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At least 883 records · Page 49

Magnetron R&D Progress for High Efficiency CW RF Sources of Industrial Accelerators

After the demonstration of using high efficiency magnetron power to combine and aim to drive a radio frequency accelerator at 2450MHz in CW mode [1], we have used trim coils adding to a water-cooled magnetron and three amplitude modulation methods in an open-loop control to further suppress the 120Hz side-band noise to -46.7dBc level. We have also successfully demonstrated the phase-locking to an industrial grade cooking magnetron transmitter at 915MHz with a 75kW CW power delivered to a water load by using a -26.6dBc injection signal. The sideband noise at 360Hz from the 3-Phase SCRs DC power supply can be reduced to -16.2dBc level. Their power combing scheme and higher power application to industrial accelerators are foreseeing.

Wang, H.↗

Analog Signal Multiplexing System for the Iota Proton Injector

The Fermilab Accelerator Science and Technology (FAST) Facility at FNAL is a dedicated research and development center focused on advancing particle accelerator technologies for future applications worldwide. Currently, a key objective of FAST Operations is to commission the 2.5 MeV IOTA Proton Injector (IPI) and enable proton injection into the Integrable Optics Test Accelerator (IOTA) storage ring. The low and medium-energy sections of the IPI include four frame-style dipole trims and two multi-function correctors with independently controlled coils, requiring readout of 32 analog channels for current and voltage monitoring in total. To reduce cost and optimize rack space within the PLC-based control system, a 32-to-4 analog signal multiplexing system was designed and implemented. This system enables real-time readback of excitation parameters from all magnetic correctors. This paper presents the design, construction, implementation, and performance of the multiplexing system.

MacLean, Daniel R. [Fermilab] (ORCID:0000000210103↗

Demonstration of Magnetron as an Alternative RF Source for SRF Accelerators

Magnetron has been considered as alternate high-efficiency, low-cost RF sources for linacs and storage rings [1] for national labs and industrial applications. After the demonstration of magnetrons power to drive and combine for a radio frequency cavity at 2450 MHz in CW mode, we have used trim coils adding to a water-cooled magnetron and amplitude modulation feedback to further suppress the side-band noise to -46.7 dBc level. We also demonstrated the phase-locking to an industrial grade cooking magnetron transmitter at 915 MHz with a 75 kW CW power delivered to a water load by using a -26.6 dBc injection signal [2]. The sideband noise from the 3-Phase SCRs DC power supply can be reduced to -16.2 dBc level. Further noise reduction and their power combining scheme using magic-tee and cavity type combiners for higher power application (2x75kW) are to be presented. We intent to use one power station to drive the normal conducting and superconducting RF cavities for the inductrial linac. We also going to demonstarte a vertical SRF cavity test with a high input coupling Q using a 2.45GHz magnetron and comparing with a baseline test result using a solid state amplifier.

Wang, H.↗

Detecting Passing Valves at Scale Across Different Buildings and Systems: A Brick Enabled and Mortar Tested Application

Heating hot water distribution systems are typically used in commercial buildings to condition spaces to provide occupant thermal comfort. However, recent research shows significant distribution losses within these systems that drive down the overall hot water plant efficiency. This research focuses on detecting passing valves in reheat coils found in variable air volume (VAV) terminal units to reduce distribution losses. A passing valve allows hot water flow when the actuator on the valve is commanded to be closed. The fluid causes unintentional heating or cooling to occur, causing comfort and control issues, and wasting energy. We developed the passing valve detection algorithm using a framework based on the Brick schema and Mortar platform to ensure that the application is portable and can scale to many buildings. We applied the same application to analyze 1,335 VAV reheat terminal units in 20 buildings. The diversity found in these large datasets increases confidence that any building with VAV reheat terminal units with the required sensors and Brick data model can run our open-source algorithm with little or no modification. In aggregate, 5% of VAV units analyzed were categorized as having a sensor fault, 14% with potential passing valve fault, and 81% with no faults detected. However, there is a significant variation in the proportion of VAV units with a passing valve detected (1% to 83%) of each building’s analyzed units.

