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DOE OSTI2024

Autonomous hybrid optimization of a SiO 2 plasma etching mechanism

Computational modeling of plasma etching processes at the feature scale relevant to the fabrication of nanometer semiconductor devices is critically dependent on the reaction mechanism representing the physical processes occurring between plasma produced reactant fluxes and the surface, reaction probabilities, yields, rate coefficients, and threshold energies that characterize these processes. The increasing complexity of the structures being fabricated, new materials, and novel gas mixtures increase the complexity of the reaction mechanism used in feature scale models and increase the difficulty in developing the fundamental data required for the mechanism. This challenge is further exacerbated by the fact that acquiring these fundamental data through more complex computational models or experiments is often limited by cost, technical complexity, or inadequate models. In this paper, we discuss a method to automate the selection of fundamental data in a reduced reaction mechanism for feature scale plasma etching of SiO 2 using a fluorocarbon gas mixture by matching predictions of etch profiles to experimental data using a gradient descent (GD)/Nelder–Mead (NM) method hybrid optimization scheme. These methods produce a reaction mechanism that replicates the experimental training data as well as experimental data using related but different etch processes.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Assessment of MELCOR condensation models with the presence of noncondensable gas in natural convection flow regime

Condensation of steam vapor is an important mode of energy removal from the reactor containment. The presence of noncondensable gas complicates the process and makes it difficult to model. MELCOR, one of the more widely used system codes for containment analyses, uses the heat and mass transfer analogy to model condensation heat transfer. To investigate previously reported nodalization-dependence in natural convection flow regime, MELCOR condensation model as well as other models are studied. The nodalization-dependence issue is resolved by using physical length from the actual geometry rather than node size of each control volume as the characteristic length scale for MELCOR containment analyses. At the transition to turbulent natural convection regime, the McAdams correlation for convective heat transfer produces a better prediction compared to the original MELCOR model. The McAdams correlation is implemented in MELCOR and the prediction is validated against a set of experiments on a scaled AP600 containment. The MELCOR with our implemented model produces improved predictions. For steam molar fractions in the gas mixture greater than about 0.58, the predictions are within the uncertainty margin of the measurements. The simulation results still underestimate the heat transfer from the gas-steam mixture, implying that conservative predictions are provided.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2014

Photo-ionization and residual electron effects in guided streamers

Complementary experiments and numerical modeling reveal the important role of photo-ionization in the guided streamer propagation in helium-air gas mixtures. It is shown that the minimum electron concentration ∼10{sup 8 }cm{sup −3} is required for the regular, repeated propagation of the plasma bullets, while the streamers propagate in the stochastic mode below this threshold. The stochastic-to-regular mode transition is related to the higher background electron density in front of the propagating streamers. These findings help improving control of guided streamer propagation in applications from health care to nanotechnology and improve understanding of generic pre-breakdown phenomena.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS2015

The Two-Phase Flow Separator Experiment Breadboard Model: Reduced Gravity Aircraft Results

Life support systems in space depend on the ability to effectively separate gas from liquid. Passive cyclonic phase separators use the centripetal acceleration of a rotating gas-liquid mixture to carry out phase separation. The gas migrates to the center, while gas-free liquid may be withdrawn from one of the end plates. We have designed, constructed and tested a breadboard that accommodates the test sections of two independent principal investigators and satisfies their respective requirements, including flow rates, pressure and video diagnostics. The breadboard was flown in the NASA low-gravity airplane in order to test the system performance and design under reduced gravity conditions.

phase separation↗

DOE OSTI2015

Complexation behavior of oppositely charged polyelectrolytes: Effect of charge distribution

Complexation behavior of oppositely charged polyelectrolytes in a solution is investigated using a combination of computer simulations and experiments, focusing on the influence of polyelectrolyte charge distributions along the chains on the structure of the polyelectrolyte complexes. The simulations are performed using Monte Carlo with the replica-exchange algorithm for three model systems where each system is composed of a mixture of two types of oppositely charged model polyelectrolyte chains (EGEG){sub 5}/(KGKG){sub 5}, (EEGG){sub 5}/(KKGG){sub 5}, and (EEGG){sub 5}/(KGKG){sub 5}, in a solution including explicit solvent molecules. Among the three model systems, only the charge distributions along the chains are not identical. Thermodynamic quantities are calculated as a function of temperature (or ionic strength), and the microscopic structures of complexes are examined. It is found that the three systems have different transition temperatures, and form complexes with different sizes, structures, and densities at a given temperature. Complex microscopic structures with an alternating arrangement of one monolayer of E/K monomers and one monolayer of G monomers, with one bilayer of E and K monomers and one bilayer of G monomers, and with a mixture of monolayer and bilayer of E/K monomers in a box shape and a trilayer of G monomers inside the box are obtained for the three mixture systems, respectively. The experiments are carried out for three systems where each is composed of a mixture of two types of oppositely charged peptide chains. Each peptide chain is composed of Lysine (K) and glycine (G) or glutamate (E) and G, in solution, and the chain length and amino acid sequences, and hence the charge distribution, are precisely controlled, and all of them are identical with those for the corresponding model chain. The complexation behavior and complex structures are characterized through laser light scattering and atomic force microscopy measurements. The order of the apparent weight-averaged molar mass and the order of density of complexes observed from the three experimental systems are qualitatively in agreement with those predicted from the simulations.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Modeling delayed thermal runaway in nitric acid-soaked cat litter mixed with radioactive waste

