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At least 1,549 records · Page 86

Embedded Sensors and Controls to Improve Component Performance and Reliability -- Bench-scale Testbed Design Report

Embedded instrumentation and control systems that can operate in extreme environments are challenging due to restrictions on sensors and materials. As a part of the Department of Energy's Nuclear Energy Enabling Technology cross-cutting technology development programs Advanced Sensors and Instrumentation topic, this report details the design of a bench-scale embedded instrumentation and control testbed. The design goal of the bench-scale testbed is to build a re-configurable system that can rapidly deploy and test advanced control algorithms in a hardware in the loop setup. The bench-scale testbed will be designed as a fluid pump analog that uses active magnetic bearings to support the shaft. The testbed represents an application that would improve the efficiency and performance of high temperature (700 C) pumps for liquid salt reactors that operate in an extreme environment and provide many engineering challenges that can be overcome with embedded instrumentation and control. This report will give details of the mechanical design, electromagnetic design, geometry optimization, power electronics design, and initial control system design.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Center for Efficiency in Sustainable Energy Systems

The main goal of the Center for Efficiency in Sustainable Energy Systems is to produce a methodology that evaluates a variety of energy systems. Task I. Improved Energy Efficiency for Industrial Processes: This task, completed in partnership with area manufacturers, analyzes the operation of complex manufacturing facilities to provide flexibilities that allow them to improve active-mode power efficiency, lower standby-mode power consumption, and use low cost energy resources to control energy costs in meeting their economic incentives; (2) Identify devices for the efficient transformation of instantaneous or continuous power to different devices and sections of industrial plants; and (3) use these manufacturing sites to demonstrate and validate general principles of power management. Task II. Analysis of a solid oxide fuel cell operating on landfill gas: This task consists of: (1) analysis of a typical landfill gas; (2) establishment of a comprehensive design of the fuel cell system (including the SOFC stack and BOP), including durability analysis; (3) development of suitable reforming methods and catalysts that are tailored to the specific SOFC system concept; and (4) SOFC stack fabrication with testing to demonstrate the salient operational characteristics of the stack, including an analysis of the overall energy conversion efficiency of the system. Task III. Demonstration of an urban wind turbine system: This task consists of (1) design and construction of two side-by-side wind turbine systems on the YSU campus, integrated through power control systems with grid power; (2) preliminary testing of aerodynamic control effectors (provided by a small business partner) to demonstrate improved power control, and evaluation of the system performance, including economic estimates of viability in an urban environment; and (3) computational analysis of the wind turbine system as an enabling activity for development of smart rotor blades that contain integrated sensor/actuator/controller modules to enhance energy capture and reduce aerodynamic loading and noise by way of virtual aerodynamic shaping. Accomplishments: Task I. Improved Energy Efficiency for Industrial Processes: We organized an energy management training session held on February 22, 2011, which was advertised through a regional manufacturing association to provide wide-ranging notification. Over two dozen companies were represented a the seminar, ranging from heavy manufacturing businesses with $5,000,000 per year energy expenses, to small, light manufacturing facilities. Task 2. Landfill Fuel Cell Power Generation Solid Oxide Fuel Cells (SOFCs) were constructed and evaluated as a means of obtaining electrical energy from landfill gas. Analysis of landfill gas. Attempts at collecting gas samples at the landfill and evaluating them on campus were still unsuccessful. Even a Teflon® sample bag would lose its H2S content. Evaluation of Gas Clean-up We consider this a confirmation of the CO2 effect on the solubility of H2S in water making much less sulfide available for the photocatalyst. It also means that another method should be employed to clean up landfill gas. Nonetheless, composition of impurities in landfill gas was reduced sufficiently to allow successful operation of the test fuel cell. Comparison to a PEM fuel cell system. If a PEMFC were to be operated with landfill gas as the fuel, the gas would have to be treated for sulfur removal, and then processed in a reformer large enough to drive the equilibrium far toward the products, so that negligible CO would flow into the fuel cell. Analysis of a fuel cell running on landfill gas. Using a Gow-Mac gas chromatograph with a thermal conductivity detector, unambiguous determination of CO can be made, at least as a primary constituent Task 3: Task 3 Plasma Controlled Turbine Blades Wind Turbine Selection. After carefully reviewing the various model available in the market the team selected the ARE 110 (2.5kW). The ARE 110 provides a very long life with little maintenance due to their relatively low rotational speeds (low RPM). The turbines large swept area (10.2ms2/110sq.ft), high-efficiency blades, purpose built alternator, and optimized power electronics ensure maximum energy capture from a wide range of wind speeds. Two wind turbines were installed side-by-side at the Melnick Hall site to compare their performance. Evaluate and Optimize Aerodynamically Enhanced Turbine Blades Due to delays in the installation of the wind turbines, no actual data was obtained within the contract period. At this time, the turbines are installed and operational at YSU with standard blades. We are in contact with Orbital Research and in discussion as to how best the required data can be obtained.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Assessment of U.S. Manufacturing Capability for Next-Generation Wind Turbine Drivetrains

