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DOE OSTI2020

Integrating Health and Energy Efficiency in Multi-Family Buildings

The intersection between health and the built environment has long been known. Since the 18 th century, public health officials have been targeting building issues, such as crowding, poor sanitation, and inadequate ventilation in efforts to reduce infectious diseases and fire hazards. More recently, federal agencies, such as the U.S. Environmental Protection Agency (EPA), the Centers for Disease Control and Prevention, HUD, and the DOE have been working to reduce or eliminate indoor building factors that are known to have adverse health impacts on Americans, including reducing lead in housing and indoor air pollution that causes respiratory disease, and ensuring access to adequate heating, cooling, and moisture control. PNNL, in support of FEMP’s HBI, undertook a review of literature and existing best practices to identify current activities and research on the intersection between traditional energy-efficiency measures and occupant health within multi-family buildings. While the HBI methodology has focused on traditional office building spaces, it is now expanding into additional building use types. This overview explores some of the most impactful resources to help property owners and managers understand more about multi-family residential buildings that are both healthy and energy efficient. The federal government provides direct oversight and operation across several types of multi-family residential housing, including dormitories, barracks, and senior community living centers.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

HEMP Testing of Substation Yard Circuit Breaker Control and Protective Relay Circuits

There are concerns about the effects of High-Altitude Electromagnetic Pulses (HEMP) on the electric power grid. Activities to date tested and analyzed vulnerability of digital protective relays (DPRs) used in power substations, but the effect of HEMP on the greater substation environment is not well known. This work establishes a method of testing the vulnerability of circuit breaker control and protective relay circuits to the radiated E1 pulse associated with HEMP based on coupling to the cables in a substation yard. Two DPRs from Schweitzer Engineering Laboratories, Inc. were independently tested. The test setup also included a typical cable in a substation yard with return plane to emulate the ground grid and other ground conductors near the yard cable, cabinetry housing the installed DPRs, station battery and battery charger, terminal block elements, and a breaker simulator to emulate a substation yard configuration. The DPRs were powered from the station battery and the transformer inputs energized with a three-phase source to maintain typical operating conditions during the tests. Vulnerability testing consisted of a conducted E1 pulse injected into the center of the yard cable of the DPR circuits. Current measurements on the yard cable and DPR inputs indicated significant attenuation of the conducted pulse arriving at the control house equipment from the emulated substation yard. This reduction was quantified with respect to the equivalent open-circuit voltage on the yard cable. No equipment damage or undesired operation occurred on the tested circuits for values below 180 kV, which is significantly higher than the anticipated coupling to a substation yard cable.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2020

Materials response under hypersonic flow conditions probed by multi-modal diagnostics in a benchtop wind tunnel

In this LDRD “Materials response under hypersonic flow conditions probed by multi-modal diagnostics in a benchtop wind tunnel” a peer-reviewed lab-scale hypersonic wind tunnel (WT) was planned to be assembled in-house, along with time and space resolved and related flow and materials diagnostics to derive high quality measurements and the science that is able to inform the development of our modeling and simulation codes for the hypersonic regime. The baseline capability to achieve Mach 3 flow was scheduled to be completed in Q4 2020, in the first year of the LDRD. However due to the COVID-19 delays and travel restrictions starting in March, 2020 this task could not be completed to carry out the materials response studies in-house, or those planned with external partners that were engaged during this LDRD (NASA Langley, NASA Ames, Texas A&M university, and Virginia Tech). Still, using our hypersonic computational fluid simulation codes, many of the hypersonic components have been designed (for Mach 3, 5, and 7) and procured (or in procurement phase), and a new dedicated hypersonic laboratory was facilitized, 2 WT test sections have been manufactured, and a Mach 3 nozzle was 3D printed for prototyping. In parallel, unique materials diagnostics have been tested under static conditions and fully specified and awaiting validation in our partner facilities. Due to the new hypersonic initiative announced in January, 2020 we proposed a related scope increase in hypersonics research requiring energy interactions and new diagnostics well beyond what could be supported by an LDRD ER. A decision was made to end the current LDRD ER and formally propose a new LDRD SI that leverages the current effort, which will be starting in FY21. As a result of the uniqueness of this LDRD work, our early efforts have been encouraged and well received in the hypersonic research community, and is now part of multiple unsolicited internal and external project proposals expected to be funded in the coming years, which is encouraging to make LLNL a leader in experimentally probing extreme physics of local energetics critical to hypersonics.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Integrated Optimization and Control of a Hybrid Gas Turbine/sCO 2 Power System

