Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “design challenges”

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.

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

At least 487 records · Page 27

Deploying Purpose-Grown Energy Crops for Sustainable Aviation Fuel (Workshop Summary Report)

From June 6–7, 2023, the U.S. Department of Energy (DOE) Bioenergy Technologies Office (BETO) hosted the workshop “Deploying Purpose-Grown Energy Crops for Sustainable Aviation Fuel” in Kansas City, Missouri. The purpose of the workshop was to examine topics related to large-scale cultivation of purpose-grown energy crops—including algae—that can contribute feedstocks for the production of biofuels and bioproducts. This workshop was a means to gather a variety of stakeholders with the intent to identify elements for a potential future research strategy designed to overcome challenges and delve into the barriers related to the large-scale cultivation of purpose-grown crops. This document provides an overview and summary of the workshop’s presentations, breakout session discussions, and outcomes.

09 BIOMASS FUELS↗

Predicting Catalyst Surface Stability Under Reaction Conditions Using Deep Reinforcement Learning and Machine Learning Potentials

Catalysts are critical for most large-scale energy intensive chemical transformation processes, such as energy storage, liquid fuel production, and the formation of chemical building blocks. The catalyst composition, structure, and morphology impact the performance under reaction conditions and influences properties like activity and selectivity. Many industrial catalysts offer imperfect activity/selectivity, or contain expensive metals. Further, catalysts can deactivate over time as the morphology changes or harsh reactive environments alter the surface structure. Methods to automatically model and predict the kinetics of how catalyst surfaces will restructure would enable engineers to design around these challenges, improve performance, increase longevity. This project investigated a specific type of machine learning model, deep reinforcement learning, machine learning models to act as surrogates for the physical system, and compared the results of these approaches with a specialized high-throughput experimental synthesis and measurement platform.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

The Durability of Piston Seals in Hydraulic Power Take-off Systems in Wave Energy Converters

Hydraulic cylinder seals are a critical component of hydraulic power take-off (PTO) systems in wave energy converters (WECs). Primary hydraulic piston seal wear is a major concern for the longevity of hydraulic PTOs, especially in the context of the effort and expense associated with seal replacement. Piston seals, made from polymeric elastomers, are used to contain and isolate high pressure fluids within PTO systems. A specific challenge for WEC designers is knowing, with confidence, the relative expected lifetimes of commercially available seals and seal materials for the unique long travel and continuous use case of WEC hydraulic systems. This information is critical to accurately determine operating expense (OPEX) and levelized cost of electricity (LCOE). If failures of seals occur earlier than their designed lifetime, the estimated operations, and maintenance (O&M) and LCOE costs may double based on estimation. Unfortunately, information from seal manufacturers on longevity in these applications is not generally available and quantitative performance comparison between different manufacturers is not available, creating significant uncertainty on use of hydraulic PTO system in wave power generation. In this project, PNNL, with advice from different WEC device and seal manufacturers, has created a framework to address the industry need for available, dependable and comparative data for seals and seals materials for WEC hydraulic applications including piston seals, glide rings, and shaft seals. Commonly used and candidate seal materials were identified and available information on the materials such as mechanical and fatigue performance, chemical (fluid) compatibility, and cost has been compiled. Hardware and strategy for bench scale measurement of key materials and seal performance and pathway for publicly available library of hydraulic seal materials, properties, suppliers, and options have also been identified for future implementation. The results of this project were presented at WPTO Seedling Symposium 2023 and OCEANS 2023. The results of the literature review including identified polymer seals and ideal operating conditions were summaried and compiled to a database WEC-SealsDB hosted locally at PNNL.

16 TIDAL AND WAVE POWER↗

Reinforcement Learning for In-Spill Optimization of the Mu2e Resonant Extraction: Compensating Non-Stationarity

