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DOE OSTI2022

Predictive modeling of a subcritical pulverized-coal power plant for optimization: Parameter estimation, validation, and application

As renewable power generation deployment increases, fossil fuel plants are increasingly required to operate more flexibly. Many coal-fired power plants were originally designed to operate at base load and do not operate optimally at partial load. Predictive first-principles plant-wide models can be employed to identify opportunities for flexibility improvements and diagnose low-load operating issues. This paper describes the application of the Institute for the Design of Advanced Energy Systems Integrated Platform (IDAES) to model and optimize flexible power plant operations. The key benefits of using IDAES are that it provides an open-source, fully equation-oriented modeling framework for efficient modular model construction, reuse, and customization, together with a mathematical optimization framework leveraging powerful, state-of-the-art solvers. The process systems engineering workflow from predictive process simulation to parameter estimation, model validation, and plant optimization is applicable to a variety of existing and next-generation energy systems as well as other chemical and environmental processes. Here, to demonstrate this capability, a physics-based, steady-state model was developed to improve full- and part-load performance of the Escalante Generating Station, a 245 MWe (net) subcritical pulverized coal-fired power plant owned and operated by Tri-State Generation and Transmission Association. Specifically, sixty-nine model parameters were simultaneously estimated from several months of operating data enabling prediction of flow rates, temperatures, pressures, and steam quality throughout the plant. The validated model was leveraged by Escalante to reduce the minimum operating load from 90 MW to 50 MW by diagnosing a low-load water-hammer issue, enabling coal usage and emissions reductions during periods of low power demand. Additionally, opportunities for heat rate reduction (i.e., efficiency improvement) through a steeper sliding-pressure approach to load-following and optimization of other boiler operating variables were also identified and quantified. For example, a potential efficiency improvement of 0.7 percentage points was observed at half-load operation.

01 COAL, LIGNITE, AND PEAT↗

NASA NTRS2017

Cart3D Simulations for the Second AIAA Sonic Boom Prediction Workshop

Simulation results are presented for all test cases prescribed in the Second AIAA Sonic Boom Prediction Workshop. For each of the four nearfield test cases, we compute pressure signatures at specified distances and off-track angles, using an inviscid, embedded-boundary Cartesian-mesh flow solver with output-based mesh adaptation. The cases range in complexity from an axisymmetric body to a full low-boom aircraft configuration with a powered nacelle. For efficiency, boom carpets are decomposed into sets of independent meshes and computed in parallel. This also facilitates the use of more effective meshing strategies - each off-track angle is computed on a mesh with good azimuthal alignment, higher aspect ratio cells, and more tailored adaptation. The nearfield signatures generally exhibit good convergence with mesh refinement. We introduce a local error estimation procedure to highlight regions of the signatures most sensitive to mesh refinement. Results are also presented for the two propagation test cases, which investigate the effects of atmospheric profiles on ground noise. Propagation is handled with an augmented Burgers' equation method (NASA's sBOOM), and ground noise metrics are computed with LCASB.

Prediction↗

NASA NTRS1995

Features and applications of the Groove Analysis Program (GAP)

An IBM Personal Computer (PC) version of the Groove Analysis program (GAP) was developed to predict the steady state heat transport capability of an axially grooved heat pipe for a specified groove geometry and working fluid. In the model, the capillary limit is determined by the numerical solution of the differential equation for momentum conservation with the appropriate boundary conditions. This governing equation accounts for the hydrodynamic losses due to friction in liquid and vapor flows and due to liquid/vapor shear interaction. Back-pumping in both 0-g and 1-g is accounted for in the boundary condition at the condenser end. Slug formation in 0-g and puddle flow in 1-g are also considered in the model. At the user's discretion, the code will perform the analysis for various fluid inventories (undercharge, nominal charge, overcharge, or a fixed fluid charge) and heat pipe elevations. GAP will also calculate the minimum required heat pipe wall thickness for pressure containment at design temperatures that are greater than or lower than the critical temperature of the working fluid. This paper discusses the theory behind the development of the GAP model. It also presents the many useful and powerful capabilities of the model. Furthermore, a correlation of flight test performance data and the predictions using GAP are presented and discussed.

