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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 487 records · Page 27
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Boiler Health Monitoring Using a Hybrid First Principles-Artificial Intelligence Model

Due to increased penetration of the intermittent renewables to the grid, pulverized coal (PC) plants are being forced to cycle their load frequently and rapidly, operate at low load condition for sustained period, and start up and shut down several hundred times in a year in the worst case. These severe operations are causing substantial damage to the boiler components compromising the reliability of PC plants. An online health monitoring tool can be instrumental in understanding the impacts of load-following and can eventually help PC plants to develop advanced process control strategies for improved flexibility without compromising safety nor reliability.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2023

Natural Fracture Pattern Development Using 3D Coupled Numerical Model: Mechanics and Diagenesis

In the earth's crust, while tectonic processes can mechanically create natural fractures, cementation can simultaneously grow on the surfaces of the fractures. This crystallization can affect the growth of the fractures. To more accurately address the modeling of natural fracture development, both mechanical deformation and chemical diagenesis should be carried out in an integrated manner. Here, we achieve this with a three-dimensional (3D) simulator that couples mechanical and chemical processes for natural fracture pattern development in layer confined situations. Tectonic loading over geologic time is mimicked by displacement driven boundary conditions in a 3D displacement discontinuity method (DDM) scheme. Quartz diagenesis competes with mechanical fracture opening, resulting in three different cementation conditions - open, bridging or fully infilled – which define fracture element stiffness that is used as feedback within the 3D-DDM code during propagation. An important milestone of this work is that this coupled structural diagenetic model can reproduce power-law aperture population statistics which cannot be generated using mechanics alone. More accurately estimated mechanical fracture apertures and their cementation condition is a critical step toward better permeability estimation and fluid path analysis for subsurface reservoirs.

58 GEOSCIENCES↗
DOE OSTI2022

CyOTE ASSET OWNER ENGAGEMENT – SIDE CHANNEL POWER ANALYSIS PROTOTYPE

The U.S. Department of Energy’s (DOE) Office of Cybersecurity, Energy Security, and Emergency Response (CESER), through the Cybersecurity for the Operational Technology Environment (CyOTE) Program, worked with energy sector asset owners and operators (AOOs), partners, and Idaho National Laboratory (INL) to develop capabilities for AOOs to independently identify adversarial tactics, techniques, and procedures (TTPs) within their operational technology (OT) environments. The CyOTE methodology seeks to identify adversarial techniques within an AOO OT environment that could result in physical disruptions to energy flow or damage to equipment. CyOTE provides a general roadmap for AOOs, starting from a triggering event, or the point in time and space they perceive an anomalous event or condition meriting investigation, and culminating when the AOO has sufficient confidence to make a business risk decision on the appropriate resolution. This paper outlines the results of one such engagement with the New York Power Authority (NYPA), where the CyOTE program partnered with an AOO to develop a design specification for a power side channel detector to identify anomalous changes to device load. It describes the goal of developing this capability, the development process, the challenges the technical teams faced and the future steps an AOO will need to take to install and use this detector in its OT environment.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2023

Error containment for enabling local checkpoint and recovery

Various embodiments include a parallel processing computer system that detects memory errors as a memory client loads data from memory and disables the memory client from storing data to memory, thereby reducing the likelihood that the memory error propagates to other memory clients. The memory client initiates a stall sequence, while other memory clients continue to execute instructions and the memory continues to service memory load and store operations. When a memory error is detected, a specific bit pattern is stored in conjunction with the data associated with the memory error. When the data is copied from one memory to another memory, the specific bit pattern is also copied, in order to identify the data as having a memory error.

Cherukuri, Naveen↗
DOE OSTI2024

Fabrication and Testing of DOE Standard Canister Closure Leak Test Assembly

DOE manages over 300 types of SNF, most of which are located at the INL site. “Road-ready dry storage” is a management concept where SNF is packaged into dry, sealed canisters, which are then placed in on-site storage in anticipation of later removal. The Idaho Cleanup Project and INL are collaborating on the Road-Ready Capability Demonstration Project, which will develop and demonstrate the designs, technology, processes, and regulatory framework for packaging DOE SNF for road-ready dry storage. In support of establishing a large-scale road-ready dry storage program at the INL site, the demonstration will package a select amount of DOE-managed SNF into DOE Standard Canisters. The closure process for the DOE Standard Canisters will include fuel and basket loading, welding, inspection, leak testing, and if needed, repair. As a follow-up to previous discussion on the design of the DOE Closure Leak Test Assembly, this report describes recent fabrication and testing efforts performed at INL. DOE Standard Canisters are sealed by two sequential gas tungsten arc welds. Both are performed by remotely operated and semi-autonomous welding systems. The first weld is a circumferential pipe weld that completes assembly of the canister body and lid assembly. The second and final closure weld connects the vent plug to the vent port with an identical butt joint to the circumferential pipe weld. After the second weld is performed on the vent port, these welds are helium leak tested using an inside-out technique. In addition to the commercially available vacuum and leak detector systems, the DOE Standard Canister Closure Leak Test Assembly was designed for both remote and manual operation. This report describes fabrication and performance testing associated with the inside-out technique. INL staff designed and tested systems to accomplish these tasks. Hardware fabrication occurred at INL facilities. Forthcoming work includes design optimization, integration to existing systems, and implementation to packaging demonstration operations.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

