Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “data conditioning”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,315 records · Page 73
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Linear systematics mitigation in galaxy clustering in the Dark Energy Survey Year 1 Data

ABSTRACT We implement a linear model for mitigating the effect of observing conditions and other sources of contamination in galaxy clustering analyses. Our treatment improves upon the fiducial systematics treatment of the Dark Energy Survey (DES) Year 1 (Y1) cosmology analysis in four crucial ways. Specifically, our treatment (1) does not require decisions as to which observable systematics are significant and which are not, allowing for the possibility of multiple maps adding coherently to give rise to significant bias even if no single map leads to a significant bias by itself, (2) characterizes both the statistical and systematic uncertainty in our mitigation procedure, allowing us to propagate said uncertainties into the reported cosmological constraints, (3) explicitly exploits the full spatial structure of the galaxy density field to differentiate between cosmology-sourced and systematics-sourced fluctuations within the galaxy density field, and (4) is fully automated, and can therefore be trivially applied to any data set. The updated correlation function for the DES Y1 redMaGiC catalogue minimally impacts the cosmological posteriors from that analysis. Encouragingly, our analysis does improve the goodness-of-fit statistic of the DES Y1 3 × 2pt data set (Δχ2 = −6.5 with no additional parameters). This improvement is due in nearly equal parts to both the change in the correlation function and the added statistical and systematic uncertainties associated with our method. We expect the difference in mitigation techniques to become more important in future work as the size of cosmological data sets grows.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2020

Mechanistic Studies of the Oxidation of Cyclohexene to 2-Cyclohexen-1-one over ALD Prepared Titania Supported Vanadia

Selective oxidation of cyclohexene to 2-cyclohexen-1-one over titania supported vanadia (VO x /TiO 2 ) has been studied using temperature dependent in-situ FTIR spectroscopy in both the presence and absence of oxygen. The VO x /TiO 2 samples were prepared using one atomic layer deposition (ALD) cycle and characterized by Raman spectroscopy. In-situ FTIR data for the oxidation of cyclohexene and perdeuterocyclohexene allow for the formulation of a molecular level reaction mechanism, which is initiated by the transfer of an allyl hydrogen. Oxidation of perdeuterocyclohexene provides a direct probe of the formation of OD and HDO moieties that support the involvement of specific steps in the proposed mechanism. The presence of gas phase oxygen does not lead to a change in the products versus anaerobic conditions. However, gas phase oxygen is significantly incorporated in the CO 2 over-oxidation product above ~250 °C. Data were also obtained with cyclohexene epoxide as the reactant in an effort to determine whether there is a parallel reaction pathway, which is initiated by C=C activation in cyclohexene, that involves cyclohexene epoxide as an intermediate. Furthermore, though a minor pathway involving a cyclohexene epoxide intermediate cannot be ruled out, these data demonstrate that, under experimental conditions, the dominant pathway from cyclohexene to cyclohexene-1-one is initiated by an allyl-H activation step and does not involve an epoxide intermediate.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Numerical and experimental investigation of the flame kernel growth in a methane/air mixture near the lean flammability limit

Lean combustion has the potential to improve the thermal efficiency of spark-ignition engines, but it faces the significant challenge of increased cycle-to-cycle variation due to low mixture reactivity and unstable flame dynamics. Computational fluid dynamics (CFD) employing predictive models can guide engine design and optimize operating strategies for lean combustion. However, ignition and combustion models have rarely been validated at fuel-lean conditions, and a fundamental understanding of the early flame kernel growth process is also lacking for a successful sub-model development. Here, the present study develops a numerical simulation framework used to investigate early flame kernel growth in methane/air mixtures. A nanosecond-pulsed discharge (NPD) approach is employed to effectively decouple the flame kernel growth from the electrical discharge due to their difference in timescales, and equivalence ratios near the experimentally measured lean flammability limit (LFL) are selected to focus on challenging mixture conditions. Three numerical investigations, such as the choice of turbulence modeling, grid size, and grid control strategies, are examined to match both LFL and flame kernel structure measured from experiments. It is demonstrated that a quasi-direct numerical simulation (QDNS) with a fixed grid embedding of 10 μm can predict the LFL as φ CFD =0.61 and match the displacement speed of the kernel’s boundary marked in schlieren images. To predict the LFL and flame kernel shape, a fine grid (Δ≤12.5 μm) is needed to capture the consumption of formaldehyde (CH 2 O) in kernel’s reaction branches attached to the anode, and adaptive mesh refinement is replaced with the fixed embedding due to loss of simulation accuracy. Also, it is found that a large-eddy simulation (LES) using the Dynamic Structure model is not suitable for the NPD-induced flame kernel simulation because artificial sub-grid turbulent kinetic energy induced by shock dynamics alters the flow velocity calculation, resulting in divergence of LES from QDNS. Lastly, the simulation well matches the experimental data for the flame kernel evolution in three mixture conditions (φ = 0.7, 0.61, 0.55), showing toroidal flame kernel expansion and flame kernel growth/extinction.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

