SEARCH · Engineering Papers

Results for “electrical fluids”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 469 records · Page 26

All sources NASA NTRS DOE OSTI

DOE OSTI2021

Cabin Thermal Management Analysis for SuperTruck II Next-Generation Hybrid Electric Truck Design

In this article, we present a multistage, coupled thermal management simulation approach, informed by physical testing where available, to aid design decisions for PACCAR's SuperTruck II hybrid truck cabin concept. Focus areas include cabin insulation, battery sizing, and sleeper curtain position, as well as heating, ventilating, and air-conditioning (HVAC) component and accessory configurations, to maintain or improve thermal comfort while saving energy. The authors analyzed weather data and determined the national vehicle miles traveled weighted temperature and solar conditions for long-haul trucks. Example weather day profiles were selected to approximate the 5th and 95th percentile weighted conditions. A daylong drive cycle was developed to impose appropriate external wind conditions during rest and driving periods. Using the National Renewable Energy Laboratory's vehicle HVAC modeling and simulation tool VTCab, HVAC load design trade-off studies for the new truck geometry concept were completed. Parameters analyzed included effects of paint color, insulation, glass transmissivity, and curtain location. Simulation results helped with early design material selections for efficient cabin climate control. A detailed three-dimensional computer-aided engineering (CAE), computational fluid dynamics (CFD), radiation, and human physiology co-simulation, referred to in this article as CAE Thermal-CFD, was used to evaluate thermal comfort and energy impacts of diffuser configurations and air supply settings in driving and hoteling modes. Analysis revealed that it is more difficult to heat the cabin in hoteling mode during the winter than to cool the space in the summer. This seasonal load profile drives the requirement of additional energy storage for heating comfort. To determine the battery capacity requirement, multiday HVAC operation drive cycle simulations were then completed, showing that a 15-kWh battery would be required for HVAC operation during hoteling. Results helped reduce cabin thermal loads, determine component sizing requirements, and improve occupant comfort to save fuel and contribute to the economic viability of the hybrid system.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2022

Kinetic simulations of collision-less plasmas in open magnetic geometries

Laboratory plasmas in open magnetic geometries can be found in many different applications such as (a) scrape-of-layer (SOL) and divertor regions in toroidal confinement fusion devices, (b) linear divertor simulators, (c) plasma-based thrusters and (d) magnetic mirrors etc. A common feature of these plasma systems is the need to resolve, in addition to velocity space, at least one physical dimension (e.g. along flux lines) to capture the relevant physics. In general, this requires a kinetic treatment. Fully kinetic particle-in-cell (PIC) simulations can be applied but at the expense of large computational effort. A common way to resolve this is to use a hybrid approach: kinetic ions and fluid electrons. In the present work, the development of a hybrid PIC computational tool suitable for open magnetic geometries is described which includes (a) the effect of non-uniform magnetic fields, (b) finite fully-absorbing boundaries for the particles and (c) volumetric particle sources. Analytical expressions for the momentum transport in the paraxial limit are presented with their underlying assumptions and are used to validate the results from the PIC simulations. A general method is described to construct discrete particle distribution functions in a state of mirror-equilibrium. This method is used to obtain the initial state for the PIC simulation. Collisionless simulations in a mirror geometry are performed. The results show that the effect of magnetic compression is correctly described and momentum is conserved. The self-consistent electric field is calculated and is shown to modify the ion velocity distribution function in a manner consistent with analytic theory. Based on this analysis, the ion distribution function is understood in terms of a loss-cone distribution and an isotropic Maxwell-Boltzmann distribution driven by a volumetric plasma source. Finally, the inclusion of a Monte Carlo based Fokker-Planck collision operator is discussed in the context of future work.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2022

EGS Collab Experiment 1: Time-series geochemistry data of the long-term circulation test

This submission presents the weekly geochemistry data of the long-term flow test performed within EGS Collab Experiment 1 from early 2019 to early 2020. The fluids from each producing borehole/interval (PI, PB, PDT and PST) along with the injectate were sampled roughly weekly from April 2019 to January 2020 for geochemistry analysis. The geochemical measurement was part of a long-term microbial profiling project (see details in the PNAS paper linked below). Additional background and methodologies are available in the PNAS paper linked bellow.

