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All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Implementing Zero Energy Design with the U.S. Department of Energy Solar Decathlon

The U.S. Department of Energy Solar Decathlon® Design Challenge is a collegiate competition that challenges student teams to design high performance buildings that push the boundaries of the industry. In the 2020 competition, DOE is piloting Design Partners, a low-risk opportunity for builders and building owners to harness student innovation and explore zero energy design for current or upcoming projects. Design Partners provide a student team of architects and engineers with project requirements. By the end of the Challenge, Design Partners receive a zero energy alternative and cost estimate for their project. The collaboration allows Design Partners to incorporate innovative concepts such as grid-interactivity, resilience, and low embodied carbon in a low-risk environment and provides the future generation of engineers and architects with invaluable experience designing a building for a client under real-world circumstances. Attendees will leave understanding the “perfect storm” of policy, technology, health, and economic trends that make zero energy buildings desirable and feasible and the value of the U.S. DOE Solar Decathlon to industry. They will also get a sneak peek at innovative solutions 2020 Design Partner pilot projects are bringing to the building industry and how becoming a Design Partner in 2021 could benefit their organization.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2023

Aerodynamic Rotor Design for a 25 MW Offshore Downwind Turbine

Continuously increasing offshore wind turbine scales require rotor designs that maximize power and performance. Downwind rotors offer advantages in lower mass due to reduced potential for tower strike, and is especially true at large scales, e.g., for a 25 MW turbine. In this study, three 25 MW downwind rotors, each with different prescribed lift coefficient distributions were designed (chord, geometry, and twist) and compared to maximize power production at unprecedented scales and Reynolds numbers, including a new approach to optimize rotor tilt and coning based on aeroelastic effects. To achieve this objective the design process was focused on achieving high power coefficients, while maximizing swept area and minimizing blade mass. Maximizing swept area was achieved by prescribing pre-cone and shaft tilt angles to ensure the aeroelastic orientation when the blades point upwards was nearly vertical at nearly rated conditions. Maximizing the power coefficient was achieved by prescribing axial induction factor and lift coefficient distributions which were then used as inputs for an inverse rotor design tool. The resulting rotors were then simulated to compare performance and subsequently optimized for minimum rotor mass. To achieve these goals, a high Reynolds number design space was developed using computational predictions as well as new empirical correlations for flatback airfoil drag and maximum lift. Within this design space, three rotors of small, medium and large chords were considered for clean airfoil conditions (effects of premature transition were also considered but did not significantly modify the design space). The results indicated that the medium chord design provided the best performance, producing the highest power in Region 2 from simulations while resulting in the lowest rotor mass, both of which support minimum LCOE. The methodology developed herein can be used for the design of other extreme-scale (upwind and downwind) turbines.

downwind rotors↗
DOE OSTI2024

Who will be making wave energy? A community-driven design approach toward just and sustainable energy futures in Alaska

Renewable energy transition, once thought of as a singular, large-scale switch in industrial energy generating technologies from fossil fuels to renewables, have gained a broader set of requirements, including the need for justice and environmental protection. While discourse around policy and process has grown to consider these requirements, the focus of design of new renewable energy projects and technologies remains dominantly fixed on maximizing energy production, and renewables are falling short of meeting the requirements of just energy transitions. Meanwhile, in design studies, participatory and co-design approaches which explicitly consider justice in both process and outcomes have long been theorized and applied. However, applications of these approaches to renewable energy project design are under-theorized. In this paper, we explore the effectiveness of the adoption and adaptation of a co-design approach called Community-Driven Design (CDD) in enabling meaningful participation prior to technological maturity and bringing the attention of designers to a more diverse set of energy futures focused on justice and sustainability. Here, we do so by developing and testing the approach with community members in Sitka, AK, USA. We conclude that the approach has the potential to increase meaningful participation. Furthermore, we conclude that through diverse understandings of energy and the emergence of design narratives that engage with the complexity of vulnerability, accountability, and resilience, CDD led designers to consider justice, sustainability, and a diverse set of possible energy futures both within and beyond Sitka.