Lost Circulation Materials in Geothermal Drilling: Thermal Degradation, Viscosity, Compression, and Flow Loop Tests

This dataset provides a set of experimental data on the performance of lost circulation materials (LCMs) used in geothermal drilling operations. It includes results from four distinct tests: thermal degradation, viscosity measurements, compression tests, and high-temperature flow loop experiments. The materials tested, such as cedar fiber, cotton seed hulls, magma fiber, microcellulose, and sawdust, were analyzed under a range of conditions to assess their effectiveness in mitigating fluid losses in geothermal wells. Data on thermal degradation explores mass loss, water loss, and gas release for each material when subjected to temperatures between 90C and 250C. Viscosity measurements capture the behavior of LCM mixtures under different temperatures, while compression tests investigate the structural integrity of both undegraded and thermally degraded materials. The high-temperature flow loop experiments simulate geothermal well conditions, analyzing how different materials and mixtures affect fluid flow and sealing performance in a fractured reservoir environment. In addition to the experimental data, the dataset includes photos documenting the materials, schematics of test setups, and several published manuscripts that provide detailed insights into the experimental methods and findings.

15 GEOTHERMAL ENERGY↗
DOE OSTI2023

Degradation and Modeling of Large-Format Commercial Lithium-Ion Cells as a Function of Chemistry, Design, and Aging Conditions

Demand for large-format (>10 Ah) lithium-ion batteries has increased substantially in recent years, due to the growth of both electric vehicle and stationary energy storage markets. The economics of these applications is sensitive to the lifetime of the batteries, and end-of-life can either be due to energy or power limitations. Despite this, there is little information from cell manufacturers on the sensitivity of cell degradation to environmental conditions or battery use. This work reports accelerated aging test data from four commercial large-format lithium-ion batteries from three manufacturers, with varying design (thickness, casings, ...), chemistry (lithium-iron-phosphate (LFP) or lithium-nickel-manganese-cobalt-oxide positive electrodes (NMC), with graphite (Gr) negative electrodes), and capacity (50 to 250 Amp hours). The tested LFP|Gr cell is found to be relatively insensitive to cycling conditions like temperature or voltage window, while NMC|Gr cells have varying sensitivity. Degradation trends are further investigated by training predictive models: simple polynomial trend lines, a semi-empirical reduced-order model, and an empirical reduced-order model identified using machine-learning based on symbolic regression. Calendar and cycle life are simulated over a variety of conditions to directly compare the various batteries. Cell size and thickness are found to substantially impact sensitivity to temperature during cycle aging, while electrode chemistry impacts depth-of-discharge sensitivity. Real-world battery lifetime is evaluated by simulating residential energy storage and commercial frequency containment reserve systems in several U.S. climate regions. Predicted lifetime across cell types varies from 7 years to 20+ years, though all cells are predicted to have at least 10 year life in certain conditions.

battery lifetime↗
DOE OSTI2020

Resonant Frequency Derived from the Rayleigh-Wave Dispersion Image: The High-Impedance Boundary Problem

In this work, we present a simple and automated approach to estimate primary site-response resonance, layer thickness, and shear-wave velocity directly from a dispersion image for a layer over half-space problem. We demonstrate this for high-impedance boundary conditions that lie in the upper tens of meters. Our approach eliminates the need for time-consuming dispersion curve picking and 1D shear-wave velocity inversion for large data volumes that can capture velocity structure in profile. We highlight important relationships between dispersion characteristics and resonance parameters through synthetic modeling and field data acquired over Atlantic Coastal Plain sediments. In this environment, shallow soil conditions are critical to accurately estimate earthquake site response. We suggest that this image processing approach can be applied to a range of high-impedance conditions, at a range of scales, or can provide model constraints for more complex velocity structures.