Robust U.S. wind turbine manufacturing capabilities and supply chains are important for the United States to reduce the cost of electricity generated from wind turbines. These capabilities and supply chains are also critical to the invention and commercialization of new wind turbine technologies while providing high-quality jobs. The development of advanced drivetrain technologies for windturbine applications is advancing the state of the art for drivetrain design by producing higher capacity and operating reliability than conventional drivetrains. Advanced drivetrain technologies such as medium-speed and direct-drive generators, silicon-carbide (SiC) IGBT-based power electronics, and high torque density speed increasers require different manufacturing and supply chaincapabilities that present both risks and opportunities for U.S. wind turbine manufacturers and the wind industry as a whole. The primary objective of this project is to assess how advanced drivetrain technologies and trends will impact U.S. wind turbine manufacturing and its supply chains. The U.S. Department of Energy and other industry participants will use the information from this study toidentify domestic manufacturing gaps, barriers, and opportunities for developing U.S. wind turbine manufacturing capabilities and supply chains for next-generation drivetrain technologies. This report also includes recommendations for prioritizing technology areas for possible investments by public, private, or nonprofit entities that will reduce the cost of wind-generated electricity. Suchinvestments foster opportunities to invent and commercialize new wind turbine technologies, and provide high-quality jobs in the United States.

17 WIND ENERGY↗

Electric Drive Dynamic Thermal System Model for Advanced Vehicle Propulsion Technologies: Cooperative Research and Development Final Report, CRADA Number CRD-09-360

Electric drive systems, which include electric machines and power electronics, are a key enabling technology for advanced vehicle propulsion systems that reduce the dependence of the U.S. transportation sector on petroleum. However, to penetrate the market, these electric drive technologies must enable vehicle solutions that are economically viable. The push to make critical electric drivesystems smaller, lighter, and more cost-effective brings respective challenges associated with heat removal and system efficiency. In addition, the wide application of electric drive systems to alternative propulsion technologies ranging from integrated starter generators, to hybrid electric vehicles, to full electric vehicles presents challenges in terms of sizing critical components andthermal management systems over a range of in-use operating conditions. This effort focused on developing a modular modeling methodology to enable multi-scale and multi-physics simulation capabilities leading to generic electric drive system models applicable to alternative vehicle propulsion configurations. The primary benefit for the National Renewable Energy Laboratory (NREL) is the abilityto define operating losses with the respective impact on component sizing, temperature, and thermal management at the component, subsystem, and system level. However, the flexible nature of the model also allows other uses related to evaluating the impacts of alternative component designs or control schemes depending on the interests of other parties.

33 ADVANCED PROPULSION SYSTEMS↗

Manufacturing Demonstration Facility: Low Temperature Materials Synthesis

The Manufacturing Demonstration Facility (MDF) low temperature materials synthesis project was established to demonstrate a scalable and sustainable process to produce nanoparticles (NPs) for advanced manufacturing. Previous methods to chemically synthesize NPs typically required expensive, high-purity inorganic chemical reagents, organic solvents and high temperatures. These processes were typically applied at small laboratory scales at yields sufficient for NP characterization, but insufficient to support roll-to-roll processing efforts or device fabrication. The new NanoFermentation processes described here operated at a low temperature (~60 C) in low-cost, aqueous media using bacteria that produce extracellular NPs with controlled size and elemental stoichiometry. Up-scaling activities successfully demonstrated high NP yields and quality in a 900-L pilot-scale reactor, establishing this NanoFermentation process as a competitive biomanufacturing strategy to produce NPs for advanced manufacturing of power electronics, solid-state lighting and sensors.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