Thermal ignition of radioactive waste within a 55-gallon drum was simulated by using a pressure-dependent waste decomposition model (Hobbs et al. in Process Saf Environ Prot https://doi.org/10.1016/j.psep.2022.09.047, 2022) calibrated with data from full-scale drum experiments (Parker et al. in The thermolytic response of a surrogate RNS waste mixture at the drum scale. Los Alamos National Laboratory Report LA-UR-16-21760, 2016) and validated with experiments from multiple laboratories (Hobbs et al. in Thermal analysis of aged nitric acid-soaked kitty litter in TRU waste drums-23370.WM2023 Conference, Phoenix, AZ, 2023). The acceleration of nitric acid chemistry reacting with an organic cat litter leading to thermal ignition was likely triggered by a restricted vent in the drum. Here, we address whether the form of the rate equation in (Hobbs et al. in Process Saf Environ Prot https://doi.org/10.1016/j.psep.2022.09.047, 2022) is sufficient to extrapolate thermal ignition within aged drums of similar content that have been stored in Texas for over nine years by investigating four different reaction rate forms for waste decomposition. A critical reaction rate reduction analysis is performed on each of these models to determine if delayed thermal runaway within vented aged waste is possible after nine years. We found that a pressure-dependent first-order rate expression not only predicted the accidental ignition of the waste drum, but the form also matches multiple experiments from different laboratories. Even though the waste composition decreases over time, the model predicts that acceleration leading to thermal runaway is possible if the waste is confined, even after 9 years. In conclusion, waste containing oxidizers such as nitric acid should not be mixed with organic adsorbents, especially if the waste is confined.

cookoff↗

DOE OSTI2019

Deconvolving distribution of relaxation times, resistances and inductance from electrochemical impedance spectroscopy via statistical model selection: Exploiting structural-sparsity regularization and data-driven parameter tuning

The distribution of relaxation times (DRT) has drawn increasing attention for interpreting electrochemical impedance spectroscopy (EIS). Deconvolution of DRT from EIS is a challenging ill-posed problem that requires regularization methods. In this work, we formulate DRT reconstruction task as a statistical model selection problem with structural-sparsity penalties. We utilize the Elastic net regularization that simultaneously benefits from Ridge and Lasso regularizations with optimal tuning parameter automatically determined by the information criteria. We benchmark our approach on four synthetic experiments (a ZARC element, ZARC mixtures, a RC circuit and a Fractal element) and two real EIS datasets of a Lithium ion battery and an organic-inorganic halide class of perovskites in oxygen environment at different gas pressures. We demonstrate the superiority of proposed model selection procedure, that is capable of eliminating pseudo peaks and representing asymmetries in DRT as well as precisely estimating resistances. Here, we highlight our approach is robust to reducing and subsampling EIS frequency range, making it a promising tool for timing-resolved, localized and large scale EIS data analysis. For the Lithium ion battery data analysis, we extend the classical DRT model to incorporate the inductive effect and illustrate DRT as a guidance for equivalent circuit modeling to refine impedance reconstruction at low risks of overfitting. Furthermore, the structural-sparsity regularization could be extended for multidimensional and Bayesian EIS data analysis.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2015

Designing a mixture experiment when the components are subject to a nonlinear multiple-component constraint

This article presents a case study of developing an experimental design for a constrained mixture experiment when the experimental region is defined by single-component constraints (SCCs), linear multiple-component constraints (MCCs), and a nonlinear MCC. Traditional methods and software for designing constrained mixture experiments with SCCs and linear MCCs are not directly applicable because of the nonlinear MCC. A modification of existing methodology to account for the nonlinear MCC was developed and is described in this article. The case study involves a 15-component nuclear waste glass example in which SO3 is one of the components. SO3 has a solubility limit in glass that depends on the composition of the balance of the glass. A goal was to design the experiment so that SO3 would not exceed its predicted solubility limit for any of the experimental glasses. The SO3 solubility limit had previously been modeled by a partial quadratic mixture (PQM) model expressed in the relative proportions of the 14 other components. The PQM model was used to construct a nonlinear MCC in terms of all 15 components. In addition, there were SCCs and linear MCCs. This article discusses the waste glass example and how a layered design was generated to (i) account for the SCCs, linear MCCs, and nonlinear MCC and (ii) meet the goals of the study.

