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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 1,063 records · Page 59
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

A Cybersecurity Testbed for Smart Buildings

Smart buildings are equipped with a plethora of cyber-physical systems, such as Internet of Things (IoT) devices and building automation systems. These devices, especially in commercial buildings, use legacy communications and hardware that were not designed with cybersecurity in mind. With increasing cyber threats in recent years, smart buildings have become an increasing target for attacks, but not enough published data are available from these incidents to study or replicate the scenarios to defend buildings. As part of the U.S. Department of Energy-funded project focusing on developing the Building Intelligence with Layered Defense Using Security-Constrained Optimization and Security Risk Detection (BUILD-SOS) platform, we developed a cybersecurity test bed for smart buildings. This test bed includes a building simulation tool, virtual devices, emulated operational technology networks, and remote hardware-in-the-loop. Using this test bed, we performed different cyberattacks on the smart building model and collected both physical building data, to understand the impacts on the building, and network data, to aid in separating mechanical faults from cyberattacks during the detection. This test bed is a significant tool in protecting smart buildings from cyberattacks because they can aid in both cybersecurity analysis and the evaluation of cyberattack detection tools by testing the tools in a secure environment without impacting the building operations.

alfalfa↗
DOE OSTI2024

Impact of Janssen effect on thermal transport in granular flow

Using a modulated photothermal radiometry (MPR) technique capable of measuring thermal transport in particle beds, we find asymptotically increasing effective thermal conductivity and decreasing near-wall thermal resistance along gravity-driven downward granular flows through a 1-meter-long narrow vertical channel owing to the Janssen effect. The Janssen effect is confirmed by similar asymptotic trends from particle bed apparent mass measurements as well as separate MPR heat transfer measurements on stationary particle beds under compression at different heights of the channel with and without pressure screening. Furthermore, local heat transfer coefficient along the 1-meter-long channel was modeled based on measured spatially resolved thermal conductivity and near-wall thermal resistance due to the Janssen effect. This work reveals for the first time the impact of the over century-old Janssen effect on heat transfer in granular media. Furthermore, the results from this work can lead to a better understanding of heat transfer in granular flow.

14 SOLAR ENERGY↗
DOE OSTI2020

Spectral Radiative Properties of Ceramic Particles for Concentrated Solar Thermal Energy Storage Applications

This work investigates the spectral radiative properties of ceramic particles using a monochromator and a Fourier-transform infrared spectrometer (FTIR) with integrating spheres at wavelengths from 0.38 μm to 15 μm. Particles are encased between two transparent windows to obtain the directional-hemispherical reflectance of the particle bed. Two types of commercially available particles with three different sizes are examined. Integration over the solar spectrum reveals that the solar absorptance of the particle beds is between 0.940 and 0.957. The total emittance at 1000 K is also estimated by assuming the spectral emittance is independent of temperature. The optical constants of particles are modeled with effective medium approaches, considering the optical properties of individual constituent materials. The absorptance of the particle is estimated using the effective optical constants and compared with that of the particle bed from the measurement. Finally, this work facilitates the characterization of radiative properties of particles with a windowed method and provides a modeling scheme for approximating the radiative properties of composite ceramic materials.

14 SOLAR ENERGY↗
DOE OSTI2021

A Bayesian Approach to the Eagar–Tsai Model for Melt Pool Geometry Prediction with Implications in Additive Manufacturing of Metals

Here, this paper focuses on improving the melt pool geometry predictions and quantifying uncertainties using an adapted version of the Eagar–Tsai (E–T) model that incorporates temperature-dependent properties of the material as well as powder conditions. Additionally, Bayesian inference is employed to predict distributions for the E–T model input parameters of laser absorptivity and powder bed porosity by incorporating experimental results into the analysis. Monte Carlo uncertainty propagation is then used with these parameter distributions to estimate the melt pool depth and associated uncertainty. Our results for the 316L stainless steel suggest that both the absorptivity and powder bed porosity are strongly influenced by the laser power. In contrast, the scanning speed has only a marginal effect on both the absorptivity and powder bed porosity. We constructed a printability map using the Bayesian E–T model based on power-dependent input parameter values to demonstrate the merit of the approach. The Bayesian approach improved the accuracy in predicting the keyhole regions in the laser power-scan speed parameter space for the 316L stainless steel. Although applied to a specific adaptation of the E–T model, the method put forth can be extended to quantify uncertainties in other numerical models as well as in the estimation of unknown parameters.

