Results for “design (process simulation)” — Page 3

DOE OSTI2020

Modeling and simulation of gas separations with spiral–wound membranes

Models for gas separations with spiral–wound membranes are developed and found to exhibit good agreement with experiments performed on N 2 /O 2 mixtures. The two–dimensional (2D) model can be accurately approximated by a one–dimensional (1D) surrogate model when the spacer widths are chosen to make the channel pressure drops small. Subsequently, the separation of propane/propylene mixtures from the recycle purge stream of a polypropylene reactor is investigated. Assuming ideal gas is found to lead to significant overestimations in membrane stage cuts (sometimes more than 10%), an extent comparable to that associated with extrapolating constant olefin permeance from a low–pressure condition. While olefin permeance can change significantly with pressure, using a constant–permeance formulation can result in a small (< 2.5%) underprediction in stage cut if the value for the permeance is taken from the feed condition. Finally, membrane properties and costs necessary for a viable separation process are discussed.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2007

Development of High Fidelity, Fuel-Like Thermal Simulators for Non-Nuclear Testing

Non-nuclear testing can be a valuable tool in development of a space nuclear power or propulsion system. In a non-nuclear test bed, electric heaters are used to simulate the heat from nuclear fuel. Work at the NASA Marshall Space Flight Center seeks to develop high fidelity thermal simulators that not only match the static power profile that would be observed in an operating, fueled nuclear reactor, but to also match the dynamic fuel pin performance during feasible transients. Comparison between the fuel pins and thermal simulators is made at the fuel clad surface, which corresponds to the sheath surface in the thermal simulator. Static and dynamic fuel pin performance was determined using SINDA-FLUINT analysis, and the performance of conceptual thermal simulator designs was compared to the expected nuclear performance. Through a series of iterative analysis, a conceptual high fidelity design will be developed, followed by engineering design, fabrication, and testing to validate the overall design process. Although the resulting thermal simulator will be designed for a specific reactor concept, establishing this rigorous design process will assist in streamlining the thermal simulator development for other reactor concepts.

Bragg-Sitton, S. M.↗

DOE OSTI2014

Bench-Scale Development of a Hot Carbonate Absorption Process with Crystallization-Enabled High Pressure Stripping for Post-Combustion CO 2 Capture

This report summarizes the methodology and preliminary results of a techno-economic analysis on a hot carbonate absorption process (Hot-CAP) with crystallization-enabled high pressure stripping for post-combustion CO 2 capture (PCC). This analysis was based on the Hot-CAP that is fully integrated with a sub-critical steam cycle, pulverized coal-fired power plant adopted in Case 10 of the DOE/NETL’s Cost and Performance Baseline for Fossil Energy Plants. The techno-economic analysis addressed several important aspects of the Hot-CAP for PCC application, including process design and simulation, equipment sizing, technical risk and mitigation strategy, performance evaluation, and cost analysis. Results show that the net power produced in the subcritical power plant equipped with Hot-CAP is 611 MWe, greater than that with Econoamine (550 MWe). The total capital cost for the Hot-CAP, including CO 2 compression, is $\$ $399 million, less than that for the Econoamine PCC ($\$ $493 million). O&M costs for the power plant with Hot-CAP is $\$ $175 million annually, less than that with Econoamine ($\$ $178 million). The 20-year levelized cost of electricity (LCOE) for the power plant with Hot-CAP, including CO 2 transportation and storage, is 119.4 mills/kWh, a 59% increase over that for the plant without CO 2 capture. The LCOE increase caused by CO 2 capture for the Hot-CAP is 31% lower than that for its Econoamine counterpart.

