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DOE OSTI2020

Validation and application of a multiphase CFD model for hydrodynamics, temperature field and RTD simulation in a pilot-scale biomass pyrolysis vapor phase upgrading reactor

Accurate prediction of transport phenomena is critical for VPU reactor design, optimization, and scale-up. The current study focused on the validation and application of a multiphase CFD model within an open-source code MFiX for hydrodynamics, temperature field, and residence time distribution (RTD) simulation in a non-reacting circulating fluidized bed riser for biomass pyrolysis vapor phase upgrading (VPU). First, an Eulerian-Eulerian approach three-dimensional CFD model was employed to simulate the pilot-scale VPU riser on the supercomputer Joule. Excellent quantitative agreement between experimental and simulated results was achieved for pressure drops and temperature field in a range of operating conditions. Then the validated multiphase CFD model was applied to predict gas and solid residence time distributions (RTDs) since prediction and analysis of RTD is an important tool to study the complex multiphase flow behavior and mixing inside chemical reactors. The predictions show that solid mean residence time is 3.5 times the gas residence time; the solid RTD is more sensitive to the process gas flow rate than the solids circulation rate.

09 BIOMASS FUELS↗

DOE OSTI2022

Coal Fired Power Plant Configuration and Operation Impact on Plant Effluent Contaminants and Conditions

The primary objective of this project is to characterize coal contaminants in coal-fired power plant wastewater as a function of coal type, unit configurations, and unit operation profile with uncertainty analysis. This project was in response to the U.S. Department of Energy (DOE) Solicitation DE-FOA-0001842. The project duration was between September 01, 2018, and December 31, 2021 (no-cost extension filed, due to the Covid-19 pandemic restrictions, and approved). Field and lab test program was conducted with the main goal to characterize coal contaminants in coal-fired power plant wastewater as a function of coal type, unit configurations, and unit operation profile with uncertainty analysis. In this project, the team of Lehigh University (prime recipient) and Western Kentucky University identified two suitable Thermoelectric Power Plants (TTPs) firing bituminous and sub-bituminous coals respectively, designed test plans, and performed sample collection. Sampling included coal from each TTPs power generation units, Wet Flue Gas Desulfurization (WFGD) slurry material and waste-water samples taken from the outlet of the water treatment tank prior to discharge and other pertinent locations. Coal samples are dried, crushed, and pulverized according to the American Society for Testing and Materials (ASTM) methods. The prepared coal samples are analyzed for normal proximate and ultimate analysis tests in addition to the toxic metals and anions according to ASTM methods. The FGD slurry materials are analyzed for toxic metals and anions according to Electric Power Research Institute (EPRI) or Environmental Protection Agency (EPA) methods, as appropriate. The wastewater samples from the water treatment tank outlet are analyzed for toxic metals and anions according to EPA methods. The effluent species analyzed include mercury, arsenic, selenium, nitrate/nitrite, bromide, and chlorine. This project provided results of effluent conditions as a function of coal type, unit configuration, and unit operation profile, and identified the levels of uncertainty in the effluent results.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2023

Technoeconomic Model and Pathway to <$2/kg Green Hydrogen Using Integrated Halide Perovskite Photoelectrochemical Cells

The cost of gray hydrogen produced via fossil fuel-based steam-methane reforming has led the U.S. Department of Energy to specify <$\$$2/kg H 2 as a target for commercially competitive green hydrogen generation methods. Integrated photoelectrochemical cells have been proposed as a solar-to-hydrogen conversion technology. In this paper we describe a technoeconomically feasible pathway to reaching <$\$$2/kg green H 2 using integrated photoelectrochemical cells with halide perovskite photoabsorbers, low-cost conductive barriers, and low precious metal-content catalysts in an aqueous, membrane-separated cell. A base-case solar-to-hydrogen conversion efficiency of 20%, stable lifetime of 10 years, and a combined electrocatalyst-plus-panel cost of $\$$50/m 2 enabled a levelized cost of hydrogen of $\$$2.43/kg, which dropped below $\$$2/kg with improved performance metrics including material cost, improvements in process design, or subsidies. We relate these metrics to lab-scale reports to recommend best research practices for scientists and funding agencies working at this intersection of photovoltaics, electrocatalysis, and surface science.