During phase-I, the project team led by Echogen Power Systems (EPS) had two primary objectives based on investigating the application of gas turbines with supercritical carbon dioxide (sCO 2 ) power cycles. The first objective was to improve the overall efficiency and performance of a hybrid gas turbine/sCO 2 power system through a joint optimization of the two subsystems (gas turbine and sCO 2 power cycle) using non-linear optimization techniques that simultaneously evaluate thermal performance of the combined cycle. The hybrid power system included several points of interaction, including (but not limited to) gas turbine exhaust, fuel heating, inlet chilling and turbine cooling. The second objective was to establish a baseline transient response model of the hybrid power system and a notional microgrid and begin steps to integrate the control systems of the three major elements (gas turbine, sCO 2 cycle and grid controller). The project team established a baseline performance for a combined cycle power plant using a production gas turbine and scaled sCO 2 power cycle only utilizing exhaust heat recovery. Echogen’s non-linear techno-economic optimization code was extended by adding gas turbine component models derived from a in-house developed gas turbine design code. With the two cycles coupled by the gas turbine exhaust, design parameters of both cycles were allowed to vary simultaneously to determine performance opportunity versus isolated designs. Returning to the baseline gas turbine/sCO 2 power cycle transient models: Echogen had in-house developed sCO 2 cycle transient model in GT-Suite system simulation software, and had partnered with Siemens Finspång for gas turbine transient model, and Siemens PTI group to provide micro-grid load profile as well as hybrid power cycle generated load (power and frequency) analysis. The transient model for the SGT-750 Siemens gas turbine was a “black-box” functional mock-up interface (FMI) model developed by Siemens Industrial Turbomachinery in Finspång, Sweden. The SGT-750 is a twin-shaft gas turbine that produces 40 MW electricity with an efficiency of about 40% at ISO conditions. At 100% gas turbine throttle (load), the SGT-750 has average exhaust conditions of 114.6 kg/s and 469.8°C. The transient model for sCO 2 power cycle was developed by Echogen in GT-SUITE 1D system simulation software platform. The basic CO 2 flow circuit has single-shaft turbomachinery with net 11.5 MW electrical power output at design conditions. The power turbine has a double-ended shaft with one end connected to synchronous generator through a fixed-ratio gearbox. The other end of power turbine is connected to the compressor through a continuously variable transmission. The major components of the sCO 2 power cycle modeled include air cooled condenser/cooler, CO 2 compressor, recuperator, two waste heat exchanger coils, power turbine, continuous variable transmission, gearbox and generator. Integration of SGT-750 transient model and sCO 2 power cycle transient model was done in Matlab Simulink. In the integrated model, the gas turbine and sCO 2 power cycle interacted at two points, first one being the gas turbine exhaust gas flow rate and temperature, which were inputs to sCO 2 power cycle model. The second point was the distribution of micro-grid load demand signal between the SGT-750 generator and sCO 2 cycle generator. For a given combined-cycle load demand, the gas turbine load demand was equal to the total demand minus the sCO 2 cycle power generated. In the present study the integrated model was simulated for two cases of grid load demand: (i) for a step change, both positive-step and negative-step, in grid load demand (ii) for a micro-grid load demand curve provided by Siemens PTI group. Finally, the time series plots representing load demand versus integrated system response were presented including the sCO 2 power cycle control system performance plots. The actual generated power and frequency of both the generators, gas turbine and sCO 2 power cycle, was supplied to Siemens PTI group for dynamic grid assessment, results of which are provided in appendices.

