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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.

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At least 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Deployment of Dynamic Neural Network Optimization to Minimize Heat Rate During Ramping for Coal Power Plants (Final Technical Report)

Much success was achieved throughout the course of this project. A successful implementation of Dynamic Neural Network Optimization (D-NNO) was coupled with Adaptive Predictive Controls (APC) and a novel hardware installation comprised of an advanced sensor network (ASN) measuring mass-weighted averages of flue gas constituents above the horizontal superheater of a coal-fired utility boiler. From 2019 through 2023 (including an extension due to COVID delays), the team was able to prototype, evaluate, deploy, iterate, and ultimately finalize an advanced closed-loop control D-NNO system which demonstrated the ability to: •improve unit efficiency ~2.0% relative to unoptimized operation (represented as total fuel fired per MWh generated) •improve unit NOx emission rates 10%+ beyond static optimization baselines •improve unit temperature stability as much as 58% and on average 12% •improve operating load stability as much as 35% The culmination of this project has generated an advanced methodology of deploying specially designed recurrent neural networks (long short-term memory, gated recurrent unit, encoder-decoder networks, transformers, etc.), customized trajectory planning and closed-loop optimization modules capable of adapting to live electric grid responses and demands, self-tuning and adaptive expert controls constantly adjusting prediction parameters to real-time unit behavior, and a hardware/software package able to reliably calculate net unit heat rate (NUHR) in real-time using flue gas constituents, machine learning, and known combustion relationships. Through this real-time NUHR value, immediate feedback on system adjustments relative to operating efficiency was available, allowing for rapid improvements to system performance. In addition to development and deployment of the advanced D-NNO system, the approach methodology has been readily commercialized through the project platform Griffin Open Systems, LLC, the D-NNO software platform host. Similar methodologies to those developed by this project have already been deployed at 5 other units across the United States, with another 6 implementations scheduled, and more expected. Over the course of the project, multiple academic papers were submitted and accepted for publication within esteemed academic journals, and PhD students were trained and graduated, as well as undergraduate students becoming involved and participating to project objectives.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

Model-based predictive control of multi-stage air-source heat pumps integrated with phase change material-embedded ceilings

This paper presents a model-based predictive control strategy to optimize the operations of phase change material (PCM) ceiling panels coupled with a multi-stage air-source heat pump. A three-stage prototype heat pump unit has been built and tested in the laboratory, with the low and medium stages designed for space heating/cooling and the high compression stage dedicated to charging of the PCM energy storage. To facilitate optimal control of the integrated heat pump system, a mixed-integer linear programming formulation is derived through linearization of the heat pump model and a mixed-integer reformulation of the PCM dynamic governing equations. A predictive control strategy is synthesized based on the resultant control formulation and implemented in a receding horizon scheme that optimizes the PCM charging and the zone temperature schedules simultaneously to leverage both the passive (associated with building construction materials) and active (PCM) storage capacities of a building. The control strategy has been tested along with three benchmarking control scenarios using a co-simulation platform for a prototypical detached house in Atlanta, GA. In this study, test results showed that application of the proposed control strategy to the PCM-integrated heat pump could provide 27.1% electricity cost savings while a fine tuned rule-based control strategy could achieve cost savings of 20.4%, compared to a baseline case without PCM storage, under a time-of-use rate tariff.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Design of a custom vapor transport co-deposition system for scalable production of perovskite solar cells

Vacuum-deposited perovskites provide a more direct path to manufacturing large area solar cells because of ready compatibility with multilayered architectures and historic use in the electronics industry. However, vacuum compatible co-deposition of organic-inorganic perovskites remains difficult due to issues of precisely controlling the organic precursor flux. Here, we demonstrate a manufacturing prototype specifically designed for co-depositing organic-inorganic perovskites and evaluate it with respect to the influence of process parameters on film growth. Through depositing and characterizing methylammonium lead iodide (MAPbI3) perovskite films, we highlight the necessary design requirements while measuring the influence of film growth parameters on deposition rate and perovskite phases.