316L Stainless Steel (SS).↗
DOE OSTI2024

SCALE inventory and reactivity analysis as part of the Hermes 2021 PSAR review

The readiness of SCALE for comprehensive studies of pebble-bed reactors has been demonstrated through detailed analysis of a fluoride salt–cooled, high-temperature pebble-bed reactor (PB-FHR). The methods developed for pebble-bed reactor modeling in SCALE, particularly for inventory generation, have proven effective in gaining insights into the reactor physics of this advanced reactor. Excellent agreement with another code package has been observed, further highlighting SCALE’s strong performance. The SCALE results supported the US Nuclear Regulatory Commission’s construction permit application review of the Hermes low-power PB-FHR demonstration reactor. A SCALE model of the Hermes reactor was developed at Oak Ridge National Laboratory using information from the Preliminary Safety Analysis Report (PSAR) and supplemented with publicly available data. SCALE reactivity coefficient simulations reproduced PSAR results within 1σ statistical uncertainties. Sensitivity studies emphasized the importance of graphite specifications for accurate keff predictions.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2024

Model-based optimization strategies for direct hydrogenation of carbon dioxide to dimethyl ether

Here, this study discusses model-based optimization strategies for CO 2 hydrogenation to dimethyl ether (DME) over aCuZnZr (CZZ) and ferrite (FER) mixed catalyst system in a packed-bed reactor configuration. A two-dimensional axisymmetric, nonisothermal packed-bed reactor model was developed using COMSOL Multiphysics 6.2 software. The model solves two-dimensional (radial and axial) heat and mass transport equations in the packed-bed and integrates intraparticle diffusion and heat transfer in a 1D approach. This powerful feature differs from a traditional porous media approach and takes into account any heat and mass transfer limitations that may exist. Analysis shows that the heat transfer limitations are negligible, but strong internal mass transfer limitations were observed at 10 ≤ WHSV ≤ 90 h -1 on the FER catalyst and at 240 °C. The optimum catalyst composition (i.e., mixing ratio) varies depending on the operating regime. The FER catalyst weight in the mixture can be as low as 5 wt.%, but the ideal composition de-pends on the internal mass transfer limitation and its relationship with the operating regime (i.e., weight hourly space velocity, temperature). A catalyst composition of 80 wt.% CZZ and 20 wt.% FER was suggested; this composition can provide high CO 2 conversion and DME production rates at a wide range of temperatures and flow rates.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Scaled-up fabrication of durable and porous adsorbent-coated minichannels on aluminum for CO 2 separation

A method was developed to fabricate zeolite 13X adsorbent-coated minichannels on aluminum for CO₂ adsorption applications in this study. It emphasizes the innovative use of aluminum as a substrate, which offers airtight assembly, paving the way for highly efficient adsorption systems. An optimized coating process was developed using a slurry of Zeolite 13X, yeast, sugar, and xanthan gum, resulting in durable and highly porous layers that enhance CO₂ capture performance. A PETG peeler was designed to remove the top layer of the yeast-engineered adsorbent coatings, revealing a super porous and foamy structure. The teeth of the peeler were designed and fabricated for high repeatability and rapid prototyping. Breakthrough experiments were conducted on the scaled-up adsorbent bed using gas mixtures of 80% CO₂, 20% N₂, and 20% CO₂, 80% N₂ to represent different industrial scenarios. The performance of the bed was evaluated at flow rates of 160 and 190 cm³ min -1 using a Raman Laser Gas Analyzer (RLGA), demonstrating stable adsorption without degradation across multiple cycles. Computational modeling of integral transport phenomena under the chosen experimental conditions was pursued using gPROMS ProcessBuilder™, and the modeling results were compared with those from the tests for adsorption time, which resulted in an error margin of 2% to 9% for the breakthrough time, confirming the easy reproducibility of the design through modeling. This research advances CO₂ capture technologies by providing an effective and scalable solution for producing aluminum-based adsorbent coated beds, supporting industrial carbon capture efforts.