$1/kg↗

DOE OSTI2024

Pre-Transient Characterization of Historic EBR-II Pins for Transient Testing

Current interest in sodium-cooled fast reactor (SFR) designs, such as TerraPower’s Natrium Reactor, has highlighted the need for advanced reactor fuel technology development. Modern U-Zr and U- Pu-Zr pin designs are primary candidates to fuel SFRs and boast high fuel utilization capacity, increased fuel-cladding compatibility, and improved safety through inherent feedback mechanisms. Despite over 60 years of metallic fuel irradiation, uncertainties exist in the performance of the fuel system, particularly under transient overpower (TOP) and loss of flow (LOF) scenarios. Throughout historical testing within the Experimental Breeder Reactor II (EBR-II) and the Fast Flux Test Facility (FFTF), fuel behavior has demonstrated benign response to transient reactor conditions; however, accurate predictions of failure thresholds to inform operational limitations rely heavily on fuel composition, burnup, and irradiation history. In expanding TOP and LOF testing, the Transient Heat sink Overpower Response (THOR) Capsule will be used to test modern fuel technologies in a static sodium environment in the Transient Reactor Test (TREAT) Facility. The THOR capsule is highly instrumented and will provide time-dependent thermal behavior of SFR fuel pins subjected to accident conditions within TREAT. The THOR-Metallic (THOR- M) campaign aims to validate and expand historical TOP and LOF testing on high burnup U-Zr and U-Pu- Zr fuel alloys previously irradiated in EBR-II by running the rods to failure. This contribution focuses primarily on the pre-transient engineering-scale destructive and non- destructive characterization that has been conducted on both the test and sibling pins used for the TOP and LOF tests. All pins underwent visual examination, neutron radiography, element contact profilometry, and precise gamma scan. The sibling pins used for each test were further analyzed using gas assay, sampling, and recharge analysis (GASR), and optical microscopy. The results from each technique confirmed that the fuel pins were intact and devoid of any atypical developments when compared to historical data. Additionally, the analyzed measurements establish a baseline for comparison to post-transient analysis. Key fuel behaviors quanitifed include axial elongation of the fuel column, diametral strain of the pin, patterns in fluff structure geometry, changes in axial isotope distribution, evolution of constituent redistribution, porosity, and fission gas release. The pre-transient measurements and changes attributed to transient behavior from post-transient measurement will be compared to historical data to capture the behavioral dependence on composition, burnup, and irradiation history. Results from this work advance the initiatives of the THOR-M campaign, which aid in informing fuel performance models and establishing safety criteria for SFR operational limits. The novel combination of test environment, in-situ instrumentation, and comprehensive suite of characterization methods provides greater understanding of transient fuel behavior. Overall, information on the time and condition of pin failure for high burnup U-Pu-Zr will greatly expand the limited existing TOP and LOF test data.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Pre-Transient Characterization of Historic EBR-II Pins for Transient Testing

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Engineering and characterization of carbohydrate‐binding modules for imaging cellulose fibrils biosynthesis in plant protoplasts

Abstract Carbohydrate binding modules (CBMs) are noncatalytic domains that assist tethered catalytic domains in substrate targeting. CBMs have therefore been used to visualize distinct polysaccharides present in the cell wall of plant cells and tissues. However, most previous studies provide a qualitative analysis of CBM‐polysaccharide interactions, with limited characterization of engineered tandem CBM designs for recognizing polysaccharides like cellulose and limited application of CBM‐based probes to visualize cellulose fibrils synthesis in model plant protoplasts with regenerating cell walls. Here, we examine the dynamic interactions of engineered type‐A CBMs from families 3a and 64 with crystalline cellulose‐I and phosphoric acid swollen cellulose. We generated tandem CBM designs to determine various characteristic properties including binding reversibility toward cellulose‐I using equilibrium binding assays. To compute the adsorption ( nk on ) and desorption ( k off ) rate constants of single versus tandem CBM designs toward nanocrystalline cellulose, we employed dynamic kinetic binding assays using quartz crystal microbalance with dissipation. Our results indicate that tandem CBM3a exhibited the highest adsorption rate to cellulose and displayed reversible binding to both crystalline/amorphous cellulose, unlike other CBM designs, making tandem CBM3a better suited for live plant cell wall biosynthesis imaging applications. We used several engineered CBMs to visualize Arabidopsis thaliana protoplasts with regenerated cell walls using confocal laser scanning microscopy and wide‐field fluorescence microscopy. Lastly, we also demonstrated how CBMs as probe reagents can enable in situ visualization of cellulose fibrils during cell wall regeneration in Arabidopsis protoplasts.

