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At least 721 records · Page 40

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DOE OSTI2024

Waste heat recovery power electronics cooling

A cooling system for an electrified vehicle includes a first cooling loop for circulating coolant for cooling at least one of power electronics and a motor/generator of the vehicle. The first coolant loop includes a heat exchanger for exchanging heat with the coolant in the first cooling loop. A second cooling loop is provided for circulating coolant for cooling a battery of the vehicle. The second cooling loop includes a coolant chiller connected to a refrigeration system of the vehicle for exchanging heat in the coolant received from the battery with the refrigeration system of the vehicle.

Ernst, Timothy C.↗

DOE OSTI2026

Modeling of a Four-Stage Linear Ionization Cooling Channel for a Muon Collider in G4Beamline

A previous study of an eight-stage rectilinear ionization cooling channel in the ICOOL software demonstrated a five-order-of-magnitude reduction in a muon beam’s 6D emittance. In this study, we look to compare the ways ICOOL and Muons, Inc.’s g4Beamline software model ionization cooling by comparing their modeling of the first four stages to this optimized cooling channel constructed in ICOOL. We begin by identifying the parameters used to construct the optimized ionization cooling channel in ICOOL. We then reconstruct this beam in g4Beamline with identical parameter specifications and simulate the cooling of an identical input beam. Finally, we compare the two simulations based on their beam transmission, longitudinal emittance, and transverse emittance along the channel length. Through this process, we demonstrate that G4Beamline accurately reproduces transverse cooling results but predicts systematically different longitudinal emittance evolution while maintaining similar overall cooling performance, reproducing a 97.9% reduction in 6D emittance over four stages.

Keeler, Dominic [Purdue U., West Lafayette] (ORCID↗

DOE OSTI2020

Comparison of electro-thermal performance of advanced cooling techniques for electric vehicle motors

Permanent magnet synchronous motors are commonly used in the powertrain of electric vehicles because of their high power and torque densities. Attempts to increase power and torque densities beyond the state-of-the-art often suffer from thermal limitations of the adopted winding-wire insulation class. In this paper, overall effectiveness of four different cooling technologies, namely conventional stator jacket cooling, embedded circular and rectangular cooling channels within stator core, and direct winding heat exchangers have been studied numerically. Here, by realizing temperature dependent magnetic and material properties, winding and core losses, a two-way coupling algorithm has been utilized to study the detailed electro-magnetic and thermal performance of BMW i3 motor with aforementioned cooling techniques. The numerical results illustrated that the direct winding heat exchangers approach provides better electro-thermal performance in comparison to the other cooling techniques analyzed. On the contrary, embedded rectangular and circular channel in stator core adversely affect the electro-magnetic performance and overall efficiency of the motor, despite their superior thermal performance compared to the jacket cooling

42 ENGINEERING↗

DOE OSTI2019

Potential benefits of cool walls on residential and commercial buildings across California and the United States: Conserving energy, saving money, and reducing emission of greenhouse gases and air pollutants

Solar-reflective “cool” walls reduce absorption of sunlight by the building envelope, which may decrease cooling load in warm weather and increase heating load in cool weather. Changes to annual heating, ventilation, and air conditioning (HVAC) energy use depend on climate, wall construction, wall orientation, building geometry, HVAC efficiency, and operating schedule. Changes to annual energy cost and energy-related emissions further vary with local energy prices and emission factors. In this work, we used EnergyPlus to perform over 100,000 whole-building energy simulations, spanning 10 different building categories, three building vintages, 16 California climate zones, and 15 United States (U.S.) climate zones. We find that cool walls yielded annual source energy, energy cost, and emission savings in all California climate zones and in warm U.S. (ASHRAE) climate zones. In California, annual whole-building HVAC energy cost savings were 4.0–27% in single-family homes, 0.5–3.8% in medium office buildings, and 0.0–8.5% in stand-alone retail stores. In warm U.S. climates—zones 1A (Miami, FL) through 4B (Albuquerque, NM)—annual HVAC energy cost savings were 1.8–8.3% in single-family homes, 0.3–4.6% in medium office buildings, and 0.5–11% in stand-alone retail stores. California and U.S. fractional source energy and emission savings were comparable to fractional energy cost savings. Per unit surface area modified, cool-wall savings often exceeded cool-roof savings because building codes typically prescribe much less wall insulation than roof insulation.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Peak cooling load shift capability of a thermal energy storage system integrated with an active insulation system in US climate zones