15 GEOTHERMAL ENERGY↗

DOE OSTI2022

Multiscale Experiments and Multiphysics Simulation of Multiphase Flow for Transportable Small Modular Reactors

A new type of safe, small, transportable nuclear reactor would address the intense and ever-growing global demand for energy produced via a resilient, carbon-free energy source. In this regard, transportable small modular reactors (SMRs) are being designed and developed for electricity generation within small/micro-grid/off-grid isolated systems, as well as for heat generation in industrial/residential applications. These reactors feature the capability to be fully factory fabricated and then directly transported to utilities’ sites as “plug-and-play” systems. Research and development (R&D) programs are underway at Idaho National Laboratory (INL) to successfully design, develop, and demonstrate such safe-by-design mobile reactor technologies, in collaboration with partner organizations. Multiscale experimental facilities and multiphysics simulation tools are required for reactor design verification and validation (V&V), and licensing. These advanced reactors are intended to feature passive safety systems such as passive containment cooling systems (PCCS), which consist of multiphase flows and multispecies distributions. This seminar talk will focus on designing and analyzing transportable SMR PCCS by using multiscale experiments and multiphysics computational fluid dynamics (CFD) simulations to support reactor licensing and safety. The corresponding research challenges are addressed via supportive verification and validation results generated by the models and simulation tools in combination with selective parametric and uncertainty analysis. This solution approach could blaze the trail for commercial adoption of such technologies. The facilities, simulation capabilities, and research opportunities available at INL in regard to such reactors and the integrated energy systems with which they go hand in hand are also discussed briefly, and may spark interest in deeper research as well as new collaborative projects.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2020

Development of a Comprehensive Two-Phase Flow Database for the Validation of NEK-2P

Three-dimensional (3-D) two-phase Computational Fluid Dynamics (CFD) codes are emerging as a powerful and potentially practical tool for applications in which detailed local flow information is needed. However, two-phase flow models and associated closure relations are not well established for CFD applications, which is partly due to the lack of high-quality validation data. The main objective of this work is to develop a comprehensive database of two-phase flows that can be used to validate two-phase CFD codes such as NEK-2P. In this project, four advanced local measurement systems, including Particle Image Velocimetry and Planar Laser-Induced Fluorescence (PIV-PLIF), high-speed imaging, x-ray densitometry, and multi-sensor conductivity probe are employed to measure the local two-phase flow parameters of both gas and liquid phases. By combining these techniques, the local void fraction, bubble velocity, interfacial area concentration, bubble frequency, liquid velocity, turbulence intensity, etc., in various two-phase flow regimes can be obtained. These local measurement techniques are first used in a 25.4 mm circular pipe test section. Seven air-water two-phase flow conditions spanning the bubbly, slug, churn-turbulent, and annular flow regimes are measured in this facility. The obtained database contains the radial profiles of both gas- and liquid-phase parameters at three axial locations along the test section. The second facility used in this work contains a 30 mm × 10 mm rectangular test section, in which three two-phase flow and two single-phase flow conditions are measured. Two-dimensional distributions of local two-phase flow parameters in the cross-sectional plane are measured in this facility at three axial locations as well. A facility featuring a 3×3 electrically heated rod bundle is also designed and being constructed in this project. This facility is specially designed for optical measurements and is expected to provide high-quality boiling data in the future. Preliminary analyses have been performed for the data taken in the 25.4 mm circular pipe. Both center-peaked and wall-peaked void fraction profiles have been observed in the data depending on the two-phase flow conditions and/or developing lengths. The 1-D drift-flux model was evaluated with the newly obtained datasets, in which both gas- and liquid-phases data were directly measured. The distribution parameter model has been optimized based on a new void-profile classification method proposed in this study. The optimized drift-flux model shows a significant improvement in predicting both gas velocity and void fraction. The measured liquid-phase turbulence was used to benchmark Sato’s turbulence model considering the bubble-induced shear stress for the three tested bubbly flows. The benchmark results showed good agreement between the PIV measurements and model predictions. In the bubbly flows tested that have low void fractions less than 3%, the effect of the bubble-induced turbulence was found not significant. However, the bubble-induced shear stress becomes important with the increase of the void fraction. The Conjugate Heat Transfer (CHT) model was developed and implemented in NEK-2P. This model allows the coupled simulation of the solid domain and two-phase fluid domain, allowing the specification of realistic boundary conditions. The CHT implementation was verified first with non-boiling simulations. The predicted temperatures in the fluid domain were shown to be identical in simulations with or without the CHT model. The CHT model was then validated through simulations of three Becker benchmark CHF tests performed under both Dryout (DO) and Departure from Nucleate Boiling (DNB) conditions. Reasonably good agreement was obtained between calculated wall temperatures and corresponding experimental data.