58 GEOSCIENCES↗
DOE OSTI2021

Energetics of surface melt in West Antarctica

We use reanalysis data and satellite remote sensing of cloud properties to examine how meteorological conditions alter the surface energy balance to cause surface melt that is detectable in satellite passive microwave imagery over West Antarctica. This analysis can detect each of the three primary mechanisms for inducing surface melt at a specific location: thermal blanketing involving sensible heat flux and/or longwave heating by optically thick cloud cover, all-wave radiative enhancement by optically thin cloud cover, and föhn winds. We examine case studies over Pine Island and Thwaites glaciers, which are of interest for ice shelf and ice sheet stability, and over Siple Dome, which is more readily accessible for field work. During January 2015 over Siple Dome we identified a melt event whose origin is an all-wave radiative enhancement by optically thin clouds. During December 2011 over Pine Island and Thwaites glaciers, we identified a melt event caused mainly by thermal blanketing from optically thick clouds. Over Siple Dome, those same 2011 synoptic conditions yielded a thermal-blanketing-driven melt event that was initiated by an impulse of sensible heat flux and then prolonged by cloud longwave heating. The December 2011 synoptic conditions also generated föhn winds at a location on the Ross Ice Shelf adjacent to the Transantarctic Mountains, and we analyze this case with additional support from automatic weather station data. In contrast, a late-summer thermal blanketing period over Pine Island and Thwaites glaciers during February 2013 showed surface melt initiated by cloud longwave heating and then prolonged by enhanced sensible heat flux. One limitation thus far with this type of analysis involves uncertainties in the cloud optical properties. Nevertheless, with improvements this type of analysis can enable quantitative prediction of atmospheric stress on the vulnerable Antarctic ice shelves in a steadily warming climate.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Physics-based model of irradiation creep for ferritic materials under fusion energy operation conditions

Irradiation creep is known to be an important process for structural materials in nuclear environments, potentially leading to creep failure at temperatures where thermal creep is generally negligible. While there is a great deal of data for irradiation creep in steels and zirconium alloys in light water reactor conditions, much less is known for first wall materials under fusion energy conditions. Lacking suitable fusion neutron sources for detailed experimentation, modeling, and simulation can help bridge the dose-rate and spectral-effects gap and produce quantifiable expectations for creep deformation of first wall materials under standard fusion conditions. In this paper, we develop a comprehensive model for irradiation creep created from merging a crystal plasticity representation of the dislocation microstructure and a defect evolution simulator that accounts for the entire cluster dimensionality space. Both approaches are linked by way of a climb velocity that captures dislocation-biased defect absorption and a dislocation strengthening term that reflects the accumulation of defect clusters in the system. Here, we carry out our study in Fe under first wall fusion reactor conditions, characterized by a fusion neutron spectrum with average recoil energies of 20 keV and a damage dose rate of ≈3×10 –7 dpa/s at temperatures between 300 and 800 K.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Sensor Anomaly Detection for Nuclear Reactor Systems Utilizing Linear Regression and K-Means Unsupervised Machine Learning

Nuclear reactors and related systems are becoming increasingly complex due to advancing technologies in next-generation power reactors. This increased complexity necessitates enhanced automation and data management capabilities. To successfully realize autonomous systems, methods must be developed to handle vast volumes of data and effectively distinguish anomalous data from noise and expected data. While impressive models utilizing digital twins and similar approaches are under development, here we propose a simplified model for analyzing fundamental methods and techniques. Initially, we created a general dataset by using initial data from PCTRAN in order to represent ideal steady-state conditions. We then inserted anomalies based on prevalent sensor anomaly types (e.g., point anomalies, linear drift, and downward deviations), along with unusual anomalies such as exponential drift and upward deviations. To detect anomalies, we developed a program that employs data partitioning and linear regression to preprocess and filter the anomalous data. A K-Means machine learning (ML) method was then applied to separate and count the data within the anomalous partition. The results from all datasets—apart from exponential growth—demonstrated positive outcomes, with each returning multiple instances of greaterthan-95% accuracy. We conducted further investigations using Idaho National Laboratory’s RAVEN software to perform a sensitivity analysis on the input variables (R 2 Tolerance, Slope Tolerance, and Window Size) and found that the output variables (Accuracy and Time) were most sensitive to the Window Size. Despite the promising results published, further development is required to effectively apply these methods to nuclear systems. Nevertheless, the strengths of this approach are evident and hold promise for future applications in the field.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2024

