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At least 1,207 records · Page 67

Embedded Sensors and Controls to Improve Component Performance and Reliability -- Bench-scale Testbed Design Report

Embedded instrumentation and control systems that can operate in extreme environments are challenging due to restrictions on sensors and materials. As a part of the Department of Energy's Nuclear Energy Enabling Technology cross-cutting technology development programs Advanced Sensors and Instrumentation topic, this report details the design of a bench-scale embedded instrumentation and control testbed. The design goal of the bench-scale testbed is to build a re-configurable system that can rapidly deploy and test advanced control algorithms in a hardware in the loop setup. The bench-scale testbed will be designed as a fluid pump analog that uses active magnetic bearings to support the shaft. The testbed represents an application that would improve the efficiency and performance of high temperature (700 C) pumps for liquid salt reactors that operate in an extreme environment and provide many engineering challenges that can be overcome with embedded instrumentation and control. This report will give details of the mechanical design, electromagnetic design, geometry optimization, power electronics design, and initial control system design.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Mathematical Optimization of NGCC Solvent-based Carbon Capture Processes to Explore High Capture Designs

For point-source capture, much of the work to date has focused on achieving 90% capture – a somewhat arbitrary target above which parasitic losses to drive carbon capture and compression systems were believed to be too great to be economically justifiable. The recent push for deep decarbonization has caused this target to be revisited, and existing literature is of limited usefulness as most published studies have focused on carbon capture percentages of 90%. In this work, numerous mathematical optimizations were performed between carbon capture targets between 90%-99.8% of a Natural Gas Combined Cycle (NGCC) plant to better understand incremental cost of these systems so they may be compared to other decarbonization technologies, and to inform technical risk associated with targeting higher capture performance for these types of systems.

carbon capture↗

Semivolatile POA and parameterized total combustion SOA in CMAQv5.2: impacts on source strength and partitioning

Abstract. Mounting evidence from field and laboratory observations coupled with atmospheric model analyses shows that primary combustion emissions of organic compounds dynamically partition between the vapor and particulate phases, especially as near-source emissions dilute and cool to ambient conditions. The most recent version of the Community Multiscale Air Quality model version 5.2 (CMAQv5.2) accounts for the semivolatile partitioning and gas-phase aging of these primary organic aerosol (POA) compounds consistent with experimentally derived parameterizations. We also include a new surrogate species, potential secondary organic aerosol from combustion emissions (pcSOA), which provides a representation of the secondary organic aerosol (SOA) from anthropogenic combustion sources that could be missing from current chemical transport model predictions. The reasons for this missing mass likely include the following: (1) unspeciated semivolatile and intermediate volatility organic compound (SVOC and IVOC, respectively) emissions missing from current inventories, (2) multigenerational aging of organic vapor products from known SOA precursors (e.g., toluene, alkanes), (3) underestimation of SOA yields due to vapor wall losses in smog chamber experiments, and (4) reversible organic compounds–water interactions and/or aqueous-phase processing of known organic vapor emissions. CMAQ predicts the spatially averaged contribution of pcSOA to OA surface concentrations in the continental United States to be 38.6 and 23.6 % in the 2011 winter and summer, respectively. Whereas many past modeling studies focused on a particular measurement campaign, season, location, or model configuration, we endeavor to evaluate the model and important uncertain parameters with a comprehensive set of United States-based model runs using multiple horizontal scales (4 and 12 km), gas-phase chemical mechanisms, and seasons and years. The model with representation of semivolatile POA improves predictions of hourly OA observations over the traditional nonvolatile model at sites during field campaigns in southern California (CalNex, May–June 2010), northern California (CARES, June 2010), the southeast US (SOAS, June 2013; SEARCH, January and July, 2011). Model improvements manifest better correlations (e.g., the correlation coefficient at Pasadena at night increases from 0.38 to 0.62) and reductions in underprediction during the photochemically active afternoon period (e.g., bias at Pasadena from −5.62 to −2.42 µg m−3). Daily averaged predictions of observations at routine-monitoring networks from simulations over the continental US (CONUS) in 2011 show modest improvement during winter, with mean biases reducing from 1.14 to 0.73 µg m−3, but less change in the summer when the decreases from POA evaporation were similar to the magnitude of added SOA mass. Because the model-performance improvement realized by including the relatively simple pcSOA approach is similar to that of more-complicated parameterizations of OA formation and aging, we recommend caution when applying these more-complicated approaches as they currently rely on numerous uncertain parameters. The pcSOA parameters optimized for performance at the southern and northern California sites lead to higher OA formation than is observed in the CONUS evaluation. This may be due to any of the following: variations in real pcSOA in different regions or time periods, too-high concentrations of other OA sources in the model that are important over the larger domain, or other model issues such as loss processes. This discrepancy is likely regionally and temporally dependent and driven by interferences from factors like varying emissions and chemical regimes.