09 BIOMASS FUELS↗

DOE OSTI2021

Fossil fuel CO 2 emissions over metropolitan areas from space: A multi-model analysis of OCO-2 data over Lahore, Pakistan

Urban areas, where gathering more than 55% of the global population, alone contributed to more than 70% of anthropogenic fossil fuel carbon dioxide (CO 2ff ) emissions. Accurate quantification of CO 2ff emissions from urban areas is of great importance to the formulation of global warming mitigation policies to achieve carbon neutrality by 2050. Satellite-based inversion techniques are unique among “top-down” approaches, potentially allowing us to track CO 2ff emission changes over cities globally. However, its accuracy is still limited by incomplete background information, cloud blockages, aerosol contaminations, and uncertainties in models and emission inventories used as prior. To evaluate the current potential of space-based quantification techniques, we present the first attempt to monitor long-term changes in CO 2ff emissions based on the OCO-2 satellite measurements of column-averaged dry-air mole fractions of CO 2 (X CO2 ) over a fast-growing Asian metropolitan area: Lahore, Pakistan. We first examined the OCO-2 data availability at global scale. About 17% of OCO-2 soundings are marked as high-quality soundings by quality flags over the global 70 most populated cities over the period 2014-2019. Cloud blockage and aerosol contamination are the two main causes of data loss. As an attempt to recover additional soundings, we evaluated the effectiveness of OCO-2 quality flags at the city level by comparing three flux quantification methods (WRF-Chem, X-STILT, and flux cross-sectional integration method), all based on the Open-Data Inventory for Anthropogenic Carbon dioxide (ODIAC) product. The satellite/bottom-up emissions (OCO-2/ODIAC) ratios of the high-quality tracks better converged across the three methods compared to the all-data tracks with reduced uncertainties in emissions. Thus, OCO-2 quality flags are useful filters of low-quality OCO-2 retrievals at local scales, although originally designed for global-scale studies. All three methods consistently suggested that the ratio medians are greater than 1, which implies that the ODIAC slightly underestimated the CO2ff emissions over Lahore. Additionally, our estimation of the a posteriori CO2ff emission trend was about 734 kt C/year (i.e., an annual 6.7% increase). 10,000 Monte Carlo simulations of the Mann-Kendall upward trend test showed that less than 10% prior uncertainty for 8 tracks (or less than 20% prior uncertainty for 25 tracks) is required to achieve a greater-than-50% trend significant possibility at a 95% confidence level. It implies that the trend is driven by the prior and not due to the assimilation of OCO-2 retrievals. The key to improving the role of satellite data in CO 2 emission trend detection lies in collecting more frequent high-quality tracks near metropolitan areas to achieve significant constraints from X CO2 retrievals.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2024

Temperature effect on turbulent burning velocity of lean premixed hydrogen/air flames

Hydrogen has drawn great attention in recent years as a carbon-free fuel. The turbulent burning velocity (S T ) is an important parameter for the design and modeling of hydrogen-fueled engines given the high propagation speed of hydrogen flames. It has been well documented that S T of hydrogen flames can be dramatically increased by thermo-diffusive effects which are sensitive to thermodynamic conditions. Previous studies have mainly focused on the pressure effect on S T of lean hydrogen flames, while the temperature effect has been largely ignored. Here, in the present study, the turbulent burning velocity for a lean hydrogen/air mixture over a wide range of temperatures (300–641 K) and pressures (1–15 atm) is investigated through direct numerical simulations of statistically planar turbulent premixed flames. Results show that the variation of normalized turbulent burning velocity (S T /S L , where S L is the laminar flame speed) with temperature and pressure is mainly controlled by the variation of the stretching factor I 0 . While S T /S L is only marginally dependent on temperature at the atmospheric pressure, it exhibits a decreasing trend with temperature at an elevated pressure (10 atm). This is associated with different temperature dependencies of flame surface area enlargement at the two different pressures, despite the monotonically decreasing trends of I 0 with temperature at both pressures. In addition, under engine-relevant conditions where the temperature and pressure increase simultaneously, the promotion effect of pressure is found to be largely canceled out by the suppression effect of temperature, leading to only a slight increase in I 0 and S T /S L . The observed trends are further explained through detailed flame dynamic analysis. Furthermore, I 0 at different temperatures and pressures is found to correlate very well with the enhancement of fuel consumption rate in the critically strained laminar flames. The present study elucidates the strong impact of temperature on S T of lean premixed hydrogen/air flames at elevated pressures and provides new insights into the modeling of S T , especially for engine-relevant conditions.

