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DOE OSTI2020

Bench Scale Testing of Next Generation Hollow Fiber Membrane Modules

This project seeks to develop a next generation membrane material (PI-2) for application in Air Liquide’s (AL) hybrid process. Combining the cold membrane operation with an integrated CO 2 Compression and Purification Unit (CPU) significantly reduces the overall cost of CO 2 capture. The proposed work will accelerate the membrane bundle fabrication, scale-up and performance validation of this new material. The proposed novel membrane development, combined with the results of the previous Cold Membrane Project, will provide the best opportunity for AL to meet the long term development targets of the DOE with respect to timing, cost, and performance for CO 2 capture. Our previous field test program (DE-FE0013163) showed promising results for the hybrid process utilizing the existing commercial AL membrane bundles (PI-1 material). The project work has also shown the potential for significant improvements through initial laboratory tests with the novel material (PI-2). The initial PI-2 results show a step-change in membrane permeance. This will enable further reduction in the cost of CO 2 capture by reducing the number of membrane modules and associated equipment in the system. In order to capture this value, however, the new material needs to be validated by field testing of large bundles, representative of commercial production. Lastly, a comprehensive evaluation of novel hybrid processes and costs needs to be completed to ensure optimal use of this improved material performance. The current project seeks to develop this next generation membrane to TRL 5 (approximately 600 - 1,000 Nm3/h flue gas, 350 - 600 scfm, 0.2 - 0.3 MWe equivalent). Air Liquide manufacturing methodology will be applied to fabricate prototype (4”) membrane modules from PI-2 material. Once the manufacturing methods prove reliable with the new material, and performance is demonstrated in line with expectation, 6” commercial scale bundles will be fabricated. Recognizing that a low cost membrane solution by itself may not meet DOE’s LCOE target for CO 2 capture, we will also perform simulation studies of novel hybrid processes in combination with the next generation membrane technology. This approach has the best potential for exceeding the DOE targets. The best evaluation of the new commercial units will be performance testing under real flue gas at the NCCC. Finally, a rigorous TEA, which incorporates the novel process studies and field performance, will be completed.

36 MATERIALS SCIENCE↗

NASA NTRS2010

Glass Bubbles Insulation for Liquid Hydrogen Storage Tanks

A full-scale field application of glass bubbles insulation has been demonstrated in a 218,000 L liquid hydrogen storage tank. This work is the evolution of extensive materials testing, laboratory scale testing, and system studies leading to the use of glass bubbles insulation as a cost efficient and high performance alternative in cryogenic storage tanks of any size. The tank utilized is part of a rocket propulsion test complex at the NASA Stennis Space Center and is a 1960's vintage spherical double wall tank with an evacuated annulus. The original perlite that was removed from the annulus was in pristine condition and showed no signs of deterioration or compaction. Test results show a significant reduction in liquid hydrogen boiloff when compared to recent baseline data prior to removal of the perlite insulation. The data also validates the previous laboratory scale testing (1000 L) and full-scale numerical modeling (3,200,000 L) of boiloff in spherical cryogenic storage tanks. The performance of the tank will continue to be monitored during operation of the tank over the coming years.

Glass bubble↗

NASA NTRS1992

Status of the Validation of High-Angle-Of-Attack Nose-Down Pitch Control Margin Design Guidelines

This paper presents a summary of results obtained to date in an ongoing cooperative research program between NASA and the U.S. Navy to develop design criteria for high-angle-of-attack nose- down pitch control for combat aircraft. A fundamental design consideration for aircraft incorporating relaxed static stability in pitch is the level of stability which achieves a proper balance between high- speed performance considerations and low-speed requirements for maneuvering at high angles of attack. A comprehensive data base of piloted simulation results was generated for parametric variations of critical parameters affecting nose-down control capability. The results showed a strong correlation of pilot rating to the short-term pitch response for nose-down commands applied at high- angle-of-attack conditions. Using these data, candidate design guidelines and flight demonstration requirements were defined. Full- scale flight testing to validate the research methodology and proposed guidelines is in progress, some preliminary results of which are reviewed.

