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DOE OSTI2021

Impacts of turbine and plant upsizing on the levelized cost of energy for offshore wind

Turbine and plant upsizing are major trends in offshore wind deployment, although the quantitative impact on project costs has not been well-characterized. The uncertain value of continued wind turbine and project growth limits the ability of the supply chain to prepare for future technology trends, leading to challenges in the realization of larger projects. This analysis explores the levelized cost of energy impacts of turbine ratings between 6 and 20 MW and plant capacities between 250 and 2,500 MW for fixed-bottom offshore wind using techno-economic cost models for foundation, electrical, installation, and operation and maintenance costs, along with annual energy production. We consider a nominal set of technology assumptions for all scenarios to isolate economies of size and scale without additional benefits from decreasing turbine capital costs, quantity discounts for larger projects, or optimized technology solutions. These results indicate that using a 20-MW wind turbine in a 2,500-MW power plant array can reduce the levelized cost of energy by over 23% relative to the global average turbine and plant size installed in 2019; primarily because of reductions in the balance-of-system and operation and maintenance costs. We also identify improved installation vessels, optimized export systems, and novel operation and maintenance strategies as additional cost reduction opportunities. These results suggest that upsizing represents a significant cost reduction opportunity for offshore wind energy and will continue to be a main factor in shaping the future of the sector.

17 WIND ENERGY↗

DOE OSTI2023

Economic Evaluation of a Coupled Nuclear Power Plant and Hydrogen Production Facility: A Case Study

This study optimized the design sizes and operation of a power-to-hydrogen-to-power integrated energy system to allow a baseload power plant to operate flexibly in the energy market. In collaboration with a utility industry partner, the system, consisting of an electrolyzer, compressors, storage tank, and fuel cell, was optimized under conditions specific to the proposed project at the site of a nuclear power plant. The Design Integration and Synthesis Platform to Advance Tightly Coupled Hybrid Energy Systems (DISPATCHES) maximized net present value by optimizing sizing of components and dispatch decisions. Revenues included sale of electricity, capacity payments typical of the New York Independent System Operator, and the section 45V hydrogen production tax credit of the Inflation Reduction Act of 2022 (the tax credit was assumed to be available to legacy plants in the absence of clear guidance at present). Under default assumptions which excluded many capital expenditures, the base case optimized solution had a net present value of $\$$1.4 million over a 30 year lifetime, with a 0.365 MW fuel cell operating nearly continuously and 85% of revenues supplied by the hydrogen production tax credit (which was counted as a revenue regardless of profit, thus assuming credit monetization or offset of taxes within the larger firm was possible in all years). Beyond the base case, a sensitivity study elucidated drivers of the economics as capacity payment rate and hydrogen production tax credit rate vary. Additional sensitivity studies also extended results to variation of other, previously fixed parameters, including the fuel cell capital cost, and to imposition of further constraints. Optimization was also repeated for the default assumptions but recognizing tax credits upon use of hydrogen rather than upon its production, producing no change in the optimal solution. Most notably, capacity payments above $\$$15/kW-month drove optimal fuel cells multiple times larger than those with the default estimated capacity payment of $\$$2.5/kW-month (approaching 11 vs. 0.365 MW), and these larger fuel cells operated rarely (capacity factors of ~0.03). Furthermore, when the hydrogen production tax credit was provided for only 10 years, under the specific assumptions of this study (e.g., neither site preparation costs nor electrolyzer capital cost counted), the optimal solution avoided economic loss by ceasing system operation after the 10th year. Viewed broadly, this study demonstrated the capabilities of DISPATCHES, which can be user-adapted to serve other industrial case studies.

08 HYDROGEN↗

NASA NTRS1988

Integrated structural-aerodynamic design optimization

This paper focuses on the processes of simultaneous aerodynamic and structural wing design as a prototype for design integration, with emphasis on the major difficulty associated with multidisciplinary design optimization processes, their enormous computational costs. Methods are presented for reducing this computational burden through the development of efficient methods for cross-sensitivity calculations and the implementation of approximate optimization procedures. Utilizing a modular sensitivity analysis approach, it is shown that the sensitivities can be computed without the expensive calculation of the derivatives of the aerodynamic influence coefficient matrix, and the derivatives of the structural flexibility matrix. The same process is used to efficiently evaluate the sensitivities of the wing divergence constraint, which should be particularly useful, not only in problems of complete integrated aircraft design, but also in aeroelastic tailoring applications.

