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DOE OSTI2025

Pressure Gain, Stability, and Operability of Methane/Syngas Based RDEs Under Steady and Transient Conditions (Final Project Report)

The scope of this work addresses key issues associated with losses associated with the detonation wave and other processes internal to the RDE operation, as well as it develops modeling tools for the evaluation of these losses and exhaust emissions in RDEs. The main challenge in studying RDEs is that RDE performance is highly reliant on the specifics of the design so much so that simple/canonical systems alone cannot provide useful engineering information, but practical RDE designs are sufficiently complex and involve extreme operational environments that detailed access either experimentally (laser diagnostics, for instance) or computationally (direct numerical simulations) are as yet to become practical. To overcome this challenge, we have conducted a combined experimental/simulation/analytical study investigating key phenomena that control the characteristics of operation of RDEs. As a result, the study has developed tools and methods that can be used to evaluate performance and design approaches using reduced-physics models, with the assumptions validated using detailed simulations, and the model prediction tested using experimental observations. The specific objectives of the research were: (1) Develop and demonstrate a low-loss fully axial injection concept, taking advantage of stratification effects to alter the detonation structure and position the wave favorably within the combustor; (2) Obtain stability and operability characteristics of an RDE across operating conditions to aid in the development of operability and performance rules for the operations of other systems; and (3) Develop quantitative metrics for performance gain as well as quantitative description of the loss mechanisms through a combination of diagnostics development, reduced-order modeling, and detailed simulations. The work conducted here has made contribution on design of low-loss inlets that has broad application within the power generation industry for use with pressure gain combustion. The operability and stability of different designs, while focusing on axial air inlet designs, has been analyzed. The effect of nozzle and injection conditions was studied. Models and simulations of exhaust emissions, focusing on NOx emission has been developed and used to investigate how operation of the RDE affect NOx production using Lagrangian analysis of RDE simulations. This work has built on previous programs, with the goal of further understanding operation of RDEs and elevate the readiness of design consideration. In addition, a suite of diagnostic and modeling tools have been developed to obtain quantitative metrics on performance based on measurements, which can be readily transferred to other experimental configurations.

08 HYDROGEN↗

DOE OSTI2011

Highly Integrated Quality Assurance – An Empirical Case

Highly Integrated Quality Assurance – An Empirical Case Drake Kirkham1, Amy Powell2, Lucas Rich3 1Quality Manager, Radioisotope Power Systems (RPS) Program, Idaho National Laboratory, P.O. Box 1625 M/S 6122, Idaho Falls, ID 83415-6122 2Quality Engineer, RPS Program, Idaho National Laboratory 3Quality Engineer, RPS Program, Idaho National Laboratory Contact: Voice: (208) 533-7550 Email: Drake.Kirkham@inl.gov Abstract. The Radioisotope Power Systems Program of the Idaho National Laboratory makes an empirical case for a highly integrated Quality Assurance function pertaining to the preparation, assembly, testing, storage and transportation of 238Pu fueled radioisotope thermoelectric generators. Case data represents multiple campaigns including the Pluto/New Horizons mission, the Mars Science Laboratory mission in progress, and other related projects. Traditional Quality Assurance models would attempt to reduce cost by minimizing the role of dedicated Quality Assurance personnel in favor of either functional tasking or peer-based implementations. Highly integrated Quality Assurance adds value by placing trained quality inspectors on the production floor side-by-side with nuclear facility operators to enhance team dynamics, reduce inspection wait time, and provide for immediate, independent feedback. Value is also added by maintaining dedicated Quality Engineers to provide for rapid identification and resolution of corrective action, enhanced and expedited supply chain interfaces, improved bonded storage capabilities, and technical resources for requirements management including data package development and Certificates of Inspection. A broad examination of cost-benefit indicates highly integrated Quality Assurance can reduce cost through the mitigation of risk and reducing administrative burden thereby allowing engineers to be engineers, nuclear operators to be nuclear operators, and the cross-functional team to operate more efficiently. Applicability of this case extends to any high-value, long-term project where traceability and accountability are determining factors.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2019