Energy Harvesting from Pipeline Vibration: CRADA Final Report

Investigating the extraction of energy from pipeline vibrations related to operations in the oil and gas industry. The wasted energy in the form of mechanical vibrations can be exploited to generate useful energy for low and medium power electronic devices (e.g., sensors) operating independently in deep sea and surface environments. Existing energy harvesting technologies and literature were surveyed to come up with a feasible design employing piezoelectric material. The project was important to reduce energy wastage and hence to national energy security.

30 DIRECT ENERGY CONVERSION↗

LEReC Machine Protection System

The LEReC Machine Protection System (MPS) is designed to alleviate the risk of possible damage to in-vacuum components of the accelerator from high power electron beam.

43 PARTICLE ACCELERATORS↗

FY2015 Propulsion Materials Annual Report

The Propulsion Materials Program actively supports the energy security and reduction of greenhouse emissions goals of VTO by investigating and identifying the materials properties that are most essential for continued development of cost-effective, highly efficient, and environmentally friendly next-generation heavy and light-duty powertrains. The technical approaches available to enhance propulsion systems focus on improvements in both vehicle efficiency and fuel substitution, both of which must overcome the performance limitations of the materials currently in use. Propulsion Materials Program activities work with national laboratories, industry experts, and VTO powertrain systems (e.g., Advanced Combustion Engines [ACE], Advanced Power Electronics and Electrical Machines [APEEM], and fuels) teams to develop strategies that overcome materials limitations in future powertrain performance. The technical maturity of the portfolio of funded projects ranges from basic science to subsystem prototype validation. Projects within a Propulsion Materials Program activity address materials concerns that directly impact critical technology barriers within each of the above programs, including barriers that impact fuel efficiency, thermal management, emissions reduction, improved reliability, and reduced manufacturing costs. The program engages only the barriers that result from material property limitations and represent fundamental, high-risk materials issues.

33 ADVANCED PROPULSION SYSTEMS↗

Apparent Fracture Toughness of Pressureless Sintered Silver Interconnects

This study uses three-point flexural testing to estimate the room-temperature apparent fracture toughness ( K Ic_app ) of a pressureless sintered-silver interconnect - a candidate material for use in power electronic devices. The K Ic_app estimation occurs via work-of-fracture measurement of a chevron-shaped sintered-silver joint centrally located in an “interconnect bend test specimen”. The chevron-shape was stencil-printed on a silver (Ag)-plated direct bonded copper (DBC) substrate, mated to an Ag-plated DBC substrate, and then sintered. The chevron-shape, used for decades in fracture mechanics examinations and in standardized tests of monolithic materials, enables controlled stable crack initiation and propagation that are prerequisites for valid K Ic_app estimation. The employed combination of an interconnect bend test specimen and bend test method is robust and simple, enables a means for interpreting the resistance to crack growth and delamination in an interconnect, provides a dependable way to judge the efficacies of sintered-silver processing conditions, and ultimately supports process optimization of sintered-silver interconnects.

36 MATERIALS SCIENCE↗

Conceptual Design Report: Radial RF Injectors for Improved Waste Stream Processing

In June 2017, the US Department of Energy Accelerator Stewardship Program [1] released its “FY2017 Research Opportunities in Accelerator Stewardship” [2], including a call for design studies of four types of high-power electron accelerators for energy and environmental applications. Table 1 lists the target performance for the “Type 1” and “T ype 2” accelerators in this call.

54 ENVIRONMENTAL SCIENCES↗

Creation of System Validation Platform

The objective of this CRADA between Sandia National Laboratories (SNL) and SunSpec Alliance (SunSpec) was to create a software test platform called the System Validation Platform (SVP) that performs end-to-end certification testing of photovoltaic (PV) inverters, energy storage systems, and other distributed energy resources (DERs). The SVP automates interactions of test equipment (PV and grid simulators), data acquisition systems, and interoperable DERs to certify the devices for advanced grid-support functions and interoperability. To assist electricity grid, operators maintain voltage and frequency, new interconnection requirements in the U.S. and Europe require DERs to have grid-support functions with adjustable settings. Automating the certification process for DER devices impacts the bottom line of NRTLs because they do not need to rely on test engineers running days (or weeks) of experiments to validate the performance of the equipment. These savings can then be passed down to the DER vendors so the certification process becomes less expensive and lowers the barrier to market for PV inverters, charge controllers, and other grid-interconnected equipment. This technology can also be used as a research platform for SNL, other national labs, and universities that would like to run hardware tests with power electronics equipment.