14 SOLAR ENERGY↗
DOE OSTI2024

Improving Cost and Efficiency of the Scalable Solid Oxide Fuel Cells Power System

The objective of this project was to design and develop a 20kW range small-scale solid oxide fuel cells (SOFC) power system for applications such as data centers and commercial buildings. The original plan included a 5,000 hours demonstration and a Techno-Economic Analysis (TEA) which were dropped as part of project termination. The original project plan was to use a stack with a cross-flow cell design which had previously been tested for 500 hours at a community college in Malta, NY. However, it was decided to move to the advanced R-SOFC co-flow cell developed under Department of Energy Award DE-FE0031971. The advanced cell design has the advantage of a larger active area for the same manufacturing footprint which results in fewer required cells for the same stack power, hence a higher volumetric power density (kW/L) and lower cost per kW than the original cross-flow cell design. A full SOFC system Simulink model was developed and calibrated with testing data from a fuel cell stack and BOP (balance of plant) components. The simulation results from the calibrated model showed an acceptable match with the experimental data. A structural analysis conducted for various load scenarios indicated no high stress areas for all spatial directions. Major electrical system components were acquired, built and successfully tested. System sensors were verified and validated against controls. Safety checks, a diagnostic check, PID tuning, and control software commissioning tasks were also conducted. The power electronics prototype was delivered and trial testing completed. Balance of Plant component testing and simulation work was conducted to characterize Reformer-Heat Exchanger heat transfer and backpressure and reformer catalyst methane conversion and product selectivity. Simulations were conducted to design the Anode and Cathode fluid passages and size the air-air and fuel-fuel heat exchangers. A Burner operation map was created from test data and the Anode Gas Recirculation blower was tested to evaluate its durability. The SOFC system used a horizontal style design where components sit directly on a casting with a direct connection to the skid. This design has efficient packaging and a small footprint with approximate dimensions of 750 mm x 700 mm x 1700 mm. An SOFC system was built and successfully tested at the Malta, NY facility The system for over 500 hours under load of which over 300 hours was at full load of 20 kW.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2024

Slow control and TDAQ systems installation and tests in the Mu2e experiment

The Mu2e experiment at Fermilab will attempt to detect a coherent neutrinoless conversion of a muon into an electron in the field of an aluminum nucleus, with a sensitivity that is 10,000 times greater than existing limits. The Mu2e trigger and data acquisition system (TDAQ) uses the otsdaqframework as its online Data Acquisition System (DAQ) solution. Developed at Fermilab, otsdaq integrates several components, such as an artdaq-based DAQ, an art-based event processing, and an EPICS-based detector control system (DCS), and provides a uniform multi-user interface toits components through a web browser. The data streams from the Mu2e tracker and calorimeter are handled by the artdaq-based DAQ and processed by a one-level software trigger implemented within the art framework. Events accepted by the trigger have their data combined, post-trigger, with the separately read-out data from the Mu2e Cosmic Ray Veto system. The foundation of Mu2e DCS, EPICS, an Experimental Physics and Industrial Control System, is an open-source platform for monitoring, controlling, alarming, and archiving. Over the last three years, a prototype ofthe TDAQ and DCS systems has been built and tested at Fermilab’s Feynman Computing Center.Currently, the production system installation is underway. At the end, this work presents a brief update on the installation of racks and DAQ hardware.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

Peak Load Management in Distribution Systems Using Legacy Utility Equipment and Distributed Energy Resources: Preprint

The ability to perform peak load management in distribution systems has several benefits for utilities, including reduced demand charges and improved reliability, efficiency, and utilization of the network infrastructure. This paper demonstrates the coordinated operation of an advanced distribution management system (ADMS) and a distributed energy resource management system (DERMS) to achieve peak load management using a realistic laboratory test bed. A commercial ADMS reduces the peak demand by reducing system voltages using a dynamic voltage regulation (DVR) application. A prototype DERMS—based on real-time optimal power flow—controls distributed battery energy storage systems to further reduce the feeder power. Results from the experiments conducted using a model of a real distribution feeder show that the coordinated operation of the ADMS and DERMS is effective in accomplishing peak load management.