DEVELOPMENT OF INEXPENSIVE HIGH TEMPERATURE NITI-BASED SHAPE MEMORY ALLOYS FOR POWDER BED ADDITIVE MANUFACTURING

NiTi and NiTi-based Shape Memory Alloys (SMA) exhibit a reversible solid-state phase transformation from martensite to austenite driven by thermal energy. High temperature (Mf>100°C) SMAs are martensite at room temperature and can be fabricated into solid-state actuators that return to a pre-programmed shape against a designed load after heating to transformation threshold. Reactive as-fabricated additively manufactured parts (4-D printing) is the current state of the art in manufacturing of SMAs but requires compositions compliant to rapid solidification. Existing actuator designs are developed from commercially available, highly investigated material compositions. However, existing high temperature high performance (high actuation strain, low thermal hysteresis) shape memory alloys contain significant (>10% at.) portions of high-cost Platinum Group Metals (PGMs). It is of significant scientific interest to investigate material compositions that are peer performing or superior to PGMs whose constituent elements represent a significant cost savings. Shape memory alloy properties vary significantly with small (0.1% at.) compositional changes making robust investigative sample sets very large. Computational material design can be deployed to shrink the compositional space of possible alloy combinations and reduce the experimental load in material discovery. Investigating shape memory effect (SME) and validating process additive process parameters for a single novel composition is cost intensive in both time and consumed materials. Additionally, sub-optimal processing, oxygen, or solidification rate sensitivity could render additively manufacturing specimens without micro, macro cracks, or significant chemical variance impossible. Unfortunately, such failure susceptibility cannot be simulated. Therefore, a research pathway to validate novel shape memory alloy compositions for powder bed fusion additive manufacturing without the need for powdered feedstock is also proposed. This research investigates novel high temperature shape memory alloys for actuators without platinum group alloying elements to discover one that could be commercially viable as an additive manufacturing feedstock.

Sundermann, Tayler↗
DOE OSTI2020

Combustion, criteria pollutant and soot property assessment of mixing-controlled high-load engine operation with gasoline and diesel

Gasoline compression ignition (GCI) is an emerging technology that can achieve high fuel efficiency and low criteria emissions in diesel engine platforms using gasoline and gasoline-like fuels. While low- and mid-range loads are enabled with low temperature combustion (LTC) approaches, high-loads are more efficient with high temperature combustion (HTC) requiring mixing-controlled combustion (MCC). Lower soot emissions are achieved with gasoline even in high-load MCC than with diesel, but detailed soot properties from gasoline and diesel have been rarely discussed. In order to better understand how high-load operations affect soot properties, in this study gasoline and diesel were tested in a six-cylinder heavy duty engine at 14 bar brake mean effective pressure (BMEP) at similar combustion phasing. Effects of pilot mass ratio and EGR on heat release rates, cylinder temperatures, ignition delay (ID) and combustion duration (CD) were examined, relating with emissions variations with applications of the two fuels. Soot mass and particle number emissions were slightly lower with gasoline than with diesel, resulting in a more favorable NOx-soot trade-off with gasoline like other reports. Contrary to other findings in the literature, gasoline and diesel soot samples presented similar particle distribution shapes, carbon crystalline structures and primary particle sizes, regardless of fuel type and EGR rate. Consequently, the current result proposes that soot particles have undergone similar soot formation and oxidation processes despite reactivity difference and oxygen availability under the examined high-load MCC with similar combustion phases.