42 ENGINEERING↗

DOE OSTI2024

Solar Energy Technical Publications Catalog: Solar Thermal Technology

The research and development described in these documents was conducted within the U.S . Department of Energy's (DOE) Solar Thermal Technology Program. The goal of this program is to advance the engineering and scientific understanding of solar thermal technology and to establish the technology base from which private industry can develop solar thermal power production options for introduction into the competitive energy market. Solar thermal technology concentrates the solar flux using tracking mirrors or lenses onto a receiver where the solar energy is absorbed as heat and converted into electricity or incorporated into products as process heat. The two primary solar thermal technologies, central receivers and distributed receivers, employ various point and line-focus optics to concentrate sunlight. Current central receiver systems use fields of heliostats (two-axis tracking mirrors) to focus the sun's radiant energy onto a single, tower- mounted receiver. Point focus concentrators up to 17 meters in diameter track the sun in two axes and use parabolic dish mirrors or Fresnel lenses to focus radiant energy onto a receiver. Troughs and bowls are line-focus tracking reflectors that concentrate sunlight onto receiver tubes along their focal lines. Concentrating collector modules can be used alone or in a multimodule system. The concentrated radiant energy absorbed by the solar thermal receiver is transported to the conversion process by a circulating work fluid. Receiver temperatures range from l00 degrees C in low-temperature troughs to over 1500 degrees C in dish and central receiver systems. The Solar Thermal Technology Program is directing efforts to advance and improve each system concept through solar thermal materials, components, and subsystems research and development and by testing and evaluation. These efforts are carried out with the technical direction of DOE and its network of field laboratories that works with private industry. Together they have established a comprehensive, goal-directed program to improve performance and provide technically proven options for eventual incorporation into the nation's energy supply. To successfully contribute to an adequate energy supply at reasonable cost, solar thermal energy must be economically competitive with a variety of other energy sources. The Solar Thermal Technology Program has developed components and system-level performance targets as quantitative program goals. These targets are used in planning research and development activities, measuring progress, assessing alternative technology options, and developing optimal components. These targets are pursued vigorously to ensure a successful program. This catalog represents part of an effort to provide information on publications about solar thermal research and development activities conducted by DOE's laboratories. Publications listed include technical and research reports and special publications. The following national laboratories are represented in this edition: Sandia National Laboratories, Solar Energy Research Institute, Jet Propulsion Laboratory. This catalog is a product of the DOE Solar Technical Information Program, which is dedicated to providing information to scientific and industrial users in ways most convenient and useful to them. This catalog focuses on solar thermal technologies, and its purpose is to keep the scientific and industrial communities informed of the latest developments in federally sponsored research in this technology.

