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DOE OSTI2023

Development of a Low-Cost, Sensitivity-Optimized Fluorescence Sensor for Visible Spectrum Analysis

This paper presents an economically viable, sensitivity-optimized fluorescence sensor for detecting low concentrations of fluorophores in the visible spectrum range. The sensor employs a deep ultraviolet (DUV) 275-nm LED and a dichroic mirror to establish a co-axial optical path for excitation and emission. Instead of utilizing a general-purposed spectrometer optimized for high spectral resolution, the sensor strikes a balance between resolution and sensitivity by using an appropriate aperture size and optimized optical design tailored for the spectral characteristics of fluorophores. Here, the manuscript demonstrates measurements of ppb-level rare earth element (REE) samples containing terbium (Tb), europium (Eu), dysprosium (Dy), and samarium (Sm) in aqueous solutions. Through balanced design that optimizes collection of fluorescence emission without losing spectral information, this work shows the feasibility of developing a low-cost, compact, and highly sensitive fluorescence sensors with improved detection sensitivity when compared to bench-top commercial spectrofluorometers at far higher costs.

47 OTHER INSTRUMENTATION↗

NASA NTRS1993

Advanced launch system. Advanced development oxidizer turbopump program

On May 19, 1989, Pratt & Whitney was awarded contract NAS8-37595 by the National Aeronautics and Space Administration, Marshall Space Flight Center, Huntsville Alabama for an Advanced Development Program (ADP) to design, develop and demonstrate a highly reliable low cost, liquid oxygen turbopump for the Advanced Launch System (ALS). The ALS had an overall goal of reducing the cost of placing payloads in orbit by an order of magnitude. This goal would require a substantial reduction in life cycle costs, with emphasis on recurring costs, compared to current launch vehicles. Engine studies supporting these efforts were made for the Space Transportation Main Engine (STME). The emphasis on low cost required design simplification of components and subsystems such that the ground maintenance and test operations was minimized. The results of the Oxygen Turbopump ADP technology effort would provide data to be used in the STME. Initially the STME baseline was a gas generator cycle engine with a vacuum thrust level of 580,000 lbf. This was later increased to 650,000 lbf and the oxygen turbopump design approach was changed to reflect the new thrust level. It was intended that this ADP program be conducted in two phases. Phase 1, a basic phase, would encompass the preliminary design effort, and Phase II, an optional contract phase to cover design, fabrication and test evaluation of an oxygen turbopump at a component test facility at the NASA John C. Stennis Space Center in Mississippi. The basic phase included preliminary design and analysis, evaluation of low cost concepts, and evaluation of fabrication techniques. The option phase included design of the pump and support hardware, analysis of the final configuration to ensure design integrity, fabrication of hardware to demonstrate low cost, DVS Testing of hardware to verify the design, assembly of the turbopump and full scale turbopump testing. In December 1990, the intent of this ADP to support the design and development was changed. The design effort for the oxygen turbopump became part of the STME Phase B contract. The status of the pump design funded through this ADP was presented at the Preliminary Design Review (PDR) at the MSFC on October 24, 1990. Advancements in the design of the pump were subsequently continued under the Phase B Contract. The emphasis of this ADP became the demonstration of individual technologies that would have the greatest potential for reducing the recurring cost and increasing reliability. In October of 1992, overall program funding was reduced and work on this ADP was terminated.

Source record↗

DOE OSTI2021

Potential Early Markets for Fusion Energy

We examine potential early markets for fusion energy and their projected cost targets, based on analysis and synthesis of many relevant, recent studies and reports. Seeking to provide guidance to ambitious fusion developers aspiring to enable commercial deployment before 2040, we examine cost requirements for fusion-generated electricity, process heat, and hydrogen production based on today’s market prices but with various adjustments relating to possible scenarios in 2035, such as ‘‘business-as-usual,’’ high renewables penetration, and carbon pricing up to 100 $/tCO 2 . Key findings are that fusion developers should consider focusing initially on high-priced global electricity markets and consider including integrated thermal storage, depending on techno-economic factors, in order to maximize revenue and compete in markets with high renewables penetration. Process heat and hydrogen production will be tough early markets for fusion, but may open up to fusion as markets evolve and if fusion’s levelized cost of electricity falls below 50 $/MWh e . Finally, we discuss potential ways for a fusion plant to increase revenue via cogeneration (e.g., desalination, direct air capture, or district heating) and to lower capital costs (e.g., by minimizing construction times and interest or by retrofitting coal plants).

