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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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Rotor Wake Vortex Definition Using 3C-PIV Measurements: Corrected for Vortex Orientation

Three-component (3-C) particle image velocimetry (PIV) measurements, within the wake across a rotor disk plane, are used to determine wake vortex definitions important for BVI (Blade Vortex Interaction) and broadband noise prediction. This study is part of the HART II test program conducted using a 40 percent scale BO-105 helicopter main rotor in the German-Dutch Wind Tunnel (DNW). In this paper, measurements are presented of the wake vortex field over the advancing side of the rotor operating at a typical descent landing condition. The orientations of the vortex (tube) axes are found to have non-zero tilt angles with respect to the chosen PIV measurement cut planes, often on the order of 45 degrees. Methods for determining the orientation of the vortex axis and reorienting the measured PIV velocity maps (by rotation/projection) are presented. One method utilizes the vortex core axial velocity component, the other utilizes the swirl velocity components. Key vortex parameters such as vortex core size, strength, and core velocity distribution characteristics are determined from the reoriented PIV velocity maps. The results are compared with those determined from velocity maps that are not corrected for orientation. Knowledge of magnitudes and directions of the vortex axial and swirl velocity components as a function of streamwise location provide a basis for insight into the vortex evolution.

Burley, Casey L.↗

P69 Using the NASA-Unified WRF to Assess the Impacts of Real-Time Vegetation on Simulations of Severe Weather

Since June 2010, the NASA Short-term Prediction Research and Transition (SPoRT; Goodman et al. 2004; Darden et al. 2010; Stano et al. 2012; Fuell et al. 2012) Center has been generating a real-time Normalized Difference Vegetation Index (NDVI) and corresponding Green Vegetation Fraction (GVF) composite based on reflectances from NASA s Moderate Resolution Imaging Spectroradiometer (MODIS) instrument. This dataset is generated at 0.01 resolution across the Continental United States (CONUS), and updated daily. The goal of producing such a vegetation dataset is to improve over the default climatological GVF dataset in land surface and numerical weather prediction models, in order to have better simulations of heat and moisture exchange between the land surface and the planetary boundary layer. Details on the SPoRT/MODIS vegetation composite algorithm are presented in Case et al. (2011). Vegetation indices such as GVF and Leaf Area Index (LAI) are used by land surface models (LSMs) to represent the horizontal and vertical density of plant vegetation (Gutman and Ignatov 1998), in order to calculate transpiration, interception and radiative shading. Both of these indices are related to the NDVI; however, there is an inherent ambiguity in determining GVF and LAI simultaneously from NDVI, as described in Gutman and Ignatov (1998). One practice is to specify the LAI while allowing the GVF to vary both spatially and temporally, as is done in the Noah LSM (Chen and Dudhia 2001; Ek et al. 2003). Operational versions of Noah within several of the National Centers for Environmental Prediction (NCEP) global and regional modeling systems hold the LAI fixed, while the GVF varies according to a global monthly climatology. This GVF climatology was derived from NDVI data on the NOAA Advanced Very High Resolution Radiometer (AVHRR) polar orbiting satellite, using information from 1985 to 1991 (Gutman and Ignatov 1998; Jiang et al. 2010). Representing data at the mid-point of every month, the climatological dataset is on a grid with 0.144 (~16 km) spatial resolution and is distributed with the community WRF model (Ek et al. 2003; Jiang et al. 2010; Skamarock et al. 2008).

