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At least 1,063 records · Page 59

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DOE OSTI2022

Full-scale Demonstration of Multi-process Sensor at a Cycling PC-fired Boiler

The main objective of this research program is to design, manufacture, and demonstrate a miniaturized, multi-process, monitoring system (mMPMS) for boiler condition management and easy system deployment to obtain a higher spatial resolution. This system will facilitate a Condition-Based Maintenance (CBM) philosophy that actively monitors the health of assets to predict and prevent failures and maximize availability and generating capacity at a reduced cost. CBM systems can provide boiler data that the advanced process control (APC) system can utilize for plant performance optimization, which is increasingly relevant as coal power plants shift from predominantly base-load operation to predominantly transient operation involving large load swings. The mMPMS is based on an electrochemical sensor that provides a real-time indication of the risk of damage to key locations in the radiant or convective section of a coal-fired boiler such as metal loss rates, heat flux, metal surface temperature, and deposit thickness. These indications can be utilized to optimize boiler performance as well as improve boiler availability in conjunction with corresponding operating conditions. This monitoring system was developed and tested in the high-temperature regions of coal-fired utility boilers in this project but can be applied to many other industries and applications as well. This project leveraged the existing electrochemical noise-based monitoring system and the new sensor design is small enough to be installed through the webbing of the waterwalls without the need for long shut-downs to bend tubes and to make it feasible to obtain high spatial resolution in the boiler. Data is transferred to the plant distributed control system (DCS) and any other control system. The sensor body that houses the sensor assembly was designed to ensure good conductive contact with boiler tubes to ensure the sensor is held at an identical temperature to the tube surface temperature. The data acquisition and signal conditioning modules were redesigned into a small footprint with optimized cooling of the module. System software was developed specifically for the new signal conditioning module and is compatible with plant PLCs. After the preliminary testing at a pilot-scale facility, the three mMPMS were installed at a full-scale pulverized coal-fired plant, PacifiCorp’s Hunter 3. The systems were demonstrated over 20,000 hours at the plant during regular operation. Also, the sensor data was fed to the plant’s advanced process control system to evaluate the corrosion control by the operation changes and utilized to understand the impacts of load cycling with different ramping up and down speeds. At the end of the project, the systems were converted to the permanent installation at the power plant to be used with the advanced process control system installed at the plant.

Advanced Sensors, Corrosion, Ash Deposition, Optim↗

DOE OSTI2021

High-Temperature Multi-Process Sensor Development and Demonstration at a Full-scale PC Combustion System

Advanced Sensors, Corrosion, Ash Deposition, Optim↗

DOE OSTI2023

Characterizing the Self-Assembly Properties of Monoolein Lipid Isosteres

Living cells feature lipid compartments which exhibit a variety of shapes and structures that assist essential cellular processes. Many natural cell compartments frequently adopt convoluted nonlamellar lipid architectures that facilitate specific biological reactions. Improved methods for controlling the structural organization of artificial model membranes would facilitate investigations into how membrane morphology affects biological functions. Monoolein (MO) is a single-chain amphiphile which forms nonlamellar lipid phases in aqueous solution and has wide applications in nanomaterial development, the food industry, drug delivery, and protein crystallization. However, even if MO has been extensively studied, simple isosteres of MO, while readily accessible, have seen limited characterization. An improved understanding of how relatively minor changes in lipid chemical structure affect self assembly and membrane topology could instruct the construction of artificial cells and organelles for modeling biological structures and facilitate nanomaterial-based applications. Here, we investigate the differences in self-assembly and large-scale organization between MO and two MO lipid isosteres. We show that replacing the ester linkage between the hydrophilic headgroup and hydrophobic hydrocarbon chain with a thioesther or amide functional group results in the assembly of lipid structures with different phases not resembling those formed by MO. Using light and cryo-electron microscopy, small-angle X-ray scattering, and infrared spectroscopy, we demonstrate differences in the molecular ordering and large-scale architectures of the self-assembled structures made from MO and its isosteric analogues. These results improve our understanding of the molecular underpinnings of lipid mesophase assembly and may facilitate the development of MO-based materials for biomedicine and as model lipid compartments.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2019

Water-Mediated Heterogeneously Catalyzed Reactions

Nature takes advantage of the pervasive presence of water to control many enzymatic reactions by utilizing the unique properties of water, which in turn help regulating reaction rates, selectivity, and rates of mass transfer. Some of the natural phenomena in which water plays the role of solvent, reactant, or byproduct find parallels in industrially relevant reactions catalyzed by synthetic heterogeneous catalysts. Here, we address different mechanistic features of catalytic reactions influenced by water. They include modification of reactant (or product) solubility and rate of mass transport; stabilization of reactants, products, and transition states, both in open and confined spaces; and direct participation in the catalytic phenomenon by remote bond polarization, H-shuttling, or acting as a cocatalyst.

