Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “plant operations”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 721 records · Page 40
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Initial Engineering and Design for CO 2 Capture from Ethanol Facilities

The Energy & Environmental Research Center, in partnership with the U.S. Department of Energy (DOE) and North Dakota ethanol producer Red Trail Energy, LLC (RTE) and with technical support from Trimeric Corporation and the KLJ engineering firm, completed an initial engineering design (IED) for a hybrid capture system to estimate associated costs for retrofitting the operational RTE ethanol plant. The project goal supports the DOE objective to achieve negative emissions using commercially available technologies to attain Technology Readiness Level 6+ from a facility emitting >100,000 tonnes of carbon dioxide (CO 2 ) annually. The RTE CCS (carbon capture and storage) Project is currently operating a CO 2 capture facility, adjacent to the RTE ethanol facility in western North Dakota, and injecting the CO 2 more than a mile below RTE property for permanent storage. This novel hybrid capture system would process about 310,000 tonnes of CO 2 annually for the RTE host site and includes CO 2 capture and compression from bioprocessing as well as capturing CO 2 produced from natural gas boilers. The bioprocessing capture process, based on past RTE studies investigating ammonia liquefaction technology with CO 2 produced from natural gas boilers captured utilizing chemical absorption with amine, was shown to be technically feasible for the RTE site. Activities conducted to support the project goal included 1) designing a hybrid capture system using CO 2 emissions from both bioprocessing and heat production at the host site facility; 2) conducting a pre-front-end engineering and design analysis of the hybrid capture system to include environmental health and safety, a constructability report, identification of permits, and corporate approvals; and 3) performing a techno-economic assessment in accordance with DOE’s methodology, as demonstrated by the bituminous baseline study. In addition, a life cycle assessment (LCA) was completed for the RTE site to estimate the carbon life cycle for ethanol-CCS implementation using the designed hybrid capture system to determine potential for net-negative carbon emissions. Results of the IED showed the hybrid system to be technically viable, with a moderate estimated cost of $55/tonne CO 2 captured for the hybrid system. The cradle-to-gate LCA showed preliminary net-negative carbon emissions potential anticipated from implementing a hybrid CCS system at a commercial scale. Recommended next steps toward potential implementation include hybrid capture system demonstration testing for detailed engineering and LCA model comparisons with low-carbon fuel incentive programs for financial support.

01 COAL, LIGNITE, AND PEAT↗
NASA NTRS1977

Interface design in the process industries

Every operator runs his plant in accord with his own mental model of the process. In this sense, one characteristic of an ideal man-machine interface is that it be in harmony with that model. With this theme in mind, the paper first reviews the functions of the process operator and compares them with human operators involved in control situations previously studied outside the industrial environment (pilots, air traffic controllers, helmsmen, etc.). A brief history of the operator interface in the process industry and the traditional methodology employed in its design is then presented. Finally, a much more fundamental approach utilizing a model definition of the human operator's behavior is presented.

Beaverstock, M. C.↗
NASA NTRS1977

Compiled data on the vascular aquatic plant program, 1975 - 1977

The performance of a single cell, facultative sewage lagoon was significantly improved with the introduction of vascular aquatic plants. Water hyacinth (Eichhornia crassipes) was the dominant plant from April to November; duckweed (Lemna spp.) and (Spirodela spp.) flourished from December to March. This 2 ha lagoon received approximately 475 cu m/day of untreated sewage and has a variable COD sub 5 loading rate of 22-30 kg/ha/day. During the first 14 months of operation with aquatic plants, the average influent BOD sub 5 was reduced by 95% from 110 mg/l to an average of 5 mg/l in the effluent. The average influent suspended solids were reduced by 90% from 97 mg/l to 10 mg/l in the effluent. Significant reductions in nitrogen and phosphorus were effected. The monthly kjeldahl nitrogen for influent and effluent averaged 12.0 and 3.4 mg/l, respectively, a reduction of 72%. The total phosphorus was reduced on an average of 56% from 3.7 mg/l influent to 1.6 mg/l effluent.

Wolverton, B. C.↗
NASA NTRS1989

A variable-gain output feedback control design approach

A multi-model design technique to find a variable-gain control law defined over the whole operating range is proposed. The design is formulated as an optimal control problem which minimizes a cost function weighing the performance at many operating points. The solution is obtained by embedding into the Multi-Configuration Control (MCC) problem, a multi-model robust control design technique. In contrast to conventional gain scheduling which uses a curve fit of single model designs, the optimal variable-gain control law stabilizes the plant at every operating point included in the design. An iterative algorithm to compute the optimal control gains is presented. The methodology has been successfully applied to reconfigurable aircraft flight control and to nonlinear flight control systems.

