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At least 1,495 records · Page 83

Demonstration of Improved CHP Systems utilizing Improved Gas Turbine and sCO2 Cycles Using Additive Manufacturing (AM) Components

This project seeks to integrate a sCO2 bottoming cycle with a 5.3 MW gas turbine to develop a CHP system that is able to transition rapidly between 50% and 100% load by engaging or bypassing the bottoming cycle while maintaining electrical system efficiency above 30% at all times. The project team will engineer an optimized design of the power systems. The needed new key components, such as advanced heat exchangers and a steam injection system for the gas turbine, will be developed and their performance demonstrated in rig tests. The feasibility of the whole integrated CHP system will be validated through a cyber-physical approach.

36 MATERIALS SCIENCE↗

Impact of solenoid induced residual magnetic fields on the prototype SSR1 CM performance

A prototype cryomodule containing eight Single Spoke Resonators type-1 (SSR1) operating at 325 MHz and four superconducting focusing lenses was successfully assembled, cold tested, and accelerated beam in the framework of the PIP-II project at Fermilab. The impact of induced residual magnetic fields from the solenoids on performance of cavities is presented in this contribution. In addition, design optimizations for the production cryomodules as a result of this impact are highlighted.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

Water Recovery From Cooling Tower Plumes

According to studies by the UN and the US State Department, we are on the path to an extreme freshwater shortage by 2030. The US’s largest water withdrawal source is power plants, which account for 39% of total US freshwater withdrawals, mostly for cooling. Cooling towers are the most common cooling system. To solve these problems and enable efficient water- based cooling – Infinite Cooling’s novel technology uses electric fields to ionize the air, charge the escaping water leaving cooling towers and direct the water toward mesh collectors where it collects and gets recycled for use in the cooling system. This technology was developed at MIT and was reduced to practice on a lab-scale prototype, and a prototype at the MIT Cogeneration Power Plant. This DOE award funded taking this technology from a lab-scale prototype to TRL 5 on an operating cooling tower in the field at the MIT Nuclear Research Laboratory. The funding helped to design and optimize an electrostatic plume collection system and test it in high-fidelity lab setting and in actual field conditions on a cooling tower. Throughout the award, Infinite Cooling investigated the formation of plumes on cooling towers, used that information to optimize the design, material and electrical properties of the collection device and quantified the collection yield via flow rate and water quality.

20 FOSSIL-FUELED POWER PLANTS↗

Additive Manufacturing for Large Displacement Unmanned Underwater Vehicles (LDUUVs)

Oak Ridge National Laboratory partnered with Anduril Industries to develop the process for adapting large format additive manufacturing for the production of underwater vehicles. This research started by defining and selecting a polymer for the vehicle panels. Coatings were tested at 9000PSI to ensure proper bonding to the 3D printed panels, then tensile tested to understand the mechanical properties. A vehicle panel fairing set was design optimized for the 3D printing process and then 3D printed. Additional work optimized coatings and tested additional reinforcements methods such as fiber weave and z-casting with fiber rods and resin. Finally, a full vehicle was constructed and successfully tested in open water by Anduril.

36 MATERIALS SCIENCE↗

Neutrino Program at Fermilab - Enhancing Proton Beam Power and Accelerator Infrastructure

The upcoming long baseline neutrino experiments aim to enhance proton beam power to multi-MW scale and utilize large-scale detectors to address the challenge of limited event statistics. The DUNE experiment at LBNF will test the three-neutrino flavor paradigm and directly search for CP violation by studying oscillation signatures in the high intensity (anti-) beam to (anti-) measured over a long baseline. Higher beam power and improved accelerator up-time will enhance neutrino flux for the neutrino program by increasing the number of protons on target. LBNF/DUNE, as well as PIP-II upgrade and Accelerator Complex Evolution (ACE) plan, play a vital role in this effort. The scientific potential of ACE plan extends beyond neutrino physics, encompassing endeavors such as the Muon Collider, Charged Lepton Flavor Violation (CLFV), Dark Sectors, and exploration of neutrinos beyond DUNE.\par In the era of higher-power accelerator operation, research in target materials and beam instrumentation is crucial for optimizing design modifications. This abstract discusses Fermilab ACE, the science opportunities it provides, and how Fermilab is pushing the limits of proton beam power and accelerator infrastructure. By tackling neutrino beam challenges and exploring research and development ideas, we are advancing our understanding of fundamental particles and their interactions.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