This study aims to evaluate a thermal energy storage (TES) system integrated with an active insulation system (AIS) to form a TES + AIS integrated wall system as a partition and as a secondary cooling system to shift the peak load and reduce cooling energy consumption. To understand and demonstrate its cooling performance, the TES + AIS integrated wall system was installed in an office building in Oak Ridge, Tennessee. To investigate the effect of the TES + AIS integrated wall system in a typical office building and various climate zones, the US Department of Energy’s prototype office building model was modified to accommodate the proposed system. In this work, results showed that the minimum size of the proposed system to achieve energy savings varies depending on climate conditions. The minimum size of the proposed system for cooling energy saving and shifting peak cooling demand in climate zones 2, 3, and 5 is 29.7 m 2 , whereas it is 44.6 m 2 in zones 4 and 6. By installing the minimum size of the proposed system, 11.3 % to 16.4 % of cooling energy can be shifted during discharge hours in a representative summer day.

25 ENERGY STORAGE↗

DOE OSTI2023

Effects of additively manufactured surface roughness on small diameter plenums with multiple side discharges for high temperature gas turbine blade cooling applications

Combined heat and power (CHP) applications have significant environmental and economic benefits that are consistent with the goals of the U.S. Department of Energy (DOE). One area that is currently being studied includes the potential benefits of CHP turbine operation at higher turbine inlet temperatures. Internal cooling concepts enabled by additive manufacturing (AM) are of primary interest. Here, the effectiveness of internal cooling is hindered by many factors such as velocity distribution of the cooling air to the hot surface considering impingement cooling. To simulate cooling air exiting from a series of orifices for internal cooling in an airfoil, a straight smooth wall tubing with multiple side discharging orifices is used and compared to additively manufactured tubing (Ti6Al4V Grade 23) with orifice size and spacing as well as inner and outer diameters identical to the smooth wall tubing. Similar to flow discharging form perforated pipes, the flow discharged from individual orifices along the tubes in this study is found to be nonuniformly distributed, and the horizontal (axial direction) momentum can be observed from the experimental data. Discharge velocities have been measured with two-dimensional (2D) particle imaging velocimetry (PIV) and single element hot wire anemometry. Numerical analysis has also been conducted to predict the velocity distributions along the orifices in the smooth wall and additive manufacturing (AM) tubing, which are inherited with surface roughness. Numerical and measured results in this study are compared, presented, and discussed.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2019

A Thermal Model for the Performance Analysis of Large Scale Spent Fuel Cooling Pond - 19173

This paper presents a thermal model for the performance analysis of a large scale cooling pond for the long term storage of spent nuclear fuel. The model has been developed using the knowledge gained from fundamental investigation using CFD and has been validated by comparing against reliable experimental and/or numerical data. It was then applied in the context of operation of a large scale pond to ascertain the sensitivity of various operational and environmental conditions. To develop the model, the water body along with the heating elements was considered as one zone and humid air inside the building as another zone, both of which are considered as well-mixed zones. Various input conditions namely, total heat load from the heat source, environmental temperature and relative humidity, ventilation rate, efficiency of the cooling tower, recirculation and make-up water flow rates have been programmed in the model. The statistical method AVONA has been used to assess the influence of the above variables. The results reveal that the efficiency of the cooling tower is the most influential parameter on the cooling performance of cooling pond within the considered values of heat load. It has also been found that the majority of the heat is taken by the recirculating water for very high heat load while the other modes of heat transfer are small but not insignificant. The model is capable of simulating the scenario of loss of cooling water and suggests that it can be used for managing a large pond efficiently as well as recovery from an accident situation. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2018

Changes in ENSO amplitude under climate warming and cooling

The response of ENSO amplitude to climate warming and cooling is investigated using the Community Earth System Model (CESM), in which the warming and cooling scenarios are designed by adding heat fluxes of equal amplitude but opposite sign onto the ocean surface, respectively. Results show that the warming induces an increase of the ENSO amplitude but the cooling gives rise to a decrease of the ENSO amplitude, and these changes are robust in statistics. A mixed layer heat budget analysis finds that the increasing (decreasing) SST tendency under climate warming (cooling) is mainly due to an enhancement (weakening) of dynamical feedback processes over the equatorial Pacific, including zonal advective (ZA) feedback, meridional advective (MA) feedback, thermocline (TH) feedback, and Ekman (EK) feedback. As the climate warms, a wind anomaly of the same magnitude across the equatorial Pacific can induce a stronger zonal current change in the east (i.e., a stronger ZA feedback), which in turn produces a greater weakening of upwelling (i.e., a stronger EK feedback) and thus a larger thermocline change (i.e., a stronger TH feedback). In response to the climate warming, in addition, a slowdown of the subtropical cells (STCs) will result in a narrower meridional width of SST anomaly around the equator and thus a stronger MA feedback. And vice versa for the cooling case. Bjerknes linear stability (BJ) index is also evaluated for the linear stability of ENSO, with significantly larger (smaller) BJ index found for the warming (cooling) case.

