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DOE OSTI2024

Investigation of precooling unit design options in hydrogen refueling station for heavy-duty fuel-cell electric vehicles

Precooling gaseous hydrogen fuel to a cold temperature before refueling a heavy-duty (HD) hydrogen fuel cell electric vehicle (HFCEV) is essential to avoid overheating the vehicle tank, as well as achieving a high state of charge (SOC). Because a large volume of hydrogen is dispensed during each fill, the need for a shorter fill time amplifies the need to precool each load for refueling a HFCEV. Thus, the design and operation of a precooling unit (PCU), as well as the associated capital and operating costs, plays a pivotal role in any plans for heavy-duty hydrogen refueling stations. Here, in this paper, we present a thermodynamic and technoeconomic analysis of a PCU in a gaseous hydrogen refueling station (HRS) for HD HFCEVs. By employing Argonne National Laboratory's hydrogen station cost optimization and performance evaluation (H2SCOPE) model, the refueling of 50 kg of hydrogen on-board type IV tank at ambient temperatures of 15–45 °C and varying fill rates is simulated. The required degree of precooling temperature to obtain either 100% or the maximum possible SOC is obtained from the simulation. Additionally, the simulation results demonstrate that the average flow rate of hydrogen is approximately 40% lower than the maximum flow rate during a typical fill; which motivates further evaluation of the instantaneous hydrogen mass flow rate profile and suggests the scope of improving precooling unit design. Accordingly, a hybrid strategy of precooling hydrogen has been proposed to address the cooling load by sizing the refrigeration unit for the average flow rate of hydrogen, while supplementing the above average peak hydrogen flow cooling load through thermal buffering. The combined technique enables the downsizing of the original PCU capacity by 25–40% and demonstrates a potential cost reduction of the PCU by approximately 30%, which translates to an installed cost reduction of ∼$125,000 per dispenser.

25 ENERGY STORAGE↗

NASA NTRS1991

A unified viscous theory of lift and drag of 2-D thin airfoils and 3-D thin wings

A unified viscous theory of 2-D thin airfoils and 3-D thin wings is developed with numerical examples. The viscous theory of the load distribution is unique and tends to the classical inviscid result with Kutta condition in the high Reynolds number limit. A new theory of 2-D section induced drag is introduced with specific applications to three cases of interest: (1) constant angle of attack; (2) parabolic camber; and (3) a flapped airfoil. The first case is also extended to a profiled leading edge foil. The well-known drag due to absence of leading edge suction is derived from the viscous theory. It is independent of Reynolds number for zero thickness and varies inversely with the square root of the Reynolds number based on the leading edge radius for profiled sections. The role of turbulence in the section induced drag problem is discussed. A theory of minimum section induced drag is derived and applied. For low Reynolds number the minimum drag load tends to the constant angle of attack solution and for high Reynolds number to an approximation of the parabolic camber solution. The parabolic camber section induced drag is about 4 percent greater than the ideal minimum at high Reynolds number. Two new concepts, the viscous induced drag angle and the viscous induced separation potential are introduced. The separation potential is calculated for three 2-D cases and for a 3-D rectangular wing. The potential is calculated with input from a standard doublet lattice wing code without recourse to any boundary layer calculations. Separation is indicated in regions where it is observed experimentally. The classical induced drag is recovered in the 3-D high Reynolds number limit with an additional contribution that is Reynold number dependent. The 3-D viscous theory of minimum induced drag yields an equation for the optimal spanwise and chordwise load distribution. The design of optimal wing tip planforms and camber distributions is possible with the viscous 3-D wing theory.

