Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “process loads”

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.

At least 1,657 records · Page 92
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Rapidly ramp cryogenic air separation unit without loss of O2 product purity—application for low-carbon fossil-fuel plants

The rapid integration of intermittent renewable sources into the electricity grid is driving the need for low-carbon, fossil-fuel power plant capable of rapid ramping. Therefore, a cryogenic air separation unit (ASU) as part of low-carbon, fossil-fuel power plant should be capable of rapid ramping. However, highly integrated and nonlinear processes of the ASU would significantly restrict this rapid ramping. To overcome this fundamental issue, we study the basic dynamic process of a state-of-the-art double-column ASU. A flow-driven dynamic model was established in Aspen Plus Dynamics, assuming perfect flow controls, to capture the basic dynamics of ramping ASU. We find the vapor-liquid counter-current flow structure in the low-pressure column is critical to the air separation when rapidly ramping the ASU. This flow structure is established based on a complicated heat integration process. It is simplified as an apparent counter-current heat transfer process in this work, which greatly reduces the complexity for studying the dynamics of ASU. For keeping this basic flow structure, the heat integration is maintained as its heat duty follows the ASU load, through several basic feed-forward and feed-back controllers on the critical stream flowrates. Moreover, we find a fundamental issue of mismatched dynamics in the low-pressure column, resulting in a significant loss of O2 product purity when rapidly ramping down the ASU and an obvious fluctuation of O2 product purity. Based on these explorations, we propose a basic control method for rapidly ramping the ASU without loss of O2 product purity. Results show the ASU basic dynamic process successfully ramps at a rate up to 10%/min (40-100% load) while maintaining the O2 product purity within 95.2-95.6 mol%.

Cheng, Mao↗
DOE OSTI2025

ASSESSING THE EFFECTIVENESS OF ULTRASONIC IMPACT TREATMENT ON RESIDUAL STRESS PROFILES IN DISSIMILAR WELDED JOINTS

Residual stresses (RS) induced during welding processes are a critical concern in materials engineering, as they can significantly impair the mechanical performance of components by reducing fatigue strength and tensile load capacity. This challenge is especially pronounced in dissimilar metal welds (DMWs), where variations in thermal expansion properties between the joined alloys exacerbate the formation of tensile RS. Conventional post-weld heat treatments, though effective for homogeneous materials, often require substantial energy, specialized equipment, and extensive processing time, making them less practical for DMW applications. Thus, there is a clear need for innovative, energy-efficient techniques to mitigate these detrimental stresses. This study investigates ultrasonic impact treatment (UIT) as a possible alternative for mitigating tensile RS in both similar and dissimilar metal welds. To evaluate UIT’s effectiveness, neutron diffraction (ND) was employed as a nondestructive technique to quantify RS in three orthogonal directions—longitudinal, transverse, and normal. The results showed that UIT significantly reduced peak tensile RS, particularly in the longitudinal direction, by up to 180 MPa in similar welds and up to 150 MPa in dissimilar welds. Given the limited literature on UIT application in DMWs, this work contributes valuable data on stress redistribution mechanisms and highlights UIT’s potential as a practical stress-relief method. The findings lay the groundwork for further investigations aimed at optimizing process parameters and understanding long-term performance in welded joints.

EisaZadeh, Hamid [Western Carolina University, Cul↗
DOE OSTI2020

Bichromatic Wave Selection for Validation of the Difference-Frequency Transfer Function for the OC6 Validation Campaign: Preprint

The focus of the Offshore Code Comparison Collaboration, Continuation, with Correlation and unCertainity (OC6) project, which operates under the International Energy Agency (IEA) Wind Task 30, is to refine the accuracy of engineering tools used to design offshore wind turbines. In support of this work, a new validation campaign is being developed that seeks to better understand the nonlinear wave loading that excites floating wind systems at their low-frequency, rigid-body modes in surge and pitch. The validation data will be used in a three-way validation between simplified engineering tools and higher-fidelity tools, such as computational fluid dynamics (CFD). Irregular wave spectrums, which are traditionally used to examine the nonlinear wave interaction with offshore structures, are too computationally expensive to be simulated in CFD tools, and so bichromatic wave cases will be used instead. This paper reviews the process used to choose the bichromatic wave pairs to be used in the campaign to validate the second-order difference-frequency quadratic and potential loads at the surge and pitch natural frequencies of a floating semisubmersible.