Cooperative catalysis↗

DOE OSTI2020

Nonlinear Multiobjective MPC-Based Optimal Operation of a High Consistency Refining System in Papermaking

As one of the most important unit in the papermaking industry, the high consistency (HC) refining system is confronted with challenges such as improving pulp quality, energy saving, and emissions reduction in its operation processes. Here in this correspondence, an optimal operation of HC refining system is presented using nonlinear multiobjective model predictive control strategies that aim at set-point tracking objective of pulp quality, economic objective, and specific energy (SE) consumption objective, respectively. First, a set of input and output data at different times are employed to construct the subprocess model of the state process model for the HC refining system, and then the Wiener-type model can be obtained through combining the mechanism model of Canadian Standard Freeness and the state process model that determines their structures based on Akaike information criterion. Second, the multiobjective optimization strategy that optimizes both the set-point tracking objective of pulp quality and SE consumption is proposed simultaneously, which uses NSGA-II approach to obtain the Pareto optimal set. Furthermore, targeting at the set-point tracking objective of pulp quality, economic objective, and SE consumption objective, the sequential quadratic programming method is utilized to produce the optimal predictive controllers. In conclusion, the simulation results demonstrate that the proposed methods can make the HC refining system provide a better performance of set-point tracking of pulp quality when these predictive controllers are employed. In addition, while the optimal predictive controllers orienting with comprehensive economic objective and SE consumption objective, it has been shown that they have significantly reduced the energy consumption.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Grid-scale Energy Storage Hazard Analysis & Design Objectives for System Safety

Battery based energy storage systems are becoming a critical part of a modernized, resilient power system. However, batteries have a unique combination of hazards that can make design and engineering of battery systems difficult. This report presents a systematic hazard analysis of a hypothetical, grid scale lithium-ion battery powerplant to produce sociotechnical "design objectives" for system safety. We applied system's theoretic process analysis (STPA) for the hazard analysis which is broken into four steps: purpose definition, modeling the safety control structure, identifying unsafe control actions, and identifying loss scenarios. The purpose of the analysis was defined as to prevent event outcomes that can result in loss of battery assets due to fires and explosions, loss of health or life due to battery fires and explosions, and loss of energy storage services due to non- operational battery assets. The STPA analysis resulted in identification of six loss scenarios, and their constituent unsafe control actions, which were used to define a series of design objectives that can be applied to reduce the likelihood and severity of thermal events in battery systems. These design objectives, in all or any subset, can be utilized by utilities and other industry stakeholders as "design requirements" in their storage request for proposals (RFPs) and for evaluation of proposals. Further, these design objectives can help to protect firefighters and bring a system back to full functionality after a thermal event. We also comment on the hazards of flow battery technologies.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2022

Modular Hybrid Solid State Transformer (H-SST) for Next Generation Flexible and Adaptable Large Power Transformer (LPT) (Final Technical Report)

A 500 kVA HSST, the world first of such system, has been successfully developed. The HSST has the capability to regulate the power flow of the transmission or distribution power lines, or provide voltage regulation. The HSST design is modular therefore it has the ability to be connected in series of parallel to form a large power transformer with smart controllability. The project has enabled a high TRL level prototype be demonstrated at University of Texas at Austin which can lead to additional commercialization and demonstration opportunities. A large number of students were trained under this program that will benefit the power grid industry. A number of publications are published at well known international conferences and journals, further accomplish the mission of knowledge development and dissemination.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2020

Performance Evaluation of High-Temperature Ultrasonic Communication System

Ultrasonic communication is a technique that allows transmitting information through a solid material such as tubes or bars using high-frequency elastic waves. The communication channels often extend into a high-temperature range in the field of power, oil, or nuclear industry. When the temperature is taken into consideration, the ultrasonic wave propagation through the solid channel is complex and unpredictable. It is necessary to study the influence of temperature on the ultrasonic guided wave to improve ultrasonic communication. In this study, a temperature control system is assembled to adjust the temperature of a steel pipe channel ranging from room temperature to 150 degrees C. The temperature performance evaluation is conducted to estimate the signal-to-noise ratio (SNR) and bit error rate (BER) of transferring the ultrasonic signal. The work aims to develop a reliable ultrasonic communication system in a high-temperature environment. The system temperature can be maintained at 150 degrees C and the LiNbO3 transducers are used as transmitters and receivers. No power amplifier is used in the communication system. The high-temperature ultrasonic communication system (HT-UCS) is feasible at 150 degrees C and can achieve a bit rate of 10 kbps without any error.