03 NATURAL GAS↗

DOE OSTI2020

Q4FY20 Quarterly Report. LL20-AM-sensor

Tardigrade is an effort to create tunable thermal expansion materials for use in a ruggedized lens housing. This requires new computational algorithms to model and predict thermal performance of meta-materials composed of multiple structured base materials and void-space, along with matching and developing 3D print technology to demonstrate the housing. Project is 13 months into the 30 month on complete project plan. We are continuing effort on 3 main technical thrusts: algorithm development, multi-material additive manufacturing process exploration, and sensor/optics design and engineering. In FY20 we underspent the initial budget, partly due to work restrictions from Covid-19 pandemic, but are working to make up lost time

42 ENGINEERING↗

DOE OSTI2020

Tardigrade: Summary (LL20-AM-sensor)

Tardigrade is an effort to create small, passive remote sensor for material detection and identification. The microbolometer based sensor design uses custom bandpass filter bands combined with tuned thermal expansion materials in a ruggedized lens housing to provide passive mechanical correction for optical changes across a wide temperature range. This requires developing computational tools to model and predict thermal performance of meta-materials composed of multiple structured base materials and void-space, along with matching and developing 3D print technology to demonstrate the housing. Current efforts in the project are in 3 areas: material design algorithm development (transitioning into full 3D material design space), multi-material additive manufacturing process exploration, and sensor/optics design and engineering.

42 ENGINEERING↗

DOE OSTI2021

LL20-AM-sensor (Quarterly Report)

42 ENGINEERING↗

DOE OSTI2021

Q2FY21 Quarterly Report LL20-AM-sensor

42 ENGINEERING↗

DOE OSTI2021

Q3FY21 Quarterly Report LL20-AM-sensor

36 MATERIALS SCIENCE↗

DOE OSTI2021

Model-based Design Optimization to Achieve the Performance Goals (16.0 SEER/9.5 HSPF), Developing Heat Pump by Using Low-GWP Refrigerants and 5 mm Diameter Tubes

Usage of low-GWP refrigerants can reduce the Green House Gas (GHG) emission of HVAC systems. Our research in previous milestone report has shown that using heat exchangers with 5 mm diameter tubes instead of 9 mm diameter tubes is a promising solution to meet the performance goals of heat pump using low-GWP refrigerants. In addition, the 5mm tube heat exchangers can lead to lower system refrigerant charge and as a result, reduce environmental impact further. However, shifting to small tube diameters requires in-depth heat exchanger design optimization to adapt to the transition to low-GWP refrigerants. In the 2nd quarter of FY21, we conducted multi-objective optimizations using Particle Swarm Optimization algorithm on a residential 5-ton air source heat pump to investigate the potential system performance improvements and material savings. 4 low-GWP refrigerants, ARM20A, ARM20B, R454A and R454C are investigated in this study. The objectives of the optimization are to minimize the heat pump material cost and to maximize the system performance simultaneously. As a result, the HXs material cost is reduced by up to 77% according to the copper and aluminum material price in current market. Under heating mode operation, the smart 4-way valve guarantees that the optimal low-GWP systems maintain or outperform the heating performance of the R410A baseline system. The model-based design optimization yields 18.3-18.9 SEER and 10.6-11.9 HSPF for optimal systems using different low-GWP refrigerants. The initial performance goals (16.0 SEER/9.5 HSPF) are achieved. Furthermore, up to 50% system refrigerant charge reduction is possible in the optimized low-GWP heat pump system using ARM20B. And 91%-95% predicted life-time direct CO 2 emission reduction is achieved by using the optimal 5mm tube low-GWP heat pumps. The significant material saving, charge reduction and direct CO 2 emission reduction help in reducing the environmental impacts of heat pump systems. The optimal heat exchangers resulting from this research can fit into the original baseline indoor and outdoor fan-coil unit. This can reduce the retrofitting effort by minimizing the change in manufacturing and installation of the heat pumps and guarantee the compatibility with end-users’ house structure. Finally, the new products can be easily accepted by manufacturers and end-users.

