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Recent SEL experiments and studies

The studies discussed in this paper are all examples of activities that are performed as part of the Software Engineering Laboratory's (SEL's) process improvement model. Using this model, the SEL starts by understanding the product and process, then assesses the impact of new technologies, and finally packages what was learned. The preliminary examination of maintenance effort, error, and change profiles to establish a maintenance baseline exemplifies understanding-phase activities. The ongoing testing study that is examining the effects of various testing approaches on process and product measures is an example of typical assessing efforts. Finally, the derivation of cost and schedule estimation models from locally driven factors such as reuse level, application type, and language is an example of experience packaging. In the SEL, no study is ever really completed. Studies will be repeated and iterated upon in the future as part of the ongoing software improvement process.

Pajerski, Rose↗

Thermoplastic Aircraft Manufacturing Model

A manufacturing process to produce 80 single aisle sized thermoplastic composite aircraft a month is presented. Within the Hi-Rate Composite Aircraft Manufacturing (HiCAM) program a baseline aircraft fuselage was designed and modeled based on the Boeing 787 one-piece barrel build, but scaled down to a single aisle aircraft. Key Performance Parameters (KPPs) of recurring cost, non-recurring cost, and weight are calculated from the model. The outcome of this simulation indicated a prohibitively high non-recurring cost, so the thermoplastic team modeled the manufacturing flow for a panelized fuselage concept. The minimum success criteria is a 30% cost reduction and less than two percent increase in weight compared to the baseline aircraft. Automated Fiber Placement (AFP) is used to layup skins, stamp forming is used to make body frames, stringers, and passenger door surround parts. In the model, Co-Fusion was used to consolidate the skin while simultaneously welding on stringers to make stiffened panels. Additional welding technologies were considered to minimize fastener use and a vertical build concept was used for final assembly to reduce factory size. This manufacturing concept for a thermoplastic aircraft indicated a 39% cost and 12% weight savings compared to the baseline. Additional trade studies were conducted using Northrop Grumman’s Automated Stiffener Forming technology to make stringers and stamp forming instead of AFP to make skins.

thermoplastic composites↗

W2VPCA: A Machine Learning Method for Measuring Attitudes With Natural Language

Company strategy influences many decisions in freight transportation. Behavioral models of company decision-making therefore could benefit from including strategy variables. However, strategy is difficult to observe and quantify. Attitudinal surveys of company executives can be used to collect measurements of latent strategy to use in quantitative models. However, surveys are costly and burdensome. Text mining methods to collect measurements overcome these issues somewhat, but typically require manual intervention and ignore the context of words, which can be problematic. This study introduces a new machine learning method to generate strategy measurement data from existing big text data. The new method, called W2VPCA, combines Natural Language Processing and Principal Components Analysis. W2VPCA produces measurement data that serve as quantitative indicators of latent strategy in behavioral models. W2VPCA is unsupervised, data-driven, and uses information on word context. We apply W2VPCA to generate measurements of latent strategies using readily available, large-scale text data: annual company reports. The empirical measurements are used successfully to associate two latent strategies, one focusing on distribution and the other on products, with truck fleet and distribution center outsourcing decisions. The main empirical outcome is that the W2VPCA measurements outperform Bag-of-Words measurements in a psychometric analysis of latent firm strategies. While this study focuses on freight behavioral models, W2VPCA may also have applications in behavioral modeling in other domains.

97 MATHEMATICS AND COMPUTING↗

Model Energy Codes End-Use Opportunity Analysis

Model energy codes (ASHRAE Standard 90.1 and IECC) has significantly impacted programs and policies aimed at improving energy efficiency both in United States and across the globe. Standard 90.1, first published in 1975 (originally referred to as Standard 90) provides minimum energy efficiency guidelines for designing, constructing, operating, and maintaining new construction and renovated buildings. It is updated continuously, with new editions published every 3 years. Pacific Northwest National Laboratory (PNNL) conducts simulated energy and cost savings analysis of model energy codes to determine their expected impact and to track progress toward net-zero goals and efficiency targets. Additionally, the simulation outputs are examined to assess how energy is used across primary systems within prominent U.S. commercial building types to understand how energy is used in each building type at the end-use level and to identify areas for improvements in future code cycles. This end-use opportunity analysis of model energy codes provides ASHRAE technical committees and other interested parties a better understanding of how the Standard affects various building systems and end uses, specifically, those in the Standard that most prominently influence energy efficiency. Additionally, findings provide industry stakeholders guidance in identifying building types and end-uses with the most potential for energy efficiency improvements through energy codes and those that may require beyond code measures to meet energy use reduction targets. This paper summarizes features and functionalities of a webtool created by PNNL to explore and visualize the End-Use opportunity analysis.