CO2 capture↗
DOE OSTI2025

Techno-economic evaluation of emission control configurations for AMP/PZ-based post-combustion CO 2 capture

Minimizing the environmental impacts of amine-based post-combustion carbon capture technologies is essential for regulatory compliance and public acceptance. Experimental campaigns at RWE's CO 2 capture pilot plant in Niederaussem using CESAR1 demonstrated that combining existing emission abatement technologies can substantially reduce the concentration of amines and degradation products in the CO 2 -depleted flue gas to below the detection limit of an infrared spectrometer. The campaign confirmed that a proprietary dry bed technology (OEASE aerozone™) or a second water wash can reduce AMP and PZ emissions to below 1 mg/Nm 3 . However, an acid or chemically active wash downstream of the water wash is necessary to reduce NH 3 emissions to very low levels (<2 mg/Nm 3 ). Combining a dry bed with an acid wash significantly reduces both the required acid solution and the resulting acid waste. The techno-economic analysis indicates that implementing emission mitigation technologies provides substantial environmental benefits for the CESAR1 process, with only a marginal increase (<1 €/tCO 2 ) in both the carbon capture cost (CCC) and CO 2 avoidance cost (CAC). The additional capital cost associated with extra column packing is offset by operational cost savings from reduced solvent losses. For stringent emission permits targeting NH 3 , a configuration combining a dry bed upstream of the water wash followed by an acid wash achieves the best balance between emission control and cost efficiency. This configuration results in a Levelized Cost of Electricity (LCOE) of 143 €/MWh, a CCC of 45.4 €/tCO 2 , and a CAC of 88.4 €/tCO 2 .

AMP↗
DOE OSTI2023

Additive manufacturing process parameter determination for a new Fe-C-Cu alloy

As a potential replacement for stainless steel alloys commonly used to print parts with laser powder bed fusion, a new Cu precipitation strengthened ferrous alloy, with composition Fe-0.2C-6Cu (wt%), was recently developed. This material is Co- and Ni-free, printable, has mechanical properties comparable to that of high strength stainless steels (approximately 1300 MPa UTS), and is cost-advantaged relative to existing low-alloy steels for additive manufacturing of parts with complex shapes. To gain traction for broader application, optimal laser powder bed fusion (LPBF) processing conditions to produce nearly defect-free parts without compromising mechanical strength are needed. Here, an optimal processing window based upon laser speeds that achieve minimal porosity was quantified via comparisons of measured melt pool penetration, scan speeds, printed material density and laser beam energy density on a commercial LPBF unit operating at 350 W, 80 μm hatch spacing, and 50 μm layer thickness based upon optimal parameters for 17-4PH. Furthermore, the window is 300 to 500 mm/s to achieve >99.8 % dense Fe-0.2C-6Cu (wt%) specimens. Other defects such as burning, spatter, and lack of fusion were also avoided in this window. The window was validated with in-situ synchrotron X-ray imaging that enabled visualization of the vapor cavity, melting, and solidification during a single laser track scan on a miniature powder bed sample. In addition, in-situ infrared imaging provided temperature fields, cooling rate and solidification range, and confirmed minimal printing defects and spatter within the processing window.

36 MATERIALS SCIENCE↗
DOE OSTI2022

At-Line Sampling and Characterization of Pyrolytic Vapors from Biomass Feedstock Blends Using SPME-GC/MS-PCA: Influence of Char on Fast Pyrolysis

Solid-phase microextraction (SPME) coupled with GC-MS analysis was used for at-line sampling of pyrolytic vapors produced during fast pyrolysis of biomass. The pure and binary blends of switchgrass (SWG) and pine harvest residues (PT6) were used as feedstock. Sequential SPME sampling allowed for monitoring of changes in the pyrolysis vapors as char accumulated in the fluid bed. The concentration and composition of the vapors desorbed from the SPME fibers were investigated using GC-MS, and the data sets were then analyzed using principal component analysis (PCA) to compare the composition of the pyrolysis vapors over the course of the pyrolysis run. The chemical composition of both carbohydrate and lignin fragments varied as the char builds up in the reactor bed. Fragments derived from cellulose and xylan included anhydrosugars, furans and light oxygenated compounds. Lignin fragments included methoxyphenols, phenolic ketones and aldehydes, low molecular weight aromatics. The composition of the carbohydrate fragments changed more than the lignin fragments as the char build-up in the fluid bed. This combination of SPME-GC/MS-PCA were a novel, easy and effective method for measuring the composition and changes in the composition of pyrolysis vapors during the fast pyrolysis process. Here, this work also highlighted the effect of char build-up on the composition of the overall pyrolysis vapors.

