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DOE OSTI2020

Analysis of Laminar Convective Heat Transfer Over Structured Non-Wetting Surfaces

Structured non-wetting surfaces provide alternating no-slip and partial slip boundary conditions to the fluid flow which, in turn, affects the convective heat transfer performance over the surfaces. In this work, an analytical model is developed for the interfacial Nusselt number, the overall Nusselt number and a thermal hydraulic performance factor for fluid flow in a cylinder patterned with structured non-wetting surfaces, for the two cases of uniform wall heat flux and uniform wall temperature. In addition, by considering the stability of the Cassie state of wettability and its transition to the Wenzel state for flow over superhydrophobic surfaces, the present model overcomes certain limitations of the previously reported studies in the literature. Based on the analytical formulations and the stability constraints, the present paper provides optimum design maps for tailoring structured non-wetting surfaces for maximizing convective heat transfer and the combined thermal-hydraulic performance in applications. Use of the design maps on example cases is also discussed. It is shown that the use of structured non-wetting surfaces is most effective for low Reynolds numbers and/or small cylinder radius.

42 ENGINEERING↗

DOE OSTI2024

Alternating conduction and convection drying of paper – an experimental analysis with a continuous data acquisition approach

In conventional multi-cylinder drying of paper and board, both conductive drying from steam-heated dryer cylinders and convective drying by flowing air over the paper surface in the pockets are used. Conductive drying from steam-heated drying cylinders is a critical component in providing the necessary thermal energy to paper and board as they dry. Steam temperature and internal and external resistances at the contacting surface are critical process parameters influencing the conductive drying process. An experimental setup was developed to study the alternating conductive and convective drying of paper and board. Paper sheet moisture, temperature, and temperature distribution within the heated platen and the instantaneous heat flux as the sheet was being dried were measured. The instantaneous heat flux, contact heat transfer coefficient, and drying rates were determined as drying proceeds. Experimental results, as well as comparisons to literature and commercial data, are presented. The conductive heat transfer coefficients determined were compared to traditional correlations normally used in the modeling of paper drying. Similarly, the convective heat and mass transfer coefficients are also determined and compared to literature data. In addition to the evaluation of alternating conductive and convective drying characteristics of paper and board, the potential inclusion of auxiliary energy components will also be included. Experimental results from the conduction and convection drying system are presented. Furthermore, this data will be useful in process development, intensification of manufacturing processes, and modeling and simulation of paper drying processes.

42 ENGINEERING↗

DOE OSTI2025

MOOSE ProbML: Parallelized probabilistic machine learning and uncertainty quantification for computational energy applications

Here, this paper presents the development and demonstration of massively parallel probabilistic machine learning (ML) and uncertainty quantification (UQ) capabilities within the Multiphysics Object-Oriented Simulation Environment (MOOSE), an open-source computational platform for parallel finite element and finite volume analyses. In addressing the computational expense and uncertainties inherent in complex multiphysics simulations, this paper integrates Gaussian process (GP) variants, active learning, Bayesian inverse UQ, adaptive forward UQ, Bayesian optimization, evolutionary optimization, and Markov chain Monte Carlo (MCMC) within MOOSE. It also elaborates on the interaction among key MOOSE systems — Sampler, MultiApp, Reporter, and Surrogate — in enabling these capabilities. The modularity offered by these systems enables development of a multitude of probabilistic ML and UQ algorithms in MOOSE. Example code demonstrations include parallel active learning and parallel Bayesian inference via active learning. The impact of these developments is illustrated through five applications relevant to computational energy applications: UQ of nuclear fuel fission product release, using parallel active learning Bayesian inference; very rare events analysis in nuclear microreactors using active learning; advanced manufacturing process modeling using multi-output GPs (MOGPs) and dimensionality reduction; fluid flow using deep GPs (DGPs); and tritium transport model parameter optimization for fusion energy, using batch Bayesian optimization. These capabilities are part of the MOOSE framework.

