SEARCH · Engineering Papers
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.
Two multifamily buildings planned in Climate Zone 4 were analyzed to determine the cost, energy and performance implications of redesigning them to comply with Zero Energy Ready Home, a recognition program of the U.S. Department of Energy. Energy modeling was conducted on one representative apartment in each building using BEopt.
Current generation automotive power electronics packages utilize silicon devices and lead-free solder alloys. To meet stringent technical targets for 2020 and beyond (for cost, power density, specific power, efficiency and reliability), wide-bandgap devices are being considered since they offer advantages such as operation at higher frequencies, voltages, and temperatures. Traditional power electronics packages must be redesigned to utilize the full potential of wide-bandgap devices, and the die- and substrate-attach layers are key areas where new material development and validation is required. Present solder alloys do not meet the performance requirements for these new package designs while also meeting cost and hazardous substance restrictions. Sintered silver (Ag) promises to meet the needs for die- and substrate-attach interfaces but synthesis optimization and reliability evaluation must be completed. Sintered Ag material was proposed as an alternative solution in power electronics packages almost 20 years back. However, synthesis pressure requirements up 40 MPa caused a higher complexity in the production process and more stringent flatness specifications for the substrates. Recently, several manufacturers have developed sintered Ag materials that require lower (3-5 MPa) or even no bonding pressures. Degradation mechanisms for these sintered Ag materials are not well known and need to be addressed. We are addressing these aspects to some extent in this project. We are developing generalized (i.e., independent of geometry) stress intensity factor versus cycles-to-failure relations for sintered Ag. Because sintered Ag is a relatively new material for automotive power electronics, the industry currently does not have a good understanding of recommended synthesis parameters or expected reliability under prescribed conditions. It is an important deliverable of this project to transfer findings to industry to eliminate barriers to using sintered Ag as a viable and commercialized die- and substrate-attach material. Only a few manufacturers produce sintered Ag pastes and may consider some processing conditions as proprietary. It is the goal of this project to openly explore and define best practices in order to impact the maximum number of power electronics module manufacturers and suppliers.
The purpose of this summary is to detail the studies that enable new nuclear physics experiments currently limited by neutron intensity or energy resolution available at LANSCE. The target is being redesigned so that the Flight Paths (FP) in the upper tier provide a higher intensity in the epithermal and medium energy ranges.
This report documents the characterization and analysis of a high current power supply for the building 865 Hypersonic Wind Tunnel at Sandia National Laboratories. The system described in this report became operational in 2013, replacing the original 1968 system which employed an induction voltage regulator. This analysis and testing was completed to help the parent organization understand why an updated and redesigned power system was not delivering adequate power to resistive heater elements in the HWT. This analysis led to an improved understanding of the design and operation of the revised 2013 power supply system and identifies several reasons the revised system failed to achieve the performance of the original power supply installation. Design modifications to improve the performance of this system are discussed.
This is a presentation given at Los Alamos National Laboratory (LANL) on the design of the next generation target at Lujan center, LANSCE. The motivation for this design is to enable new nuclear physics experiments (defense program applications (DANCE)) that are currently limited by neutron intensity or energy resolution available at LANSCE. The target is being redesigned so that the Flight Paths in the upper tier provide a higher intensity in the epithermal and medium energy ranges.
This report summarizes the results of a three year program awarded to Unico, Inc. to commercialize a residential cold climate heat pump. Several designs were investigated. Compressors were selected using analysis from Oakridge National Laboratories followed by prototype construction and lab testing in a specially built environmental chamber capable of reaching -30°F. The initial design utilized two variable speed compressors in series with very good capacity results and acceptable efficiency at very cold temperatures. The design was then modified to reduce cost and complexity by redesigning the system using three dual-stage compressors: two in parallel followed by one in series. Extensive testing found significant challenge with oil management, reliability, weight and cost which prevented the system from being fully commercialized. Further analysis of other conceptual designs indicated that these challenges could be overcome in the future.