Case, Jonathan L.↗

Structural Design Exploration of an Electric Powered Multi-Propulsor Wing Configuration

Advancements in aircraft electric propulsion may enable an expanded operational envelope for electrically powered vehicles compared to their internal combustion engine counterparts. High aspect ratio wings provide additional lift and drag reduction for a proposed multi-propulsor design, however, the challenge is to reduce the weight of wing structures while maintaining adequate structural and aeroelastic margins. Design exploration using a conventional design-and-build philosophy coupled with a finite element method (FEM)-based design of experiments (DOE) strategy are presented to examine high aspect ratio wing structures that have spanwise distributed electric motors. Multiple leading-edge-mounted engine masses presented a challenge to design a wing within acceptable limits for dynamic and aeroelastic stability. Because the first four primary bending eigenmodes of the proposed wing structure are very sensitive to outboard motor placement, safety-of-flight requirements drove the need for multiple spars, rib attachments, and outboard structural reinforcements in the design. Global aeroelasticity became an increasingly important design constraint during the on-going design process, with outboard motor pod flutter ultimately becoming a primary design constraint. Designers successively generated models to examine stress, dynamics, and aeroelasticity concurrently. This research specifically addressed satisfying multi-disciplinary design criteria to generate fluid-structure interaction solution sets, and produced high aspect ratio primary structure designs for the NASA Scalable Convergent Electric Propulsion Technology and Operations Research (SCEPTOR) project in the Aeronautic Research Mission Directorate at NASA. In this paper, a dynamics-driven, quasi-inverse design methodology is presented to address aerodynamic performance goals and structural challenges encountered for the SCEPTOR demonstrator vehicle. These results are compared with a traditional computer aided design based approach.

Moore, James B.↗

Cognitive Communications for NASA Space Systems

The growing complexity of spacecraft constellations, communication relay offerings, and mission architectures drives the need for the development of autonomous communication systems. NASA has traditionally launched single spacecraft missions that are served by the Space Communication and Navigation (SCaN) program. Operations on SCaN networks are typically scheduled weeks in advance, and often each asset serves a single user spacecraft at a time. Recent movement towards swarm missions could make the current approach unsustainable. Additionally, the integration of commercial communication service providers will substantially increase the data transfer options available to new missions. NASA science missions have found benefit in launching swarms of spacecraft, allowing coordinated simultaneous observations from different perspectives. Inter-spacecraft communication (mesh networking) is an enabler for this architecture, as are CubeSats that allow cost-effective provisioning of distributed mission assets. As more complex swarm missions launch, one challenge is coordinating communication within the swarm and choosing the appropriate mechanism for telemetry, tracking, control, and data services to and from Earth. Cognitive communications research conducted by SCaN aims to mitigate the increasing communication complexity for mission users by increasing the autonomy of links, networks, and service scheduling. By considering automation techniques including recent advances in artificial intelligence and machine learning, cognitive algorithms and related approaches enable increased mission science return, improved resource utilization for service provider networks, and resiliency in unpredictable or unplanned environments. The Cognitive Communications Project at the NASA Glenn Research Center develops applications of data-driven, non-deterministic methods to improve the autonomy of space communication. The project emphasizes development of decentralized space networks with artificial intelligence agents optimizing communication link throughput, data routing, and system-wide asset management. This paper discusses the objectives, approaches, and opportunities of the research to address growing needs of the space communications community.

Chelmins, David↗

Evaluation of Aggregated EV Flexibility With TSO-DSO Coordination

Electric vehicles (EVs) are becoming a promising source of grid ancillary services due to the temporal and spatial charging flexibility, quick response and storage capability. Such advantages are increasing with government policy promotion and technology improvement. However, the exploration of EV flexibility requires the coordination of both transmission system operators (TSOs) and distribution system operators (DSOs), to ensure the safe and reliable operation of power network. In this paper, we propose a coordinated evaluation method that determines the optimal utilization of EV temporal flexibility without compromising EV owners’ usage. At the distribution level, DSOs first evaluate EV aggregators’ operational boundaries to exploit distribution level services. At the transmission level, TSOs then determine EV charging schedules and ancillary service capacity simultaneously, taking into account the requirement from DSOs. Here, we validate the model in a case study using the IEEE 123 node test feeder and EV charging sessions obtained from a transportation simulation tool that uses real-world data.