16 TIDAL AND WAVE POWER↗
DOE OSTI2022

Massively parallel, computationally guided design of a proenzyme

Proteins have shown promise as therapeutics and diagnostics, but their effectiveness is limited by our inability to spatially target their activity. To overcome this limitation, we developed a computationally guided method to design inactive proenzymes or zymogens, which are activated through cleavage by a protease. Since proteases are differentially expressed in various tissues and disease states, including cancer, these proenzymes could be targeted to the desired microenvironment. We tested our method on the therapeutically relevant protein carboxypeptidase G2 (CPG2). We designed Pro-CPG2s that are inhibited by 80 to 98% and are partially to fully reactivatable following protease treatment. The developed methodology, with further refinements, could pave the way for routinely designing protease-activated protein-based therapeutics and diagnostics that act in a spatially controlled manner. Confining the activity of a designed protein to a specific microenvironment would have broad-ranging applications, such as enabling cell type-specific therapeutic action by enzymes while avoiding off-target effects. While many natural enzymes are synthesized as inactive zymogens that can be activated by proteolysis, it has been challenging to redesign any chosen enzyme to be similarly stimulus responsive. Here, we develop a massively parallel computational design, screening, and next-generation sequencing-based approach for proenzyme design. For a model system, we employ carboxypeptidase G2 (CPG2), a clinically approved enzyme that has applications in both the treatment of cancer and controlling drug toxicity. Detailed kinetic characterization of the most effectively designed variants shows that they are inhibited by ∼80% compared to the unmodified protein, and their activity is fully restored following incubation with site-specific proteases. Introducing disulfide bonds between the pro- and catalytic domains based on the design models increases the degree of inhibition to 98% but decreases the degree of restoration of activity by proteolysis. A selected disulfide-containing proenzyme exhibits significantly lower activity relative to the fully activated enzyme when evaluated in cell culture. Structural and thermodynamic characterization provides detailed insights into the prodomain binding and inhibition mechanisms. The described methodology is general and could enable the design of a variety of proproteins with precise spatial regulation.

59 BASIC BIOLOGICAL SCIENCES↗
NASA NTRS2005

Probabilistic Risk Assessment for Concurrent, Conceptual Design of Space Missions

NASA is expanding its capability to perform PRA. This capability gives insight into the links of a suggested design and drives the refinement of the design by identifying optimal areas for investments. Clearly, it is more viable and less expensive to refine a design at the time that it is being conceived. Hence the utility of conducting PRA at the conceptual design phase. Concurrent engineering teams greatly reduce the design time and costs. However, there is currently no standardized means for building probabilistic risk models to assess risks associated with a design produced by such teams. The capability to produce a consistent and valid risk metric associated with such designs would greatly enhance the value of such design teams. This paper explains the experimental results obtained to date from building probabilistic risk models for sample studies conducted at the concurrent engineering design team at the Jet Propulsion Laboratory (TeamX).

conceptual designs↗
DOE OSTI2021

A Review on Bioinspired Proton Exchange Membrane Fuel Cell: Design and Materials

With the climate crisis gathering recognition, there has been significant interest in clean energy. As a reliable and clean energy solution, markets transitioning toward sustainable energy have identified polymer electrolyte membrane fuel cells (PEMFCs) as a critical technology. The increasing interest in PEMFCs is primarily due to their high energy density, high efficiency and zero greenhouse gas emission. However, additional development is required to overcome the current barriers associated with fuel cell component design, high manufacturing cost, and insufficient stability. Bioinspired designs have the potential to provide new and valuable insights using novel techniques for extracting design inspirations from biological structures. Applying these design concepts to develop materials and structures for various fuel cell components can be transformative. The well–adapted structures and functional features of biological systems have been proven to greatly enhance the performance of current designs through novel and optimized pathways. Bioinspired designs have indeed lived up to performance expectations and even exceed them. Herein, the potential and value of using these bioinspired designs are discussed. Recent studies and advancements based on nature–inspired structures for components of PEMFCs and how these design considerations substantiate their claim as an attractive alternative to conventional designs are discussed.

