SEARCH · Engineering Papers
Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
Using computational fluid dynamics (CFD), we will simulate the wind loading on a solar awning that is attached to the wall of a manufactured home while being towed behind a semi-truck.
The goal of the project was to develop, verify and validate an advanced two-phase boiling flow modeling capability that enhances the existing two-phase flow modeling of the STAR-CCM+ Computational Fluid Dynamics (CFD) code. The project focused on the simulation of two phase flow and heat transfer phenomena that occur in Boiling Water Reactor (BWR) and Pressurized Water Reactor (PWR) fuel bundles under various operating conditions. The extended STAR-CCM+ two-phase flow models implemented during the project follow the approach similar to the Extended Boiling Framework [1-6] previously developed at Argonne but include more fundamental physical models of boiling phenomena. The development and validation of the extended two-phase models is supported by the U.S. DOE GAIN program and performed in collaboration with Framatome U.S. Inc.
This is a collaborative effort between Lawrence Livermore National Security, LLC as manager and operator of Lawrence Livermore National Laboratory (“LLNL”) and Guardian Glass, LLC ("Guardian Glass") to develop a fast-running emulator of the reactive Computational Fluid Dynamics (“CFD”) simulations needed to understand the complex reactions and flows in the glass melting, fining, and forming subprocesses. This CRADA project is sponsored under the High-Performance Computing for Manufacturing (“HPC4Mfg”) Program of the Department of Energy’s Advanced Manufacturing Office (“AMO”) within the Energy Efficiency and Renewable Energy (“EERE”) Office.
Provides an overview of recent collaborations between SNLs wind tunnel and CFD teams.
An efficient battery manufacturing process is the key to the mass production of Electric Vehicles (EV), in which drying is one of the most energy-intensive steps significantly influencing the battery cell performance. An accurate 3D CFD model for drying is essential for predicting the drying mechanism and optimizing its parameters. By optimizing the drying process, it is possible to reduce energy consumption and cost during battery manufacturing, minimize binder loading and maximize active material loading to achieve superior electrochemical performances and facilitate wider and faster public adoption of EV. This project aims to optimize the drying process during electrode manufacturing by leveraging high-fidelity, porous electrode simulations for solvent evaporation. By optimizing this process, we seek to reduce energy consumption during battery manufacturing, while minimizing binder loading and maximizing active material loading, with the overall goal of enhancing electrical vehicle performance.
The main goal of this study is to design a drainage window in an 81" single slope barrier wall for on-grade and sag conditions that could replace the standard ODOT I-3 barrier catch basin. The ODOT design guidelines are as follows: a) Examine configurations of the opening to the flume behind the wall under the wall section to maximize conveyance of flow to a roadside ditch section. b) Examine window lengths and configurations to maximize hydraulic efficiency on a grade up to an absolute maximum window length of 20 ft. c) Use a minimum opening height of 4 in. and consider tapering to an increased height at the outlet to the flume to reduce the potential for debris clogging beneath the barrier section. On-grade locations are analyzed for longitudinal slope up to 5% and spread up to 10 ft. Sag locations, represented by pavement at zero longitudinal slope, are analyzed for water depths up to 18 in. The roadway cross section consists of a 10-ft shoulder at a 4.0% cross slope and pavement at a 1.6% cross slope. All surfaces are represented with Manning’s n = 0.015. Computational fluid dynamics (CFD) is used to perform the analysis. The modeling approach follows previous studies by the authors. The new design is similar to a slotted inlet: a rectangular opening cut into the bottom of a barrier (e.g., a temporary barrier or single slope barrier wall), which typically has a uniform cross section. Findings from laboratory tests of flow under Florida DOT barrier walls were used for additional validation of the modeling approach used in this study.
Multispecies incompressible flows occur widely in engineering and environmental applications, such as chemical reactors, fuel cells, ocean mixing, and biomedical systems. However, accurately resolving the complex transport and mixing phenomena associated with multiple interacting species remains computationally challenging, especially for large-scale problems. In this study, we present a robust, high-performance computing--enabled multispecies incompressible Navier–Stokes solver integrated within the Vertex-CFD framework. Our solver employs a fully coupled, implicit, finite element--based formulation that accurately captures the advection, diffusion, and interaction of multiple species in incompressible flows by leveraging the Kokkos library for parallel computing to achieve high computational efficiency. For pressure coupling, the entropically damped artificial compressibility method is utilized. We validated the solver against canonical test cases, including multispecies advection, diffusion, and Bateman systems; the results demonstrate second- and third-order spatial accuracy and consistent convergence. Additionally, we demonstrated the strong and weak scaling study results obtained on the leadership-class high-performance computing system, Frontier at Oak Ridge National Laboratory.