This report presents the results of the sensor development and testing at the Wabash River gasifier. The project work was initiated with modification of the sensor software (Task 2) to enable real time temperature data acquisition, and to process and provide the obtained gasifier temperature information to the gasifier operators. The software modifications were conducted by the North Carolina State University (NCSU) researchers. The modified software was tested at the Gas Technology Institute (GTI) combustion laboratory to assess the temperature recognition algorithm accuracy and repeatability. Task 3 was focused on the sensor hardware modifications needed to improve reliability of the sensor system. NCSU conducted numerical modeling of the sensor probe’s purging flow. Based on the modeling results the probe purging system was redesigned to prevent carbon particulates deposition on the probe’s sapphire window. The modified design was evaluated and approved by the Wabash representative. The modified gasifier sensor was built and installed at the Wabash River gasifier on May 1 2014. (Task 4) The sensor was tested from the startup of the gasifier on May 5, 2015 until the planned autumn gasifier outage starting in the beginning of October, 2015. (Task 5) The project team successfully demonstrated the Gasifier Sensor system’s ability to monitor gasifier temperature while maintaining unobstructed optical access for six months without any maintenance. The sensor examination upon completion of the trial revealed that the system did not sustain any damage.
An experimental and computational effort was undertaken in order to evaluate the capability of the fluid-structure interaction (FSI) simulation tools to describe the deflection of a Missouri University Research Reactor (MURR) fuel element plate redesigned for conversion to lowenriched uranium (LEU) fuel due to hydrodynamic forces. Experiments involving both flat plates and curved plates were conducted in a water flow test loop located at the University of Missouri (MU), at conditions and geometries that can be related to the MURR LEU fuel element. A wider channel gap on one side of the test plate, and a narrower on the other represent the differences that could be encountered in a MURR element due to allowed fabrication variability. The difference in the channel gaps leads to a pressure differential across the plate, leading to plate deflection. The induced plate deflection the pressure difference induces in the plate was measured at specified locations using a laser measurement technique. High fidelity 3-D simulations of the experiments were performed at MU using the computational fluid dynamics code STAR-CCM+ coupled with the structural mechanics code ABAQUS. Independent simulations of the experiments were performed at Argonne National Laboratory (ANL) using the STAR-CCM+ code and its built-in structural mechanics solver. The simulation results obtained at MU and ANL were compared with the corresponding measured plate deflections.
Organizations are constantly responding to new technologies that require an appropriate response to remain competitive. Depending on the nature of the technologic changes, incremental changes may be adequate. However, at some point, the technical demands may be disruptive because the organization is unable to respond adequately. In this case study of a biotechnology production facility, rapidly changing customer and technological demands created a crisis manifested in rising employee injuries and production interruptions. The crisis was ultimately addressed through a comprehensive redesign of human-system relationships. Key ingredients included: a management willing to examine the entire production system, a multidisciplinary team coordinating efforts towards a common goal, engagement of staff at all levels of the organization, and the creation of feedback channels to better guide the actions of supervisors and managers. The methods used in this successful case study, involving a macroergonomics approach, can be applied to any private or public enterprise.
Hydrodynamic instability growth is a fundamentally limiting process in many applications. In High Energy Density Physics (HEDP) systems such as inertial confinement fusion implosions and stellar explosions, hydro instabilities can dominate the evolution of the object and largely determine the final state achievable. Of particular interest is the process by which instabilities cause perturbations at a density or material interface to grow nonlinearly, introducing vorticity and eventually causing the two species to mix across the interface. Although quantifying instabilities has been the subject of many investigations in planar geometry, few have been done in converging geometry. During FY17, the team executed six convergent geometry instability experiments. Based on earlier results, the platform was redesigned and improved with respect to load centering at installation making the installation reproducible and development of a new 7.2 keV, Co He-a backlighter system to better penetrate the liner. Together, the improvements yielded significantly improved experimental results. The results in FY17 demonstrate the viability of using experiments on Z to quantify instability growth in cylindrically convergent geometry. Going forward, we will continue the partnership with staff and management at LANL to analyze the past experiments, compare to hydrodynamics growth models, and design future experiments.