Haylo, Nesim↗
DOE OSTI2024

Computational Analysis of the Effect of Structured Packing Design on Absorption Column Hydrodynamics for Post-Combustion Carbon Capture Applications

Solvent based post-combustion carbon capture technologies have a potential for reducing carbon emissions from fossil-fuel-fired power plants and industrial sources where CO2 emissions are inherently harder to mitigate, such as steel or cement industries. A prominent technology to achieve this is by retrofitting absorption columns to the existing infrastructure. While these systems have been among the less costly alternatives for carbon capture, they still impose a considerable energy penalty to the operation of power plants or industrial facilities. The optimization of CO2 capture rate in solvent-based absorption process is complex as it depends on several factors including CO2 solubility, solvent reaction kinetics and temperature effects on the solubility, reaction rates, surface tension, and thermophysical properties of the solvent and the flue gas. The overall heat and mass transfer also depends on the hydrodynamics, which in turn, is affected by the packing geometry. In the current work, we systematically quantify the effects the design of the structured packing has on the column hydrodynamics, by performing detailed CFD simulations for different geometrical configurations and operating conditions. We then obtain relationships between the key hydrodynamic metrics, such as liquid holdup, interfacial area, wetted area, and pressure drop to the parameters defining the packing geometries and identify new more effective packing designs for the given operating conditions.

Shah, Yash Girish↗
DOE OSTI2023

Sensitivity and Importance Measure Analyses for Various Design Architectures for High Safety-Significant Safety-Related Digital Instrumentation and Control Systems of Nuclear Power Plants

A transition from analog instrumentation and control (I&C) technologies to digital I&C technologies is taking place for license renewals of existing nuclear power plants and for operating licenses of new advanced reactors. This transition necessitates research on risk and economic assessments of digital I&C technologies to ensure the long-term safety and reliability of vital systems, reduce uncertainty in licensing costs in addition to timeline, support integration of digital I&C systems in the plant, and find the most efficient technology upgrades. Adding redundancy within systems or components is a common means of improving design safety; however, it can also make designs more prone to common-cause failures (CCFs). Introducing diversity into redundant systems or components is a way to mitigate and possibly eliminate CCFs, but it also increases plant complexity and may be costly. The balance between redundancy and diversity remains a challenge for digital I&C systems. This study performs sensitivity and importance analyses for four design architectures of two digital I&C systems—the reactor-trip system and the engineered safety features actuation system. For each system, two architectures are examined, including a redundant, non-diverse configuration and a redundant, diverse configuration. The sensitivity analysis will provide insights on the impact of introducing diversity to system reliability. The importance results will help identify risk-significant and risk-sensitive components and failure modes, which may be good candidates for future design improvement.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2022

Real-time dispatch optimization for concentrating solar power with thermal energy storage

Concentrating solar power (CSP) plants present a promising path towards utility-scale renewable energy. The power tower, or central receiver, configuration can achieve higher operating temperatures than other forms of CSP, and, like all forms of CSP, naturally pairs with comparatively inexpensive thermal energy storage, which allows CSP plants to dispatch electricity according to market price incentives and outside the hours of solar resource availability. Currently, CSP plants commonly include a steam Rankine power cycle and several heat exchange components to generate high-pressure steam using stored thermal energy. The efficiency of the steam Rankine cycle depends on the temperature of the plant's operating fluid, and so is a main concern of plant operators. However, the variable nature of the solar resource and the conservatism with which the receiver is operated prevent perfect control over the receiver outlet temperature. Therefore, during periods of solar variability, collection occurs at lower-than-design temperature. To support operator decisions in a real-time setting, we develop a revenue-maximizing non-convex mixed-integer, quadradically-constrained program which determines a dispatch schedule with sub-hourly time fidelity and considers temperature-dependent power cycle efficiency. The exact nonlinear formulation proves intractable for real-time decision support. Here we present exact and inexact techniques to improve problem tractability that include a hybrid nonlinear and linear formulation. Our approach admits solutions within approximately 3% of optimality, on average, within a five-minute time limit, demonstrating its usability for decision support in a real-time setting.

