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DOE OSTI2020

Comparison and Discussion on Shortcircuit Protections for Silicon-Carbide MOSFET Modules: Desaturation Versus Rogowski Switch-Current Sensor

Survivability of silicon-carbide (SiC) mosfet modules during short circuit (SC) is essential for modern power electronics systems due to large economic implications. SiC mosfet modules exhibit narrow SC withstand times and generally much lower SC robustness than silicon (Si) insulated-gate bipolar transistors (IGBTs). This puts a critical concern on their utilization, further stressing the importance of reliable protection. This article presents a comprehensive analysis and discussion on the SiC mosfet module SC protection and performance comparison between conventional desaturation detection, previously used for Si IGBT protection, and Rogowski switch-current sensor (RSCS) detection. In addition, this article presents the experimental design for soft turn-off as a reaction to the SC detection to avoid excessive overshoots during the abrupt turn-off of the SC current. To perform different types of SC with various fault inductances on different temperatures, and for the sake of fair comparison under the same conditions, a gate-driver unit for 1.2 kV SiC mosfet half-bridge modules is developed containing both detection methods. The results demonstrate that both methods are successful in protecting the module in all SC types, with superiority of the RSCS detection and concerns for desaturation detection in high-inductance and high dc-bus voltage SC events.

42 ENGINEERING↗

DOE OSTI2020

Design, Analysis, Comparison, and Experimental Validation of Insulated Metal Substrates for High-Power Wide-Bandgap Power Modules

Direct bonded copper (DBC) substrates used in power modules have limited heat spreading and manufacturing capability due to ceramic properties and manufacturing technology. The ceramic and copper bonding is also subject to high mechanical stress due to coefficient of thermal expansion mismatch between the copper and the ceramic. For wide-bandgap (WBG) devices, it is of interest exploring new substrate technologies that can overcome some of the challenges of direct bonded copper substrates. In this technical paper, the design, analysis, and comparison of insulated metal substrates (IMSs) for high-power wide-bandgap semiconductor-based power modules are discussed. This paper starts with technical description and discussion of state-of-the-art DBC substrates with different ceramic insulators such as aluminum nitride (AlN), Al 2 O 3 , and Si 3 N 4 . Next, an introduction of IMSs and their material properties, and a design approach for SiC (silicon carbide) metal-oxide-semiconductor field-effect transistor (MOSFET)-based power modules for high-power applications is provided. The influence of dielectric thickness on the power handling capability of the substrate are also discussed. The designed IMS and DBC substrates were characterized in terms of steady-state and transient thermal performance using finite element simulation. Finally, the performance of the IMS and DBC are validated in an experimental setup under different loading and cooling temperature conditions. We report the simulation and experimental results showed that the IMS can provide high steady-state thermal performance for high-power modules based on SiC MOSFETs. Furthermore, the IMS provided enhanced transient thermal performance, which provided a reduced junction temperature when the module is operated at low fundamental output frequencies in traction drive systems.

42 ENGINEERING↗

DOE OSTI2025

A Combined Computational and Mathematical Analysis of Interconnect Fatigue Potential in Photovoltaic Modules

A finite element model of a 60-cell monocrystalline silicon glass-polymer photovoltaic module was simulated with ±1.0 kPa and ±2.4 kPa loads applied to the glass to calculate the deformation under load. Cell-to-cell displacements were used to approximate interconnect strain and stress. A mathematical fatigue cycle life relation was fitted to data for the interconnect material (copper), to generate a life prediction at each interconnect location based on the local stress means, reversal extents, and amplitudes. Interconnect stress was found to be significantly asymmetric about zero despite symmetric positive and negative module loads due to laminate thickness offsets about the neutral plane and the effects of module framing. Cycle life results indicated that interconnect fatigue failure was unlikely to occur over a 30-year lifetime of conservative wind and snow load cycles since the typical cell design feature of leaving some unconstrained length between the cell edge and first solder pad increases the effective gauge length and decreases the stress levels below the material endurance limit. Follow-up analyses found that 3.6 mm and 6.4 mm were the minimum unconstrained lengths required to survive the assumed lifetime of wind and snow cycles, respectively, confirming that typical industrial module constructions with 8–15 mm unconstrained lengths should survive conservatively. Notably, large magnitude, low-cycle snow loading was consistently the limiting factor requiring a longer unconstrained interconnect length. Finally, insights and workflows from this study inform module interconnection design limits for survival against mechanical fatigue in deployment environments.