ASHRAE 90.1, Energy Codes, Tableau↗

Potential Heating Energy and Cost Savings of Dual Fuel Heat Pump Controls as a Residential Building Equipment Retrofit in the U.S.

This study investigated the energy and cost savings potential by modeling a dual fuel heat pump system with its control for a residential building in (5A) cold climate in U.S. The simulation analysis showed that the application of the DFHP system and its control to the target building can save the heating energy by 42% over a gas furnace system (baseline system). Although the HP-only system can save more heating energy (i.e.,53%) over the baseline system than DFHP system does, the DFHP with its control demonstrated the higher cost savings when a time of use electricity rate was considered.

Dual Fuel Heat Pump, Control, Residential Building↗

Model-based and Model-free Designs for an Extended Continuous-time LQR with Exogenous Inputs

We present an extended linear quadratic regulator (LQR) design for continuous-time linear time-invariant (LTI) systems in the presence of exogenous inputs. We first propose a model-based solution with cost minimization guarantees for states and inputs using dynamic programming (DP). The control law consists of a combination of the optimal state feedback and an additional optimal term dependent on the exogenous inputs. The control gains for the two components are obtained by solving a set of matrix differential equations. We provide these solutions for both finite horizons and steady-state cases. In the second part of the paper, we formulate a reinforcement learning (RL) based algorithm which does not need any model information except the input matrix, and can compute an approximate steady-state LQR gain using measurements of the states, the control inputs, and the exogenous inputs. Both model-based and data-driven optimal control algorithms are tested with a numerical example under different exogenous inputs showcasing the effectiveness of the designs.

Mukherjee, Sayak↗

Costs and benefits of lunar oxygen: Engineering, operations, and economics

Oxygen is the most commonly discussed lunar resource. It will certainly not be the easiest to retrieve, but oxygen's fundamental place in propulsion and life support guarantees it continued attention as a prime candidate for early in situ resource utilization (ISRU). The findings are reviewed of recent investigation, sponsored by NASA-Ames, into the kinds of technologies, equipment, and scenarios (the engineering and operations costs) that will be required even to initiate lunar oxygen production. The infrastructure necessary to surround and support a viable oxygen-processing operation is explained. Selected details are used to illustrate the depth of technology challenges, extent of operations burdens, and complexity of decision linkages. Basic assumptions, and resulting timelines and mass manifests, are listed. These findings are combined with state-of-the-art knowledge of lunar and Mars propulsion options in simple economic input/output and internal-rate-of-return models, to compare production costs with performance benefits. Implications for three realistic scales of exploration architecture - expeditionary, aggressive science, and industrialization/settlement - are discussed. Conclusions are reached regarding the contextual conditions within which production of lunar oxygen (LLOX) is a reasonable activity. LLOX appears less useful for Mars missions than previously hoped. Its economical use in low Earth orbit hinges on production of lunar hydrogen as well. LLOX shows promise for lunar ascent/descent use, but that depends strongly on the plant mass required.

Sherwood, Brent↗

Accelerating room air conditioner efficiency in India: Grid, economic, and policy implications through 2035

India is poised for a rapid surge in space cooling demand, driven by rising incomes, urbanization, and intensifying heat. Between 2025 and 2035, the country is expected to add 130–150 million new room air conditioners (ACs). If Minimum Energy Performance Standards (MEPS) continue to improve at the historical rate of 2–3 % annually, room ACs alone could contribute over 180 GW to peak electricity demand by 2035-nearly 30 % of the projected national total. This study evaluates the impact of an accelerated MEPS trajectory, proposing to raise the 1-star threshold to ISEER 5.0 by 2027, ISEER 6.3 by 2030, and ISEER 7.4 by 2033. Drawing on engineering cost analysis, stock turnover modeling, and retail pricing data, we find that this pathway could reduce peak demand by over 60 GW, save 118 TWh of electricity annually, avoid 49 MtCO₂ of electricity-related emissions per year, avert ₹7.5 trillion (∼US$85 billion) in power system investments, and yield ₹0.7–2.3 trillion (∼US$8–26 billion) in net consumer savings by 2035. Contrary to affordability concerns, empirical trends show that higher efficiency does not increase AC prices. These results highlight the value of ambitious MEPS as a cost-effective strategy for improving grid reliability, reducing emissions, and advancing consumer welfare in emerging economies.