Ogburn, Marilyn E.↗

DOE OSTI2026

Dynamic analysis of fully constrained Cable-Driven Parallel Robots for automated prefabricated component installation

This paper presents a dynamic analysis and validation framework to assess a fully constrained six-anchor Cable-Driven Parallel Robot (CDPR) for automated installation of prefabricated facade components. Compared with conventional eight-anchor systems, the six-anchor configuration simplifies setup and reduces cost, but it also reduces control authority, shrinks the wrench-feasible workspace, and tightens orientation limits. Consequently, it is unclear a priori whether dynamically feasible trajectories exist to move the end effector from pickup to the facade. A constrained trajectory optimization is formulated to enforce the system dynamics, cable-tension bounds, and pose/velocity limits, and the framework is evaluated in simulation at three levels: (i) an idealized reference model, (ii) a lab-scale prototype model incorporating measured anchor misalignments and identified damping, and (iii) a full-scale three-story building model with load decomposition for structural feasibility checks. Across these scenarios, the analysis shows that optimal, constraint-satisfying trajectories exist that move the end effector from pickup to installation while maintaining a near-plumb, level orientation at the final pose. Collectively, this multi-scale dynamic analysis and validation framework supports the deployment readiness of the six-anchor CDPR and provides a prototype-based sensitivity case study of how measured anchor placement deviations affect feasibility.

CDPR↗

NASA NTRS2005

Scanning Backscatter Lidar Observations for Characterizing 4-D Cloud and Aerosol Fields to Improve Radiative Transfer Parameterizations

Clouds have a powerful influence on atmospheric radiative transfer and hence are crucial to understanding and interpreting the exchange of radiation between the Earth's surface, the atmosphere, and space. Because clouds are highly variable in space, time and physical makeup, it is important to be able to observe them in three dimensions (3-D) with sufficient resolution that the data can be used to generate and validate parameterizations of cloud fields at the resolution scale of global climate models (GCMs). Simulation of photon transport in three dimensionally inhomogeneous cloud fields show that spatial inhomogeneities tend to decrease cloud reflection and absorption and increase direct and diffuse transmission, Therefore it is an important task to characterize cloud spatial structures in three dimensions on the scale of GCM grid elements. In order to validate cloud parameterizations that represent the ensemble, or mean and variance of cloud properties within a GCM grid element, measurements of the parameters must be obtained on a much finer scale so that the statistics on those measurements are truly representative. High spatial sampling resolution is required, on the order of 1 km or less. Since the radiation fields respond almost instantaneously to changes in the cloud field, and clouds changes occur on scales of seconds and less when viewed on scales of approximately 100m, the temporal resolution of cloud properties should be measured and characterized on second time scales. GCM time steps are typically on the order of an hour, but in order to obtain sufficient statistical representations of cloud properties in the parameterizations that are used as model inputs, averaged values of cloud properties should be calculated on time scales on the order of 10-100 s. The Holographic Airborne Rotating Lidar Instrument Experiment (HARLIE) provides exceptional temporal (100 ms) and spatial (30 m) resolution measurements of aerosol and cloud backscatter in three dimensions. HARLIE was used in a ground-based configuration in several recent field campaigns. Principal data products include aerosol backscatter profiles, boundary layer heights, entrainment zone thickness, cloud fraction as a function of altitude and horizontal wind vector profiles based on correlating the motions of clouds and aerosol structures across portions of the scan. Comparisons will be made between various cloud detecting instruments to develop a baseline performance metric.