We present design considerations and challenges for the fast machine learning component of a third-order resonant beam extraction regulation system being commissioned to deliver steady beam rates to the mu2e experiment at Fermilab. Dedicated quadrupoles drive the tune toward the 29/3 resonance each spill, extracting beam at kV multiwire septa. The overall Spill Regulation System consists of (1) a “slow” process using ~100-spill averages to adjust the base quad ramp infrequently, (2) a feedforward harmonic content compensator, and (3) the “fast” ML agent reacting during each ongoing spill with on-the-fly additive corrections to the sum of (1) and (2). We have demonstrated improved beam-rate steadying for a fast ML agent compared to a PID controller using a quasi-physical spill simulation, and demonstrated distillation of that simulation into a predictive surrogate model. Current work includes a data-and-training pipeline to generate data-aware surrogates with real-world dynamics, even as the dynamics shift unpredictably. The surrogates are to act as RL environments against which to train our fast ML control agents before deploying them on FPGA in the live system. Further current efforts focus on modeling and controlling beam loss around the storage ring, understanding additional available hardware inputs to the model, and the interplay of these with beam-steadying performance.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

Deployable Element Ultra-High Vacuum Pump

This poster briefly highlights the challenge the senior design team was tasked with, and the events that led up to the ultimate solution. Described within the poster are problem statements, the design tasks that were formed based on the problem statement, the design processes and deliverables of the project, as well as the project outcome/impact.

Etayem, Brandon [Northern Illinois U.]↗

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↗

Fermilab Italian Student Program (Final Report)

I participated to the 2019 Fermilab Italian Student Program under the supervision of Anadi Canepa and Lorenzo Uplegger. I worked with the Fermilab research group that is involved with the R&D of the CMS Outer Tracker. The Compact Muon Solenoid (CMS) is a a general-purpose detector located at the Large Hadron Collider (LHC), the world's most powerful particle accelerator. In the next years LHC will undergo the High-Luminosity LHC upgrade, which will bring its luminosity from 1 × 10 34 cm -2 s -1 to 1.5 × 10 34 cm -2 s -1 . This increase in luminosity will require an upgrade of CMS as well, in order to comply with the augmented rate of particles which will cross the detector. The CMS tracker is a detector, composed of various modules made of silicon pixel trackers and silicon strip trackers, whose aim is to reconstruct the trajectories of the particles produced by the collisions in LHC. The tracker is ideally divided in Inner Tracker and Outer Tracker. The HL-LHC upgrade put important challenges in the designing of the tracker. It will have to withstand the irradiation of a large fluence of particles, without suffering a too severe deterioration of its performance. In addition to this, in order to comply with the increased rate of events that CMS will need to detect, the tracker will be exploited for triggering at the fully hardware Level 1 Trigger, in contrast to the current tracker, whose data are only used for the software High-Level Trigger. This feature is managed by the "stub logic", which will be explained in chapter 2. During the months of August and September at Fermilab I carried out the data analysis of three test beam runs performed in the last two years on the 2S Outer Tracker Minimules. The 2S Minimoule consists of two silicon strip trackers placed one upon the other with the strips kept parallel.

43 PARTICLE ACCELERATORS↗

Developing a Vaccine Platform for a Balanced Mucosal Immune Response (CB11446), Project Report: Year 1

Mucosal vaccines can elicit protective immune responses at the infection site of respiratory or aerosolized pathogens. Achieving balanced mucosal and systemic responses is a key challenge in the design of mucosal vaccines, especially in terms of developing a broadly applicable vaccine delivery platform amenable to a wide range of subunit vaccine antigens. The overarching goal of the project entitled “Developing a Vaccine Platform for a Balanced Mucosal Immune Response” is to develop a pathogen-agnostic vaccine platform that elicits robust and balanced mucosal immune responses upon intranasal vaccination, in the context of a nanolipoprotein particle (NLP) platform. In year one, we investigated NLP-based vaccine formulations incorporating select immune adjuvants (Monophosphoryl Lipid A (MPLA), FSL-1, L18-muramyl dipeptide (MDP), and cholesterol-tagged ODN2006 (cCpG)) along with antigens relevant to plague (LcrV), tularemia (IglC), and Ebola virus (GP). We demonstrated the ability to prepare, characterize, and quantify these formulations. We then carried out studies in vivo using a BALB/c mouse model, comparing intranasal and intramuscular administration and systematically evaluated the resulting mucosal and systemic immune responses using ELISpot and ELISAs. All proposed tasks (Table 1) were completed within the twelve-month base period, and the established go/no go metric was successfully achieved. Numerous adjuvant:LcrV:NLP formulations were found to have statistically significant increases in IgA titers in serum and/or lung upon IN administration (compared to IM administration), while also producing robust IgG responses in serum. Some formulations also showed significant IFNγ responses using restimulated splenocytes. The data collected during the base period provide valuable insights for the future design of safe and effective mucosal subunit vaccines while also highlighting areas of research that merit further investigation.