61 RADIATION PROTECTION AND DOSIMETRY↗
DOE OSTI2022

Automated Control for Nuclear Thermal Propulsion Start-Up using MOOSE-based Applications

This report presents a Griffin/Bison/RELAP-7 numerical model of a prototypical NTP system that features fuel assemblies arranged in rings, and which was designed to simulate rapid startup transients. The physics modeled include full-core neutronics, assembly-wise heat conduction, and conjugate heat transfer, with the balance of plant mainly imposed through boundary conditions. In addition, various forms of automated reactivity control were deployed by using the MOOSE to autonomously drive the model and simulate the reactor transitioning from assumed initial conditions to nominal power in a fraction of a minute. To generate the cross-sections of the neutronics model, and in an effort to simultaneously account for the tremendous axial temperature gradients in the reactor and to limit the number of state points required for cross-section generation, the average component temperatures and hydrogen densities in the cooling channels were correlated to the average fuel and moderator temperatures, and fixed axial profiles were derived for nominal conditions and then used during the transient. With this approximation, a tractable cross-section library tabulated with fuel/moderator temperatures and CD angles was generated using Serpent. The full-core SPH correction procedure and the CD decusping technology in Griffin, respectively, ensure preservation of the multiplication factor and reaction rates at state points, along with a reasonably accurate reactivity worth between tabulated CD angles, despite using a coarse mesh. Feedback from other physics was calculated by modeling one representative fuel assembly per ring, along with the corresponding fuel and moderator cooling channels. To limit power overshoots during startup, another layer of multiphysics coupling was added to the model in order to automatically control the drums. Two different technologies presented herein showed outstanding performance in this regard: (1) a novel hybrid PID controller based on both power and reactivity signals, and (2) a PGC that relies on kinetics parameters and reactivity coefficients to predict future behavior and adjust the desired signal accordingly. A challenging benchmark was devised, featuring a power demand curve that exponentially increases by a factor of 500 within 30 seconds, then levels out after that. Both control approaches create a simulated power curve that closely follows the power demand curve and limits power overshoots to 1% or less. While the former approach requires more tuning of the internal parameters, the latter requires additional knowledge of the reactivity feedback coefficients and rates of change of the corresponding variables, including fuel and moderator temperature, which could be difficult to dynamically measure for a real NTP system. Fortunately, some inaccuracy in these quantities will not drastically degrade the PGC performance. Subsequently, a more realistic startup sequence was considered, in which the mass flow rate and outlet pressures are ramped up to model bootstrap and thrust build-up phases prior to reaching steady-state conditions, demonstrating the ability of the hybrid PID and PGCs to handle such transients, with both types of controllers exhibiting very similar behavior. Nevertheless, a significant chamber temperature overshoot was observed, caused by the demanded power signal and assumed mass flow rate. This issue could be mitigated by deploying a reactor controller that follows the chamber temperature signal and actuates both the control valves and drums (rather than using a power signal based solely on the drums to control reactivity). Enhancement of the hydrogen fluid properties available in MOOSE, as well as a better understanding of prototypical initial conditions, are also needed to further enhance this startup model. Finally, a study was performed to model decay heat post-shutdown, and to prepare for extending this model to predict shutdown behavior and post-shutdown pulsed cooling requirements.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

An evaluation of the demand response potential of integrated dynamic window and HVAC systems

