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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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At least 991 records · Page 55
All sourcesNASA NTRSDOE OSTI
DOE OSTI2012

Solid Oxide Fuel Cell Systems PVL Line

In July 2010, Stark State College (SSC), received Grant DE-EE0003229 from the U.S. Department of Energy (DOE), Golden Field Office, for the development of the electrical and control systems, and mechanical commissioning of a unique 20kW scale high-pressure, high temperature, natural gas fueled Stack Block Test System (SBTS). SSC worked closely with subcontractor, Rolls-Royce Fuel Cell Systems (US) Inc. (RRFCS) over a 13 month period to successfully complete the project activities. This system will be utilized by RRFCS for pre-commercial technology development and training of SSC student interns. In the longer term, when RRFCS is producing commercial products, SSC will utilize the equipment for workforce training. In addition to DOE Hydrogen, Fuel Cells, and Infrastructure Technologies program funding, RRFCS internal funds, funds from the state of Ohio, and funding from the DOE Solid State Energy Conversion Alliance (SECA) program have been utilized to design, develop and commission this equipment. Construction of the SBTS (mechanical components) was performed under a Grant from the State of Ohio through Ohio's Third Frontier program (Grant TECH 08-053). This Ohio program supported development of a system that uses natural gas as a fuel. Funding was provided under the Department of Energy (DOE) Solid-state Energy Conversion Alliance (SECA) program for modifications required to test on coal synthesis gas. The subject DOE program provided funding for the electrical build, control system development and mechanical commissioning. Performance testing, which includes electrical commissioning, was subsequently performed under the DOE SECA program. Rolls-Royce Fuel Cell Systems is developing a megawatt-scale solid oxide fuel cell (SOFC) stationary power generation system. This system, based on RRFCS proprietary technology, is fueled with natural gas, and operates at elevated pressure. A critical success factor for development of the full scale system is the capability to test fuel cell components at a scale and under conditions that can be accurately extrapolated to full system performance. This requires specially designed equipment that replicates the pressure (up to 6.5 bara), temperature (about 910 C), anode and cathode gas compositions, flows and power generation density of the full scale design. The SBTS fuel cell anode gas is produced through the reaction of pipeline natural gas with a mixture of steam, CO2, and O2 in a catalytic partial oxidation (CPOX) reactor. Production of the fuel cell anode gas in this manner provides the capability to test a fuel cell with varying anode gas compositions ranging from traditional reformed natural gas to a coal-syngas surrogate fuel. Stark State College and RRFCS have a history of collaboration. This is based upon SSCAs commitment to provide students with skills for advanced energy industries, and RRFCS need for a workforce that is skilled in high temperature fuel cell development and testing. A key to this approach is the access of students to unique SOFC test and evaluation equipment. This equipment is designed and developed by RRFCS, with the participation of SSC interns. In the near-term, the equipment will be used by RRFCS for technology development. When this stage is completed, and RRFCS has moved to commercial products, SSC will utilize this equipment for workforce training. The RRFCS fuel cell design is based upon a unique ceramic substrate architecture in which a porous, flat substrate (tube) provides the support structure for a network of solid oxide fuel cells that are electrically connected in series. These tubes are grouped into a {approx}350-tube repeat configuration, called a stack/block. Stack/block testing, performed at system conditions, provides data that can be confidently scaled to full scale performance. This is the basis for the specially designed and developed test equipment that is required for advancing and accelerating the RRFCS SOFC power system development program. All contract DE-EE0003229 objectives were achieved and deliverables completed during the period from March 1, 2010 through March 31, 2011. As a result of program completion, the Stack Block Test System was ready to support installation and electrical operation of a RRFCS solid oxide fuel cell (SOFC) stack block in the second quarter of 2011.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

An integrated integral projection model ( IPM 2 ) to disentangle size‐structured harvest and natural mortality