ENSO amplitude, Climate Warming, Climate cooling, ↗

DOE OSTI2018

Prediction of Cooling Curves for Controlled Unidirectional Solidification Under the Influence of Shrinkage: A Semi-analytical Approach

Quality of casting products can be significantly improved by controlling the crystal growth rate. Both dendritic and equiaxed grain structures depend strongly on crystal growth rate along the crystallographic direction. Uncontrolled solidification processes may lead to the formation of porous and columnar material with an extremely non-homogeneous composition distribution. These undesirable micro-structures can be avoided by adopting an optimal cooling rate (K/s) during the crystal growth. The present work focuses on determining suitable cooling curves to obtain desired unidirectional crystal growth rates, by implementing a semi-analytical model. Here, we defined cooling curve as the time history of temperature evolution at the cold boundary. The proposed semi-analytical heat transfer model is diffusion driven and accounts for shrinkage effect during solidification. The proposed model is found capable of predicting cooling curves for prescribed interface velocities. The model is self-sufficient in validating itself by means of solving inverse and forward problems. The cooling curve prediction by the model is validated by using it as the transient boundary condition for an existing enthalpy updating scheme-based numerical model. The proposed model is also applied to empirical data reported in literature, to validate the model against experimental results. All the validations showcased excellent fit. The proposed model will facilitate controlled unidirectional crystal growth rate by providing cooling rate (K/s) as an input for the experiments involving directional solidification.

36 MATERIALS SCIENCE↗

DOE OSTI2018

The Effects of Alloying Elements on the Continuous Cooling Transformation Behavior of 2¼Cr-1Mo Steels

The continuous cooling transformation (CCT) behavior of eight 2¼Cr-1Mo steels from a statistically designed matrix was determined. These steels contained two levels of carbon (0.07 and 0.16 wt.%), manganese (0.35 and 0.85%), chromium (1.5 and 2.8%), and molybdenum (0.3 and 1.25%). Each steel was tested in a quenching dilatometer at five to six cooling rates between 725 and 1.2 °C/min. For each CCT sample, the change in length, microstructure, and macrohardness were determined. The ferrite content was also measured for samples cooled near the ferrite nose. Pearson correlation and multiple regression analyses were performed for various CCT diagram parameters. The correlation analysis showed that carbon and chromium contents significantly affected the critical temperatures and the bainite and martensite transformation temperatures. Increasing carbon content significantly increased the hardness for the bainite and martensite range of cooling rates, but hardness at slower cooling rates was unaffected by alloying elements. Regression equations were obtained for the critical temperatures and the ferrite nose cooling rate.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Effective properties of semitransparent radiative cooling materials with spectrally variable properties

Radiative cooling is a promising solid-state, non-vapor-compression technology for passive refrigeration and air conditioning. Although this phenomenon occurs naturally, achieving a significant amount of cooling to make it a technically and economically viable technology requires highly engineered, spectrally selective radiative surfaces. These characteristics make radiative cooling difficult to estimate, particularly when it is integrated with other systems such as photovoltaic panels or building envelopes. The complexity further increases when the substrate also participates in the radiative cooling (along with the radiative coating). Energy estimation is becoming increasingly critical because of the recent focus on the semitransparent radiative coatings that transmit a variety of colors to enhance the aesthetic appeal of the system. In this work, we propose an iterative method to calculate the effective radiative properties, which provides the same net radiative cooling that would be observed using the spectral properties at both the coating and substrate surfaces. Compared to traditional methods that rely on either computationally expensive full spectral analysis or methods for averaging each radiative surface parameter locally, our proposed method focuses on calculating effective properties that provide the same the net cooling effect as a full spectral analysis by accounting the emissivity, absorptivity, and transmissivity collectively, thereby providing an overall estimation error of less than 0.2%. We believe that this study will be beneficial to the engineering communities that employ complex simulation codes and require lumped solar and thermal radiation related parameters.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

On the validity and limitations of 1D model for heat and mass transfer performance evaluation in a multilayer binder-free desiccant dehumidifier: isothermal dehumidification with internal cooling