20 FOSSIL-FUELED POWER PLANTS↗

NASA NTRS1979

Control and stabilization of the DOE/NASA Mod-1 two megawatt wind turbine generator

This paper describes the controls design, performance simulation process and specialized dynamic considerations for the DOE/NASA Mod 1 wind turbine generator (WTG). It shows controls, structural and utility interface considerations of the wind turbine generator and shows how a wind turbine generator can be integrated with a synchronous power system. Differences with respect to fossil or hydro generation and their implications are vital to long-term WTG reliability and availability and acceptance by utilities and consumers. The paper describes the control performance requirements to provide stable pitch and excitation control with drivetrain torsional dynamics, and the control of power swing stability and utility feeder voltage due to wind gusts.

Barton, R. S.↗

NASA NTRS1988

A CAD approach to magnetic bearing design

A design methodology has been developed at the Magnetic Bearing Research Laboratory for designing magnetic bearings using a CAD approach. This is used in the algorithm of an interactive design software package. The package is a design tool developed to enable the designer to simulate the entire process of design and analysis of the system. Its capabilities include interactive input/modification of geometry, finding any possible saturation at critical sections of the system, and the design and analysis of a control system that stabilizes and maintains magnetic suspension.

Jeyaseelan, M.↗

NASA NTRS2002

Measuring the Resilience of Advanced Life Support Systems

Despite the central importance of crew safety in designing and operating a life support system, the metric commonly used to evaluate alternative Advanced Life Support (ALS) technologies does not currently provide explicit techniques for measuring safety. The resilience of a system, or the system s ability to meet performance requirements and recover from component-level faults, is fundamentally a dynamic property. This paper motivates the use of computer models as a tool to understand and improve system resilience throughout the design process. Extensive simulation of a hybrid computational model of a water revitalization subsystem (WRS) with probabilistic, component-level faults provides data about off-nominal behavior of the system. The data can then be used to test alternative measures of resilience as predictors of the system s ability to recover from component-level faults. A novel approach to measuring system resilience using a Markov chain model of performance data is also developed. Results emphasize that resilience depends on the complex interaction of faults, controls, and system dynamics, rather than on simple fault probabilities.

Bell, Ann Maria↗

DOE OSTI2025

Simulation-driven design optimization of reaction injection molding (RIM) process for polydicyclopentadiene (pDCPD): Minimizing cycle time, defects, and warpage

Replacing metal components in trucks, trailers, and buses with lightweight polymer composites is challenging due to high temperatures and complex manufacturing. The Reaction Injection Molding (RIM) process using Dicyclopentadiene (DCPD) resin offers a solution by producing robust parts with excellent stiffness, impact strength, and resistance properties. Simulations are essential for optimizing this process, predicting defects, and improving quality. However, most commercial software is tailored for thermoplastics, requiring thermoset users to generate their own datasets. In this study, a material data card for DCPD was developed to perform RIM simulations. Design of Experiments (DOE) was used to identify key factors affecting filling, curing, and warpage, aiming to minimize cycle time and defects. The simulations explored varying injection gate parameters (size, location, number) and process conditions (mold/resin temperature, injection/curing pressure). Results showed that gate design significantly impacts filling behavior and defects. A single central gate provided balanced flow with fewer defects, while two corner gates led to more defects. Additionally, lower injection pressure increased filling time, while higher mold temperature accelerated curing but led to more warpage. In conclusion, this optimization framework aims to enhance DCPD part performance and promote sustainable manufacturing by reducing waste and energy consumption.

42 ENGINEERING↗

DOE OSTI2020

Adaptive simulations enable computational design of electron beam processing of nanomaterials with supersonic micro-jet precursor