Schwemmer, Geary K.↗

NASA NTRS2007

Utility of AIRS Retrievals for Climate Studies

Satellites provide an ideal platform to study the Earth-atmosphere system on practically all spatial and temporal scales. Thus, one may expect that their rapidly growing datasets could provide crucial insights not only for short-term weather processes/predictions but into ongoing and future climate change processes as well. Though Earth-observing satellites have been around for decades, extracting climatically reliable information from their widely varying datasets faces rather formidable challenges. AIRS/AMSU is a state of the art infrared/microwave sounding system that was launched on the EOS Aqua platform on May 4, 2002, and has been providing operational quality measurements since September 2002. In addition to temperature and atmospheric constituent profiles, outgoing longwave radiation and basic cloud parameters are also derived from the AIRS/AMSU observations. However, so far the AIRS products have not been rigorously evaluated and/or validated on a large scale. Here we present preliminary assessments of monthly and 8-day mean AIRS "Version 4.0" retrieved products (available to the public through the DAAC at NASA/GSFC) to assess their utility for climate studies. First we present "consistency checks" by evaluating the time series of means, and "anomalies" (relative to the first 4 full years' worth of AIRS "climate statistics") of several climatically important retrieved parameters. Finally, we also present preliminary results regarding interrelationships of some of these geophysical variables, to assess to what extent they are consistent with the known physics of climate variability/change. In particular, we find at least one observed relationship which contradicts current general circulation climate (GCM) model results: the global water vapor climate feedback which is expected to be strongly positive is deduced to be slightly negative (shades of the "Lindzen effect"?). Though the current AIRS climatology covers only -4.5 years, it will hopefully extend much further into the future.

Molnar, Guyla I.↗

NASA NTRS2015

Technical Report Series on Global Modeling and Data Assimilation: Soil Moisture Active Passive (SMAP) Project Assessment Report for the Beta-Release L4_SM Data Product - Volume 40

ubRMSE↗

DOE OSTI2024

Development of Low-Cost, High-Performance, Easy-To-Apply, Non-Flammable, Inorganic Phase Change Material (PCM) Technology (Project Final Report)

This report describes a 45-months long research program focused on the development of novel, easy-to-apply, non-flammable, and high-performance inorganic phase change materials (PCMs) for building and industrial applications. The University of Massachusetts Lowell (UML) formed a world-class team consisting of researchers form InsolCorp (only N. American manufacturer of inorganic PCM systems for building applications), and a group of industrial advisors, to develop a universal/multipurpose, simple-to-manufacture and cost-effective PCM technology. The project team expects that the results of this work will spur in the future the adoption of thermal storage materials – a key building energy saving technology as identified by DOE BTO – for a variety of building envelope applications. The main goal of this project was to demonstrate a suite of low-cost, multipurpose, and durable inorganic PCM formulations with phase transition temperatures encompassing typical building applications (between +5 o C and +55 o C). The first objective was to design, fabricate, and experimentally validate a performance of inexpensive, durable, highly efficient, non-flammable, and easy to manufacture PCMs. To allow a variety of building applications, the project team focused on formulations that exhibit repeatable phase transitions between +5 o C and +55 o C. To follow the DOE BTO cost efficiency target without compromising thermal performance, our work was based on inorganic compounds (mostly salt hydrates) and their blends, which represent a fraction of the cost of most of organic PCMs with about twice as high density as well as significantly higher thermal conductivity and phase change enthalpy. The second objective was to develop easy-to-manufacture and -install packaging/encapsulation designs that are 1) a superior barrier to current state-of-the-art macro-packaging, which significantly reduces the risk of loss of hydration water and PCM leak, and 2) optimal in enhancing the heat exchange rates with the surroundings and within the PCM core to ensure complete charging/discharging of the entire PCM within the product. Finally, the project’s intend was to scale-up the fabrication process to demonstrate installation on system-scale applications, and to validate the performance under field conditions. This work aimed at developing low-cost, high-energy storage, and reliable latent heat storage technology for building applications. This development was realized by formulating and integrating the following two technology components: 1) inorganic salt hydrate based PCMs that have high latent enthalpies and are low-cost and durable, and 2) PCM encapsulation (packaging) technology that maximizes PCM concentration and enhances heat transport characteristics in the product and with the external environment/materials. High thermal storage capacity, low cost and fire resistance are key to the building market entry for PCM technology. Therefore, the project’s focus was on salt-hydrate-based formulations which satisfy all these criteria. Packaging and/or encapsulation of PCM is a key processing step. The project team recognized that a low-cost and simple-to-manufacture salt hydrate-based PCM technology holds the best chance to be successful in the building construction market, a market which is traditionally extremely sensitive to cost and where commodity thermal insulations are the benchmark for envelope-related energy saving measures. That is why, in this project, the main intention was to minimize the production cost and maximize the product energy storage density without sacrificing the PCM performance. It was achieved through: 1. Minimizing the non-PCM components (plastics, additives, packaging/encapsulation materials, etc.) because they are significantly more expensive than salt hydrates, 2. Using highly thermally conductive and lightweight PCM carrier (packaging material) to facilitate more complete phase cycling, and 3. Optimizing the thickness and minimizing air spaces in product design (such as in pouched PCM). For this purpose, our approach was to enable an easy system design, including selection of the PCM operating temperatures, optimizing the necessary heat storage capacity (by stacking together several layers of PCM products), and if needed, a synchronized usage of PCM products of different temperatures. A specially designed, robust, highly thermally conducting and highly impermeable packaging (to retain salt hydrate water during phase transition cycles) was designed and tested to increase the overall system thermal performance and durability. All PCM products developed during this project were tested in both lab scale and in full scale field conditions. It is expected that, after further developments and commercialization, the developed PCM technologies may be also applied in space conditioning, energy storage technologies, and heat transfer applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Hysteresis Patterns of Watershed Nitrogen Retention and Loss Over the Past 50 years in United States Hydrological Basins