33 ADVANCED PROPULSION SYSTEMS↗

Developing Flexible, Networked Lighting Control Systems That Reliably Save Energy in California Buildings

An important strategy to meet California's ambitious energy efficiency goals is to use innovative wireless communications, embedded sensors, data analytics and controls to significantly reduce lighting energy use in commercial buildings. This project developed a suite of networked lighting solutions to further this goal. The technologies include a platform for low-cost sensing, distributed intelligence and communications, the “PermaMote,” which is a self-powered sensor and controller for lighting applications. The project team also developed a task ambient daylighting system that integrates sensors with data-driven daylighting control using an open communication interface, called the “Readings-At-Desk” (RAD) system. To address the problem of building occupants being confused about how to operate traditional lighting control systems, the research team created content that could be the basis for a user interface standard for lighting controls. Finally, to address the difficulty of ensuring that advanced lighting control systems actually deliver their promised energy savings, the project team developed a new method for evaluating and specifying lighting systems’ performance. The research team validated these technologies in the laboratory, showing significant lighting energy savings, up to 73% for the PermaMote sensor system from occupancy control and daylight dimming features, compared to the same light source (LED replacement lamps) operated via simple on/off scheduling. The project team also developed a proposed standard lighting data model and user interface elements, which were contributed to the ANSI Lighting Systems Committee (C137) for standardization. Existing data models are incomplete and inconsistent, whereas the lighting-specific data model developed here is clear and comprehensive, to serve as a starting point for creating common, universally agreed upon semantic definitions of key lighting parameters, to promote interoperability. For the task on verifiable performance of lighting systems, the project team developed a more effective metric for capturing the actual energy impact of a lighting system over time — the energy usage intensity (kWh/ft2/year). Three commercial lighting systems were tested in FLEXLAB® using this new metric, and the tests show a wide range in the accuracy of the self-reported energy-use metric, from 0.5% to 28% error compared to direct measurement of lighting energy using dedicated submeters. Overall, the project team estimates that these advanced technologies can reduce California office lighting energy use by 20% (above and beyond normal advanced lighting controls mandated by Title 24), resulting in about 1,600 GWh/year in savings.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Design Methods, Tools, and Data for Ceramic Solar Receivers

This report presents the development of tools and methods for evaluating the reliability and performance of ceramic materials in high temperature solar receivers. As Concentrating Solar Power (CSP) technologies aim for higher operating temperatures to enhance efficiency and meet industrial process heat requirements, current high temperature metallic materials face challenges in maintaining structural integrity. This report explores advanced ceramics as a promising alternative, given their superior high temperature strength and lower thermal expansion, compared to metals. To address the need for effective ceramic receiver design tools, this report integrates statistical failure models of ceramics into the existing srlife tool: an open-source software package designed to estimate the life of high temperature CSP components. These failure models account for the inherent variability and flaw distribution in ceramics, as well as the impact of subcritical crack growth under high temperature cyclic loads. The report also presents experimental data collected for a commercially available ceramic material, SiC, and details the process of estimating reliability model parameters from these data. A comparative design analysis is then performed between ceramic (SiC) and metallic (current nickel-based superalloys A740H and A282) receiver. This comparison demonstrates that SiC receivers can achieve service life exceeding 30 years under high incident heat flux conditions, compared to just a few years for metallic receivers.

14 SOLAR ENERGY↗

Southeast Regional CO 2 Utilization and Storage Acceleration Partnership (SECARB-USA): Initial Inventory of Non-Technical Challenges to CCUS Deployment