Ku, Jentung↗

DOE OSTI2020

Turbulence-parameter estimation for current-energy converters using surrogate model optimization

Surrogate models maximize information utility by building predictive models in place of computational or experimentally expensive model runs. Marine hydrokinetic current energy converters require large-domain simulations to estimate array efficiencies and environmental impacts. Meso-scale models typically represent turbines as actuator discs that act as momentum sinks and sources of turbulence and its dissipation. An OpenFOAM model was developed where actuator disc k-ε turbulence was characterized using an approach developed for flows through vegetative canopies. Turbine-wake data from laboratory flume experiments collected at two influent turbulence intensities were used to calibrate parameters in the turbulence-source terms in the k-ε equations. Additionally, parameter influences on longitudinal wake profiles were estimated using Gaussian process regression with subsequent optimization minimizing the objective function within 3.1% of those obtained using the full model representation, but for 74% of the computational cost (far fewer model runs). This framework facilitates more efficient parameterization of the turbulence-source equations using turbine-wake data.

16 TIDAL AND WAVE POWER↗

NASA NTRS2003

Computational Methods for Jet Noise Simulation

The purpose of our project is to develop, analyze, and test novel numerical technologies central to the long term goal of direct simulations of subsonic jet noise. Our current focus is on two issues: accurate, near-field domain truncations and high-order, single-step discretizations of the governing equations. The Direct Numerical Simulation (DNS) of jet noise poses a number of extreme challenges to computational technique. In particular, the problem involves multiple temporal and spatial scales as well as flow instabilities and is posed on an unbounded spatial domain. Moreover, the basic phenomenon of interest, the radiation of acoustic waves to the far field, involves only a minuscule fraction of the total energy. The best current simulations of jet noise are at low Reynolds number. It is likely that an increase of one to two orders of magnitude will be necessary to reach a regime where the separation between the energy-containing and dissipation scales is sufficient to make the radiated noise essentially independent of the Reynolds number. Such an increase in resolution cannot be obtained in the near future solely through increases in computing power. Therefore, new numerical methodologies of maximal efficiency and accuracy are required.

Goodrich, John W.↗

NASA NTRS1975

Fixed-range optimum trajectories for short-haul aircraft

An algorithm, based on the energy-state method, is derived for calculating optimum trajectories with a range constraint. The basis of the algorithm is the assumption that optimum trajectories consist of, at most, three segments: an increasing energy segment (climb); a constant energy segment (cruise); and a decreasing energy segment (descent). This assumption allows energy to be used as the independent variable in the increasing and decreasing energy segments, thereby eliminating the integration of a separate adjoint differential equation and simplifying the calculus of variations problem to one requiring only pointwise extremization of algebraic functions. The algorithm is used to compute minimum fuel, minimum time, and minimum direct-operating-cost trajectories, with range as a parameter, for an in-service CTOL aircraft and for an advanced STOL aircraft. For the CTOL aircraft and the minimum-fuel performance function, the optimum controls, consisting of air-speed and engine power setting, are continuous functions of the energy in both climb and descent as well as near the maximum or cruise energy. This is also true for the STOL aircraft except in the descent where at one energy level a nearly constant energy dive segment occurs, yielding a discontinuity in the airspeed at that energy. The reason for this segment appears to be the relatively high fuel flow at idle power of the engines used by this STOL aircraft. Use of a simplified trajectory which eliminates the dive increases the fuel consumption of the total descent trajectory by about 10 percent and the time to fly the descent by about 19 percent compared to the optimum.