Proper thermal management of an electric motor for vehicle applications extends its operating range. One cooling approach is to impinge Automatic Transmission Fluid (ATF) onto the rotor end ring. Increased ATF coverage correlates to enhanced heat transfer. Computational Fluid Dynamics (CFD) analytical tools provide a mechanism to assess motor thermal management prior to hardware fabrication. The complexity of the fluid flow (e.g., jet atomization, interface tracking, wall impingement) and heat transfer makes these simulations challenging. Computational costs are high when solving these flows on high-speed rotating meshes. Typically, a Volume-of Fluid (VOF) technique (i.e., two-fluid system) is used to resolve ATF dynamics within this rotating framework. Suitable numerical resolution of the relevant physics for thin films under strong inertial forces at high rotor speeds is computationally expensive, further increasing the run times. In this work, a numerical study of rotor-ring cooling by ATF is presented using a patent automated Cartesian cut-cell based method coupled with Automatic Mesh Refinement (AMR). This approach automatically creates the Cartesian mesh on-the-fly and can effectively handle complex rotating geometries by adaptively refining the mesh based on local gradients in the flow field which results in better resolution of the air-ATF interface. A Single non-inertial Reference Frame (SRF) approach is used to account for the rotating geometry and to further improve the overall computational efficiency. Quasi-steady state conditions are targeted in the analysis of the results. Important physics such as ATF jet structure, velocity detail near the air-jet interface, ATF coverage/accumulation on the ring surface, and cooling capacity are presented for a low-resolution Reynolds averaged Navier-Stokes (RANS), high-resolution RANS, and high-resolution Large-Eddy Simulation (LES) models. Computations are scaled over hundreds of cores on a supercomputer to maximize turnaround time. Each numerical approach is shown to capture the general trajectory of the oil jet prior to surface impingement. The high-resolution LES simulation, however, is superior in capturing small scale details and heat transfer between the free jet and surrounding air.
Gas fermentation technology offers sustainable and high carbon-efficiency routes to fuels and chemicals. However, efficiently delivering low-solubility substrate gases to production-scale bioreactors is a significant technical challenge that could limit productivity. We perform fundamental and applied multiphysics computational fluid dynamics (CFD) research targeting specific challenges of gas delivery in fermentation systems that utilize varied gas-compositions, for e.g. CO2/CO/CH4/H2 substrates: bubble dynamics, coupled mass-transfer and reaction, that can lead to optimal reactor designs at scale. This work will support BETO goals towards greenhouse gas reduction, derisking technologies toward commercialization/deployment and sustainable-aviation-fuel synthesis targets.
The exascale computing era comes with the release of MFIX-Exa, a new code for studying gas-particle fluidization using CFD-DEM and PIC models on massively parallel, heterogeneous high-performance computing architectures. However, as compute resources continue to grow in scale and complexity, so too does the impetus to use them efficiently. Here, we propose a novel bootstrapping method to minimize neglected simulation time and cast the approach more broadly among a growing field of multi-fidelity methods.
This paper focuses on the development and validation of a combustion model for Computational Fluid Dynamics (CFD) modeling of a Rotating Detonation Engines (RDE).
CFD Modeling of NOx Formation in a Rotating Detonation Engine
In this work, we explore the use of CO2-selective flat sheet membranes for capturing CO2 from point sources. We employ Computational Fluid Dynamics (CFD) models to design high-flux plate-and-frame membrane modules to achieve uniform flow distribution among membrane elements, minimize dead-end zones, and ease the common concentration polarization issue for gas separation membranes. The goal is to drive membrane technology improvements by providing better module designs for given membrane properties and operating conditions.
Efficient utilization of biomass is challenging due to the complexity of the feedstock at molecular, particle, and reactor scales. Direct coupling of particle scale model and reactor scale simulation is computationally infeasible. In this work, the results from a particle resolved simulation were used to calibrate the heat transfer and reaction kinetics of particles. A hybrid drag model was used to consider the different fluidization properties of sands and biomass particles. The computation cost was reduced using a coarse-grained Discrete Element Method (DEM). The simulated conversion rate, char yield, tar yield, and pyrolysis gas yield compare well with experiment. The residence time and axial distributions of biomass were also analyzed. This novel multi-scale method provides an efficient and accurate tool for the modeling of biomass pyrolysis reactors.