140000* -- Solar Energy↗

DOE OSTI2025

EM-Enhanced HyPOR Loop for Fast Fusion Cycles

Vacuum pumps are the heart of a fusion energy facility – fusion power cannot be generated without them. Nevertheless, the vacuum technology needed to operate a viable fuel cycle for a compact fusion power plant does not exist. Commercial vacuum technology offers the best solution to this challenge, but a pump oil recycling and detritiation system is necessary. Conventional oil detritiation processes have only been developed to deal with legacy waste and are too slow and destructive to the oil. Further, post hoc detritiation strategies are intrinsically inefficient. Our approach is to rethink the challenge holistically by designing the pumping fluid and tritium extraction system in an integrated manner to achieve an innovative solution. By selecting an oil for the specific task of pumping tritium and then designing our catalytic system to selectively target the tritium-bearing functional groups, an effective detritiation system (hydrocarbon pump oil recycling, HyPOR, loop) for fusion power plants can be obtained. The project demonstrated a HyPOR loop process that can selectively remove heavier hydrogen isotopes from pump oil, reaching the target of 99.5 % removal, with an uptake of less than 0.01% of tritium throughput, while also purifying the oil of radiation-induced damage. The recycled oil retained its pumping characteristics over 7 recycles and gamma irradiation over 30 MGy. By meeting these targets, the project enable a reduction in pump operational costs from $\$$14.5M/year to $\$$103k/year (>140× reduction), reducing pump electric power consumption from 2.8 MW to 0.25 MW (>10× reduction), and reducing in-process tritium inventory from 2.03 kg to 0.48 kg (>4× reduction).

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

Component level modeling of materials degradation for insights into operational flexibility of Existing Coal Power Plants

Increasingly, coal-fired power plants are required to balance power grids by compensating for the variable electricity supply from renewable energy sources. Fossil-fueled power plants, originally designed to be base loaded, will increasingly need to operate on a load following or cyclic basis. This demanding requirement for operational flexibility needs insights into accelerated material degradation arising due to the harsh operating conditions (e.g., fatigue, early oxide exfoliation due to stresses) along with current damage mechanisms (fireside corrosion, creep and erosion) observed in service. Our research objective is to develop component level modeling toolkit for materials-based degradation for two key mechanisms that can accelerate with cyclic operations. In more detail, this includes the fireside corrosion/steam oxidation/erosion/creep/fatigue of superheaters/reheaters and steam pipework and also the water droplet erosion/ fatigue of last stage steam turbine blades degradation mechanisms, that demand routine and sometimes unplanned maintenance and repair. The innovation is in developing a computational fluid dynamics/finite element (CFD/FE) modeling toolkit for the component level models of the boilers and low-pressure steam turbines in coal power plants that can tackle multidisciplinary failure mechanisms occurring concurrently for extreme environment materials. Lifetime assessment in such environments also needs to account for the unit-specific analyses, operational history and fuel feedstock; this can only be obtained by destructive analysis of components. This, in turn, enables validation of the model toolkits utilizing service feedback data, improving the probability of time/temperature dependent life prediction.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2021

Forecasting Dynamic Line Rating with Spatial Variation Considerations

Dynamic line rating (DLR) is a technology that allows the ampacity of an electrical conductor to be calculated using real-time or forecasted weather conditions. Historically, the ampacity of a conductor has been determined using a static line rating method which assumes conservative weather assumptions. Therefore, not only can DLR give a more accurate measurement of the true ampacity of a conductor, but it can also increase its ampacity during weather conditions with greater thermal mitigations. The two primary cooling factors in the ampacity calculations are wind speed and direction. In complex terrain, wind speed and direction can have large variations over short distances. Therefore, accurately identifying the limiting span of a transmission line requires high spatial resolution of the wind along its path. One solution is to install dense weather stations along their path, though this can become costly over long distances. Therefore, researchers have investigated the use of Computation Fluid Dynamic (CFD) simulations to accurately compute the wind field along the path of a transmission line and use these results to identify the limiting section of the conductor. This work presents a case study that evaluates the coupling of CFD simulations and forecasted weather simulations using the High-Resolution Rapid Refresh (HRRR) model points over a 2-year span within a region in south eastern Idaho. The primary goal of the work is the evaluation of the number of HRRR model points used, i.e., weather stations, along the path of the line and the accuracy of the resulting DLR ampacity. This was done using 4, 10, 17, 26, and 35 HRRR model points along two transmission line paths. The results indicate that as the number of model points are increased, the DLR ampacity of the lines decrease, yet converge as more points are added and demonstrate little change with additional HRRR points. It is expected that these results can help transmission line operators identify the number of weather stations that must be installed when coupled with CFD simulations and DLR ampacity to ensure accurate ratings and safe operations.