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2021

Fluid dynamic simulation and analysis of water-cooling systems for the Electron-Ion Collider

The Electron-Ion Collider is the newest large-scale project at Brookhaven National Laboratory. The collider’s purpose is to provide further advancements in the knowledge of the universe’s origin by accelerating particles near the speed of light. Our project for this 3.8 km ring was to create a thermal hydraulic steady-state simulation design of the water-cooling system to be cost-effective and energy efficient, as envisioned by Charlie Foltz, the EIC Infrastructure Division Director. The system would include a supply and return header, which cools several thousand components of the ring. The water would then be returned and cooled down using a system of cooling towers and plate and frame heat exchangers. Due to the size of the system and the complexity of the network analysis, a fluid dynamic simulation software, AFT Fathom, was used. Since previous methods of maintaining systems relied on building upon smaller real-life models and implementing empirical data, this flow model was unique and first of a kind in the domain of accelerator design, construction and operation. Therefore, our hydraulic team piloted a new method to perform network analysis on a large scale cooling system. We successfully created several test scenarios for system behavior in a shorter time compared to the method of performing hand calculations. Cooling specifications for heat rejection, pressure drop, flow rate, and pipe sizing were changed based on the individual systems of the vacuum, radio frequency (RF), magnet and power supply, and cryogenics sections. Finally, we used DOE guidelines to perform life-cycle cost analysis with net present value and carbon saving analysis on the systems where pipe size could be optimized.

43 PARTICLE ACCELERATORS↗

DOE OSTI2023

2.3.4.104 - Lignin Conversion to Sustainable Aviation Fuel Blendstocks

The Lignin Conversion to Sustainable Aviation Fuel Blendstocks (LigSAF) project focuses on the conversion of lignin-rich streams to deoxygenated aromatic and cycloalkane blendstocks in the jet fuel range. This work is done in close collaboration with the BETO-funded Lignin-First Biorefinery Development project and industrial scale-up partners, and the work is closely guided by analysis to develop cost-effective and sustainable routes to produce lignin-based SAF blendstocks. To date, we have demonstrated the continuous catalytic conversion of a lignin oil from poplar to deoxygenated aromatic products at -85% C-mol yield. This hydrodeoxygenation process uses a stable, earth-abundant catalyst and requires no solvent. We have also established a baseline process model and associated techno-economic analysis and life cycle assessment that together demonstrate the potential to achieve cost parity with fossil carbon-based jet fuel at -70% reduction in greenhouse gas emissions. Current work is focused on expanding the slate of feedstocks for hydrodeoxygenation to include lignin oils from softwoods, agricultural residues, and grasses as well as from hydrolysis lignin substrates from biochemical conversion and pulp-and-paper processes. We are also undertaking catalyst development efforts to tune the reaction selectivity from aromatic compounds to cycloalkanes. Lastly, we are investigating reaction engineering strategies to slurry solids for hydrodeoxygenation reactions.

aromatics↗

NASA NTRS1974

The Energy Systems Optimization Computer Program /ESOP/ developed for Modular Integrated Utility Systems /MIUS/ analysis

A significant energy and cost savings can be obtained by integrating various utility services (space heating and cooling, electrical power generation, solid waste disposal, potable water, and waste water treatment) into a single unit which provides buildings or groups of buildings with these services. This paper presents a description of a computer program, called the Energy Systems Optimization Program (ESOP). This program predicts the loads, energy requirements, equipment sizes, and life-cycle costs of alternative methods of meeting these utility requirements. The program has been used extensively for performing energy analyses of Modular Integrated Utility Systems (MIUS).

Ferden, S. L.↗

NASA NTRS1976

Cost/benefit tradeoffs for reducing the energy consumption of the commercial air transportation system. Volume 1: Technical analysis

The effectiveness and associated costs of operational and technical options for reduced fuel consumption by Douglas aircraft in the domestic airline fleet are assessed. Areas explored include alternative procedures for airline and flight operations, advanced and state of the art technology, modification and derivative configurations, new near-term aircraft, turboprop configuration studies, and optimum aircraft geometry. Data for each aircraft studied is presented in tables and graphs.