Abhyankar, Nikit↗

Techno-Economic Analysis of Biofuel Production via Catalytic Upgrading of Carbohydrates in Paper Sludge

A full-plant model was developed using correlations from a rigorous mass and energy balance and based on experimental results to determine the MFSP and its Sensitivity Analysis in the production of a hydrocarbon product from Paper Sludge. In this base case a preliminary MFSP of $5.97/GGE has been determined. This value is higher than the results reported in recent NREL reports. The difference is explained since much larger capacity plants are considered in those reports, and because we are not considering the production of co-products that bring the fuel costs down. The obtained model is being used to guide the next steps in our laboratory work since the team is now aware of which are the more sensitive process parameters "impacting" the MFSP of the final product.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

A survey of unsupervised learning methods for high-dimensional uncertainty quantification in black-box-type problems

Constructing surrogate models for uncertainty quantification (UQ) on complex partial differential equations (PDEs) having inherently high-dimensional O(10 n ), n ≥ 2, stochastic inputs (e.g., forcing terms, boundary conditions, initial conditions) poses tremendous challenges. The “curse of dimensionality” can be addressed with suitable unsupervised learning techniques used as a pre-processing tool to encode inputs onto lower-dimensional subspaces while retaining its structural information and meaningful properties. In this work, we review and investigate thirteen dimension reduction methods including linear and nonlinear, spectral, blind source separation, convex and non-convex methods and utilize the resulting embeddings to construct a mapping to quantities of interest via polynomial chaos expansions (PCE). Here, we refer to the general proposed approach as manifold PCE (m-PCE), where manifold corresponds to the latent space resulting from any of the studied dimension reduction methods. To investigate the capabilities and limitations of these methods we conduct numerical tests for three physics-based systems (treated as black-boxes) having high-dimensional stochastic inputs of varying complexity modeled as both Gaussian and non-Gaussian random fields to investigate the effect of the intrinsic dimensionality of input data. We demonstrate both the advantages and limitations of the unsupervised learning methods and we conclude that a suitable m-PCE model provides a cost-effective approach compared to alternative algorithms proposed in the literature, including recently proposed expensive deep neural network-based surrogates and can be readily applied for high-dimensional UQ in stochastic PDEs.

42 ENGINEERING↗

Quadrature Moments Method for the Simulation of Turbulent Reactive Flows

A sub-filter model for reactive flows, namely the DQMOM model, was formulated for Large Eddy Simulation (LES) using the filtered mass density function. Transport equations required to determine the location and size of the delta-peaks were then formulated for a 2-peak decomposition of the FDF. The DQMOM scheme was implemented in an existing structured-grid LES solver. Simulations of scalar shear layer using an experimental configuration showed that the first and second moments of both reactive and inert scalars are in good agreement with a conventional Lagrangian scheme that evolves the same FDF. Comparisons with LES simulations performed using laminar chemistry assumption for the reactive scalar show that the new method provides vast improvements at minimal computational cost. Currently, the DQMOM model is being implemented for use with the progress variable/mixture fraction model of Pierce. Comparisons with experimental results and LES simulations using a single-environment for the progress-variable are planned. Future studies will aim at understanding the effect of increase in environments on predictions.

Raman, Venkatramanan↗

Development of an Optimized Gasoline Surrogate Formulation for PACE Experiments and Simulations