97 - MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Modal dynamics of wind turbine wake meandering from lidar observations

Horizontal scans from nacelle-mounted lidars provide time series measurements of wind turbine wakes across diverse atmospheric conditions, enabling analysis of coherent turbulent structures that influence wake meandering through proper orthogonal decomposition (POD). While low-order modes capture the most energetic turbulent structures, our analysis reveals that they do not necessarily dominate wake meandering dynamics. We evaluate more than 16,000 combinatorial reconstructions of the flow field for each inflow case, demonstrating that mode relevance depends on mode symmetry, turbulent kinetic energy content, and inflow characteristics. Cases with low turbulence intensity and large integral timescales show stronger correlations between POD modes and wake meandering, whereas higher turbulence conditions (turbulence intensity > 7%) are less effectively described by reduced-order models. However, the qualitative similarity of POD modes across varied atmospheric conditions suggests the potential existence of a semi-universal basis for representing wind turbine wakes, with implications for improving engineering wake models.

17 WIND ENERGY↗

DOE OSTI2023

Evolution of LIBS technology to mobile instrumentation for expediting firearm-related investigations at the laboratory and the crime scene

Gunshot residue (GSR) is one of the few forensic disciplines that lack accurate screening techniques. This study proposes using a mobile LIBS instrument to detect inorganic GSR and compares performance to a previously validated laboratory instrument. The mobile LIBS is designed with advanced configurations specifically for on-site GSR analysis, including a CMOS detector and a sampling chamber that holds up to six typical GSR collection devices with separate gas flow ports to prevent cross-contamination. A significant novelty of the portable instrument is its image magnification, which allows quick searching and visualization of GSR particle morphology. The single-particle imaging and elemental composition capability is one of a kind and offers superior confirmatory features for GSR. The mobile LIBS performance was evaluated for residues collected from the hands of shooters (100 samples) and non-shooters (200 background samples), analyzed sequentially by the mobile instrument and then the laboratory instrument. Accuracies better than 98.8% were obtained by both instruments, demonstrating their suitability for trace IGSR detection from skin specimens. Implementation of this methodology is anticipated to drastically speed up response times (i.e., from several hours per sample by standard SEM-EDS practice to a few minutes by LIBS). The screening methods can be easily incorporated into workflows to improve decision-making processes at the crime scene and laboratory settings, reduce backlogs, and improve case management.

47 OTHER INSTRUMENTATION↗

DOE OSTI2022

Multi-fidelity information fusion with concatenated neural networks

Recently, computational modeling has shifted towards the use of statistical inference, deep learning, and other data-driven modeling frameworks. Although this shift in modeling holds promise in many applications like design optimization and real-time control by lowering the computational burden, training deep learning models needs a huge amount of data. This big data is not always available for scientific problems and leads to poorly generalizable data-driven models. This gap can be furnished by leveraging information from physics-based models. Exploiting prior knowledge about the problem at hand, this study puts forth a physics-guided machine learning (PGML) approach to build more tailored, effective, and efficient surrogate models. For our analysis, without losing its generalizability and modularity, we focus on the development of predictive models for laminar and turbulent boundary layer flows. In particular, we combine the self-similarity solution and power-law velocity profile (low-fidelity models) with the noisy data obtained either from experiments or computational fluid dynamics simulations (high-fidelity models) through a concatenated neural network. We illustrate how the knowledge from these simplified models results in reducing uncertainties associated with deep learning models applied to boundary layer flow prediction problems. The proposed multi-fidelity information fusion framework produces physically consistent models that attempt to achieve better generalization than data-driven models obtained purely based on data. While we demonstrate our framework for a problem relevant to fluid mechanics, its workflow and principles can be adopted for many scientific problems where empirical, analytical, or simplified models are prevalent. In line with grand demands in novel PGML principles, this work builds a bridge between extensive physics-based theories and data-driven modeling paradigms and paves the way for using hybrid physics and machine learning modeling approaches for next-generation digital twin technologies.