14 SOLAR ENERGY↗

Basic Research Needs for Microelectronics: Report of the Office of Science Workshop on Basic Research Needs for Microelectronics, October 23 – 25, 2018

Moore’s Law — realized via a combination of device physics advances, technology investments, and economic returns— allowed the number of transistors on a chip to double roughly every two years for over five decades. During those five decades, the cost of a unit of computing dropped by eight orders of magnitude. Those declines and the associated computing advances have dramatically affected every aspect of society, from science and technology through business and health to national security. Today, further computing advances are limited by the economics of chip fabrication and the physical limits on transistors, electrical interconnects, and memory elements at the nanoscale. If we are to evolve new generations of computing systems over the next decades that are both faster and more energy efficient, a complete reorganization of the science and technology underlying computing is needed. Within the Department of Energy’s (DOE’s) mission, which includes a pivotal and historical role in the evolution of computing, the needs are critical as well. Advanced computing and simulation underpin all aspects of DOE missions in energy, the environment, and national security, requiring energy-efficient computing beyond the exascale range. Edge computing, low-power computing technologies, and computers optimized for artificial intelligence are key to next-generation scientific facilities for high-energy physics research, as well as neutron and x-ray facilities. Finally, microelectronics will also play a major role in reshaping the U.S. electricity grid: from its current state to one that is cleaner, more efficient, cyber-secure, and resilient to widespread events, both natural and manmade. Realizing this vision will require advancements in both system architecture and power electronics. To enable continued advances in computing technologies, a fundamental rethinking is needed of the science behind the materials, synthesis and placement technologies, architectures, and algorithms. This cannot be modular and linear, as it has been in the past. Rather, these advances must be developed collectively, in a spirit of co-design, where each scientific discipline informs and engages the other to achieve orders of magnitude improvements in system-level performance. To explore these challenges, the Office of Science convened a Basic Research Needs Workshop for Microelectronics in October 2018 and charged workshop participants to conduct a thorough assessment of the scientific issues associated with advanced microelectronics technologies for applications relevant to the DOE mission. The workshop examined research relevant to the extension of complementary metal oxide semiconductor (CMOS) and beyond CMOS technologies; however, topics of direct relevance to quantum information science and quantum computing were outside the scope of this workshop.

42 ENGINEERING↗

Batteries Annual Progress Report (FY2019)

The Vehicle Technologies Office (VTO) of the Department of Energy (DOE) conducts research and development (R&D) on advanced transportation technologies that would reduce the nation’s use of imported oil and would also lead to reductions in harmful emissions. Technologies supported by VTO include electric drive components such as advanced energy storage devices (primarily batteries), power electronics and electric drive motors, advanced structural materials, energy efficient mobility systems, advanced combustion engines, and fuels. VTO is focused on funding early-stage high-reward/high-risk research to improve critical components needed for more fuel efficient (and cleaner-operating) vehicles. One of the major VTO objectives is to enable U.S. innovators to rapidly develop the next generation of technologies that achieve the cost, range, and charging infrastructure necessary for the widespread adoption of plug-in electric vehicles (PEVs). An important prerequisite for the electrification of the nation’s light duty transportation sector is development of more cost-effective, longer lasting, and more abuse-tolerant PEV batteries. One of the ultimate goals of this research, consistent with the current vehicle electrification trend, is an EV which can provide the full driving performance, convenience, and price of an internal combustion engine (ICE) vehicle. To achieve this, VTO has established the following overarching goal (Source: FY2021 Congressional Budget Justification1): …identify new battery chemistry and cell technologies with the potential to reduce the cost of electric vehicle battery packs by more than half, to less than $100/kWh (ultimate goal is $60/kWh battery cell cost), increase range to 300 miles, and decrease charge time to 15 minutes or less by 2028. VTO works with key U.S. automakers through the United States Council for Automotive Research (USCAR) – an umbrella organization for collaborative research consisting of Fiat Chrysler Automobiles (FCA), the Ford Motor Company, and General Motors. Collaboration with automakers through the partnership known as U.S. Driving Research and Innovation for Vehicle Efficiency and Energy Sustainability (U.S. DRIVE) attempts to enhance the relevance and the success potential of its research portfolio. VTO competitively selects projects for funding through funding opportunity announcements (FOAs). Directly-funded work at the national laboratories are awarded competitively through a lab-call process. During the past year, VTO continued R&D in support of PEVs. Stakeholders for VTO R&D include universities, national laboratories, other government agencies and industry (including automakers, battery manufacturers, material suppliers, component developers, private research firms, and small businesses). This document summarizes the progress of VTO battery R&D projects supported during the fiscal year 2019 (FY 2019).

