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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.

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NASA NTRS1975

Simulation verification techniques study: Simulation performance validation techniques document

Techniques and support software for the efficient performance of simulation validation are discussed. Overall validation software structure, the performance of validation at various levels of simulation integration, guidelines for check case formulation, methods for real time acquisition and formatting of data from an all up operational simulator, and methods and criteria for comparison and evaluation of simulation data are included. Vehicle subsystems modules, module integration, special test requirements, and reference data formats are also described.

Duncan, L. M.↗

NASA NTRS1989

Some issues related to simulation of the tracking and communications computer network

The Communications Performance and Integration branch of the Tracking and Communications Division has an ongoing involvement in the simulation of its flight hardware for Space Station Freedom. Specifically, the communication process between central processor(s) and orbital replaceable units (ORU's) is simulated with varying degrees of fidelity. The results of investigations into three aspects of this simulation effort are given. The most general area involves the use of computer assisted software engineering (CASE) tools for this particular simulation. The second area of interest is simulation methods for systems of mixed hardware and software. The final area investigated is the application of simulation methods to one of the proposed computer network protocols for space station, specifically IEEE 802.4.

Lacovara, Robert C.↗

DOE OSTI2026

From Cell to System: Accelerated hpc Simulations of BESS Aging under Frequency Regulation and Arbitrage use cases

Lithium-ion battery energy storage systems (BESS) packs have emerged as a leading solution for grid-scale energy storage, enhancing resiliency and balancing load fluctuations. Yet, experimental characterization of large-format LIB packs-particularly to assess performance and degradation over hundreds of cycles - demands substantial hardware investment and multi-year testing campaigns. In this work, we couple a hierarchical, physics-based modeling framework agnostic to electrode chemistries with high-performance computing to accelerate systems level evaluation by upto two orders of magnitude. Building on the open-source liionpack platform, we implement cell, module, and pack-scale electrochemical models enriched with mechanistic aging mechanisms and deploy them on an HPC cluster to simulate 150−200kWh systems over 500 - 1,000 cycles with in days. We subject these virtual B ESS to both constant-current cycling and realistic grid service profiles spanning frequency regulation, ramp-rate support, and energy arbitrage-and quantify the resulting degradation patterns. Our results reveal that localized cell aging can induce substantial nonuniformity at module and pack levels, with service-specific cycling protocols driving distinct aging modes. This rapid, multiscale modeling approach provides a powerful design-space exploration tool for optimizing electrical architecture, control strategies, and operational schedules to prolong pack lifetime and lower total cost of ownership.

Ayalasomayajula, Surya [ORNL] (ORCID:0009000860788↗

DOE OSTI2026

Field and Model Data Associated with the Manuscript “Drivers of Streamflow Intermittency in Humid Regions: 1. Evaluating Above- and Below-ground Controls of Flow Persistence in a Forested Catchment”