17 WIND ENERGY↗
DOE OSTI2022

Advancing Chemical Separations: Unraveling the Structure and Dynamics of Phase Splitting in Liquid–Liquid Extraction

Liquid-liquid extraction (LLE), the go-to process for a variety of chemical separations, is limited by spontaneous organic phase splitting upon sufficient solute loading, called third phase formation. In this study we explore the applicability of critical phenomena theory to gain insight into this deleterious phase behavior with the goal of improving separations efficiency and minimizing waste. Here, a series of samples representative of rare earth purification were constructed to include each of one light and one heavy lanthanide (cerium and lutetium) paired with one of two common malonamide extractants (DMDOHEMA and DMDBTDMA). The resulting postextraction organic phases are chemically complex and often form rich hierarchical structures whose statics and dynamics near the critical point were probed herein with small-angle X-ray scattering and high-speed X-ray photon correlation spectroscopy. Despite their different extraction behaviors, all samples show remarkably similar critical behavior with exponents well described by classical critical point theory consistent with the 3D Ising model, where the critical behavior is characterized by fluctuations with a single diverging length scale. This unexpected result indicates a significant reduction in relevant chemical parameters at the critical point, indicating that the underlying behavior of phase transitions in LLE rely on far fewer variables than are generally assumed. The obtained scalar order parameter is attributed to the extractant fraction of the extractant/diluent mixture, revealing that other solution components and their respective concentrations simply shift the critical temperature but do not affect the nature of the critical fluctuations. These findings point to an opportunity to drastically simplify studies of liquid-liquid phase separation and phase diagram development in general while providing insights into LLE process improvement.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Screening method for Enzyme-based liquefaction of corn stover pellets at high solids

Liquefaction of high solid loadings of unpretreated corn stover pellets has been demonstrated with rheology of the resulting slurries enabling mixing and movement within biorefinery bioreactors. However, some forms of pelleted stover do not readily liquefy, so it is important to screen out lots of unsuitable pellets before processing is initiated. This work reports a laboratory assay that rapidly assesses whether pellets have the potential for enzyme-based liquefaction at high solids loadings. Twenty-eight pelleted corn stover (harvested at the same time and location) were analyzed using 20 mL enzyme solutions (3 FPU cellulase/ g biomass) at 30 % w/v solids loading. Imaging together with measurement of reducing sugars were performed over 24-hours. Further, some samples formed concentrated slurries of 300 mg/mL (dry basis) in the small-scale assay, which was later confirmed in an agitated bioreactor. Also, the laboratory assay showed potential for optimizing enzyme formulations that could be employed for slurry formation.

Laboratory assay↗
NASA NTRS1991

Secondary orientation effects in a single crystal superalloy under mechanical and thermal loads

The nickel-base single crystal superalloy PWA 1480 is a candidate blading material for the advanced turbopump development program of the SSME. In order to improve thermal fatigue resistance of the turbine blades, the single crystal superalloy PWA 1480 is grown along the low modulus zone axes (001) crystal orientation by a directional solidification process. Since cubic single crystal materials such as PWA 1480 exhibit anisotropic elastic behavior, the stresses developed within the single crystal superalloy due to mechanical and thermal loads are likely to be affected by the exact orientation of the secondary crystallographic direction with respect to the geometry of the turbine blade. The effects of secondary crystal orientation on the elastic response of single crystal PWA 1480 superalloy were investigated.