The “Southeast Regional CO 2 Utilization and Storage Acceleration Partnership” (SECARBUSA) project supports the U.S. Department of Energy (DOE) Office of Fossil Energy's (FE) mission to help the United States meet its need for secure, affordable, and environmentally sound fossil energy supplies by utilizing the advancements made by the current Regional Carbon Sequestration Partnership (RCSP) Initiative to continue to identify and address knowledge gaps. The primary project objective is to identify and address regional onshore storage and transport challenges facing commercial deployment of carbon dioxide (CO 2 ) capture, utilization, and storage (CCUS) technologies. The Research Partners and a selected industry network of experienced CCUS project developers and operators will coordinate their capabilities to accelerate CCUS deployment by achieving four primary research objectives: 1) address key technical challenges; 2) facilitate data collection, sharing and analysis; 3) assess transportation and distribution infrastructure; and 4) promote regional technology transfer and dissemination of knowledge. The SECARB-USA Region includes the states of Alabama, Arkansas, Florida, Georgia, Louisiana, Mississippi, North Carolina, South Carolina, Tennessee, and Virginia and portions of Kentucky, Missouri, Oklahoma, Texas, and West Virginia. Under subtask 5.2: Non-Technical Challenges to CCUS Deployment, the Southern States Energy Board (SSEB) will define and identify An Inventory of Non-Technical Challenges to CCUS Deployment. As an initial step, SSEB organized an Industry and Non-Governmental Organization (NGO) Working Group comprised of knowledgeable market participants to assist in the development of an initial list of non-technical challenges to CCUS development.

42 ENGINEERING↗

Advanced power system protection and incipient fault detection and protection of spaceborne power systems

This research concentrated on the application of advanced signal processing, expert system, and digital technologies for the detection and control of low grade, incipient faults on spaceborne power systems. The researchers have considerable experience in the application of advanced digital technologies and the protection of terrestrial power systems. This experience was used in the current contracts to develop new approaches for protecting the electrical distribution system in spaceborne applications. The project was divided into three distinct areas: (1) investigate the applicability of fault detection algorithms developed for terrestrial power systems to the detection of faults in spaceborne systems; (2) investigate the digital hardware and architectures required to monitor and control spaceborne power systems with full capability to implement new detection and diagnostic algorithms; and (3) develop a real-time expert operating system for implementing diagnostic and protection algorithms. Significant progress has been made in each of the above areas. Several terrestrial fault detection algorithms were modified to better adapt to spaceborne power system environments. Several digital architectures were developed and evaluated in light of the fault detection algorithms.

Russell, B. Don↗

Induction motor control

Electromechanical actuators developed to date have commonly utilized permanent magnet (PM) synchronous motors. More recently switched reluctance (SR) motors have been advocated due to their robust characteristics. Implications of work which utilizes induction motors and advanced control techniques are discussed. When induction motors are operated from an energy source capable of controlling voltages and frequencies independently, drive characteristics are obtained which are superior to either PM or SR motors. By synthesizing the machine frequency from a high frequency carrier (nominally 20 kHz), high efficiencies, low distortion, and rapid torque response are available. At this time multiple horsepower machine drives were demonstrated, and work is on-going to develop a 20 hp average, 40 hp peak class of aerospace actuators. This effort is based upon high frequency power distribution and management techniques developed by NASA for Space Station Freedom.