This package contains field data, modeling files, and scripts supporting the investigation of the drivers of streamflow intermittency in a forested catchment. It includes the field data collected from electrical resistivity tomography (ERT) surveys, ground penetrating radar (GPR), continuous self-potential (SP) monitoring, electromagnetic (EM) imaging, groundwater and stilling well. In addition, it contains the data and results of the coupled water- and electrical-flow model developed using the COMSOL Multiphysics and Advanced Terrestrial Simulator (ATS), as well as software files and Jupyter notebooks used to process the data and generate figures in the manuscript submitted for peer review. The data archive is organized in the following directories: 1) Climate Includes hourly precipitation and daily evapotranspiration time series (2024 – 2025) provided as CSV files, alongside a text file detailing dataset units. 2) Coupled_model Contains two subfolders: Synthetic and Field_Application subfolder. Synthetic subfolder contains the ATS XML input script (can be opened using any code editor) for the four synthetic hydrological cases tested (Connected and gaining, Connected and losing, Disconnected and losing, and dry stream). It also includes other experimental cases to test the influence of precipitation and concentration gradient. For each synthetic case, the flow model simulation is executed using the ATS XML scripts and the included Python script (generate_data_set.py) to convert ATS output to COMSOL-ready input. COMSOL Multiphysics template (.mph can be opened with the commercial software COMSOL and requires a license) is executed using the ATS output data to simulate the potential field. It also includes the Synthetic_model_plot.ipynb (can be opened using any code editor) to visualize the SP result and generate manuscript figures. The data subfolder contains mesh files to run both the ATS (.exo and .stl files can be viewed using Paraview; .h5 files can be opened using HDFView software and h5py Python package) and COMSOL models. Field_Application subfolder contains two subfolders: ES_MDA_inversion and Final_Model. ES_MDA_inversion contains the Python script (.py can be opened using any code editor) and SP observation data used to run the Ensemble Smoother with Multiple Data Assimilation (ES-MDA) inversion sequence to get the optimal model parameters. The Final_model subfolder contains the ATS XML input scripts, data files, output data for the two SP sites. The same workflow steps outlined for the Synthetic subfolder apply here. It also contains the Jupyter notebook (Plot_final_calib.ipynb) to visualize the results of the modeled SP, stream-groundwater exchange and moisture content. 3) Discharge Includes the electrical conductivity (EC) time series (provided as CSV files) from salt slug injections. It also includes the Jupyter notebook (Discharge_process.ipynyb) used to estimate discharge. All discharge measurements collated into rating_curve_processed.csv 4) EM Contains the CSV file of the EM data from the DUALEM-42, including spatial coordinates (x, y, z), apparent conductivity, and in-phase measurements at 2 m coil separations for horizontal coplanar (HCP) and perpendicular (PRP) geometries. 5) ERT Contains raw resistivity data (provided as CSV files), spatial location of each of the electrodes (provided as CSV files), and files used for the resistivity inversion (.resipy can be opened with the open-source ResIPy software). 6) GPR Includes GPR field datasets collected at 100 MHz and 250 MHz antenna frequencies, along with the processing/interpretation project file (GPR_process.gpz can be viewed using EKKO_Project 6, a commercial software by Sensors & Software that requires a license). 7) Slug_test Includes the slug test data at all the groundwater wells provided as CSV files, as well as the Jupyter notebook (Slug_test.ipynb) for calculating hydraulic conductivity. 8) SP Contains the SP data collected in field at the two SP sites (one in the perennial reach and the other in the intermittent reach), provided as DAT files. 9) Well_data Contains two subfolders: 1) Raw, which provides unprocessed pressure, electrical conductivity and temperature timeseries downloaded from the loggers in all the groundwater and stilling wells, and 2) Processed, which contains sorted, QA/QC timeseries data for each well. The data archive also contains data_process.ipynb, a Jupyter notebook used for field data analysis and generating figures (plotting well, SP, climate, and discharge data, as well as calculating head gradient at sites with nested groundwater wells). It also includes DTW.ipynb, a Jupyter notebook containing the code for the dynamic time warping (DTW) with sliding window to evaluate SP signal synchronicity.

ATS↗

DOE OSTI2022

Velocity-dependent annihilation radiation from dark matter subhalos in cosmological simulations

Here, we use the suite of Milky Way-like galaxies in the Auriga simulations to determine the contribution to annihilation radiation from dark matter subhalos in three velocity-dependent dark matter annihilation models: Sommerfeld, p-wave, and d-wave models. We compare these to the corresponding distribution in the velocity-independent s-wave annihilation model. For both the hydrodynamical and dark-matter-only simulations, only in the case of the Sommerfeld-enhanced annihilation does the total annihilation flux from subhalos exceed the total annihilation flux from the smooth halo component within the virial radius of the halo. Progressing from Sommerfeld to the s, p, and d-wave models, the contribution from the smooth component of the halo becomes more dominant, implying that for the p-wave and d-wave models the smooth component is by far the dominant contribution to the radiation. Comparing to the Galactic center excess observed by Fermi-LAT, for all simulated halos the emission is dominated by the smooth halo contribution. However, it is possible that for Sommerfeld models, extrapolation down to mass scales below the current resolution limit of the simulation would imply a non-negligible contribution to the gamma-ray emission from the Galactic Center region.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2025

An Improved Convection Parameterization with Detailed Aerosol–Cloud Microphysics for a Global Model

Abstract A new microphysical treatment that includes aerosol–cloud interactions and secondary ice production (SIP) mechanisms is implemented in the convection scheme of the Community Atmosphere Model, version 6 (CAM6). The approach is to embed a 1D Lagrangian parcel model in the bulk convective plume of the existing deep convection parameterization. Aerosol activation, growth processes including collision/coalescence, and three processes of SIP mechanisms, two of which are normally overlooked in atmospheric models, are represented in this embedded parcel model. These microphysical processes are treated with a hybrid bin/bulk scheme and a high spatial and temporal resolution for the integration of the embedded parcel in 1D, allowing vertical velocity to determine the microphysical evolution following the in-cloud motion during ascent. Simulations of an observed case (Midlatitude Continental Convective Clouds Experiment) of a mesoscale convective system in Oklahoma, United States, with a single-column model (SCAM) version of CAM, are compared with aircraft in situ and ground-based observations of microphysical properties from the convection and precipitation. Results from the validation show the new microphysical scheme has a good representation of the ice initiation in the bulk convective plume, including the known and empirically quantified pathways of primary and secondary initiation, with benefits for the accuracy of properties of its supercooled cloud liquid. The sensitivity simulations and use of tagging tracers for the validated simulation confirm that the newly included SIP mechanisms are of paramount importance for convective microphysics and can be successfully treated in the global model.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1993