17 WIND ENERGY↗

DOE OSTI2021

Forecasting Dynamic Line Rating with Spatial Variation Considerations

Dynamic line rating (DLR) is a technology that allows the ampacity of an electrical conductor to be calculated using real-time or forecasted weather conditions. Historically, the ampacity of a conductor has been determined using a static line rating method which assumes conservative weather assumptions. Therefore, not only can DLR give a more accurate measurement of the true ampacity of a conductor, but it can also increase its ampacity during weather conditions with greater thermal mitigations. The two primary cooling factors in the ampacity calculations are wind speed and direction. In complex terrain, wind speed and direction can have large variations over short distances. Therefore, accurately identifying the limiting span of a transmission line requires high spatial resolution of the wind along its path. One solution is to install dense weather stations along their path, though this can become costly over long distances. Therefore, researchers have investigated the use of Computation Fluid Dynamic (CFD) simulations to accurately compute the wind field along the path of a transmission line and use these results to identify the limiting section of the conductor. This work presents a case study that evaluates the coupling of CFD simulations and forecasted weather simulations using the High-Resolution Rapid Refresh (HRRR) model points over a 2-year span within a region in south eastern Idaho. The primary goal of the work is the evaluation of the number of HRRR model points used, i.e., weather stations, along the path of the line and the accuracy of the resulting ampacity. This was done using 4, 10, 17, 26, and 35 HRRR model points along two transmission line paths. The results indicate that as the number of model points are increased, the DLR ampacity of the lines decrease, yet converge as more points are added and demonstrate little change with additional HRRR points. It is expected that these results can help transmission line operators identify the number of weather stations that must be installed when coupled with CFD simulations and DLR ampacity to ensure accurate ratings and safe operations.

17 WIND ENERGY↗

DOE OSTI2022

Modelica-based modeling and simulation of district cooling systems: A case study

While equation-based object-oriented modeling language Modelica can evaluate practical energy improvements for district cooling systems, few have adopted Modelica for this type of large-scale thermo-fluid system. Further, to our best knowledge, district cooling modeling studies have yet to include hydraulics in piping networks alongside plant models featuring realistic mechanical systems and controls. These are critical details to include when looking to make energy and control improvements in many physical system installations. To fill these gaps, this study released new open-source district cooling models at the Modelica Buildings Library and leveraged these models for a real-world case study at the University of Colorado Boulder. Here, the site includes six buildings connected to a central chiller plant featuring a waterside economizer. Several energy saving strategies are pursued based on the validated model, including control setpoint optimization, equipment modification, and pump setpoint adjustments. Results indicate that a combination of the studied measures can save the campus annually 84.6 MWh of energy, 8.9% of electricity costs, 58.0 metric tons of carbon dioxide emissions, while the waterside economizer cuts down chillers’ run times by 201 days/year, reducing maintenance costs and extending chiller life.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Collaborative Research: Explosive reconnection in relativistic magnetically-dominated plasmas (Final Report)