Yates, John E.↗

DOE OSTI2021

Advanced absorber heat integration via heat exchange packings

A rate-based model of an absorption column was developed and used to analyze several intercooling strategies utilizing “heat exchange packings.” These packings are capable of removing heat from the column and transferring it to a cooling fluid within the packing. For absorption of CO 2 into aqueous monoethanolamine under industrial conditions, intercooling via heat exchange packings placed along 10–20% of the column could reduce the column height by ~15%. The height of these columns was close to the minimum theoretical value, calculated by numerically optimizing the temperature profile. Effective intercooling could also be achieved by using the cool, rich solvent as the cooling fluid. This reduces the cooling load and facilitates recovery of waste heat. Heat exchange packings could also be used to redistribute heat within the column, reducing the column height with no net cooling load. However, this approach requires larger heat transfer coefficients than have been experimentally observed.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2020

A data-driven model for thermodynamic properties of a steam generator under cycling operation

The varying electricity demand from coal power plants due to the intermittent nature of renewable sources leads to load-follow and on/off operations referred to as cycling. Cycling causes transients of properties such as pressure and temperature within various components of the steam generation system.These transients cause increased damage because of fatigue and creep-fatigue interactions shortening the life of components. An algorithm is developed to identify cycling operations from the gross power data. The data-driven model based on artificial neural networks (ANN) is developed using 10 years data from Coal Creek Station power plant located in North Dakota, USA to estimate properties of the steam generator components during cycling operations. Furthermore, the uniqueness of this model is the ability to predict component properties for the cycling as well as base-load operations and is reported for the first time. The ANN model estimates the component properties, for a given gross power profile and initial conditions, as they vary during cycling operations. As a representative example, the ANN estimates are presented for the superheater outlet pressure, reheater inlet temperature, and flue gas temperature at the air heater inlet. The changes in these variables as a function of the gross power over the time duration are compared with measurements to assess the predictive capability of the model. Mean square errors of 4.49E-04 for superheater outlet pressure, 1.62E-03 for reheater inlet temperature, and 4.14E-04 for flue gas temperature at the air heater inlet were observed.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2026

UV–Vis–NIR Reflectance Spectroscopy and Chemometrics for Monitoring Pu Directly on an Ion Exchange Column

Here, we present a fiber-optic UV–vis–NIR reflectance spectroscopy method for direct, noninvasive monitoring of Pu(IV) in a glass ion exchange column during dynamic loading and elution in a glovebox. A movable probe enables spatially resolved spectral acquisition along the column axis, capturing distinct features associated with Pu(IV) nitrate complexes during loading and free ions during elution. Principal component analysis was applied to extract the dominant spectral variance and resolve relative concentration profiles without requiring precise knowledge of optical penetration depth or species identity. This in situ approach reveals spatial gradients and speciation dynamics in real time, which provides actionable insight into Pu(IV) ion migration, resin saturation, and breakthrough behavior under evolving flow conditions. The method offers a practical, fiber-compatible strategy to monitor glass column–based separations for Pu and other lanthanides or actinides and to characterize metal–resin interactions in flow-through systems.

actinide↗

NASA NTRS1966

Binary fluid amplifier solves stability and load problems

Digital fluid amplifier has load intensity, high stability, and operates at low reynolds numbers. It contains specially designed nozzles to provide uniform exit-velocity profiles and to ensure jets of low turbulence.

Larkin, B. D.↗

NASA NTRS1975

Earliest abort once around time for the first orbital flight test mission

The earliest abort once around (AOA) time for the first orbital flight test (OFT-1) mission is determined. The latest estimates of vehicle weights and propulsion for OFT-1 are used. Trade analyses to indicate variations in AOA time for shuttle subsystem changes (such as orbital maneuvering system (OMS) or reaction control system (RCS) propellant loadings) are included. In addition, the effects of first stage attitude steering as a function of relative velocity for a nominal profile are presented. Data are presented to indicate the effect of designing first stage steering for earliest AOA time and then having engine out at times after the design point.