42 ENGINEERING↗

DOE OSTI2025

Enhancing traffic safety analysis with digital twin technology: integrating vehicle dynamics and environmental factors into microscopic traffic simulation

Traffic safety is a critical concern in transportation engineering and urban planning. Traditional traffic safety analysis requires trained observers to collect data in the field, which is time-consuming, labor-intensive, and sometimes inaccurate. In recent years, microscopic traffic simulation, which simulates individual vehicles’ movements within a transportation network, have been utilized to study traffic safety. However, microscopic traffic simulation only focuses on traffic-related factors, such as traffic volume, traffic signals, and lane configurations, neglecting vehicle dynamics and environment-related factors like weather and lighting conditions, which can significantly impact traffic safety. In light of this, this paper explores the application of digital twin technology in traffic safety analysis, integrating vehicle simulators, which consider vehicle dynamics and environmental factors, and microscopic traffic simulators, which simulate the operations of traffic flow, for enhanced safety evaluations. Various scenarios, including different weather conditions and visibility levels, are simulated using a digital twin of a road segment in Tuscaloosa, Alabama. The simulations employ Surrogate Safety Measures (SSMs) like Time to Collision (TTC) and Deceleration Rate to Avoid a Crash (DRAC) to assess safety under varying conditions. The results demonstrate that traffic digital twin can identify potential safety issues that traditional microscopic simulation cannot, providing insights for improving traffic control strategies and transportation infrastructure to enhance traffic safety.

Civil engineering↗

DOE OSTI2022

Nanopore facilitated monohydrocalcitic amorphous calcium carbonate precipitation

Predicting the precipitation of solids is important in both natural systems and subsurface energy applications. The factors controlling reaction mechanisms, phase selection and conversion between phases are particularly important. In this contribution the precipitation and growth of an amorphous calcium carbonate species from flowing aqueous solution in a nanoporous controlled pore glass is followed in situ with differential X-ray pair distribution function analysis. It is discovered that the local atomic structure of this phase indicates monohydrocalcite-like pair–pair correlations, yet is functionally amorphous because it lacks long-range structure. The unexpected occurrence of synthetic proto-monohydrocalcite amorphous calcium carbonate, precipitated from a solution undersaturated with respect to published solubilities, suggests that nanopore confinement facilitates formation of an amorphous phase at the expense of more favorable crystalline ones. Finally, this result illustrates that confinement and interface effects are physical factors exerting control on mineral nucleation behavior in natural and geological systems.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Scaling patch analysis of planar turbulent wakes

In this work, a scaling patch approach is used to investigate the proper scales in planar turbulent wakes. A proper scale for the mean axial flow is the well-known maximum velocity deficit U ref = U ∞ –U ctr , where U ∞ is the free stream velocity and U ctr is the mean axial velocity at the wake centerline. From an admissible scaling of the mean continuity equation, a proper scale for the mean transverse flow is found as V ref = (dδ/dx)U ref , where dδ/dx is the growth rate of the wake width. From an admissible scaling of the mean momentum equation, a proper scale for the kinematic Reynolds shear stress is found as R uv,ref = U ∞ V ref , which is a mixed scale of the free stream velocity and the mean transverse flow scale. Expressions are derived for the scaled mean transverse velocity and Reynolds shear stress in the far field of planar turbulent wakes. Using a Gaussian function for the mean axial velocity deficit, approximate functions for the scaled mean transverse velocity and Reynolds shear stress are developed and found to agree well with experimental and simulation data. This work reveals that the mean transverse flow, despite its small magnitude, plays an important role in the scaling and understanding of the planar turbulent wake.