59 BASIC BIOLOGICAL SCIENCES↗

Scalable Membrane Electrode Assembly Stack Production for Reliable Thermal Electrochemical Converters (SMART)

This Final Close Out Report documents all activities, progress, and results accomplished under the SMART project, funded by the Department of Energy (DOE), during Budget Period 1 (BP1), covering 10/01/2023 to 07/31/2025. Although official preaward approval was granted on 05/10/2024, contracting delays shifted the award and formal project start to 10/01/2024. In the absence of an official kick-off meeting, early interactions focused on planning for key technical challenges, particularly the design and logistics for the JTEC device test platform.

30 DIRECT ENERGY CONVERSION↗

Improved Microalgal Carbon Utilization Efficiency via Integrated CO 2 Electro-Conversion to Formate and Microalgal Sequestration

This project developed a process to convert industrial carbon dioxide (CO 2 ) emissions into high-value, sustainable products through genetically engineered algae cultivation. While traditional microalgae cultivation depends on sparging CO 2 gas through water, this method is often inefficient because much of the gas escapes into the atmosphere before the algae can consume it. To overcome this challenge, the project designed an integrated system that first uses a CO 2 to formic acid electrolyzer to convert CO 2 into water-soluble formic acid/formate, then introduces formic acid/formate into the algae pond for cultivation, which allows the algae to access and utilize nearly all of the provided carbon, greatly increasing the efficiency of carbon utilization. The project team has successfully scaled up the CO 2 to formic acid electrolyzer from lab-scale to 1000 cm² and demonstrated industrially relevant current densities with the scaled-up electrolyzers using a CO 2 source that simulates industrial CO 2 waste.

42 ENGINEERING↗

A Survey of Machine Learning-Based Physics Event Generation

Event generators in high-energy nuclear and particle physics play an important role in facilitating studies of particle reactions. We survey the state of the art of machine learning (ML) efforts at building physics event generators. We review ML generative models used in ML-based event generators and their specific challenges, and discuss various approaches of incorporating physics into the ML model designs to overcome these challenges. Finally, we explore some open questions related to super-resolution, fidelity, and extrapolation for physics event generation based on ML technology.

Alanazi, Yasir↗

The Role of Blockchains in Multi-Stakeholder Transactive Energy Systems

Power grids are undergoing major changes due to rapid growth in renewable energy and improvements in battery technology. Prompted by the increasing complexity of power systems, decentralized solutions are emerging that arrange local communities into transactive microgrids. This paper addresses the problem of implementing transactive energy mechanisms in a distributed setting, providing both privacy and safety. Specifically, we design and implement an automated auction and matching system that ensures safety (e.g., satisfaction of line capacity constraints), preserves privacy, and promotes local trade and market efficiency for transactive energy systems. This design problem is challenging because safety, market efficiency, and privacy are competing objectives. We implement our solution as a decentralized trading platform built on blockchain technology and smart contracts. To demonstrate the viability of our platform, we analyze the results of experiments with dozens of embedded devices and energy production and consumption profiles using an actual dataset from the transactive energy domain.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Development of Structure–Property Relationships for Ammonium Transport through Charged Organogels

Ammonia is a promising carbon-free fuel, but current methods to produce ammonia are energy intensive. New methods are thereby needed, with one promising method being electrochemical nitrogen reduction cells. Efficient cell operation requires robust catalysts but also efficient membrane separators that permit the selective transport of ions while minimizing the transport of the products across the cell. Commercial membranes have an unknown morphology which makes designing improved cells challenging. To address this problem, we synthesized a series of membranes with controlled crosslinking density and chemical composition to understand their impact on ammonium transport. Higher crosslinking density led to lower ammonium permeability. At the highest crosslinking density, similar ammonium permeability was observed independent of the water volume fraction and hydrophobicity of the monomers. These results suggest new directions to develop membranes with reduced ammonium crossover to improve the efficiency of these electrochemical cells.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Exploring the Role of Glycans in the Interaction of SARS-CoV-2 RBD and Human Receptor ACE2