Wang, Yiqing [Argonne National Laboratory (ANL), A↗

DOE OSTI2022

Analyzing the Multiscale Impacts of Implementing Energy-Efficient HVAC Improvements Through Energy Audits and Economic Input–Output Analysis

Abstract Heating, ventilation, and air-conditioning (HVAC) systems are usually an industry’s highest consumer of energy, most of which goes toward space cooling in buildings. Industrial energy-efficiency audits not only benefit manufacturers but also generate significant economic and environmental benefits to localities, states, and the nation. This article analyzes the micro- and macro scale impacts of implementing energy-efficient HVAC systems by integrating the industrial building energy data with the macroeconomic regional economic flow model. Micro-scale data include 10 years of historical energy, cost, and carbon dioxide savings achieved from energy-efficient HVAC implementation offered to manufacturers through industrial energy audits. The data were integrated into the macroeconomic modeling framework to illuminate the cascading regional economic impacts of implementing energy-efficient HVAC recommendations in manufacturing facilities. Results show that if recommendations had been implemented throughout all manufacturers in the region, $656 M energy costs would have been directly saved, 7.8 million metric tons of carbon dioxide emissions would have been avoided, and 4387 jobs could have been created, resulting in a total annual economic impact of $899 M stemming from direct, indirect, and induced impacts. The results offer insight into how industrial energy systems can be designed and provide models for how communities can accomplish a net-zero society.

Energy & Fuels↗

DOE OSTI2026

An Anisotropic Yield and Damage Material Model to Improve the Contact Pressure Analysis in a Biomass Shredding System

Size reduction systems used in biomass processing break biomass into smaller pieces by utilizing the kinetic energy from the sharp rotating blades. Abrasive and/or erosive wear caused by biomass comminution results in blade wear of the sharp edged cutters, deteriorating the process efficiency. Here, this study aims to optimize the blade design and improve the system efficiency by attempting to understand the interactions between the blades and biomass particles. Since real-time monitoring of these interactions is impractical during operation, mechanical simulations offer a viable alternative for investigating the shredding process. Yet, the irregular geometry and complex mechanical properties of biomass—such as the anisotropic nature of woodchips and their nonlinear fracture behavior—pose significant challenges for accurately simulating contact pressure. In this work an anisotropic yield material model, along with a damage initiation and evolution function, is applied to the woodchip particle to study the contact pressure on shredder blade, offering a scientific basis for improved blade design and process efficiency. This approach can be extended to other biomass processing systems with similar anisotropic feedstocks, making it a valuable tool for advancing sustainable biomass utilization.

09 - BIOMASS FUELS↗

DOE OSTI2025

Modeling and Optimization of a Rotating Packed Bed Contactor with a Tetraamine-Appended Metal−Organic Framework for CO 2 Capture

A potential contactor technology for sorbent-based CO 2 capture is the rotating packed bed that contains separate sections for continuous adsorption and desorption. A heat exchanger can be embedded to remove heat in the adsorption section and add heat in the desorption section. In this work, we develop a two-dimensional (2D) model of a rotating packed bed for use in CO 2 capture applications. Mass and energy balances for the model are developed based on a Ljungström-type air preheater, which accounts for the counter-current axial flow of gas phases in separate sections of the bed and the rotation of a solid sorbent, which cycles between adsorption and desorption sections. The sorbent used for this analysis is the tetraamine-appended metal−organic framework Mg 2 (dobpdc)(3−4− 3), chosen for its stability and affinity for CO 2 at low partial pressures, such as those from a natural gas power plant source. An optimization problem is solved that considers the trade-off between maximizing the productivity of the bed and minimizing energy consumption. Maximum productivity and minimum energy are found to be 8.53 kg/h/m 3 and 3.84 MJ/kg, respectively, when these objectives are optimized independently. It is observed that the flue gas pressure and bed rotational speed are the desired operating variables to vary for model-based design of experiments to reduce uncertainty in parameter estimation, as these two variables yielded the most information content based on the Fisher information matrix.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2021

Plasma–surface interaction in the stellarator W7-X: conclusions drawn from operation with graphite plasma-facing components