Low-activity waste↗

NASA NTRS1988

Thermodynamics of dense molecular hydrogen-helium mixtures at high pressure

Effective intermolecular pair potentials derived from liquid hydrogen and helium shock wave experiments are presently used in Monte Carlo simulations of mixtures of hydrogen and helium, at densities of up to 1.2 g/cu cm. The model interaction Helmholtz free energy derived accurately reproduces both the Monte Carlo calculation results and the experimental data obtained for densities of up to about 0.6 g/cu cm. An equation of state is derived from the free energy expression that could be useful in interior models of such Jovian planets as Saturn.

Marley, Mark S.↗

NASA NTRS2000

Characterizing the Use of Ultrasonic Energy in Promoting Uniform Microstructural Dispersions in Immiscible Mixtures

Gravity driven separation and preferential wetting precludes uniform microstructural distributions during solidification processing of immiscible, liquid-liquid mixtures. Historically, it is, however, established that liquid/liquid suspensions can be established and maintained by utilizing ultrasound. Following a brief introduction the results of experiments on immiscible mixtures subjected to ultrasonic energy during solidification processing will be compared and evaluated in view of a recently developed mathematical model. The presentation continues by discussion of scaling the model to commercial viability and concludes with the implications of such processing in a microgravity environment.

Grugel, R. N.↗

NASA NTRS2001

Characterizing the Use of Ultrasonic Energy in Promoting Uniform Microstructural Dispersions in Immiscible Mixtures

Grugel, R. N.↗

DOE OSTI2019

Single-Fuel Reactivity Controlled Compression Ignition Combustion Enabled by Onboard Fuel Reformation (Final Report)

Reactivity-Controlled Compression Ignition (RCCI) is a promising new advanced, low temperature combustion mode that offers efficiencies equal to or greater than conventional diesel combustion, but significantly lower soot and NOx emissions. Additionally, RCCI has enhanced controllability over the combustion process compared to some of the other advanced combustion modes. Therefore, RCCI combustion has the potential to be of great benefit to the public by increasing the efficiency and reducing the harmful pollutant emissions from transportation. However, RCCI combustion achieves this favorable level of performance through the use of two distinct fuels (e.g., diesel and gasoline, diesel and natural gas, or diesel and ethanol). In a vehicle application, RCCI therefore requires two different fuel tanks and fuel injection systems, which presents a significant drawback to the commercialization RCCI. This project proposed a new concept to enable RCCI combustion from a single parent fuel stored onboard the vehicle in a single fuel tank. Specifically, the parent fuel would be stored in the fuel tank and one branch of the fuel system would deliver the parent fuel, unaltered, to the cylinder, while a second branch of the fuel system would route the parent fuel through a fuel reformer to chemically react the fuel into a gaseous fuel mixture, called “reformate”, that has different properties from the original parent fuel. In this way, there can be two fuels at the engine that have different properties, but only one parent fuel needs to be stored and refilled in the vehicle. This initial, exploratory investigation into the feasibility of this promising new concept included reacting three potential parent fuels (diesel, gasoline, and natural gas) in a fuel reformer and determining the composition of the gaseous reformate fuel that exited the fuel reformer. There are different types of reformation processes, but since this project was a proof-of-concept investigation into the potential of Single-Fuel RCCI and the combustion process in the cylinder, a catalytic partial oxidation (CPOX) reformation process was selected, which is more straightforward to perform and control, and would potentially be easier to implement in a vehicle application compared to other reformation processes. Once the three parent fuels were reformed to varying degrees and their reformate compositions were determined, their autoignition tendencies were experimentally determined by comparing advanced combustion results of the reformate mixtures with known reference fuels. This showed that diesel fuel and its reformate fuel mixture exhibited the largest reactivity separation, which is necessary to enable RCCI combustion in the cylinder. Using diesel fuel as the parent fuel, experimental testing was conducted to provide a better understanding of the operational considerations, benefits, and drawbacks of Single-Fuel RCCI with onboard fuel reformation. The experimental testing was accompanied by computational fluid dynamics and system-level modeling to help complement the experiments and further expand the understanding. The main conclusions are that Single-Fuel RCCI using diesel fuel as the direct injected, high reactivity fuel and diesel’s gaseous reformate mixture as the premixed, low reactivity fuel is viable. The efficiencies were equal to, or sometimes greater than, RCCI with conventional fuel pairs, and the emissions were comparable as well. A key consideration is that gaseous reformate fuel contains a large amount of diluents in the fuel which displace air entering the cylinder and act as EGR inside the cylinder. Additionally, the reactivity separation between diesel and its reformate fuel mixture is larger than diesel-gasoline, but less than diesel-natural gas, and the combustion process therefore responded in a manner that was between the two conventional fuel pairs. Finally, although achievable in the cylinder, there are practical drawbacks or other disadvantages of Single-Fuel RCCI with onboard fuel reformation. First, this project used a CPOX reformation process which is exothermic, meaning that a portion of the fuel’s energy was released in the reformer where it could not be converted into useful work. This constituted an efficiency penalty of the system of on the order of 10% or 4 percentage points. Future research should therefore focus on alternate reforming processes including steam-methane reforming or autothermal reforming where there might not be any energy released in the reformer, or there could even be an energy gain in the reformer (through an endothermic process with waste heat recovery). Practical drawbacks that exist, but were beyond the scope of this preliminary proof-of-concept research project, are the added cost of the fuel reformer, which is a catalyst made of precious metals, transient response of the system, and the lifetime of the fuel reformer.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2016