02 PETROLEUM↗
DOE OSTI2022

Rapid Evaluation and Response to Impacts on Critical End-Use Loads Following Natural Hazard-Driven Power Outages: A Modular and Responsive Geospatial Technology

The disparate nature of data for electric power utilities complicates the emergency recovery and response process. The reduced efficiency of response to natural hazards and disasters can extend the time that electrical service is not available for critical end-use loads, and in extreme events, leave the public without power for extended periods. This article presents a methodology for the development of a semantic data model for power systems and the integration of electrical grid topology, population, and electric distribution line reliability indices into a unified, cloud-based, serverless framework that supports power system operations in response to extreme events. An iterative and pragmatic approach to working with large and disparate datasets of different formats and types resulted in improved application runtime and efficiency, which is important to consider in real time decision-making processes during hurricanes and similar catastrophic events. This technology was developed initially for Puerto Rico, following extreme hurricane and earthquake events in 2017 and 2020, but is applicable to utilities around the world. Given the highly abstract and modular design approach, this technology is equally applicable to any geographic region and similar natural hazard events. In addition to a review of the requirements, development, and deployment of this framework, technical aspects related to application performance and response time are highlighted.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

High-performance ionomerless cathode anion-exchange membrane fuel cells with ultra-low-loading Ag–Pd alloy electrocatalysts

Rapid translation of catalysts from fundamental studies to high-performance devices could facilitate the process of developing and commercializing anion-exchange membrane fuel cells (AEMFCs). Traditionally, translation from material screening in three-electrode rotating disk electrode (RDE) cells to AEMFCs is complicated by differences in microenvironments, e.g. solid ionomer/membrane vs liquid electrolyte. Herein, we introduce a platform for translation to devices that utilizes ionomerless ultra-low-loading Ag-Pd alloy electrocatalyst cathodes synthesized by co-physical vapor deposition (PVD). Our ionomerless cathodes allow for systematic H 2 -O 2 AEMFC experiments while demonstrating comparable activity trends to those in three-electrode cells. Furthermore, here we show that our Ag 10 Pd 90 -based AEMFC reaches a peak power density of ~1 W cm$_{geo}^{-2}$ and ~10 W mg$_{PGM Cathode}^{-1}$ satisfying the U.S. Department of Energy’s platinum-group-metal (PGM) loading and cost targets. Our approach shows promise in facilitating the rapid translation between three-electrode studies and AEMFCs, offering a simple and effective design for decreasing PGM loadings.

25 ENERGY STORAGE↗
DOE OSTI2022

Effect of loading path on grain misorientation and geometrically necessary dislocation density in polycrystalline aluminum under reciprocating shear

Solid phase processing (SPP) is a promising alloy fabrication technique to produce fine and homogeneous grain structures for high-performance alloys. However, there is very limited modeling capability to understand and predict the grain refinement during SPP. In this work, the crystal plasticity theory was used to study elastic-plastic deformation in polycrystalline aluminums under large shear deformation. Two approaches, kernel averaged misorientation (KAM) and grain reference orientation deviation (GROD), were used to assess the grain misorientations. The geometrically necessary dislocation (GND) density was computed with the plastic strain rate. The deformation simulations were carried out under two loading conditions to investigate the effect of loading paths on the evolutions of grain misorientation and GND density. The results show that the regions with high misorientation and GND density first appear near grain boundaries. These regions then extend toward interior grains. The loading path affects dislocation system activation and dislocation recovery, hence dislocation evolution and misorientation. In conclusion, both two- and three-dimensional simulations showed that the spatial and temporal evolutions of GROD, KAM, and GND density in are closely correlated, which indicates they all can be used as criteria of grain refinement or recrystallization.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Investigation of the benefits of diabatic microreactors for process intensification of the water-gas shift reaction within the steam reforming process

Presently, the steam reforming process is the largest industrial source of hydrogen. Improving its efficiency can help to reduce associated carbon emissions and hydrogen production costs. Intensifying the water-gas shift reaction using microreactors with integrated cooling is one way of achieving this. In this study, a 2-D computational model of one of these microreactors is developed, validated with experimental data, and then used to demonstrate how microreactors can enhance the conversion of the water-gas shift reaction beyond what can be achieved using conventional packed bed reactors. These results are then generalized into a full system model of the steam reforming process to demonstrate how microreactors can reduce hydrogen production costs. The results suggest that microreactors can significantly reduce the required reactor volume and catalyst loading for the water-gas shift reaction and can similarly reduce the hydrogen production costs associated with the steam reforming process.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Performing k eff Validation of As-Loaded Criticality Safety Calculations Using UNF-ST&DARDS: Applicable Experiment Selection