Haftka, R. T.↗

DOE OSTI2023

U.S. Domestic Security-by-Design: On Site Response Force Strategies

U.S. nuclear power facilities face increasing challenges in meeting dynamic security requirements caused by evolving and expanding threats while keeping cost reasonable to make nuclear energy competitive. The past approach has often included implementing security features after a facility has been designed and without attention to optimization, which can lead to cost overruns. Incorporating security in the design process can provide robust, cost- effective, and sufficient physical protection systems. The purpose of this work is both to develop a framework for the integration of security into the design phase of High Temperature Gas Reactors (HTGRs) that utilize pebble-based fuels and microreactors. Specifically, this effort focuses on integrating security into the design phase of a model HTGR and microreactor that meets current Nuclear Regulatory Commission (NRC) physical protection requirements and providing advanced solutions to improve physical protection and decrease costs. A suite of tools, including SCRIBE3D©, PATHTRACE© and Blender© were used to model a hypothetical, generic domestic HTGR facility and microreactor facility. Physical protection elements such as sensors, cameras, barriers, and onsite response forces were added to the model based on best practices for physical protection systems. Multiple outsider sabotage scenarios were examined with four-to-eight adversaries to determine security metrics. The results of this work will influence physical protection system designs and facility designs for U.S. domestic HTGRs and microreactors. This work will also demonstrate how a series of experimental and modeling capabilities across the Department of Energy (DOE) Complex can lead to efficient security systems that utilize an onsite response force. The conclusions and recommendations in this document may be applicable to all SMR designs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Small Modular Reactor and Microreactor Security-by-Design Lessons Learned: Integrated PPS Designs

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

U.S. Domestic Molten Salt Reactor: Security-by-Design

U.S. nuclear power facilities face increasing challenges in meeting dynamic security requirements caused by evolving and expanding threats while keeping costs reasonable to make nuclear energy competitive. The past approach has often included implementing security features after a facility has been designed and without attention to optimization, which can lead to cost overruns. Incorporating security in the design process can provide robust, economical, and effective physical protection systems (PPS). The purpose of this work is both to develop a framework for the integration of security into the design phase of a molten salt reactor (MSR) and show how to effectively design a PPS with a reduced staffing headcount. Specifically, this work focuses on integrating PPS design features into a developed facility layout by making minor modifications to building structures. A suite of tools, including Scribe3D©, PathTrace©, and Blender©, were used to model a hypothetical, generic domestic MSR facility. Physical protection elements such as sensors, cameras, barriers, and responders were added into the model based on defending the hypothetical MSR facility against a hypothetical design basis threat (DBT). Multiple outsider sabotage scenarios were examined, with adversary team sizes ranging from 4–8 to determine security system effectiveness. The results of this work will influence PPS designs and facility designs for U.S. domestic MSRs. This work will also demonstrate how a series of experimental and modeling capabilities across the Department of Energy (DOE) complex can impact the design and completion of security-by-design (SeBD) for small modular reactors (SMRs). The conclusions and recommendations in this document may be applicable to all SMR designs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2026

Towards a self-driving trigger at the LHC: adaptive response in real time

Real-time data filtering and selection—or trigger—systems at high-throughput scientific facilities such as the experiments at the Large Hadron Collider must process extremely high-rate data streams under stringent bandwidth, latency, and storage constraints. Yet these systems are typically designed as static, hand-tuned menus of selection criteria grounded in prior knowledge and simulation. In this work, we further explore the concept of a self-driving trigger, an autonomous data-filtering framework that reallocates resources and adjusts thresholds dynamically in real-time to optimize signal efficiency, rate stability, and computational cost as instrumentation and environmental conditions evolve. We introduce a benchmark ecosystem to emulate realistic collider scenarios and demonstrate real-time optimization of a menu including canonical energy sum triggers as well as modern anomaly-detection algorithms that target non-standard event topologies using machine learning. Using simulated data streams and publicly available collision data from the Compact Muon Solenoid experiment, we demonstrate the capability to dynamically and automatically optimize trigger performance under specific cost objectives without manual retuning. Our adaptive strategy shifts trigger design from static menus with heuristic tuning to intelligent, automated, data-driven control, unlocking greater flexibility and discovery potential in future high-energy physics analyses.