Abstract Body size is one of the most important traits governing individual‐level demographic rates and modulating population‐level processes. Multiple size‐dependent demographic rates can simultaneously change population structure, so distinguishing their individual contributions to overall population dynamics remains a challenge. Disentangling size‐dependent harvest rates from other demographic rates is critical for assessing the impact of removal on populations of invasive species. Inference about invasive populations can be difficult, however, as observations are often collected opportunistically as part of removal programs, rather than experimentally designed. Yet accurate inference is essential for understanding the feasibility of population suppression and optimising management decisions. We develop an integrated integral projection model (IPM 2 ) that leverages the strengths of the integrated population model and integral projection model to enable inference about complex, size‐structured demographic rates from imperfect observations. We apply the IPM 2 in the context of invasive European green crab ( Carcinus maenas ), a species for which individual body size strongly regulates both the observation‐generating process and latent, population dynamics. The IPM 2 facilitates the distinct estimation of green crab size‐structured harvest and natural mortality rates, parameters for which no explicit data is collected and that are unidentifiable in component datasets of the integrated population model. The model represents how the green crab population changes over time, providing the first estimates of size‐structured abundance of this high‐priority species. By forecasting the stable size distribution and equilibrium population size under varying removal efforts, we demonstrate that extremely high levels of removal effort can reduce the equilibrium green crab population size. Yet these high mortality rates also shift the stable size distribution and increase the equilibrium abundance of smaller crabs, since size‐selective removal alters intraspecific interactions. The ecological outcome of this shift in size structure will be variable, as green crab size modulates only some of its interactions with other species. These results highlight the value of the IPM 2 framework for inferring complex population dynamics with information needs that outpace information in individual observational datasets, providing a path forward for accurate assessment of conservation programs.

Keller, Abigail G. [Department of Environment Scie↗
DOE OSTI2011

Three-Phase Solid Oxide Fuel Cell Anode Microstructure Realization Using Two-Point Correlation Functions

A Monte Carlo methodology is developed as a means for three-dimensional (3D) reconstruction of the microstructure of a three-phase anode used in solid oxide fuel cells, based on two-point statistical functions. The salient feature of the presented reconstruction methodology is the ability to realize the 3D microstructure from its 2D SEM image for a three-phase medium extendable to n-phase media. In the realization procedure, different phases of the heterogeneous medium are represented by different cells which are allowed to grow. The growth of cells, however, are controlled via several optimization parameters related to rotation, shrinkage, translation, distribution and growth rates of the cells. Indeed, the proposed realization algorithm can be categorized as a member of dynamic programming methods and is designed so comprehensive that can realize any desired microstructure. To be more specific, at first the initial 2D image is successfully reconstructed and then the final optimization parameters are used as the initial values for the initiation of the 3D reconstruction algorithm. This paper presents a novel hybrid stochastic methodology based on the colony and kinetic algorithm for the simulation of the virtual microstructure. The simulation procedure involves repeated realizations where each realization in turn consists of nucleation and growth of cells. For each of the subsequent realizations, the controlling parameters get updated by minimization of an objective function at the end of the preceding realization. Here, the objective function is defined based on the two-point correlation functions from the simulated and real microstructures. The kinetic growth algorithm is established on the cellular automata approach which facilitates the simulation procedure. Comparison of the two-point correlation functions from different sections of the final 3D reconstructed microstructure with the initial real microstructure shows a satisfactory agreement which confirms the proposed methodology.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Front-End Engineering Design for Piperazine with the Advanced Stripper