Efficient green and yellow light-emitting diodes (LEDs) for solid-state lighting applications

In this project, Lumileds, the University of Michigan, the University of New Mexico, Sandia National Laboratories, and Ohio State University conducted a collaborative and comprehensive research effort to investigate the most promising approaches to improve green and yellow InGaN LEDs. Advanced LED characterization methods and predictive model calculations were applied to design optimization experiments more effectively and accelerate the pace of improvements.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Mid-IR UAV-based sensing platform with deep learning to Identify and Quantify Gaseous Emission in Gas Flares

This report details the development and evaluation of a Mid-Infrared (Mid-IR) Unmanned Aerial Vehicle (UAV)-based sensing platform integrated with deep learning algorithms for the identification and quantification of gaseous emissions in gas flares. The project, spearheaded by Omega Optics, Inc., aimed to address environmental monitoring challenges by leveraging advanced photonic technologies and autonomous UAV operations. The research focused on designing, optimizing, and fabricating photonic crystal waveguides and grating couplers to enhance the sensitivity and accuracy of gas detection. A comprehensive drone-based system was developed, featuring a miniaturized sensor, GPS module, and microcontroller communication network for real-time gas concentration monitoring. The system's adaptive sampling algorithm, implemented using the Robot Operating System (ROS), enables autonomous detection and localization of gas emission sources. Preliminary results demonstrate the platform's capability to detect and monitor gas emissions with high precision, cost-effectiveness, and scalability. Future work will expand upon this foundation by introducing 3D wind model-based learning for dynamic environmental conditions and further enhancing the user interface and data processing algorithms to support broader environmental monitoring applications. Overall, this project represents a significant step forward in UAV-based environmental sensing technologies, offering robust solutions for detecting and mitigating the impacts of gaseous emissions on public health and safety.

47 OTHER INSTRUMENTATION↗

Exploration of Options for Ultra-Fast Mass Spectroscopy for Pulsed Power Applications

Mega-ampere class pulsed power machines drive intense currents into small volumes to study high energy and density environments. Power lost during these events is a difficult and paramount problem to solve. For example, facilities such as Sandia National Laboratories’ Z machine experience meaningful power loss, which can be linked to non-linear ohmic heating at high currents (i.e., 26 MA on Z) leading to thermal desorption of contaminants and subsequent shunt plasma formation. Characterizing and understanding this type of thermal desorption is key to design optimizations necessary to minimize current loss, which will be even more important for next generation pulsed power. This type of characterization requires the ability to identify and determine concentration of analytes with nanosecond resolution given the pulse width of Z is on the order of 100 ns. This report summarizes progress on a small exploratory project focused on investigating options to meet this challenge using mass spectrometry. The main focus of these efforts utilized an Energy and Velocity Analyzer for Distributions of Electric Rockets intending to determine how quickly transient data could be resolved. This probe combines an electrostatic analyzer with a Wien velocity filter (ExB) to obtain ion energy and velocity distributions. Primary results from this exploratory project indicate significant additional work is needed to demonstrate a nanosecond time scale mass spectrometer for this application and also highlight that alternative detection methods such as laser-based diagnostics should be considered to meet the need for ultra-fast detection.