Patterns of watershed nitrogen (N) retention and loss are shaped by how watershed biogeochemical processes retain, biogeochemically transform, and lose incoming atmospheric deposition of N. Loss patterns represented by concentration, discharge, and their associated stream exports are important indicators of integrated watershed N retention behaviors. We examined continental United States (CONUS) scale N deposition (e.g., wet and dry atmospheric deposition), vegetation trends, and stream trends as potential indicators of watershed N-saturation and retention conditions, and how watershed N retention and losses vary over space and time. By synthesizing changes and modalities in watershed nitrogen loss patterns based on stream data from 2200 U.S. watersheds over a 50 years record, our work revealed two patterns of watershed N-retention and loss. One was a hysteresis pattern that reflects the integrated influence of hydrology, atmospheric inputs, land-use, stream temperature, elevation, and vegetation. The other pattern was a one-way transition to a new state. We found that regions with increasing atmospheric deposition and increasing vegetation health/biomass patterns have the highest N-retention capacity, become increasingly N-saturated over time, and are associated with the strongest declines in stream N exports—a pattern, that is, consistent across all land cover categories. We provide a conceptual model, validated at an unprecedented scale across the CONUS that links instream nitrogen signals to upstream mechanistic landscape processes. Our work can aid in the future interpretation of in-stream concentrations of DOC and DIN as indicators of watershed N-retention status and integrators of watershed hydrobiogeochemical processes.

58 GEOSCIENCES↗

DOE OSTI2021

Towards testing the theory of gravity with DESI: summary statistics, model predictions and future simulation requirements

Shortly after its discovery, General Relativity (GR) was applied to predict the behavior of our Universe on the largest scales, and later became the foundation of modern cosmology. Its validity has been verified on a range of scales and environments from the Solar system to merging black holes. However, experimental confirmations of GR on cosmological scales have so far lacked the accuracy one would hope for — its applications on those scales being largely based on extrapolation and its validity there sometimes questioned in the shadow of the discovery of the unexpected cosmic acceleration. Future astronomical instruments surveying the distribution and evolution of galaxies over substantial portions of the observable Universe, such as the Dark Energy Spectroscopic Instrument (DESI), will be able to measure the fingerprints of gravity and their statistical power will allow strong constraints on alternatives to GR. In this paper, based on a set of N-body simulations and mock galaxy catalogs, we study the predictions of a number of traditional and novel summary statistics beyond linear redshift distortions in two well-studied modified gravity models — chameleon f(R) gravity and a braneworld model — and the potential of testing these deviations from GR using DESI. These summary statistics employ a wide array of statistical properties of the galaxy and the underlying dark matter field, including two-point and higher-order statistics, environmental dependence, redshift space distortions and weak lensing. We find that they hold promising power for testing GR to unprecedented precision. The major future challenge is to make realistic, simulation-based mock galaxy catalogs for both GR and alternative models to fully exploit the statistic power of the DESI survey (by matching the volumes and galaxy number densities of the mocks to those in the real survey) and to better understand the impact of key systematic effects. Using these, we identify future simulation and analysis needs for gravity tests using DESI.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2020