09 BIOMASS FUELS↗
DOE OSTI2021

Pronghorn: A Multidimensional Coarse Mesh Application for Advanced Reactor Thermal-Hydraulics

This paper presents an overview of Pronghorn, a multiscale thermal-hydraulic (T/H) application developed by Idaho National Laboratory and the University of California, Berkeley. Pronghorn, built on the open-source finite element Multiphysics Object-Oriented Simulation Environment (MOOSE), leverages state-of-the-art physical models, numerical methods, and nonlinear solvers to deliver fast-running advanced reactor T/H simulation capabilities within a modern software engineering environment. This work summarizes the physical models, multiphysics and multiscale coupling, and numerical discretization in Pronghorn with emphasis on our initial target application to pebble bed reactors (PBRs). A diverse set of applications are shown to depressurized natural circulation in the SANA experiments, forced convection in the Pebble Bed Modular Reactor, three-dimensional (3-D)/one-dimensional coupling of Pronghorn and RELAP-7 systems T/H for loop analysis in the High Temperature Reactor Power Module, and forced convection in the Mark-1 Pebble Bed Fluoride-Salt-Cooled High-Temperature Reactor. A multiphysics coupling of Pronghorn, RELAP-7, and Griffin deterministic neutronics for a gas-cooled PBR demonstrates the capability of the MOOSE framework for reactor design calculations. These applications highlight the verification and validation underlying Pronghorn’s software development while emphasizing features that improve upon capabilities offered by legacy tools in areas such as 3-D unstructured meshing, physics modeling, and multiphysics coupling.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Micromechanical origin of heat transfer to granular flow

Heat transfer across a granular flow is comprised of two resistances in series : near the wall and within the bulk particle bed, neither of which is well understood due to the lack of experimental probes to separate their respective contribution. Here, we use a frequency modulated photothermal technique to separately quantify the thermal resistances in the near-wall and the bulk bed regions of particles in flowing states. Compared to the stationary state, the flowing leads to a higher near-wall resistance and a lower thermal conductivity of bulk beds. As a result, coupled with discrete element method simulation, we show that the near-wall resistance can be explained by particle diffusion in granular flows.

14 SOLAR ENERGY↗
DOE OSTI2024

Modeling scale-up of particle coating by atomic layer deposition

Atomic layer deposition (ALD) is a promising technique to functionalize particle surfaces for energy applications including energy storage, catalysis, and decarbonization. In this work, we present a set of models of ALD particle coating to explore the transition from lab scale to manufacturing. Our models encompass the main particle coating manufacturing approaches including rotary bed, fluidized bed, and continuously vibrating reactors. These models provide key metrics, such as throughput and precursor utilization, required to evaluate the scalability of ALD manufacturing approaches and their feasibility in the context of energy applications. Our results show that designs that force the precursor to flow through fluidized particles transition faster to a transport-limited regime where throughput is maximized. They also exhibit higher precursor utilization. In the context of continuous processes, our models indicate that it is possible to achieve self-extinguishing processes with almost 100% precursor utilization. A comparison with past experimental results of ALD in fluidized bed reactors shows excellent qualitative and quantitative agreement.

25 ENERGY STORAGE↗
DOE OSTI2022

Effects of Particle Size Distribution with Efficient Packing on Powder Flowability and Selective Laser Melting Process

The powder bed-based additive manufacturing (AM) process contains uncertainties in the powder spreading process and powder bed quality, leading to problems in repeatability and quality of the additively manufactured parts. This work focuses on identifying the uncertainty induced by particle size distribution (PSD) on powder flowability and the laser melting process, using Ti6Al4V as a model material. The flowability test results show that the effect of PSDs on flowability is not linear, rather the PSDs near dense packing ratios cause significant reductions in flowability (indicated by the increase in the avalanche angle and break energy of the powders measured by a revolution powder analyzer). The effects of PSDs on the selective laser melting (SLM) process are identified by using in-situ high-speed X-ray imaging to observe the melt pool dynamics during the melting process. The results show that the powder beds made of powders with dense packing ratios exhibit larger build height during laser melting. The effects of PSD with efficient packing on powder flowability and selective laser melting process revealed in this work are important for understanding process uncertainties induced by feedstock powders and for designing mitigation approaches.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Comprehensive experimental investigation on biomass-glass beads binary fluidization: A data set for CFD model validation