Kraus, E. F.↗

NASA NTRS2002

Statistical Methods for Rapid Aerothermal Analysis and Design Technology

The cost and safety goals for NASA's next generation of reusable launch vehicle (RLV) will require that rapid high-fidelity aerothermodynamic design tools be used early in the design cycle. To meet these requirements, it is desirable to establish statistical models that quantify and improve the accuracy, extend the applicability, and enable combined analyses using existing prediction tools. The research work was focused on establishing the suitable mathematical/statistical models for these purposes. It is anticipated that the resulting models can be incorporated into a software tool to provide rapid, variable-fidelity, aerothermal environments to predict heating along an arbitrary trajectory. This work will support development of an integrated design tool to perform automated thermal protection system (TPS) sizing and material selection.

Morgan, Carolyn↗

NASA NTRS2018

Insight and Evidence Motivating the Simplification of Dual-Analysis Hybrid Systems into Single-Analysis Hybrid Systems

Many hybrid data assimilation systems currently used for NWP employ some form of dual-analysis system approach. Typically a hybrid variational analysis is responsible for creating initial conditions for high-resolution forecasts, and an ensemble analysis system is responsible for creating sample perturbations used to form the flow-dependent part of the background error covariance required in the hybrid analysis component. In many of these, the two analysis components employ different methodologies, e.g., variational and ensemble Kalman filter. In such cases, it is not uncommon to have observations treated rather differently between the two analyses components; recentering of the ensemble analysis around the hybrid analysis is used to compensated for such differences. Furthermore, in many cases, the hybrid variational high-resolution system implements some type of four-dimensional approach, whereas the underlying ensemble system relies on a three-dimensional approach, which again introduces discrepancies in the overall system. Connected to these is the expectation that one can reliably estimate observation impact on forecasts issued from hybrid analyses by using an ensemble approach based on the underlying ensemble strategy of dual-analysis systems. Just the realization that the ensemble analysis makes substantially different use of observations as compared to their hybrid counterpart should serve as enough evidence of the implausibility of such expectation. This presentation assembles numerous anecdotal evidence to illustrate the fact that hybrid dual-analysis systems must, at the very minimum, strive for consistent use of the observations in both analysis sub-components. Simpler than that, this work suggests that hybrid systems can reliably be constructed without the need to employ a dual-analysis approach. In practice, the idea of relying on a single analysis system is appealing from a cost-maintenance perspective. More generally, single-analysis systems avoid contradictions such as having to choose one sub-component to generate performance diagnostics to another, possibly not fully consistent, component.

Todling, Ricardo↗

NASA NTRS2018

Improved Mars Helicopter Aerodynamic Rotor Model for Comprehensive Analyses

The Mars Helicopter is part of the NASA Mars 2020 rover mission scheduled to launch in July of 2020. Its goal is to demonstrate the viability and potential of heavier-than-air vehicles in the Martian atmosphere. Ultimately, it aims to bridge the resolution gap between orbiters and the rover as well as allow access to otherwise inaccessible regions. The low density of the Martian atmosphere and the relatively small-scale rotor result in very low Reynolds number flows. The low density and low Reynolds numbers reduce the lifting force and lifting efficiency, respectively. This paper describes the generation of the improved Mars Helicopter aerodynamic rotor model. The goal is to generate a performance model for the Mars Helicopter rotor using a free wake analysis, since this has a low computational cost for design. The improvements in the analysis are two-fold and are expanded on from two prior publications. First, the fidelity of the simulations is increased by performing higher-order two-dimensional time-accurate OVERFLOW simulations allowing for higher accuracy aerodynamic coefficients and a better understanding of the boundary layer behavior as well as its transient features. Second, a version of the model is generated to duplicate the exact testing conditions in the 25-ft. diameter Space Simulator at the Jet Propulsion Laboratory, which allows for better correlation of rotor performance figures. Previous work correlated performance with that test, but did not consider the higher temperatures in the experiment compared to those of the Martian atmosphere. The higher temperatures in the experiment are expected to give conservative performance estimates, as they give rise to an increase in speed of sound and decrease in observed Reynolds numbers.