This Department of Energy (DOE) funded project was executed with the goal of preparing a Front-End Engineering Design (FEED) for the capture and compression of 90% of the CO2 that would normally be emitted from an existing natural gas combined cycle (NGCC) plant. The FEED focused on the application of the piperazine advanced stripper (PZAS) process at Mustang Station of the Golden Spread Electric Cooperative (GSEC), which consists of two gas turbines with common heat recovery steam generator (HRSG). The University of Texas at Austin (UT) served as the prime contractor, and subcontracted AECOM Technical Services and Trimeric Corporation to support FEED development. This project team has worked together to advance PZAS for more than a decade. ExxonMobil, Chevron, and Total provided project co-funding. The objectives of this work included: 1. To advance engineering design such that a comprehensive estimate for the total installed cost of a full-scale PZAS CO2 Capture Plant with CO2 compression can be developed on an existing NGCC power plant. a. These detailed costs can also be used to qualify PZAS and other related second generation (2G) amine scrubbing processes for use on cogeneration facilities in refineries and chemical plants that use gas turbines with HRSGs to produce steam. b. These detailed costs will help qualify 2G amine scrubbing for use on NGCC power plants and establish a more accurate baseline cost to be used as a target by other capture technologies. 2. To provide cost details to be used in the economic optimization of the process features of PZAS and other 2G amine scrubbing processes. 3. To provide DOE with a more detailed understanding of carbon capture costs in a commercial application, enabling DOE to better design its R&D program to improve the economics for carbon capture. 4. To provide the host site and cost share partners with the information necessary to determine whether a commercial project to capture and use CO2 for enhanced oil recovery (EOR) or for sequestration can be justified (when accounting for the 45Q tax credit). A key component of the FEED is the estimated total installed cost, which provides a basis for the likely capital investment necessary to implement the PZAS carbon capture process at this location and scale. In combination with the included economic analysis, which accounts for potential revenue from the produced CO2, potential avenues to profitability are explored. The major findings of the FEED are as follows: The Mustang Station PZAS CO2 Capture Plant estimated total project cost of $698 MM of which $384 MM was direct costs. The annual operating costs were $32.6 MM. The total investment for a PZAS facility at Mustang Station is $725 MM. This estimate includes owner’s cost of $25 million and a contingency of $110 MM. • The study estimated the CO2 capture plant at Mustang Station would generate CO2 at $110/tonne for EOR, assuming a 12% IRR (internal rate of return) and an 85% capacity factor. For CO2 storage, the same case would achieve a 12% IRR at about $114/tonne. At a capacity factor of 52%, the storage and EOR cases would break even when carbon is priced ~$150/tonne. The economic analysis determined that the capacity factor and utility pricing, among other variable factors, had a significant effect on the economics and will need additional studied. • The energy penalty of the PZAS plant would be about 46 MW in connected power and 35 MW in operating load. The natural gas requirement (for the Gas Boiler package) would be about 354 MMBTU/hr. • The FEED revealed no major risks in process maturity. However, some areas were outlined for further engineering during detailed design, which included the Gas Boiler system, general arrangement and site layout, air coolers, schedule development, and optimization of the process for higher CO2 removal. • If PZAS were to be implemented at another host site, additional opportunities for cost reduction for would include cost reduction through use of cooling water and steam extraction.

03 NATURAL GAS↗
DOE OSTI2024

Current TRISO Fuel Performance Capabilities and Considerations for Expanded Operational Envelopes

Current TRISO Fuel Performance Capabilities and Considerations for Expanded Operational Envelopes. US-DOE TRISO Fuel Development, AGR Fuel Design and Performance Requirements, AGR Program Fuel Irradiations, UCO Fuel Performance Evaluation Results, Performance Limiting Phenomena, Coated-Particle-Fueled Reactor Concepts and Fuel Designs, Expanded Fuel Performance Envelope, and Accelerated Fuel Qualification.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Versatile Test Reactor Conceptual Core Design