HT-UCS↗

DOE OSTI2024

Scale up, Field Testing, and Optimization of Nontoxic, Durable, Economical Coatings for Control of Invasive mussels at Hydropower Facilities (Final Report for CRADA 527)

In this effort, Pacific Northwest National Laboratory (PNNL) demonstrated the technical maturation of a durable, economical, and nontoxic coating (Superhydrophobic Lubricant Infused Composite, SLIC) that prevents invasive mussels and other unwanted organisms from growing on hydropower and marine structures. The physical characteristics of SLIC were measured using a variety of industry standard methods, just as a commercially available paint would, to show that it can rival other antifouling paints on the market not just in antifouling efficacy, but in structural integrity. SLIC also underwent extensive field testing in diverse field sites across the US to demonstrate that it is effective in varying environments. Engagement with industrial partners showed there is continued interest and need for a cost-effective, durable antifouling coating such as SLIC.

13 HYDRO ENERGY↗

DOE OSTI2025

NEXT Generation Energy Technologies for Connected and Automated On-Road Vehicles (NEXTCAR Phase I & II)

The Ohio State University’s ARPA-E NEXTCAR project was a multi-phase, multi-year research, development, and demonstration program focused on improving the energy efficiency of connected and automated vehicles (CAVs). The team developed and validated advanced vehicle motion and powertrain control algorithms that coordinate propulsion and automation systems to optimize energy use. Key technologies included Dynamic Skip Fire engine control, predictive eco-driving functions such as Eco-Approach and Departure (Eco-AND) and Eco-Adaptive Cruise Control (Eco-ACC), and powertrain-agnostic optimization frameworks for hybrid, plug-in hybrid, and battery electric vehicles. The project successfully demonstrated up to 30% energy-efficiency improvement during real-world testing at the Transportation Research Center and the American Center for Mobility. The outcomes provide a foundation for scalable, cost-effective deployment of energy-optimized CAV technologies across the automotive industry.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Effects of a Layered Morphology on Drip Suppression in Burning Polymers

Fire safety in polymers is critically important with products such as textiles and consumer goods, as well as materials used in construction, aerospace, transportation, and furniture. Additives used as anti-dripping and flame-retardant agents impose acute human health issues and have negative environmental impacts. With a focus on developing additive-free solutions, here we used multilayer coextrusion to fabricate layered polyethylene/polypropylene (PE/PP) films and investigated the effect of a layered morphology on dripping and burning rates. The experimental results for multilayered PE/PP samples were compared to control groups of melt blended PE/PP samples. The multilayer configuration provides two significant advantages: 154% delay in the time to the first drip and up to 87% reduction in the number of drips compared to the value for the melt blended samples with no additives. PE/PP blends with up to 2 wt % polytetrafluoroethylene, a commonly used anti-dripping agent in the industry, showed only 85% delay in the time to the first drip and about 60% reduction in the number of drips. We discovered a linear relationship between film thickness and burning rate, which allows for the use of the volumetric burning rate to normalize the effect of film thickness. No benefit in the burning rate was observed when comparing multilayered structures and conventional melt blended architectures or blends with PTFE. Annealing studies and transmission electron microscopy at areas close to the combustion zones confirmed that higher extensional viscosities induced by the layered structures and morphological changes due to the layer breakup play an important role in reducing dripping. By combining the first drip time and overall drip numbers, a parameter, “dripping index”, was defined to establish a fire safety map to simplify material comparisons. This study demonstrates that a multilayer film geometry can provide an additive-free solution to yield control over fire safety parameters in polymers.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Optimization of key energy and performance metrics for drug product manufacturing

During the development of pharmaceutical manufacturing processes, detailed systems-based analysis and optimization are required to control and regulate critical quality attributes within specific ranges, to maintain product performance. As discussions on carbon footprint, sustainability, and energy efficiency are gaining prominence, the development and utilization of these concepts in pharmaceutical manufacturing are seldom reported, which limits the potential of pharmaceutical industry in maximizing key energy and performance metrics. Based on an integrated modeling and techno-economic analysis framework previously developed by the authors, this study presents the development of a combined sensitivity analysis and optimization approach to minimize energy consumption while maintaining product quality and meeting operational constraints in a pharmaceutical process. The optimal input process conditions identified were validated against experiments and good agreement resulted between simulated and experimental data. Here, the results also allowed for a comparison of the capital and operational costs for batch and continuous manufacturing schemes under nominal and optimized conditions. Using the nominal batch operations as a basis, the optimized batch operation results in a 71.7% reduction of energy consumption, whereas the optimized continuous case results in an energy saving of 83.3%.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2023