The nonlinear Galerkin method: A multi-scale method applied to the simulation of homogeneous turbulent flows

Using results of Direct Numerical Simulation (DNS) in the case of two-dimensional homogeneous isotropic flows, the behavior of the small and large scales of Kolmogorov like flows at moderate Reynolds numbers are first analyzed in detail. Several estimates on the time variations of the small eddies and the nonlinear interaction terms were derived; those terms play the role of the Reynolds stress tensor in the case of LES. Since the time step of a numerical scheme is determined as a function of the energy-containing eddies of the flow, the variations of the small scales and of the nonlinear interaction terms over one iteration can become negligible by comparison with the accuracy of the computation. Based on this remark, a multilevel scheme which treats differently the small and the large eddies was proposed. Using mathematical developments, estimates of all the parameters involved in the algorithm, which then becomes a completely self-adaptive procedure were derived. Finally, realistic simulations of (Kolmorov like) flows over several eddy-turnover times were performed. The results are analyzed in detail and a parametric study of the nonlinear Galerkin method is performed.

Debussche, A.↗

NASA NTRS2016

Agricultural Fires in the Southeastern U.S. During SEAC4RS: Emissions of Trace Gases and Particles and Evolution of Ozone, Reactive Nitrogen, and Organic Aerosol

Emissions from 15 agricultural fires in the southeastern U.S. were measured from the NASA DC-8 research aircraft during the summer 2013 Studies of Emissions and Atmospheric Composition, Clouds and Climate Coupling by Regional Surveys (SEAC4RS) campaign. This study reports a detailed set of emission factors (EFs) for 25 trace gases and 6 fine particle species. The chemical evolution of the primary emissions in seven plumes was examined in detail for ~1.2 h. A Lagrangian plume cross-section model was used to simulate the evolution of ozone (O3), reactive nitrogen species, and organic aerosol (OA). Observed EFs are generally consistent with previous measurements of crop residue burning, but the fires studied here emitted high amounts of SO2 and fine particles, especially primary OA and chloride. Filter-based measurements of aerosol light absorption implied that brown carbon (BrC) was ubiquitous in the plumes. In aged plumes, rapid production of O3, peroxyacetyl nitrate (PAN), and nitrate was observed with (Delta)O3/(Delta)CO, (Delta)PAN/(Delta)NOy, and (Delta)nitrate/(Delta)NOy reaching approx. 0.1, approx. 0.3, and approx.0.3. For five selected cases, the model reasonably simulated O3 formation but underestimated PAN formation. No significant evolution of OA mass or BrC absorption was observed. However, a consistent increase in oxygen-to-carbon (O/C) ratios of OA indicated that OA oxidation in the agricultural fire plumes was much faster than in urban and forest fire plumes. Finally, total annual SO2, NOx, and CO emissions from agricultural fires in Arkansas, Louisiana, Mississippi, and Missouri were estimated (within a factor of approx. 2) to be equivalent to approx. 2% SO2 from coal combustion and approx. 1% NOx and approx. 9% CO from mobile sources.

OA mass or BrC absorption↗

DOE OSTI2023

Improvements to the Simplified Loads Methodology in IEC 61400-2: November 22, 2021 - November 21, 2022

The "Simplified Loads Model" (SLM) of IEC 61400-2 provides a simple methodology to assess the structural integrity of a small wind turbine (SWT). The SLM is unique to the small wind turbine standard. It was included to allow SWT manufacturers with limited resources to undertake integrity checks at a reasonable cost in time and resources and avoid the expense of detailed aeroelastic simulations. Unfortunately, the SLM has gained the reputation of being overly conservative and this has reduced its value to the SWT community and its use in SWT design and certification. Conservatism in design standards is needed but excessive conservatism is not. The aim of this report is to address the principal areas of excess conservatism and recommend changes to the SLM that preserve its simplicity but reduce the excess. The changes for the ultimate loads are consistent with their treatment in aeroelastic modelling for certification and with related codes for wind loading on structures. The recommendations for a new fatigue design load case are also based on aeroelastic simulations, in this case of five SWTs of varying configurations with rated power from 2.4 to 50 kW. It is also pointed out the design load case for yawed operation omits an important term. The recommended inclusion of this term would make the SLM slightly more conservative for this case.