14 SOLAR ENERGY↗

DOE OSTI2022

Thermal Optimization of a Silicon Carbide, Half-Bridge Power Module

This project describes the modeling process to design the packaging and heat exchanger for a half-bridge wide-bandgap (WBG) power semiconductor module. The module uses two silicon carbide, metal-oxide-semiconductor field-effect transistor (MOSFET) devices per switch position that are soldered to an aluminum nitride, direct-bond copper (DBC) substrate. A baseplate cooling configuration (e.g., no thermal grease) is used along with a water-ethylene glycol, jet-impingement-style heat exchanger. The heat exchanger was designed to be fabricated using prototyping equipment from the National Renewable Energy Laboratory, complies with automotive standards (for minimal channel sizes, flow rates, and coolant), and considers reliability aspects (i.e., erosion/corrosion). Device-scale computational fluid dynamics (CFD) is used first to design the slot jet impingement cooling configuration and compute the effective heat transfer coefficient (HTC) of the concept. The computed HTCs are then used as boundary conditions for a finite element study to optimize the package geometry (e.g., device layout and baseplate thickness) to minimize thermal resistance and minimize temperature variation between the module's four devices. Finally, a fluid manifold is designed to generate the slot jets and cool the devices. Module-scale CFD predicts a relatively low junction-to-fluid thermal resistance of 16.7 mm2 K/W, a 1.4 degrees C temperature variation between devices, and a total pressure drop of 5,860 Pa (0.85 psi) for the design. The thermal resistance of the module design is about 67% lower than the 2015 BMW i3 power electronics/modules thermal resistance.

DIRECT ENERGY CONVERSION↗

DOE OSTI2024

Multiphysics Co-Optimization Design and Analysis of Double-Side Cooled Silicon Carbide-Based Power Module: Preprint

With the rapid growth of Electric Vehicles (EVs) and Hybrid Electric Vehicles (HEVs), much more rigorous design targets have been set for automotive power electronics, including high power density, high reliability, and low cost. Novel power module and inverter technologies based on wide bandgap (WEG) semiconductors have been developed to meet these design targets, while providing optimal power semiconductor operating temperature and promising thermomechanical performance. Compared with conventional cooling techniques which are normally applied only on one side of power module, double-side cooling approach is now believed to be the solution to enable high power density and low thermal resistance of WEG semiconductor-based power electronics. In this work, we develop a three-phase power module that is double-sided cooled using dielectric fluid jet impingement. In each phase, four silicon carbide (SiC) power semiconductors are bonded to copper busbars without electrical insulation layers. A finite element analysis (FEA) model is created for thermal and thermomechanical analysis. Based on FEA modeling results, we select particular dimensions for a parametric study to optimize thermal and mechanical performance. Using a multi-objective genetic algorithm (MOGA)-based optimization method, we have minimized the maximum junction temperature and thermal stresses within the power module. The multiphysics co-optimization approach has enabled an efficient design process of power modules with greatly reduced computational cost, as compared to conventional processes that rely on exhaustive numerical simulations and iterations.

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2019

Atmospheric charged $$K/\pi $$ ratio and measurement of muon annual modulation with a liquid scintillation detector at Soudan

We report a measurement of muon annual modulation in a 12-l liquid scintillation detector with a live-time of more than 4 years at the Soudan Underground Laboratory. Muon minimum ionization in the detector is identified by its observed pulse shape and large energy deposition. The measured muon rate in the detector is $$28.69\pm 2.09$$ 28.69 ± 2.09 muons per day with a modulation amplitude of ( $$2.64\pm 0.07$$ 2.64 ± 0.07 )% and a phase at Jul $$22 \pm 36.2$$ 22 ± 36.2 days. This annual modulation is correlated with the variation of the effective atmospheric temperature in the stratosphere. The correlation coefficient, $$\alpha _{T}$$ α T , is determined to be $$0.898 \pm 0.025$$ 0.898 ± 0.025 . This can be interpreted as a measurement of the atmospheric charged kaon to pion ( $$K/\pi $$ K / π ) ratio of $$0.094^{+0.044}_{-0.061}$$ 0 . 094 - 0.061 + 0.044 for $$E_{p} > 7$$ E p > 7 TeV, consistent with the measurement from the MINOS far detector. To further constrain the value of $$K/\pi $$ K / π ratio, a Geant4 simulation of the primary cosmic-ray protons with energy up to 100 TeV is implemented to study the correlation of $$K/\pi $$ K / π ratio and the muon annual modulation for muon energy greater than 0.5 TeV. We find out that a charged $$K/\pi $$ K / π ratio of 0.1598, greater than the upper bound (0.138) from this work at the production point 30 km above the Earth surface in the stratosphere cannot induce muon annual modulation at the depth of Soudan.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2025