Intern Poster - Characterizing Wildland Fire Conditions for Lab-Scale Testing of Advanced Conductors

As the demand for energy increases each year, electric utilities face the challenge of delivering more power than before. Current transmission/distribution networks have proved reliable in the past but are physically unable to meet higher energy demands. Traditional overhead conductor cables (such as Aluminum Conductor Steel Reinforced (ACSR)) are limited in their ability to hold more voltage due to increased temperatures and resulting sag. When the cable sags, it comes closer to the ground, violating clearance standards and presenting an environmental risk. Newly developed advanced conductors, aluminum conductors with carbon fiber composite cores (instead of steel) mitigate this risk. Advanced conductors are engineered to perform in higher operating temperatures without sagging, thus possessing higher capacity potential. Regardless, utilities are hesitant to adopt this new technology due to scarcity of use data. The largest looming risk for utilities is wildland fires. There is little to no data on how advanced conductors perform in the event of a wildland fire. To address these concerns, this project aims to test the mechanical performance of advanced conductors in these conditions, providing utilities use data for their reference. The initial steps of the project will be to design and construct a fire table apparatus to reproduce wildland fire conditions, calculate proper parameters for this testing, and analyze the impact mathematically. After completing these actions, the next steps will be to test the advanced conductors in the laboratory fire chamber.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

Advanced defrosting techniques in air source heat pumps: A review of vapor injection, thermal energy storage, and experimental frost accumulation data

Electrification is a critical step for reducing greenhouse gas emissions from heating. Air source heat pumps (ASHPs) are a promising alternative to fossil fuel-based systems due to their high coefficients of performance (COP), dual heating and cooling capability, and lower carbon footprint. However, for ASHPs to achieve widespread adoption, they must operate reliably across all climates, including cold regions. Additionally, defrosting techniques should be energy efficient and minimally disruptive to indoor comfort. Vapor injection (VI) technology can address the high-pressure and high-temperature lift challenges encountered in low ambient conditions. More recently, in addition to enhancing heating performance, VI has also been shown to improve the speed and efficiency of reverse cycle defrosting. Likewise, thermal energy storage (TES) has steadily gained attention for its ability to serve as an auxiliary heat source during both normal operation and defrosting. This review analyzes the benefits and limitations of VI- and TES-assisted defrosting approaches. While both technologies show strong potential individually, no studies to date have explored their combined use in ASHP systems. Additionally, to support continued development of defrosting strategies, both in modeling and experimental work, it is critical to establish frost accumulation data under a range of operating conditions. By compiling the available data from the literature, this paper also highlights the limited availability of such experimental data and the wide variation in frosting and defrosting durations and termination criteria, which are often influenced by system design and test setups.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Expanded Understanding of the Western Antarctic Peninsula Sea‐Ice Environment Through Local and Regional Observations at Palmer Station

Abstract The Western Antarctic Peninsula (WAP) has been experiencing rapid regional warming since at least the 1950s, however, the impacts of this warming at the local scale are variable and nuanced. Previous studies that have linked sea‐ice variability to biogeochemical cycles and food web dynamics often combine local‐scale biogeochemical data with coarse‐resolution regional satellite sea‐ice data, which may not adequately capture local sea‐ice conditions. In this study, we analyzed local‐scale in situ sea‐ice observations collected as part of a 28‐year record (1992–2020) from the Palmer Long‐Term Ecological Research site at Anvers Island, mid‐WAP, in conjunction with isotopically‐derived sea‐ice meltwater (SIM) fractions and satellite‐derived sea‐ice motion and concentration, to quantify the variability and long‐term trends in local sea‐ice behavior. In situ sea ice observations at Palmer Station displayed higher variability than satellite observations and showed no significant declines over this time, despite region‐wide declines identified in prior studies. Higher spring SIM fractions were attributed to strong northward sea‐ice motion throughout the winter. Applying these local‐scale sea‐ice insights to similarly scaled stratification and chlorophyll‐ a measurements, we found that a longer‐lasting, more consistent sea‐ice pack led to greater water column stratification following the spring sea‐ice retreat. Greater sea‐ice persistence and stronger stratification led to larger peaks in chlorophyll‐ a , though sea‐ice metrics did not explain the positive temporal trends in either stratification strength or chlorophyll‐ a . Through this study, we identify how local sea‐ice observations and meltwater data can enhance satellite data to build an understanding of the intricate connections between ice, water column dynamics, and phytoplankton.