Emami, Shaghayegh [Michigan U.] (ORCID:00090007589↗

NASA NTRS1967

Study of the influence of size of a manned lifting body entry vehicle on research potential and cost. Part I - Summary Final report

Optimization of manned lifting body entry vehicle used for conducting space research tasks

MANNED REENTRY↗

DOE OSTI2020

Experimental Validation of Approximate Dynamic Programming Based Optimization and Convergence on Microgrid Applications

Stochastic optimization can better address uncertainties in power system problems. However, when state space and action space become large, many existing approaches become computationally expensive and even infeasible. Approximate dynamic programming (ADP) attracts researchers’ attention as a powerful tool for solving power system optimization problems with reduced computational cost. In this paper, in light of the existing literature, we investigate how the ADP approach with post-decision value function approximation converges to the nearly optimal solution with improved computational speed and experimentally validate the performance of the approach for a microgrid energy optimization problem. The approximation error versus the number of iteration is studied for convergence analysis of the post-decision ADP. A flowchart is provided to illustrate the proposed ADP algorithm for a microgrid energy optimization problem. The performance of ADP and dynamic programming (DP) is compared in terms of optimization error and computational time. It has found that the post-decision ADP approach can achieve competitive optimality with improved computational speed compared to the traditional DP.

Das, Avijit↗

NASA NTRS1991

A tailored approach to electromagnetic compatibility requirements in space applications

An approach is outlined which defines the requirements for electromagnetic compatibility (EMC) between NASA and military technologies with attention given to electromagnetic interference (EMI) requirements. In order to minimize the cost and weight impact of the changes needed for compatibility the plan emphasizes the incorporation of off-the-shelf technology with current nonstandard methods. NASA designs are structured to meet EMI requirements rather than processing waivers against military-type specifications. The NASA-wide EMI requirements can be documented in three sections: requirements, test methods, and tailoring guidelines. It is shown that a NASA-wide EMC specification would decrease the costs of achieving compatibility by increasing efficiency and optimizing the relationship between EMC design and performance and cost.

Javor, Ken↗

NASA NTRS2017

Computationally Efficient Motion Planning Algorithms for Agile Autonomous Vehicles in Cluttered Environments

Fast, real-time motion planning of an agile, autonomous vehicle in a cluttered environment, with many geometrically-fixed obstacles, is a very complex problem, especially because of the vehicle dynamics constraints and resource constrained computational capabilities onboard the vehicle. In this paper, we present computationally-efficient versions of our novel motion planning algorithm called the Spherical Expansion and Sequential Convex Programming (SE–SCP) algorithm. The SE–SCP algorithm first uses a spherical-expansion-based randomized sampling algorithm to explore the workspace. Oncea path is found from the start position to the goal position, the algorithm computes a locally optimal trajectory, within its homotopy class for a desired cost function, by solving a sequence of convex optimization problems. Thus, the SE–SCP algorithm is anytime locally optimal and the trajectory is globally optimal if the number of samples tends to infinity. In this paper, we further enhance the computational efficiency of the SE–SCP algorithm using uni-directional and bi-directional rewiring techniques. We also present a detailed proof of the local optimality characteristics of the new SE–SCP algorithms for aspecial case of vehicle dynamics. Simulation examples involving quadrotor and spacecraft help demonstrate the effectiveness of our new algorithms.