Stabilization of point-defect spin qubits by quantum wells

Defect-based quantum systems in wide bandgap semiconductors are strong candidates for scalable quantum-information technologies. However, these systems are often complicated by charge-state instabilities and interference by phonons, which can diminish spin-initialization fidelities and limit room-temperature operation. Here, we identify a pathway around these drawbacks by showing that an engineered quantum well can stabilize the charge state of a qubit. Using density-functional theory and experimental synchrotron X-ray diffraction studies, we construct a model for previously unattributed point defect centers in silicon carbide as a near-stacking fault axial divacancy and show how this model explains these defects' robustness against photoionization and room temperature stability. These results provide a materials-based solution to the optical instability of color centers in semiconductors, paving the way for the development of robust single-photon sources and spin qubits.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2014

Constraint-Based Modeling of Carbon Fixation and the Energetics of Electron Transfer in Geobacter metallireducens

Geobacter species are of great interest for environmental and biotechnology applications as they can carry out direct electron transfer to insoluble metals or other microorganisms and have the ability to assimilate inorganic carbon. Here, we report on the capability and key enabling metabolic machinery of Geobacter metallireducens GS-15 to carry out CO2 fixation and direct electron transfer to iron. An updated metabolic reconstruction was generated, growth screens on targeted conditions of interest were performed, and constraint-based analysis was utilized to characterize and evaluate critical pathways and reactions in G. metallireducens. The novel capability of G. metallireducens to grow autotrophically with formate and Fe(III) was predicted and subsequently validated in vivo. Additionally, the energetic cost of transferring electrons to an external electron acceptor was determined through analysis of growth experiments carried out using three different electron acceptors (Fe(III), nitrate, and fumarate) by systematically isolating and examining different parts of the electron transport chain. The updated reconstruction will serve as a knowledgebase for understanding and engineering Geobacter and similar species. Author Summary The ability of microorganisms to exchange electrons directly with their environment has large implications for our knowledge of industrial and environmental processes. For decades, it has been known that microbes can use electrodes as electron acceptors in microbial fuel cell settings. Geobacter metallireducens has been one of the model organisms for characterizing microbe-electrode interactions as well as environmental processes such as bioremediation. Here, we significantly expand the knowledge of metabolism and energetics of this model organism by employing constraint-based metabolic modeling. Through this analysis, we build the metabolic pathways necessary for carbon fixation, a desirable property for industrial chemical production. We further discover a novel growth condition which enables the characterization of autotrophic (i.e., carbon-fixing) metabolism in Geobacter. Importantly, our systems-level modeling approach helped elucidate the key metabolic pathways and the energetic cost associated with extracellular electron transfer. This model can be applied to characterize and engineer the metabolism and electron transfer capabilities of Geobacter for biotechnological applications.

Feist, AM↗

DOE OSTI2016

Best-Estimate-Plus-Uncertainty-Informed Deterministic Safety Evaluation

Nuclear power plant (NPP) utilities operate contingent on receiving a favorable safety assessment from their national regulatory and safety authority. Among the many facets of NPP safety addressed is verification of integral design-basis performance - a demonstration of a plant's response to a suite of challenging transient and accident scenarios. Thermal-hydraulic system computer codes like RELAP5, TRAC, CATHARE, and ATHLET are used as the simulation engine as part of a broader evaluation model that accounts for a variety of uncertainties. It is common for these evaluation models to apply either a super-bounding/ deterministic or best-estimate plus uncertainty (BEPU) approach. The trend over the past two decades has been away from the classical deterministic methods towards methods explicitly incorporating parametric uncertainty models. These methods center upon the evaluation of parametric and system response uncertainties, where these uncertainties are derived from the convolution of one or more parametric uncertainty models. Acceptance of BEPU methods has provided the nuclear industry benefits regarding operational flexibility and, in some cases, power output. The advantage of BEPU for new NPPs is less obvious. Generally, these new designs include engineered safety features that practically eliminate fuel damage resulting from design-basis events. To substantiate such claims, applying super-bounding assumptions on uncertainties may be a more expedient demonstration of a plant's safety case than those based on BEPU. In addition, the requirements on design inputs for a deterministic evaluation model are substantially less than that for a BEPU evaluation model. As such, applying a deterministic evaluation model is expected to have the advantage of reducing the duration of the licensing review process. For the current operating fleet of light-water reactors (LWRs), the nuclear safety authorities in most countries have followed the U.S. Nuclear Regulatory Commission's rules for the preparation of safety analysis. These rules are specified in the U.S. Code of Federal Regulations, most notably in, Part 10, Section 50.46, entitled 'acceptance criteria for emergency core cooling systems for light-water nuclear power reactors' and its Appendix K. Notably, Appendix K specifies deterministic requirements for analysis of the loss-of-coolant accident (LOCA), which is generally regarded as the maximum credible accident for LWRs. Projecting 10 CFR 50, Appendix K, to new plants is not obviously applicable as it addresses light water fluid flow and heat transfer phenomena associated with core uncovery. Preventing core uncovery is a requirement for several designs in the class of small modular reactors (SMR). In doing so, the majority of phenomenological uncertainties prescribed in Appendix K are eliminated. Similarly, the impact of other phenomena to effect a change in various safety measures, i.e., figures-of-merit, is expected to be different. The implication is that development of a deterministic evaluation model must be derived with an original technical basis rather than solely rely on Appendix K. While a logical conclusion, the expectation of original bases, regardless of the treatment of uncertainties, is embodied in the U.S. NRC's Regulatory Guide (RG) 1.203, Transient and Accident Analysis. Within the evaluation model development and application process framework of RG 1.203, this paper describes a BEPU-informed deterministic evaluation model for NPPs with large inherent safety margins. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2013