Magnetic fields can be the dominant component of astrophysical plasmas, so that the magnetic energy density might exceed even the rest-mass energy density of matter. In this extreme (and largely unexplored) regime the magnetic field controls the overall plasma evolution, dissipation, and acceleration of non-thermal particles. This plasma regime, applicable to a variety of astrophysical sources - magnetars, pulsars and pulsar wind nebulae (PWNe), jets of Active Galactic Nuclei (AGNs) and Gamma-Ray Bursters (GRBs) - is dramatically different from laboratory plasmas, the magnetospheres of planets, and the interplanetary plasma. Relativistic astrophysical sources then provide an unique opportunity to study the fundamental plasma physics of magnetically-dominated plasmas; a novel and fast-evolving field of theoretical research which, by investigating energy conversion and particle energization processes in plasmas, is of vital importance to the Fusion Energy Sciences DoE program. Data coming from astrophysical high-energy missions, especially the Crab Nebula flares recently observed by the Fermi and AGILE satellites, suggest that the acceleration of non-thermal particles to the highest energies occurs in magnetic reconnection events - a major change of paradigm in high-energy astrophysics. Most importantly, observations demand that particle acceleration should proceed extremely fast (with accelerating electric field of the order of the magnetic field) and on macroscopic scales (much larger, e.g., than the microscopic plasma skin depth). We are conducting studies of the microphysics of magnetically-dominated plasmas focussing in particular on the highly dynamic regime of explosive reconnection and associated particle acceleration in relativistic plasmas. We are studying the stability and explosive plasma dynamics, particle acceleration and radiation production in a number of idealized plasma configurations that approximate relevant astrophysical sources (like the magnetic ABC structures and interacting flux tubes, as well as generalizations of analytical models of X-point collapse to relativistic plasmas). The well-studied case of the Crab Nebula is taken as a prototypical example for the application of the model. We are combining analytical studies of explosive magnetic dynamics and dissipation in relativistic plasmas with particle-in-cell (PIC) simulations and fluid simulations. The theoretical model, fluid and particle-in-cell simulations are cross-checked for agreement and convergence.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Experimental Characterization of High-Surface Area Thermal Energy Storage

There is growing interest in energy storage technologies due to the expansion of renewable energy sources that are inherently intermittent and the increasing frequency of extreme weather events that disturb the power grid. Power consumption in buildings makes up approximately 76% of all electricity usage on the grid and is primarily used for thermal applications such as space conditioning, hot water, and cooking. This makes thermal energy storage (TES) an ideal solution for many of these applications. Many TES technologies rely on latent energy storage, which utilizes the melting/solidification of phase change materials (PCM) to store energy. Typically, TES designs suffer from low power density due to their low inherent thermal conductivity. This limitation makes the deployment of TES in active applications difficult as the ease of access to energy is essential for effective use. Common routes for improving power density include high thermal conductivity additives or extended features such as fins that increase cost. This study presents an alternative approach to improving performance through increasing the overall surface area to volume ratio of the device, to increase the available area for convection to occur between the working fluid and PCM. In the study a commercial PCM was selected with a transition temperature ideal for space heating applications. The heat exchanger design utilizes a unique application of triply periodic minimal surfaces (TPMS) for macro-encapsulation of the PCM. The use of TPMS for heat exchangers has been growing in interest due to their high-surface area to volume ratios, which were previously unmanufacturable until the development of additive manufacturing. A modular system was designed and manufactured with a stereolithography resin printing system that is then backfilled with PCM. An experiment test set-up is designed to test the charge and discharge performance of the thermal storage using a conditioned air stream. The pressure drop of the design is tested across a variety of flow rates. When compared to existing experimental data within literature, there is excellent agreement based on the Reynolds number at similar hydraulic diameters. Several inlet temperatures are tested at consistent temperature differences from the phase change temperature for both charging and discharging. Additionally, the volumetric flow rate is varied for each temperature set point. It was found that increasing flow rate had diminishing returns in reducing the overall charge time of the TES. The temperature delta from the melting temperature was the primary contributor to the change in average heat flux with limited variation in average heat transfer rate between charging and discharging at similar inlet temperatures and flow rates. The TPMS heat exchanger design has a high air-side pressure drop but it provides high heat transfer rates. This helps maintain a high outlet temperature during discharge, which is important to thermal comfort applications. The design, manufacturing, and experimental characterization of the TES device will be presented as part of this study.

25 ENERGY STORAGE↗

DOE OSTI2021

Noise and error analysis and optimization in particle-based kinetic plasma simulations