42 ENGINEERING↗

DOE OSTI2023

Mitigation of resistive drift wave and ion temperature gradient instabilities by velocity shear

The effects of velocity shear on the resistive drift wave instability in the non-adiabatic limit and the toroidal ion temperature gradient instability are investigated for a plasma of inhomogeneous density/ion temperature, respectively. For the resistive drift wave, we find that the instability growth rate decreases monotonically with increasing magnitude of shear, but we find that complete stabilization is impossible. For the ion temperature gradient instability, we find that the standard WKB approximation is insufficient to describe the full behavior of the instability, and that an analysis of the localized eigenmode problem reveals two separate unstable solutions, which the WKB approximation does not predict. The impact of flow shear on these two new unstable solutions is discussed. In both resistive drift wave and ion temperature gradient instabilities, the sheared flow causes a shifting, tilting, and sharpening of the electrostatic potential eddies.

Physics↗

DOE OSTI2024

Macroscopic modeling of gas permeability in hierarchical micro/nanoporous media: A unified characterization of rarefaction using Klinkenberg theory and equivalent diameter

Estimating gas transport through a hierarchical micro/nanoporous system is challenging due to non-equilibrium gas dynamics. The primary difficulty lies in determining the rarefaction level, because identifying a representative flow dimension in a complex porous system with multiple pore scales is not straightforward. Our study performed a pore-level analysis for gas permeability in dual-scale porous media with varying porosity, throat size, and secondary pore size under different rarefaction conditions. We found that secondary porosity negatively affects permeability due to increased friction forces, with this influence growing as the secondary pore size and porosity increase until the secondary pore becomes comparable to the throat. However, rarefaction reduces the effects of secondary pores due to boundary slip. Traditional Knudsen number (Kn) calculations based on Darcy-defined height failed to accurately describe the rarefaction effects on gas permeability. Instead, we introduced an equivalent diameter to calculate the Kn, which provided an accurate normalization of apparent gas permeability independent of pore geometry. Furthermore, the extended Kozeny–Carman–Klinkenberg model developed in our previous study successfully yielded a macroscopic model for apparent gas permeability in hierarchical micro/nanoporous systems as a function of the traditional Darcy height and porosity.

04 OIL SHALES AND TAR SANDS↗

DOE OSTI2023

Thermal-Hydraulic Analysis of the AFIP-7 Irradiation Test in the Advanced Test Reactor - Oxide Growth Prediction and Correlation

Knowing the thickness of the oxide layer on the surface of aluminum fuel cladding is vitally important for predicting fuel temperature due to the low thermal conductivity of the oxide layer. Several correlation models for predicting oxide growth can be found in the literature. In previous research, the correlations were combined with heat transfer simulations in Abaqus, a finite element analysis code, to forecast the oxide growth. However, this approach requires heat transfer coefficients for modeling heat exchanges with the external flow field, and such coefficients were obtained through empirical equations. Since different empirical equations yield varying heat transfer coefficients, the cladding temperature and predicted oxide thickness both carry a high degree of uncertainty. Here, this research develops a new approach that integrates the fluid flow, fluid and solid heat transfer, and oxide growth correlation(s) into a single computational fluid dynamics model. We demonstrate this approach’s ability to predict oxide development on the AFIP-7 plates during two Advanced Test Reactor (ATR) irradiation cycles. The projected oxide thickness falls within the experimental measurements taken during post irradiation examination.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2021

Simultaneous velocity and density measurements of fully developed Rayleigh-Taylor mixing