25 ENERGY STORAGE↗
DOE OSTI2021

Control co-design of 13 MW downwind two-bladed rotors to achieve 25% reduction in levelized cost of wind energy

Wind energy is recognized worldwide as cost-effective and environmentally friendly and is among the fastest-growing sources of electrical energy. To further decrease the cost of wind energy, wind turbines are being designed at ever larger scales, which is challenging due to greater structural loads and deflections. Large-scale systems such as modern wind turbines increasingly require a control co-design approach, whereby the system design and control design are performed in a more integrated fashion. We overview a two-bladed downwind morphing rotor concept that is expected to lower the cost of energy at wind turbine sizes beyond 13 megawatts (MW) compared with continued upscaling of traditional three-bladed upwind rotor designs. We describe an aero-structural-control co-design process that we have used in designing such extreme-scale wind turbines, and we discuss how we were able to achieve a 25% reduction in levelized cost of energy for our final turbine design compared to a conventional upwind three-bladed rotor design.

17 WIND ENERGY↗
DOE OSTI2025

Parallel derivative-free optimization for simulation-based design of behind-the-meter energy systems

In this work, the integrated design and dispatch of behind-the-meter or distributed resources (e.g. stationary battery storage and solar PV generation) is considered. A simulation-based framework is employed, generating high-fidelity results with closed-loop predictive control at a fine resolution, at the expense of high computational cost (several minutes to a few hours per design point). To address this challenge, parallel derivative-free design methods are considered. Four methods are compared, including state-of-the-art surrogate-based methods (Radial-Basis Functions and Gaussian processes) and sampling strategies, an evolutionary-based method, and a simple sequential grid refinement method. As a case study, two types of design problem with increasing complexity are considered, namely, the design of behind-the-meter resources (three design variables) and the inclusion of grid capacity (four design variables). The second yields a constrained design problem for which violations can only be determined after solving the computationally expensive simulation. For the three-dimensional case, all methods present a good performance, achieving a solution within 1% of the optimum after the first iteration, with the sequential grid refinement exhibiting the fastest convergence and achieving the best final objective value. This indicates that the parallel evaluation of multiple sampling points may be more important than the choice of method for small decision spaces. For the four-dimensional constrained case, the Genetic Algorithm presents the best tradeoff between performance and computational effort, while the rough objective function terrain generated by constraint violation penalties reduces the performance of surrogate-based methods. Contour plots with flat regions indicate flexibility in the optimal design and highlight the importance of characterizing the solution space.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Design options for a superconducting ion linac

Following a review of the design options for a superconducting ion linac, we present here an alternative design for the pre-stripper section of the superconducting driver linac for the rare isotope science project (RISP) of the Institute for Basic Science in Korea. The proposed alternative design takes advantage of the recent accelerator developments at Argonne, namely for the recent ATLAS intensity and efficiency upgrade and the Fermilab proton improvement plan project (PIP-II). In particular, the state-of-the-art performance of quarter-wave (QWRs) and half-wave resonators (HWRs), the integrated steering correctors and cold beam position monitors (BPMs) for a compact cryomodule design. In order to simplify the design and avoid frequency transitions, we used two types of QWRs at 81.25 MHz while the baseline design has QWRs at 81.25 MHz and HWRs at 162.5 MHz. The new QWR types were optimized for β ~0.05 and ~0.11, respectively, and corrected for beam steering effects. Nine cryomodules are required to reach the stripping energy of 18.5 MeV/u for uranium beam. An alternative radio-frequency quadrupole (RFQ) design was also developed. It is optimized with the multi-harmonic buncher (MHB) to produce a much smaller longitudinal emittance, offering much needed flexibility for beam tuning and more tolerance to errors. Following the lattice design optimization, end-to-end beam dynamics simulations including most important sources of machine error were performed. The results showed that the design is robust and tolerant to errors with no beam loss observed for typical machine errors.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Structural design challenges and implications for high temperature concentrating solar power receivers