Bandyopadhyay, Saptarshi↗

DOE OSTI2026

Optimal Operation of Residential High Performance Water Heater for Reduction of Electricity Cost and Peak Demand Through Field Validation

Water heating accounts for about 18% of a typical US home’s energy use. Modern water heaters have enabled control options through APIs, offering customers the opportunity to reduce their energy cost and peak demand by dynamically adjusting settings. A water heater’s capacity to store energy using its storage tank makes it an asset for peak demand reduction and energy cost savings. For this reason, a mixed-integer linear programming model is proposed to minimize the energy cost of a high-performance water heater while also reducing the peak demand of the residential household under a time-of-use utility rate by dynamically changing the water heater’s running mode. Specifically, a multi-objective optimization model is formulated to determine the mode settings of the water heater considering hot water use, time-of-use rate, and peak demand limit of the residential household. The mode settings are associated with different dead bands of water temperature for triggering on/off action of the heat pump and heating element. A 66-gal hybrid electric high performance water heater was used for numerical simulation and practical experiments. The simulation results were well aligned with measurements of practical experiments, validating the soundness of the thermodynamic model. In addition, reductions of energy cost, enabling affordability, and reducing peak demand are demonstrated. The research team also developed a software framework with dashboards to automatically and continuously monitor and manage devices.

Liu, Guodong [ORNL] (ORCID:0000000213498608)↗

DOE OSTI2021

Potential benefits and optimization of cool-coated office buildings: A case study in Chongqing, China

Increasing envelope facet albedos considerably reduces solar heat gain, thus yielding building cooling energy savings. Few studies have explored the potential benefits of utilizing cool coatings on building envelopes (“cool-coated buildings”) based on life-cycle cost analysis. A holistic approach integrating the field testing, building energy simulation, and a 20-year life-cycle-based optimization was developed to explore cool-coated building performance and the maximum net savings of optimal building envelope retrofit and design. Experimental results showed that applying cool coatings to a west wall of an office building in Chongqing, China reduced its exterior surface temperature by up to 9.3 °C in summer. Additionally, simulation results showed that in Chongqing, making the roof and walls cool could reduce annual HVAC electricity use by up to 11.9% in old buildings (with poorly insulated envelopes) and up to 5.9% in new buildings. Retrofitting old buildings with a cool roof provided the net savings per modified area with present values up to 42.8 CNY/m2; retrofitting a new building with a cool roof or cool walls was not cost-effective. Optimizing both envelope insulation and envelope albedo can achieve 5.6 times the net savings of optimizing the insulation only, and 1.6 times that of optimizing albedo only.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Hard Rock Drilling Optimization Software

The main objective of the developed software is to reduce the cost per foot during drilling, in other words, optimize the drilling operational parameters in achieving optimum ROP while avoiding critical operational parameters due to either low ROP, drillstring vibration, accelerated cutter wear, or low MSE. The developed software can also be used for post-well analysis to provide insight and lessons learned for future drilling operations. Several functions are available in the software to help the user perform drilling analysis, optimization, and simulation.

15 GEOTHERMAL ENERGY↗

NASA NTRS1976

A multilevel optimization of large-scale dynamic systems

A multilevel feedback control scheme is proposed for optimization of large-scale systems composed of a number of (not necessarily weakly coupled) subsystems. Local controllers are used to optimize each subsystem, ignoring the interconnections. Then, a global controller may be applied to minimize the effect of interconnections and improve the performance of the overall system. At the cost of suboptimal performance, this optimization strategy ensures invariance of suboptimality and stability of the systems under structural perturbations whereby subsystems are disconnected and again connected during operation.

Siljak, D. D.↗

DOE OSTI2022

Layer Time Control for Large Scale Additive Manufacturing Using High Performance Computing