Impact of Module Configuration on Lithium-Ion Battery Performance and Degradation: Part I. Energy Throughput, Voltage Spread, and Current Distribution

Batteries are commonly connected in series and parallel to create modules that fulfill the power and energy requirements of specific applications. However, conclusions about battery performance and degradation under different conditions, as well as predictive models, are often derived from single cell cycling results. In this study, we evaluate the performance of six different series-parallel configurations of commercial lithium nickel manganese cobalt cells over hundreds of cycles. Each cell within the modules was individually instrumented for voltage, current, and temperature monitoring. We quantified the impact of module configuration on overall energy throughput, the voltage spread among series-connected cells, and the current heterogeneity in parallel-connected cells. This module cycling study, one of the broadest reported to date, supports systematic evaluation of the performance trade-offs, pack penalty, and safety implications of different module configurations.

25 ENERGY STORAGE↗

DOE OSTI2022

CMEC Module Manager

The CMEC module manager package is designed install and update CMEC modules (https://cmec.llnl.gov/). CMEC modules are independent climate model analysis packages. Individual scripts are provided in the module manager that outline the installation process for each module in a robust way, and a wrapper python script is provided that lets users install a chosen CMEC package with a single command.

Ordonez, AnaC↗

DOE OSTI2021

NEMA-Phase Compliant Traffic Signal Controller Module in SUMO

The controller modules in SUMO use a stage-based control structure. A phase is defined as a stage of all allowed movements at a time instance. However, traffic signal controllers used in North America widely use National Electrical Manufacturers Association (NEMA) phase definition. A NEMA phase is defined by a certain flow movement at an intersection. At one time, more than one NEMA phase could happen together as long as they do not conflict with each other. We can visualize the NEMA phases and timings in Ring-and-Barrier structured NEMA diagrams. For one controller, only one phase from a ring can be activated at a time. Phases from different rings could be activated together as long as they are not from the different sides of a barrier. When a controller is operated in fixed-time control mode, we can model the NEMA phase timing as a corresponding stage-based control timing without any issues. When introducing actuation into the signal control, a Ring-and-Barrier structured traffic signal controller can be more flexible than stage-based controller by allowing different possible phase combinations. We made two efforts in modeling Ring-and-Barrier structured controllers in SUMO. One is to translate a NEMA phases timing into SUMO-readable phases and timings as an additional file for SUMO. This translation worked well for fixed-time control. To model actuated control and coordinated actuated control, we augmented the SUMO source code by adding a Ring-and-Barrier structured controller module. This module could implement traffic signal timing from controllers using NEMA phases. We also augmented TraCI to be able to set new NEMA phase timings during simulations. We examined the Ring-and-Barrier structured traffic signal controller module by both visually observing the simulation animations and the simulation records. The developed control module can model the generalized Ring-and-Barrier structured traffic signal timing that is used in North America. SEE: https://github.com/eclipse/sumo/blob/main/src/microsim/traffic_lights/NEMAController.cpp

Wang, Qichao↗

DOE OSTI2019

Gas Ingress and Egress of MEMS Multi-Chip Modules and MEMS Devices

Hermetic microcircuit packaging was the dominant method of protecting semiconductor devices in the 1960s and 1970s. After losing majority market sectors to plastic encapsulated microelectronics over the last a few decades, hermetic packaging remains the preferred method of protecting semiconductor devices for critical applications such as in military, space, and medical fields, where components and systems are required to serve for several decades. MEMS devices impose additional challenges to packaging by requiring specific internal cavity pressures to function properly or deliver the needed quality (Q) factors. In MEMS multichip modules, internal pressure requirement conflicts arise when different MEMS devices require different internal gases and pressures. The authors developed a closed-formed equation to model pressure changes of hermetic enclosures due to gas ingression. This article expands the authors mathematical model to calculate gas pressure of a MEMS multichip module package as well as those of MEMS devices inside the multichip module package. These equations are not only capable of calculating service lifetimes of MEMS devices and multi-chip modules but can also help develop MEMS device packaging strategies to extend the service life of MEMS multi-chip modules.