Efficient humidity control is essential for maintaining indoor thermal comfort, yet conventional vapor-compression-based dehumidifiers are energy-intensive. Employing separate sensible and latent cooling through desiccant-coated heat exchangers (DCHEs) combined with evaporative coolers offers energy savings of up to 80 % compared to conventional systems. However, the dehumidification performance of DCHEs remains limited due to the use of polymer binders for coating desiccant materials onto heat exchange surfaces. In our previous study, we developed a multilayer fixed-bed binder-free desiccant dehumidifier (MFBDD) that demonstrated high dehumidification capacity and low pressure drop compared to rotary desiccant wheels. Nevertheless, its potential for further enhancement through internal cooling and the use of step-shaped adsorption isotherms has not been explored. In this study, a physics-based one-dimensional (1D) transient model is developed and validated to capture the coupled heat and mass transfer processes in the MFBDD and extended to simulate internal cooling using a high-capacity composite metal–organic framework, MIL-101/GO-6 (water uptake ≈1.6 g/g within 35–47 % RH). The model enables detailed analysis of local air and bed temperature dynamics and quantifies how internal cooling affects the dehumidification performance under a wide range of operating conditions. Results show that integrating internal cooling and using MIL-101/GO-6 enhance mass adsorbed, moisture removal capacity, and dehumidification effectiveness by 50 %–99 % compared with the M.S. Gel baseline. The study further reveals that achieving near-isothermal operation requires simultaneous enhancement of the convective heat transfer coefficient and heat exchange surface area. In conclusion, this work provides the first detailed physical insight into the interplay between internal cooling and step-shaped isotherms in a binder-free desiccant device and establishes a validated modeling framework for scaling up and system-level performance evaluation of next-generation energy-efficient dehumidification systems.

Heat and mass transfer↗

DOE OSTI2021

Investigation of pre-cooling as a recommended measure to improve residential buildings’ thermal resilience during heat waves

More intense heat waves are expected to occur more frequently in the twenty-first century. During severe heat waves, cooling capacity shortfall and overheating are likely to occur in residential buildings, and this will adversely affect occupant's thermal comfort and productivity. We propose a strategy of pre-cooling the house during off-peak hours to mitigate overheating during heat waves. Additionally, simulation results of a prototype single-family house show that adopting the rule-based control (RBC) of pre-cooling thermostat setpoint schedule is effective in reducing thermal discomfort, and that the efficacy of pre-cooling depends upon several building characteristics. An optimized control (OC) of the thermostat setpoint schedule was developed based on the simulation of a prototype building. A simplified yet improved RBC (IRBC) pre-cooling schedule was then extracted from the OC schedule for practical implementation at a larger scale. The effects of the RBC schedule and IRBC schedule were evaluated in the King District of Fresno, which contains 814 residential buildings. Results show that both thermostat setpoint schedules can reduce overheating effectively and that IRBC is slightly better than RBC for most buildings. The findings support the California government's recommendation on pre-cooling to mitigate overheating, which can be further improved with an optimized thermostat setpoint schedule broadcast to residents through early alert messages before a heat wave.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Real-time gas cooling of flowing liquid lithium limiter for the EAST

A novel continuously flowing liquid lithium limiter (FLiLi) which employs an in-vessel electro-magnetic pump to drive liquid Li flowing on the surface of limiter has been successfully designed and tested in the experimental advanced superconducting tokamak (EAST) device in 2014. In order to better control the surface temperature, an upgraded design and the real-time gas cooling were performed in 2016. Two kinds of cooling gas, helium (He) and argon (Ar) were tested on the FLiLi system prior to the experiment. It was found that the cooling rates of He and Ar at 2.5 MPa are 34.2 °C/min, 10.2 °C/min or 31.7 °C/kL and 28.1 °C/kL, respectively. The cooling performance of He is more effective than Ar. Experimental results show that the real-time He cooling could effectively contain the FLiLi surface temperature increase and prevent the strong passive evaporation of lithium during plasma discharges. Limiter heat flux up to 0.2 MW/m2 was removed during ohmic discharge with 2.5 MPa He gas. Finally, Because of the upgraded design and real-time gas cooling, the surface of FLiLi was not damaged by heat flux after entire plasma discharge.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Exploring the Potential of Rainwater Harvesting for Cooling Towers: A Systematic Review and Regional Feasibility Assessment