54 ENVIRONMENTAL SCIENCES↗

Developing Near Optimal Control Sequences for Chiller Plants with Water-side Economizers: A Case Study in a Warm and Marine Climate

Various advanced control sequences for chiller plants with water-side economizers (WSE) have been proposed in literature, but the optimization of those controls is limited. It is possible to maximize energy savings by developing near-optimal control sequences, which are dependent on several factors such as the load profile. To address these gaps, we first identify an advanced control sequence and three key control parameters for chiller plants with WSE. Next, optimizations are performed to minimize energy consumption for seven combinations of control parameters. A chiller plant with WSE system in a warm and marine climate is studied and two load profiles are considered. The system and controls are modeled using the Modelica Buildings library. The results show optimizing the selected control parameters can reduce energy consumption by up to 11% depending on the load profile. Specifically, optimizing the cooling tower efficiency threshold in the condenser water reset control can significantly reduce energy savings for the variable load profile by efficiently shifting the load from the cooling tower to the chiller. This paper provides practical guidance for developing near-optimal control sequences for chiller plant with WSE systems considering impacts such as the load profile.

chiller plant↗

Non-linear Model Predictive Control of Wave Energy Converters with Realistic Power Take-off Configurations and Loss Model

Model Predictive Control (MPC) has been recognized as a well-developed control strategy for optimizing the performance of wave energy converters (WECs). The standard problem involves maximizing the absorbed power from oncoming waves while respecting motion constraints of the device and force constraints of the power take-off (PTO). The generated electrical power is then calculated by assuming an ideal PTO with no power conversion losses or limitations to power flow. In this article, we remove the assumption of an ideal PTO and present four different control options that reflect unique combinations of PTO control and power flow constraints. We also recast the MPC problem to maximize the generated power instead of the absorbed power by accounting for the losses in the power train. Using a WEC with a hydraulic PTO, we develop a loss model suitable for controls optimization. Lastly, we illustrate the process of setting up the non-linear MPC problem and compare the performance of competing control strategies using a common benchmark based on annual energy captured at a reference site.

16 TIDAL AND WAVE POWER↗

Scaling laser preheat for MagLIF with the Z-Beamlet laser

Optimizing the performance of the Magnetized Liner Inertial Fusion (MagLIF) platform on the Z pulsed power facility requires coupling greater than 2 kJ of preheat energy to an underdense fuel in the presence of an applied axial magnetic field ranging from 10 to 30 T. Achieving the suggested optimal preheat energies has not been experimentally achieved so far. In this work, we explore the preheat design space for cryogenically cooled MagLIF targets, which represent a viable candidate for increasing preheat energies. Using 2D and 3D HYDRA MHD simulations, we first discuss the various physical effects that occur during laser preheat, such as laser energy deposition, self-focusing, and filamentation. After identifying the changes that different phase plates, gas-fill densities, and magnetic fields bring to the aforementioned physical effects, we, then, consider higher laser energies that are achievable with modest upgrades to the Z Beamlet laser. Lastly, with a 6.0-kJ upgraded laser, 3D calculations suggest that it is possible to deliver 4.25 kJ into the MagLIF fuel, resulting in an expected deuterium neutron yield of Y DD ≃ 1.5 × 10 14 , or roughly 50 kJ of DT equivalent yield, at 20-MA current drive. This represents a 10-fold increase in the currently achieved yields for MagLIF.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Efficient Optimization of Large Wind Farms for Real-Time Control: Preprint