Roa, Carlos Duarte↗

Enhancement of EM Pump Performance through Modeling and Testing

Liquid sodium has seen development as a nuclear reactor coolant in the United States for over 50 years. While sodium has many desirable characteristics as a heat transfer fluid, its reactivity poses numerous engineering challenges for even the most basic plant components like pumps. Despite the challenges, mechanical pumps have seen success in sodium service albeit at the expense of simplicity and flexibility. In fact, significant failures of these pumps have been recorded which can be attributed to their complexity. Notwithstanding the complexity, mechanical pumps are still widely proposed for the main circuit pump of sodium cooled reactors. However, an alternative to mechanical pumps are Electromagnetic Induction Pumps (EMIPs) which use the principle of the Lorentz Force. EMIPs avoid mechanically moving parts in contact with sodium which simplifies the design by avoiding mechanical wear and seals. Therefore, these pumps are generally safer and more reliable than their mechanical counterparts. That being said, EMIPs suffer from relatively low efficiencies that range from 5% to 45%. Some of the inefficiencies are inherent to the EMIPs pumps; namely, inefficiencies arise in the form of resistive heating losses in the fluid itself. However, other inefficiencies arise from Edge Effects which include Finite Length and Finite Width effects. Due to the significant safety advantages EMIPs have compared to mechanical pumps, there is a strong motivation to integrate these technologies into the design of Generation IV liquid-metal-cooled nuclear power plants. However, EMIPs have low efficiencies partly attributed to Edge Effects. Much of the literature focusing on Edge Effects is dated or simply does not exist in the public domain. More recently, numerical models of EMIPs have shown promising results. However, these models are often custom solvers or use complex software suits which limit their application. This report describes the work completed to understand Edge Effects in two EMIPs designs. These designs are the Annular Linear Induction Pump (ALIP) and Permanent Magnet Induction Pump (PMIP) also known as a Moving Magnet Pump (MMP). The methodology developed during this project aim at measuring key performance parameters (pressure-flowrate and efficiency-slip performance) using high temperature liquid-sodium. Baseline experimental measurements were then used to verify the accuracy of numerical models developed in the software suit ANSYS/FLUENT. On the experimental side, instrumentation was developed to characterize the pressure-flowrate and efficiency-slip performance of both the ALIP and PMIP in high-temperature liquid-sodium. Additionally, instrumentation was developed to measure potential output pressure pulsations and the magnetic field distributions. Moreover, a specialized ALIP was constructed to study the impacts magnetic field tapering, also known as coil grading, on the Finite Length Effect. Lastly, experimental performance curves of the PMIP were collected at 300 oC and 600 oC and compared to analytical theory which accounted for Finite Width Effects. These results showed that the Finite Width Effect and non-uniform magnetic field in a PMIP impact the performance. On the numerical side, models were developed using the software suit FLUENT/ANSYS. These methods were initially compared against a simple MHD flow in a Permanent Magnet Electromagnet Flowmeter (PMEMFM). The results were significant in that they showed agreeance between the numerical model and demonstrated that PMEMFM’s could be calibrated numerically. These modeling methods were then applied to a prototypic PMIP. Results showed that this simple model provided reasonably accurate results of the PMIP p-Q performance.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Tests and Field Mapping of RODM01 Septum Magnet

RODM01 is a septum magnet located in the extraction region of LANSCE Proton Storage Ring. Tests and field mapping of RODM01 Set #2 were performed on 02/04/2020 by members of AOT-MDE, AOT-RFE and AOT-AE Groups. Setups of test and mapping are presented. Magnetic field measurements was performed using Hall probe. Results of measurements are almost identical to that of RODM01 Set #1 performed in July 2018. Trim coil current of magnet selected to be as - 9.28 A.

43 PARTICLE ACCELERATORS↗

Efficiency Enhancing Anti-Frost Coatings for Heat Exchangers

As part of the Cyclotron Road program, the participant worked to develop geometric inorganic metamaterial coatings with functional surface energies that approached theoretical minimum. Most coating technologies chemically modify surfaces by applying a fluoropolymer to cause water to bead and roll off the surface, but the metamaterial coatings studied under this project were designed to modify local surface tension of a droplet, such that it pulls down on it at the bottom like a spring and as the droplet grows, the magnitude of the surface tension force increases to overwhelm droplet adhesion forces, causing the droplet to be repelled. These attributes make this technology ideally suited for heat transfer applications. This project’s coating experiments on evaporator coils inside an air conditioning unit demonstrated significant increases in energy efficiency.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Energy Efficient Thermoplastic Composite Manufacturing