36 MATERIALS SCIENCE↗

DOE OSTI2018

The (3+3) commensurately modulated structure of the uranyl silicate mineral swamboite-(Nd), Nd 0.333 [(UO 2 )(SiO 3 OH)](H 2 O) 2.41

The uranyl mineral swamboite has been redefined to swamboite-(Nd) and its structure has been solved and refined as a commensurate structure in six-dimensional superspace. The structure is monoclinic, superspace group P 2 1 /m ( a 1, b 1, g 1)00(- a 1, b 1, g 1)00 ( a 2,0, g 2)0 s , cell parameters a =6.6560(3), b =6.9881(5), c =8.8059(6), c =11.3361(16) Å, β=102.591(5)°, modulation wave-vectors q 1 =1/3 1/3 0; q 2 = -1/3 1/3 0; q 3 =1/2 0 1/2. The structure was refined from 8717 reflections to a final R =0.0610. The model includes modulation both of atomic positions and displacement parameters, as well as occupancy waves. The structure is based upon uranyl-silicate sheets of uranophane topology alternating with an interlayer of partly occupied Nd 3+ sites and H 2 O molecules. The strong (3+3) dimensional modulation of the structure originates from the distribution of the Nd-dominated sites and further accommodation of the suitable geometry within the sheets and charge distribution within the structure. The separation distances between the corresponding occupied Nd sites are rationals of the super-cell vectors corresponding to the modulation vectors of the structure. The case of swamboite-(Nd) is the first example of a modulated structure within the oxysalts of U 6+ .

Crystallography↗

DOE OSTI2018

Site Classification for Standard Modular Hydropower Development: Characterizing Stream Reaches by Module Need

The objective of site classification for Standard Modular Hydropower (SMH) development is to develop a framework for classifying potential SMH sites in terms useful for informing SMH development, such as module need and module design requirements. While the current vision for SMH has focused on applications for new stream-reach development, these site classifications are equally useful for other applications, such as modular development at non-powered dams and other hydropower co-development opportunities. We used K-means clustering to classify sites (i.e., stream reaches) into clusters (i.e., groups of sites with similar attributes) based on simultaneous consideration of physical and biological attributes of those sites. Stream reaches included were confined to those with mean annual flow > 50 cfs and < 25,000 cfs (~350,000 reaches). Site Classification was conducted separately for six modules: hydroelectric generation, water quality, sediment passage, fish passage, foundation support, and recreation. About 340,000 stream reaches across the contiguous US were classified into 10 groups for each of the 6 different module categories. For each module category, clusters are visualized on US maps and described based on the defining variables that differentiate clusters from each other.

13 HYDRO ENERGY↗

DOE OSTI2020

Highly Integrated WBG Power Module for Next Generation Plug-In Vehicles

Current inverter technologies used in electric vehicles (EVs) are bulky, heavy, and expensive. The performance of the inverter is also limited by the traditional Si-based semiconductor and packaging technology. These constraints are responsible for extra weight and volume in the vehicle that reduces the driving range along with usable space within the vehicle. Moreover, operating temperature restrictions, and boundaries on the inverter location within the vehicle drastically reduces the inverter performance. Thus an improved inverter design is required for next generation electric vehicles. The objective of this project was to research, develop and demonstrate a highly integrated WBG power module targeting the next generation of plugin hybrid electric vehicles (PHEVs). This power module needed to be functionally and mechanically optimized for General Motors (GM) traction inverter architecture. General Motors was the prime contractor, led the project, and oversaw the design, build, and test of the integrated power module. Virginia Polytechnic Institute and State University (VT) performed modeling and simulation tasks as well as power module design support. Monolith Semiconductor, Inc provided SiC dies and consulted on devices for the inverter. Oak Ridge National Laboratory (ORNL) performed power module technology evaluations, design evaluations of interconnect options, and performed material analysis and cross-sectioning of die activities.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2020

Analysis with the ORIGEN Module of PNAR Spent Fuel Measurements for Nuclear Safeguards Applications