Erzberger, H.↗

NASA NTRS2003

Development of Erosive Burning Models for CFD Predictions of Solid Rocket Motor Internal Environments

Four erosive burning models, equations (11) to (14). are developed in this work by using a power law relationship to correlate (1) the erosive burning ratio and the local velocity gradient at propellant surfaces; (2) the erosive burning ratio and the velocity gradient divided by centerline velocity; (3) the erosive burning difference and the local velocity gradient at propellant surfaces; and (4) the erosive burning difference and the velocity gradient divided by centerline velocity. These models depend on the local velocity gradient at the propellant surface (or the velocity gradient divided by centerline velocity) only and, unlike other empirical models, are independent of the motor size. It was argued that, since the erosive burning is a local phenomenon occurring near the surface of the solid propellant, the erosive burning ratio should be independent of the bore diameter if it is correlated with some local flow parameters such as the velocity gradient at the propellant surface. This seems to be true considering the good results obtained by applying these models, which are developed from the small size 5 inch CP tandem motor testing, to CFD simulations of much bigger motors.

Wang, Qun-Zhen↗

NASA NTRS1974

Numerical and experimental studies of the natural convection within a horizontal cylinder

Numerical solutions are obtained for the quasi-compressible Navier-Stokes equations governing the time-dependent natural convection within a horizontal cylinder. The early flow development and wall heat transfer are obtained after a uniformly cold wall is imposed as a boundary condition on the cylinder. Results are also obtained for a time-varying cold wall as a boundary condition with windward explicit differencing used for the numerical solutions. The viscous truncation error associated with this scheme is controlled so that first-order accuracy is maintained in time and space. Experiments within a small-scale instrumented horizontal cylinder revealed the time development of the temperature distribution across the boundary layer as well as the decay of wall heat transfer with time. Agreement between temperature distributions obtained experimentally and numerically was generally good. The time decay of the dimensionless ratio of the Nusselt number to the one-fourth power of the Grashof number is found both numerically and experimentally, and good agreement is obtained between these two results over most of the cylinder wall.

Stewart, R. B.↗

NASA NTRS2017

Implementation of a Body Force Model in OVERFLOW for Propulsor Simulations

We present an implementation of a propulsor model based on body force method into the OVERFLOW computational fluid dynamics code to model turbofan engines and propulsors of similar type. The model estimates the forces imparted on the fluid by the blade camber surfaces as a body force source terms in the momentum and energy equations over grids that represent the rotor and stator of a fan stage. We tested the implementation on three cases: 1) Source Diagnostics Test (SDT) fan with R4 rotors, which has extensive test data on aerodynamic performance and rotor wake surveys, 2) A stand-alone Aeronaut TF8000 propulsor which is an off-the-shelf propulsor used on model aircraft and 3) The D8 aircraft model with TF8000 propulsors placed in a wind tunnel. Despite missing some of the features in the velocity profiles near the endwalls (i.e. hub and casing surfaces), the OVERFLOW simulations with body force model predicted area-averaged flow speed and total pressure rise through the SDT propulsor within a few percent of the LDV (Laser Doppler Velocimetry) measurements. In the case of TF8000 propulsor on the D8 airframe, the model under-predicted mechanical power coefficient by several percent of the wind tunnel test results when the horizontal force balance condition over the airframe is targeted by tuning rotor speed. By investigating the upstream influence of the rotor swirl, it was found out that the induced swirl velocity effects upstream were relatively small and they rapidly vanished before reaching one fan diameter upstream of the fan face. The body force model provided insights on aerothermodynamics and aeromechanics of boundary layer ingesting propulsor; these insights could not be obtained by using the uniform pressure jump model.

Propulsor↗

NASA NTRS1981

Free radical propulsion concept

The concept of a free radical propulsion system, utilizing the recombination energy of dissociated low molecular weight gases to produce thrust, is analyzed. The system, operating at a theoretical impulse with hydrogen, as high as 2200 seconds at high thrust to power ratio, is hypothesized to bridge the gap between chemical and electrostatic propulsion capabilities. A comparative methodology is outlined by which characteristics of chemical and electric propulsion for orbit raising mission can be investigated. It is noted that free radicals proposed in rockets previously met with difficulty and complexity in terms of storage requirements; the present study proposes to eliminate the storage requirements by using electric energy to achieve a continuous-flow product of free radicals which are recombined to produce a high velocity propellant. Microwave energy used to dissociate a continuously flowing gas is transferred to the propellant via three-body-recombination for conversion to propellant kinetic energy. Microwave plasma discharge was found in excess of 90 percent over a broad range of pressure in preliminary experiments, and microwave heating compared to electrothermal heating showed much higher temperatures in gasdynamic equations.