The VTR is a 300-MW(thermal) sodium-cooled fast reactor (SFR) designed for the specific purpose of delivering unique testing capabilities to enable the advancement of all reactor technologies. With its flux level, irradiation volume, and operational flexibility, the VTR will enable accelerated testing of materials, fuels, and various components needing irradiation testing. Proven SFR technologies and design approaches have been leveraged in designing the VTR core, ensuring the highest possible readiness level. This resulted in the VTR using ternary metallic fuel and delivering fast flux levels in excess of 4 x 10 15 n/cm 2 ∙ s over large useful volumes, corresponding to about 60 dpa/year in steel. As part of the design efforts, the VTR core performance has been determined for a representative configuration, ensuring that the reactivity control systems offer sufficient shutdown margins, that the core can be safely cooled in all situations, and that reactivity feedback coefficients are conducive to a favorable safety behavior. Furthermore, the incorporation of features such as fuel assembly storage in the shield region supports the flexible and reliable operation of the VTR. Additional design work has been ongoing as well. This includes thorough shielding performance evaluations to ensure safe operation of the VTR, verification and validation of the design tools used to achieve compliance with Nuclear Quality Assurance (NQA-1) requirements, early assessment of the impact of irradiation experiments on the core performance envelope and associated margins, and in-depth uncertainty quantification efforts to quantify the anticipated range of performance characteristics. An experimental program supporting the VTR core design has been set up, with the current focus being on thermal-hydraulic experiments. The purpose of this experimental program is to obtain confirmatory measurements to serve directly as part of the core design basis or as part of the validation cases supporting the simulation tools used.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Engineered Barrier System R&D and International Collaborations – LANL (FY20): Spent Fuel and Waste Disposition

The United States Department of Energy’s Spent Fuel and Waste Disposition (SFWD) program is investigating the design and safety function of generic nuclear geologic repositories in a variety of geologic settings (salt, argillite, and crystalline rock). Different configurations and loadings of spent nuclear fuel and waste within disposal canisters are also being investigated, some of which have the potential to generate repository temperatures higher than previously considered (i.e., temperatures >100ºC) by foreign and domestic concepts. This report expands on engineered barrier material stability in a high temperature crystalline rock repository through high temperature hydrothermal experiments. Experiments were designed to develop engineered barrier system (EBS) concepts in a hightemperature crystalline environment in 1) bentonite-Grimsel Granodiorite interactions, 2) bentonite-cement reactions, and 3) interaction between waste canister materials and bentonite. Experiment results are applied to understanding long-term repository performance in terms of radionuclide isolation. One hydrothermal experiment was completed in the rocking autoclaves at LANL in FY-20: IEBS-6 (Grimsel Granodiorite + Wyoming bentonite + cured ordinary Portland cement + Grimsel Granodiorite synthetic groundwater, 250ºC/150 bar, 8 weeks). Several other experiments were planned but were delayed due to the COVID-19 pause in laboratory work. In addition, some characterization of the reaction products of experiments conducted in FY-20 was prevented by COVID-19. Mineral phase chemistry was not measured via electron microprobe analyses for IEBS-6. Quantitative X-ray diffraction results from IEBS-6 and HBT-1 were not completed. The missing analyses and discussion of the results will be included in next year’s report. New characterization that was completed includes scanning electron microscopy of reaction products from IEBS-6, quantitative X-ray diffraction results are presented from IEBS-1 through IBES-5, preliminary scanning electron microscope images and chemical analyses for IEBS-6, X-ray diffraction of the clay fraction from all experiments, measurement/imaging of mineral growth on the surface of steel coupons. Major observations pertaining to bentonite stability in a Grimsel Granodiorite environment include the stability of Na-montmorillonite at 250°C, the formation of trace CSH phases, and the formation of bentonite colloids on experiment cooling. The addition of a cured chip of Portland cement to the bentonite-Grimsel system results in slightly higher pH values and the formation of diverse secondary mineral phases that were not observed in the previous experiments (e.g., analcime, garronite, CSH phases). The new characterization efforts related to the interaction of stainless-steel coupons and bentonite clay focused on thickness and mineralogy of phases that formed at the steel surface. In Wyoming bentonite + Grimsel Granodiorite systems, newly formed minerals at the bentonitesteel coupon interface included alteration of the outermost steel edge to Fe,Cr-oxide phases, followed by Fe-rich phyllosilicates (Fe-saponite, chlorite) and interbedded Fe,Cr,Ni-sulfide phases (pentlandite). Hydrothermal experiments were completed to assess uranium-carbonate complexation at conditions relevant to high-temperature disposal. Autoclave solubility experiments were conducted at 150 to 250ºC with a range of carbonate and uranium concentrations. The experiment results were characterized via situ UV-Visible spectroscopy and synchrotron-based in situ XAS techniques. Results show a significant decrease in the stability of uranyl-carbonate complexes at temperatures above 100ºC along with the precipitation of uranium oxides. Further, at T > 200ºC, results show that uranyl-hydroxyl complexes control solubility of uranium instead of the previously predicted uranyl-carbonate species. These results are significant for understanding the mobility of uranium in the EBS, which will likely contain carbonate-rich fluids. International research efforts focused on three main areas: 1) participation in international conferences, 2) building collaborations with foreign repository programs, and 3) the initiation of an experimental program to complement the full-scale HotBENT test at the Grimsel test site. This experiment included Wyoming bentonite + low carbon steel + Grimsel Granodiorite synthetic groundwater and was run at the planned maximum temperature of the HotBENT test (200°C). Complete characterization of reaction products was hindered by disruptions to laboratory work but will be reported in the next FY. The experimental results obtained in FY-20 continue to document the wide-ranging effects of bulk composition and pressure-temperature conditions in the mineralogical and geochemical evolution of a high-temperature repository environment. Concepts developed will be used to inform models of long-term material stability in a generic crystalline rock-hosted repository.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Coupled Calculations of the NuScale FIV Tests – Pre-test Simulations and Sensitivity Analysis