Hansen, Irving G.↗

Technology-enabled Airborne Spacing and Merging

Over the last several decades, advances in airborne and groundside technologies have allowed the Air Traffic Service Provider (ATSP) to give safer and more efficient service, reduce workload and frequency congestion, and help accommodate a critically escalating traffic volume. These new technologies have included advanced radar displays, and data and communication automation to name a few. In step with such advances, NASA Langley is developing a precision spacing concept designed to increase runway throughput by enabling the flight crews to manage their inter-arrival spacing from TRACON entry to the runway threshold. This concept is being developed as part of NASA s Distributed Air/Ground Traffic Management (DAG-TM) project under the Advanced Air Transportation Technologies Program. Precision spacing is enabled by Automatic Dependent Surveillance-Broadcast (ADS-B), which provides air-to-air data exchange including position and velocity reports; real-time wind information and other necessary data. On the flight deck, a research prototype system called Airborne Merging and Spacing for Terminal Arrivals (AMSTAR) processes this information and provides speed guidance to the flight crew to achieve the desired inter-arrival spacing. AMSTAR is designed to support current ATC operations, provide operationally acceptable system-wide increases in approach spacing performance and increase runway throughput through system stability, predictability and precision spacing. This paper describes problems and costs associated with an imprecise arrival flow. It also discusses methods by which Air Traffic Controllers achieve and maintain an optimum interarrival interval, and explores means by which AMSTAR can assist in this pursuit. AMSTAR is an extension of NASA s previous work on in-trail spacing that was successfully demonstrated in a flight evaluation at Chicago O Hare International Airport in September 2002. In addition to providing for precision inter-arrival spacing, AMSTAR provides speed guidance for aircraft on converging routes to safely and smoothly merge onto a common approach. Much consideration has been given to working with operational conditions such as imperfect ADS-B data, wind prediction errors, changing winds, differing aircraft types and wake vortex separation requirements. A series of Monte Carlo simulations are planned for the spring and summer of 2004 at NASA Langley to further study the system behavior and performance under more operationally extreme and varying conditions. This will coincide with a human-in-the-loop study to investigate the flight crew interface, workload and acceptability.

Hull, James↗

Bayesian GAN-Based False Data Injection Attack Detection in Active Distribution Grids With DERs

Advancements in information and communication technologies have revolutionized monitoring and control capabilities within smart grids. However, it also brings new vulnerabilities to data acquisition systems and state estimation functions, which attackers can subtly tamper with the measurement data through compromising the communication network. Moreover, the high penetration of renewable energy sources with the inherited characteristics of uncertainty and variability further complicates the design of effective intrusion detection systems. In this paper, a Bayesian deep learning-based approach is developed to detect cyber attacks and maintain the security of smart grids. Our method specifically addresses the prevalent issue of imbalanced data in real power systems, which arises from the predominance of normal system operations over compromised or attacked states. Employing a novel Bayesian GAN-based technique, our approach successfully discriminates between secure and compromised measurement data, even in scenarios with significant data imbalance. Furthermore, the proposed method accommodates various practical application factors, ensuring accurate intrusion detection despite the presence of measurement noise. The feasibility and effectiveness of the proposed detection mechanism are validated by testing on IEEE 13-node and 123-node test systems. Simulation results and comparisons with literature methods demonstrate the superiority of proposed cybersecurity solutions.

Bayesian GAN↗

Utilizing Advanced Statistics to Determine Anomalistic Conditions in Pebble-Bed Reactors

Pebble-bed reactors (PBRs) utilize hundreds of thousands of fuel pebbles, which continuously circulate through the core, in lieu of traditional fuel assemblies to generate fissions and produce power. The use of unmarked fuel pebbles presents a challenge for international safeguards verification that nuclear material is not being diverted. To ensure pebble diversion is not taking place, new methods for accounting for and monitoring the pebbles should be examined to determine an appropriate methodology for performing bulk accountancy with pebbles. Here, this work examines the use of statistical methods for determining if the reactor is within a declared range of operation by examining the statistical distribution of pebble burnup as they are discharged from the core. Using this methodology, we created a model that detects diversion over 95% of the time, over multiple diversion pathways, if the reactor core maintains a constant power density during the diversion process and only falsely labels a diversion case nominal 2% of the time. For a diversion scenario where the reactor is maintained at a constant power, the statistical analysis can correctly identify if diversion is occurring over 80% of the time; however, nearly 20% of specific diversion pathways are mislabeled nominal. These results provide a basis and framework for exploring the further use of statistical methods to determine where these methods could be most useful and where additional methods, such as machine learning, could be used to capture if diversion is occurring in pebble-bed reactors.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

The Potential for Health Monitoring in Expandable Space Modules: The Bigelow Expandable Activity Module on the ISS