Hawkins, C. E.↗

NASA NTRS1979

Computation of aerodynamic interference effects on oscillating airfoils with controls in ventilated subsonic wind tunnels

Lift interference effects are discussed based on Bland's (1968) integral equation. A mathematical existence theory is utilized for which convergence of the numerical method has been proved for general (square-integrable) downwashes. Airloads are computed using orthogonal airfoil polynomial pairs in conjunction with a collocation method which is numerically equivalent to Galerkin's method and complex least squares. Convergence exhibits exponentially decreasing error with the number n of collocation points for smooth downwashes, whereas errors are proportional to 1/n for discontinuous downwashes. The latter can be reduced to 1/n to the m+1 power with mth-order Richardson extrapolation (by using m = 2, hundredfold error reductions were obtained with only a 13% increase of computer time). Numerical results are presented showing acoustic resonance, as well as the effect of Mach number, ventilation, height-to-chord ratio, and mode shape on wind-tunnel interference. Excellent agreement with experiment is obtained in steady flow, and good agreement is obtained for unsteady flow.

Fromme, J. A.↗

NASA NTRS1999

Nonlinear Response of Composite Panels Under Combined Acoustic Excitation and Aerodynamic Pressure

A finite element formulation is presented for the analysis of large deflection response of composite panels subjected to aerodynamic pressure- at supersonic flow and high acoustic excitation. The first-order shear deformation theory is considered for laminated composite plates, and the von Karman nonlinear strain-displacement relations are employed for the analysis of large deflection panel response. The first-order piston theory aerodynamics and the simulated Gaussian white noise are employed for the aerodynamic and acoustic loads, respectively. The nonlinear equations of motion for an arbitrarily laminated composite panel subjected to a combined aerodynamic and acoustic pressures are formulated first in structure node degrees-of-freedom. The system equations are then transformed and reduced to a set of coupled nonlinear equations in modal coordinates. Modal participation is defined and the in-vacuo modes to be retained in the analysis are based on the modal participation values. Numerical results include root mean square values of maximum deflections, deflection and strain response time histories, probability distributions, and power spectrum densities. Results showed that combined acoustic and aerodynamic loads have to be considered for panel analysis and design at high dynamic pressure values.

Abdel-Motagaly, K.↗

DOE OSTI2021

Extended convex hull-based distributed optimal energy flow of integrated electricity-gas systems

Integrated electricity and gas systems are constructed to facilitate the gas-fired generation, and the distributed operation of these integrated systems have received much attention due to the increased emphasis on data security and privacy between different agencies. This paper proposes an extended convex hull based method to address optimal energy flow problems for the integrated electricity and gas systems in a distributed manner. First, a multi-block electricity-gas system model is constructed by dividing the whole system into N blocks considering both physical and regional differences. This multi-block model is then convexified by replacing the nonconvex gas transmission equation with the extended convex hull-based constraints. The Jacobi-Proximal alternating direction method of multipliers algorithm is adopted to solve the convexified model and minimize its operation cost. Finally, the feasibility of the optimal solution for the convexified model is checked, and a sufficient condition is developed. If the sufficient condition is satisfied, the optimal solution for the original nonconvex problem can be recovered from that for the convexified problem. Simulation results demonstrate that the proposed method is tractable and effective in obtaining feasible optimal solutions for multi-block optimal energy flow problems.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2026

Development of MOSCATO: A CFD-Level Electrochemistry and Corrosion Simulator for Molten Salt Systems