Advanced Energy systems require large, complex components produced from materials capable of withstanding severe operating environments (high temperature, pressure, corrosivity). Such parts can be difficult to source, as conventional material processing technologies must be tailored to ensure a safe and cost effective approach to large-scale manufacture of quality structural advanced alloy components that meet the performance specifications of AE systems. (HIP/PM) has shown advantages over other manufacturing methods when working with these materials. For example, using HIP’ing in lieu of casting means significant savings in raw material costs, which for expensive, high-nickel alloys can be considerable for large-scale production. Use of HIP/PM also eliminates the difficulties resulting from reactivity of these materials in the molten state and facilitates manufacture of the large size requirements of the AE industry, producing a part that is defect and porosity free, thus further reducing or eliminating time and expense of post processing machining and weld repair. New advances in Additive Manufacturing (AM) techniques make it possible to further expand the benefits of HIP/PM in producing AE system components to create an even more robust manufacturing approach. Traditional techniques of welding and forming sheet metal to produce the HIP canisters can be time consuming and costly, with limitations on the complexity of part which can be achieved. A key benefit of AM is the freedom of design that it offers, so use of AM could overcome such challenges, ultimately enabling redesign of complete energy systems. A critical step toward this goal is material characterization of the required advanced alloys, for use in AM. Using Haynes 282, a high nickel alloy of interest to the Fossil Energy community, particularly for Advanced-UltraSuperCritical (AUSC) operating environments, as well as the crosscutting interests of the aerospace, defense and medical markets, this research pursued three new methods of manufacturing these advanced alloys: 1) Directly built AM parts; 2) AM cans for HIP/PM; and 3) AM cans produced in the final part material. The project utilized Carpenter atomized A-282 in varied mesh sizes customized for both AM and HIP, ExOne’s binderjet technology, the fastest metal 3D printing technique on the market at the current time, coupled with an alloy specific sintering profile to produce a sufficiently dense part for final HIP by Bodycote. Final parts were subjected to chemical and physical property tests and results were compared to published and gathered data. Chemistry results for all the parts were within the published criteria. Furthermore, the AM and HIP/PM parts showed measurable improvement over previous A282 HIP/PM results, in part due to an improved HT spec, and a marked improvement over results from A282 castings. These results indicate that combining AM and HIP/PM in the manner set forth in this project provides a credible manufacturing approach of these activities are set forth in this Final Technical Report.
The goal of this project was to demonstrate a laser-based system which can shape and resurface the epidermal plate as well as generate images on acrylic. The prototype system used a pulsed diode pumped laser to ablate and shape the surface using a high absorption pigment. A CCD camera will image the epidermal plate and computer software will analyze the image to guide laser ablation. . The deliverable was for LLNL to generate a final report upon completion of the project, which summarized the results of the project and the schematics for the prototype device. This project consisted of six (6) main tasks, all of which would be performed at LLNL over a seven (7) month period. Due to lack of manpower availability which caused delays in the project work, and minor redesigns which delayed manufacturing, the project was extended for an additional five months.
The main goal of CRADA between AK Supply and NETL is to redesign the solid oxide fuel cell configuration for hybrid power generation systems for greater flexibility and operability. The new fuel cell design will consider incorporation of thermal energy storage into the fuel cell by modifying the material composition to increase the specific heat and/or the solid-solid phase transition and increasing the interconnect geometry (mass and volume) in the fuel cell. This developed technology will be tested using Hyper facility at NETL, Morgantown, to evaluate the performance in hybrid applications. Additionally, AK Supply and NETL will work on the development of a real-time, high temperature, intelligent micro-sensor for monitoring energy availability in the interconnect geometry. The will be used for control of stored energy release during load transients and will be tested on the NETL Hyper facility.
As the main H- ion source for the accelerator complex, magnetron ion sources have been used at Fermilab since the 1970’s. At the offline test stand, new R&D is carried out to develop and upgrade the present magnetron-type sources of H- ions of up to 80 mA and 35 keV beam energy in the context of the Proton Improvement Plan. The aim of this plan is to provide high-power proton beams for the experiments at FNAL. In order to reduce the amount of tuning and monitoring of these ion sources, a new electronic system consisting of a current-regulated arc discharge modulator allow the ion source to run at a constant arc current for improved beam output and operation. A solenoid-type gas valve feeds H2 gas into the source precisely and independently of ambient temperature. This summary will cover several studies and design changes that have been tested and will eventually be implemented on the operational magnetron sources at Fermilab. Innovative results for this type of io n source include cathode geometries, solenoid gas valves, current controlled arc pulser, cesium boiler redesign, gas mixtures of hydrogen and nitrogen, and duty factor reduction, with the aim to improve source lifetime, stability, and reducing the amount of tuning needed. In this summary, I will highlight the advances made in ion sources at Fermilab and will outline the directions of the continuing R&D effort.