The NEAMS program aims to develop an integrated multi-physics simulation capability “pellet-to-plant” for the design and analysis of future generations of nuclear power plants. In particular, the Reactor Product Line code suite's multi-resolution hierarchy is being designed to ultimately span the full range of length and time scales present in relevant reactor design and safety analyses, as well as scale from desktop to petaflop computing platforms. Flow-induced vibration (FIV) is widespread problem in energy systems because they rely on fluid movement for energy conversion. Vibrating structures may be damaged as fatigue or wear occurs. Given the importance of reliable components in the nuclear industry, flow-induced vibration has long been a major concern in safety and operation of nuclear reactors. In particular, nuclear fuel rods and steam generators have been known to suffer from flow-induced vibration and related failures. Advanced reactors, such as integral Pressurized Water Reactors (PWRs) considered for Small Modular Reactors (SMR), often rely on innovative component designs to meet cost and safety targets. One component that is the subject of advanced designs is the steam generator, some designs of which forego the usual shell-and-tube architecture in order to fit within the primary vessel. A significant amount of data exists on flow-induced vibration in shell-and-tube heat exchangers, and heuristic methods are available to predict FIV based on a set of given assumptions. In contrast, advanced designs have far less data available. Advanced modeling and simulation based on coupled structural and fluid simulations have the potential to predict flow-induced vibration in a variety of designs, reducing the need for expensive experimental programs, especially at the conceptual design stage. Over the past several years, the Reactor Product Line has developed a FIV capability in SHARP. SHARP contains high-fidelity single-physics codes Diablo for structural mechanics and Nek5000 for fluid mechanics calculations. Both codes are state-of-the-art, highly scalable tools that have been extensively validated. In previous reports we have discussed the implementation and validation of an FIV capability for helical steam generators and fuel assemblies. In this report we discuss one-way coupled calculations performed with Nek5000 and Diablo for the NuScale FIV tests. In the turbulent fretting regime one-way coupling is judged to be sufficient because the pressure loads do not cause substantial displacements. It is also the most common source of vibration in helical steam generators per the low flows expected in integral PWRs. The simulations precede the tests, as experimental data was not available at the delivery of this report. Several assumptions had to be made on the support-tube interaction and multiple tests and sensitivity analysis have been performed. Additional work remains to be done and it is discussed in the future work section.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2013

Evaluating the performance of two neutron spectrum unfolding codes based on iterative procedures and artificial neural networks