25 ENERGY STORAGE↗

Puget Sound Energy Glacier Energy Storage System: An Assessment of Battery Technical Performance

This report investigates the technical performance of the Glacier BESS facility, consisting of one 2 MW, 4 MWh BESS, based on a number of baseline and use case tests. Baseline tests were intended to assess the general technical capability of the BESS (e.g., stored energy capacity, ramp rate performance, ability to track varying charge/discharge commands, direct current (DC) battery internal resistance). Use case tests were used to examine the performance of the BESS while engaged in specific economic services (e.g., arbitrage, power factor correction). The project measured and/or calculated parameters that are important for understanding BESS performance when subjected to actual field operation for achieving economic benefits, e.g., round trip efficiency (RTE) with and without rest, with and without auxiliary loads, auxiliary power consumption, signal command tracking performance, temperature variations, parasitic power loss during power electronics switching during rest, and state of charge (SOC) excursions. These baseline and use case parameters were analyzed using recorded test results. In addition, the results and lessons presented herein are also beneficial for any task or effort that needs technical assessment on similar and different types of BESS based on field deployment results, since the assessment methodology remains the same.

25 ENERGY STORAGE↗

Probing Coherent States of Light and Matter in Two-Dimensional Semiconductors. Final Report

The ability to enhance light-matter interactions in engineered optical environments is well-established in micro- and nano-photonics. New classes of materials bring new rich correlations between spin, momentum, and light polarization that can be exploited in these photonic systems for information processing and low-power electronics. Interfacing these novel material features with strong optical interactions suggests the compelling capability to create hybrid light-matter systems harnessing low-energy and protected material properties such as spin. The long-term objective of this program was to investigate the interplay between pseudospin in 2D materials and light, revealing new coherent phenomena. The materials studied are the monolayer transition metal dichalcogenides (TMDs), which support polarization-sensitive optical transitions when isolated to a single sub-nanometer crystal layer in thickness. In particular, monolayer TMD semiconductors such as MoS 2 exhibit degenerate valleys in momentum space with distinct spin character. These valleys can be separately addressed by circularly polarized light, providing a tool for manipulation. Integrating this valley pseudospin of excitons in monolayer TMDs with engineered strong optical excitations to create novel coherent phenomena was a key long-term goal of this research. The scope of this research primarily focused on studying light-matter interactions of valley-sensitive excitations in monolayer TMDs. The scope also included the integration of monolayer materials that support valley-polarized emission into photonic devices. This approach extends prior work on exciton-polaritons in 2D materials toward a platform with far more control and improved light input and output characteristics to aid scalability of these polarization-sensitive phenomena to many-body, long-range optical networks. During the course of the five-year Early Career program, the approaches led to successful progress on each proposed aim. Initial successful work seeded additional research that developed from the main themes, while this program focus evolved toward coherent manipulation of valley polaritons and integration with photonics. Both of these advanced topics set the stage for new capabilities in future innovative research. The results of this project provide advances in materials and methods relevant for new visions of opto-electronics and photonics that can improve information processing in an era of increased focus on quantum and coherent phenomena. The research has also contributed to the training of two postdoctoral scholars and five graduate students.