This work proposes to optimize an additive manufacturing AM process to reduce energy and printing cost. The polymer AM process is inherently dependent on the time-temperature history of each layer to maintain geometric tolerances and mechanical integrity. Our preliminary study shows that regression-based layer time control model using thermal images could result in up to 30% build time reduction for simple geometries. This proposed work would use high-performance computing (HPC) to couple the data-driven model with thermal simulation for better predicting layer temperature profiles, improving throughput of large-scale additive manufacturing, and reducing its energy cost. We have developed a method to optimize a layer deposition time (a.k.a. layer time) for large-scale AM via physics-based simulations. A long layer time leads to an over-cooled surface on which a new layer is deposited, and therefore, it may result in a weak bonding or debonding between layers, cracking, or warping. A short layer time leads to a high temperature of the structure due to insufficient cooling, and therefore, the structure may not be stiff enough and may collapse during manufacturing. Therefore, it is important to estimate the optimal layer time in additive manufacturing for a high-quality product. The temperature of a top layer right before deposition is recommended to be slightly higher than the glass temperature of the material. A temperature cooling was approximated to an exponential function of time, and the optimized layer time was obtained based on a target temperature while maintaining a minimal printing time. The material used is carbon fiber-reinforced polycarbonate (CF/PC), and the large-scale deposition system used is LSAM TM from Thermwood Corporation. Three different layer time cases were used for experiments, and a series of thermal images were obtained via an infra-red (IR) camera during the entire AM processes. AM process simulations were performed using a finite element method and the temperature profiles from the simulation were in good agreements with those from experiments. The layer time optimization was performed based on the temperature profiles from the simulations. A layer temperature with the optimal layer time was confirmed as the target temperature through simulation. In addition to the development of a layer time optimization method, we have developed a numerical framework for AM simulation with element activations in sync with toolpath, based on an open source finite element framework, DEAL.II. A major portion of this work was presented at SAMPE 2022 Conference and Exhibition on May 2022, and published in Proceedings of SAMPE 2022.

42 ENGINEERING↗

DOE OSTI2024

Optimal Management of Grid-Interactive Efficient Buildings via Safe Reinforcement Learning

Reinforcement learning (RL)-based methods have achieved significant success in managing grid-interactive efficient buildings (GEBs). However, RL does not carry intrinsic guarantees of constraint satisfaction, which may lead to severe safety consequences. Besides, in GEB control applications, most existing safe RL approaches rely only on the regularisation parameters in neural networks or penalty of rewards, which often encounter challenges with parameter tuning and lead to catastrophic constraint violations. To provide enforced safety guarantees in controlling GEBs, this paper designs a physics-inspired safe RL method whose decision-making is enhanced through safe interaction with the environment. Different energy resources in GEBs are optimally managed to minimize energy costs and maximize customer comfort. The proposed approach can achieve strict constraint guarantees based on prior knowledge of a set of developed hard steady-state rules. Simulations on the optimal management of GEBs, including heating, ventilation, and air conditioning (HVAC), solar photovoltaics, and energy storage systems, demonstrate the effectiveness of the proposed approach.

Huo, Xiang↗

DOE OSTI2026

Reference floating wind array designs for three representative regions

This work presents the systematic development of three open-source reference floating wind array designs. The designs are tailored to representative site conditions for three regions of the United States: Humboldt Bay off the coast of California, the Gulf of Maine, and the Gulf of America. We adopted existing reference designs for the individual 15 MW turbines, semisubmersible floating platforms, substations, mooring systems, and power cables – integrating and adapting them as needed for each location. We adapted existing dynamic cable designs to use larger conductor sizes to meet the arrays' power transmission requirements, and we set up redundant mooring systems for each substation. The layout of each array is a uniform-grid design optimized to approximately minimize the levelized cost of energy (LCOE) within a square lease area while satisfying spatial constraints. These constraints ensure adequate clearances between adjacent turbines and between underwater components during the layout optimization to prevent clashing and ensure that all components reside within the lease boundaries. Substations are included to allow accounting for intra-array cable costs. They are placed within the uniform grid to maintain the navigability of the arrays. For each feasible layout considered, annual energy production and cable routing costs are calculated and updated in the LCOE objective function. After the optimization, we refined the cable routing with a mix of algorithmic and manual methods to ensure that the cables avoid mooring system components and approach the substation with adequate clearances. We confirmed the suitability of each reference array's layout by comparing the wake losses at each wind heading angle to the wind rose, observing that the optimized layouts largely avoid wake losses in the predominant wind directions. These reference arrays provide open-source baseline designs to enable future research and innovation of floating wind technology at the array scale.

17 WIND ENERGY↗