High operating temperatures along with diurnal cycling and high operating stresses bring many material and engineering challenges for concentrated solar power (CSP) receivers. Current design rules in ASME Boiler and Pressure Vessel (B&PV) Code for high temperature structural components were not intended for CSP components. The paper reviews the design rules in several sections of ASME B&PV Code in terms of their applicability in designing high temperature CSP receivers. With some restrictions and modifications, the conditions assumed in the design rules in Section III, Division 5 of ASME B&PV Code are found to closely resemble the loading conditions of CSP receiver, including accounting for the interaction between creep and fatigue damage. Further, the paper applies the proposed design rules to an external tubular receiver design and discusses several lessons learned from the design study. The creep damage accumulation due to high thermal stresses resulting from circumferentially non-uniform flux distribution is found to control the design of CSP receivers. Several mitigation actions to improve the design life of receivers are also discussed.

14 SOLAR ENERGY↗
DOE OSTI2023

De novo design of knotted tandem repeat proteins

De novo protein design methods can create proteins with folds not yet seen in nature. These methods largely focus on optimizing the compatibility between the designed sequence and the intended conformation, without explicit consideration of protein folding pathways. Deeply knotted proteins, whose topologies may introduce substantial barriers to folding, thus represent an interesting test case for protein design. Here we report our attempts to design proteins with trefoil (3 1 ) and pentafoil (5 1 ) knotted topologies. We extended previously described algorithms for tandem repeat protein design in order to construct deeply knotted backbones and matching designed repeat sequences (N = 3 repeats for the trefoil and N = 5 for the pentafoil). We confirmed the intended conformation for the trefoil design by X ray crystallography, and we report here on this protein’s structure, stability, and folding behaviour. The pentafoil design misfolded into an asymmetric structure (despite a 5-fold symmetric sequence); two of the four repeat-repeat units matched the designed backbone while the other two diverged to form local contacts, leading to a trefoil rather than pentafoil knotted topology. Our results also provide insights into the folding of knotted proteins.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2021

Potential design problems for ITER fusion device

The international thermonuclear experimental reactor (ITER) is a worldwide project currently being built in France for the demonstration of the feasibility of thermonuclear technologies for future realization of successful commercial fusion energy. ITER is of the tokamak based design using strong magnetic fields to confine the very hot plasma needed to induce the fusion reaction. Tokamak devices are currently the front leading designs. Building a successful magnetic fusion device for energy production is of great challenge. A key obstacle to such design is the performance during abnormal events including plasma disruptions and so-called edge-localized modes (ELMs). In these events, a massive and sudden release of energy occurs quickly, due to loss of full or partial plasma confinement, leading to very high transient power loads on the reactor surface boundaries. A successful reactor design should tolerate several of these transient events without serious damages such as melting and vaporization of the structure. This paper highlights, through comprehensive state-of-the-art computer simulation of the entire ITER interior design during such transient events, e.g., ELMs occurring at normal operation and disruptions during abnormal operation, potential serious problems with current plasma facing components (PFCs) design. The HEIGHTS computer package is used in these simulations. The ITER reactor design was simulated in full and exact 3D geometry including all known relevant physical processes involved during these transient events. The current ITER divertor design may not work properly and may requires significant modifications or new innovative design to prevent serious damage and to ensure successful operation.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Development of Conceptual Lead Cartridge Design to Perform Irradiation Experiments in VTR

This paper seeks to introduce the latest design of the Extended Length Test Assembly–Cartridge Lead (ELTA-CL) with associated thermal-hydraulic (TH) assessment and related experiment activities to support the critical component development performed by the ELTA-CL team (Los Alamos National Laboratory, Westinghouse Electric Company, and the University of New Mexico). The goal of the ELTA-CL program is to develop and validate an experimental capability to perform irradiation experiments in the Versatile Test Reactor (VTR) addressing Lead Fast Reactor (LFR) technology gaps, in support of the commercial development of advanced lead-cooled fast reactor concepts. Through a design maturation process and parametric study, a conceptual design is proposed to meet the requirements for material and corrosion testing. Thermal-hydraulic characteristics for the conceptual design at desired operating conditions are assessed with systems-level (one-dimensional) and computational fluid dynamics (three-dimensional) simulations. Along with the conceptual design work, experimental activities for the development of critical components such as the pump and flowmeter are undertaken. From both the modeling study and the experimental results, the design requirements of the Phase 1 ELTA-CL (e.g., 500°C and 2 m/s) are achievable with the current conceptual design. Additional design improvements and safety assessments at both steady-state and transient conditions for the final ELTA-CL design will be pursued.