Applying uncertainty quantification to multiphase flow computational fluid dynamics

Multiphase computational fluid dynamics plays a major role in design and optimization of fossil fuel based reactors. There is a growing interest in accounting for the influence of uncertainties associated with physical systems to increase the reliability of computational simulation based engineering analysis. The U.S. Department of Energy's National Energy Technology Laboratory (NETL) has recently undertaken an initiative to characterize uncertainties associated with computer simulation of reacting multiphase flows encountered in energy producing systems such as a coal gasifier. The current work presents the preliminary results in applying non-intrusive parametric uncertainty quantification and propagation techniques with NETL's open-source multiphase computational fluid dynamics software MFIX. For this purpose an open-source uncertainty quantification toolkit, PSUADE developed at the Lawrence Livermore National Laboratory (LLNL) has been interfaced with MFIX software. In this study, the sources of uncertainty associated with numerical approximation and model form have been neglected, and only the model input parametric uncertainty with forward propagation has been investigated by constructing a surrogate model based on data-fitted response surface for a multiphase flow demonstration problem. Monte Carlo simulation was employed for forward propagation of the aleatory type input uncertainties. Several insights gained based on the outcome of these simulations are presented such as how inadequate characterization of uncertainties can affect the reliability of the prediction results. Also a global sensitivity study using Sobol' indices was performed to better understand the contribution of input parameters to the variability observed in response variable.

42 ENGINEERING↗

DOE OSTI2011

Residential Real-time Price Response Simulation

The electric industry is gaining experience with innovative price responsive demand pilots and limited roll-outs to customers. One of these pilots is investigating real-time pricing signals to engage end-use systems and local distributed generation and storage in a distributed optimization process. Attractive aspects about the approach include strong scalability characteristics, simplified interfaces between automation devices, and the adaptability to integrate a wide variety of devices and systems. Experience in this nascent field is revealing a rich array of for engineering decisions and the application of complexity theory. To test the decisions, computer simulations are used to reveal insights about design, demand elasticity, and the limits of response (including consumer fatigue). Agent-based approaches lend themselves well in the simulation to modeling the participation and interaction of each piece of equipment on a distribution feeder. This paper discusses rate design and simulation experiences at the distribution feeder level where consumers and their HVAC systems and water heaters on a feeder receive real-time pricing signals.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2011

Research Needs and Impacts in Predictive Simulation for Internal Combustion Engines (PreSICE)