This report documents the analysis of the Passive Neutron Albedo Reactivity (PNAR) measurements for 23 boiling water reactor spent fuel assemblies that were performed in Finland under Action Sheet 65, which is an international collaboration on spent fuel safeguards verification methods in the context of the Finnish spent fuel encapsulation/repository system. PNAR measures the passive neutron and gamma emission rates from each of the spent fuel assemblies like a Fork detector, and it also measures the PNAR ratio, which is expected to correlate with the net neutron multiplication of the measured fuel assembly. The analysis was performed with the Oak Ridge Isotope Generation and Depletion (ORIGEN) Data Analysis Module, which was originally developed for predicting Fork detector spent fuel measurement signals in real time and has been integrated into the Integrated Review and Analysis Package developed by Euratom and the International Atomic Energy Agency. The module includes the ORIGEN burnup analysis code and integrates detector response functions pregenerated using the MCNP Monte Carlo transport code to predict the detector signals in several seconds per assembly. In this study, new response functions specific to the analyzed PNAR measurements were generated for the ORIGEN Module. The study also analyzes the impact of using detailed fuel design and operation information vs. standard safeguards information on the results calculated with the ORIGEN Module. Using detailed information reduced the standard deviation of the relative differences between calculated and measured neutron count rates among the 23 assemblies from ~10% to ~4%. The results obtained using standard safeguards information for these PNAR measurements were similar to those obtained for the Fork detector. A clear trend was found between the calculated net neutron multiplications and the measured PNAR ratios of the 23 assemblies. An uncertainty assessment of the calculations was also performed to estimate the potential impact of the accuracy and the completeness of declaration information on the calculated results for the count rates and net neutron multiplications. The ORIGEN Module predictions for PNAR signals and net neutron multiplication are expected to directly support the safeguards inspectors’ efforts to verify operator declarations of a spent fuel assembly in real time in safeguards practices.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Quantifying Optical Loss of High-Voltage Degradation Modes in PV Modules Using Spectral Analysis [Slides]

The direct current bias for photovoltaic (PV) modules interconnected in series-strings may include both high voltage negative ("HV-") and positive ("HV+") polarity with respect to the electrical ground. Multiple degradation modes, resulting in quantifiable optical loss, were found to occur during HV-/HV+ sequential stress, including: corrosion of the external glass surface, encapsulant delamination (at its interfaces with the glass and the PV cell), internal haze formation (resulting from a chemical interaction between the glass and the encapsulant), corrosion and migration of the gridlines, and corrosion of the silicon nitride (SixNy) antireflective coating on the cell. The effects of these separate modes were examined using monolithic (e.g., glass or PV cell) and laminated-coupon (glass/encapsulant/glass or glass/encapsulant/cell/encapsulant/backsheet) specimens. Characterizations during and after unbiased accelerated testing at 85 degrees C/85% relative humidity included: spectrophotometry, optical microscopy, electron microscopy, and ellipsometry. For some module components (i.e., the glass and the SixNy coating), the optical performance was determined through iterative analysis of empirical measurements. Concentrating on just their spectral effect, a novel model was then developed to estimate the transfer of light to the PV cell and the return of light from the PV module with simultaneous degradation mechanisms, which was compared to a mini-module previously subjected to HV-/HV+ stress. The model suggests one-third of the current loss observed for the mini-module can be attributed to the optical degradation of the packaging materials. The dominant degradation modes include encapsulant delamination and corrosion of the SixNy coating. Recommendations are given so that the optical model may be improved relative to accelerated testing and validated relative to field aging.