Kalluri, Sreeramesh↗
DOE OSTI2020

Balancing sugar recovery and inhibitor generation during energycane processing: Coupling cryogenic grinding with hydrothermal pretreatment at low temperatures

Pretreatment of lignocellulosic biomass at high temperatures or with oxidizing chemicals generate various inhibitors that restrict the efficient bioconversion of sugars in subsequent steps. The present study systematically investigates individual and combinatorial effects of pretreatment parameters on the generation of inhibitors. Herein, a plot between pretreatment temperature and inhibitor revealed optimum pretreatment temperature for energycane bagasse i.e., 170 °C beyond which total inhibitor production increased exponentially. No inhibitor production was observed on mechanical processing i.e., disk milling/cryogenic grinding of biomass. Evaluation of response surface regression exhibited that biomass solids loading has a significant effect on inhibitor generation at higher temperatures. The concentrations of certain inhibitors such as acetic acid, furfurals, and HMF increased more than 3-folds on doubling the solids loading. Furthermore, a novel low-severity approach of low-temperature hydrothermal pretreatment coupled with cryogenic grinding for lignocellulosic biomasses has been introduced which improved sugar yields while maintaining a low inhibitor concentration.

09 BIOMASS FUELS↗
DOE OSTI2020

A conceptual model for how to design for building envelope characteristics. Impact of thermal comfort intervals and thermal mass on commercial buildings in U.S. climates

The paper presents a simplified conceptual model for energy demand calculations based on building envelope characteristics, thermal mass and local climate. It is based on a network model and lumped analysis of the dynamic process. Characteristic parameters for the buildings are suggested; Driving temperature (DT), Driving temperature difference, (DTD), External Load Temperature (ELT), and Thermal Load Resistance (TLR). The Building Envelope Performance ( BEP 0 ), based on a controlled constant indoor temperature is introduced. Solution techniques using stable explicit forward differences based on analytical solutions are derived. The conceptual model has been used for mapping the Driving temperature difference and introduced two performance factors and . The first factor represents the effect of thermal comfort interval and thermal mass on the energy demand. The latter represents the ratio between cooling and heating energy demand. These three parameters and factors have been visualized on U.S. maps and enable a possibility to communicate the demand of energy, and cooling and the coupling to building characteristics, in a concise way.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Optimization of catholyte for halide-based all-solid-state batteries

Halide solid electrolytes gain significant attention due to their high ionic conductivity, low processing temperature, dry air compatibility, and high-voltage stability. However, low cathode active material (CAM) loading in the composite cathode constrains the realization of high energy density for halide-based all-solid-state batteries. In this study, three halide materials, raw Li 3 YBrCl 5 (LYBC-R, <30μm), milled LYBC (LYBC-M, <5 μm) and freeze-dried Li 3 InCl 6 (LIC, <500 nm), were used as catholytes, combined with LYBC-M as the electrolyte and LiIn alloy as the anode. The CAM:catholyte ratio was investigated as well as stack pressure and operating temperature. Our study demonstrates that particle size of the catholyte plays an important role only for high CAM loading or high C-rate cycling. At moderate CAM loading (65 and 70wt% LiNi 0.83 Mn 0.06 Co 0.11 O 2 ) and 0.1 C-rate, all the three catholytes perform well, providing initial discharge capacities >177 mAh/g. At high CAM loading (85wt%) and 0.1 C-rate, a cathode with the nano-scale LIC catholyte provides discharge capacity of 175 mAh/g, while the larger particle size catholytes suffer significantly reduced capacity. Both LYBC and LIC catholytes provided capacity retention >80% after 200 cycles at 0.5C. These results imply that cathode particle size is critically important for performance at high CAM loading. Furthermore, both electrolyte and cathode were tape cast to scale up size and prepare realistic layer thicknesses. A small amount of binder was used in both layers, to balance the electrochemical performance and mechanical properties. Further, the discharge capacity of a tape cell was 152mA h/g at 0.1C with a capacity retention of 81.8% after 20 cycles at 0.5C. The results demonstrate the excellent performance of LYBC as an electrolyte, and provide guidance for halide-based cathode design.