42 ENGINEERING↗
DOE OSTI2022

Design, Construction, and Testing of 0.5-m, 18-mm Period Nb 3 Sn Superconducting Undulator Magnets

We report design and fabrication of a new Nb 3 Sn-based superconducting undulator (SCU) are underway at the Advanced Photon Source (APS) of Argonne National Laboratory in collaboration with Fermilab and Lawrence Berkeley National Laboratory. To develop a robust and reliable fabrication process, the magnet development consists of several steps. First, magnetic and mechanical simulations were performed to optimize the magnet design; then, the design matured further by fabricating and testing a series of very short prototypes, ~8 cm long with a period length of 18 mm. These short prototype studies were previously reported. Second, the design was scaled to an intermediate length of ~0.5 m. These two steps led to the final design of ~1.1–m-long magnets, which are currently being fabricated. The quench behavior of each 0.5-m-long undulator magnet, as well as undulator assemblies from these magnets, was studied. The first SCU magnet assembly did not meet the design specifications due to the breakdown of the insulation. With an improved design and fabrication process based on lessons learned, the second SCU assembly achieved the design undulator field of 1.2 T. The design was further optimized, and the third set of magnets was fabricated and successfully tested.

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

Reliability-Informed Economic and Energy Evaluation for Design for Remanufacturing: A Case Study on a Hydraulic Manifold

Design for Remanufacturing (DfRem) is an attractive approach for sustainable product development. Evaluation of DfRem strategies, from both economic and environmental perspectives, at an early design stage can allow the designers to make informed decisions when choosing the best design option. Studying the long-term implications of a particular design scenario requires quantifying the benefits of remanufacturing for multiple life cycles while considering the reliability of the product. In addition to comparing designs on a one-to-one basis, we find that including reliability provides a different insight into comparing design strategies. We present a reliability-informed cost and energy analysis framework that accounts for product reliability for multiple remanufacturing cycles within a certain warranty policy. The variation of reuse rate over successive remanufacturing cycles is formulated using a branched power-law model which provides probabilistic scenarios of reusing or replacing with new units. To demonstrate the utility of this framework, we use the case study of a hydraulic manifold, which is a component of a transmission used in some agricultural equipment, and use real-world field reliability data to quantify the transmission’s reliability. Three design improvement changes are proposed for the manifold and we quantify the costs and energy consumption associated with each of the design changes for multiple remanufacturing cycles.

design for remanufacturing↗
DOE OSTI2021

An Economics-by-Design Approach Applied to a Heat Pipe Microreactor Concept

Microreactors present a potential paradigm shift in the nuclear industry. Emphasis thus far has been on large-scale multi-billion-dollar projects that cater solely to grid electricity market. These projects can be challenging to finance and execute. On the other hand, microreactors are intended to target a wide variety of smaller niche markets and are expected to be factory-fabricated and more readily deployable. While diseconomies of scale for microreactors may tend to raise their costs per energy output (MWh) relative to large nuclear plants, offsetting gains can be expected from standardization, simplification, passive safety, lower radionuclide inventories, factory fabrication, fast installation, and low financing costs. To adequately assess these contributions, designers should have a different perspective on cost drivers than for large nuclear plants and can utilize novel approaches for systematic cost reduction. To account for these important aspects of microreactors, this report proposes an economics-by-design approach that places economic considerations at the center of the design process. The methodology builds on existing frameworks such as design-to-cost and value engineering, expanding them to new markets (beyond the grid), new attributes (beyond costs alone), and introducing the approach at earlier points in the design cycle. Design parameters and technical specifications are systematically evaluated until costs meet market entry points, while also providing the high-priority performance attributes of the particular use case. Determining first-order estimates for different components early in the process enables designers to focus R&D efforts on the biggest overall cost contributors and components with the most cost uncertainty. The analysis is always guided by market needs and threshold prices. In addition to microreactors, the approach is expected to be useful for other classes of nuclear reactors as well. The analysis was applied to a concept found in the open literature (the Design A heat-pipe reactor). A comprehensive bottom-up estimate was generated by leveraging a new microreactor-specific code of accounts and a range of cost equations. The initial estimate for levelized cost of electricity (LCOE) unsurprisingly exceeded market ranges since the use case had prioritized technological readiness over economic considerations in design choices. An alternate concept was then proposed, with various assumptions/targets made to reduce the largest cost contributors. Changes in the neutron spectrum, the power output, and building structures were found to make even the first-of-a-kind of this modified concept competitive with diesel generation in some remote communities. Learning rate (LR) assumptions indicated cost reductions achieved from sequential unit deployments could expand the range of competitiveness to include additional markets as deployments proceed.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Utilization of the LMP Methodology in Support of the VTR Conceptual Safety Design Report