For both coolant and fueled variants of molten salt reactors (MSRs), the corrosion of structural materials is a significant challenge. The corrosion stems from chemical and electrochemical reactions initiated by fissile material, fission products, and impurities in the salt. Lower-fidelity models rely on empirical correlations for mass transfer, simplified lumped temperature profiles, and similar assumptions. They do not capture detailed spatial variations in complex geometries, creating the need for high-fidelity modeling to bridge this gap.As we approach the demonstration and possible deployment of MSRs in this decade, the development of a high-fidelity, high-performance simulator becomes imperative. To simulate the complex electrochemical environment and corrosion within molten salt systems, we have developed the Molten Salt Chemistry And TranspOrt (MOSCATO) code. This endeavor is comprised of three essential components. First, mass transfer equations are coupled with the Navier-Stokes equations in order to account for the transport of species in the salt. Second, the diffusion of alloy constituents, such as Cr, Fe, Ni, etc. is simulated within the structural metals. Third, the alloy and salt domains are coupled to account for the heterogeneous chemical and electrochemical reactions that occur at the salt-alloy interface.MOSCATO manages all three components within the framework of the highly scalable, open-source spectral element method computational fluid dynamics code Nek5000/NekRS. This integration enables MOSCATO to harness the immense computational power of modern high-performance computing resources, ensuring both high fidelity and computational speed.In addition to code development, we have initiated a comprehensive verification and validation campaign, utilizing data from diverse sources. First, MOSCATO's electrochemical solver was verified with reference numerical data. Then validation occurred against experiments: one of a thermal galvanic cell and the other for corrosion in flowing molten salt of FLiNaK (LiF-NaF-KF). This campaign verified and validated MOSCATO as a reliable tool for simulating electrochemical environments and corrosion in molten salt systems.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1989

Direct solar-pumped iodine laser amplifier

This semiannual progress report covers the period from September 1, 1988 to February 28, 1989 under NASA grant NAG-1-441 entitled, Direct Solar-Pumped Iodine Laser Amplifier. During this period, the research effort was concentrated on the solar pumped master oscillator power amplifier (MOPA) system using n-C3F7I. In the experimental work, the amplification measurement was conducted to identify the optimum conditions for amplification of the center's Vortek solar simulator pumped iodine laser amplifier. A modeling effort was also pursued to explain the experimental results in the theoretical work. The amplification measurement of the solar simulator pumped iodine laser amplifier is the first amplification experiment on the continuously pumped amplifier. The small signal amplification of 5 was achieved for the triple pass geometry of the 15 cm long solar simulator pumped amplifier at the n-C3F7I pressure of 20 torr, at the flow velocity of 6 m/sec and at the pumping intensity of 1500 solar constants. The XeCl laser pumped iodine laser oscillator, which was developed in the previous research, was employed as the master oscillator for the amplification measurement. In the theoretical work, the rate equations of the amplifier was established and the small signal amplification was calculated for the solar simulator pumped iodine laser amplifier. The amplification calculated from the kinetic equations with the previously measured rate coefficients reveals very large disagreement with experimental measurement. Moreover, the optimum condition predicted by the kinetic equation is quite discrepant with that measured by experiment. This fact indicates the necessity of study in the measurement of rate coefficients of the continuously pumped iodine laser system.