Analyses↗

NASA NTRS2018

Improved Mars Helicopter Aerodynamic Rotor Model for Comprehensive Analyses

The Mars Helicopter is part of the NASA Mars 2020 rover mission scheduled to launch in July of 2020. Its goal is to demonstrate the viability and potential of heavier-than-air vehicles in the Martian atmosphere. Ultimately, it aims to bridge the resolution gap between orbiters and the rover as well as allow access to otherwise inaccessible regions. The low density of the Martian atmosphere and the relatively small-scale rotor result in very low Reynolds number flows. The low density and low Reynolds numbers reduce the lifting force and lifting efficiency, respectively. This paper describes the generation of the improved Mars Helicopter aerodynamic rotor model. The goal is to generate a performance model for the Mars Helicopter rotor using a free wake analysis, since this has a low computational cost for design. The improvements in the analysis are two-fold and are expanded on from two prior publications. First, the fidelity of the simulations is increased by performing higher-order two-dimensional time-accurate OVERFLOW simulations allowing for higher accuracy aerodynamic coefficients and a better understanding of the boundary layer behavior as well as its transient features. Second, a version of the model is generated to duplicate the exact testing conditions in the 25–ft. diameter Space Simulator at the Jet Propulsion Laboratory, which allows for better correlation of rotor performance figures. Previous work correlated performance with that test, but did not consider the higher temperatures in the experiment compared to those of the Martian atmosphere. The higher temperatures in the experiment are expected to give conservative performance estimates, as they give rise to an increase in speed of sound and decrease in observed Reynolds numbers.

Grip, Håvard F.↗

NASA NTRS1976

Microeconomic analysis of military aircraft bearing restoration

Hein, G. F.↗

NASA NTRS1976

Microeconomic analysis of military aircraft bearing restoration

The risk and cost of a bearing restoration by grinding program was analyzed. A microeconomic impact analysis was performed. The annual cost savings to U.S. Army aviation is approximately $950,000.00 for three engines and three transmissions. The capital value over an indefinite life is approximately ten million dollars. The annual cost savings for U.S. Air Force engines is approximately $313,000.00 with a capital value of approximately 3.1 million dollars. The program will result in the government obtaining bearings at lower costs at equivalent reliability. The bearing industry can recover lost profits during a period of reduced demand and higher costs.

Hein, G. F.↗

DOE OSTI2022

ARETE: Accurate Error Assessment via Machine Learning-Guided Dynamic-Timing Analysis

Nanometer circuits are increasingly prone to timing errors, escalating the need for fault injection frameworks to accurately evaluate their impact on applications. Here in this paper, we propose ARETE, a novel cross-layer, fault-injection framework that combines dynamic-binary instrumentation with machine learning-guided dynamic-timing analysis. ARETE enables accurate fault-injection into any application by estimating the location of the injecting errors via dynamic-timing analysis. To accelerate fault-injection, we develop a novel, data-aware, machine learning-based mechanism that dynamically pre-selects the error-prone instructions and limits the application of the costly dynamic-timing analysis only to them. To evaluate ARETE's accuracy, our fully automated toolflow is configured to support fault-injection based on detailed post-layout gate-level simulations as well as via existing workload-agnostic error models. Our results for various workloads, including an autonomous-driving library, show that the location and time of injected errors performed by ARETE, is 89.9% consistent with fault-injection based on full gate-level simulation. On average, ARETE executes 84.6x faster than gate-level simulation and at a cost of 3.4% loss in the program output quality estimation. When compared to the existing statistical fault-injection tools that are based on workload-agnostic error models, ARETE improves the accuracy of fault-injection rate and output quality estimation by 143.9% and 40.4% on average, respectively.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2021

Big Adaptive Rotor Phase I (Final Report)