Kuhn, A. E.↗

NASA NTRS1981

Turbulence characteristics in the annulus-wall boundary layer and wake mixing region of a compressor rotor exit

The flow at the exit of a turbomachinery rotor near the annulus wall is three-dimensional with a varying degree of turbulence and nonisotropic characteristics. The characteristics of the turbulence vary considerably with radial and axial location, blade loading, Reynolds number, free-stream turbulence, and the rotor blade geometry. This paper is concerned with the turbulence properties near the annulus wall region of a moderately loaded compressor blade. The variation of the streamwise, normal, and radial intensities as well as the stresses across the wake, its profile and decay characteristics, were determined with a tri-axial hot-wire probe in the stationary frame of reference. The turbulence characteristics in the annulus-wall region of the rotor exit were found to be highly complex due to the interaction of the blade wake and the annulus wall.

Davino, R.↗

NASA NTRS2001

Design Evaluation Using Finite Element Analysis of Cooled Silicon Nitride Plates for a Turbine Blade Application

Two- and three-dimensional finite element analyses were performed on uncoated and thermal barrier coated (TBC) silicon nitride plates with and without internal cooling by air. Steady-state heat-transfer analyses were done to optimize the size and the geometry of the cooling channels to reduce thermal stresses, and to evaluate the thermal environment experienced by the plate during burner rig testing. The limited experimental data available were used to model the thermal profile exerted by the flame on the plate. Thermal stress analyses were performed to assess the stress response due to thermal loading. Contours for the temperature and the representative stresses for the plates were generated and presented for different cooling hole sizes and shapes. Analysis indicates that the TBC experienced higher stresses, and the temperature gradient was much reduced when the plate was internally cooled by air. The advantages and disadvantages of several cooling channel layouts were evaluated.

Abdul-Aziz, Ali↗

NASA NTRS2005

Rendezvous and Proximity Operations of the Space Shuttle

Space Shuttle rendezous missions presented unique challenges that were not fully recognized when the Shuttle was designed. Rendezvous targets could be passive (i.e., no lights or transponders), and not designed to facilitate Shuttle rendezvous, proximity operations and retrieval. Shuttle reaction control system jet plume impingement on target spacecraft presented induced dynamics, structural loading and contamination concerns. These issues, along with limited forward reaction control system propellant, drove a change from the Gemimi/Apollo coelliptic profile heritage to a stable orbit profile, and the development of new proximity operations techniques. Multiple scientific and on-orbit servicing missions and crew exchange, assembly and replinishment flights to Mir and to the International Space Station drove further profile and piloting technique changes, including new relative navigation sensors and new computer generated piloting cues.

Goodman, John L.↗

NASA NTRS2011

Next-Generation Aura/OMI NO2 and SO2 Products

The measurement of both SO2 and NO2 gases are recognized as an essential component of atmospheric composition missions. We describe current capabilities and limitations of the operational Aura/OMI NO2 and SO2 data that have been used by a large number of researchers. Analyses of the data and validation studies have brought to light a number of areas in which these products can be expanded and improved. Major improvements for new NASA standard (SP) NO2 product include more accurate tropospheric and stratospheric column amounts, along with much improved error estimates and diagnostics. Our approach uses a monthly NO2 climatology based on the NASA Global Modeling Initiative (GMI) chemistry-transport model and takes advantage of OMI data from cloudy scenes to find clean areas where the contribution from the trap NO2 column is relatively small. We then use a new filtering, interpolation and smoothing techniques for separating the stratospheric and tropospheric components of NO2, minimizing the influence of a priori information. The new algorithm greatly improves the structure of stratospheric features relative to the original SP. For the next-generation OMI SO2 product we plan to implement operationally the offline iterative spectral fitting (ISF) algorithm and re-process the OMI Level-2 SO2 dataset using a priori SO2 and aerosol profiles, clouds, and surface reflectivity appropriate for observation conditions. This will improve the ability to detect and quantify weak tropospheric SO2 loadings. The new algorithm is validated using aircraft in-situ data during field campaigns in China (2005 and 2008) and in Maryland (Frostburg, 2010 and DISCOVER-AQ in July 2011). The height of the SO2 plumes will also be estimated for high SO2 loading cases (e.g., volcanic eruptions). The same SO2 algorithm will be applied to the data from OMPS sensor to be launched on NPP satellite later this year. The next-generation NO2 and SO2 products will provide critical information (e.g., averaging kernels) for evaluation of chemistry-transport models, for data assimilation, and to impose top-down constraints on the SO2 and NO2 emission sources.