The general method for performing validation of as loaded criticality safety calculations using UNF ST&DARDS is presented in a paper by Clarity, which includes a description of the UNF-ST&DARDS system. Proof-of-principle analyses were performed in the summer of 2019 for MPC-32 dual purpose canisters (DPCs) containing pressurized water reactor (PWR) fuel assemblies. Summaries of these results are presented in this and a companion paper for this conference. The current paper describes the TSUNAMI-IP calculations performed to select applicable experiments for validation of 11 MPC-32 DPCs. The companion paper discusses the TSUNAMI-3D calculations used to generate sensitivity data to support the experiment selections discussed here. Experiment selection is based on the sensitivity/uncertainty (S/U) methods used to validate criticality safety calculations of as-loaded DPCs containing pressurized water reactor (PWR) spent nuclear fuel (SNF). This process has been demonstrated and is summarized in this paper. The approach is similar to that used in NUREG/CR-7109, which provides an approach for validation of PWR burnup credit (BUC), including major and minor actinides and major fission products. The premise of S/U-based validation is that applicable experiments—those having a similar bias to a given application system—will have similar sensitivities for each isotope and reaction in the two systems. It is assumed that cross sections with larger uncertainties are more likely to contain data errors which contribute to the bias. The integral index c k thus propagates the system sensitivities with the nuclear covariance data to calculate a correlation coefficient representing the similarity of the two systems. In this work, a c k value of 0.8 or higher is interpreted as identifying an experiment with sufficient similarity for use in validation. This paper presents a brief summary of the characteristics of the 11 MPC-32 DPCs used in the proof of-principle analysis for as-loaded criticality safety calculation validation and an overview of the critical experiment suite with which each of these DPC models was compared. A summary and discussion of c k results is also presented, followed by conclusions and a discussion of future work to be performed for validation of UNF ST&DARDS as-loaded criticality safety calculations.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2021

Maximum Cs-137 Curie Loading onto Crystalline Silicotitanate for the Documented Safety Analysis of the Tank Side Cesium Removal Platform

The Tank Side Cesium Removal (TSCR) system is currently being constructed to process Hanford tank waste supernates for vitrification. TSCR incorporates a filtration system and cesium (Cs) removal system using columns filled with crystalline silicotitanate (CST) ion exchanger, produced by Honeywell UOP, LLC. The documented safety analysis (DSA) developed for TSCR limits a single column curie loading to 141,600 Ci; given a 137 Cs isotopic mass fraction of 20% and the planned CST bed size of a TSCR column, this equates to 0.10 mmole Cs per g CST. Factors that influence 137Cs loading onto the CST include, but are not limited to, CST production lot (different production lots behave differently), contact temperature, contact duration, 137Cs mass fraction, and competitors in the tank waste feed. Seventeen tank waste feeds (compositions) were identified by Washington River Protection Solutions to be processed through TSCR. These feed compositions were used to develop a simulant (referred to herein as Stage 1) that would provide an upper bound to the Cs loading onto CST based on maximizing the Cs/Na activity coefficient ratios in solution while maintaining Na at no less than 5.0 M. Building upon this Stage 1 simulant, a series of four additional simulants were developed based on the cationic/anionic species that impact Cs exchange, with each successive formulation relaxing one or more matrix component concentration constraints as show in Table S.1

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

Elastic deformation as a tool to investigate watershed storage connectivity

Storage-discharge relationships and dynamic changes in storage connectivity remain key unknowns in understanding and predicting watershed behavior. In this study, we use Global Positioning System measurements of load-induced Earth surface displacement as a proxy for total water storage change in four climatologically diverse mountain watersheds in the western United States. Comparing total water storage estimates with stream-connected storage derived from hydrograph analysis, we find that each of the investigated watersheds exhibits a characteristic seasonal pattern of connection and disconnection between total and stream-connected storage. We investigate how the degree and timing of watershed-scale connectivity is related to the timing of precipitation and seasonal changes in dominant hydrologic processes. Our results show that elastic deformation of the Earth due to water loading is a powerful new tool for elucidating dynamic storage connectivity and watershed discharge response across scales in space and time.

Environmental Sciences & Ecology↗
DOE OSTI2024

Experimental investigation of heat treatments on the mechanical performance of grade 300 maraging steel strut-based lattices

Lightweight and strong components are essential for reducing energy consumption and enhancing efficiency. Lattice structures are one such geometry utilized to achieve weight reduction. This study investigates the mechanical properties of various lattice structures fabricated from Maraging Steel (EOS MS1) using the Direct Metal Laser Sintering (DMLS) method. The samples include three distinct cellular geometries: body-centered cubic (BCC), face-centered cubic (FCC), and octet truss configurations, which are subjected to tensile and compressive tests. The primary goal of this research is to evaluate the impact of heat treatment on the mechanical properties of cellular architecture under tensile and compressive loading conditions. Destructive, nondestructive testing, and simulation results were also obtained from different heat treatment processes. It was found that the age-hardened specimens performed the best overall in terms of ultimate tensile/compressive strength and elongation. The top-performing topologies in compression and tension were found to be the octet structure, as they were able to withstand the most loading and straining when compared to the other specimens.