42 ENGINEERING↗

FEM Analysis of Hybrid LTS/HTS Cos-Theta Dipole Magnet

After the recent results on Bi-2212 superconductive magnets realized and tested in canted cosine-theta and solenoid designs, respectively, at Lawrence Berkeley National Laboratory (LBNL) and NHMFL, the first Bi-2212 stress-managed cosine-theta insert magnet is in the assembly phase at Fermilab. This insert will be part of the first hybrid cosine-theta magnet made of Nb3Sn outer layers within the US-MDP effort to reach 20 T bore field. This paper reports the analytical analysis of the cosine-theta Nb3Sn/Bi-2212 hybrid magnet. As an introduction, it shows the validation of the finalized HTS coils' design optimized using the ROXIE code. Subsequently, it reports the parameters, logic, and implementation method of the 2D electromagnetic and mechanical FEM analysis of the LTS/HTS hybrid magnet. Results from the ANSYS detailed model made with sub-modeling geometry are compared with the homogeneous model implemented in the past. Moreover, a Python code was implemented to simulate the current degradation due to stresses in the detail-modeled conductor areas. The current degradation is introduced in the simulation dynamics for both conductors as an iteration process during the energization load step only after applying pre-stress and thermal loads. The numerical and graphic results of the 2D cosine-theta LTS/HTS magnet cross-section will be described and analyzed.

D'Agliano, A.↗

Test and Validate Distributed Coaxial Cable Sensors for in situ Condition Monitoring of Coal-Fired Boiler Tubes

This project aims to test, validate, and advance the technology readiness level (from TRL5 to TRL7) of a novel low-cost distributed stainless-steel/ceramic coaxial cable sensing (SSC-CCS) technology for in situ monitoring of the boiler tube temperature in existing coal-fired power plants. The novel SSC-CCS sensing technology and associated condition-based monitoring (CBM) software to be demonstrated in this project will lead to an improved understanding of the boiler tube failure mechanisms and a prognostic system to improve the overall performance, reliability, and flexibility of the nation’s coal-fired power plant fleet. A boiler tube monitoring system with distributed coaxial cable temperature sensors and a sensor acquisition system was constructed. The high-temperature coaxial cable sensor with a length of 1.3m was made by using a quartz tube (1mm inner diameter (ID) and 6mm outer diameter (OD)) to concentrically separate a 304 stainless-steel (SS) rod (1mm OD) and SS tube (7.94mm OD and 6.16mm ID). The sensor acquisition system includes a vector network analyzer (VNA), a radio frequency (RF) power amplifier, multiple switches and a USB hub. The distributed stainless-steel quartz coaxial cable sensor (SSQ-CCS) had a linear response to temperature with a resolution uncertainty of σ = 0.77℃. To withstand the harsh conditions of 3,300 steam pressures and 800℃ high temperatures, the sensor was shielded by a protective tube made of the same material as the boiler tube. The protection tube had an OD of 1.5 inches and a thickness of 0.25 inches. In the laboratory tests, the sensor showed good sensitivity and fast response. The drift was bounded between +0.33% and -0.67% during a test at 600℃ for 350 hours, indicating good stability of the sensor. A field test was conducted where four sensors were welded on four superheat tubes (SH-Ts) at a coal-fired power station over 400 days. Conventional thermocouples were welded to the superheater tubes alongside the coaxial cable sensors for the purpose of comparison. Two sensors were capable of distributed sensing, with three multiplexed sensing sections. The other two sensors were single section. During the 400-day test period, the power plant experienced startups and shutdowns. At the steady state operations, the temperature of the boiler tube is about 600℃ (1112°F). The sensors recorded the entire coal-firing processes (start-up, steady state, and shut-down) and the glitch event. A GSM modem and a Watchdog were added to the system to ensure reliable data recording. The GSM modem sent daily messages to plant managers and Clemson team to inform the status of the sensor system. If the system was not normally working, the Watchdog would reboot the system automatically. The new coaxial cable based distributed sensing technology has been proven to be successful in both laboratory and field tests. A comprehensive four-stage multi-physics computational framework has been developed to assist the design, optimization, installation, and operation of SSQ-CCS. With the consideration of various operation conditions, we predict the distributions of flue gas temperatures within coal-fired boilers, the temperature correlation between the boiler tube and SSQ-CCS, and the safety of SSQ-CCS. A conditional-based monitoring system is implemented as well. The computational framework developed in this work can guide the future operation of coal-fired plants and other power plants for the safety prediction of boiler operations.