Focused Electron Beam Induced Processing (FEBIP) is a powerful tool for the “direct-write” of nanomaterials with the possibility of atomistic control on suspended 2D material substrates. FEBIP capabilities have been significantly expanded by using a localized jet-based delivery of precursors, and especially when a thermally energized supersonic micro-jet enhances the delivery of mass flux along with controlling the far-from-equilibrium thermodynamic state of adsorbed adatoms. The possibilities of growing nanomaterials with “dialed-in” composition with ultra-high growth rates and aspect ratios up to 100:1 have been demonstrated using the supersonic micro-jet-FEBIP. Bringing this scientific discovery to the level of maturity required for practical applications in additive nanomanufacturing requires simulation tools that are capable of capturing the complex flow physics of micro-jet-substrate interactions that bridge a wide range of flow regimes from the high-density gas micro-jet expanding into the vacuum environment of FEBIP. To address this significant computational challenge, a new approach has been developed and described in this work for a multiscale adaptive DSMC (Direct Simulation Monte Carlo) algorithm to predict the micro-jet gas dynamics in an FEBIP environment, spanning the full range of flow regimes from low Knudsen (Kn) number O(0.01) continuum flow to high Kn of O(10) for the molecular flow within a unified computational framework. Here, the fundamental principles of the adaptive DSMC algorithm are described, its viability as a DSMC technique is demonstrated, and computational improvements for the benchmark cases are discussed in the context of advancing 3D nanofabrication with FEBIP. Ultimately, combining the first principle simulations via adaptive DSMC with the complementary experimental data will enable the creation of the powerful CAD tools for in silico design and optimal operation of micro-jet-FEBIP.

36 MATERIALS SCIENCE↗

NASA NTRS1978

Data Management Symposium, Huntsville, Ala., October 18, 19, 1977, Proceedings

The transfer, processing, and use of satellite data are discussed. Topics relating to simulation and processing techniques include computer design assessments through simulation, data system dynamic simulation, and future timing accuracy requirements and procedures for data processing. Subjects relevant to data base management systems and users and their needs include an image-based information system architecture for correlation satellite and topological data base, efficient searching and sorting applications using an associative array processor, analysis of user's needs for a large technical data base, and variable length data formats. The technology development outlook was considered with attention to data systems technology outlook for supporting NASA programs, a user-oriented interactive information extraction system, and flow control and sorting techniques for telemetry packets.

Castelli, A.↗

NASA NTRS1999

Transonic Flutter Suppression Control Law Design Using Classical and Optimal Techniques with Wind-Tunnel Results

The benchmark active controls technology and wind tunnel test program at NASA Langley Research Center was started with the objective to investigate the nonlinear, unsteady aerodynamics and active flutter suppression of wings in transonic flow. The paper will present the flutter suppression control law design process, numerical nonlinear simulation and wind tunnel test results for the NACA 0012 benchmark active control wing model. The flutter suppression control law design processes using (1) classical, (2) linear quadratic Gaussian (LQG), and (3) minimax techniques are described. A unified general formulation and solution for the LQG and minimax approaches, based on the steady state differential game theory is presented. Design considerations for improving the control law robustness and digital implementation are outlined. It was shown that simple control laws when properly designed based on physical principles, can suppress flutter with limited control power even in the presence of transonic shocks and flow separation. In wind tunnel tests in air and heavy gas medium, the closed-loop flutter dynamic pressure was increased to the tunnel upper limit of 200 psf. The control law robustness and performance predictions were verified in highly nonlinear flow conditions, gain and phase perturbations, and spoiler deployment. A non-design plunge instability condition was also successfully suppressed.

Mukhopadhyay, Vivek↗

NASA NTRS1999

Transonic Flutter Suppression Control Law Design, Analysis and Wind Tunnel Results

The benchmark active controls technology and wind tunnel test program at NASA Langley Research Center was started with the objective to investigate the nonlinear, unsteady aerodynamics and active flutter suppression of wings in transonic flow. The paper will present the flutter suppression control law design process, numerical nonlinear simulation and wind tunnel test results for the NACA 0012 benchmark active control wing model. The flutter suppression control law design processes using (1) classical, (2) linear quadratic Gaussian (LQG), and (3) minimax techniques are described. A unified general formulation and solution for the LQG and minimax approaches, based on the steady state differential game theory is presented. Design considerations for improving the control law robustness and digital implementation are outlined. It was shown that simple control laws when properly designed based on physical principles, can suppress flutter with limited control power even in the presence of transonic shocks and flow separation. In wind tunnel tests in air and heavy gas medium, the closed-loop flutter dynamic pressure was increased to the tunnel upper limit of 200 psf The control law robustness and performance predictions were verified in highly nonlinear flow conditions, gain and phase perturbations, and spoiler deployment. A non-design plunge instability condition was also successfully suppressed.