The objective of the project was to establish an effective and affordable method to lay-up and consolidate/join large thermoplastic composite aerospace structure with cycle times measured in minutes rather than hours. Composite airplane designs have proven efficient and effective however future potential product production rates are challenging what the current systems can efficiently produce due to material lay-down constraints and extended thermal cycle times. The ability to lay-up then rapidly heat, consolidate, and cool large complex composite structures plus very accurately tool them (i.e. matching CTE of composite materials) along with very precise thermal control is a difficult challenge. Current systems such as autoclave processing of thermoset materials require long cycle times due to method of heating and the large associated thermal masses. These extended cycle times inhibit the ability to meet higher rate production scenarios due to the need for multiple sets of equipment and tools. Thermoplastic composite materials were used to facilitate more rapid cycle times via the elimination of a need for a cure dwell at temperature. Also, utilized induction heating along with smart susceptors to enable the quick cycle times needed while providing precise intrinsic thermal control. The intrinsic control of the induction heating process via the smart susceptors along with the use of laser assisted fiber placement were the key innovations areas developed. The ability to rapidly heat and then precisely control the temperature of the consolidation component was paramount to the success of this project. It is this unique processing attribute coupled with the thermoplastic material characteristics along with rapid lay-up methods that are novel and advantageous. While many requirements and influencing factors decide the materials and processes utilized for future airplane construction, the forecast of accelerated production rates and the recent performance successes of composites in airplane construction provide an opportunity for this processing technology to have significant influence. During the course of this project a number of key accomplishments were completed. They are as follows: The needed laser assisted fiber placement capabilities have been developed and validated on a component of meaningful scale and complexity. Subsequently, a thermoplastic preform of the part scale-up part design was laser assisted fiber placed and made availalbe for consolidation. An induction consolidation system was sized, designed, and fabricated resulting in the full capability to consolidate the scale-up component. The tool for induction consolidating of the scale-up component was designed and fabricated. An aluminum pressure bladder was welded and formed for use as the pressurization membrane to perform the needed application of pressure on the part at temperature to achieve consolidation. The induction consolidation system consisting of the restraint, induction power supply, induction tool with integrated induction coils and smart susceptor liners, along with the aluminum bladder were successfully used to consolidate a large thermoplastic skin. The capability of accomplishing rapid heat-up rates and cool down rates for consolidation of large thermoplastic skins with precise thermal control and even pressure application at the consolidation temperature was validated. The general conclusion is that the use of induction consolidation with smart susceptors is an effective method to rapidly and efficiently consolidate large thermoplastic composite components and enable affordable high rate manufacturing of composites. More specific conclusions generated by this project are as follows: A restraint type induction consolidation system provides an affordable option over the standard press when using the induction consolidation processing method. Aluminum bladders can be formed to the complex shapes needed and supply uniform pressure for consolidation and co-consolidation of thermoplastic composite materials. Straightforward modifications can be made to existing fiber placement robotic systems to enable their use for thermoplastic lay-up applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Improving AHU Performance by Minimizing Approach Temperature, Reducing Air Maldistribution, and Efficiently Handling Sensible and Latent Loads (Phase 1 Interim Final Technical Report)

Residential air handling units (AHUs) have stayed the same in form and efficiency for the past 30+ years, with incremental improvements made to address safety, functionality, and energy-efficiency. The purpose of this research in Phase I, Topic 9a: Next Generation Residential Air Handlers, was to improve AHU performance by minimizing heat exchanger (HX) approach temperature, reducing air maldistribution, and developing alternative system configurations which more efficiently handle sensible and latent loads. In this research Optimized Thermal Systems (OTS) developed, modeled, and evaluated multiple alternative system concepts. A dual vapor compression system separate sensible and latent cooling (SSLC) concept was studied to inform work on alternative concepts and to show best-case performance benefit. System concepts included ejector enhanced vapor compression cycles, desiccant assisted dehumidification, dual evaporator SSLC, and alternative AHU HX configurations. A dual vapor compression system showed COP improvement of 20%, however, required additional components, increased unit size, and increased cost. Two types of ejector enhanced vapor compression cycles with dual evaporators improved system COP by 9 to 11%, and reduced AHU losses by as much as 18%, with design changes limited to the AHU, no unit physical size increase, and a moderate increase to system first cost. Desiccant assisted air-conditioning required increased air flow rate resulting in higher fan power and the desiccant wheel increased sensible heat load leading to increased compressor power and reduced system COP. Dual evaporator cycles were found to degrade performance due to increased expansion losses. Optimized single slab HX designs used in place of the traditional A-coil HX led to 44–49% reduction in aluminum, 47–60% less refrigerant charge, and improved HX velocity distribution.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Evaluation the Geotech GS-13BH Borehole Seismic Sensor

Sandia National Laboratories has tested and evaluated the Geotech GS-13BH borehole sensor. The sensor provides a response similar to that of the standard GS-13 short-period seismic sensor intended for pier-installations in a borehole package. The purpose of this seismometer evaluation was to determine a measured sensitivity, amplitude and phase response, self-noise and dynamic range, passband and acceleration response of its calibration coil.