Engineering↗
DOE OSTI2022

Carbonate Minerals and Dissimilatory Iron-Reducing Organisms Trigger Synergistic Abiotic and Biotic Chain Reactions under Elevated CO 2 Concentration

Increasing CO 2 emission has resulted in pressing climate and environmental issues. While abiotic and biotic processes mediating the fate of CO 2 have been studied separately, their interactions and combined effects have been poorly understood. To explore this knowledge gap, an iron-reducing organism, Orenia metallireducens, was cultured under 18 conditions that systematically varied in headspace CO 2 concentrations, ferric oxide loading, and dolomite (CaMg(CO 3 ) 2 ) availability. The results showed that abiotic and biotic processes interactively mediate CO 2 acidification and sequestration through "chain reactions", with pH being the dominant variable. Specifically, dolomite alleviated CO 2 stress on microbial activity, possibly via pH control that transforms the inhibitory CO 2 to the more benign bicarbonate species. The microbial iron reduction further impacted pH via the competition between proton (H + ) consumption during iron reduction and H + generation from oxidization of the organic substrate. Under Fe(III)-rich conditions, microbial iron reduction increased pH, driving dissolved CO 2 to form bicarbonate. Spectroscopic and microscopic analyses showed enhanced formation of siderite (FeCO 3 ) under elevated CO 2 , supporting its incorporation into solids. In conclusion, the results of these CO 2 -microbe-mineral experiments provide insights into the synergistic abiotic and biotic processes that alleviate CO 2 acidification and favor its sequestration, which can be instructive for practical applications (e.g., acidification remediation, CO 2 sequestration, and modeling of carbon flux).

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Filament Extension Atomization for High Solids Loading in Energy Efficient Spray Drying Systems

We demonstrate that we could scale FEA to reach outputs needed by industrial production, while increasing solids loading of the sprayed product by at least 30% and maintaining equal or better spray powder. After testing a wide range of products, in collaboration with industry partners we decided on our primary spray products of dry whey and WPC-80, two common materials processed and sold by US manufacturers with different parameters. We sprayed these with FEA at solids loadings of 70% for dry whey and 45% for WPC-80 with a spray output with particle sizes similar to industrial particles sizes and reduced variation in particle size. We simultaneously scaled up FEA first with a multi-nip with 6 nips surrounding a central roller with parallel axis of rotation and eventually with a tapered design that solved problems we encountered with our initial design. We were able to achieve output from a single array from our first design of up to 4.7 liters per minute (L/min) and from an array of our second multi-nip of 8 L/min exceeding expectations. This demonstrates that FEA technology can indeed be scaled up to meet the needs of industrial production. More arrays can be added as necessary to meet a wide range of spray dryer designs. We also tested FEA to create dried powders from a small scale (10 L/hour of water removal) spray dryer. Though we were not able to produce large quantities of powder from FEA due to challenges in integration, the powder we produced was higher quality and produced from higher solids loading materials. From our technoeconomic analysis we for a typically sized spray dryer, we estimate a 27% cost reduction and 41% energy and carbon reduction for WPC-80 and a 39-57% cost reduction and 52-76% energy reduction for sweet dry whey (depending on the exact product).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Probing Anion Exchange Membrane Fuel Cell Cathodes by Varying Electrocatalysts and Electrode Processing

To date, several high-performing anion exchange membrane fuel cells (AEMFCs) have been demonstrated, but most these studies have focused on Pt containing cathodes with high loadings. Here, we explore and compare the performance and perform electrochemical diagnostics on three leading AEMFC cathode electrocatalysts: Pt/C, Ag/C, and Fe–N–C with electrodes that have been processed with either powder or dispersion-based ionomers using perfluorinated anion exchange polymers. Pt/C had the highest performance but also showed a strong dependence on ionomer type, with powder ionomer exhibiting much higher performance. These results were consistent with the observations for Ag/C but did not hold for the Fe–N–C catalyst where almost no change was observed between powder and dispersion-based ionomers. This is the first-time the impact of powder and dispersion ionomer with different classes of cathode electrocatalysts on the fuel cell performance have been compared, and the results have strong implications for the ability to achieve high performance at low loadings and for better understanding catalyst-ionomer interactions within AEMFCs.

30 DIRECT ENERGY CONVERSION↗