14 SOLAR ENERGY↗
DOE OSTI2023

Flexible Fully-Decoupled Nuclear Plants with Thermal Energy Storage - Technoeconomic Optimization

New nuclear power plants may be one of the technologies for future zero carbon electricity production. These future systems will however also need significant flexibility to cope with fluctuating demand and large share of intermittent renewable supply, rather than running in conventional baseload generation. The present work explores the use of thermal energy storage (TES) as a buffer between the reactor heat and its conversion to electricity, enabling flexible operation of nuclear plants. The focus is on maximizing flexibility, ideally as full decoupling of the nuclear and power cycle islands, as well as on system efficiency in various modes. A system design presented for a high temperature gas cooled reactor (HTGR) presents a slightly complex solution, as separate high- and low-temperature TES systems are required in order to cover the extended temperature range. Although this configuration imposes certain limitations on the discharge system configuration, it also presents the opportunity to design a more efficient system. For this case in particular, a steam reheat cycle is advantageous. Dynamic models were developed for the decoupled system in order to generate insights into aspects of off design operation and system control. A technoeconomic analysis, furthermore, provides sizing and costing of the component, followed by size and dispatch economic optimization considering energy arbitrage. This optimization shows that in all explored markets, the addition of TES system with the proposed configuration results in positive impact on project net present value. Further sensitivity analyses show impact of multiple inputs and possible technical limitations.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Energy Storage Sizing and Operation of an Integrated Utility-Scale PV+ESS Power Plant

Integration of an energy storage system (ESS) into a large-scale grid-connected photovoltaic (PV) power plant is highly desirable to improve performance of the system and overcome the stochastic nature of PV power generation. Algorithms to size ESS within an integrated PV and ESS ( PV+ESS) power plant, conventionally, require a large number of high-resolution samples of PV generation. These algorithms are computationally expensive. In this paper, a two-day optimization algorithm that utilizes n-step constant power output dispatch every day from the PV+ESS power plant is proposed to size the ESS. Additionally, an n-step power dispatch every day through the one-year timeframe based optimization of the size of ESS is also performed. The proposed methods are computationally cheaper and provide acceptable accuracy with respect to the conventional sizing methods. The economics identified from the proposed methods are compared with the typical day-ahead hourly dispatch-based power production from the PV+ESS power plant. This comparison has shown similar economic performance showcasing the accuracy of the proposed methods in sizing the ESS. It also shows the potential for operating PV+ESS power plant in n-step constant power generation mode.

Xia, Qian↗
DOE OSTI2020

A Tool for Performing Link Analysis, Operational Sequence Analysis, and Workload Analysis to Support Nuclear Power Plant Control Room Modernization

Nuclear power continues to have an imperative role for the U.S.’s electricity generation. However, for these nuclear power plants (NPPs) to remain economically viable, new strategies for reducing operations and maintenance costs must be explored. The U.S. Department of Energy Light Water Reactor Sustainability Program is researching how to digitally transform existing analog and hybrid main control rooms into a fully integrated control room that addresses this challenge. The transformation will fundamentally change the conduct of operations for these U.S. NPPs. Human factors engineering has a vital role in this effort, where traditional task analysis methods are important in informing the design of advanced human-system interface displays. This work describes a preliminary tool to support task analysis for the development of these advanced displays. Details on the use of this tool, including the specific task analysis methods offered, are presented in this paper.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

Grid Forming Control Tuning for a Hybrid Inverter-Based Resource Power Plant

A hybrid inverter-based resource (IBR) power plant consists of grid-following (GFL) and grid-forming inverter-based resources (GFM-IBR) connected in parallel. Here, this research focuses on how to design and tune GFM's control parameters to ensure stable operation of the hybrid power plant for weak and strong grid conditions. We consider two design cases: one where the GFL-IBR does not provide frequency support, and one where it does. It is found that the GFM's power-frequency synchronizing system can lose stability when the power-frequency droop constant is large and/or the grid is strong. Additionally, if the GFL has its frequency support enabled, oscillation stability worsens. To explain the mechanism of the interactions, we construct a feedback system for the synchronizing loop, which consists of the GFM's power-frequency droop control that generates the GFM's synchronizing angle, the GFL's phase-locked loop that measures the voltage phase angle, the GFL's frequency-power control that generates its power order, and the rest of the system. The feedback system is effective in illustrating the potential stability risks. Successful design ensures that the hybrid power plant can operate smoothly and ride through grid disturbances.

feedback systems↗
DOE OSTI2025

Develop a Simulation Framework for Understanding Physico-Chemical Processes and Optimization of CHZ' Plastic Thermolyze Technology (CRADA Final Report)