New powertrain solutions are needed to address societal challenges stemming in part from a transportation sector which relies heavily on combustion of conventional hydrocarbon fuels like gasoline. One way to advance new solutions is through predictive simulations. Predictive simulations can potentially limit the extent of experimental validations, reduce time spent in engineering design cycles, unlock new strategies for high efficiency combustion with power density, and minimize tailpipe emissions. However, the simulation tools currently available are either too computationally expensive, inadequate in their accuracy, or a combination of the two. A DOE-funded consortium of national laboratories called the Partnership to Advance Combustion Engines (PACE) seeks to address this gap by rapidly delivering new knowledge and tools which enable market-competitive powertrain solutions for light-duty vehicles. Approaches to modeling combustion in powertrain systems typically incorporate computational fluid dynamics (CFD) simulations with chemical kinetic models. These CFD simulations generally use surrogate fuels featuring a limited number of existing components in a reduced kinetic model to limit computational costs. Such surrogate fuels often sacrifice matching several or more combustion and physical properties of the target gasoline fuel. Validation of surrogate fuels is also often only pursued for a small subset of standard metrics such as research or motor octane number (RON, MON). The purpose of this project is to develop an optimal E10 gasoline surrogate fuel suitable for tasks across PACE to facilitate rapid common analysis and progression toward consortium goals. This project received contributions from tasks led by eight PACE principal investigators. The project funding here reflects all tasks under Pitz, whose tasks also contributed to additional PACE projects. Based on the optimal gasoline surrogate fuel composition, a reduced chemical kinetic model will be shared with PACE researchers, industry, and the broader combustion community.

33 ADVANCED PROPULSION SYSTEMS↗

Solving large-scale dynamic systems using band Lanczos method in Rockwell NASTRAN on CRAY X-MP

The improved cost effectiveness using better models, more accurate and faster algorithms and large scale computing offers more representative dynamic analyses. The band Lanczos eigen-solution method was implemented in Rockwell's version of 1984 COSMIC-released NASTRAN finite element structural analysis computer program to effectively solve for structural vibration modes including those of large complex systems exceeding 10,000 degrees of freedom. The Lanczos vectors were re-orthogonalized locally using the Lanczos Method and globally using the modified Gram-Schmidt method for sweeping rigid-body modes and previously generated modes and Lanczos vectors. The truncated band matrix was solved for vibration frequencies and mode shapes using Givens rotations. Numerical examples are included to demonstrate the cost effectiveness and accuracy of the method as implemented in ROCKWELL NASTRAN. The CRAY version is based on RPK's COSMIC/NASTRAN. The band Lanczos method was more reliable and accurate and converged faster than the single vector Lanczos Method. The band Lanczos method was comparable to the subspace iteration method which was a block version of the inverse power method. However, the subspace matrix tended to be fully populated in the case of subspace iteration and not as sparse as a band matrix.

Gupta, V. K.↗

2022 GETEM Geothermal Drilling Cost Curve Update: Preprint

The Geothermal Electricity Technology Evaluation Model (GETEM) is an essential tool for the Department of Energy's (DOE) Geothermal Technology Office (GTO) to understand the performance and cost of technologies it is seeking to improve. This detailed model is used for supply curve analyses, assessing the current economic feasibility and Levelized Cost of Energy (LCOE) of hydrothermal geothermal systems and EGS, and evaluating the potential impact of advanced geothermal technologies. GETEM can be used to estimate the performance and costs of currently available U.S. geothermal power systems. It is also used to estimate the costs of technologies 5 to 20 years in the future, given the direction of potential research, development, and demonstration (RD&D) projects. The model is intended to help GTO determine which proposed RD&D programs and projects might offer the most efficient improvement when using taxpayer funding. The model requires annual updates as well as revisions to reflect the current state of the art. Drilling costs are a significant portion of total geothermal development costs. The current GETEM drilling cost inputs rely on drilling data from 2009 and require an updated analysis of more recent data to ensure they remain representative of current technologies. An updated, more accurate understanding of costs could help the geothermal industry secure project development financing and investment funding and better allow the oil and gas (O&G) industry (both operators and service companies) weigh potential geothermal market participation and customization. This report details recent drilling improvements from the Utah Frontier Observatory for Research in Geothermal Energy (FORGE) and O&G, comparing drilling performance and costs with values in GETEM, particularly the baseline drilling cost curves. Though drilling performance at FORGE has improved significantly, we did not find associated cost decreases that would justify lowering the GETEM baseline cost curves as of now.