Wind turbines in a wind farm typically operate individually to maximize their own performance regardless of the impact of aerodynamic interactions on neighboring turbines. Properly coordinating turbines, by operating some turbines suboptimally, within a wind farm has the potential to improve overall wind farm performance. Computing the optimal control strategy under varying atmospheric conditions can be computationally intense for large wind farms. As wind power farms increase in size and related models become more complex, computationally efficient algorithms are needed to perform real-time optimization and control. This study proposes a distributed optimization framework and computationally efficient wake steering wind farm control strategy that uses the yaw angle of a turbine to alter the behavior of a turbine wake and minimize turbine interactions. This computational efficiency allows the strategy to be feasible for real-time control.

17 WIND ENERGY↗

Interactions Enhance Ramp Reversal Memory in Locally Phase Separated Materials

The ramp-reversal memory (RRM) effect in metal–insulator transition metal oxides (TMOs), a non-volatile resistance change induced by repeated temperature cycling, has attracted considerable interest in neuromorphic computing and non-volatile memory devices. Our previous defect motion model successfully explained RRM in vanadium dioxide (VO 2 ), capturing observed critical temperature shifts and memory accumulation throughout the sample. However, this approach lacked interactions between metallic and insulating domains. Here, we extend our model by combining a correlated Random Field Ising Model with defect diffusion-segregation, enabling accurate hysteresis modeling while predicting the relationship between RRM and domain interactions. Our simulations demonstrate that the maximum RRM occurs when the turnaround temperature approaches the inflection point. This peak in RRM vs. turnaround temperature is consistent with prior transport measurements, as well as our own optical measurements reported here. Significantly, we find that increasing nearest-neighbor interactions enhances the maximum memory effect, thus providing a clear mechanism for optimizing RRM performance. Since our model employs minimal assumptions, we predict that RRM should be a widespread phenomenon in materials exhibiting patterned phase coexistence of electronic domains. This work not only advances fundamental understanding of memory behavior in TMOs but also establishes a much-needed theoretical framework for optimizing device applications.

36 MATERIALS SCIENCE↗

Moderator Optimization for the Second Target Station Final Design

This report details the results from the optimization simulations performed for the final design of the Second Target Station (STS). This is a continuation of the analysis performed in 2022 for the preliminary design. To evaluate the impact of the design changes since 2022, the analysis was repeated with updated target and moderator models. Additionally, more degrees of freedom have been considered in the premoderator dimensions which provide a refinement compared to the previous optimization analysis.

43 PARTICLE ACCELERATORS↗

Experimental Evaluation of a Microchannel Condenser for R600a Domestic Refrigerators

Domestic refrigerators are among the most common household appliances, accounting for approximately 4% of total household energy consumption, which is higher than that of clothes dryers, lighting, or cooking appliances. With nearly 13 million new domestic refrigerators sold annually, even marginal improvements in their energy performance can yield significant reductions in overall energy demand and cost. This study focuses on enhancing the performance of domestic refrigerators using R600a as the refrigerant. Most domestic refrigerators currently employ wire-and-tube condensers, which are bulky and require a larger refrigerant charge. Given that R600a is classified as an A3 flammable refrigerant under ASHRAE standards, minimizing the system charge while maintaining or improving performance is critical. To address this, a compact and light weight single-pass serpentine microchannel heat exchanger (made of aluminum) was adopted as a condenser, replacing the conventional wire-and-tube configuration. The modified system was experimentally tested according to AHAM test standards, and charge optimization was performed. The results demonstrated that the refrigerator equipped with the microchannel condenser achieved a 5.3% reduction in energy consumption compared to the baseline configuration with wire-and-tube condenser.

Murugan, Muneeshwaran [ORNL] (ORCID:00000003340352↗

Finite difference numerical method for the superlattice Boltzmann transport equation and case comparison of CPU(C) and GPU(CUDA) implementations

We present a finite difference numerical algorithm for solving two dimensional spatially homogeneous Boltzmann transport equation which describes electron transport in a semiconductor superlattice subject to crossed time dependent electric and constant magnetic fields. The algorithm is implemented both in C language targeted to CPU and in CUDA C language targeted to commodity NVidia GPU. We compare performances and merits of one implementation versus another and discuss various software optimisation techniques.