01 COAL, LIGNITE, AND PEAT↗

DECOVALEX-2023: Task A Final Report

Task A, also known as HGFrac, examines the fracturing processes that may occur in the Callovo-Oxfordian claystone (COx) in the context of the high-level (HLW) and intermediate-level long-lived (ILW-LL) radioactive waste repository in France. Understanding these processes and improving numerical models to reproduce them will aid in the design, optimization, and safety of the repository. Heat and gas fracturing are studied in two independent subtasks following a stepwise approach: laboratory tests/benchmark exercises, in-situ experiment, and finally, an application case. The in-situ heater experiment aimed to thermally induce a hydraulic fracture; temperature and pore pressure were monitored to detect any evidence of fracturing. The in-situ gas injection experiment aimed to study the effect of the stress orientation and gas injection kinetics on the gas fracturing process. The occurrence of fracturing was monitored by gas pressure measured in the injection interval. In both experiments, the excavation-induced fracture network around the heater/injection boreholes played an important role in the reduction of the compressive stress state, leading to both a tensile and shear failure response of the COx. During the first two years of the project, the research teams working on each task developed and/or proposed numerical approaches for reproducing the occurrence of fracturing in the in-situ experiments. The failure criteria were defined by reproducing the measurements from laboratory extension tests for the heat fracturing subtask. In the gas fracturing subtask, their approaches were used for simulating several benchmark exercises, and an inter-comparison between models was carried out. In both tasks, the developed approaches were compared with a simplified approach considering poro-elasticity for the mechanical behaviour of the COx. Most of the developed approaches are based on a continuous medium that takes into account variations in hydraulic properties due to mechanical degradation, such as plastic deformation or damage. Other approaches implicitly modelled weak planes or embedded discontinuities to reproduce fracture propagation. The potential for fracture initiation was also studied through of a discrete approach. In the second half of the project, the research teams mainly focused on interpretative modelling of two in-situ experiments and a blind prediction exercise to test their respective approaches. The models developed by the research teams were also applied at the repository scale to evaluate fracture initiation in a case study under vi unfavourable conditions, particularly in terms of spacing between High-Level Waste cells. The results showed that the poro-elasticity approach could be an efficient tool for understanding the main processes occurring in the COx. One example is the explicit representation of the excavation-induced fracture network around the boreholes, which yielded acceptable results compared to the measurement data. However, advanced approaches were needed to evaluate the potential increase of the excavation-induced fracture network extend and better understand fracture initiation. The stress analyses carried out by the teams revealed that hydraulic boundary conditions had a strong impact on fracture initiation in the heater experiment. Furthermore, in most cases, the results required higher pore pressure increments to reach fracturing than those measured in the experiment. This implies that the measurements may have been biased by the packer’s capacity to fully isolate the piezometric chambers, leading to lower pressures. On the contrary, there was no agreement on the fracturing mode, as some reported either shear or tensile fracturing, while others reported a combination of the two modes. In the case of gas fracturing, the research teams were limited to the comparison of a single point, which complicated their task. Nonetheless, the numerical results were able to reproduce the measurements and capture processes such as longitudinal gas flow through the excavation-induced fracture network, as suggested by some evidence in the observation piezometric chambers. The numerical models also agreed with the measurements in the sense of higher probability of developing along the injection borehole than radially towards the sound rock. The approaches developed by the research teams showed that they are capable of analysing and reproducing fracture initiation in the COx. However, areas of future work should focus on the fracture propagation and fracture aperture, which were out of the scope of this task. To this end, additional data must be gathered for the parameter characterisation and validation of the numerical models. Nonetheless, various approaches showed promising results as they were able to reproduce fracture development under certain conditions.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Printed Metal Molds for Mainstream Automotive Production

The main focus of this work was to evaluate additive manufacturing of metal molds, with significantly reduced cost and/or procurement lead time, for production of large composite components for mainstream (> 100k units/yr) automobiles. A two-component large tool with conformal heating channels was designed, optimized, printed, machined, and tested in production. The resulting analysis indicates that large scale AM is suitable for manufacturing complex geometry large scale metal molds.