The Big Adaptive Rotor (BAR) project was initiate by DOE in 2018 with the goal of identifying novel technologies that can enable large (>100m) blades for low specific power (SP) turbines. Five distinct tasks were completed to achieve this goal: 1. Assess trends, impacts, and value of low-SP turbines, 2. Wind turbine blade cost reduction roadmap study, 3. Research and Development (R&D) opportunity screening, 4. Detailed design and analysis, and 5. Low-cost carbon fiber. These tasks were completed by the national lab team consisting of Sandia National Laboratories (SNL), the National Renewable Energy Laboratory (NREL), and Lawrence Berkeley National Laboratory (LBNL). The objective of Task 1 was to assess the historical trends of low-SP of onshore deployments, and to assess the impact and value of low-SP turbines. Analysis under this task showed that there is significant value for low-SP turbines, especially in markets where there is a higher saturation of wind energy on the grid. This has to do with the fact that low-SP turbines have increased capacity factors, and can contribute more reliable energy to the grid, even in lower wind conditions. This bodes well as higher renewable scenarios are likely in the coming years. Task 2 was a detailed analysis on the logistical challenges of deploying very large (>100m) onshore blade. This work was completed by experts at DNV-GL. The report looked at various ways to get around the current transportation constraints which are estimated to be around 75m in length. The report concluded that there are viable solutions to this issue including: segmented blades (which the industry is already pursuing), lighter than air (LTA) transportation, on-site manufacturing, and controlled bending of blades on rail. The final option was recommended for further analysis and study by DOE and the national labs because keeping a single piece blade reduces manufacturing and operations and maintenance (O&M) costs. Task 3 focused on identifying novel concepts that are capable of enabling a cost effective 5MW 206m rotor for onshore deployment. The findings from the first two tasks were considered in the analysis, in that the concepts identified must be able to overcome the transportation logistics challenges. Around 20 concepts were identified and evaluated by experts within the industry. Additionally, science and engineering challenges were identified for each concept. Based on these evaluations six concepts were deemed the most impactful and were selected for further analysis in Task 4. The concepts were: highly flexible rail transportable blades, downwind rotors, distributed aerodynamic control (DAC) devices, inflatable blade, bi-wing blade, and 4/5 bladed rotors. Task 4 conducted detailed design, optimization, and analysis on the selected BAR concepts. A modeling gaps analysis was conducted, and modeling improvements were implemented that allowed for the study and design of the novel concepts. The BAR team established a set of baseline designs by which to compare the selected designs through a technoeconomic analysis. It was found that the highly flexible rail transportable blade, the downwind rotor, and the DAC devices have the most promise to deliver the BAR targets. A Phase II for BAR has been proposed to further mature these concepts and address the open science and engineering challenges identified in Task 3. Task 5 conducted research on optimized carbon fiber materials that were used throughout the BAR Phase I project. Overall, the BAR project has identified low-SP turbines as important to continued LCOE reductions for onshore turbines. Furthermore, the project has identified viable solutions to the technical and logistical challenges to realizing these goals. The most promising technologies that were identified in Phase I of the project will be further matured and de-risked in Phase II of the BAR project.

17 WIND ENERGY↗

DOE OSTI2025

Microreactor Optimization Using Simulation And Economics (mouse)