42 ENGINEERING↗

DOE OSTI2020

Initial Temperature Testing of Advanced Manufactured Melt Wire Package

As a part of the In-Pile Instrumentation Program, The Idaho National Laboratory (INL) has recently established in-house capabilities to fabricate and test new advanced manufactured sensors for measuring the peak irradiation temperature inside a nuclear test reactor. Although nuclear test reactors can use standard methods of real-time temperature monitoring, such as thermocouples, the complexity of feedthroughs and attachment complications to collect real-time measurements greatly increases the cost of the experiment. Passive monitoring techniques may be utilized that exploit the melting point of well characterized material (standard melt wires), however, the limited space available for instrumentation during experiments is also a challenge. To accommodate the challenge, INL has expanded its temperature detection instrumentation capabilities paired with the advancement of in-house advanced manufacturing options to include printed melt wires for peak irradiation temperature measurement. The advanced manufactured melt wire package can determine peak temperatures in experiments that can fit the challenging space available during irradiation. Recent results and knowledge from this ongoing work have made it possible to develop unique temperature sensors that can accomplish user specific temperature ranges inside the harsh environments experienced during radiation testing. This report summarizes the initial temperature testing using fabricated melt wires with two different melting temperatures, silver (melting temperature of ~960 °C) and solder (melting temperature of ~160 °C), that were initially tested for their relative melting points using non-standard method of furnace and hot plate testing under normal air conditions. Future work will include more controlled way of testing printed melt wires under inert gas with multiple temperature measurements followed by comparison of standard melt wire package performance for baseline characterization.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2021

Decarbonization During Predevelopment of Modular Building Solutions

Off-site construction methods offer the opportunity to compress costs of net-zero energy (NZE) housing using the advantages of mass production. There has been limited investigation on trade-offs between site-built and industrialized construction from the perspective of reducing the incremental cost of NZE strategies and reducing greenhouse gas emissions during embodied and operational stages. Blokable, LLC, a vertically integrated modular builder, wanted to know how the learning curves of mass production would help them decarbonize their existing modular housing prototype at a relative cost advantage. The method developed for this question looked at the life cycle assessment of an individual apartment and used learning-curve efficiencies to approximate the relative advantage of construction-at-scale. Greenhouse gas emissions were quantified by a learning-affected, whole-life carbon emissions model and demonstrated a path to a 60% reduction of whole-life CO2-equivalent in the 2030 production year. The resultant roadmap considers a best-first approach to decarbonizing a modular building product line, and the method can be replicated for other modular builders.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Comparison of X1 (OLD) and X3 (NEW) Aerosol Observing Systems at the North Slope of Alaska NOAA Observatory

This report describes a comparison of the overlapping X1 and X3 Aerosol Observing Systems (AOS) at the North Slope of Alaska (NSA) observatory. Due to structural issues with the original observatory building, the National Oceanic and Atmospheric Administration (NOAA) funded the design and construction of a new observatory building. Construction began in 2019 and was completed in 2020. The now decommissioned old NOAA Barrow Observatory (BRW) housed the AOS referred to as an NSA external site X1 from October 1997 through August 2021. A new observatory building next door housed the AOS referred to as an NSA external site X3 starting in October 2020. In this document we will refer to the original observatory system measurements as 'OLD' and the measurements in the new building as 'NEW'.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

Tardigrade (NA-22 Quarterly Report)

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

Characterization of the Fusion Zone in Laser Beam Welds on SS304L

Designing a welded joint requires consideration of the welding process, component/assembly structure and weld geometry, material composition, properties, and desired joint performance. The designer must also specify a set of acceptance criteria used to evaluate the welds. This study was conducted to support the design team responsible for specifying the spot weld profile by investigating the relationship between weld process parameters and the weld geometry and properties to further inform design optimization. The subjects of this study are two thin stainless steel 304L (SS304L) components joined by Laser Beam Welding (LBW). The components are the Housing, which contains flexible circuitry, and the Cover that protects the circuitry during handling, installation, and under service loads. Figure 1 illustrates coupon versions of the Cover and Housing used to simulate the interface between these components for weld testing. These coupon representations of assembly components were designed to match the material and relevant geometry related to the welded joint while other features not relevant to the welded joint are excluded.The objective of this study was to characterize the sensitivity of the weld geometry and mechanical properties to the input weld parameters to inform further Finite Element Analysis (FEA) efforts in balancing joint strength against assembly deformation caused by the welding process. Characterization was accomplished by varying laser welding parameters around the current design values and measuring weld geometry on the cross-sections. Nanoindentation with a spherical and flat-ended tip was used on polished section cuts of the weld to obtain direct estimates of the stress-strain response of the Fusion Zone (FZ) for comparison to the Base Metal (BM).