2D Materials↗

Two-Phase Cooling for High Packaging Density Planar Inverter: Cooperative Research and Development Final Report, CRADA Number CRD-15-00592

The project objective was to utilize two-phase heat transfer to enable compact and power-dense inverters. The high heat transfer capacity and near isothermal characteristics of two-phase cooling can enable higher power densities, reducing the size and cost of the power electronics system. This project focused on developing efficient, passive (no pump or compressor) two-phase cooling strategies that consist of an air-cooled condenser and evaporator. This report describes the modeling work conducted to design the evaporator and air-cooled condenser for a prototype inverter development work underway in the John Deere. Prototypes of the final evaporator and condenser designs were then fabricated via 3D printing for testing. Experiments on the evaporator confirmed that this component can meet the heat load and junction temperatures requirements for Si IGBT (insulated-gate bipolar transistor) inverter. Experiments with the air-cooled condenser were not possible due to leaks through the condenser walls.

33 ADVANCED PROPULSION SYSTEMS↗

Distributed Solar 2020 Data Update [Slides]

Berkeley Lab’s Tracking the Sun report summarizes installed prices and other trends among grid-connected, distributed solar photovoltaic (PV) systems in the United States. This report is now being published on a biannual cycle. In 2020, Berkeley Lab has released a more limited Distributed Solar 2020 Data Update, which consists of the same data otherwise published in Tracking the Sun report. The update includes data on more than 1.9 million systems installed through 2019, covering 82% of all distributed PV systems installed nationally through that timeframe.As in prior years, the data update focuses to a large degree on installed prices reported for distributed PV projects, describing both historical trends and variability in pricing across projects.With respect to the historical price trajectory, national median installed prices fell, from 2018 to 2019, by roughly 1% for residential systems, remained essentially flat for small non-residential systems, and fell by 4% for large non-residential systems. Across all three customer segments, these are the slowest annual percentage declines since 2006-2008.Pricing continues to vary widely across individual projects, reflecting, among other things, differences in system sizing and design, installer-level pricing strategies, and local market conditions. For example, among residential systems installed in 2019, the lowest 20% were priced below $3.1/W, while the highest 20% were above $4.5/W. The distributions for non-residential systems exhibit similarly wide spreads.In addition to data on installed prices, the data update also covers a broad range of trends related to distributed PV system design, including: system sizing, module efficiency, module-level power electronics, inverter-loading ratios, solar+storage installations, mounting configuration, panel orientation, third-party ownership, and customer segmentation.

14 SOLAR ENERGY↗

Medium-duty Urban Range Extended Connected Powertrain (Final Scientific Technical Report)

The project goal is to develop and demonstrate a Class 4 delivery vehicle that reduces fuel consumption by 50% or more when compared to an equivalent vehicle with a conventional internal combustion engine (ICE) powertrain driven on a comparable duty cycle. This shall be achieved using a plug-in hybrid electric (PHEV) configuration that optimizes the efficiency of the ICE. The proposed solution aims to be commercially viable for fleets to procure the system without additional incentives. To accomplish this, commercialized light-duty vehicle electric drive components shall be used. A PHEV configuration for Class 4 MD/HD vocational vehicles using commercialized light-duty vehicle electric drive components will require the development of a new topology for the hybrid powertrain applicable to medium-duty vehicles. Prior research indicates that an identified novel power split device could provide a fuel economy improvement potential of up to 51%. Utilizing an advanced battery management algorithm that will allow operation closer to the battery limits, the project will minimize battery capacity to achieve the desired performance results while maintaining the cost target for high commercialization. The solution must be cost effective to purchase and integrate into a Class 4 delivery vehicle, deliver the intended fuel economy improvement, and perform as well, or better, than the current conventional ICE powertrain. MD/HD vehicles typically require higher power, which is one factor that results in high costs for the powerful electric machines typical in larger HEV/PHEV systems. A key element in the project is the use of commercially available Bosch electric drive components (e.g., motors, batteries, and power electronics) from the larger passenger vehicle segment. This leverages the economies of scale to decrease cost and improve reliability beyond current purpose-built low-volume commercial vehicle components. These innovations will result in a game-changing PHEV system that meets DOE’s 50% fuel consumption reduction target, grants the vehicle an uncompromised driving range, and achieves the cost point for widespread adoption.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