Using CFD tools to model separate effects of HTR air ingress accident phenomena - 18508

The air ingress phenomena under the HTR conditions represent the important area of nuclear safety. Best practice guidelines for the use of CFD in nuclear safety applications are mainly based on water cooled reactors while in HTR the gas is used as a coolant. The ambition of this paper is to define the best recommendations and description of needed settings of CFD models solving the separate effects of air ingress accident phenomena. The JAERI experiments deal with phenomena of air ingress during the early stages of the accident. Experiments investigate the basic features of the flow behavior of the gas mixture and regard the phenomena of the molecular diffusion and the natural convection of the gas mixture with the graphite oxidation reaction. The separate effects simulations of air ingress accident were performed using CFD code ANSYS Fluent. Whole graphite oxidation process including all three main chemical reactions was successfully modeled. The new findings and useful information were gathered to be extrapolated to the integral effects level for the following phase. The role of the computational mesh and all important input parameters were discussed in detail and many in sensitivity studies were performed. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

NASA NTRS1984

Experiments on water/melt explosions, nature of products, and models of dispersal

Experiments were carried out in a steel pressure device using controlled amounts of water and thermite melt to examine the mechanical energy released on explosive mixing following the initial contact of the two materials. An experimental design was used to allow the direct calculation of the mechanical energy by the dynamic lift of the device as recorded both optically and physically. A large number of experiments were run to accurately determine the optimum mixture of water and melt for the conversion of thermal to mechanical energy. The maximum efficiency observed was about 12% at a water/thermite mass ratio of 0.50. These experiments are the basis for the development of models of hydroexplosions and melt fragmentation. Particles collected from the experimental products are similar in size and shape to pyroclasts produced by much larger hydrovolcanic explosions. Melt rupture at optimum ratios produces very fine particles whereas rupture at high or low water/melt ratios produces large melt fragments. Grain surface textures in the experimental products are also related to the water/melt ratio and the mechanism of explosive mixing. It is thus possible to have qualitative information about the nature of the explosion from the sizes and shapes of the fragments produced.

Sheridan, M. F.↗

DOE OSTI2020

Experimental and Simulation Analysis of Binary Mixtures of Biomass and Inert Material

A literature review was conducted to identify experiments on various scales of biomass combustion specific to circulating fluidized bed (CFB) combustors. Typical feedstock and inert bed material characteristics for biomass combustion in a CFB were gathered. This information was used to design laboratory-scale, non-reacting experiments on biomass-inert bed material mixtures in a 1-in. cylindrical test rig in the Multiphase Flow Analysis Laboratory (MFAL) in Morgantown, WV. The biomass chosen was a hardwood. Pellets from the hardwood were milled and sieved to obtain three size ranges—small, medium, and large. Three mass loadings of each of the biomass samples were fluidized with glass beads as the inert bed material to study the mixing characteristics under varying fluidizing gas velocities. Hydrodynamic data including pressure drop measurements at select vertical locations and video recordings of the mixture behavior were generated in this effort.