42 ENGINEERING↗

DOE OSTI2022

Simulation-Based Analysis of Impacts of Reduced Envelope and Duct Air Leakage on Indoor Air Pollutant Concentrations in Occupied Manufactured Homes

This report presents a simulation-based analysis that estimates the magnitude of indoor air pollutant concentration changes that could result from the proposed energy conservation standards. The analysis was conducted for a 1568 ft 2 , double-wide MH with variations in heating and cooling equipment (either furnace + air conditioner or heat pump) and various types of whole-house mechanical ventilation (continuous exhaust fan or central fan integrated supply), in three locations with varying climate conditions: Chicago IL, Fresno, CA; and Houston TX. The simulations tracked four air pollutants that can reach levels exceeding established safe target levels in homes: acrolein, formaldehyde, fine particulate matter (PM 2.5 ), and nitrogen dioxide (NO 2 ). The simulations considered acrolein and formaldehyde emitted from continuous indoor sources; acrolein, NO 2 and PM 2.5 from cooking; PM 2.5 from dispersed occupant activities; and NO 2 and PM 2.5 from outdoors, using historical data to identify typical levels. The impacts in homes operating or not operating whole-house mechanical ventilation equipment, kitchen and bath exhaust fans, and window opening as ventilation approaches were examined.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Understanding Photocarrier and Gas Dynamics to Rationally Design Heterostructured Nanocatalysts for Efficient Solar CO 2 Conversion

Recent research in CO 2 photocatalysis has largely focused on exploring new catalysts; however, details of the relationship between charge carrier dynamics and gas dynamics on the surface of nanomaterials often remain unclear. Knowledge of these processes will allow one to rationally design highly efficient catalysts for solar CO 2 conversion. This project aimed to develop state-of-the-art techniques and establish new capabilities in SRNL to enable the study of photocatalysts and other materials in detail. In FY21, we developed two new in situ techniques that are unique to SRNL, allowing the study of reaction intermediates and adsorbed gases during photocatalysis at various wavelengths of excitation. We also established a new in-house capability for catalyst synthesis and product evaluation which enables a deep understanding of how catalyst preparation methodologies impact product generation. In FY22, we gained in-house expertise and knowledge on the newly constructed a physical vapor deposition device, i.e. glancing angle deposition (GLAD) system, and constructed a flow photoreactor system for CO 2 photoconversion and other photocatalytic studies.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2022

Heating and Cooling Energy Modeling of 3D-Printed Concrete Construction of Residential Buildings [Slides]

3D printed concrete construction (C3DP) is an emerging technology that comes with the associated benefits of high thermal mass walls. We investigated using BEopt software the heating and cooling energy use of a single story C3DP-constructed house. We then compared the heating/cooling energy use of the C3DP house against the corresponding energy use in a traditional timber (wood) frame construction (WFC), as well as a concrete masonry unit (CMU) construction. Both peak energy use for heating and cooling (Btu), as well as base energy use for both heating and cooling (MMBtu/yr) of the C3DP design were compared against the WFC and CMU baseline construction of identical geometries and orientations across all eight climate zones defined in the International Energy Conservation Code (IECC). The BEopt models for all three constructions (C3DP, WFC, and CMU) were built to comply with the 2018 IECC code. Results indicate that C3DP construction has significant heating and cooling energy benefits in certain climate zones, with the highest peak cooling energy savings (9% compared to WFC, and 5% compared to CMU) in the IECC Climate Zone 1 in the month of July. The peak heating and cooling energy demand reduction of C3DP were found to be more significant than the base heating and cooling energy demand in all IECC climate zones. The 2018 IECC compliance-related U-Factor adjustments of all models also resulted in more peak energy savings of the C3DP design in the cooling-dominated climate zones (climate zones 1 and 2), moderate energy savings in moderate climate zones (climate zones 3, 4, and 6), and little to no change in energy savings in very cold climates (climate zones 7 and 8).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