This report is based on a SC/EERE Workshop to Identify Research Needs and Impacts in Predictive Simulation for Internal Combustion Engines (PreSICE), held March 3, 2011, to determine strategic focus areas that will accelerate innovation in engine design to meet national goals in transportation efficiency. The U.S. has reached a pivotal moment when pressures of energy security, climate change, and economic competitiveness converge. Oil prices remain volatile and have exceeded $100 per barrel twice in five years. At these prices, the U.S. spends $1 billion per day on imported oil to meet our energy demands. Because the transportation sector accounts for two-thirds of our petroleum use, energy security is deeply entangled with our transportation needs. At the same time, transportation produces one-quarter of the nation’s carbon dioxide output. Increasing the efficiency of internal combustion engines is a technologically proven and cost-effective approach to dramatically improving the fuel economy of the nation’s fleet of vehicles in the near- to mid-term, with the corresponding benefits of reducing our dependence on foreign oil and reducing carbon emissions. Because of their relatively low cost, high performance, and ability to utilize renewable fuels, internal combustion engines—including those in hybrid vehicles—will continue to be critical to our transportation infrastructure for decades. Achievable advances in engine technology can improve the fuel economy of automobiles by over 50% and trucks by over 30%. Achieving these goals will require the transportation sector to compress its product development cycle for cleaner, more efficient engine technologies by 50% while simultaneously exploring innovative design space. Concurrently, fuels will also be evolving, adding another layer of complexity and further highlighting the need for efficient product development cycles. Current design processes, using “build and test” prototype engineering, will not suffice. Current market penetration of new engine technologies is simply too slow—it must be dramatically accelerated. These challenges present a unique opportunity to marshal U.S. leadership in science-based simulation to develop predictive computational design tools for use by the transportation industry. The use of predictive simulation tools for enhancing combustion engine performance will shrink engine development timescales, accelerate time to market, and reduce development costs, while ensuring the timely achievement of energy security and emissions targets and enhancing U.S. industrial competitiveness. In 2007 Cummins achieved a milestone in engine design by bringing a diesel engine to market solely with computer modeling and analysis tools. The only testing was after the fact to confirm performance. Cummins achieved a reduction in development time and cost. As important, they realized a more robust design, improved fuel economy, and met all environmental and customer constraints. This important first step demonstrates the potential for computational engine design. But, the daunting complexity of engine combustion and the revolutionary increases in efficiency needed require the development of simulation codes and computation platforms far more advanced than those available today. Based on these needs, a Workshop to Identify Research Needs and Impacts in Predictive Simulation for Internal Combustion Engines (PreSICE) convened over 60 U.S. leaders in the engine combustion field from industry, academia, and national laboratories to focus on two critical areas of advanced simulation, as identified by the U.S. automotive and engine industries. First, modern engines require precise control of the injection of a broad variety of fuels that is far more subtle than achievable to date and that can be obtained only through predictive modeling and simulation. Second, the simulation, understanding, and control of these stochastic in-cylinder combustion processes lie on the critical path to realizing more efficient engines with greater power density. Fuel sprays set the initial conditions for combustion in essentially all future transportation engines; yet today designers primarily use empirical methods that limit the efficiency achievable. Three primary spray topics were identified as focus areas in the workshop: The fuel delivery system, which includes fuel manifolds and internal injector flow, The multi-phase fuel–air mixing in the combustion chamber of the engine, and The heat transfer and fluid interactions with cylinder walls. Current understanding and modeling capability of stochastic processes in engines remains limited and prevents designers from achieving significantly higher fuel economy. To improve this situation, the workshop participants identified three focus areas for stochastic processes: Improve fundamental understanding that will help to establish and characterize the physical causes of stochastic events, Develop physics-based simulation models that are accurate and sensitive enough to capture performance-limiting variability, and Quantify and manage uncertainty in model parameters and boundary conditions. Improved models and understanding in these areas will allow designers to develop engines with reduced design margins and that operate reliably in more efficient regimes. All of these areas require improved basic understanding, high-fidelity model development, and rigorous model validation. These advances will greatly reduce the uncertainties in current models and improve understanding of sprays and fuel–air mixture preparation that limit the investigation and development of advanced combustion technologies. The two strategic focus areas have distinctive characteristics but are inherently coupled. Coordinated activities in basic experiments, fundamental simulations, and engineering-level model development and validation can be used to successfully address all of the topics identified in the PreSICE workshop. The outcome will be: New and deeper understanding of the relevant fundamental physical and chemical processes in advanced combustion technologies, Implementation of this understanding into models and simulation tools appropriate for both exploration and design, and Sufficient validation with uncertainty quantification to provide confidence in the simulation results. These outcomes will provide the design tools for industry to reduce development time by up to 30% and improve engine efficiencies by 30% to 50%. The improved efficiencies applied to the national mix of transportation applications have the potential to save over 5 million barrels of oil per day, a current cost savings of $500 million per day.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2012