Goodell, E.↗
DOE OSTI2022

Dynamic Data-Driven Multiscale Modeling for Predicting Microstructure and Mechanical Properties of 316L Stainless Steel

We have developed a long short-term memory stacked ensemble (LSTM-SE) surrogate modeling approach that can provide rapid predictions of microstructural evolution and the resultant mechanical properties of American Iron and Steel Institute (AISI) 316L series stainless steel (316LSS) fuel cladding under conditions of varying temperature and radiation dose rate. To acquire training data, we developed and implemented a kinetic Monte Carlo (KMC) model to simulate precipitation kinetics of M 23 C 6 , γ', and G phases within SS316L cladding. Experimentally reported precipitation kinetics of SS316L in literature were linked to the kinetic parameters of the simulated precipitation in our KMC model. The model was then used to simulate microstructure evolution under synthetically generated treatments of varying temperature and radiation dose rate, for periods of up to 3000 hours. Changes in volume fraction, number density, and particle size of precipitates were recorded, and particle area fractions were correlated using statistical methods to develop the surrogate model. Simultaneously, the mechanical properties of the simulated microstructures were evaluated using microstructure-based finite element method (FEM) analysis to determine the elastic modulus, yield stress, ultimate tensile strength, and elongation to failure of the aged microstructures. Using this approach, our surrogate model can predict precipitation behavior within 0.25% volume fraction and mechanical properties within 6% relative error from the values predicted by the KMC and FEM models using 50 training simulations as input. The trained recurrent neural network-based model can return estimations of precipitation kinetics and mechanical properties ~1000 times faster than the physics-based codes. This work demonstrates, as a proof of concept, that reactor material service lifetimes under variable service conditions can be predicted for a statistics-based model from a practicably obtainable dataset.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Learning the boundary-to-domain mapping using Lifting Product Fourier Neural Operators for partial differential equations

Neural operators such as the Fourier Neural Operator (FNO) have been shown to provide resolution-independent deep learning models that can learn mappings between function spaces. For example, an initial condition can be mapped to the solution of a partial differential equation (PDE) at a future time-step using a neural operator. Despite the popularity of neural operators, their use to predict solution functions over a domain given only data over the boundary (such as a spatially varying Dirichlet boundary condition) remains unexplored. In this paper, we refer to such problems as boundary-to-domain problems; they have a wide range of applications in areas such as fluid mechanics, solid mechanics, heat transfer etc. We present a novel FNO-based architecture, named Lifting Product FNO (or LP-FNO) which can map arbitrary boundary functions defined on the lower-dimensional boundary to a solution in the entire domain. Specifically, two FNOs defined on the lower-dimensional boundary are lifted into the higher dimensional domain using our proposed lifting product layer. We demonstrate the efficacy and resolution independence of the proposed LP-FNO for the 2D Poisson equation.

Kashi, Aditya↗
DOE OSTI2026

Web-based Preprocessing and Visualization of 3D FIB Tomography Data for Nuclear Fuel Characterization

Three-dimensional (3D) focused ion beam (FIB) tomography enables reconstruction of internal nuclear fuel features that can't be fully evaluated through surface imaging alone. This capability supports characterization of fuel constituents and defects under thermal and irradiation conditions relevant to microreactor development. However, large tomography datasets can create data-handling, loading, and visualization challenges, especially when image-stack preparation and file conversion must be completed with separate tools. The Computational Ultraspatial Tomography Toolkit for High-Resolution Object Analysis Tools (CUTTRHOAT) is an open-source web application being developed to display FIB tomography datasets available through the Nuclear Research Data System (NRDS). The current alpha version requires prepared HDF5 datasets and has limited integrated data-preparation capabilities. This project improves CUTTHROAT by adding dataset-folder selection, automatic input detection, dataset scanning, missing-slice identification, blank-slice insertion, and image-stack-to-HDF5 conversion. Two applications will be compared: the baseline CUTTHROAT alpha workflow and the updated application containing the integrated data-handling and preprocessing functions. Evaluation will consider dataset detection accuracy, conversion success, loading time, rendering responsiveness, application stability, and user interaction. Preliminary results demonstrate successful loading of existing HDF5 files and converted image stacks, while testing also identified performance reductions caused by excessive blank-slice generation. The updated workflow reduces reliance on external preparation tools and supports more direct movement from image stacks to color-code 3D visualization. Future work includes refining missing-slice handling, integrating additional preprocessing functions, like a denoising feature, parsing TIFF metadata for automatic voxel scaling, and adding manual X, Y, and Z voxel-spacing inputs for PNG and JPEG.