Water scarcity has driven interest in rainwater harvesting, especially for U.S. industries like power and manufacturing, which dedicate a large percentage of their water needs to cooling towers. This paper provides a comprehensive systematic review of studies on the use of rainwater in cooling tower applications, along with an assessment of the regional feasibility of integrating RWH in U.S. manufacturing cooling towers. The systematic review examines the technical, economic, environmental, and policy feasibility of utilizing harvested rainwater, and the regional feasibility analysis evaluates the practical implementation of RWH in manufacturing cooling towers, considering factors such as regional RWH potential, water costs, state policies, and the industrial water use of manufacturing facilities per state. This study supports the hypothesis that RWH for cooling towers is technically feasible, economically viable, and environmentally beneficial. Harvested rainwater is naturally less conductive and soft, and rainwater reuse minimizes the ecological footprint. Supportive state policies, regional RWH potential, and rising water costs across the U.S. are important variables that may impact RWH adoption. The review highlights rooftop RWH as the most studied method and notes that implementing RWH requires infrastructure changes and filtration techniques. While initial investment costs may be high, operational and maintenance costs are low, making RWHS economically feasible over time. Regions with higher water costs and supportive policies are more likely to benefit from RWH adoption. The study provides a foundation for understanding the potential for using RWH in industrial cooling towers.

Cooling towers↗

DOE OSTI2014

Small high cooling power space cooler

The small High Efficiency pulse tube Cooler (HEC) cooler, that has been produced and flown on a number of space infrared instruments, was originally designed to provide cooling of 10 W @ 95 K. It achieved its goal with >50% margin when limited by the 180 W output ac power of its flight electronics. It has also been produced in 2 stage configurations, typically for simultaneously cooling of focal planes to temperatures as low as 35 K and optics at higher temperatures. The need for even higher cooling power in such a low mass cryocooler is motivated by the advent of large focal plane arrays. With the current availability at NGAS of much larger power cryocooler flight electronics, reliable long term operation in space with much larger cooling powers is now possible with the flight proven 4 kg HEC mechanical cooler. Even though the single stage cooler design can be re-qualified for those larger input powers without design change, we redesigned both the linear and coaxial version passive pulse tube cold heads to re-optimize them for high power cooling at temperatures above 130 K while rejecting heat to 300 K. Small changes to the regenerator packing, the re-optimization of the tuned inertance and no change to the compressor resulted in the increased performance at 150 K. The cooler operating at 290 W input power achieves 35 W@ 150 K corresponding to a specific cooling power at 150 K of 8.25 W/W and a very high specific power of 72.5 W/Kg. At these powers the cooler still maintains large stroke, thermal and current margins. In this paper we will present the measured data and the changes to this flight proven cooler that were made to achieve this increased performance.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2015

Electronic cooling using thermoelectric devices

Thermoelectric coolers or Peltier coolers are used to pump heat in the opposite direction of the natural heat flux. These coolers have also been proposed for electronic cooling, wherein the aim is to pump heat in the natural heat flux direction and from hot spots to the colder ambient temperature. In this manuscript, we show that for such applications, one needs to use thermoelectric materials with large thermal conductivity and large power factor, instead of the traditionally used high ZT thermoelectric materials. We further show that with the known thermoelectric materials, the active cooling cannot compete with passive cooling, and one needs to explore a new set of materials to provide a cooling solution better than a regular copper heat sink. We propose a set of materials and directions for exploring possible materials candidates suitable for electronic cooling. Finally, to achieve maximum cooling, we propose to use thermoelectric elements as fins attached to copper blocks.

42 ENGINEERING↗

DOE OSTI2021

Design and evaluation of an open-source, conformable skin-cooling system for body magnetic resonance guided focused ultrasound treatments

Magnetic resonance guided focused ultrasound (MRgFUS) treatment of tumors uses inter-sonication delays to allow heat to dissipate from the skin and other near-field tissues. Despite inter-sonication delays, treatment of tumors close to the skin risks skin burns. This work has designed and evaluated an open-source, conformable, skin-cooling system for body MRgFUS treatments to reduce skin burns and enable ablation closer to the skin. A MR-compatible skin cooling system is described that features a conformable skin-cooling pad assembly with feedback control allowing continuous flow and pressure maintenance during the procedure. System performance was evaluated with hydrophone, phantom and in vivo porcine studies. Sonications were performed 10 and 5 mm from the skin surface under both control and forced convective skin-cooling conditions. 3D MR temperature imaging was acquired in real time and the accumulated thermal dose volume was measured. Gross analysis of the skin post-sonication was further performed. Device conformability was demonstrated at several body locations. Hydrophone studies demonstrated no beam aberration, but a 5–12% reduction of the peak pressure due to the presence of the skin-cooling pad assembly in the acoustic near field. Phantom evaluation demonstrated there is no MR temperature imaging precision reduction or any other artifacts present due to the coolant flow during MRgFUS sonication. The porcine studies demonstrated skin burns were reduced in size or eliminated when compared to the control condition. An open-source design of an MRgFUS active skin cooling system demonstrates device conformability with a reduction of skin burns while ablating superficial tissues.

60 APPLIED LIFE SCIENCES↗