Expandable modules for use in space and on the Moon or Mars offer a great opportunity for volume and mass savings in future space exploration missions. This type of module can be compressed into a relatively small shape on the ground, allowing them to fit into space vehicles with a smaller cargo/fairing size than a traditional solid, metallic structure based module would allow. In April 2016, the Bigelow Expandable Activity Module (BEAM) was berthed to the International Space Station (ISS). BEAM is the first human-rated expandable habitat/module to be deployed and crewed in space. BEAM is a NASA managed ISS payload project in partnership with Bigelow Aerospace. BEAM is intended to stay attached to ISS for an operational period of 2 years to help advance the technology readiness for future expandable modules. BEAM has been instrumented with a suite of space flight certified sensors systems which will help characterize the module's performance for thermal, radiation shielding and impact monitoring against potential Micro Meteoroid/Orbital Debris (MM/OD) providing fundamental information on the BEAM environment for potential health monitoring requirements and capabilities. This paper will provide an overview of how the sensors/instrumentation systems were developed, tested, installed and an overview of the current sensor system operations. It will also discuss how the MM/OD impact detection system referred to as the Distributed Impact Detection System (DIDS) data is being processed and reviewed on the ground by the principle investigators.

Wells, Nathan D.↗

Results from "Charging Needs for Electric Semi-Trailer Trucks"

This data set includes modeling results from “Charging Needs for Electric Semi-Trailer Trucks” including charging demand distributions and charging speed requirements for the multiple scenarios and semi-trailer truck operating segments described in the study. Please cite as: Borlaug, B., Moniot, M., Birky, A., Alexander, M., and Muratori, M., Charging needs for electric semi-trailer trucks, Renew. Sust. Energ. Transit. (2022), 2, https://doi.org/10.1016/j.rset.2022.100038.

24 POWER TRANSMISSION AND DISTRIBUTION↗

gollnlp and magos (Final Scientific/Technical Report)

In 2018, the Advanced Research Project Agency – Energy (ARPA-E) launched the Grid Optimization Competition (GOC), a series of competitive challenges intended to accelerate innovation in decision support software used to schedule power grid operations, making them as efficient as possible, while respecting operational constraints of power equipment and operational security. This report covers the participation of teams led by the Lawrence Livermore National Laboratory (LLNL) in Challenge 1 and Challenge 2 of the competition.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Protection and Restoration Solutions to Reliable and Resilient Integration of Grid-connected PV Installations and Distributed Energy Resources: Design, Testbed, Proof of Work and Impact Studies (Final Report)