97 MATHEMATICS AND COMPUTING↗

Post-assembly magnetization of a 100 kW high speed permanent magnet rotor

A post-assembly magnetizing fixture has been designed and successfully used to magnetize the rotor of a 100 kW high speed permanent magnet synchronous motor. The rotor is a solid cylinder with outer diameter of 80 mm and total length of 515 mm. The permanent magnet material is samarium-cobalt (Sm{sub 2}Co{sub 17}) with saturation magnetizing field of 6 T. The mechanical stability of the magnetizing fixture has been studied as well as the general design methodology. The magnetizing coil is subdivided in order to reduce the electromagnetic force, and the coils are separately reinforced in different ways. The electromagnetic and structural optimization is performed by finite element analysis and verified by experiments.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

A Comprehensive Methodology to Evaluate Losses and Process Variations in Silicon Solar Cell Manufacturing

Novel, high-throughput metrology methods are used in this paper for detailed performance loss analysis of approximately 400 industrial crystalline silicon solar cells, all coming from the same production line. The characterization sequence combines traditional global cell measurements (e.g., current-voltage, Suns-VOC) with camera-based cell imaging of voltage distribution and power dissipation from photoluminescence and lock-in thermography, respectively. Spatial variations in current collection are visualized using a high-speed external quantum efficiency and reflectance measurement technique. A nondestructive transfer length method (TLM) measurement technique is also implemented, featuring circular TLM structures hidden within the busbars of the cells. The variance of individual loss parameters and their impact on cell performance are quantified for this large group of cells. Based on correlations performed across parameters, recombination losses in the bulk and rear surface of the cell are shown to be the primary limiting factor for the cell efficiency. The nature of these distributions and correlations provide important insights about loss mechanisms in industrial solar cells, helping to prioritize efforts for optimizing the performance of the production line. Additionally, many of the parameters extracted from these techniques can be tied back to incoming material quality issues (e.g., poor bulk carrier lifetime, nonuniform wafer doping) and to individual unit processes (e.g., texturing, phosphorus diffusion, silicon nitride deposition, metallization), allowing the data to be used directly for process control in manufacturing. All of the datasets are made available for download.

14 SOLAR ENERGY↗

Study of Cathode and Cavity Geometries in Electropolishing (EP): Electric Field Simulation

Niobium (Nb) superconducting radio frequency (SRF) cavities require electropolishing surface treatment to reach high acceleration gradient. EP performed in the plateau region of an I-V curve [1] leads to a smooth finish of the cavity surface including the equator surface. The equator surface is vital because a rough equator surface leads to premature quench and limit the cavity performance. Previous experimental work was performed to optimize EP parameters for low-beta (LB) 650 MHz Nb cavity [1]. It was found that different cathode surface areas vary the plateau onset voltage. A lower onset voltage was achieved for HB650 cavity with an enlarged cathode surface area. The aim of the study is to perform electrostatic and electrochemical simulation to understand the impact of both cavity geometry and cathodes. This report covers an initial result on electric field simulation performed with HB and LB 650 MHz cavities.

Loer, Bereket↗

Optimal operation of solid-oxide electrolysis cells considering long-term chemical degradation

Optimizing the performance of solid oxide electrolysis cells (SOECs) for long-term hydrogen (H 2 ) production at high temperatures is crucial, as prolonged operation leads to efficiency losses and shorter cell lifespans due to chemical degradation. Here, in this work, we adopt a quasi-steady state approach for dynamic optimization over extended operational periods to address the disparity in timescales between cell operation and degradation. Integrating a 2-D non-isothermal SOEC model with balance-of-plant (BOP) equipment, we explore three optimization objectives: minimizing terminal degradation, maximizing integral efficiency, and minimizing the levelized cost of H 2 (LCOH). Our dynamic optimization algorithm reduces LCOH by 9.5% and 16% compared to strategies focusing solely on terminal degradation and integral efficiency, respectively. For electricity prices of 0.03 $\$$/mWh and 0.3 $\$$ mWh optimal replacement schedules range from 5 to 2 years, depending on the operational mode. Furthermore, a flexible operational mode yields additional improvements in LCOH over traditional galvanostatic and potentiostatic modes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Advancing the mechanical integrity and fragmentation behavior of reactive projectiles