Overview of the TriBITS Lifecycle Model: Lean/Agile Software Lifecycle Model for Research-based Computational Science and Engineering Software

Software lifecycles are becoming an increasingly important issue for computational science & engineering (CSE) software. The process by which a piece of CSE software begins life as a set of research requirements and then matures into a trusted high-quality capability is both commonplace and extremely challenging. Although an implicit lifecycle is obviously being used in any effort, the challenges of this process--respecting the competing needs of research vs. production--cannot be overstated. Here we describe a proposal for a well-defined software lifecycle process based on modern Lean/Agile software engineering principles. What we propose is appropriate for many CSE software projects that are initially heavily focused on research but also are expected to eventually produce usable high-quality capabilities. The model is related to TriBITS, a build, integration and testing system, which serves as a strong foundation for this lifecycle model, and aspects of this lifecycle model are ingrained in the TriBITS system. Indeed this lifecycle process, if followed, will enable large-scale sustainable integration of many complex CSE software efforts across several institutions.

Agile↗

DOE OSTI2012

TriBITS Lifecycle Model: A Lean/Agile Software Lifecycle Model for Research-based Computational Science and Engineering and Applied Mathematical Software (V.1.0)

Software lifecycles are becoming an increasingly important issue for computational science and engineering (CSE) software. The process by which a piece of CSE software begins life as a set of research requirements and then matures into a trusted high-quality capability is both commonplace and extremely challenging. Although an implicit lifecycle is obviously being used in any effort, the challenges of this process - respecting the competing needs of research vs. production - cannot be overstated. Here we describe a proposal for a well-defined software lifecycle process based on modern Lean/Agile software engineering principles. What we propose is appropriate for many CSE software projects that are initially heavily focused on research but also are expected to eventually produce usable high-quality capabilities. The model is related to TriBITS, a build, integration and testing system, which serves as a strong foundation for this lifecycle model, and aspects of this lifecycle model are ingrained in the TriBITS system. Here, we advocate three to four phases or maturity levels that address the appropriate handling of many issues associated with the transition from research to production software. The goals of this lifecycle model are to better communicate maturity levels with customers and to help to identify and promote Software Engineering (SE) practices that will help to improve productivity and produce better software. An important collection of software in this domain is Trilinos, which is used as the motivation and the initial target for this lifecycle model. However, many other related and similar CSE (and non-CSE) software projects can also make good use of this lifecycle model, especially those that use the TriBITS system. Indeed this lifecycle process, if followed, will enable large-scale sustainable integration of many complex CSE software efforts across several institutions.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2016

An investigation of DTOcean foundation and anchor systems

This memo documents the mechanical loading analysis performed to date for the DTOcean program WP4 foundation and anchor systems submodule. FEA simulations were performed to validate design requirements defined by Python based analytic simulations of the WP4 program Naval Facilities Engineering Command (NAVFAC) tool. This FEA procedure focuses on worst case loading scenarios on direct mbedment anchor and suction caisson designs produced by WP4. These models include a steel casing and steel anchor with soft clay and dense sand surrounding the steel components respectively.

42 ENGINEERING↗

DOE OSTI2020

A Hybrid AI/ML and Computational Mechanics Based Approach for Time-Series State and Fatigue Life Estimation of Nuclear Reactor Components