Here, the dynamics of molecular mixing and the energy transfer process in the Rayleigh-Taylor instability (RTI) are studied through the collection of simultaneous density-velocity measurements. These experiments provide simultaneous density-velocity field measurements, in contrast to previous point measurements. Statistically stationary experiments are performed in a “convective-type” gas tunnel facility, with density contrast achieved through the injection of helium into the bottom stream. Three experiments at Atwood number ≈ 0.1 are captured at three outer scale Reynolds numbers Re = 520, 2260, and 4050. Particle image velocimetry and laser induced fluorescence are employed simultaneously. Statistics of the density and velocity show self-similar collapse of RTI profiles at large Reynolds number Re >2000. Flat velocity profiles indicate homogeneous turbulence characteristics in the core of the mixing region. Significant anisotropy develops in the flow, with horizontal velocity fluctuations being only 60% of the vertical velocity fluctuations. The turbulent mass flux is found to be asymmetric about the centerline, with increased peak towards the spike. Measurements of the molecular mixing show that mixing is maximized at the core of the flow and increases with increased Reynolds number. The transport equation of density-specific-volume correlation b shows that it is mostly produced in the core of the mixing region, and that the spatial evolution of its profile is the result of transport by bulk motion of the bubble and spike. Energy transfer from gravitational potential energy to turbulent kinetic energy and viscous dissipation is observed to occur in the experiment with a ratio of dissipated energy to potential energy released of 38%. The analysis of the turbulent kinetic energy transport equation budget reveals that production is the primary mechanism towards the growth of turbulent kinetic energy in the core of the flow, and is asymmetrically slightly skewed towards the spike. However, it is through the transport that the strong advection at the edges of the mixing region is maintained.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2021

Methods—Analyzing Electrochemical Kinetic Parameters in Deep Eutectic Solvents Using an Extended Butler-Volmer Equation

Deep eutectic solvents (DESs) are promising electrolytes for electrochemical redox reactions, which can be used in redox flow batteries (RFBs). However, in some systems like the Fe 2+/3+ redox reaction in ethaline, traditional Tafel-based kinetic analysis generates unreasonable kinetic parameters (i.e., large anodic/cathodic charge transfer coefficients ( α a , α c ) along with low exchange current densities ( i 0 )). This hinders a comprehensive kinetic and kinetic mechanism study. Here, we perform a detailed investigation of the Tafel analysis using a series of synthetic rotating disk electrode (RDE) data. We find the Tafel analysis only works well when i 0 < 0.57 i lim (limiting current density) in our scenario and leads to abnormal kinetic values once i 0 exceeds this limiting value. Thus, we propose an extended Butler-Volmer (ex-BV) analysis based on modern non-linear fitting techniques to obtain the actual kinetic parameters for such systems. The results show that this method fits the RDE data closely and generates reliable α a , α c and i 0 values, demonstrating that it is a good replacement for traditional Tafel analysis for kinetic studies in high-viscosity electrolytes such as DES systems.

Electrochemistry↗

DOE OSTI2022

3D Equilibrium Reconstruction and MHD Studies in Stellarators (Final Report)

This is the final technical report for the grant Three Dimensional Equilibrium Reconstruction and MHD Studies in Stellarators. The major goals of this project were to: further develop V3FIT code capabilities, continue to support experiments using the V3FIT code, continue theoretical support for the CTH experiment at Auburn, particularly in the area of NIMROD simulations of CTH discharges. Dr. Lopez Ortiz has made significant progress on his analysis of NIMROD simulations of CTH MHD phenomena. In particular, his study has focused on the fixed point dynamics and energy flow amongst toroidal Fourier modes in sawtooth oscillations simulations.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