36 MATERIALS SCIENCE↗

RAFT: Reconfigurable Array of High-Efficiency Ducted Turbines for Hydrokinetic Energy Harvesting

Diversifying the energy harvesting portfolio is crucial to achieving the ambitious goal of transitioning to clean energy by 2030. Marine hydrokinetic energy has garnered renewed interest due to its high harvesting potential in the U.S., and the resource's reliability and predictability—remaining relatively constant on a daily basis and available 24/7. However, there are currently few commercial devices capable of harnessing the energy from flowing water. This project aims to bridge that gap by designing and evaluating a novel hydrokinetic turbine concept that can efficiently harvest energy from both rivers and tidal streams. The RAFT (Reconfigurable Array of High-Efficiency Ducted Turbines) concept introduces a duct surrounding the turbine rotor and creates an array of small 5-kW units. The duct serves two primary purposes: (1) it enhances hydrodynamic efficiency by accelerating flow to the rotor, and (2) it functions as a structural component, facilitating the formation of modular arrays that lower costs. This project focuses on demonstrating this concept and validating these benefits through simulations and scaled prototype testing. The project team includes 8 faculty members and over 20 students from 3 universities, organized into three core areas: hydrodynamics, electrical systems, and structural analysis, with additional teams dedicated to system integration, environmental assessment and risk management, and tech-to-market strategy. The team successfully demonstrated the increased hydrodynamic efficiency of a ducted turbine compared to an unducted version using high-fidelity simulations and prototype tests. Moreover, design optimization efforts led to surpassing the SHARKS program's goal of 60% reduction of the levelized cost of energy with a significant margin.

13 HYDRO ENERGY↗

Application of Advanced Materials Processing to Enable Direct Production of Fast Reactor Fuel Alloys

Argonne National Laboratory (the Contractor), located in Lemont, IL, and Oklo, Inc. (the Participant), headquartered in Sunnyvale, CA, entered into a Cooperative Research and Development Agreement (CRADA) to integrate advanced electrorefining co-deposition and molten-salt monitoring technologies to produce a uranium-transuranic (U/TRU) alloy within a controlled composition range that can be used as fast reactor fuel for Oklo, Inc.’s advanced reactor technology. Argonne performed the integration of electrorefining and process monitoring technologies, determined operating parameters for producing U/TRU alloys, and developed optimized design and operating parameters for co-deposition of U/TRU alloys. Oklo, Inc. worked with Argonne and the Nuclear Regulatory Commission (NRC) to provide the necessary process documentation to begin implementing pyroprocessing technology in the fast reactor fuel production process. Outcomes of this project included a pilot-scale co-deposition cathode design and technical basis for the operation of the co-deposition electrorefiner to produce U/TRU alloys with controlled composition.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Hypercomplex Automatic Differentiation in the Eulerian Hydrocode PAGOSA

Enabling the computation of partial derivatives or sensitivities in production hydrocodes is beneficial for design, optimization, sensitivity analysis, and uncertainty quantification. Traditional finite difference approximations of these sensitivities are inefficient since convergence studies of the step size is required for each parameter of interest. For these reasons, HYPercomplex Automatic Differentiation (HYPAD) was implemented in the Eulerian hydrocode PAGOSA. HYPAD is analogous to forward-mode automatic differentiation except hypercomplex numbers (numbers with multiple imaginary parts) are used instead of dual numbers. Accurate partial derivatives can be computed of all state variables with respect to multiple input variables in a single run. The method was implemented using operator overloading to handle hypercomplex algebra. HYPAD was demonstrated and verified on Sod’s shock tube problem to compute derivatives of the state variables with respect to a material parameter, initial conditions, and geometry.