Environmental fatigue modeling is a complex problem due to multiple failure modes and their intermixing. The failure modes are function of various underlying causes in addition to the corrosive effect of reactor coolant environment. Some of the major causes are time-dependence of material associated with cyclic loading, load sequence effect associated with random/variable amplitude loading, effect of strain amplitude and rates, effect of varying temperature (along both temporal and spatial directions) and the effect of mean strain and stress. The nonlinear intermixing of failure modes associated with above mentioned causing parameters makes the environmental fatigue modeling is a challenging task. Because of this challenge, fatigue is traditionally being modeled based on experimental data. However, test based empirical approach often requires hundreds of fatigue tests to model the above-mentioned intermixing failure causes even for a single material system. The problem is further exaggerated for reactor component made from multi-material systems such as made from both carbon and stainless-steel base metals and their similar and dissimilar metal welds. With the difficulty of conducting hundreds of fatigue tests to capture the above-mentioned intermixing failure causes, fatigue modeling approaches often depends on empirical models based on limited available test data such as available through ASME code and NUREG 6909. However, these limited test-data-based models may not be enough to accurately predict the life of reactor components. Accurate prediction of life of reactor component would become a necessity, particularly when the license of the reactors to be extended for long-term-operation (LTO) that is for well beyond its original design life of 40 years. The requirement of extending the license of reactor under LTO requires hundreds of fatigue tests to be conducted to understand the mechanism associated with the above-mentioned interdependent failure causes. However, conducting large number of fatigue tests is not a feasibility due to the cost involved. To address this issues Argonne National Laboratory (ANL) with the sponsorship of DOE Light Water Reactor Sustainability (LWRS) program trying to develop a hybrid predictive modeling approach. This is based on limited experiment-data, Artificial-intelligence (AI) – Machine-Learning (ML) - Deep-Learning (DL) based techniques and Multiphysics-computational-mechanics based modeling tools. The hybrid approach not-only can improve the accuracy of the existing stress analysis and fatigue modeling approach but also can reduce the over-dependency on test-based approach. Towards this goal following are some of the major contributions based on ANL’s FY-20 environmental fatigue modeling activities: 1) A cyclic plasticity material model database for 82/182 dissimilar metal weld, which can be readily shared with US nuclear industry and regulatory agency on request. 2) A well validated analytical modeling methodology to perform cycle-by-cycle stress prediction under both constant amplitude fatigue loading and variable amplitude fatigue loading (with load-sequence effect). 3) An AI/ML/DL based methodology to predict unmeasurable cyclic strain based on other available sensor signals. This type of approach can be used for estimating strain in real reactor components from other sensor readings. 4) An AI/ML based approach to improve the US capability on environmental fatigue testing. This is by improving ANL’s existing environmental fatigue testing capacity to conduct ASME required strain-controlled tests (by controlling strain amplitudes and its rate), while not measuring the strain (due to the difficulty of placing an extensometer in a narrow autoclave in a PWR-water-test system). 5) A simulation and experiment based probabilistic modeling methodology for time-series fatigue state and life estimation of reactor metal such as dissimilar metal weld.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

Reducing Fuel Consumption on a Heavy-Duty Nonroad Vehicle: Conventional Powertrain Modifications

This investigation focuses on conventional powertrain technologies that provide operational synergy based on customer utilization to reduce fuel consumption for a heavy-duty, nonroad (off-road) material handler. The vehicle of interest is a Pettibone Cary-Lift 204i, with a base weight of 50,000 lbs. and a lift capacity of 20,000 lbs. The conventional powertrain consists of a US Tier 4 Final diesel engine, a non-lockup torque converter, a four-speed powershift automatic transmission, and all-wheel drive. The paper will present a base vehicle energy/fuel consumption breakdown of propulsion, hydraulic and idle distribution based on a representative end-user drive cycle. The baseline vehicle test data was then used to develop a correlated lumped parameter model of the vehicle-powertrain-hydraulic system that can be used to explore technology integration that can reduce fuel consumption. Two conventional powertrain modifications are explored that provide potential pathways that significantly alter the base powertrain and include 1.) a torque converter disconnect clutch and 2.) a low voltage stop-start system that have the potential to reduce fuel consumption on the end user representative drive cycle by 10.3% and 9.8%, respectively. Details of how the powertrain modifications would be executed, physical hardware, and application to other heavy-duty nonroad vehicle applications are included in the discussion.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2021

Digital Twin Model for Advanced Manufacture of a Rotating Detonation Engine Injector