W7-X completed its plasma operation in hydrogen with island divertor and inertially cooled test divertor unit (TDU) made of graphite. A substantial set of plasma-facing components (PFCs), including in particular marker target elements, were extracted from the W7-X vessel and analysed post-mortem. The analysis provided key information about underlying plasma–surface interactions (PSI) processes, namely erosion, transport, and deposition as well as fuel retention in the graphite components. The net carbon (C) erosion and deposition distribution on the horizontal target (HT) and vertical target (VT) plates were quantified and related to the plasma time in standard divertor configuration with edge transform ι = 5/5, the dominant magnetic configuration of the two operational phases (OP) with TDU. The operation resulted in integrated high net C erosion rate of 2.8 mg s -1 in OP1.2B over 4809 plasma seconds. Boronisations reduced the net erosion on the HT by about a factor 5.4 with respect to OP1.2A owing to the suppression of oxygen (O). In the case of the VT, high peak net C erosion of 11μm at the strike line was measured during OP1.2B which converts to 2.5 nm s -1 or 1.4 mg s -1 when related to the exposed area of the target plate and the operational time in standard divertor configuration. PSI modelling with ERO2.0 and WallDYN-3D is applied in an interpretative manner and reproduces the net C erosion and deposition pattern at the target plates determined by different post-mortem analysis techniques. This includes also the 13 C tracer deposition from the last experiment of OP1.2B with local 13 CH 4 injection through a magnetic island in one half module. The experimental findings are used to predict the C erosion, transport, and deposition in the next campaigns aiming in long-pulse operation up to 1800 s and utilising the actively cooled carbon-fibre composite (CFC) divertor currently being installed. The CFC divertor has the same geometrical design as the TDU and extrapolation depends mainly on the applied plasma boundary. Extrapolation from campaign averaged information obtained in OP1.2B reveals a net erosion of 7.6 g per 1800 s for a typical W7-X attached divertor plasma in hydrogen.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2026

Results from the last DD and DT JET campaigns in the framework of the EUROfusion Tokamak Exploitation Work Package activity

JET, the only tokamak capable of operating with deuterium–tritium (D–T) fuel (since TFTR was shutdown in 1999), has provided essential experimental data to support ITER and DEMO design and operation. Within the EUROfusion Tokamak Exploitation Work Package, JET completed its final campaigns (2022–2023), culminating in the third D–T campaign (DTE3). These experiments addressed key challenges in plasma scenarios, exhaust control, and tritium management under reactor-relevant conditions. Significant progress was achieved in demonstrating ITER-like integrated scenarios with impurity seeding, achieving partial divertor detachment and high confinement ($H_{98}(y,2)$ ≈ 0.85) at 3 MA in D–T plasmas. Advanced exhaust regimes such as quasi-continuous exhaust (QCE) and X-point radiator (XPR) were successfully achieved first in D–D and then extended to D–T operation, confirming their relevance for mixed isotope operation. Operational milestones included a new world record of 69 MJ fusion energy in tritium-rich hybrid plasmas and long-pulse H-mode operation up to 60 s, contributing with unique data to the CICLOP database. Physics studies focused on peeling-limited pedestals in support of ITER and improved understanding of edge stability and impurity screening in metallic environments. Extensive usage of the shattered pellet injector (SPI) on JET provided critical information for the design of the ITER disruption mitigation system (DMS). Real-time control systems for D/T ratio control and plasma exhaust were deployed and demonstrated in D–D and D–T, while energetic particle physics investigations unfolded the role of fast ions in turbulence suppression mechanisms. Comprehensive tritium retention studies using gas balance method, post-mortem analysis, and ITER-relevant laser induced desorption spectroscopy (LIDS) diagnostics provided essential input for tritium accountancy strategies. These results are validating the ITER operational concepts, inform DEMO design, and deliver critical experience in nuclear operation and scenario integration.

disruptions↗

DOE OSTI2023

Lignin Derived Ionic Liquids: Synthesis and Application for Biopolymer Processing (CRADA Final Report)

