolving the complex fluid flow in engines, these models can become computationally expensive when simulating detailed chemical kinetics. Likewise, zero-dimensional (0-D) models are computationally concise enough for kinetics development, but lack any flow-field information which governs the flame propagation processes in spark ignition (SI) engines. This work presents a comprehensive comparison between 3-D and 0-D closed cycle simulations at knocking conditions in a high compression ratio high stroke-to-bore ratio propane engine. In order to initialize the flow-field for the 3-D closed cycle (intake valve closing, (IVC) to exhaust valve opening, (EVO)) simulation, a motored multi-cycle 3-D model was run using Converge to create a map at IVC, reducing the computational time. The map allowed a non-homogeneous 3-D closed cycle simulation to be satisfactorily validated against experiments, while a homogeneous case using only the turbulence field mapping was also simulated, mimicking 0-D modeling. The 3-D simulations were used to prescribe the initial conditions (e.g., IVC thermodynamics, speciation, burn-rate profile) for a 2-zone 0-D SI engine model in Chemkin Pro for both cases. It was found that 2-zone 0-D modeling underpredicted the knock onset timing, likely due to the lack of thermal stratification in the unburned gas region. Future work will carry multi-zone 0-D modeling to capture the fuel auto-ignition in the unburned region.

Douvry-Rabjeau, Julien [Oakland University, Roches↗
DOE OSTI2022

Production of Fischer-Tropsch Synfuels at Nuclear Plants

A case study analysis was performed to evaluate nuclear-powered synthetic fuel production in the midwestern United States (U.S.). A Fischer-Tropsch (FT) fuel synthesis plant design was used as the basis for the analysis. The FT plant design was configured to produce a product slate consisting of diesel fuel, jet fuel, and motor gasoline blend stocks from carbon dioxide (CO 2 ) and hydrogen (H 2 ) feedstocks. The CO 2 feedstock for the FT plant was assumed to be sourced from biorefineries in the region around a Midwest light water reactor (LWR) nuclear power plant (NPP). The analysis specifies that power from the LWR is used to produce H 2 via high-temperature steam electrolysis and to operate the FT synfuel production plant. Capital costs were estimated for the FT plant while capital costs for the electrolysis plant were based on previous Idaho National Laboratory (INL) studies. In addition to labor and maintenance costs for the FT and electrolysis plants, operating costs also include the costs for CO 2 feedstock transport. An analysis was performed to determine the cost of transporting CO 2 from the distributed biorefinery sources to the centralized fuel synthesis plant as a function of the synfuel plant capacity and corresponding CO 2 demand. The primary revenue streams are associated with sales of the synthetic fuel products. The synthetic fuel products will likely follow the same market trends as the conventional fuel products. The synfuel price data was thus based on projections made by the U.S. Energy Information Administration (EIA) 2021 Annual Energy Outlook (AEO) for conventional fuel products minus federal and state taxes, as well as marketing and distribution costs. The economic analysis also considered cases that included and excluded revenues from the 2022 Inflation Reduction Act (IRA) clean hydrogen production tax credit (PTC) of $\$ $3.00/kg for the first ten years of operation. The economic analysis calculated the net present value (NPV) for cases involving steady-state synfuel production for comparison with the NPV for a business-as-usual case in which NPP continues to sell only electric power to the grid. A synfuel production “Reference Case” was considered in addition to sensitivity cases in which the plant capacity, electricity price, and synthetic fuel product prices were perturbed. The synfuel production Reference Case considered a scenario in which the electrolysis and synfuel plants utilized a combined electrical load of 1000 megawatt electrical (MWe) from the LWR with the balance of the LWR power output being sold to the electric grid. The economic analysis suggests that the synfuel production Reference Case evaluated in this analysis would lead to considerable economic potential for near-term deployment of a nuclear-based synfuel production plant. Specifically, the economic analysis suggests that the deployment of a 1000 megawatt (MW) nuclear-powered synfuel plant could result in a NPV increase of approximately $\$ $1.7 billion for a case with no clean synfuel price premium relative to conventional petroleum fuels when accounting for the additional revenues from the 2022 IRA clean hydrogen PTCs of $\$ $3/kg. Sensitivity analysis was performed to evaluate the effect of perturbation of selected model input parameters on the NPV for the synfuel production Reference Case. The sensitivity analysis indicates that the plant capacity has the largest impact on the differential NPV, with a smaller synfuel production capacity resulting in a decrease in revenue when a larger fraction of the power from the NPP is sold to the grid and a smaller fraction of the power is used to produce synthetic fuel products. The synfuel product pricing has the next largest impact on the differential NPV, with lower synfuel prices resulting in decreased NPV from decreased synfuel sales revenue while higher synfuel prices result in increased NPV from increased synfuel sales revenue. Electricity pricing has a smaller effect on the NPV than the fuel sales price since, in the Reference Case, most of the energy from the NPP is used for synfuel production and a smaller amount of the system revenues are associated with electrical power sales. However, the electricity price sensitivity does indicate that the Synfuel Integrated Energy System (IES) would have a greater NPV than the business-as-usual case (e.g., grid power sales only) when electricity market prices are low, suggesting that synfuel production could provide a strategy for decreasing the economic risks to NPPs posed by a loss of revenues attributed to falling electricity market prices.