A digital twin material model (DTMM) of an additive manufacturing (AM) process was created to advance the state of the art in rotating detonation engine (RDE) injector design. Current RDE injectors are designed with large pressure drops, enabling a stable and repeatable combustion process. However, this comes at the cost of system efficiency. For the technology to transition to commercial fossil-based power generation, it is important to develop injectors with reduced flow losses. Low-loss injectors are difficult to design and manufacture with conventional manufacturing techniques. AM enables new design options, but the AM manufacturing process must be thoroughly understood to result in a robust design. A DTMM provides the necessary insight by defining the cause-effect relationships between process parameters, microstructure features, and properties. Therefore, a DTMM to support the design and manufacturing process was developed and applied to the design of a new additively manufactured low-loss injector. The injector combustion behavior was characterized through hot-fire tests, and mechanical performance was compared to the DTMM predictions. The two project goals were the successful development of the DTMM and the demonstration of an improved RDE injector design. The RDE injector design and DTMM developments occurred on parallel but dependent paths. The injector was designed to reduce pressure drop by increasing the cross-sectional flow area ratio between the injector air passages and the combustor annulus. This resulted in less structural material, raising the concern that thin members would be susceptible to high-cycle fatigue (HCF) under the periodic loading inherent to an RDE. It was most important for the DTMM to predict behavior in these features; therefore, the injector design concept guided the material thicknesses used in fatigue tests. The DTMM development started by manufacturing a series of coupons over the range of possible AM process variations. A design-of-experiment approach was used to select which process variable combinations gave the most efficient coverage relevant to the injector design space. The microstructure in each of these coupons was characterized, and then computational methods were used to create a numerical model of the correlation between process variables and microstructure. Next, a set of HCF samples were tested to calibrate existing models that map microstructure to HCF performance. Together, these two links formed the DTMM that calculates HCF behavior from AM process variables. Two injector prototypes were additively manufactured. The first injector design strategy aggressively pursued low-loss performance by substantially increasing the oxidizer flow area. The combination of manufacturing lead times and the fatigue testing schedule meant that the DTMM was not available when building this first prototype. Therefore, its process parameters were chosen based on a manual review of the available coupon data. This prototype was built successfully and evaluated in 58 combustion tests. Sustained detonation was achieved with remarkably reduced pressure loss, and some tests even displayed pressure loss characteristics similar to conventional gas turbine combustors. This achieved the project goal of improving RDE injector design. The second injector was manufactured according to the optimized parameters predicted by the DTMM. The flow area modifications of this injector were less aggressive than the first injector since demonstrating low pressure loss was not an objective of the second hot-fire test series. Rather, the test objective was to cause high cycle fatigue failure in the part due to periodic loading from the rotating detonation wave. The observed number of cycles to failure was to be compared to the number predicted by the DTMM and thereby assess the utility of the DTMM in component design. However, the required level of vibration was not obtained during combustion. Therefore, high cycle fatigue was not experienced in the hot-fire tests of the second injector. Fatigue data was obtained by further testing the second injector in a conventional HCF test apparatus. The injector demonstrated HCF strength above the DTMM prediction. In fact, it did not fail and testing was only discontinued due to reaching the end of the period of performance. This points to some success in the project’s primary goal of successfully developing and applying the DTMM to a component design. Implementing the DTMM recommendations for optimal processing parameters led to a part with acceptable properties. The DTMM was also shown to be an efficient correlator of data and to provide insight into the relationship between process settings, microstructure, and property performance. However, the failure of the DTMM prediction to match the experimental result of the injector fatigue test also points to the need to include significantly more data in the model development. In this project, coupons made with identical processing parameters exhibited drastically different properties from each other and from the injector part, which clearly influences the accuracy of a model that predicts performance based on parameters. Uncertainties in the build process must be quantified to develop more robust models. A denser and broader matrix of coupon process and geometry variations, several repeated builds of every point, more in-situ build process measurements, and direct observation of tensile and HCF sample microstructure (as opposed to separate microstructure specimens) are recommendations to improve future AM modeling efforts.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2025

Connecting Minds: AI Use Cases to Bridge Power Systems and Large Language Models for Practical Applications

Recent advances in artificial intelligence (AI) and development of large language models (LLMs) present the opportunity to develop a new generation of power systems applications. In contrast with early power system AI applications based on structured numerical data, LLMs offer unique capabilities to perform logical reasoning using text documents, unstructured data, and application programming interface (API) calls to computational software. This paper seeks to bridge the knowledge gap between power systems engineers and LLM developers through a crosscutting explanation of use cases, characteristics, requirements, practical considerations from the perspectives of both LLM capabilities and industry needs. Specific focus is given to applications that can be realistically deployed by electric utilities. After introducing the architecture of LLMs and unique challenges of the power systems domain, this paper proposes twenty representative LLM applications grouped into categories of 1) power system operations, 2) asset management, 3) system planning and analytics, and 4) energy management and protection systems. Five use cases are presented within each category with descriptions of the motivation, objectives, approaches, example inputs / outputs, and benefits of each use case.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2023