Thermolyzer(TM) technology is a third-generation, multi-reactor, oxygen-free, low pressure, slow pyrolysis process. It has proven to be remarkably versatile in successfully processing all types of hydrocarbon waste. These include all seven types of plastics, tires, auto shredder residue, carpet, electronic waste, and composites. Working with the IACMI, Thermolyzer(TM) technology has recovered the glass and carbon fibers from wind turbine blades for reuse into new applications. Its primary output is a synthesis gas that is rich in H 2 , CH 4 , and small amounts of C 2-4 aliphatic hydrocarbons. Other components are CO and CO 2 . Three unique features set Thermolyzer(TM) apart from other pyrolysis systems: the syngas is clean enough to run in Siemens or Solar gas turbines or IC engines without fouling, clean, salable, byproducts are produced, and CO 2 emissions are lower than natural gas power plants. Research results have been obtained from an operating 7 ton/day facility. A 44 ton/day plant has successfully operated as noted above. The process works because it makes use of the recoverable embodied energy in the feedstock. Surprisingly, a pound of some plastics has the same recoverable energy content as a pound of gasoline. Thus, it is imperative to develop a process that economically converts scrap plastics (including ocean plastics) into energy and thereby conserve the non-renewable fossil fuels for future generations. The Thermolyzer(TM) technology can also be used to create liquid fuels like gasoline and diesel from hydrocarbon wastes. Because of the high hydrogen content of the synthesis gas, hydrogen can be recovered more inexpensively than the current solar or wind energy being used to electrolyze water. That hydrogen can be used for fuel cell powered vehicles or converted into ammonia for agriculture or as a hydrogen storage medium. Extension of this technology to other wastes such as tires, auto shredder residue or wood wastes would expand the circular economy.

36 MATERIALS SCIENCE↗
NASA NTRS1985

A methodology for designing robust multivariable nonlinear feedback control systems

This paper presents an outline of a methodology for the design of nonlinear dynamic compensators for nonlinear multivariable systems with guarantees of closed-loop stability, robustness, and performance. The method is an extension of the Linear-Quadratic-Gaussian with Loop-Transfer-Recovery (LQG/LTR) methodology for linear systems, thus hinging upon the idea of constructing an approximate nonlinear inverse operator for the plant. A major feature of the method is a unification of both the state-space and Input-Output formulations. The major results of the paper are: (1) Properties of the solution of certain optimal control problems; (2) New results on nonlinear estimation, including a new nonlinear observer with certain guaranteed properties; (3) The Loop Operator Recovery (LOR) procedure, and (4) Inclusion of command-following and disturbance rejection with a goal of a closed-loop stable, robust system.

Grunberg, D. B.↗
DOE OSTI2025

Liquid Alkaline Water Electrolyzers: Comparing Performance across Design, Operation, and End-of-Life Scenarios

Liquid alkaline water electrolysis (LAWE) is a demonstrated technology for hydrogen production, yet a comprehensive life cycle assessment (LCA) of their deployment is lacking. Research leading to improvements to the core component, the electrochemical stack, along with auxiliary system materials and dynamic operation of stacks from variable electricity supply offers new data that allows for detailed modeling and evaluation. Here, we present an LCA of two facility designs based on the current state-of-the-art stack and an advanced stack with zero-gap between electrodes, and capture dynamic electricity use from solar, wind, and hybrid sources and stack recycling strategies. We present life cycle impact factors characterizing the production of 1 kg of hydrogen across 12 environmental, human health, and resource impact categories (TRACI and ReCiPe) in the contiguous United States. As expected, the source of electricity will drive impacts (e.g., 83-94% of carbon intensity); however, we find that operating using wind electricity can lower hydrogen leakage and the overall carbon intensity (1.03 kgCO 2 e/kgH 2 ) relative to solar electricity (2.57 kgCO 2 e/kgH 2 ) at matched 1:1 capacity between LAWE and the electricity source. The deployment of the advanced design and stack recycling lowers impacts across all life cycle stages. We highlight opportunities to further reduce potential impacts, including the balance of plant materials and operation cycles associated with the use of variable wind and solar electricity that result in hydrogen leakage.