Fluidization behavior of biomass and glass beads binary mixtures in a bubbling fluidized bed was experimentally investigated. Mixtures containing different mass fraction of Loblolly Pine white wood and glass beads were fluidized at different fluidization velocities. The particle properties were characterized in a QICPIC that uses a dynamic image processing method to measure both particle size and sphericity. The minimum fluidization velocity was determined using the pressure drop method. An image processing method was developed to capture the dynamic expanded bed height at a very high frequency. The effect of biomass mass fraction and inlet gas velocity on mixing and segregation behavior was studied and analyzed through pressure drop measurements. Pressure drop fluctuations and expanded bed height fluctuations via fast Fourier transform were analyzed and compared. Here, the complete and accurate experimental data reported in this study could provide a benchmark data set for various computational fluid dynamics models validation, calibration, and identification.

42 ENGINEERING↗
DOE OSTI2021

Open source implementation of glued sphere discrete element method and nonspherical biomass fast pyrolysis simulation

Here, in this research, a glued-sphere Discrete Element Method (DEM) method was implemented in the open-source, Computational Fluid Dynamics (CFD) software MFiX. The implementation was verified using a cylinder-wall collision and then validated by simulating the packing and fluidization of non-spherical particles. The validated code was applied to simulate fast pyrolysis of non-spherical biomass particles in a bubbling fluidized bed. The glued sphere occupancy ratio was proposed to quantify the quality of shape resolution using glued sphere. Shape resolution showed significant influence on the packing height in the simulation of particle packing and an occupancy ratio of 80 % was recommended. Its influence is minor in fully fluidized bed but can be 8 times higher in fixed fluidized bed. Three tested heat transfer models predicted similar yields of elongated biomass fast pyrolysis. The solver developed in this research can be used to simulate other multiphase reacting flows involving non-spherical particles.

42 ENGINEERING↗
DOE OSTI2022

Measuring binary fluidization of nonspherical and spherical particles using machine learning aided image processing

Abstract The binary fluidization of Geldart D type nonspherical wood particles and spherical low density polyethylene (LDPE) particles was investigated in a laboratory‐scale bed. The experiment was performed for varying static bed height, wood particles count, as well as superficial gas velocity. The LDPE velocity field were quantified using particle image velocimetry (PIV). The wood particles orientation and velocity are measured using particle tracking velocimetry (PTV). A machine learning pixel‐wise classification model was trained and applied to acquire wood and LDPE particle masks for PIV and PTV processing, respectively. The results show significant differences in the fluidization behavior between LDPE only case and binary fluidization case. The effects of wood particles on the slugging frequency, mean, and variation of bed height, and characteristics of the particle velocities/orientations were quantified and compared. This comprehensive experimental dataset serves as a benchmark for validating numerical models.

Li, Cheng↗
DOE OSTI2021

Evolution of anisotropy with saturation and its implications for the elastoplastic responses of clay rocks

Many clay rocks have distinct bedding planes. Experimental studies have shown that their mechanical properties evolve with the degree of saturation (DOS), often with higher stiffness and strength after drying. For transversely isotropic rocks, the effects of saturation can differ between the bed-normal (BN) and bed-parallel (BP) directions, which gives rise to saturation-dependent stiffness and strength anisotropy. Accurate prediction of the mechanical behavior of clay rocks under partially saturated conditions requires numerical models that can capture the evolving elastic and plastic anisotropy with DOS. In this study, we present an anisotropy framework for coupled solid deformation-fluid flow in unsaturated elastoplastic media. Here we incorporate saturation-dependent strength anisotropy into an anisotropic modified Cam-Clay (MCC) model and consider the evolving anisotropy in both the elastic and plastic responses. The model was calibrated using experimental data from triaxial tests to demonstrate its capability in capturing strength anisotropy at various levels of saturation. Through numerical simulations, we demonstrate the role of evolving stiffness and strength anisotropy in the mechanical behavior of clay rocks. Plane strain simulations of triaxial compression tests were also conducted to demonstrate the impacts of material anisotropy and DOS on the mechanical and fluid flow responses.

36 MATERIALS SCIENCE↗