36 - MATERIALS SCIENCE↗
DOE OSTI2020

Mapping the Concentration Distribution of Contaminant Plumes to the Computational Grid of the Plateau to River Model (Ver. 8.3)

This environmental calculation file (ECF) outlines the process conducted for defining the initial condition groundwater plumes for select contaminants of interest (COIs) to the Plateau River model version 8.3 (P2Rv8.3) domain (CP-57037, Model Package Report: Plateau to River Groundwater Model Version 8.3). Various data sources were combined into a single set of files defining plume conditions at time 1/1/2018. The resulting files are intended for use as inputs for transport modeling to support forecasts of the Central Plateau contaminant plume fate and transport.

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

New data-driven approach to bridging power system protection gaps with deep learning

Protection is a critical function in power systems to avoid equipment damage, maintain personnel safety, and support system reliability. However, current protective relay technology cannot adequately protect equipment and personnel from effects of some events; these deficiencies are termed protection gaps. In this paper, a data-driven approach is proposed to complement traditional protection technology and distinguish fault conditions from transients caused by normal operations. A combined convolutional neural network and long short-term memory (CNN-LSTM) network is implemented to achieve data translation invariance and capture the temporal correlation of the time-series input data. As a result, the data-driven method can accurately detect system faults despite variation and noise in the input data. In addition, using the CNN-LSTM--based method avoids the complicated, manual feature extraction procedure required by many traditional data-driven methods. The effectiveness of the proposed approach is tested on two kinds of protection gaps: high-impedance faults and transformer inter-turn faults. Lastly, a transfer learning method is also proposed to address the common issue of data-driven methods for which real-world training data are scarce. Extensive study results demonstrate that the proposed approach can accurately bridge power system protection gaps.

42 ENGINEERING↗
DOE OSTI2023

Modeling of Reactor Design and Optimization for Scale-Up of the Catalyxx Process for Ethanol Conversion to Higher Alcohol Biofuels

This report summarizes the results of a collaborative efforts between Oak Ridge National Laboratory (ORNL) and Catalyxx Inc. to investigate scale-up of Catalyxx’s Ethanol upgrading to higher alcohols process. The study was funded by the U.S. Department of Energy (DOE) Bioenergy Technologies Office (BETO) under CRADA (Cooperative Research and Development Agreement) No: NFE-20-08396. The project is part of the Direct Funding Opportunity (DFO) for Computational Science to Enable Bioenergy program which utilized computational toolsets developed by the Consortium for Computational Physics and Chemistry, a multi-laboratory consortium in BETO. The report here summarizes a packed-bed reactor modeling effort spanning the range from lab to industrial scale (from 4 gram to 5-ton catalyst beds), and examining reactor design, process optimization strategies, and suggested design and operating conditions for Catalyxx’s ethanol upgrading plants. The results in this report have been shared in monthly steering meetings and presentations are available in the shared data house owned by Catalyxx. The modeling effort helped to define optimum operation conditions for maximum alcohol selectivity and yield: i.e., temperature control scenarios ranging from adiabatic to isothermal, feed rate, pressure, and inlet H 2 /Ethanol ratio. The modeling results were verified at lab-(4 gram) and pre-pilot (4 kg) scales and has been used to evaluate a 5-ton packed-bed reactor and identify operating conditions to maximize the butanol yield. Special focus was given to understanding mass-transfer effects in the pre-pilot and pilot-scale reactors, over the domain of flow rate, pressure, feed composition, pellet size, shape, porosity, bed voidage, and reactor dimensions (i.e., length/diameter). Modeling was also used to evaluate innovative reactor design concepts such as water removal to improve alcohol selectivity and yield, and a reactor with an additional side inlet to facilitate quenching. These concepts were thoroughly explored, and potential benefits were disclosed. The results in this report are summarized and described qualitatively to protect the IP rights of Catalyxx. The details have been shared with the Catalyxx team in the regular steering meetings. At the end of the project, Catalyxx Inc. announced a successful demonstration of pilot scale operation in Seville, Spain.

02 PETROLEUM↗