Krotkov, Nickolay↗

DOE OSTI2020

Nonlinear power flow control for networked AC/DC microgrids

A method for designing feedforward and feedback controllers for integration of stochastic sources and loads into a nonlinear networked AC/DC microgrid system is provided. A reduced order model for general networked AC/DC microgrid systems is suitable for HSSPFC control design. A simple feedforward steady state solution is utilized for the feedforward controls block. Feedback control laws are provided for the energy storage systems. A HSSPFC controller design is implemented that incorporates energy storage systems that provides static and dynamic stability conditions for both the DC random stochastic input side and the AC random stochastic load side. Transient performance was investigated for the feedforward/feedback control case. Numerical simulations were performed and provided power and energy storage profile requirements for the networked AC/DC microgrid system overall performance. The HSSPFC design can be implemented in the Matlab/Simulink environment that is compatible with real time simulation/controllers.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

Advancing Multi-Hazard Risk and Safety Considerations for Aging Nuclear Facilities

While probabilistic risk assessment (PRA) of nuclear facilities is expected to include internal and external hazards for a risk-informed and performance-based design, the current state of practice treats each hazard independently. However, such an independent treatment of hazards may not account for the correlations between different hazards and their response of and damage to the structures, systems, and components (SSCs) in a plant resulting in underestimating the overall risk. This project proposes to advance the multi-hazard PRA of nuclear facilities to more adequately evaluate concurrent hazards and contribute to an increased safety of nuclear plants. A framework for multi-hazard PRA will be developed by identifying concurrent hazard events (both internal and external) and event sequences that include interdependencies through the response of SSCs. An example application of the multi-hazard PRA framework will be demonstrated by considering a generic pressurized water reactor (PWR) subjected to seismic and internal flooding hazards. Computational models for the response of components will be developed to generated multi-hazard fragility surfaces under seismic and flooding loads. A PRA model consisting of event and fault trees will also be developed to quantify the multi-hazard risk profile and compare it with the independent hazard risk profile. Overall, by advancing the multi-hazard PRA of nuclear facilities, this project enhances nuclear safety and reduces costs by mitigating unforeseen consequences caused by correlations between concurrent hazards.

97 - MATHEMATICS AND COMPUTING↗

NASA NTRS2010

Low-Friction, Low-Profile, High-Moment Two-Axis Joint

The two-axis joint is a mechanical device that provides two-degrees-of-freedom motion between connected components. A compact, moment-resistant, two-axis joint is used to connect an electromechanical actuator to its driven structural members. Due to the requirements of the overall mechanism, the joint has a low profile to fit within the allowable space, low friction, and high moment-reacting capability. The mechanical arrangement of this joint can withstand high moments when loads are applied. These features allow the joint to be used in tight spaces where a high load capability is required, as well as in applications where penetrating the mounting surface is not an option or where surface mounting is required. The joint consists of one base, one clevis, one cap, two needle bearings, and a circular shim. The base of the joint is the housing (the base and the cap together), and is connected to the grounding structure via fasteners and a bolt pattern. Captive within the housing, between the base and the cap, are the rotating clevis and the needle bearings. The clevis is attached to the mechanical system (linear actuator) via a pin. This pin, and the rotational movement of the clevis with respect to the housing, provides two rotational degrees of freedom. The larger diameter flange of the clevis is sandwiched between a pair of needle bearings, one on each side of the flange. During the assembly of the two-axis joint, the circular shims are used to adjust the amount of preload that is applied to the needle bearings. The above arrangement enables the joint to handle high moments with minimal friction. To achieve the high-moment capability within a low-profile joint, the use of depth of engagement (like that of a conventional rotating shaft) to react moment is replaced with planar engagement parallel to the mounting surface. The needle bearings with the clevis flange provide the surface area to react the clevis loads/moments into the joint housing while providing minimal friction during rotation. The diameter of the flange and the bearings can be increased to react higher loads and still maintain a compact surface mounting capability. This type of joint can be used in a wide variety of mechanisms and mechanical systems. It is especially effective where precise, smooth, continuous motion is required. For example, the joint can be used at the end of a linear actuator that is required to extend and rotate simultaneously. The current design application is for use in a spacecraft docking-system capture mechanism. Other applications might include industrial robotic or assembly line apparatuses, positioning systems, or in the motion-based simulator industry that employs complex, multi-axis manipulators for various types of motions.