Demand response (DR) increases the flexibility and reliability of the electricity grid as use of intermittent renewable energy sources increases. HVAC and envelope DR measures present the largest aggregate energy and peak demand savings potential of all commercial building end uses because their net demand savings occur during critical peak demand periods. Controllable envelope measures include switchable electrochromic windows, operable window attachments such as outdoor louvers, roller shades, and awnings, as well as other innovative facade technologies that can modulate both solar heat gain and daylight admission over a broad solar-optical range. This study evaluated the technical potential of DR-enabled dynamic windows to reduce critical peak demand for a prototypical medium office building situated in all 16 U.S. climates. Model predictive control (MPC) algorithms were designed to minimize electricity cost in daylit perimeter office zones through control of an electrochromic window with and without HVAC thermostat setpoint control. Conventional and time-of-use rates were used to shape the degree of DR. Median annual peak demand savings with window and thermostat control across all climate zones were 24.3 kW (4.4 W/m 2 ) per building or 15.9 W/m 2 for non-north perimeter zones. Resource adequacy at the whole building level was estimated to be 13.1 to 43.4 $/kW per year over the 30-year life of the installation. Co-benefits were increased energy efficiency, and reduced electricity cost and emissions. Visual and thermal comfort requirements were met at all times. Dynamic facades controlled by MPC have substantial technical potential for DR across all U.S. climates and warrant serious consideration for inclusion in DR portfolios.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Microreactor Automated Control System - Digital Twin Models and Advanced Control Systems Updates

Automation of control systems is expected to be important in the economic and safe operation of microreactors. Therefore, there is a need to develop and demonstrate automated control for microreactors, along with the development of testbeds for this purpose. This report provides updates on the status of a nonnuclear microreactor automated control system (MACS)—a real-time, hardware-in-the-loop testbed for non-nuclear testing of microreactor control system automation. A real-time hardware-in-the-loop testbed incorporates the realistic dynamics of physical systems into control system development and testing. The collaborative effort between Oak Ridge National Laboratory (ORNL) and Idaho National Laboratory (INL) resulted in the development of a prototypic microreactor plant-level digital twin that includes the reactor and a balance of plant system. Advanced control strategies were incorporated to demonstrate testing of control automation solutions. The gRPC communication protocol, which was implemented in the hardware-in-the-loop testbed by INL, was coupled to a digital twin model developed using the TRANsient Simulation Framework of Reconfigurable Models (TRANSFORM) library in Modelica. This digital twin simulation was tested with the ViBRANT hardware for realistic feedback and visual representation of control action in real time. A modular Python client structure was developed to manage functional mock-up unit-based simulation and real-time gRPC communication. Hardware-in-the-loop testing indicated that the modeled reactor—a natural-convection, molten-salt coolant loop configuration—responds well to control of drum positioning for modulation of reactor core power, as well as system-level control and downstream demand changes. Ongoing research is focused on integrating additional control algorithms that utilize data from newly included sensors within the MACS hardware testbed, as well as demonstrating and assessing the performance of the different automated control algorithms on multiple additional operational scenarios.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Integration of a DER Management System in Riverside. Final report

The tasks in this project covered various aspects, including algorithm development, algorithm integration into a commercial Active Network Management (ANM) platform, hardware-in-the-loop (HIL) testing in an industry-standard testing platform, pilot demonstration in Riverside, California, and also cost and benefit analysis. The DERMS platform in this project can host different algorithms developed on different platforms (e.g., MATLAB and Python) and it can interact with different hardware devices (e.g., different PV inverters, battery inverters, and different sensors). The DER control solution are based on an advanced model-free, layered, and clustered DER control paradigm. At the core of the DER control algorithms was the concept of Extremum Seeking (ES), which is a model-free probing-based control technique. The ES-based control algorithms were tested on major real-world inverters; both individually and in a cluster. It was shown that even legacy equipment (or when paired with a few additional advanced equipment) can support such advanced control. The monitoring algorithms utilize a heterogeneous set of legacy and advanced sensor measurements, such as behind-the-meter DER sensors, distribution-level Phase Measurement Units, distribution-substation Supervisory Control and Data Acquisition (SCADA), and line current sensors, with their limited availability; in order to infer practical network conditions. Sensor data are utilized to achieve resource forecasting, phase identification, and distribution system state estimation. The technology that was developed and demonstrated in this project could be transformational to utilities, including the smaller municipal utilities such as in Riverside, which may not have the resources to deploy advanced distribution system and DERMS solutions in order to support high penetration of solar power integration. This project created a real-world prototype to provide utilities with an assessment of smart grid monitoring and control technologies.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