17 WIND ENERGY↗

DOE OSTI2025

Bayesian Optimization for Reactor Design Optimization

This study present a test case in which the Bayesian Optimization method is applied to a simulation-based reactor core design optimization problem. The test case aims to showcase the potential of an automated design optimization algorithm for reactor designs by streamlining the reactor core design workflow, given the high computational cost of simulations. The contributions of this work are threefold. First, the existing HTGR model is converted into a simulation-based design optimization test case by developing a pipeline that enables modification of key design parameters and evaluates design performance based on simulation outputs. Second, Bayesian Optimization is implemented and adapted to demonstrate the feasibility of automatic design optimization for nuclear reactor core. Proposed approach leverages Gaussian Process models to characterize the relationship between design variables and performance metrics, while incorporating novel acquisition functions that balance exploration of the design space with exploitation of promising configurations. This implementation lays the foundation for the future developments of reactor design optimization algorithms.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

Dimensional stability of low-cost thermoplastic composite molds

This report addresses a key question for using additively manufactured tooling from carbon fiber reinforced thermoplastic composites. How does the distortion of the molded part change with the print orientation used in the manufacture of tooling? The objective of this research was to discuss the distortion of parts molded with such tooling, in relation to the deflections in the tooling during the compression molding process. This was achieved through both model simulations and experimental molding runs. A vertical orientation was used in printing the mold with a distinctly non-planar surface: this orientation allowed for higher performance along the press closing direction -- higher thermal conductivity, higher stiffness, and lower coefficient of thermal expansion. Epoxy-carbon fiber twill weave fabric prepreg was then compression molded in this mold. The thermomechanical properties of the tooling material and the molded part were measured and used in simulation of mold deformation as well as part distortion. The thermomechanical anisotropy of the mold is quite different from that of the molded part because in the mold, the stiffest direction is the z-axis, while in the molded thermoset part, the z-axis is the weakest direction. The connection between mold deformation during the compression molding process and the final part distortion can be seen from the simulation results. The simulation results for the case where the mold was four times as stiff as the part along the press closing direction compared well with experiment. When the mold stiffness was lowered in relation to the part stiffness, the mold deformation during the compression molding increased; but this led to a smaller extent of part distortion.

36 MATERIALS SCIENCE↗

NASA NTRS2005

Effect of Impact Location on the Response of Shuttle Wing Leading Edge Panel 9

The objective of this paper is to compare the results of several simulations performed to determine the worst-case location for a foam impact on the Space Shuttle wing leading edge. The simulations were performed using the commercial non-linear transient dynamic finite element code, LS-DYNA. These simulations represent the first in a series of parametric studies performed to support the selection of the worst-case impact scenario. Panel 9 was selected for this study to enable comparisons with previous simulations performed during the Columbia Accident Investigation. The projectile for this study is a 5.5-in cube of typical external tank foam weighing 0.23 lb. Seven locations spanning the panel surface were impacted with the foam cube. For each of these cases, the foam was traveling at 1000 ft/s directly aft, along the orbiter X-axis. Results compared from the parametric studies included strains, contact forces, and material energies for various simulations. The results show that the worst case impact location was on the top surface, near the apex.

Lyle, Karen H.↗

DOE OSTI2023

Extrapolation of the Rainflow-Counted Load Ranges for Fatigue Assessment of the Wind Turbine's Blades

Wind turbine design standards recommend the use of statistical modeling coupled with extrapolation of the short-term load data to long-term periods for fatigue reliability assessment. However, statistical error and computational expense can limit the accuracy of such approaches. In the case of wind turbine blades, the errors are more significant because of the high material fatigue exponent that makes the damage estimations more sensitive to variations. In addition, due to different excitation sources, the flapwise load range histogram is not unimodal, and thus its statistical modeling is complex. In the present work, we provide three methods for statistical modeling of the flapwise bending moment ranges including a novel approach based on frequency-based separation of the modes. The first two methods are simplified approaches for modeling the most crucial load ranges using unimodal distributions and the third method involves multimodal distribution fitting. The research is based on 3600 10-minute aeroelastic simulations of DTU 10MW case study wind turbine from which a benchmark damage equivalent load (DEL) is calculated. The DEL calculated by each of the three proposed methods is compared to this reference. The results show that the conventional approach based on using 6 seeds as well as using mixture models fitted on the limited data lead to under-conservative results with errors up to 23%. On the other hand, the simplified unimodal approaches provided in this work can provide conservative estimations of the fatigue damage with mean values 5% and 12% higher than the benchmark. However, the variability of the DEL estimates is higher when using unimodal extrapolation of the load ranges, and the data can be conservative by 17.5%. The proposed unimodal fits suggested for modeling and extrapolation of the blade's load ranges provide less errors relatively and most importantly conservative DEL estimations while maintaining computational efficiency.