Mukhopadhyay, Vivek↗

NASA NTRS1999

Transonic Flutter Suppression Control Law Design, Analysis and Wind-Tunnel Results

The benchmark active controls technology and wind tunnel test program at NASA Langley Research Center was started with the objective to investigate the nonlinear, unsteady aerodynamics and active flutter suppression of wings in transonic flow. The paper will present the flutter suppression control law design process, numerical nonlinear simulation and wind tunnel test results for the NACA 0012 benchmark active control wing model. The flutter suppression control law design processes using (1) classical, (2) linear quadratic Gaussian (LQG), and (3) minimax techniques are described. A unified general formulation and solution for the LQG and minimax approaches, based on the steady state differential game theory is presented. Design considerations for improving the control law robustness and digital implementation are outlined. It was shown that simple control laws when properly designed based on physical principles, can suppress flutter with limited control power even in the presence of transonic shocks and flow separation. In wind tunnel tests in air and heavy gas medium, the closed-loop flutter dynamic pressure was increased to the tunnel upper limit of 200 psf. The control law robustness and performance predictions were verified in highly nonlinear flow conditions, gain and phase perturbations, and spoiler deployment. A non-design plunge instability condition was also successfully suppressed.

Mukhopadhyay, Vivek↗

NASA NTRS1999

Transonic Flutter Suppression Control Law Design, Analysis and Wind-Tunnel Results

The benchmark active controls technology and wind tunnel test program at NASA Langley Research Center was started with the objective to investigate the nonlinear, unsteady aerodynamics and active flutter suppression of wings in transonic flow. The paper will present the flutter suppression control law design process, numerical nonlinear simulation and wind tunnel test results for the NACA 0012 benchmark active control wing model. The flutter suppression control law design processes using classical, and minimax techniques are described. A unified general formulation and solution for the minimax approach, based on the steady state differential game theory is presented. Design considerations for improving the control law robustness and digital implementation are outlined. It was shown that simple control laws when properly designed based on physical principles, can suppress flutter with limited control power even in the presence of transonic shocks and flow separation. In wind tunnel tests in air and heavy gas medium, the closed-loop flutter dynamic pressure was increased to the tunnel upper limit of 200 psf. The control law robustness and performance predictions were verified in highly nonlinear flow conditions, gain and phase perturbations, and spoiler deployment. A non-design plunge instability condition was also successfully suppressed.

Mukhopadhyay, Vivek↗

NASA NTRS1999

Transonic Flutter Suppression Control Law Design Using Classical and Optimal Techniques with Wind-Tunnel Results

The benchmark active controls technology and wind tunnel test program at NASA Langley Research Center was started with the objective to investigate the nonlinear, unsteady aerodynamics and active flutter suppression of wings in transonic flow. The paper will present the flutter suppression control law design process, numerical nonlinear simulation and wind tunnel test results for the NACA 0012 benchmark active control wing model. The flutter suppression control law design processes using (1) classical, (2) linear quadratic Gaussian (LQG), and (3) minimax techniques are described. A unified general formulation and solution for the LQG and minimax approaches, based on the steady state differential game theory is presented. Design considerations for improving the control law robustness and digital implementation are outlined. It was shown that simple control laws when properly designed based on physical principles, can suppress flutter with limited control power even in the presence of transonic shocks and flow separation. In wind tunnel tests in air and heavy gas medium, the closed-loop flutter dynamic pressure was increased to the tunnel upper limit of 200 psf. The control law robustness and performance predictions were verified in highly nonlinear flow conditions, gain and phase perturbations, and spoiler deployment. A non-design plunge instability condition was also successfully suppressed.