10 SYNTHETIC FUELS↗
DOE OSTI2023

Virtual Design and Analysis of the Balancing Element of an External Gear Machine Considering Cavitation and Mixed Lubrication Effects

This report presents a simulation based approach for sizing the axial balance elements of a pressure compensated external gear machine. The reference hydraulic unit must be able to guarantee operation in two quadrants, as either a pump or a motor. It also needs to operate in a wide operating range of speed and pressure, as it is to be used as primary hydraulic unit for an electro-hydraulic actuator (EHA). The design procedure builds upon past work at the author’s center, but it extends it to the case of multiple quadrant units. Also, a unique method for modeling of both mixed lubrication and cavitation that might occur in the lubricating film is used. After describing the design procedure, the paper discusses the features of the balancing of a reference unit, along with the effects of both cavitation and mixed lubrication.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

The BiDFET Device and Its Impact on Converters

The matrix converter topology for direct ac-to-ac conversion offers elimination of the bulky and unreliable D.C. link capacitors used in the popular Voltage-Source Inverter (VSI) with a front-end rectifier. The resulting more compact and higher efficiency implementation is a desirable solution for a wide variety of applications, such as photovoltaic energy generation, motor drives, and energy storage systems. The development of matrix converters has been hampered by the lack of availability of commercial bidirectional power switches with the ability to block high voltages in the first and third quadrants, carry on state current in both quadrants with low voltage drop, exhibit large forward-biased safe-operating-area (FBSOA), and low switching power losses. Consequently, many implementations have been tried in the past using discrete devices, as listed in Table I. Two implementations utilize commonly available asymmetric blocking IGBTs, while two cases make use of SiC power MOSFETs. They generally have a large parts count (4-6 individual switches) that occupies significant space in the converter where multiple bi-directional switches are required. They also have a high on-state voltage drop that degrades efficiency. As a result, one implementation utilizes symmetric blocking IGBT to achieve a low parts count (2), but its switching losses are unacceptably high.