blade fatigue↗

DOE OSTI2022

Evaluation of a quasi-steady-state approximation of the cloud droplet growth equation (QDGE) scheme for aerosol activation in global models using multiple aircraft data over both continental and marine environments

This research introduces a numerically efficient aerosol activation scheme and evaluates it by using stratus and stratocumulus cloud data sampled during multiple aircraft campaigns in Canada, Chile, Brazil, and China. The scheme employs a quasi-steady-state approximation of the cloud droplet growth equation (QDGE) to efficiently simulate aerosol activation, the vertical profile of supersaturation, and the activated cloud droplet number concentration (CDNC) near the cloud base. The calculated maximum supersaturation values using the QDGE scheme were compared with multiple parcel model simulations under various aerosol and environmental conditions. The differences are all below 0.18 %, indicating good performance and accuracy of the QDGE scheme. We evaluated the QDGE scheme by specifying observed environmental thermodynamic variables and aerosol information from 31 cloud cases as input and comparing the simulated CDNC with cloud observations. The average of mean relative error ($\overline{MRE}$) of the simulated CDNC for cloud cases in each campaign ranges from 17.30 % in Brazil to 25.90 % in China, indicating that the QDGE scheme successfully reproduces observed variations in CDNC over a wide range of different meteorological conditions and aerosol regimes. Additionally, we carried out an error analysis by calculating the maximum information coefficient (MIC) between the MRE and input variables for the individual campaigns and all cloud cases. MIC values were then sorted by aerosol properties, pollution level, environmental humidity, and dynamic condition according to their relative importance to MRE. Based on the error analysis, we found that the magnitude of MRE is more relevant to the specification of input aerosol pollution level in marine regions and aerosol hygroscopicity in continental regions than to other variables in the simulation.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Evaluation of a Stochastic Mixing Scheme in the Deep Convective Gray Zone Using a Tropical Oceanic Deep Convection Case Study

Abstract A stochastic horizontal subgrid‐scale mixing scheme is evaluated in ensemble simulations of a tropical oceanic deep convection case using a horizontal grid spacing (Δ h ) of 3 km. The stochastic scheme, which perturbs the horizontal mixing coefficient according to a prescribed spatiotemporal autocorrelation scale, is found to generally increase mesoscale organization and convective intensity relative to a non‐stochastic control simulation. Perturbations applied at relatively short autocorrelation scales induce differences relative to the control that are more systematic than those from perturbations applied at relatively long scales that yield more variable outcomes. A simulation with mixing enhanced by a constant factor of 4 significantly increases mesoscale organization and convective intensity, while turning off horizontal subgrid‐scale mixing decreases both. Total rainfall is modulated by a combination of mesoscale organization, areal coverage of convection, and convective intensity. The stochastic simulations tend to behave more similarly to the constant enhanced mixing simulation owing to greater impacts from enhanced mixing as compared to reduced mixing. The impacts of stochastic mixing are robust, ascertained by comparing the stochastic mixing ensembles with a non‐stochastic mixing ensemble that has grid‐scale noise added to the initial thermodynamic field. Compared to radar observations and a higher resolution Δ h = 1 km simulation, stochastic mixing seemingly degrades the simulation performance. These results imply that stochastic mixing produces non‐negligible impacts on convective system properties and evolution but does not lead to an improved representation of convective cloud characteristics in the case studied here.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

Experiments towards a neutron target for measurements in inverse kinematics

Neutron-induced reactions play an important role in fundamental nuclear physics, nuclear astrophysics, and applications. In the case of reactions on rare isotopes, there are limited options for direct experimental measurements. The Neutron Target Demonstrator project at Los Alamos National Laboratory seeks to test the feasibility of moderating spallation neutrons within a 1 m 3 graphite cube to create a standing neutron target for neutron-induced reaction measurements in inverse kinematics. This paper presents the results of experimental neutron flux distribution tests using neutron sources (ranging from 1 keV to 50 MeV) created by accelerators at the University of Notre Dame and Texas A&M University. Measurements were made with both the full graphite cube as well as a ”half cube” setup in which half of the graphite cube was removed. The measured distributions agree with simulated distributions in the case of the full cube moderator, although there remain discrepancies in certain cases for the half cube moderator. The results shown here will provide useful information for an upcoming experimental campaign to test the neutron target proof-of-principle.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