We have established a scalable and economically viable process to convert lignin into ionic liquids for use in biopolymer processing. We have studied the four main topics: 1) lignin depolymerization to produce vanillin through oxidation, 2) lignin reduction to produce guaiacols, 3) oxidation process scale up, and 4) ionic liquid synthesis and application for biopolymer processing. The main accomplishment is summarized below: A maximal vanillin yield of 4.9% (8.8% total product yield) was achieved under optimal oxidation conditions using design of experiments (DOE); Aminophenol with 94.5% purity was synthesized via reductive amination using vanillin isolated from ion-exchange chromatography; At a higher lignin loading (10%), the vanillin yield in the scale up reaction was lower than the bench scale reaction; The filtration-based downstream separation of the scale-up process was able to recover 76% of vanillin; A maximal lignin reduction product (guaiacols) yield of 6.5% was achieved in the presence of Ru/C, formic acid, and methanol; The lignin reduction product yield and composition were affected by the use of different solvent and catalytic reagents (methanol in combination of Ru/C and formic acid gives the highest product yield); Lignin oxidation and reduction products: vanillin, acetovanillone, guaiacols, and eugenol are successfully used for IL synthesis; XX based ILs showed cellulose solubility with up to xx%; Technoeconomic analysis results indicate the potential of producing affordable ILs from kraft lignin (MSP: $14/kg); Life-cycle assessment results show the potential to reduce GHG emissions by up to 85% relative to existing ILs ([Ch][Lys]) with GHG emission: 1.2 kg CO 2e /kg of IL produced.

09 BIOMASS FUELS↗

DOE OSTI2019

Results from the third Galaxy Serpent tabletop exercise demonstrating the utility of nuclear forensics libraries in support of an investigation

Galaxy Serpent is a virtual, web-based international ongoing series of tabletop exercises designed to mature the concept of National Nuclear Forensics Libraries (NNFL) and illustrate their utility in answering investigative questions or providing investigative leads as part of an investigation involving nuclear or other radioactive material (R/N) out of regulatory control (MORC). Two prior versions of the exercise have been conducted; the first utilizing surrogate data for spent nuclear fuel as the material of interest, and the second using synthetic sealed radioactive source data. Teams participating in the recently concluded third version of the exercise were provided with synthetic uranium ore concentrate (UOC) data mimicking actual data characteristics (e.g. trace element concentrations), which was used to compile a model NNFL. Teams decided how to organize and interpret the data they were provided, dealt with real world features such as missing data, and assessed discriminating attributes. Next, a hypothetical scenario involving three UOC samples found out of regulatory control was provided, and each team had to assess the self-consistency of the individual sources in the unknown data, and employ their model NNFL as a comparative assessment instrument to determine whether the three UOC materials in question were consistent with any of the types of materials in their library. In conclusion, the design of the exercise, methodologies utilized by participating teams, and aggregate results of the exercise will be presented, along with challenges encountered and benefits realized.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

DOE OSTI2022

Pressure Drop in Seven-Pin Wire-Wrapped Rod Bundle for the Sodium Cartridge Loop in Versatile Test Reactor

This work studies the hydrodynamics of the seven pin wire-wrapped rod bundle in the sodium cartridge loop for the Versatile Test Reactor (VTR) through scaled water experiments and computational fluid dynamics (CFD) simulations. Here, the scaling analysis is first performed to demonstrate the hydrodynamic similarity between water and sodium flows at the same Reynolds number Re. A separate-effects test facility is designed and constructed based on the scaling analysis. Detailed experimental data on the pressure drop covering a wide range of Re values (1165 to 27 689) are obtained, which are used to evaluate existing correlations for friction factor and to benchmark CFD simulations. The experimentally determined friction factors f Exp agree well with the Upgraded Cheng and Todreas Detailed Correlation and Pacio-Chen-Todreas Detailed Model within ±7% but are significantly underpredicted by Rehme's correlation by 25%. Various CFD near-wall treatment methods are tested using ANSYS Fluent and evaluated by experimental data. It is found that when the recommended wall y + values are met, most of the near-wall treatment methods can give accurate friction factor predictions. The resolved near-wall method (y + ~ 1) with the Shear Stress Transport k - ω turbulence model and the scalable wall functions (y + > 12) with the realizable k - ε turbulence model can predict f Exp within ±5% The standard wall functions (y + > 30) and nonequilibrium wall functions (y + > 30) with the realizable k - ε model can predict f Exp within ±10%.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

Atomic Layer Deposition (ALD) to Extend Catalyst Lifetime for Biobased Adipic Acid Production