Lewis, James L.↗

NASA NTRS2020

Investigation of Atmospheric Boundary-Layer Effects on Launch-Vehicle Ground Wind Loads

A launch vehicle ground-wind-loads program is underway at the NASA Langley Transonic Dynamics Tunnel. The objectives are to quantify key aerodynamic and structural characteristics that impact the occurrence of large wind-induced oscillations of a launch vehicle when exposed to ground winds prior to launch. Of particular interest is the dynamic response of a launch vehicle when a von Kármán vortex street forms in the wake of the vehicle resulting in quasiperiodic lift and drag forces. Vehicle response to these quasiperiodic forces can become quite large when the frequency of vortex shedding nears that of a lowly-damped structural mode thereby exciting a resonant response. Wind approaching the vehicle can be characterized by a varying speed with height and turbulence content. The combination of both the varying speed and turbulence content is referred to herein as the atmospheric boundary-layer. The importance of the atmospheric boundary-layer upon launch vehicle wind-induced oscillation response has long been questioned, and its effects are not well understood. Although there are several facilities around the world dedicated to replicating atmospheric boundary layers, the development of such a boundary layer in a wind tunnel capable of producing flight-representative Reynolds numbers for aeroelastically-scaled launch vehicle models has only recently been accomplished. The NASA Langley Transonic Dynamics Tunnel is capable of simulating flight-representative Reynolds numbers of launch vehicles on the pad and is uniquely capable of replicating many fluid-structure scaling parameters typical of aeroelastic tests. Recent test efforts successfully developed representative atmospheric boundary-layers for three launch sites in the Transonic Dynamics Tunnel, thereby allowing all known aerodynamic and fluid-structure coupling parameters to be simultaneously simulated for those sites. Dynamic aeroelastically-scaled models representative of typical large launch vehicles were constructed for testing. Aeroelastic scaling includes matching geometry, mode shapes, reduced frequencies, damping, running mass ratios, and running stiffness ratios. The models were tested in smooth uniform flow and then immersed in the atmospheric boundary-layer for comparison of these effects. Dynamic data were acquired measuring unsteady pressure, acceleration, and base bending moment. It was discovered that peak dynamic loads resulting from resonant wind-induced oscillation response are similar when acquired in either smooth uniform flow or an atmospheric boundary-layer. This indicates that resonant lock-in events are minimally impacted by representative turbulence and/or wind profile. Alternately, nonresonant wind-induced oscillation response events are stronger when acquired in an atmospheric boundary-layer. This indicates that a lowly-damped structural response will increase when exposed to an increased magnitude of random excitation, which is consistent with historical comparisons. Loads created by the resonant response events were substantially stronger than those from the nonresonant response events. Therefore, if testing is done to simply identify worst-case conditions and load magnitude, then smooth uniform flow is likely an adequate test technique. However, if nonresonant response loads are of primary interest, then atmospheric boundary-layer simulation is required.