14 SOLAR ENERGY↗

DOE OSTI2023

Scalable Manufacturing of Efficient Perovskite/Silicon Tandem Modules

Crystalline-Si (c-Si) technology produces excellent solar cells with conversion efficiencies of up to 26.7%—nearly their practical limit of 27%—and has been commercialized extensively to produce panels below $\$0.40$/W. Techno-economic analysis shows that module efficiency will continue to be a primary cost driver because of high balance-ofsystems costs, and there is no path to higher efficiencies with single-junction silicon cells. In this project, three research teams from University of North Carolina, Arizona State University and National Renewable National Laboratory worked together to develop perovskite-silicon tandem cells with a high throughput process which can handle 5000 wafers per hour, enabled by very low added CAPEX of ~$20k for a doctor-blade coater. This can potentially increase the module efficiency to 30% (with grid) with small increase of cost, which will drive down the cost of silicon modules to be at least 16% cheaper than present silicon PERC modules. We also explored the alternative narrow bandgap perovskites as silicon replacement for all perovskite tandem cells. This project has substantially advanced the progress of solution-process perovskitessilicon tandem solar cells and perovskite-perovskite tandem solar cells with many inventions and discoveries, evidenced by 18 publications and 6 invention disclosures. Several notable examples include 1) we developed the new idea of small pyramid in combination with solution grown perovskites and demonstrated record-efficiency of 28.5% for 1 cm2 on textured silicon bottom cells and 25.2% for 24 cm2 on chemically etched silicon bottom cells for perovskite-silicon tandem cells. 2) We developed perovskite ink that can coat perovskites onto texture silicon without voids;, and new device structure to enhance the yield of fabrication by reducing shunting 3) We identified the origin of open circuit voltage on mixed halide wide bandgap perovskites, and came with a solution for this problem, reducing the voltage loss to a record small value, which can potentially push the perovskite-silicon tandem cell efficiency to over 31%; 4) We have developed efficient alternative low bandgap semiconductors, i.e. gradient-doped Sn based perovskites by Ba ions, new oxide hole transport layers which increase the efficiency of perovskite/perovskite tandem cells reached record efficiency of 26.3%; 5) We developed bifacial perovskite/perovskite tandem cells by overcoming contacts issues and regaining light absorption, further boosting the equivalent efficiency to 29.3% under 1 sun illumination with 30% albedo light; 6) We developed the first all perovskite tandem module fabricated in air by discovery a combination of oxidization and reduction couples, yield an aperture efficiency of 21.6% for all perovskite mininodules, exceeding that of single junction perovskite minimodules. These discoveries not only accelerate the commercialization of perovskite-silicon tandem solar cells, but also provide guidance in designing other type of perovskite solar cell technologies.

14 SOLAR ENERGY↗

DOE OSTI2024

Predictive Models and Novel Accelerated Tests for the Reliability of Cell Metallization in Photovoltaic Modules (Final Report)

Studies of metallization corrosion m photovoltaics have mainly been limited to comparisons of modules placed in accelerated chambers to fielded modules [1]. Damp Heat accelerated tests and phenomenological equations [2] are used to assess metallization corrosion without understanding the effect of UV light and temperature and humidity cycles on encapsulant adhesion degradation. The roles of encapsulant in-and out-diffusions of moisture and encapsulant impurities are important. Furthermore, few photovoltaic metallization corrosion studies included the role of bias and leakage currents, which are crucial in the electrochemical reaction of metallization. Leakage currents can highly accelerate the corrosion mechanism and are important to include in the studies of corrosion. In our research plan, we will address the following gaps in the PV community's understanding of metallization corrosion: (1) metallization corrosion with bias, humidity, and impurities in the encapsulant or metallization; (2) humidity diffusion through fresh and degraded encapsulants; and (3) comparison of model predictions with outdoor field modules and SunPower's extensive data for its back-contact and front-contact fleets [2] along with NREL's store of >20 year old modules. Our goal is to build models and accelerated tests to predict long term degradation of metallization corrosion of photovoltaic modules in the field. Our studies will include metals used in c-Si solar cells (Cu, Ag, and Al) and commonly used encapsulants (EV A (ethylene vinyl acetate), TPO (thermoplastic olefin), and silicone).

14 SOLAR ENERGY↗

DOE OSTI2024

Experimental and Theoretical Evaluation of Feed Flow Collar Design for Shell Fed Hollow Fiber Membrane Modules

An experimental and theoretical study of module collar design is presented here. Hollow fiber membranes are prepared by dip coating a poly(vinylidene) (PVDF) support with a polydimethylsiloxane (PDMS) gutter layer and a Pebax 2533 selective layer. Fiber bundles with a well-defined fiber packing are prepared using a 3D printed module. A parallel fiber bundle consisting of 4-9 uniformly spaced fibers is created with printed tabs that align the fibers and create a tubesheet. The tabs are sealed within a printed case that possesses a series of external ports for gas introduction and removal. Uniquely, both port location and the use of a collar to assist fluid distribution in the shell can be varied for the same fiber bundle. Experimental measurements are compared to computational fluid dynamics (CFD) simulations. The experimental module design allows high-fidelity representation of the fiber bundle and module case in the simulations. Comparisons between experiment and simulation are in good agreement over a broad range of experimental conditions. The detrimental effect of having ports located too close, leading to stagnation regions, is captured as well as the beneficial effects of using a collar for shell-side fluid distribution around the fiber bundle. Such results help validate the use of CFD to develop high-performance module designs.

Tran, Thien↗