The Biological Systems Science Division (BSSD) within the U.S. Department of Energy’s (DOE) Office of Biological and Environmental Research (BER) funds basic research on plants and microbes relevant to several DOE bioenergy and environmental mission areas. BSSD’s long history of developing and supporting genomic characterization of biological systems has led, in part, to the high-throughput DNA sequencing technology available to researchers worldwide. In recent years, genome sequencing has vastly outpaced the ability to interpret genome function. Fully maximizing this wealth of data will require new technology advancements, along with improvements and an increase in the throughput of existing methods for characterizing molecular- to cellular-level processes important for inferring biological function. BSSD research seeks to understand the fundamental genome-encoded properties of plants and microbes that can be harnessed or redesigned for beneficial purposes. Current emphases are leading to the discovery, development, and understanding of numerous plant and microbial species with traits suitable for the production of fuels and chemical products from renewable biomass that could be grown synergistically with food or animal feed crops while not competing with other societal needs. Additionally, BSSD further supports research leading to an understanding of the complex and essential interactions among plants, microbial communities, and the environment to find new ways to sustainably produce biomass for a range of bioenergy and bioproduct applications. This research also is relevant for incorporation into larger-scale environmental models such as those developed through the research supported by BER’s Earth and Environmental Systems Sciences programs.
In its Global Risks 2014 report, the World Economic Forum (WEF; WEF 2014) lists 10 current global risks of highest concern. Of these, four are science-related and all are central to the mission scope of the U.S. Department of Energy’s (DOE) Office of Biological and Environmental Research (BER): (1) water crises, (2) failure of climate change mitigation and adaptation, (3) greater incidence of extreme weather events, and (4) food crises tightly linked to the use of biomass for sustainable fuel production. The WEF report also notes the interdependencies between environmental and societal risks that make solutions to these stresses ever more important for global stability. These solutions will hinge on understanding the underlying processes of entire systems—from molecular to global scales—and will range from redesigning microbes and plants to understanding the roles of Earth’s biogeochemical systems in determining climate and contaminant transport and transformation. Clearly, however, the success of these endeavors critically depends on understanding the reliable coupling between molecular and mesoscale phenomena.
Human factors researchers at Idaho National Laboratory are collaborating with a utility partner to address human factors in the modernization of their radiological waste control room. The collaborating utility, Palo Verde, plans to remove all control boards associated with the liquid radiological waste system, which include controls, indicators, and alarm systems, and replace them with modernized digital instrumentation and controls and displays. To be sure the new system either supports current operational performance or enhances it, researchers have carried out three planning and analysis activities: expert operator review, function allocation analysis, and human factor principles and design applications. Researchers utilized access to expert operators to gain information about the system. Operators were asked to detail a procedure exemplifying typical interactions with the liquid radiological waste system and provide it to Idaho National Laboratory with a list of functionalities to incorporate (Section 4.1). Later, operators were asked to provide additional feedback to inform a prototype with adequate realism to support sound analysis of the system design (Section 4.2). Other operators not associated with the utility partner were also involved in experiment design and prototype evaluation (Section 4.2). Due to the extent of the upgrade, care was given to measure the change in the operator’s role (Section 7). As part of the modernization, some plant systems are expected to be equipped with automation or sensors that send information directly to the control where previously operators were required to enter controlled areas to find the information. Such updates made slight changes to operator role requirements, but the impact was negligible. The way the system is operated will remain largely the same, but operator convenience and safety is expected to increase. Additionally, to map operator tasks during the selected procedure, an Operational Sequence Diagram was created (Section 7.1). The diagram helped to account for every interaction and piece of equipment needed to create the prototype design. Alternatively, the diagram can be created following the final design to identify any function reallocations due to redesign. Human factors principles were also applied to the design. An ergonomic assessment was performed on the workspace resulting in various recommendations for placing and designing the new workstation (Section 6). A 3 D mockup of the control room was created to depict the options available with in-depth descriptions of each. Furthermore the prototype design incorporates well known human factors principles. However, to be sure the principles are sound in the control room context, the researches have designed an experiment to measure the impact design decision has on operator performance. The experiment is described in detail in Section 5. Lastly, a tool emerged as this effort began called the NUREG 0711 Crosswalk (Section 8). The tool has multiple uses, but it was primarily intended to communicate how the researcher’s action directly mapped to specific results suggested in the Nuclear Regulatory Commission review guideline. The tool also maps how current results impact future decisions in the modernization process.