Han, Kwang S.↗

NASA NTRS2021

Speed Limits for Radiation-driven SMBH Winds

Context. Ultra-fast outflows (UFOs) have become an established feature in analyses of the X-ray spectra of active galactic nuclei (AGN). According to the standard picture, they are launched at accretion disc scales with relativistic velocities, up to 0.3-0.4 times the speed of light. Their high kinetic power is enough to induce an efficient feedback on a galactic scale, possibly contributing to the co-evolution between the central supermassive black hole (SMBH) and the host galaxy. It is, therefore, of paramount importance to gain a full understanding of UFO physics and, in particular, of the forces driving their acceleration and the relation to the accretion flow from which they originate. Aims. In this paper, we investigate the impact of special relativity effects on the radiative pressure exerted onto the outflow. The radiation received by the wind decreases for increasing outflow velocity, v, implying that the standard Eddington limit argument has to be corrected according to v. Due to the limited ability of the radiation to counteract the black hole gravitational attraction, we expect to find lower typical velocities with respect to the non-relativistic scenario. Methods. We integrated the relativistic-corrected outflow equation of motion for a realistic set of starting conditions. We concentrated on a range of ionisations, column densities, and launching radii consistent with those typically estimated for UFOs. We explore a one-dimensional, spherical geometry and a three-dimensional setting with a rotating, thin accretion disc. Results. We find that the inclusion of special relativity effects leads to sizeable differences in the wind dynamics and that v is reduced up to 50% with respect to the non-relativistic treatment. We compare our results with a sample of UFOs from the literature and we find that the relativistic-corrected velocities are systematically lower than the reported ones, indicating the need for an additional mechanism, such as magnetic driving, to explain the highest velocity components. Finally, we note that these conclusions, derived for AGN winds, are generally applicable.

A Luminari↗

DOE OSTI2021

A high-order WENO-limited finite-volume algorithm for atmospheric flow using the ADER-differential transform time discretization

A high-order-accurate weighted essentially non-oscillatory (WENO) limited upwind finite-volume scheme is detailed for the compressible, nonhydrostatic, inviscid Euler equations using an arbitrary derivatives (ADER) time-stepping scheme based on differential transforms (DTs). A second-order-accurate alternating Strang dimensional splitting is compared against multidimensional simulation with 2D transport using solid body rotation of various data. The two were found to give nearly identical accuracy in orthogonal, Cartesian coordinates. Orders of convergence are demonstrated at up to ninth-order accuracy with 2D transport. 1D transport is used to confirm that error decreases monotonically with increasing order of accuracy with WENO limiting even for discontinuous data. Further, WENO limiting always decreased the error compared with simulation without limiting in the L 1 norm. A series of standard 2D compressible nonhydrostatic Euler equation test cases were validated against previous results from literature. Finally, it was demonstrated that increasing the order of accuracy led to better resolved features and increased power for kinetic energy at small wavelengths.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Optimization-Inspired Pin-Fin Array for Supercritical Carbon Dioxide Recuperator

Additively manufactured heat exchangers are one possible route to cost-effective sCO 2 power cycles. In this paper, experimental results are obtained for two helical pin fin tubes that were designed following parametric optimization of the fin array. Neither the numerical optimization nor the experimental testing have been previously reported in the literature. The two tube designs were, (1) the optimization inspired design, and (2) the optimization-inspired design with a fin diameter increased by a factor of 2. To characterize the print, the designs were scanned using X-ray computed tomography to measure feature sizes and heat transfer area. The optimization was conducted in a commercial, computational fluid dynamics code. The code solved the Reynolds Averaged Navier-Stokes (RANS) and energy equations with turbulence closure provided by the shear stress transport (SST) k-ω model. In the experiments, the Nusselt number augmentation was measured using the Wilson plot technique and the friction factor was determined with mass flow and pressure drop measurements. The experimental testing indicated that the optimization-inspired design had a friction factor that was four times less than the baseline tube design at equal Nusselt number. Additionally, the optimization-inspired design had a 14% improvement in Nusselt number, at equal friction factor, relative to the best performing computational fluid dynamics (CFD) trial points. Tube design (2), with the larger diameter pin fins, had similar performance, within experimental error, as the tube with the smaller diameter pin fins (1). Both tubes achieved overall fin array efficiencies near 1. A performance factor, V/V 0 , equal to the volume of the enhanced heat exchanger divided by the volume of the baseline (no-fins) heat exchanger, is recommended to quantify internal cooling performance. In conclusion, the experimental shell and tube heat exchanger, using the additively manufactured tube, is competitive with printed circuit heat exchangers in its pressure drop class and could be further improved by optimizing a shell-and-tube heat exchanger utilizing this heat transfer enhancement feature.

42 ENGINEERING↗