COVID-19 is a highly infectious respiratory disease caused by the novel coronavirus SARS-CoV-2. It has become a global pandemic and its frequent mutations may pose new challenges for vaccine design. During viral infection, the Spike RBD of SARS-CoV-2 binds the human host cell receptor ACE2, enabling the virus to enter the host cell. Both the Spike and ACE2 are densely glycosylated, and it is unclear how distinctive glycan types may modulate the interaction of RBD and ACE2. Detailed understanding of these determinants is key for the development of novel therapeutic strategies. To this end, we perform extensive all-atom simulations of the (i) RBD-ACE2 complex without glycans, (ii) RBD-ACE2 with oligomannose MAN9 glycans in ACE2, and (iii) RBD-ACE2 with complex FA2 glycans in ACE2. These simulations identify the key residues at the RBD-ACE2 interface that form contacts with higher probabilities, thus providing a quantitative evaluation that complements recent structural studies. Notably, we find that this RBD-ACE2 contact signature is not altered by the presence of different glycoforms, suggesting that RBD-ACE2 interaction is robust. Applying our simulated results, we illustrate how the recently prevalent N501Y mutation may alter specific interactions with host ACE2 that facilitate the virus-host binding. Furthermore, our simulations reveal how the glycan on Asn90 of ACE2 can play a distinct role in the binding and unbinding of RBD. Finally, an energetics analysis shows that MAN9 glycans on ACE2 decrease RBD-ACE2 affinity, while FA2 glycans lead to enhanced binding of the complex. Together, our results provide a more comprehensive picture of the detailed interplay between virus and human receptor, which is much needed for the discovery of effective treatments that aim at modulating the physical-chemical properties of this virus.

60 APPLIED LIFE SCIENCES↗

High-Frequency Gravitational Wave Search with ABRACADABRA-10 cm

ABRACADABRA-10 cm has had great success as a pathfinder lumped-element axion dark matter experiment, setting limits on axion dark matter at the GUT scale. Now, using the interaction of gravitational waves with electrodynamics and a change in readout strategy, we use the ABRA-10 cm detector for the first search for high-frequency gravitational waves using a modified axion detector. Potential sources at these high frequencies (10 kHz to 5 MHz) include merging primordial black hole binaries or superradiance, among other beyond the standard model phenomena. This paper presents the design, results, and challenges from the ABRA-10 cm high-frequency gravitational wave search, showing it is possible to simultaneously look for axions and high-frequency gravitational waves with both searches matching theoretical expectations for sensitivity. Additionally, we conducted the first time series transient search with data from an axion experiment, achieving sensitivity to $10^{-4}$ in strain. Scaled directly to the next generation axion experiment, DMRadio-GUT, this sensitivity would imply a reach to 0.01 $M_{\odot}$ primordial black hole mergers at distances around 3 pc, with prospects to go significantly further with modifications to the readout.

Pappas, Kaliroë M.W. [MIT, LNS] (ORCID:00000003425↗

Assessing and Reducing Plug and Process Loads in Office Buildings

Plug and process loads (PPLs) account for 33% of U.S. commercial building electricity consumption (McKenney et al. 2010). (See Figure 1.) Minimizing these loads is a significant challenge in the design and operation of an energy-efficient building. Lobato et al. (2011) and Lobato et al. (2012) define PPLs as energy loads that are not related to general lighting, heating, ventilation, cooling, and water heating, and that typically do not provide comfort to the occupants. The percentage of total building energy use from PPLs is increasing. According to the U.S. Department of Energy (DOE), by 2030, commercial building energy consumption is expected to increase by 24%; PPL energy consumption is anticipated to increase by 49% in the same time frame (DOE 2010). These trends illustrate the importance of PPL energy reduction to achieve an overall goal of reducing whole-building energy consumption.

30 DIRECT ENERGY CONVERSION↗

Assessing and Reducing Plug and Process Loads in Retail Buildings

Plug and process loads (PPLs) account for 33% of U.S. commercial building electricity consumption (McKenney et al. 2010). (See Figure 1.) Minimizing these loads is a significant challenge in the design and operation of an energy-efficient building. Lobato et al. (2011) and Lobato et al. (2012) define PPLs as energy loads that are not related to general lighting, heating, ventilation, cooling, and water heating, and that typically do not provide comfort to the occupants. The percentage of total building energy use from PPLs is increasing. According to the U.S. Department of Energy (DOE), by 2030, commercial building energy consumption is expected to increase by 24%; PPL energy consumption is anticipated to increase by 49% in the same time frame (DOE 2010). These trends illustrate the importance of PPL energy reduction to achieve an overall goal of reducing whole-building energy consumption.