08 HYDROGEN↗
NASA NTRS1985

Overview and highlights of Early Warning and Crop Condition Assessment project

Work of the Early Warning and Crop Condition Assessment (EW/CCA) project, one of eight projects in the Agriculture and Resources Inventory Surveys Through Aerospace Remote Sensing (AgRISTARS), is reviewed. Its mission, to develop and test remote sensing techniques that enhance operational methodologies for crop condition assessment, was in response to initiatives issued by the Secretary of Agriculture. Meteorologically driven crop stress indicator models have been developed or modified for wheat, maize, grain sorghum, and soybeans. These models provide early warning alerts of potential or actual crop stresses due to water deficits, adverse temperatures, and water excess that could delay planting or harvesting operations. Recommendations are given for future research involving vegetative index numbers and the NOAA and Landsat satellites.

Boatwright, G. O.↗
DOE OSTI2025

The Staged, Pressurized Oxy-Combustion Technology: Status and Application to Boiler Retrofits to Yield Carbon-Negative Power via Biomass

Recognizing the benefits of pressurization and fuel staging on the efficiency of oxy-combustion, the staged, pressurized oxy-combustion (SPOC) process was introduced in 2012. The combination of fuel staging and pressurized oxy-combustion results in a more compact plant, a higher plant efficiency and reduced costs for pollutant and greenhouse gas removal compared with plants equipped with conventional carbon capture. This approach to power generation enables a modular boiler design and optimizes the plant for flexible operation, which is essential to meet the demands of the modern grid when it contains intermittent power sources. Originally designed to burn coal, the SPOC process is well-suited for biomass because the combustion of biomass leads to a high moisture content in the flue gas and the SPOC process is able to recover the latent heat of this moisture, enhancing system performance over that of traditional biomass combustion at atmospheric pressure. The present work is focused on evaluating the potential for utilizing the SPOC process in retrofit applications wherein the boilers of an existing plant are replaced with the SPOC process, and woody biomass is used as the fuel to yield carbon-negative power. Two applications are considered: power generation and cogeneration (heat and power). Modeling these systems in Aspen Plus demonstrates that the SPOC process surpasses the performance of baseline plants with post-combustion capture (PCC) for both power generation and cogeneration. Specifically, compared to a PCC equipped plant, the SPOC power plant has 33% higher efficiency, and the SPOC cogeneration plant reaches 42% higher net energy. Experimentally, the existing SPOC facility was fired for the first time with 100% biomass and after minor improvements were made to the feeding system, the facility demonstrated excellent performance during startup, steady-state operation and turndown.

Carbon capture and storage↗
DOE OSTI2021

Stellarators as a fast path to fusion

Herein this paper is focused on three points: (1) overcoming obstacles to tokamak power plants may require a configuration modification as large as that of a stellarator. (2) The demonstrated reliability of the computational design of stellarators should change fusion strategy. (3) Deployment of carbon-free energy sources is mandated by the thirty-year doubling of carbon dioxide emissions. Carbon-free energy options must be developed and fully deployed within a few doubling times. Unit size and cost of electricity are only relevant in comparison to alternative worldwide energy solutions. Intermittency, site specificity, waste management, and nuclear proliferation make fusion attractive as the basis for a carbon-free energy system compared to the alternatives. Nonetheless, fusion is not an option for deployment until a power plant has successfully operated. A critical element in a minimal time and risk program is the use of computational design as opposed to just extrapolation. Only the stellarator has an empirical demonstration of the reliable computational design through large changes in configuration properties and scale. The computational design of stellarators should proceed while the inventions necessary for a more tokamak-like power plant are sought. The cost of computational design is extremely small, but adequate time is required for the development of ideas that maximize attractiveness and minimize risk. Rapid power-plant construction without many intermediate steps may seem risky, but the price is small compared to the cost of trillions of dollars for each year's delay in addressing carbon-dioxide emissions.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Measurement of DC Arc-Flash Incident Energy in Large-Scale Photovoltaic Plants: A Basis for Standardization

The deployment of high-power dc equipment is increasing in solar photovoltaic (PV) plants, but very few studies have quantified dc arc-flash risks. Currently, PV plant owners and operators rely on theoretical, simplified models, such as those in NFPA-70E and other publications, for the assessment of risk associated with dc arc-flash. Here, this article presents an overview of arc-flash risks in a PV system based on a series of field experiments based on IEEE-1584 in two large-scale ground-mounted PV plants. The experiments include various high-power dc equipment of a PV plant, such as central inverters, combiner boxes, recombiner boxes, string inverters, and multiple configurations of electrodes in a 20-in calibration cube. The study reveals that none of the available dc arc-flash models are applicable for a PV plant. This work is an important first step toward developing an improved model that more accurately assesses dc arc-flash risk in a PV plant.

14 SOLAR ENERGY↗