NASA NTRSDate not supplied

Probabilistic Blast Damage Modeling Uncertainties and Sensitivities

Blast overpressure is the predominant source of ground damage posed by potentially hazardous asteroid strikes. Estimates of the extent, severity, and likelihoods of potential blast damage regions will be one of the key metrics needed to mount civil defense or disaster response plans in the face of an impending impact. However, there are many inherent sources of uncertainty in evaluating the damage, both in characterizing the properties of the incoming object and in the approaches used to model the entry/impact and resulting damage, which make it difficult to produce a single ‘accurate’ or ‘best guess’ prediction of ground damage. The current 2021 PDC hypothetical impact scenario poses a particular challenge due to its short warning time. The need for rapid disaster response to prepare for an immanent impact, combined with lack of observational opportunities to refine basic knowledge about the object’s basic size and properties, make understanding the range and relative likelihood of consequences particularly critical. The potential damage caused by these blasts can be evaluated using a range of modeling and simulation approaches and levels of fidelity. Fast-running engineering-level models can be used to run large numbers of probabilistically sampled cases covering wide variations of uncertain properties or parameters. High-fidelity simulations, on the other hand, can capture more detailed/accurate blast physics, but can only be performed for a small selection of specific cases, requiring many assumptions to be made about the initial object and its unpredictable entry/breakup characteristics. In order to provide a more complete picture of the potential threat for effective disaster response, both types of analysis need to be employed together. In this approach, high-fidelity simulations are used to refine and anchor engineering models, and the probabilistic engineering models are used to evaluate broad parameters spaces and guide selection of the most pertinent simulation cases for a given scenario. This presentation expands upon the probabilistic asteroid impact risk assessments being performed as part of the 2021 PDC hypothetical impact exercise, focusing on key aspects of blast damage modeling uncertainties and sensitivities. We review the current modeling and simulation approaches employed in the current assessment, compare the relative levels of uncertainty stemming from each main element of the problem (i.e., knowledge of the asteroid properties, modeling of the atmospheric entry/breakup and airburst, and estimates of the ground damage from the resulting blasts waves), and highlight any notable trends and sensitivities for the current scenario case.

SMD↗

DOE OSTI2022

Air classification of forest residue for tissue and ash separation efficiency

The goal of this Case Study was to evaluate the performance of air classification of logging residues toward meeting conversion CMAs for carbon and ash contents, as compared to the static status quo Base Case system in which the residues are first dried and then ground in a hammer mill with a 6 mm screen and fines < 1.18 mm are removed. Also considered were moisture and ash impacts on throughput and Overall Operating Effectiveness (OOE), as well as delivered feedstock cost and minimum fuel selling price (MFSP). Laboratory data on the impacts of fan speed and moisture content on the separation efficiency of soil ash, needles and bark from white wood were received from FCIC Subtask 5.2. Average throughput and energy consumption data were obtained from the Bioenergy Feedstock National User Facility (BFNUF) for the same air classifier. These data were utilized to develop the necessary response surface equations to perform throughput analysis using discrete event simulation. Because the Base Case status quo system utilizes drying prior to grinding, we modeled the Case Study with drying prior to air classification and subsequent grinding of the separated white wood to isolate the individual quality and cost impacts of air classification relative to the Base Case system. Key takeaways from this Case Study are that air classification improves the quality of the final material, but increases the production cost, especially when lights are disposed; this becomes a tradeoff between increased conversion yield and the extra cost. Removing material should be done as early in the process as possible. Each operation that occurs prior to removing the material increases the cost of the disposed material and leads to wasted energy expenditures. As processes are included or modified, the impact on monetary and energy cost should be included in the decision process. Identifying alternative uses and the associated value for material that is separated from the feedstock stream will have a significant impact on the delivered cost of the material. Although there was an increase in production cost by adding air classification, there was a resulting benefit to the MFSP when meeting or exceeding all of the conversion CMAs; this was an important finding that should be explored further with FCIC Subtask 8.3 and potentially FCIC Task 6.

09 BIOMASS FUELS↗