The overall goal of the project was to demonstrate solvent liquefaction as a viable path to stable intermediates for subsequent upgrading to fuel blendstocks. Iowa State University (ISU) utilized technology developed by Chevron to produce “green crude” via continuous biomass liquefaction to bio-oil without catalyst or reducing gas, then upgraded the crude to drop-in hydrocarbon liquid transportation fuels. Original benchmarks for the project included conversion of biomass to bio-oil at a yield of 50% or more, produce bio-oil with oxygen content below 20 wt%, and recycle a portion of the bio-oil product for use as solvent, displacing initial hydrocarbon solvent. Initial testing and technology development was completed by Chevron using a custom Small Continuous Liquefaction Unit (SCLU) operated in “once-through” mode. In this system, liquid product and solid residual/char was collected together and required both off-line solids removal and product separation. This unit was disassembled and major components incorporated into a redesigned solvent liquefaction system at ISU capable of processing biomass at rates up to 1 kg/h. Online, continuous solids separation and bio-oil recovery/separation systems were successfully implemented. Online solids removal using an acetone injection to aid in separation achieved over 99% solids removal efficiency, and acetone recovery of greater than 97% was achieved. The gas stripping system developed for the separation of medium wood oil (MWO) for the recycle stream from the heavy wood oil (HWO) product stream was also successful in recovering approximately 93 wt% of the initial solvent from the biomass-derived products. Due to the generation of fine particulate and the high molecular weight of the HWO which both negatively affect the ability to separate the product oil, solvent recycle was not fully implemented in the system. The biomass used in this project is loblolly pine forest residue. The solvent was a blend of two hydrocarbon liquids. The majority of the solvent was comprised of commercially available naphthalene-depleted heavy aromatic solvent. The hydrogen donor solvent was a proprietary cut of light cycle oil (LCO) that was hydrotreated. As much as 25 wt% of the solvent mixture was comprised of the hydrotreated LCO. Higher blend ratios were limited by the economics of providing hydrogen to the process in this manner. Two cases were evaluated for technical feasibility on the SCLU. These are 1. Simulated phenolic solvent recycle and 2. Hydrocarbon-rich solvent processing. The simulated phenolic solvent recycle case was based on an idealistic solvent mixture where only 5% makeup or hydrogen donor solvent entered the system. The resulting solvent mixture at steady state was estimated to be 75 wt% depleted hydrogen donor, 20 wt% biomass derived phenolic monomers, and 5 wt% HLCO. This case resulted in the highest bio-oil organic yield observed in the project of 66.7 wt% on a solvent-less, dry biomass basis and relatively low oxygen content of 12%. Additionally, these conditions deconstructed the biomass so well, that extremely fine particulate was generated such that 5 micron barrier filters were unable to remove the material. Offline addition of acetone, centrifugation and acetone removal were required in order to remove the particulate prior to fractionation with the stripping column. The resulting HWO had a high molecular weight and was therefore very viscous in nature, remaining solid at room temperature. Additionally, the column was unable to sustainably strip enough MWO to close the recycle loop balance while maintaining flowability of product oil exiting the column. It was determined that additional HLCO would be required at the front of the process to decrease product viscosity both by dilution and additional hydrogen transfer into the HWO product oil. The hydrocarbon rich mixture was the preferred mixture for a majority of the project and featured a 25% donor or HLCO content and 75% depleted hydrogen donor mix. A series of three tests were conducted using this mixture and serve as the basis for a paper detailing the system. While the online acetone injection system for high pressure solids removal was demonstrated early on using this mixture, difficulty controlling process flows led to the use of an atmospheric stirred tank filtration system. At these high donor solvent levels, the product stream easily partitioned with sufficient MWO to close the recycle loop balance. Additionally, this mixture produced HWO product oil at just over 55% yield, <5% oxygen content, and a reasonable viscosity at room temperature. A 56 hour campaign was conducted with the ISU pilot to produce a large enough batch of HWO product oil to conduct upgrading experiments at Chevron’s Richmond, CA facility. Benchtop hydrotreating units were used to conduct long-duration hydrogenation/hydrogenolysis reactions in order to provide yield data and help validate assumptions made in the TEA model. Resulting products featured an oxygen content of <1%, near the detectability limit. Hydrocracking simulations were also performed, and a distribution of heavy wood oil to refinery products was determined. These distributions are based on a database of commercial and pilot plant operation used by Chevron to estimate product yield from novel inputs based on the input physical and chemical characteristics. While multi-week benchtop hydrotreating tests were successfully conducted without fouling, analysis and testing of the heavy wood oil suggest it may be better suited for hydrocracking. Metals content in the heavy wood oil would likely create catalyst fouling over time and reduce lifetime of hydrotreating catalysts. Yields and product partitioning were also more favorable from hydrocracking compared to those from hydrotreating.