Thomas G Ivanco↗

DOE OSTI2024

Quantifying Variability and Controls of Riverine Dissolved Organic Carbon Exported to Arctic Coastal Margins of North America (Final Report)

This project involved implementation and application of a coupled permafrost hydrology and dissolved organic carbon process models to investigate how spatial and seasonal variations in terrestrial hydrology and soil freeze/thaw dynamics influence the mobilization, loading, and export of organic carbon to the stream network for selected arctic basins across northern Alaska and northwest Canada. The model simulations were constrained by detailed observations of in- stream chemistry, soil active layer profile moisture and temperature dynamics, streamflow, soil carbon inventories and satellite microwave remote sensing based assessments of surface soil freeze-thaw dynamics. We developed and applied the numerical modeling and data analysis, incorporating observed data for calibration and validation, in order to investigate the terrestrial hydrology, permafrost dynamics, and associated DOC production and loading to rivers across a region encompassing watersheds draining to the coast. The project produced six publications and three datasets archived in public repositories.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Freestream turbulence effects on unsteady wind turbine loads and wakes: An IDDES study

We investigate numerically the effects of freestream turbulence on the unsteady aerodynamics and wakes of the National Renewable Energy Laboratory Phase VI wind turbine rotor for increasing wind speed. Turbulence is modeled using the Improved Delayed Detached-Eddy Simulation (IDDES) method. As a first step, a detailed mesh resolution study is conducted with the decaying freestream turbulence model at turbulence intensity of 0.5%. Our blade-resolved IDDES simulations show that grid-independent average torque and thrust results can be achieved with relatively coarse meshes, whereas dramatically higher mesh resolution is required for grid-independent results for power spectral densities of thrust force, especially in the deep-stall regime. Comparing the loads with the Shear-Stress Transport model demonstrates the superiority of IDDES in predicting massively separated flows. The aerodynamic performance and wake predictions with the decaying freestream turbulence model are compared with the synthetic freestream turbulence model. Both models predict nearly the same loads, spectral energy content, and wake characteristics. The properties of both the near- and far-wake regions are then examined. Furthermore, we show that separated boundary layers accelerate turbulent mixing and entrainment of the external flow, which results in faster wake recovery. The effect of increasing turbulence intensity to 6% is investigated using the synthetic freestream turbulence model. In contrast with the fully attached boundary layer, higher freestream turbulence in deep stall does not significantly affect the loads and vortex-shedding characteristics. However, the turbulent mixing in the wake is enhanced, which further hastens the recovery of the self-similar velocity profile. In general, increasing the wind speed at high turbulence intensity shifts the recovery farther upstream and increases the wake width.

17 WIND ENERGY↗

DOE OSTI2022

Steady state thermo-mechanics and material property definition framework for analyzing DCLL blanket in the fusion nuclear science facility

In this work, a thermo-mechanics model that relies on creating the material property definition framework (MPDF) and multiphysics coupling of the heat transfer and the solid mechanics modules is developed to determine the structural integrity of the recently designed dual cooled lead lithium (DCLL) inboard blanket (IB) for the Fusion Nuclear Science Facility under steady state loads. The MPDF is called to supply fusion relevant neutron irradiation and temperature induced changes in material properties during multiphysics finite element runs, and PbLi temperature profiles are used to approximate Magnetohydrodynamics effect and the nuclear volumetric heating on the PbLi. Neutron irradiation and temperature induced reduction of the yield and ultimate strengths of F82H steel at the first wall (FW) are quantified for one year. A blanket in an assembly with gaps between blanket sectors and another blanket in an assembly with no gaps between blanket sectors, both exposed to radiation damage that lasted for one year are analyzed. Analysis using the elastic ITER structural design criteria for in-vessel components (ITER SDC-IC) design rules and a linear isotropic-hardening-type elastoplastic material model are used where most appropriate. The IB blanket with gaps between blanket sectors will withstand the steady state combined thermal and coolant loads for one year operational period but will fail if no gaps are allowed between blanket sectors. It is recommended that a gap of about 7.62 mm should be provided between IB blanket sectors during assembly which would close up during service, stop neutron streaming, reduce stresses and reduce bending of the FW into the scrape-off layer.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