Performance and wake flow characterization of a 1:8.7-scale reference USDOE MHKF1 hydrokinetic turbine to establish a verification and validation test database

As hydrokinetic turbine technologies continue to advance towards commercialization, public datasets on the performance characteristics for these devices and their flow field effects are invaluable to advance our understanding of these technologies and to validate analytical and numerical models. The Applied Research Laboratory at The Pennsylvania State University (ARL Penn State) collaborated with Sandia National Laboratories and the University of California at Davis to design, fabricate (at a 1:8.7 scale), and experimentally test a novel hydrokinetic turbine rotor design to provide an open platform and dataset for further study and development. The water tunnel test of this three-bladed, horizontal-axis rotor recorded power production, blade loading, the near-wake flow, cavitation effects, and noise generation. These state-of-the-art measurements demonstrate much of the complex physics associated with the flow through an unducted, horizontal-axis turbine, and they elucidate the performance characteristics and flow field effects at an unprecedented fidelity, accuracy and resolution. Measurements of powering coefficients (power, torque and thrust) as a function of tip-speed-ratio were performed. The dataset also includes unsteady measurements of driveshaft loading, blade strain, tower pressures, and radiated noise. Detailed flow mapping using laser Doppler velocimetry, and planar and stereo particle image velocimetry includes measurements of mean velocity and Reynolds stresses. Although the wake measurements are limited to less than half a diameter, they reveal the complex flow patterns in the near-wake structure of the rotor. The full database, available at the United States Department of Energy’s marine and hydrokinetic data repository, includes tunnel and model Computer Aided Design geometry files and inflow data sufficient for a “Model-the-Test” computational Verification and Validation study.

13 HYDRO ENERGY↗

DOE OSTI2020

Lattice physics calculations using the embedded self-shielding method in polaris, Part II: Benchmark assessment

Polaris is a 2D multigroup lattice physics capability in the SCALE code system used for the analysis of light water reactor fuel designs. In this work, verification and validation results of Polaris in SCALE 6.2 are presented. The SCALE/KENO continuous-energy Monte Carlo code is used as a reference to compare the results of more than 2,000 combinations of pressurized water reactor and boiling water reactor lattice designs and state points. Radiochemical assay measurements were also used to assess the accuracy of depletion calculations. Results show that Polaris, with ENDF/B-VII.1 cross section library, produces accurate lattice physics data for core simulators.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

Improving deep learning performance for predicting large-scale geological ${{CO}_{2}}$ sequestration modeling through feature coarsening

Physics-based reservoir simulation for fluid flow in porous media is a numerical simulation method to predict the temporal-spatial patterns of state variables (e.g. pressure p) in porous media, and usually requires prohibitively high computational expense due to its non-linearity and the large number of degrees of freedom (DoF). This work describes a deep learning (DL) workflow to predict the pressure evolution as fluid flows in large-scale 3-dimensional(3D) heterogeneous porous media. In particular, we develop an efficient feature coarsening technique to extract the most representative information and perform the training and prediction of DL at the coarse scale, and further recover the resolution at the fine scale by spatial interpolation. We validate the DL approach to predict pressure field against physics-based simulation data for a field-scale 3D geologic CO 2 sequestration reservoir model. We evaluate the impact of feature coarsening on DL performance, and observe that the feature coarsening not only decreases the training time by >74% and reduces the memory consumption by >75%, but also maintains temporal error 0.63% on average. Besides, the DL workflow provides predictive efficiency with 1406 times speedup compared to physics-based numerical simulation. The key findings from this research significantly improve the training and prediction efficiency of deep learning model to deal with large-scale heterogeneous reservoir models, and thus it can also be further applied to accelerate workflows of history matching and reservoir optimization for close-loop reservoir management.