97 MATHEMATICS AND COMPUTING↗

Develop an efficient and cost-effective novel anaerobic digestion system producing high purity of methane from diverse waste biomass

This project focuses on developing an advanced, intensified anaerobic digestion system aimed at transforming the treatment and conversion of organic wastes into valuable products, specifically renewable natural gas. The motivation for this research stems from the limitations of conventional anaerobic digestion technologies, which often face challenges such as long retention times, high operational costs, and incomplete organic material degradation. The new technology called Intensified Versatile Anaerobic Digestion (IVAD), is developed to address these challenges by incorporating innovative reactors and processes that enhance the overall efficiency and output of anaerobic digestion. The significance of this project lies in its potential to revolutionize waste management practices and waste biomass utilization. The IVAD system integrates a hyperthermophilic anaerobic acidification reactor, a hydrothermal treatment (HTT) unit, and both thermophilic and mesophilic methanogenic reactors. This combination enables a higher rate of organic breakdown and energy recovery, resulting in faster processing times, reduced reactor sizes, and lower operational costs compared to traditional systems. Key data include an increase in methane productivity to 1.18 m 3 /m 3 /day, a significant improvement compared to the baseline technology’s 0.64 m 3 /m 3 /day. Additionally, the IVAD system achieves a 45% reduction in levelized cost of energy (LCOE), down to $\$$10.04/MMBTU, and an energy return on investment (EROI) of 3.19, representing an 87% increase over baseline levels. Technical and economic analyses highlight that the IVAD system significantly reduces hydraulic retention time (HRT) and solid retention time (SRT). The HRT for the HTT reactor can be reduced from 1 hour to 0.5 hours, while decoupling SRT from HRT in the anaerobic acidification reactor (AAR) allows for further reductions. These design optimizations lead to smaller reactor volumes, cutting down equipment and construction costs. Despite these advancements, energy consumption remains comparable to conventional methods due to a novel heat recovery strategy, enhancing overall process productivity. The system also achieves in-situ CO 2 removal and ammonia stripping features, resulting in biogas with a methane purity level of 75%, and produces high-quality nitrogen fertilizer as an additional by-product. Public benefits of the IVAD system are substantial, contributing to sustainable waste management and renewable energy production. By providing a scalable solution that can be adopted by dairy farms and similar agricultural operations, the IVAD system helps reduce waste, produce renewable natural gas (RNG) suitable for transportation fuel, and generate fertilizer, supporting a circular economy. This project plays a role in achieving broader environmental objectives by mitigating greenhouse gas emissions and promoting energy independence. Additionally, it offers a pathway for farmers to lower operational costs while adopting practices that are both environmentally sustainable and economically advantageous.

03 NATURAL GAS↗

Broadband mm-Wave Substrate Integrated Waveguides [Poster]

At mm-wave frequencies, signals need to be supported by specialized, low-loss transmission lines such as waveguides. Substrate-integrated waveguides (SIWs) combine the good electrical properties of rectangular waveguides with the compactness of planar transmission lines. Additionally, SIWs can be fabricated using standard PCB manufacturing techniques and can be easily integrated with other mm-wave components. This study explores SIWs in the 50-75 GHz range, with designs optimized for simple fabrication.

42 ENGINEERING↗

Ultracoherent SRF Cavity-Based Multi-Qudit Platform with Error-Resilient Control

Superconducting radio-frequency (SRF) cavities offer a promising platform for quantum computing due to their long coherence times, yet integrating nonlinear elements like transmons for control often introduces additional loss. We report a multimode quantum system based on a 2-cell elliptical shaped SRF cavity, comprising two cavity modes weakly coupled to an ancillary transmon circuit, designed to preserve coherence while enabling efficient control of the cavity modes. We mitigate the detrimental effects of the transmon decoherence through careful design optimization that reduces transmon-cavity couplings and participation in the dielectric substrate and lossy interfaces, to achieve single-photon lifetimes of 20.6\,ms and 15.6\,ms for the two modes, and a pure dephasing time exceeding 40\,ms. This marks an order-of-magnitude improvement over prior 3D multimode memories. Leveraging sideband interactions and novel error-resilient protocols, including measurement-based correction and post-selection, we achieve high-fidelity control over quantum states. This enables the preparation of Fock states up to $N = 20$ with fidelities exceeding 95\%, the highest reported to date to the authors' knowledge, as well as two-mode entanglement with an estimated coherence-limited fidelities of 99.9\% after post-selection. These results establish our platform as a robust foundation for quantum information processing, allowing for future extensions to high-dimensional qudit encodings.

Kim, T. [Northwestern U.]↗