Overcoming the Technical Challenges of Coordinating Distributed Load Resources at Scale (Final Report)

Significant recent research has investigated the potential for loads to provide balancing services to the grid. However, this research has not addressed key issues that may arise when such schemes are applied at scale including: 1. Distribution Network Issues. Coordination of large numbers of loads could result in power flows that violate distribution network constraints; 2. Stability Issues. Certain strategies to control loads can exhibit nonlinearity in the form of period-adding bifurcations and chaos. Other control strategies can potentially synchronize the behavior of large numbers of loads. In both cases, the outcome can be power oscillations and instability; 3. Communication Network Issues. Bidirectional low-latency communication channels between a central controller (or several distributed controllers) and each resource are expensive and likely not necessary for effective coordination. Our research questions were: What network, stability, and communication issues might arise in practice when we coordinate large aggregations of loads? How can we coordinate loads to achieve performance objectives in a cost effective manner while avoiding these issues? The ultimate technical goal of the project was the development of network-aware, communication-constrained, non-disruptive load control strategies with stability guarantees that achieve the performance requirements of typical balancing services at a sufficiently low cost to enable the load aggregator and customer to profit. The overall goal was to establish credibility for load control at scale and contribute to U.S. energy security and environmental goals. The team succeeded in answering these research questions and developing these control strategies. The overall approach was based on the development of three testing environments: a simulation testbed, an experimental testbed (20 physical model houses with window-box air conditioners) coupled with the simulation testbed, and a field testbed (100 actual homes in Austin, TX) coupled with the simulation testbed, which enabled controller testing, identification of issues, controller development, and controller validation. The resulting controller was used to demonstrate fast timescale grid balancing (frequency regulation) by aggregations of physical and virtual air conditioners, with sufficient quality to participate in the electricity market. Cost benefit analysis showed overall benefits to the participating households, load aggregators, and the grid, especially if the control technology was integrated directly into existing programmable communicating thermostats. The project provides a variety of wider benefits. Our technology transfer and outreach activities lead us to choose an open-source licensing commercialization pathway, enabling the project results to be available to researchers, industry, and the public. Furthermore, new grid balancing technologies will increase grid flexibility and will enable higher penetrations of intermittent renewable energy resources, such as wind and solar, to be connected to the grid, reducing its environmental impact, and mitigating climate change to the benefit of society.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Ventilation: Fume Hoods Self-Study Course # 48002

This course presents an overview of the requirements and safe work practices for the use of engineered ventilation controls (EVCs) at Los Alamos National Laboratory (LANL). EVCs addressed in this manual include fume hoods, local exhaust ventilation (LEV) systems other than fume hoods, portable and in-place high-efficiency particulate air (HEPA) filtration systems. Requirements from LANL Procedure P101-16, Industrial Ventilation (non-HVACR) that address EVC certification and use, along with responsibilities of workers who use EVCs and the responsible line managers (RLMs) of such workers, are also presented. Per 101-16, 6.1, workers who use, maintain, or certify (i.e., inspect and test) fume hoods, or Persons in Charge (PICs) who oversee others in those tasks, must complete this course.

42 ENGINEERING↗

DOE OSTI2021

Aerosol transport pathways and source attribution in China during the COVID-19 outbreak

Abstract. Due to the coronavirus disease 2019 (COVID-19) pandemic, human activities and industrial productions were strictly restricted during January–March 2020 in China. Despite the fact that anthropogenic aerosol emissions largely decreased, haze events still occurred. Characterization of aerosol transport pathways and attribution of aerosol sources from specific regions are beneficial to air quality and pandemic control strategies. This study establishes source–receptor relationships in various regions covering all of China during the COVID-19 outbreak based on the Community Atmosphere Model version 5 with Explicit Aerosol Source Tagging (CAM5-EAST). Our analysis shows that PM2.5 burden over the North China Plain between 30 January and 19 February is mostly contributed by local emissions (40 %–66 %). For other regions in China, PM2.5 burden is largely contributed from nonlocal sources. During the most polluted days of the COVID-19 outbreak, local emissions within the North China Plain and eastern China contributed 66 % and 87 % to the increase in surface PM2.5 concentrations, respectively. This is associated with the anomalous mid-tropospheric high pressure at the location of the climatological East Asia trough and the consequently weakened winds in the lower troposphere, leading to the local aerosol accumulation. The emissions outside China, especially those from South Asia and Southeast Asia, contribute over 50 % to the increase in PM2.5 concentration in southwestern China through transboundary transport during the most polluted day. As the reduction in emissions in the near future is desirable, aerosols from long-range transport and unfavorable meteorological conditions are increasingly important to regional air quality and need to be taken into account in clean-air plans.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