API↗

Connected three-body terms in single-reference unitary many-body theories: Iterative and perturbative approximations

This work introduces various approaches to include connected three-body terms in unitary many-body theories, focusing on the driven similarity renormalization group (DSRG). Starting from the least approximate method—the linearized DSRG truncated to one-, two-, and three-body operators [LDSRG(3)]—we develop several approximate LDSRG(3) models with reduced computational cost. Through a perturbative analysis, we motivate a family of iterative LDSRG(3)-n and -n' (n = 1, 2, 3, 4) methods that contain a subset of the LDSRG(3) diagrams. Among these variants, the LDSRG(3)-2 scheme has the same computational complexity of coupled cluster theory with singles, doubles, and triples (CCSDT), but it outperforms CCSDT in the accuracy of the predicted correlation energies. We also propose and implement two perturbative triples corrections based on the linearized DSRG truncated to one- and two-body operators augmented with recursive semi-quadratic commutators [qDSRG(2)]. Overall, the resulting qDSRG(2)+(T) approach matches the accuracy of the “gold-standard” coupled cluster theory with singles, doubles, and perturbative triples model on the energetics of twenty-eight closed-shell atoms and small molecules.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Passive Energy-Saving Solutions for Clothes Dryers: A Modeling and Experimental Study for Improved Efficiency and Affordability

Dryers are integral appliances in modern households, yet their significant power consumption remains a critical challenge for reducing energy bills and upgrades. This work presents the outcomes of a comprehensive investigation aimed at lowering the operating energy costs of the dryer through modeling and experimental approaches. Specifically, the objectives of this research are twofold: (1) to reduce energy consumption without negatively impacting drying performance or time; and (2) to ensure affordability by developing retrofittable solutions characterized by low cost and a quick payback period. These strategies promise universal applicability to all dryer categories, encompassing both gas and electric models, by tackling core issues such as unnecessary heat loss and excess energy supply, both prevalent across dryer designs. Our methodology combines robust modeling frameworks and experimental validation to target energy efficiency improvements through three primary pathways: (1) effective heat loss management using ultralow-cost insulation materials tailored for dryer systems; (2) heat management across the drying cycle, facilitated by passive heat transfer mechanisms, and (3) optimization of heat supply to the load to ensure precise energy delivery, minimizing waste. These innovations are designed to seamlessly integrate with existing dryer configurations, providing a scalable and retrofittable solution that ensures affordability without requiring substantial redesigns or expensive components. Using these methods, the study demonstrates improvement opportunities in dryer energy consumption while maintaining the desired performance. The modeling component utilizes computational simulations to evaluate the thermal and energy performance of these innovations under varied operational conditions, providing foundational insights for experimental design. By addressing critical areas such as heat loss, energy recovery, and supply optimization, this work proposes impactful solutions for lowering the energy costs in domestic clothes dryers. The ultralow-cost, retrofittable nature of the proposed strategies ensures widespread adoption potential across diverse dryer categories, making significant strides toward affordable household energy practices.

Cheekatamarla, Praveen [ORNL] (ORCID:0000000248827↗

Benefit-cost methodology study with example application of the use of wind generators

An example application for cost-benefit methodology is presented for the use of wind generators. The approach adopted for the example application consisted of the following activities: (1) surveying of the available wind data and wind power system information, (2) developing models which quantitatively described wind distributions, wind power systems, and cost-benefit differences between conventional systems and wind power systems, and (3) applying the cost-benefit methodology to compare a conventional electrical energy generation system with systems which included wind power generators. Wind speed distribution data were obtained from sites throughout the contiguous United States and were used to compute plant factor contours shown on an annual and seasonal basis. Plant factor values (ratio of average output power to rated power) are found to be as high as 0.6 (on an annual average basis) in portions of the central U. S. and in sections of the New England coastal area. Two types of wind power systems were selected for the application of the cost-benefit methodology. A cost-benefit model was designed and implemented on a computer to establish a practical tool for studying the relative costs and benefits of wind power systems under a variety of conditions and to efficiently and effectively perform associated sensitivity analyses.

Zimmer, R. P.↗

NRAP Task 5: Preliminary Evaluation of the Cost of Responding to a Hypothetical Leakage Scenario Using the NRAP/SMART TALES Model and other NRAP Tools

Poster presentation illustrating the use of tools developed as part of Task 5 of Phase 3 of NRAP to estimate the technical performance and costs of implementing remedial responses to address a leak of fluid out of the storage formation at a CO2 saline storage project. Presented at the 2024 FECM - NETL Carbon Management Research Project Review Meeting, 5-9 August, 2024, Pittsburgh, PA.

Morgan, David↗