In this work the performance of two neutron spectrum unfolding codes based on iterative procedures and artificial neural networks is evaluated. The first one code based on traditional iterative procedures and called Neutron spectrometry and dosimetry from the Universidad Autonoma de Zacatecas (NSDUAZ) use the SPUNIT iterative algorithm and was designed to unfold neutron spectrum and calculate 15 dosimetric quantities and 7 IAEA survey meters. The main feature of this code is the automated selection of the initial guess spectrum trough a compendium of neutron spectrum compiled by the IAEA. The second one code known as Neutron spectrometry and dosimetry with artificial neural networks (NDSann) is a code designed using neural nets technology. The artificial intelligence approach of neural net does not solve mathematical equations. By using the knowledge stored at synaptic weights on a neural net properly trained, the code is capable to unfold neutron spectrum and to simultaneously calculate 15 dosimetric quantities, needing as entrance data, only the rate counts measured with a Bonner spheres system. Similarities of both NSDUAZ and NSDann codes are: they follow the same easy and intuitive user's philosophy and were designed in a graphical interface under the LabVIEW programming environment. Both codes unfold the neutron spectrum expressed in 60 energy bins, calculate 15 dosimetric quantities and generate a full report in HTML format. Differences of these codes are: NSDUAZ code was designed using classical iterative approaches and needs an initial guess spectrum in order to initiate the iterative procedure. In NSDUAZ, a programming routine was designed to calculate 7 IAEA instrument survey meters using the fluence-dose conversion coefficients. NSDann code use artificial neural networks for solving the ill-conditioned equation system of neutron spectrometry problem through synaptic weights of a properly trained neural network. Contrary to iterative procedures, in neural net approach it is possible to reduce the rate counts used to unfold the neutron spectrum. To evaluate these codes a computer tool called Neutron Spectrometry and dosimetry computer tool was designed. The results obtained with this package are showed. The codes here mentioned are freely available upon request to the authors.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

The Future of Building Science Education with the U.S. Department of Energy Solar Decathlon: Preprint

Experience the future of Building Science Education with the U.S. Department of Energy Solar Decathlon, from community-focused designs to real-life innovative zero energy buildings constructed by students. In this paper, we will introduce the Solar Decathlon programs and a reimagined Building Science Education curriculum that is transforming education to inspire future building design professionals and bring sustainable, equitable design and construction strategies to the real world. The Solar Decathlon is a collegiate-level building design competition that challenges students in 10 Contests, from embodied environmental impact to affordability and resilience. We will cover the structure of the competition and its two Challenges - the Build Challenge and the Design Challenge - as well as additional programs that impact all aspects of the buildings industry. These programs include the Solar Decathlon Building Science Education course, a free online video series that provides students and working professionals with building science fundamentals; the Design Partners Program, which connects innovative student design teams and local building owners seeking low-risk, low-cost opportunities to incorporate sustainable design alternatives into their building portfolio; and Solar Decathlon Pro, a program piloted in 2021 that brings Solar Decathlon resources to design professionals. The Solar Decathlon's effective approach to bringing real-world solutions to building science empowers future professionals to do impactful work.

buildings↗
DOE OSTI2013

Materials and Modules for Low Cost, High Performance Fuel Cell Humidifiers (Final Report)