Intensified Catalytic Conversion of CO2 into High Value Chemicals

The utilization of CO2 produced from power generation plants as a feedstock for creating new valuable products offers a strategy to reduce GHG emissions, offset carbon capture costs, and facilitate the rebalancing of the carbon cycle. After considering the thermodynamic requirement of potential products from CO2 utilization and their market size, formic acid is a desirable target that offers widespread utility in industrial chemical production and chemical energy storage as a liquid fuel. To effectively utilize CO2 from power generation plants, UK proposes an enhanced bimetallic oxide carbon utilization process (EBOCU) that enables electrochemical CO2 conversion to formic acid. The UK intensified electrocatalytic process combines three main components: 1) a novel bimetallic oxide electrocatalyst; 2) a stable electrochemical reactor using robust electrodes; and 3) a pressurized electrochemical reactor. The output from this project showed the economic viability of producing high-value formic acid from CO2 to both offset the cost associated with post-combustion CCS and reduce GHG emissions. This project developed and screened a series engineered catalysts to selectively reduce CO2 directly to formic acid. The best performing catalyst based on formic acid production, stability, and Faradaic efficiency, was immobilized on carbon electrodes, and tested inside a flow through reactor. After lab-scale testing was completed, the experimental data was used to perform a Life-Cycle Analysis (LCA) and conduct an Initial Technical and Economic Feasibility Study. The LCA showed a pathway to a net negative CO2 utilization process with the incorporation of renewable energy, while the TEA showed the potential to produce formic acid below the current commercial price. The UK EBOCU process was successfully demonstrated at the TRL3 level and has a clear pathway to further development and contribution to the nation’s ambitious decarbonization goals.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2023

Heat Exchanger Intensification Through Powder Processing and Enhanced Design (HIPPED)

High intensity, supercritical CO 2 heat exchangers capable of operating at temperatures between 800 and 1100 ˚C and pressures greater than 80 bar are considered a critical component for high efficiency power generation and a range of next-generation industrial processes. A novel heat exchanger concept was proposed in this project. The proposed concept involved a plate-type architecture with three-dimensional fins, called twisted s-shaped fins, that capitalize on additive manufacturing. Four manufacturing processes were studied to realize the complex envisioned design: press and sinter of metallic powders, directed energy deposition, laser powder bed fusion, and a novel powder bed process involving a photoreactive polymer called SEAM (scalable expeditious additive manufacturing), that later was developed at MSU. The team was able to manufacture subscale heat exchangers using laser powder bed fusion (LPBF) and SEAM. The team settled on using SEAM as a final manufacturing approach due to its very low cost. The SEAM-manufactured heat exchanger, however, when tested under pressure, exhibited leaks and the process still requires further development beyond the timeline of the project. To support the heat exchanger design and testing, the team developed a new high temperature flow loop allowing testing under high temperature and pressure. Computational modeling of the heat exchanger was also performed for the twisted s-shaped fins and the computations were validated with experimental data. The new twisted fins resulted in enhanced heat transfer and reduced pressure drop. To further minimize pressure drop in the plate heat exchanger, the team also developed a simplified model for flow maldistribution in the manifolds, providing a new tool for designers that eliminates the need for complex CFD calculations. A technoeconomic analysis was also developed to contrast SEAM with LPBF, this tool indicated that SEAM is several times less costly and offer significant promises as a rapid low cost additive manufacturing process for metallic systems.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2023

GOOML (Geothermal Operational Optimization with Machine Learning) [SWR-23-01]

The Geothermal Operational Optimization with Machine Learning (GOOML) is a partnership between NREL and Upflow, NZ, awarded in response to the U.S. Department of Energy's Geothermal Technologies Office's Funding Opportunity Announcement (FOA) to expand the role of advanced analytics and automation in geothermal operations through machine learning. Partnering with industry (Contact Energy Limited ("Contact"), Ngati Tuwharetoa Geothermal Assets Limited ("NTGA"), Ormat Technologies Inc. ("Ormat") and Flow State Solutions Limited ("FSS"), GOOML was created to improve the operational efficiency of geothermal power plant steam fields through the analysis of historical operational data and the application of custom machine learning algorithms. NREL's contributions include machine learning, coding, and data management expertise as well as access to high-performance compute solutions. GOOML can increase geothermal operational efficiency through development of a digital system twin that can be utilized to provide optimal geothermal operating conditions for real-world geothermal fields. GOOML allows users to analyze field production histories in detail, develop models, and train machine learning algorithms to identify opportunities for increased geothermal efficiency, detect potential trouble, and allow predictive scenario modeling. Preliminary experiments have demonstrated a potential to increase total generation by as much as 12% through ML optimization of the utilization of existing steam field resources.

Buster, Grant↗