58 GEOSCIENCES↗

DOE OSTI2023

Combined Heat Shield and Solar Thermal Propulsion System for an Oberth Maneuver

As humanity continues its exploration of space, many space missions are enabled by increases in speed. Examples include outer planet and dwarf planet exploration missions and missions that travel through our solar system into interstellar space. For many of these applications speeds of >10 astronomical units per year (AU/yr) are desired. A powered gravity assist around the Sun may offer the best option for reaching this goal; however, current heat shields and kick stages are too heavy or generate too little thrust. Solar thermal propulsion overcomes this tradeoff by converting the heat of the Sun into thrust. By tripling the specific impulse relative to chemical propulsion and by enabling a smaller perihelion through active cooling, this approach nearly doubles the escape velocity. Our team has designed and built working solar thermal propulsion prototypes out of materials that can survive 2700 K at a 30 x 30 cm scale. These benchtop-scale demonstrations have thus far validated the simplifying assumptions that underlie our thermal and propulsion models. Despite growing confidence that a full-scale heat shield/heat exchanger can survive an Oberth maneuver, many questions remain regarding the feasibility of long-term cryogenic storage of hydrogen propellant.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS2016

Soil Moisture Active Passive Mission L4_SM Data Product Assessment (Version 2 Validated Release)

During the post-launch SMAP calibration and validation (Cal/Val) phase there are two objectives for each science data product team: 1) calibrate, verify, and improve the performance of the science algorithm, and 2) validate the accuracy of the science data product as specified in the science requirements and according to the Cal/Val schedule. This report provides an assessment of the SMAP Level 4 Surface and Root Zone Soil Moisture Passive (L4_SM) product specifically for the product's public Version 2 validated release scheduled for 29 April 2016. The assessment of the Version 2 L4_SM data product includes comparisons of SMAP L4_SM soil moisture estimates with in situ soil moisture observations from core validation sites and sparse networks. The assessment further includes a global evaluation of the internal diagnostics from the ensemble-based data assimilation system that is used to generate the L4_SM product. This evaluation focuses on the statistics of the observation-minus-forecast (O-F) residuals and the analysis increments. Together, the core validation site comparisons and the statistics of the assimilation diagnostics are considered primary validation methodologies for the L4_SM product. Comparisons against in situ measurements from regional-scale sparse networks are considered a secondary validation methodology because such in situ measurements are subject to up-scaling errors from the point-scale to the grid cell scale of the data product. Based on the limited set of core validation sites, the wide geographic range of the sparse network sites, and the global assessment of the assimilation diagnostics, the assessment presented here meets the criteria established by the Committee on Earth Observing Satellites for Stage 2 validation and supports the validated release of the data. An analysis of the time average surface and root zone soil moisture shows that the global pattern of arid and humid regions are captured by the L4_SM estimates. Results from the core validation site comparisons indicate that "Version 2" of the L4_SM data product meets the self-imposed L4_SM accuracy requirement, which is formulated in terms of the ubRMSE: the RMSE (Root Mean Square Error) after removal of the long-term mean difference. The overall ubRMSE of the 3-hourly L4_SM surface soil moisture at the 9 km scale is 0.035 cubic meters per cubic meter requirement. The corresponding ubRMSE for L4_SM root zone soil moisture is 0.024 cubic meters per cubic meter requirement. Both of these metrics are comfortably below the 0.04 cubic meters per cubic meter requirement. The L4_SM estimates are an improvement over estimates from a model-only SMAP Nature Run version 4 (NRv4), which demonstrates the beneficial impact of the SMAP brightness temperature data. L4_SM surface soil moisture estimates are consistently more skillful than NRv4 estimates, although not by a statistically significant margin. The lack of statistical significance is not surprising given the limited data record available to date. Root zone soil moisture estimates from L4_SM and NRv4 have similar skill. Results from comparisons of the L4_SM product to in situ measurements from nearly 400 sparse network sites corroborate the core validation site results. The instantaneous soil moisture and soil temperature analysis increments are within a reasonable range and result in spatially smooth soil moisture analyses. The O-F residuals exhibit only small biases on the order of 1-3 degrees Kelvin between the (re-scaled) SMAP brightness temperature observations and the L4_SM model forecast, which indicates that the assimilation system is largely unbiased. The spatially averaged time series standard deviation of the O-F residuals is 5.9 degrees Kelvin, which reduces to 4.0 degrees Kelvin for the observation-minus-analysis (O-A) residuals, reflecting the impact of the SMAP observations on the L4_SM system. Averaged globally, the time series standard deviation of the normalized O-F residuals is close to unity, which would suggest that the magnitude of the modeled errors approximately reflects that of the actual errors. The assessment report also notes several limitations of the "Version 2" L4_SM data product and science algorithm calibration that will be addressed in future releases. Regionally, the time series standard deviation of the normalized O-F residuals deviates considerably from unity, which indicates that the L4_SM assimilation algorithm either over- or under-estimates the actual errors that are present in the system. Planned improvements include revised land model parameters, revised error parameters for the land model and the assimilated SMAP observations, and revised surface meteorological forcing data for the operational period and underlying climatological data. Moreover, a refined analysis of the impact of SMAP observations will be facilitated by the construction of additional variants of the model-only reference data. Nevertheless, the “Version 2” validated release of the L4_SM product is sufficiently mature and of adequate quality for distribution to and use by the larger science and application communities.