Light Water Reactor Sustainability Program Plant Modernization Technical Program Plan for FY 2021

This report presents the Technical Program Plan for FY 2019 for the Department of Energy Light Water Reactor Sustainability Program – Plant Modernization research pathway. A summary of the vision and strategy is provided to explain how this program addresses key issues and barriers for modernizing instrumentation and control technologies and infrastructure in domestic nuclear power plants. The report describes the pilot projects that have been formulated to develop and validate enabling technologies over the next several years that will result in digital alternatives to the legacy analog II&C systems in place today. This will allow much needed modernization of these systems to address reliability and obsolescence problems, as well as serve as a platform for substantial operational improvement. The report further describes key project resources and cooperative relationships, including the Electric Power Research Institute, the Nuclear Energy Institute )NEI), the Institute of Nuclear Power Operations (INPO), the IFE Halden Reactor Project, the Nuclear Regulatory Commission, and industry suppliers, that are instrumental to the success of the program. The report also lists the schedule for all program products, including the titles and report numbers for all published reports under this program.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2021

Integration of proteomics and metabolomics into the Design, Build, Test, Learn cycle to improve 3-hydroxypropionic acid production in Aspergillus pseudoterreus

Biological engineering of microorganisms to produce value-added chemicals is a promising route to sustainable manufacturing. However, overproduction of metabolic intermediates at high titer, rate, and yield from inexpensive substrates is challenging in non-model systems where limited information is available regarding metabolic flux and its control in production conditions. Integrated multi-omic analyses of engineered strains offers an in-depth look at metabolites and proteins directly involved in growth and production of target and non-target bioproducts. Here we applied multi-omic analyses to overproduction of the polymer precursor 3-hydroxypropionic acid (3HP) in the filamentous fungus Aspergillus pseudoterreus. A synthetic pathway consisting of aspartate decarboxylase, beta-alanine pyruvate transaminase, and 3HP dehydrogenase was designed and built for A. pseudoterreus. Strains with single- and multi-copy integration events were isolated and multi-omics analysis consisting of intracellular and extracellular metabolomics and targeted and global proteomics was used to interrogate the strains in shake-flask and bioreactor conditions. Production of a variety of co-products (organic acids and glycerol) and oxidative degradation of 3HP were identified as metabolic pathways competing with 3HP production. Intracellular accumulation of nitrogen as 2,4-diaminobutanoate was identified as an off-target nitrogen sink that may also limit flux through the engineered 3HP pathway. Elimination of the high-expression oxidative 3HP degradation pathway by deletion of a putative malonate semialdehyde dehydrogenase improved the yield of 3HP by 3.4× after 10 days in shake-flask culture. This is the first report of 3HP production in a filamentous fungus amenable to industrial scale biomanufacturing of organic acids at high titer and low pH.

Pomraning, Kyle R.↗

DOE OSTI2020

State-of-the-art on research and applications of machine learning in the building life cycle

Fueled by big data, powerful and affordable computing resources, and advanced algorithms, machine learning has been explored and applied to buildings research for the past decades and has demonstrated its potential to enhance building performance. This study systematically surveyed how machine learning has been applied at different stages of building life cycle. By conducting a literature search on the Web of Knowledge platform, we found 9579 papers in this field and selected 153 papers for an in-depth review. The number of published papers is increasing year by year, with a focus on building design, operation, and control. However, no study was found using machine learning in building commissioning. There are successful pilot studies on fault detection and diagnosis of HVAC equipment and systems, load prediction, energy baseline estimate, load shape clustering, occupancy prediction, and learning occupant behaviors and energy use patterns. None of the existing studies were adopted broadly by the building industry, due to common challenges including (1) lack of large scale labeled data to train and validate the model, (2) lack of model transferability, which limits a model trained with one data-rich building to be used in another building with limited data, (3) lack of strong justification of costs and benefits of deploying machine learning, and (4) the performance might not be reliable and robust for the stated goals, as the method might work for some buildings but could not be generalized to others. Finally, findings from the study can inform future machine learning research to improve occupant comfort, energy efficiency, demand flexibility, and resilience of buildings, as well as to inspire young researchers in the field to explore multidisciplinary approaches that integrate building science, computing science, data science, and social science.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