Abstract Predictive high‐fidelity modeling of wind turbines with computational fluid dynamics, wherein turbine geometry is resolved in an atmospheric boundary layer, is important to understanding complex flow accounting for design strategies and operational phenomena such as blade erosion, pitch‐control, stall/vortex‐induced vibrations, and aftermarket add‐ons. The biggest challenge with high‐fidelity modeling is the realization of numerical algorithms that can capture the relevant physics in detail through effective use of high‐performance computing. For modern supercomputers, that means relying on GPUs for acceleration. In this paper, we present ExaWind, a GPU‐enabled open‐source incompressible‐flow hybrid‐computational fluid dynamics framework, comprising the near‐body unstructured grid solver Nalu‐Wind, and the off‐body block‐structured‐grid solver AMR‐Wind, which are coupled using the Topology Independent Overset Grid Assembler. Turbine simulations employ either a pure Reynolds‐averaged Navier–Stokes turbulence model or hybrid turbulence modeling wherein Reynolds‐averaged Navier–Stokes is used for near‐body flow and large eddy simulation is used for off‐body flow. Being two‐way coupled through overset grids, the two solvers enable simulation of flows across a huge range of length scales, for example, 10 orders of magnitude going from O(μm) boundary layers along the blades to O(10 km) across a wind farm. In this paper, we describe the numerical algorithms for geometry‐resolved turbine simulations in atmospheric boundary layers using ExaWind. We present verification studies using canonical flow problems. Validation studies are presented using megawatt‐scale turbines established in literature. Additionally presented are demonstration simulations of a small wind farm under atmospheric inflow with different stability states.
Experimental instantaneous shadowgraph visualizations on transparent glass nozzle replicas of high-pressure fuel injectors have been used to validate a novel in-house high-fidelity LES-VOF multiphase solver, to study the evolution of vortex flow and fuel cavitation. Both experiments and simulations capture the formation of an unsteady vapor structure inside the nozzle volume, which is referred to as 'string-cavitation'; strings are found at the core of the recirculation zones. Furthermore, high-fidelity simulations provide a very detailed insight into the vortex generation in the injector nozzle; strings appear within the time scales that are relevant for fast injection events (on the order of 0.1 milliseconds) and, for the problem under consideration, their generation seems mostly related to the flow pattern in the sac. It is also shown that vortexes interact, merge till they disrupt and favor the temporary inception of shear cavitation.
A novel graphical processing unit-based discrete element method solver is introduced to improve stability, performance, and provide seamless integration into commercial or open-source computational fluid dynamics software. A key innovation is eliminating a need for network communication between solvers, which was previously required for cross-platform coupling. This is accomplished by a direct coupling method that employs dynamic-linked libraries. Furthermore, the solver optimizes memory usage by streamlining the particle-cell search algorithm by eliminating the cells' searching grid. This ensures the solver is compatible with a wide range of mesh types, providing high geometric flexibility. The approach simplifies the simulation process by directly incorporating computational fluid dynamics mesh information into the discrete element method solver. The performance analysis indicates about sixteen times boost in computational speed compared to benchmark central processing unit-based solvers. Finally, the solver's compatibility with polyhedral meshes, a vital advantage for complex geometries, is tested against a referenced study regarding the simulation of an immersed-tube fluidized bed.
The accurate prediction of pressure drop in tightly packed, low–Reynolds number (Re) bare rod bundles is essential for the thermal-hydraulic design of the Microreactor Applications Research Validation and EvaLuation (MARVEL) reactor and other microreactor concepts. However, existing friction factor correlations, particularly the upgraded Cheng-Todreas (UCTD) correlation, have limited validation for the small pitch-to-diameter ratios (P/Ds) and transitional flow conditions characteristic of these systems. In this work, we perform high-fidelity large-eddy simulations (LESs) of both an infinite bare rod bundle and a finite bare 37-pin scalloped rod bundle across the range 1000≤ 𝑅𝑒 ≤5500. The simulations reveal strong gap vortex–driven transitional behavior and indicate that the UCTD may underpredict the friction factor by up to 28% at 𝑃/𝐷 = 1.05. Using the LES-calculated pressure drops, we formulate a new friction factor correlation that follows the Cheng-Todreas functional form but is calibrated for low-Re and tightly packed geometries representative of a MARVEL-like reactor. The correlation is implemented in the MOOSE (Multiphysics Object-Oriented Simulation Environment) subchannel module and compared against both the LES and UCTD predictions. Across all subchannel types, the proposed model reduces the streamwise velocity differences from as high as 44% (UCTD) to below 9%, and decreases the pressure gradient differences from 13% to 25% (UCTD) to 0.7% to 7% relative to the LES results. These results suggest that the new correlation has the potential to improve the pressure drop and flow field predictions for such geometries, highlighting the importance of high-fidelity simulations in supporting microreactor thermal-hydraulic model development and motivating future pressure drop experiments for compact rod bundles to further validate these findings.