SMAP L4_SM↗

DOE OSTI2021

A simplified integrated framework for predicting the economic impacts of feedstock variations in a catalytic fast pyrolysis conversion process

Feedstock attributes of lignocellulosic biomass, such as particle size, compositional makeup, and moisture content, can vary substantially even within pre-processed materials and have a significant effect on conversion in fast pyrolysis-based processes. However, the economic impacts of these attributes are not well understood. To address this, biomass deconstruction phenomena captured with a versatile particle-scale simulation were linked to techno-economic impacts via reduced-order models. Parametric analysis of the particle-scale model, which was validated using literature data, was used in combination with multiple linear regression models to develop correlations between feedstock attributes and yields of pyrolysis oil, gas, and char. Yields were then correlated with the minimum fuel selling price (MFSP) using a techno-economic model, bridging the gap between physics-based biomass conversion simulations and predictions of MFSP for a catalytic fast-pyrolysis process. Empirical correlations derived from the literature regarding the impact of mineral matter (ash) on oil yield were also considered. The model correlations deployed in the integrated framework capture the impacts of variation in feedstock attributes on the MFSP. Variations in ash were shown to have the biggest impact, varying MFSP by -13%/+22% due to catalytic effects and lower relative amounts of convertible lignocellulosic material. It was also found that, if ash can be controlled to low levels, the increased extractives in forest residues can help compensate for some yield losses associated with increased ash. As a result, other inputs considered (particle size, moisture content, and reactor temperature) had relatively negligible effects on process economics within the ranges analyzed considering particle-scale effects alone.

BIOMASS FUELS↗

DOE OSTI2021

Impacts of Anisotropic Porosity on Heat Transfer and Off-Gassing during Biomass Pyrolysis

The pore structure of biogenic materials imbues the ability to deliver water and nutrients through a plant from root to leaf. This anisotropic pore granularity can also play a significant role in processes such as biomass pyrolysis that are used to convert these materials into useful products like heat, fuel, and chemicals. Evolutions in modeling of biomass pyrolysis as well as imaging of pore structures allow for further insights into the concerted physics of phase change-induced off-gassing, heat transfer, and chemical reactions. In this work, we report a biomass single particle model which incorporates these physics to explore the impact of implementing anisotropic permeability and diffusivity on the conversion time and yields predicted for pyrolysis of oak and pine particles. Simulation results showed that anisotropic permeability impacts predicted conversion time more than 2 times when the Biot number is above 0.1 and pyrolysis numbers (Py 1 , Py 2 ) are less than 20. Pore structure significantly impacts predicted pyrolytic conversion time (>8 times) when the Biot number is above 1 and the pyrolysis number is below 1, i.e., the “conduction controlled” regime. Therefore, these nondimensional numbers reflect that when internal heat conduction limits pyrolysis performance, internal pyrolysis off-gassing further retards effective heat transfer rates as a closely coupled phenomenon. Overall, this study highlights physically meaningful opportunities to improve particle-scale pyrolysis modeling and experimental validation relevant to a variety of feedstock identities and preparations, guiding the future design of pyrolyzers for efficient biomass conversion.