Mukhopadhyay, Vivek↗

DOE OSTI2024

Control And Optimization Modular Modeling Application For Nuclear Deployment

The purpose of the COMMAND code is to provide a flexible, scalable tool for use in developing, integrating, and testing the technologies necessary for achieving autonomous operations of advanced nuclear reactors. The code enables users to efficiently implement custom simulations and experiments by combining key methods from different software modules. These modules are focused on: modeling and simulation tools, such as nuclear simulation tools used for high-fidelity modeling (e.g., Reactor Excursion and Leak Analysis Program [RELAP5-3D] and Monte Carlo N-Particle [MCNP]); machine learning and optimization tools (e.g., anomaly detection and data-driven modeling techniques); advanced control in its digital, high-performance, and supervisory control forms (e.g., proportional integral derivative (PID) control and model predictive control (MPC); and integration with hardware through industrial communication protocols. To ensure flexibility and scalability, COMMAND was designed to be both modular—the software “pieces” all inherit from generic building blocks and can be combined and connected to create complicated simulations—and high performing—designed for parallel processing, enabling simulations and experiments to take advantage of multi-core computers, servers, and nodes. The code is written in the Python programming language due to the language's popularity, active community, and open-source and cross-platform nature. Maintaining consistency with other simulation tools used within the nuclear energy community, users implement simulations and experiments through text input files, which define components, parameters, connections, etc., through lines of text. Given that COMMAND is written in Python, these input files are native Python scripts, and so use the standard Python structure and formatting. This also enables users to take advantage of Python's extensive package library to develop custom capabilities for their specific use cases.

Faber, Jacob [Idaho National Laboratory (INL), Ida↗

NASA NTRS1981

An approach to real-time simulation using parallel processing

A preliminary simulator design that uses a parallel computer organization to provide accuracy, portability, and low cost is presented. The hardware and software for this prototype simulator are discussed. A detailed discussion of the inter-computer data transfer mechanism is also presented.

Blech, R. A.↗

DOE OSTI2019

Using cylindrical implosions to investigate hydrodynamic instabilities in convergent geometry

Hydrodynamic instabilities such as the Rayleigh–Taylor (RT) and Richtmyer–Meshkov instabilities disrupt inertial confinement fusion (ICF) implosions through the growth of 3D perturbations. Growth of these 3D imperfections at the interfaces of an ICF capsule during implosion lead to mixing between materials that is detrimental to performance. These instabilities have been studied extensively in planar geometry, but such experiments lack the effects of convergence in spherical implosions. While several studies have been performed in spherical geometry, these often lack a direct means to measure perturbation growth. Experiments in cylindrical geometry include convergence effects while maintaining direct diagnostic access. Although cylinders have less compression than spheres, they do provide an excellent platform to validate modeling for convergent geometries. The problem with previous cylindrical implosion experiments was that the convergence ratios were limited to ~4. With the National Ignition Facility (NIF), larger cylindrical targets can be driven to convergences of 10–15 while maintaining a large enough final diameter to measure perturbation growth. This paper reviews the design process used to both benchmark radiation hydrodynamics codes and enable 1D post-processed simulations to explore design space to separate compression effects from acceleration/deceleration RT instability. Results from 1D simulations suggest that cylindrical implosions on the NIF can produce high-convergence experiments to validate RT instability growth for ICF implosions.

36 MATERIALS SCIENCE↗

NASA NTRS2003

Modeling and Simulation for Mission Operations Work System Design

Work System analysis and design is complex and non-deterministic. In this paper we describe Brahms, a multiagent modeling and simulation environment for designing complex interactions in human-machine systems. Brahms was originally conceived as a business process design tool that simulates work practices, including social systems of work. We describe our modeling and simulation method for mission operations work systems design, based on a research case study in which we used Brahms to design mission operations for a proposed discovery mission to the Moon. We then describe the results of an actual method application project-the Brahms Mars Exploration Rover. Space mission operations are similar to operations of traditional organizations; we show that the application of Brahms for space mission operations design is relevant and transferable to other types of business processes in organizations.

Sierhuis, Maarten↗