Robust heterogeneous catalysts are essential for enabling biomass conversion; however, harsh reaction environments introduce durability challenges for many conventional catalyst materials [1]. The hydrogenation of biobased muconic acid to adipic acid is one such emerging chemistry that faces PGM catalyst stability challenges [2]. Muconic acid is a heavily-investigated biobased platform chemical that can be converted into an array of large-market commodity chemicals [2]. PGM catalysts are exceptionally effective for muconic acid hydrogenation to adipic acid, with Pd the most active to date. [2] However, Pd leaches in an acidic environment and this chemistry has a high propensity for fouling. Atomic layer deposition (ALD) is one such material design strategy that has emerged to stabilize supported metal catalysts [3]. ALD coatings are theorized to stabilize supported metal active sites by i) covering high-energy facets most susceptible to degradation, ii) disrupting the physical mobility of active sites, and iii) reinforcing the structure of the underlying catalyst support [3]. However, ALD coatings for catalyst durability with carboxylic acids remains an underdeveloped area of research and literature reports have yet to consider the techno-economic tradeoffs between the ALD manufacturing cost and catalyst lifetime productivity. This study examines low-cycle Al2O3 ALD coatings to stabilize Pd/TiO2 against deactivation during muconic acid hydrogenation. The unique harshness of muconic acid for Pd leaching was evaluated by both experiment and computation. Based on batch reactor screening results, uncoated and ALD coated catalysts were evaluated in a continuous flow reactor for their productivity, stability, and post-reaction regenerability at 700 degrees C. Characterization was performed to assess the impact of ALD coatings on catalyst morphology, as well as following regeneration. Finally, techno-economic analysis models evaluated the value proposition for ALD-coated catalysts within an nth-generation adipic acid biorefinery.

09 BIOMASS FUELS↗

DOE OSTI2021

Tailored Fiber Placement for Complex Preforms

Tailored Fiber Placement (TFP) offers a novel approach to optimize fiber architecture for the fabrication of complex, structural parts not traditionally suitable for advanced composites. This technology not only offers new routes for weight reduction via metal substitution, it also offers cost reduction through minimization of material scrap and reduced labor. This reduction in component weight leads to increased fuel efficiency, and reduced production energy consumption, thereby, helping to achieve the stated IACMI technical goals. This technology leverages centuries of manufacturing development in support of the textile and embroidery industry. One major drawback to this technology is the lack of commercial or non- proprietary structural performance data and robust analytical tools used to optimize fiber architecture and predict performance. This project was structured to utilize common sub-element features to validate analytical performance tools, generate performance data, and gather cost and performance data on components of interest. This project was designed to give industry sponsors the confidence and ability to take full advantage of TFP to fabricate primary, highly loaded structure and integrate features such as metallic fasteners. The project focused principally on the use of high strength carbon fiber, such as T700, and the use of aerospace epoxy resin matrix to primarily support development of new composite applications in vehicle, aerospace, and industrial markets. This project applied previously developed analytical tools to predict the performance of TFP produced parts. This work focused on developing the pipeline to characterize material in order to accurately predict component performance when modifying the TFP print paths and stitch density. This focused on experimental characterization via standardized ASTM testing, alongside experimental testing of more representative service components by testing curved beam strength, beam shear performance, a large scale TFP lug, and ultimately designing a fully TFP clip bracket that reduced weight and cost compared to a traditional metallic component. The new knowledge gained from this program included: 1) development and demonstration of novel analytical tools applied to analysis of TFP preforms; 2) development and demonstration of a building block approach using coupons and sub-elements to optimize the design of a more complex component; 3) demonstration that optimized fiber orientation using TFP can exceed performance of conventional textile composite materials and can open new applications currently limited to metallic components; 4) Demonstration of performance and cost benefits of the TFP process as compared to metallic and conventional textile composites. Recommendations for follow-on work include development of design allowables to assess the impact of high temperature/moisture exposure or saturation during loading, tracking the impact of stitching needle wear on the performance of parts and ability to stitch thicker preforms, using TFP preforms as local reinforcement at areas of bearing or complex loading, and topology optimization of components by tow steering. The expertise developed during the course of this project can be leveraged to provide commercial engineering design and fabrication services using TFP. UDRI is in the process of formalizing their partnership with Spintech, who will serve as the commercialization partner for this technology and provide molding services and deliver finished components to the end user. UDRI will continue to produce the preforms until the economics allow Spintech to procure its own TFP equipment or lease UDRI equipment, at which point UDRI will step away from manufacture and serve as the engineering and design lead on product development.

36 MATERIALS SCIENCE↗