The Versatile Test Reactor (VTR) is a fast spectrum test reactor currently being developed in the United States under the direction of the US Department of Energy (DOE), Office of Nuclear Energy. The VTR is utilizing a risk-informed performance-based (RIPB) approach for design support and authorization by the DOE, derived from recent efforts by the US industry led Licensing Modernization Project (LMP). This document contains an overview of the implementation of the LMP approach in support of the VTR Conceptual Safety Design Report (CSDR). The work reported here is the result of studies supporting a VTR conceptual design, cost, and schedule estimate for DOE-NE to make a decision on procurement. As such, it is preliminary. The VTR RIPB authorization approach utilizes information from the probabilistic risk assessment (PRA), coupled with deterministic analyses, to aid in decision-making regarding the identification and categorization of safety basis events (SBEs), the classification of structures, systems, and components (SSCs), and the evaluation of defense-in-depth (DID) adequacy. As part of initial reactor design efforts, a VTR conceptual design PRA was developed to support the RIPB process, which focused on at-power internal events, with scoping analyses for seismic and sodium fire hazards. In addition to supporting numerous design studies, preliminary results from the RIPB approach and the VTR conceptual design PRA were utilized as the basis of the VTR CSDR. The initial identification and categorization of SBEs, SSC classification, and DID evaluation were contained within the CSDR, which was submitted to DOE in 2019 as part of the CD-1 submittal package. Following review, DOE approved the CSDR in April 2020 and the CD-1 package in late 2020. Valuable experience was gained through the implementation of the RIPB approach for design and authorization during the VTR conceptual design phase, which is summarized in this document. To the extent possible, this experience has been shared with the advanced reactor industry, through publications and participation in licensing tabletops, in addition to informing DOE:NE advanced reactor regulatory development efforts. Furthermore, the approval of the CSDR by the DOE as part of CD-1 represents a significant milestone in the use of RIPB approaches for advanced reactor licensing.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
NASA NTRS2004

Taking evolutionary circuit design from experimentation to implementation: some useful techniques and a silicon demonstration

Current techniques in evolutionary synthesis of analogue and digital circuits designed at transistor level have focused on achieving the desired functional response, without paying sufficient attention to issues needed for a practical implementation of the resulting solution. No silicon fabrication of circuits with topologies designed by evolution has been done before, leaving open questions on the feasibility of the evolutionary circuit design approach, as well as on how high-performance, robust, or portable such designs could be when implemented in hardware. It is argued that moving from evolutionary 'design-for experimentation' to 'design-for-implementation' requires, beyond inclusion in the fitness function of measures indicative of circuit evaluation factors such as power consumption and robustness to temperature variations, the addition of certain evaluation techniques that are not common in conventional design. Several such techniques that were found to be useful in evolving designs for implementation are presented; some are general, and some are particular to the problem domain of transistor-level logic design, used here as a target application. The example used here is a multifunction NAND/NOR logic gate circuit, for which evolution obtained a creative circuit topology more compact than what has been achieved by multiplexing a NAND and a NOR gate. The circuit was fabricated in a 0.5 mum CMOS technology and silicon tests showed good correspondence with the simulations.

digital circuits designs↗