Microreactor Optimization Using Simulation and Economics (MOUSE) is a tool that integrates both nuclear microreactor design and reactor economics to provide comprehensive evaluations and optimizations. This tool enables stakeholders to explore the interplay between technical and economic variables, guiding them towards effective and competitive microreactor solutions. For the reactor core simulations, MOUSE leverages the OpenMC Monte Carlo Particle Transport Code to perform detailed core simulations for various microreactor designs. The included OpenMC models are 2D core designs of a Liquid Metal Thermal Microreactor (LMTR), a Gas-Cooled TRISO-Fueled Microreactor (GCMR), and a Heat Pipe Microreactor. Beyond core design, MOUSE includes simplified calculations for: - Calculating the masses of heat exchangers within the system. - Mechanical power of pumps. - Estimating the area occupied by various buildings within the nuclear plant. For the economic analysis, MOUSE provides detailed bottom-up cost estimates, encompassing a wide range of costs including preconstruction costs, direct costs, indirect costs, training costs, financial costs, operation & maintenance (O&M) costs, and fuel costs. These cost estimations are developed using data from the MARVEL project and additional literature sources, enabling the calculation of total capital costs and levelized cost of energy for both first-of-a-kind and nth-of-a-kind microreactors. MOUSE also enables analysis of the cost drivers and competitiveness in the electricity market. MOUSE allows users to modify a wide array of technical and economic parameters to evaluate different scenarios and their impacts. Examples of these parameters include: Fuels, coolants, or reflector materials Enrichment levels Control drum materials and geometry Fuel pin geometry and materials Moderator pin geometry and materials Reactor core and reflector dimensions Packing factor for the TRISO particles Nuclear reactor power and reactor burnup Number of sensors Shielding thickness Reactor vessel and guard vessel dimensions Operational staff requirements Number of emergency shutdowns Levelization period Interest rate Construction duration Since MOUSE is powered by the WATTS toolkit, it supports optimization studies, parametric analyses, and uncertainty calculations/propagation. The optimization techniques enable users to identify optimal design and economic configurations. The parametric analysis tools allow users to explore the sensitivity of various parameters, while uncertainty propagation helps quantify the impact of uncertainties on overall performance and cost. User Interface and Workflow: Currently, MOUSE is a command-line-based tool. Users can input various reactor design or economic parameters, modify the designs, run simulations, and visualize results through comprehensive data visualization and reporting capabilities. The typical workflow involves setting up the reactor model, defining economic parameters, running simulations, and analyzing the results to make informed decisions. By combining advanced design calculations with detailed economic modeling, MOUSE provides a robust framework for optimizing nuclear microreactor technologies, enhancing their competitiveness, and guiding stakeholders towards innovative and cost-effective solutions.

Hanna, Botros [Idaho National Laboratory (INL), Id↗

NASA NTRS1985

Economic Evaluation of Computerized Structural Analysis

This completed effort involved a technical and economic study of the capabilities of computer programs in the area of structural analysis. The applicability of the programs to NASA projects and to other users was studied. The applications in other industries was explored including both research and development and applied areas. The costs of several alternative analysis programs were compared. A literature search covered applicable technical literature including journals, trade publications and books. In addition to the literature search, several commercial companies that have developed computerized structural analysis programs were contacted and their technical brochures reviewed. These programs include SDRC I-DEAS, MSC/NASTRAN, SCADA, SUPERSAP, NISA/DISPLAY, STAAD-III, MICAS, GTSTRUDL, and STARS. These programs were briefly reviewed as applicable to NASA projects.

Fortin, P. E.↗

NASA NTRS2018

Challenges in Development of Online Visualization and Analysis Tools for Satellite Data

Over the years, various online visualization and analysis tools have been developed to facilitate satellite data access and help scientific users around the world to conduct research and develop applications (e.g., data product evaluation, what-if questions, etc.). For those who are new to satellite data products, using them can be a daunting task due to many obstacles in data processing such as data formats, complex data structures, special software packages, unfamiliar terminology, etc., especially when one is not sure whether a dataset is suitable for his/er research project. Even for experienced users, developing software for data processing and analysis can be a costly and time-consuming task. Online visualization tools can overcome many of these difficulties and allow users to focus on scientific questions. For example, Giovanni (the Geospatial Interactive Online Visualization and Analysis Infrastructure, https://giovanni.gsfc.nasa.gov), developed by the NASA Goddard Earth Sciences Data and Information Services Center (GES DISC), allows access over 1900 satellite and model variables in 82 measurement groups of 8 disciplines without downloading data and software. Main features include basic functions for data analysis and visualization, data provenance, output data in different formats (ASCII, NetCDF, GeoTIFF), and more. Over the years, ~1700 peer-reviewed publications in different disciplines have been benefited from Giovanni in research activities (e.g. initial investigation, what-if questions, product evaluation). Despite the success of online visualization and analysis tools, challenges and new opportunities still exist and more can be done with new requirements and technology. Examples are: a) how to increase the efficiency of dataset search by enhancing intuitive aspects; b) how to facilitate interdisciplinary research; c) how to provide data quality information; d) how to engage users to participate in data quality assessment; and more. NASA Earth Observing System Data and Information System (EOSDIS) satellite-based data products are processed at various levels ranging from Level 0 to Level 4. While most users use data products at higher levels (Level-3 and 4), products at lower levels are still important for case studies, algorithm development, ground validation, etc. In this presentation, we will use Giovanni as an example to present and discuss challenges and near-future opportunities for satellite data online visualization and analysis tools.

Liu, Zhong↗