47 OTHER INSTRUMENTATION↗

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↗

White Paper to Justify the Use of Strip Effluent in the Defense Waste Processing Facility During Slurry Mix Evaporator Processing

At the request of Savannah River Remediation (SRR), a white paper was written to assess whether it would be acceptable to process Strip Effluent (SE) in both the Sludge Receipt and Adjustment Tank (SRAT) and Slurry Mix Evaporator (SME) in the Defense Waste Processing Facility (DWPF) for the nitric-glycolic acid flowsheet. Savannah River National Laboratory (SRNL) experimental data and DWPF Sludge Batch 9 (SB9) process data was reviewed, looking at batches which included Precipitate Reactor Feed Tank (PRFT) and/or Strip Effluent Feed Tank (SEFT) feeds that led to long processing times. These batches were reviewed looking for processing problems such as melter feed trips, foamovers, heating rod or steam coil fouling, missed Reduction/Oxidation (REDOX) targets, and other process anomalies.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Final Report for US DOE Grant DE-FG02-99ER54527

The failure of the NSTX-U coil in 2016 resulted in a redirection of UCLA’s NSTX-U research program. At that time UCLA had two functioning fluctuation reflectometer systems installed on the tokamak and was in the process of installing the new DBS/CPS system. These projects were placed on hold due to the NSTX-U recovery effort. UCLA in consultation with DOE OFES began a program of utilizing the equipment installed at NSTX-U in order to maximize the science output. In these discussion it was decided to move the V-band 50-75 GHz and the W-band 83-88 GHz multifrequency fluctuation reflectometer systems to the DIII-D tokamak. This would achieve two goals – to continue to provide important scientific input the US fusion research program and to test the new W-band system in a fusion research relevant plasma.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Pulsating Heat Pipes for Accelerator Magnets. Phase I Final Report

The primary objective of the Phase 1 award was to investigate the performance of cryogenic pulsating heat pipes (PHPs) and their use in practical large superconducting magnet systems. PHPs exhibit an effective thermal conductivity an order of magnitude and more over high purity metals such as copper and aluminum. They can therefore be utilized to reduce cold mass and effectively transfer heat from the magnet system components such as the coil pack, shields, or current leads to cryocoolers or cryogen reservoirs.

43 PARTICLE ACCELERATORS↗

Highly Integrated Wide Bandgap Power Module for Next Generation Plug-In Vehicles (Final Report)

Wide bandgap devices are key enablers for high power density traction inverters. A highly integrated wide bandgap (WBG) power module enables higher temperature operation, higher inverter efficiency and overall smaller die area with the same power delivery. However, it requires careful design of the power module to take advantage of all the superior material properties that silicon carbide (SiC) provides over conventional silicon (Si) Insulated Gate Bipolar Transistor (IGBT) based design. This project developed an efficient and densely packed SiC power module for an automotive traction inverter application. Extensive study was performed to select the best performing SiC die considering a wide range of temperature variation, suitability to integrate into target packaging, robust body diode performance and overall high electrical efficiency. Multiple design ideas were explored to achieve lower stray inductance for both power loop and signal loop, uniform current distribution, compact form factor, and very high thermal performance. The final power module package includes all six inverter switches in the same module (six-pack) with die sintered at both bottom and top surfaces utilizing high performance substrate to achieve high electrical and thermal performance. Two power module variants were developed using 900 V and 1200 V devices for operating at two different high voltage levels (> 600 V HV battery). Both power modules were comprehensively characterized, and high efficiency operation of the inverter was confirmed through analysis. Finally, a complete functional inverter was built with the 1200V power modules using other essential components (HV capacitors, gate driver board, controller board, current sensor, connectors etc.) and tested using GM’s standard test procedure. There are several challenges associated with adopting WBG devices for high voltage operation. In order to assess and mitigate those challenges, GM and subrecipients of this project have conducted multiple detailed studies. This includes phase current reconstruction using integrated Rogowski coil, device junction temperature estimation using on-state gate resistance, modeling and testing the effect of high voltage and fast switching on motor insulation and bearings, partial discharge inception voltage measurement under different environmental conditions. Findings of all these studies are summarized in this report.

33 ADVANCED PROPULSION SYSTEMS↗

High Performance Superconducting Undulator Development

Initial Phase I work has involved a collaborative technical analysis of the superconducting magnet design. ANL has provided CMI with a history of the SCAPE prototype including the short 0.5m wet coil versions as well as thoughts on possible manufacturing methods.

43 PARTICLE ACCELERATORS↗

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↗

High current, high-temperature operation test of the superconducting magnets in the RHIC yellow ring

We report on the tests conducted at the end of RHIC Run 21 to evaluate the operation of superconducting magnets in the RHIC yellow ring at higher currents – up to 5500 A for the arc dipoles and all other magnets on the dipole bus and the focusing arc quadrupoles, up to 5750 A for defocusing arc quadrupoles and up to 6000 A for the insertion quadrupoles Q1 through Q9 – and higher temperatures – up to 5.1 K – than routine. None of the magnets quenched. This is an encouraging finding as the superconducting magnet coils could reach up to 4.9 K during operation with the 275 GeV EIC hadron beams.

43 PARTICLE ACCELERATORS↗