42 ENGINEERING↗
DOE OSTI2021

Powering the Blue Economy: A Survey of Station-Keeping Methods for Mooringless Platforms

The term “ocean platform” is used to reference everything from stationary, typically moored, buoys to mobile water vehicles, whether they operate on the ocean’s surface or underwater. For certain applications for which relatively stationary station-keeping conditions are desired, the use of mooring systems is not always a viable alternative either for economic, environmental, regulatory, or otherwise practical reasons, or a combination thereof, (e.g., short deployments, sensitive ecosystems, very deep project sites). Maintaining a platform at a single waypoint or reference location without being moored would require additional control systems and a power source to counteract the drift forces that would naturally displace it. Mobile platforms, which are usually untethered except for remotely operated vehicles, typically require energy input to power their station-keeping capabilities so that they hold or control their location in the ocean. Currently, most of these platforms use combustion engines or batteries for this purpose, which, depending on the specific systems, may be costly, pollute the environment, or create limitations on the length of the deployment. However, powering this kind of platforms with surrounding renewable resources (waves, currents, winds, or sun) has been identified as a promising solution to expand their application. The intent of this report is to investigate station-keeping methods for various ocean platforms that are not moored or otherwise anchored to the ocean floor, or another platform or vessel, paying particular interest to technologies that use marine renewable resources to power their operation, because that is of particular interest to the U.S. Department of Energy’s Powering the Blue Economy (PBE) initiative. As a first step, 72 articles and technical reports related to mooringless station-keeping methods were collected for review. The preliminary literature review provided a broad overview of common themes across the literature from which a descriptive methodology for analyzing various platforms was developed. That is, station-keeping methods were categorized based on their predominant energy source and consumption (renewable, nonrenewable, or hybrid if the platform uses renewable and nonrenewable resources equally), and their localization strategy (drift reduction, “path-planning or “waypoint-holding”). In addition, platform types were segregated into the following groups: buoys, surface drifters, and unoccupied surface vehicles (USVs); offshore renewable energy systems; and unoccupied underwater vehicles (UUVs). The main types of station-keeping methods encountered in this report achieve their intended localization strategy by means of drift mitigation, steering, and/or propulsion. Drift mitigation is commonly accomplished via drogues and sea anchors. Stand-along steering subsystems use control surfaces (e.g., ship rudder, wing sail, etc.) that react to ocean currents, waves, or winds to provide varying-degrees of course adjustments. Combined steering and propulsion subsystems include differential thrusters, directional thrusters separate from a primary thruster that cause the platform to pitch up/down or yaw clockwise/counterclockwise, or vectored thrusters that direct the propulsion in a range of directions relative to the platform’s local coordinate system. Propulsion is often achieved by running a motor and applying active control strategies but can also involve buoyancy shifts and using sails to generate lifting forces that propel a platform in a desired direction. Future research is primarily expected to take place in the form of a technoeconomic analysis that would aim to determine the technological viability, cost, and added value of mooringless station-keeping use cases identified through this research, including docking for UUV recharging or for georeferencing drifter buoys, deep-sea floating wind farms, U.S. Navy sonar arrays, and a Pacific Ocean wave buoy network.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Identification of Promising Alternative Mono-Alcohol Fuel Blend Components for Spark Ignition Engines

Alcohols are attractive fuel blendstocks for spark ignition engines due to their high octane values and potentially positive influence on performance and emission. Although methanol, ethanol, and butanol have been widely studied, other biomass-derived alcohols may have similar or better properties. However, it is not feasible to experimentally investigate the fuel potential of every molecule. The goals of this study were to develop a methodology for rapid screening of a fuel property database for mono-alcohols and to identify alcohols with the potential of blending to produce advantaged motor gasolines. A database was developed with 13 fuel properties of all saturated C1–C10 mono-alcohols. A decision framework was used to evaluate alcohols suitable for blending in gasoline for spark ignition engines in two scenarios: low-range (up to 15 vol%) blends and high-range (greater than 40 vol%) blends. The low-range blend cases resulted in the identification of 48 alcohols. In the case of high-range blending, only six alcohols were found to be suitable. This is the first study to systematically evaluate all C1–C10 saturated alcohols for blending with gasoline using relevant fuel properties. A novel aspect of this study is the evaluation of the influence of errors in predicted property values. These scenario screenings focus attention on a smaller number of promising candidate molecules, and the approach could be modified for other classes of fuel molecules, engine types, and fuel blending goals.

42 ENGINEERING↗