To gain a better understanding of the complex transients in a utility grid with a large number of solar PV installations coupled by PWM inverters during the protection and restoration period of the power grid, in this project a kW-level experimental system with dominating inverter-based resources and a hardware-in-loop simulation system with transmission and distribution models, as well as several SEL protective relays have been built and used. The major research findings of the project are summarized below in two perspectives: Experimental research: A self-organized ultra-high frequency solitary waveform is discovered and demonstrated in the hardware experimental system. Despite the familiarities, such a solitary waveform is distinct from any harmonics, transient, or resonance waves in that, it is 1) non-dispersive over time and space, 2) not associated with any active source or the linear superposition of sources, 3) half-cycle asymmetric, 4) not responding to filters or change of system characteristic resonance frequency, 5) ubiquitous as it occurs simultaneously everywhere in the system from DC supply, power lines, and the utility grid, and 6) explosive through tripping the protection or damaging susceptible devices or circuits. Analytical study: The nature of such a new waveform and an analytical explanation of its formation are studied based on related physics and non-linear science principles, with the following highlights: 1) such a new waveform follows the solutions to the Non-linear Schrödinger equation, so the classic linear perturbation theory is unable to explain or predict such a unique waveform as confirmed with the research team of RTDS; 2) the critical condition of occurrence of such a waveform is derived, which indicates that the breakings of solitary wave is a system synchronous issue between the utility grid in the 60Hz phasor domain and duty-ratio modulation of DC sources in the inverter switching frequency domain; 3) such a waveform carries energy mass so it could be detrimental; 4) such a waveform is deceiving as it is not readily detectable in the energy propagation direction by the primary protection equipment, while it is detrimental in the perpendicular direction of energy propagation, i.e. voltage direction. Thus, it has more likely challenges to the second primary equipment and devices, particularly at the weakest link and point such as aging insulation and inappropriate setting of susceptible devices. Therefore, such a waveform can be easily ignored in the aftermath investigation. The intellectual merits: The experimental discovery reveals certain unfamiliar transient phenomena that could challenge the integration of large-scale grid-connected solar PV installation during the group ride-through period of solar PV installations, commissioning of large-solar farms, or dramatic change of solar radiation conditions. Particularly, the research findings suggest that the occurrence of the unfamiliar transient phenomena is uniquely associated with the inverter-based solar PV installation, which is less likely to happen for rotary energy systems. The physics and non-linear science-based research work laid down an analytical path to the challenging transient stability problems including those that have been observed currently and future calls. Both experimental and analytical research results explain the limitation of many current research effects including some DoE research undertakings as well as possible solutions. The broader impacts: The research outcome of the project advances the understanding of the possible transient problems for the integration of inverter-based solar PV installation. It also highlights the theoretical and technical barriers for applying the conventional theory and technology to design and implement countermeasures against their adverse impacts of the large-scale solar PV installation and operation on grid reliability and security. More broadly, the research outcomes have shed some light on the open, fundamental challenges in the integration of large-scale solar photovoltaic energy into current and next-generation power grids across the country, and worldwide. The advanced physics and non-linear science-based analysis open up a path to harmonization of the renewables for societal energy needs via building a resilient and sustainable electric power infrastructure.

14 SOLAR ENERGY↗

Enabling microbial electrolysis cell scale-up via electrochemistry-, hydrodynamic-, and microbial ecology-informed framework

Microbial electrolysis cells (MECs) can produce green hydrogen while removing organic contaminants from liquid waste streams by leveraging the metabolic activity of electroactive microorganisms. Despite their potential in a sustainable, circular economy, large-scale MECs that can treat relevant volumes of wastewater have failed to deliver performance proportional to their lab-scale counterparts. The reason behind this lower performance at scale remains unclear. Here, in this study, we developed a combined electrochemistry-, hydrodynamic-, and microbial ecology-informed framework to analyze and optimize MEC performance during scale-up, enabling accurate quantification of major limitations and the identification of strategies to overcome them, ultimately facilitating equivalent performance at scale. Applying this framework to the scale-up of a zero-gap MEC from 9 cm 2 electrode area to 100 cm 2 electrode area, resulted in similar maximum current densities in a 100 cm 2 MEC (21.7 ± 1.1 A/m 2 ) compared to a 9 cm 2 system (25.1 ± 2.7 A/m 2 ), as well as equivalent hydrogen production rates of 69.3 L/L-d (100 cm 2 ) and 67.7 ± 2.4 L/L-d (9 cm 2 ). COMSOL flow dynamics simulations were used to scale up the reactor configuration without negatively affecting electrolyte velocity and distribution in the cell, minimizing the increase in internal resistances during scale-up (11.7 ± 0.5 mΩm 2 at 9 cm 2 ; 19.7 ± 1.3 mΩm 2 at 100 cm 2 ). Microbial community structures were assessed at both scales using high-throughput sequencing, highlighting the differences of populations across electrode dimensions and operational parameters. The framework presented here accelerates the development of effective strategies toward the scale-up of MECs by furthering the understanding of how electrochemical, hydrodynamic, and microbial ecology parameters change as the reactor dimension is increased. Ultimately, this approach contributes to advancing electrochemical biotechnology toward practical deployment in energy-efficient wastewater treatment systems.

Flow path↗