Over the past 20 years, great technical progress has been made in improving power density and durability of fuel cell stacks. Yet, operating durably at high performance levels under very dry conditions, e.g., < 20% RH at 80 °C or above, remains beyond even the best fuel cell membrane electrode assemblies. Thus, today it is essential to humidify the gases supplied to the fuel cell inlets. In this work, we have produced a new, inexpensive, composite membrane capable of very high water vapor transport and low air cross-over. The composite structure consists of a very thin ionomer layer (e.g., < 5 μm) sandwiched between two microporous polymer layers. The thin ionomer layer facilitates the rapid water transport and provides an impermeable layer to prevent gas cross-over. Such an approach reduces cost, but maintains performance. The microporous layer protects the thin ionomer layer from mechanical damage during handling; confers strength to the thin layer allowing it to be more durable during use; and allows it to withstand higher automotive pressures and temperatures. The composite structure will therefore allow lower total cost while still meeting automotive humidifier water transport and durability targets. Because the transport rates of these new materials are so high, existing planar membrane humidifier module designs available at the start of the program were incapable of efficiently utilizing the high rates. Therefore, the assembled team designed, tested and demonstrated an innovative, low-cost humidifier module with customized channel geometries that can take advantage of the high the water transport rates. Program Results: The objectives of the program have been fully met. The optimized membrane produced in the program has very high transport rates, nearly twice that of the closest competitive option, a homogeneous perfluorosulfonic acid (PFSA) membrane. Furthermore, the composite structure imparts significant durability advantages, allowing the membrane to remain gas impermeable during 20,000 relative humidity (RH) cycles, unlike the closest competitive options that fail very rapidly. It does suffer from a loss of performance with time at temperature because of inherent properties of the PFSA polymer, but this degradation is manageable through relatively simple system design changes. The final membrane of this program has been produced on manufacturing level equipment in a roll to roll form in the scale of hundreds of square meters. The process is readily scalable to automotive level volumes to allow production of a low-cost membrane required for this application. A full scale automotive air-to-air humidifier module has been designed, tested and built. The final module meets the design specifications required for automotive fuel cell use, and exceeds all the DOE 2017 targets for a cathode humidification module as determined in independent testing at Ford Motor Company. It has a small volume, less than 5 liters; a high water transfer rate, significantly greater than 5 g/s at the DOE specified conditions; acceptably low pressure drop; and is projected to maintain these properties over 5000 hours. Additionally, high volume cost projections suggest that the module can be produced for less than $100 per unit in a scale of 500,000 units per year.

08 HYDROGEN↗
DOE OSTI2015

On the Design, Development, and Analysis of Optimized Matrix-Vector Multiplication Routines for Coprocessors

The manycore paradigm shift, and the resulting change in modern computer architectures, has made the development of optimal numerical routines extremely challenging. In this work, we target the development of numerical algorithms and implementations for Xeon Phi coprocessor architecture designs. In particular, we examine and optimize the general and symmetric matrix-vector multiplication routines (gemv/symv), which are some of the most heavily used linear algebra kernels in many important engineering and physics applications. We describe a successful approach on how to address the challenges for this problem, starting with our algorithm design, performance analysis and programing model and moving to kernel optimization. Our goal, by targeting low-level and easy to understand fundamental kernels, is to develop new optimization strategies that can be effective elsewhere for use on manycore coprocessors, and to show significant performance improvements compared to existing state-of-the-art implementations. Therefore, in addition to the new optimization strategies, analysis, and optimal performance results, we finally present the significance of using these routines/strategies to accelerate higher-level numerical algorithms for the eigenvalue problem (EVP) and the singular value decomposition (SVD) that by themselves are foundational for many important applications.

Kabir, Khairul↗
DOE OSTI2019

A generalized superstructure-based framework for process synthesis

We propose a general framework for the formulation of superstructure-based optimization models for holistic process synthesis. First, we redefine the fundamental problems of reactor, separation, and heat exchanger network synthesis, by presenting generalized problem statements, to make them amenable to seamless integration with each other. Second, we describe the general forms of models that can be developed to address these generalized problems and identify some key characteristics. Notably, for each system, we identify internal variables used only within the system, cost variables used in the objective function, and, importantly, coupling variables for the coupling between systems. Third, we outline some literature models that can be used to address the generalized problems and present new models to couple the three systems. Finally, we show how the individual components (systems and coupling models) can be integrated to formulate a single simultaneous reactor, separation, and heat exchanger network synthesis.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2016