09 BIOMASS FUELS↗

DOE OSTI2025

Multiscale and Machine Learning Modeling for Process-informed Microstructure Prediction in Additively Manufactured Materials using MALAMUTE

The Advanced Materials and Manufacturing Technologies (AMMT) program under the Department of Energy Office of Nuclear Energy aims to develop and qualify additively manufactured materials for nuclear applications. One key challenge to this is the microstructural variability observed in the additively manufactured products and their impact on the properties and performance of the material in extreme environments. AMMT is using a combination of high-throughput experimental and modeling techniques to accelerate qualification. Conventionally, in-situ and ex-situ characterizations and testing are performed to correlate different aspects of the additive manufacturing process to the final product and its performance. However, adopting a trial-and-error approach to experimentally evaluate the vast range of process parameters required to capture microstructural variability is cost-prohibitive. Modeling and simulation provide a comparatively inexpensive way to understand and correlate the microstructural evolution to the processing conditions. The modeling and simulation work-packages within the AMMT program aims to use physics-based and machine learning models to develop a digital twin for additive manufacturing that can correlate the process conditions to the final product and establish a process-structure-property-performance (PSPP) correlation. The melting and subsequent solidification that occurs during the additive process is a complex phenomenon that requires multiscale multiphysics analysis. This work package focuses on understanding the role of process variabilities on the unique microstructural characteristics of additively manufactured materials. Microstructural features at the subgrain level, such as compositional micro-heterogeneity and dislocation cells, are of particular interest here since they can influence the creep properties and radiation performance. Idaho National Laboratory’s Multiphysics Object-Oriented Simulation Environment (MOOSE), specifically the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) software, provides an ideal platform for developing the multiphysics multiscale model to explore the intricacies of the microstructural evolution during the AM processes within a single framework. Furthermore, given that such full-fidelity simulations can be computationally intensive, reduced order models are necessary to explore the PSPP space for additively manufactured materials in an efficient, reliable, and cost-effective way. This work focuses on capturing the microstructural variabilities at the subgrain level that are often missing in the part-scale models. In fiscal year 2025, we significantly advanced upon our work in the last fiscal year, in terms of the predictive capabilities of the physics-based and ML models, by adding the capabilities to capture subgrain-level micro-segregation during solidification using phase-field model and to predict the time-dependent dynamics of the AM process through the MOGPAR model. The alloy solidification model in MOOSE incorporates the thermodynamic properties and free energy relevant to 316 stainless steel. The model demonstrates the Cr and Ni segregation that occurs during solidification, including that the rate of solidification. The microstructural evolution model is connected to the process conditions via the surrogate model developed in this work. This enables predictions of the final microstructure in conjunctions with the manufacturing process. This work supports AMMT's rapid qualification goals by laying the foundation for an efficient and cost-effective model establishing the PSPP correlation for AM. The generated microstructures and predicted micro-segregation can be used by other work packages under AMMT to evaluate the properties and environmental response of the material at the mesoscale. Thus, this work helps to identify the key microstructural features at the subgrain level that are significant in property and performance predictions of additively manufactured components. This work will also provide inputs to the large-scale process variability models to reevaluate and validate assumptions and simplifications made in the part-scale models. Furthermore, through active learning this work can help identify the data need from both modeling and experimental sides for development of a robust digital twin for additive manufacturing and accelerate the AMMT's qualification efforts.

36 - MATERIALS SCIENCE↗