30 DIRECT ENERGY CONVERSION↗

Technical Performance of Refractory Liners for Molten Chloride Salt Thermal Energy Storage Systems

A chloride-based molten-salt system that uses a ternary blend of MgCl2/KCl/NaCl is investigated to provide higher temperature thermal energy storage capability. Despite higher thermal stability, molten chlorides present several unique challenges, including the design of internal refractory-ceramic liners to prevent the corrosion and thermal stress of alloy tank shells. This work discusses issues and potential solutions related to containment of molten chloride salt, specifically the optimization of the refractory material at the molten salt interface (hot face). The down-selected hot face candidate limits permeation of salt through the material and forms a highly stable secondary surface phase in equilibrium with the molten salt. A mortar is created using the corrosion resistant hot face brick. Brick and mortar composite are subjected to mechanical stress/strain analysis, in order to calculate composite material properties and better inform thermomechanical models. The U.S. Department of Energy Generation 3 (DOE Gen3) program seeks to develop higher efficiency CSP plants that can provide cost-competitive, flexible power in the U.S. electric grid. The proposed Gen3 Liquid Pathway CSP plant closely resembles the configuration of current nitrate salt power towers with two-tank storage (Gen2). The differences between Gen2 and Gen3 include the types of compatible materials used in salt storage tank construction. Stainless steel loses strength at Gen3 temperatures, and although nickel superalloys would be capable of withstanding sustained high temperatures, these materials are prohibitively expensive at scale. Uninsulated tank shells also pose a significant risk as common steels are highly susceptible to chemical attack from molten chloride salt. To address these concerns, refractory-ceramic based containment materials are proposed to line the inside of the hot and cold storage tanks. In doing so, stainless or carbon steel shells may be used in construction depending on the level of insulation provided. The composition of the internal liner requires careful consideration to maximize the efficacy of multiple parameters including corrosion resistance, strength at operating temperature, durability, and cost. This is particularly true for the material at the interface with the salt, known as the "hot face", which is responsible for protecting the insulating layers between the tank shell and the hot face brick layer. The molten salt in this system is superheated over 300 °C above its freeze temperature. Therefore, unlike other industrial processes which use refractory-lined vessels, it is not expected that a freeze plane will develop in the hot face. Therefore, the hot face must be designed to withstand chemical corrosion and inhibit permeation of molten salt into the insulating layers. A down selection was performed to identify a hot face candidate best equipped to maintain thermal, mechanical, and chemical integrity when exposed to molten salt over extended periods of time. Long-duration chemical capability experiments were conducted with the down selected hot face refractory fully immersed in molten chloride salt for up to 3000 hours. The average salt penetration does not exceed 100 microns. When extrapolated to 20 and 30 years of continuous exposure, the expected salt penetration depth is approximately 2.0 mm and 2.9 mm, respectively. A magnesium-rich secondary phases develops at the salt/refractory interface. X-ray diffraction identifies the material as forsterite (Mg2SiO4), which is reported to form synthetically in molten chloride salt solutions. These results suggest the selected hot face will adequately inhibit salt permeation. While there is optimism that the hot face brick will inhibit salt permeation, mortar joints are typically the weakest point of a refractory brick liner. From a thermochemical perspective, differing thermal expansion coefficients may result in the mortar and brick to grow independent of each other, creating gaps through which molten salt can penetrate. To address this issue, NREL has developed an in-house mortar composed of the down selected hot face brick that has been shown to be compatible with the salt. Compressive stress/strain analyses have been performed on the brick/ mortar composites to generate stress/strain curves. Modulus of elasticity and Poisson's ratio of the composite may be calculated from the stress/strain curves, in order to provide more representative data to finite element mechanical models for accurate approximation of stress on the tank shell and the amount of thermal expansion expected within the tank liner.

41 EE - Solar Energy Technologies Office (EE-4S)↗