Detailed Laboratory Evaluation of Electric Demand Load Shifting Potential of Controlled Heat Pump Water Heaters

The demand profile management of electric end uses is vital research for utilities and policymakers planning greenhouse gas emission reductions. In this study, detailed laboratory research was conducted on the load shifting potential of 4 grid-connected HPWHs and one electric resistance water heaters (ERWH). The testing applied different CTA-2045 shed and critical peak command designs under three water draw profiles. Highly-controlled laboratory experiments were conducted in Florida. One of the four HPWHs was a prototype incorporating the new CTA-2045-B protocol feature allowing ‘advanced’ load-up above tank setpoint. A three-hour morning (6 – 9 AM) and four-hour evening curtailment (4 – 8 PM) were defined as the shed or critical peak periods reflecting high-value control periods for utility coincident load for system-wide electric demand reductions. Tests were performed under baseline conditions (no load shift) and under varied load-shifting schemes, including load up and advanced load up, ahead of shed and critical peak commands. Data were collected from December 2020 – February 2022 in the laboratory and compared with field experiments in Florida and the Pacific Northwest. Grid-connected HPWHs were found to reduce peak demand by up to 0.47 kW compared to uncontrolled HPWH units, depending on time of day, control scheme, draw profile, and temperature cluster. The load up strategy demonstrated the ability of all units to utilize heat pump mode for extended periods ahead of peak events. Demand reductions for the HPWHs were much larger when compared with the ERWH— up to 1.64 kW with large hot water draws in winter.

Fenaughty, Karen↗
DOE OSTI2024

Proof-of-Concept for Sensor Modeling in MOOSE for the Design of Autonomous Nuclear Reactor Control

Autonomous operation is essential for the deployment of microreactors and fission batteries, both in terrestrial and space applications. For this reason, recent studies have investigated autonomous control by using adaptive model predictive control and multi-objective optimization for heat pipe–cooled microreactors under normal and heat pipe failure conditions. However, prototypes of microreactors and fission batteries do not exist yet, and even the design space has not been narrowed down conclusively, making the instrumentation and control system design difficult. For this reason, there is a need for flexible computational capabilities to create a numerical stand-in of potential microreactor and fission battery designs. The latter can be used to design and test control strategies to support autonomous operations. In this poster, we describe the initial implementation of a pluggable sensor system for the easy implementation of realistic sensor models in the multiphysics object-oriented simulation environment (MOOSE) framework. This new capability will enable MOOSE users to create a numerical stand-in of microreactors and fission batteries, ultimately allowing them to easily test new control algorithms, and instrumentation strategies for advanced systems in the design phase.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Data acquisition and slow control interface for the Mu2e experiment

The Mu2e experiment at the Fermilab Muon Campus will search for the coherent neutrinoless conversion of a muon into an electron in the field of an aluminum nucleus with a sensitivity improvement by a factor of 10000 over existing limits. The Mu2e Trigger and Data Acquisition System (TDAQ) uses otsdaq as the online Data Acquisition System (DAQ) solution. Developed at Fermilab, otsdaq integrates both the artdaq DAQ and the art analysis frameworks for event transfer, filtering, and processing. otsdaq is an online DAQ software suite with a focus on flexibility and scalability and provides a multi-user, web-based, interface accessible through a web browser. The data stream from the detector subsystems is read by a software filter algorithm that selects events which are combined with the data flux coming from a cosmic ray veto system. The Detector Control System (DCS) has been developed using the Experimental Physics and Industrial Control System (EPICS) open source platform for monitoring, controlling, alarming, and archiving. The DCS system has been integrated into otsdaq. A prototype of the TDAQ and the DCS systems has been built at Fermilab's Feynman Computing Center. In this study, we report on the progress of the integration of this prototype in the online otsdaq software.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

Dielectric screening and electric field control of ferromagnetism at the CaMnO 3 /CaRuO 3 interface