Hierarchical reconstruction of 3D well-connected porous media from 2D exemplars using statistics-informed neural network

The relationships between porous microstructures and transport properties are of fundamental importance in various scientific and engineering applications. Due to the intricacy, stochasticity and heterogeneity of porous media, reliable characterization and modeling of transport properties often require a complete dataset of internal microstructure samples. However, it is often an unbearable cost to acquire sufficient 3D digital microstructures by purely using microscopic imaging systems. Herein this paper presents a machine learning-based technique to hierarchically reconstruct 3D well-connected porous microstructures from one isotropic or several anisotropic low-cost 2D exemplar(s). To compactly characterize the large-scale microstructural features, a Gaussian image pyramid is built for each 2D exemplar. Local morphology patterns are collected from the Gaussian image pyramids, and then they serve as the training data to embed the 2D morphological statistics into feed-forward neural networks at multiple length levels. By using a specially-developed morphology integration scheme, the 3D morphological statistics at different levels can be inferred from the statistics-informed neural networks. Gibbs sampling is adopted to hierarchically reconstruct 3D microstructures by using multi-level 3D morphological statistics, where the large-scale, regional and local morphological patterns are statistically generated and successively added to the same 3D random field. The proposed method is tested on a series of porous media with distinct morphologies, and the statistical equivalence between the reconstructed and the real microstructures is systematically evaluated by comparing morphological descriptors and transport properties. The results demonstrate that the proposed 2D-to-3D microstructure reconstruction method is a universal and efficient approach to generating morphologically and physically realistic samples of porous media.

42 ENGINEERING↗

DOE OSTI2021

Energize: An Interactive Evaluation Tool for Engaging the General Public with Energy Decision Making - Final Report

The public has an ever-increasing interest in the economic, environmental, and social impacts of global energy production. To support informed decision making, the scientific community has a responsibility to communicate reliable and straight-forward information to the general public, in an engaging way, regarding energy systems and how choices made at different stages of an energy technology life cycle can impact the cost, amount of materials used, and waste produced. Our objective is to enhance public engagement via an interactive electrical energy game (Energ!ze) through which players interact with one another in their quest to develop an electrical energy portfolio that optimizes economic (e.g., company profit), environmental (e.g., reduced CO 2 emissions), and social (e.g., public opinion) impacts. The design and development of Energ!ze was an iterative process involving an interdisciplinary team of engineers, discipline-based scientists, computer scientists, and education experts. The development objectives were two-fold: (1) Accurate and quantifiable modeling of electrical energy systems and (2) Engaging and interactive user interface within the construct of the game narrative. The major game mechanics in the current playable Energ!ze version focus on economic metrics, and the database is scaffolded to add environmental and social metrics for future versions. This report details the outcome of the funding period (Section 2 and 3) and describes the development process, along with recommendations for future development (Section 4).

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2019

A cell-free system for production of 2,3-butanediol is robust to growth-toxic compounds

The need for sustainable, low-cost production of bioenergy and commodity chemicals is increasing. Unfortunately, the engineering potential of whole-cell catalysts to address this need can be hampered by cellular toxicity. When such bottlenecks limit the commercial feasibility of whole-cell fermentation, cell-free, or in vitro, based approaches may offer an alternative. Here, we assess the impact of three classes of growth toxic compounds on crude extract-based, cell-free chemical conversions. As a model system, we test a metabolic pathway for conversion of glucose to 2,3-butanediol (2,3-BDO) in lysates of Escherichia coli . First, we characterized 2,3-BDO production with different classes of antibiotics and found, as expected, that the system is uninhibited by compounds that prevent cell growth by means of cell wall replication and DNA, RNA, and protein synthesis. Second, we considered the impact of polar solvent addition (e.g., methanol, n-butanol). We observed that volumetric productivities (g/L/h) were slowed with increasing hydrophobicity of added alcohols. Finally, we investigated the effects of using pretreated biomass hydrolysate as a feed stock, observing a 25% reduction in 2,3-BDO production as a result of coumaroyl and feruloyl amides. Overall, we find the cell-free system to be robust to working concentrations of antibiotics and other compounds that are toxic to cell growth, but do not denature or inhibit relevant enzymes.

09 BIOMASS FUELS↗