In this paper we analyze the noise in macro-particle methods used in plasma physics and fluid dynamics, leading to approaches for minimizing the total error, focusing on electrostatic models in one dimension. We begin by describing kernel density estimation for continuous values of the spatial variable x, expressing the kernel in a form in which its shape and width are represented separately. The covariance matrix of the noise in the density is computed, first for uniform true density. The bandwidth of the covariance matrix C(x,y) is related to the width of the kernel. A feature that stands out is the presence of constant negative terms in the elements of the covariance matrix both on and off-diagonal. These negative correlations are related to the fact that the total number of particles is fixed at each time step; they also lead to the property ∫C(x,y)dy = 0. We investigate the effect of these negative correlations on the electric field computed by Gauss's law, finding that the noise in the electric field is related to a process called the Ornstein-Uhlenbeck bridge, leading to a covariance matrix of the electric field with variance significantly reduced relative to that of a Brownian process. For non-constant density, p(x), still with continuous x, we analyze the total error in the density estimation and discuss it in terms of bias-variance optimization (BVO). For some characteristic length l, determined by the density and its second derivative, and kernel width h, having too few particles within h leads to too much variance; for h that is large relative to l, there is too much smoothing of the density. The optimum between these two limits is found by BVO. For kernels of the same width, it is shown that this optimum (minimum) is weakly sensitive to the kernel shape. Next, we repeat the analysis for x discretized on a grid. In this case the charge deposition rule is determined by a particle shape. An important property to be respected in the discrete system is the exact preservation of total charge on the grid; this property is necessary to ensure that the electric field is equal at both ends, consistent with periodic boundary conditions. We find that if the particle shapes satisfy a partition of unity property, the particle charge deposited on the grid is conserved exactly. Further, if the particle shape is expressed as the convolution of a kernel with another kernel that satisfies the partition of unity, then the particle shape obeys the partition of unity. This property holds for kernels of arbitrary width, including widths that are not integer multiples of the grid spacing. Furthermore, we show results relaxing the approximations used to do BVO optimization analytically, by doing numerical computations of the total error as a function of the kernel width, on a grid in x. The comparison between numerical and analytical results shows good agreement over a range of particle shapes. We discuss the practical implications of our results, including the criteria for design and implementation of computationally efficient particle shapes that take advantage of the developed theory.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Carbon nanotube coated metal mesh: Bridging nanoscale and macroscale

A novel hybrid structure has been developed by growing carbon nanotubes (CNTs) on a metal mesh that functions as a literally unlimitedly extendable backbone. This hybrid material structure provides a new approach of extending CNTs’ advantageous properties such as ultrahigh thermal and electrical conductivities, high sensitivity to gases, and distinctive wettability for different liquids with chemical inertness to macroscale—otherwise available only in nano- and microscales. In this feasibility work, CNTs were grown on a Type 316 stainless steel (SS) mesh by self-catalytical chemical vapor deposition (CVD) without the need of an externally added catalyst or catalyst support. For the radially aligned and entangled CNT forest on the SS mesh, the average CNT diameter is around 50 nm, while the length varies from 20 to 25 µm. High-resolution transmission electron microscopy analysis revealed the multiwall structure of the CNTs with >30 rolled-up graphitic sheets. Raman spectra of the CNTs showed a dominant G band, indicating a well-ordered graphitic nanostructure. Being highly hydrophobic with a water contact angle of ∼145° and oleophilic, the CNT-coated SS mesh could be used in fluid separation and organic contaminant removal from water. Moreover, CNTs are recognized for their exceptional thermal conductivity and the CNT-coated mesh offers a supportive structure with directly connected CNTs for efficient heat transfer. Proof of concept has been achieved for the CNT-coated mesh’s potentials as a liquid filter and an thermal interface material (TIM). Specifically, the CNT-coated mesh demonstrated the capability of capturing water from a water-organic mixture with a 100 % efficiency while allowing organic liquids to pass through the filter. Furthermore, when used as a TIM, the CNT-coated mesh reduced the interfacial thermal impedance by >30 %.