A multivariant statistical approach was used to identify treatment conditions that improve the survivability of structural reactive material (SRM) projectiles upon launch and enhance energy release upon impact. The study included both mechanical testing of projectiles as well as their reactive characterization. The projectiles were launched in a high-velocity impact-ignition testing system and impacted an anvil for vented chamber calorimetry. This study examined a link between ultimate compressive stress and combustion performance. Two treatments were applied to consolidated aluminum projectiles including annealing and addition of silica (SiO 2 ) inclusions. Results showed annealing at moderate temperatures resulted in intact SRM projectiles upon launch. Adding small concentrations (1–2 wt. %) of SiO 2 to the SRM promoted fragmentation and combustion performance upon impact. Compared to the untreated projectiles, annealing with SiO 2 inclusion processing treatments improved the energy conversion efficiency from 37–84% (for untreated projectiles) up to 54–98%. In conclusion, increasing interparticle dislocation recovery by annealing while balancing inclusions promoting fragmentation upon impact was the key to optimizing combustion performance for SRM ballistic impact applications.

42 ENGINEERING↗

Microstructural Materials Design Via Deep Adversarial Learning Methodology

Identifying the key microstructure representations is crucial for computational materials design (CMD). However, existing microstructure characterization and reconstruction (MCR) techniques have limitations to be applied for microstructural materials design. Some MCR approaches are not applicable for microstructural materials design because no parameters are available to serve as design variables, while others introduce significant information loss in either microstructure representation and/or dimensionality reduction. In this work, we present a deep adversarial learning methodology that overcomes the limitations of existing MCR techniques. In the proposed methodology, generative adversarial networks (GAN) are trained to learn the mapping between latent variables and microstructures. Thereafter, the low-dimensional latent variables serve as design variables, and a Bayesian optimization framework is applied to obtain microstructures with desired material property. Due to the special design of the network architecture, the proposed methodology is able to identify the latent (design) variables with desired dimensionality, as well as capturing complex material microstructural characteristics. The validity of the proposed methodology is tested numerically on a synthetic microstructure dataset and its effectiveness for microstructural materials design is evaluated through a case study of optimizing optical performance for energy absorption. Additional features, such as scalability and transferability, are also demonstrated in this work. In essence, the proposed methodology provides an end-to-end solution for microstructural materials design, in which GAN reduces information loss and preserves more microstructural characteristics, and the GP-Hedge optimization improves the efficiency of design exploration.

Engineering↗

Optimization of TiO{sub 2} photoelectrode with titanium isopropoxide for flexible dye sensitized solar cells

Flexible DSSC uses plastic substrate such as polyethylene terephthalate (PET) to deposit photoelectrode, resulting in poor photoconversion efficiency of the solar cell due to the low temperature applied in the fabrication process. In this research, optimization process was examined in order to optimize the performance of flexible DSSC by adding titanium isopropoxide (TTIP) as a binder to TiO{sub 2} paste for DSSC photoelectrode. Small portion of TTIP with molar percentages of 0%, 5%, and 10% were added to a mixture of TiO{sub 2} nanocrystaline, butanol, DI water, and reflector powder. The mixtures were stirred using a magnetic stirrer for 24 hours. Each of various pastes was then deposited on a plastic substrate with doctor blade method on 1 cm{sup 2} area. The films were sintered at temperature of 150 °C for 4 hours and soaked in dye solution for 24 hours. Furthermore, TiO{sub 2} photoelectrode and Pt counter electrode were assembled and injected by electrolyte. Flexible DSSCs were characterized by SEM and XRD to determine their morphological structures. J-V measurement was performed by sun simulator to calculate DSSC photoconversion efficiency. The optimum performance of flexible DSSC was achieved by DSSC with 10 mol% TTIP content.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