Control of magnetism by an applied electric field is a desirable technique for the functionalization of magnetic materials. Motivated by recent experiments, we study the electric field control of the interfacial magnetism of CaRuO 3 /CaMnO 3 (CRO/CMO) (001), a prototype interface between a non-magnetic metal and an antiferromagnetic insulator. Even without the electric field, the interfacial CMO layer acquires a ferromagnetic moment due to a spin-canted state, caused by the Anderson-Hasegawa double exchange (DEX) between the Mn moments and the leaked electrons from the CRO side. An electric field would alter the carrier density at the interface, leading to the possibility of controlling the magnetism, since DEX is sensitive to the carrier density. We study this effect quantitatively using density-functional calculations in the slab geometry. We find a text-book like dielectric screening of the electric field, which introduces polarization charges at the interfaces and the surfaces. The extra charge at the interface enhances the ferromagnetism via the DEX interaction, while away from the interface the original AFM state of the Mn layers remains unchanged. The effect could have potential application in spintronics devices.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2022

Development of Quality Control Methods for Robust and Reliable Sensor Design

The successful adoption of additive manufacturing for the rapid prototyping of printed sensors requires the establishment of quantifiable metrics that can interrogate device performance. One measure of performance is the adhesion strength between the substrate and sensor interface, which is critical since the strength of this interface can dictate the accuracy and reliability of the printed sensor. In this work, a non-contact laser-induced spallation technique was used to quantify the adhesion of silver prints on an aluminum alloy substrate. The laser-based method was compared to a standardized pull-off adhesion test, which provided baseline measurements of adhesion strength. The sintering conditions were shown to play an important role in the film-substrate adhesion strength, as well as the cohesion and ductility of the film itself. The methods and results described in this work supports the establishment of process control steps that are necessary for verifying the reliability of printed devices prior to its deployment in critical experiments.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Theory and phase-field simulations of electrical control of spin cycloids in a multiferroic

Cycloidal spin orders are common in multiferroics. One of the prototypical examples is BiFeO 3 (BFO) which shows a large polarization and a cycloidal antiferromagnetic (AFM) order at room temperature. Here, we employ Landau theory and phase-field simulations to analyze the coupled switching dynamics of polarization and cycloidal AFM orders in BFO. We identify 14 types of transitional spin structures between two cycloids and nine electric-field-induced spin switching paths. We demonstrate the electric-field-induced rotation of wave vectors of the cycloidal spins and discover two types of cycloidal spin switching dynamics: fast local spin flips and slow rotation of wave vectors. Also, we construct roadmaps to achieve the switching between any two spin cycloids through multistep applications of electric fields. Furthermore, this paper provides a theoretical framework for the phenomenological description of spin cycloids and a fundamental understanding of the switching mechanisms to achieve electrical control of magnetic orders.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2021

Nickel-based superalloy single crystals fabricated via electron beam melting

Additive manufacturing technologies have emerged as potential disruptive processes whose possible impacts range from supply chain logistics, prototyping, and novel materials synthesis. Numerous works illustrate the ability to control mi- crostructure in fusion based processes and a few recent authors have even produced single crystals. However, a number of open questions remain regarding the process window which enables printing of single crystals. Furthermore, it has been observed that these additively manufactured single crystals exhibit a preferred $\langle$011$\rangle$ secondary orientation. In this work we investigate fabrication conditions which enable printing of single crystals via electron beam melting. A space filling design of experiments is utilized to efficiently explore the fabrication space. Single crystals were success- fully obtained using both commercially available powders and custom melt alloys. Microstructures obtained via these exploratory experiments exhibited a continuum of columnar structures ranging from weakly textured polycrystals, near single crystal, and fully single crystalline material. Complex geometry experiments are performed to study the grain selection mechanism. We find that the grain selection mechanism is independent of the bulk scale geometry and must therefore by driven by local heat transfer and solidification dynamics. Furthermore, grain selection is shown to be driven by competing driving forces; one which prefers epitaxial growth and another which is driven by the imposed scan pattern geometry. Finally, a mechanism is proposed for the anomalous secondary orientation preference.

36 MATERIALS SCIENCE↗