09 BIOMASS FUELS↗

DOE OSTI2019

Comparing D-optimal designs with common mixture experimental designs for logistic regression

Mixture experiments are used in applications where the proportion of mixing components affects a response variable, such as in studies involving chemical formulations. In many applications, the response is dichotomous or binary (e.g., pass or fail) and a concern for researchers is how to efficiently and informatively design such experiments. A naive approach is to use design recommendations derived from linear normal-theory models with constant variance. In this research, we investigate the potential risks of such designs by comparing them to D-optimal mixture designs for binary responses and evaluating the D-efficiency of these design alternatives for several parameter subspaces. Standard designs for normal theory models generally do not work well for binary responses due to the tendency of these designs to favor boundary points. In addition, D-optimal mixture designs for binary responses tend to locate design points in the region where the magnitude of predicted response probabilities are moderate. Lastly, we recommend that researchers pay close attention to what is known about the characteristics of the underlying process models in selecting appropriate mixture designs for binary-response applications.

D-optimality↗

DOE OSTI2024

Extreme compression of planetary gases: High-accuracy pressure-density measurements of hydrogen-helium mixtures above fourfold compression

Hydrogen (H 2 ) and helium (He), the most abundant elements in the universe, pose a unique challenge in measuring the equation of state of the mixture, owing to their differing physical properties. There remains a need for data with high enough precision to discriminate between existing equation of state (EOS) mix models in order to understand the internal structure of gas-giant planets. Here, we have measured the EOS of precompressed H 2 - He mixtures at conditions directly relevant to the planetary interiors using hypervelocity gas guns and Sandia’s Z machine with less than 10% uncertainty in density, enabling validation of mixture models. We precompressed 50:50 molar mixtures of H 2 -He to 0.1–0.2 GPa and directly measured particle velocity (in gas-gun experiments) and shock velocities (in Z-machine experiments). To complement the experimental efforts, we also computed the Hugoniots of precompressed H 2 -He mixtures using density-functional-theory-based molecular dynamics. Furthermore, we observe approximately 3- to 4.3-fold density compression at pressures up to 44 GPa.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

NASA NTRS2001

CFD Simulation of Liquid Rocket Engine Injectors

Detailed design issues associated with liquid rocket engine injectors and combustion chamber operation require CFD methodology which simulates highly three-dimensional, turbulent, vaporizing, and combusting flows. The primary utility of such simulations involves predicting multi-dimensional effects caused by specific injector configurations. SECA, Inc. and Engineering Sciences, Inc. have been developing appropriate computational methodology for NASA/MSFC for the past decade. CFD tools and computers have improved dramatically during this time period; however, the physical submodels used in these analyses must still remain relatively simple in order to produce useful results. Simulations of clustered coaxial and impinger injector elements for hydrogen and hydrocarbon fuels, which account for real fluid properties, is the immediate goal of this research. The spray combustion codes are based on the FDNS CFD code' and are structured to represent homogeneous and heterogeneous spray combustion. The homogeneous spray model treats the flow as a continuum of multi-phase, multicomponent fluids which move without thermal or velocity lags between the phases. Two heterogeneous models were developed: (1) a volume-of-fluid (VOF) model which represents the liquid core of coaxial or impinger jets and their atomization and vaporization, and (2) a Blob model which represents the injected streams as a cloud of droplets the size of the injector orifice which subsequently exhibit particle interaction, vaporization, and combustion. All of these spray models are computationally intensive, but this is unavoidable to accurately account for the complex physics and combustion which is to be predicted, Work is currently in progress to parallelize these codes to improve their computational efficiency. These spray combustion codes were used to simulate the three test cases which are the subject of the 2nd International Workshop on-Rocket Combustion Modeling. Such test cases are considered by these investigators to be very valuable for code validation because combustion kinetics, turbulence models and atomization models based on low pressure experiments of hydrogen air combustion do not adequately verify analytical or CFD submodels which are necessary to simulate rocket engine combustion. We wish to emphasize that the simulations which we prepared for this meeting are meant to test the accuracy of the approximations used in our general purpose spray combustion models, rather than represent a definitive analysis of each of the experiments which were conducted. Our goal is to accurately predict local temperatures and mixture ratios in rocket engines; hence predicting individual experiments is used only for code validation. To replace the conventional JANNAF standard axisymmetric finite-rate (TDK) computer code 2 for performance prediction with CFD cases, such codes must posses two features. Firstly, they must be as easy to use and of comparable run times for conventional performance predictions. Secondly, they must provide more detailed predictions of the flowfields near the injector face. Specifically, they must accurately predict the convective mixing of injected liquid propellants in terms of the injector element configurations.

Farmer, Richard↗