Fabrication and testing of U–7Mo monolithic plate fuel with Zircaloy cladding

The Materials Management and Minimization program is developing fuel designs to replace highly enriched fuel with fuels of low enrichment. In the most challenging cases, U–(7–10wt%)Mo monolithic plate fuel are proposed. The chosen design includes aluminum-alloy cladding, which provides some challenges in fabrication and fuel/cladding interaction in service. We investigated zircaloy cladding, specifically Zry–4as an alternative cladding, and development of a fabrication method was performed by researchers with the Comisión Nacionalde Energia Atómica (CNEA) in Argentina, resulting in test fuel plates (Zry–4 clad U–7Mo) which were subsequently tested in the Advanced Test Reactor in Idaho. Because Zry–4 and U–(7–10)Mo have similar high-temperature mechanical properties, fabrication was simplified in that the fuel foil and cladding could be co-rolled and bonded. The challenge was to prevent a thermal-expansion mismatch which could destroy the fuel/cladding bond before complete bonding was achieved; the solution was to prevent the composites from cooling significantly between roll passes. Our final product performed very well in-reactor, showing good bonding, very little fuel/cladding interaction, either from fabrication or in-reactor testing, and little swelling, especially no detectable heterogeneous bubble formation at the fuel/cladding interface tested to a fission density of up to 2.54E+21

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

Detailed measurements of local thickness changes for U-7Mo dispersion fuel plates with Al-3.5Si matrix after irradiation at different powers in the RERTR-9B experiment

The Materials Management and Minimization program is developing fuel designs to replace highly enriched fuel with fuels of low enrichment. Swelling is an important irradiation behavior that needs to be well understood. Data from high resolution thickness measurements performed on U-7Mo dispersion fuel plates with Al-Si alloy matrices that were irradiated at high power is sparse. This paper reports the results of detailed thickness measurements performed on two dispersion fuel plates that were irradiated at relatively high power to high fission densities in the Advanced Test Reactor in the same RERTR-9B experiment. Both plates were irradiated to similar fission densities, but one was irradiated at a higher power than the other. The goal of this work is to identify any differences in the swelling behavior when fuel plates are irradiated at different powers to the same fission densities. Based on the results of detailed thickness measurments, more swelling occurs when a U-7Mo dispersion fuel with Al-3.5Si matrix is irradiated to a high fission density at high power compared to one irradiated at a lower power to high fission density.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Key insights from US Department of Energy Better Plants workforce development bootcamps (2022–2025)

This study examines the effectiveness of the US Department of Energy’s Better Plants Program Bootcamps, which are designed to enhance participants’ technical skills in improving energy efficiency and optimizing operations in manufacturing facilities. Through the analysis of survey data collected from 529 participants across 9 bootcamps, the research investigates the motivations, benefits, and demographic trends of attendees. The findings reveal that skill acquisition and improvement are primary drivers for participation, with key benefits including hands-on training on diagnostic equipment and software tools, networking opportunities, and access to technical resources. The analysis shows strong participation from sectors characterized by high energy consumption and employment, such as chemical and transportation equipment manufacturing. Over 50% of participants have job titles that include “EHS” or “Energy” showing their key roles in leading energy efficiency and energy management efforts in manufacturing. Furthermore, the analysis highlights the distribution of participants across managerial, engineering, and technical roles, revealing a higher representation of managers and engineers. This observation suggests a need for targeted outreach to engage technicians, equipment operators, maintenance staff, and floor workers to ensure comprehensive workforce development. The post-bootcamp survey showed that the participants highly valued the opportunities for peer learning and idea exchange, and the benefits they gained from them. This research contributes to the advancement of manufacturing education by demonstrating the efficacy of specialized training in addressing critical industry challenges and fostering a more competent and empowered workforce.

Energy efficiency↗
DOE OSTI2021

OPTIMADE, an API for exchanging materials data

Abstract The Open Databases Integration for Materials Design (OPTIMADE) consortium has designed a universal application programming interface (API) to make materials databases accessible and interoperable. We outline the first stable release of the specification, v1.0, which is already supported by many leading databases and several software packages. We illustrate the advantages of the OPTIMADE API through worked examples on each of the public materials databases that support the full API specification.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗
DOE OSTI2022

Three individually addressable spin qubits in a single molecule

Here, an asymmetric bis-phenol-β-diketone (H 4 L) has been designed as a ligand programmed to promote the assembly of a molecular arrangement composed of three magnetically exchanged [NiCu] pairs, each exhibiting an S = 1/2 spin. The latter are shown by EPR and magnetometry to be good qubit realizations and non-equivalent within the molecule in the solid state, as required for conditional quantum gates.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