Carbon nanotubes (CNTS)↗

DOE OSTI2023

Cold-cap structure in a slurry-fed electric melter

We report as glass batch is charged into an electric melter, a cold cap forms on the glass melt surface. Heat transfer to the cold cap from the molten glass below and the melter atmosphere above determines the melting rate. A mathematical model of the cold cap and the experimental kinetic data of the feed-to-glass conversion that were collected for several simulated low-activity and high-level waste melter feeds allowed us to develop relationships between the internal structure of the cold cap, its properties, its thickness, and the internal heat transfer. This contribution shows the distribution of major crystalline phases and the cumulative evolution of gases within the cold cap. It also examines the temperature, conversion degree, and heating rate the melter feed is experiencing during the passage through the cold cap and their effects on the cold-cap bottom temperature and morphology, which are important for the computational fluid dynamics simulations of melters.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Experimental and analytical study of the hydrodynamic and single and two-phase convective heat transfer performance of flexible PDMS microchannels with micropillar arrays

Various copper and silicon based thermal management systems are used in the cooling of electronics. However, the rigid nature of these materials along with their high thermal and electrical conductivity pose a difficulty in developing direct contact embedded flexible cooling systems that can offer robust cooling performance. The low density, thermal stability, chemical inertness, and electrical insulation of Polydimethylsiloxane (PDMS) make it an ideal material to develop lightweight direct contact thermal management systems for electronics. Its ease of fabrication with tunable flexibility provides the opportunity to go beyond traditional electronics and develop advanced active and passive thermal management systems for a wide–range of applications in foldable and wearable electronics, liquid cooling garments, microgravity, and electric motors. In this study, a flexible PDMS based microchannel with micropillar arrays, which enhance the thermal performance of the device through capillary-assisted flow, has been developed. The hydrodynamic and convection heat transfer performance of three PDMS wick pillar geometries, ranging from a porosity of 0.8–0.91, are investigated and compared under single-phase and two-phase conditions. Dielectric coolant FC-3283 is employed and permeability measurements are made for mass fluxes ranging from 53 kg/m 2 s to 369 kg/m 2 s. Given its conformability, the device demonstrates a deviation from Darcy’s Law, within the laminar regime, with an increasing permeability with mass flux at the rate of ~0.5–0.8 Darcy/(kg/m 2 s). A semi-analytical model has been developed and reported to quantify the conformability of the device. The heat transfer performance is experimentally evaluated using the same dielectric fluid for mass flux ranging from 105 kg/m 2 s to 420 kg/m 2 s with heat fluxes ranging from 1.5 W/cm 2 to 16 W/cm 2 . Heat transfer coefficients of up to 7000 W/m 2 K are observed, which are comparable to copper and silicon microchannels. The effect of porosity on the single phase thermal performance has been evaluated against the pumping power to provide a basis for thermal management system design. Finally, high-speed imaging is performed to study the two-phase flow characteristics to provide insight into the vapor formation and removal.

42 ENGINEERING↗

DOE OSTI2025

Coarse-grained simulation of colloidal self-assembly, cation exchange, and rheology in Na/Ca smectite clay gels

Knowledge Gap: The aggregation of clay minerals—layered silicate nanoparticles—strongly impacts fluid flow, solute migration, and solid mechanics in soils, sediments, and sedimentary rocks. Experimental and computational characterization of clay aggregation is inhibited by the delicate water-mediated nature of clay colloidal interactions and by the range of spatial scales involved, from 1 nm thick platelets to flocs with dimensions up to micrometers or more. Simulations: Using a new coarse-grained molecular dynamics (CGMD) approach, we predicted the microstructure, dynamics, and rheology of hydrated smectite (more precisely, montmorillonite) clay gels containing up to 2,000 clay platelets on length scales up to 0.1 μm. Further, simulations investigated the impact of simulation time, platelet diameters (6 to 25nm), and the ratio of Na to Ca exchangeable cations on the assembly of tactoids (i.e., stacks of parallel clay platelets) and larger aggregates (i.e., assemblages of tactoids). We analyzed structural features including tactoid size and size distribution, basal spacing, counterion distribution in the electrical double layer, clay association modes, and the rheological properties of smectite gels. Findings: Our results demonstrate new potential to characterize and understand clay aggregation in dilute suspensions and gels on a scale of thousands of particles with explicit representation of counterion clouds and with accuracy approaching that of all-atom molecular dynamics (MD) simulations. For example, our simulations predict the strong impact of Na/Ca ratio on clay tactoid formation and the shear-thinning rheology of clay gels.

42 ENGINEERING↗