25 ENERGY STORAGE↗
DOE OSTI2023

MXene/graphene oxide nanocomposites for friction and wear reduction of rough steel surfaces

Development of solid lubricant materials that render reliable performance in ambient conditions, are amenable to industrial size and design complexities, and work on engineered surfaces is reported. These coatings are composed of Ti 3 C 2 T x -Graphene Oxide blends, spray-coated onto bearing steel surfaces. The tribological assessment was carried out in ambient environmental conditions and high contact pressures in a ball-on-disc experimental set-up. The evaluation yielded that the use of Ti 3 C 2 T x -Graphene-Oxide coatings led to substantial reduction in friction down to 0.065 (at 1 GPa contact pressure and 100 mm/s) in comparison to the uncoated of single-component-coated surfaces, surpassing the state-of-the-art. The coatings also provided excellent protection against wear loss of the substrate and counter-face. The results were explained based on the observations from Raman spectroscopy, scanning electron microscopy, transmission electron microscopy, and nanoindentation measurements. In operando formation of a dense, hard and stiff, dangling-bond-saturated tribolayer was observed to be the reason for the sustained lubricity even at high test loads and sliding speeds. This report presents the holistic exploration and correlation of structure-property-processing pertaining to the advancement of solid lubrication science.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Production of renewable alcohols from maple wood using supercritical methanol hydrodeoxygenation in a semi-continuous flowthrough reactor

Biomass conversion to alcohols using supercritical methanol depolymerization and hydrodeoxygenation (SCM-DHO) with CuMgAl mixed metal oxide is a promising process for biofuel production. Here, we demonstrate how maple wood can be converted at high weight loadings and product concentrations in a batch and a semi-continuous reactor to a mixture of C 2 –C 10 linear and cyclic alcohols. Maple wood was solubilized semi-continuously in supercritical methanol and then converted to a mixture of C 2 –C 9 alcohols and aromatics over a packed bed of CuMgAlO x catalyst. Up to 95 wt% of maple wood can be solubilized in the methanol by using four temperature holds at 190, 230, 300, and 330 °C. Lignin was solubilized at 190 and 230 °C to a mixture of monomers, dimers, and trimers while hemicellulose and cellulose solubilized at 300 and 330 °C to a mixture of oligomeric sugars and liquefaction products. The hemicellulose, cellulose, and lignin were converted to C 2 –C 10 alcohol fuel precursors over a packed bed of CuMgAlO x catalyst with 70–80% carbon yield of the entire maple wood. The methanol reforming activity of the catalyst decreased by 25% over four beds of biomass, which corresponds to 5 turnovers for the catalyst, but was regenerable after calcination and reduction. In batch reactions, maple wood was converted at 10 wt% in methanol with 93% carbon yield to liquid products. The product concentration can be increased to 20 wt% by partially replacing the methanol with liquid products. The yield of alcohols in the semi-continuous reactor was approximately 30% lower than in batch reactions likely due to degradation of lignin and cellulose during solubilization. These results show that solubilization of whole biomass can be separated from catalytic conversion of the intermediates while still achieving a high yield of products. However, close contact of the catalyst and the biomass during solubilization is critical to achieve the highest yields and concentration of products.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

The three-way junction structure of the HIV-1 PBS-segment binds host enzyme important for viral infectivity

HIV-1 reverse transcription initiates at the primer binding site (PBS) in the viral genomic RNA (gRNA). Although the structure of the PBS-segment undergoes substantial rearrangement upon tRNALys3 annealing, the proper folding of the PBS-segment during gRNA packaging is important as it ensures loading of beneficial host factors. DHX9/RNA helicase A (RHA) is recruited to gRNA to enhance the processivity of reverse transcriptase. Because the molecular details of the interactions have yet to be defined, we solved the solution structure of the PBS-segment preferentially bound by RHA. Evidence is provided that PBS-segment adopts a previously undefined adenosine-rich three-way junction structure encompassing the primer activation stem (PAS), tRNA-like element (TLE) and tRNA annealing arm. Disruption of the PBS-segment three-way junction structure diminished reverse transcription products and led to reduced viral infectivity. Because of the existence of the tRNA annealing arm, the TLE and PAS form a bent helical structure that undergoes shape-dependent recognition by RHA double-stranded RNA binding domain 1 (dsRBD1). Mutagenesis and phylogenetic analyses provide evidence for conservation of the PBS-segment three-way junction structure that is preferentially bound by RHA in support of efficient reverse transcription, the hallmark step of HIV-1 replication.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2020

An Integrated Indexing and Search Service for Distributed File Systems

Data services such as search, discovery, and management in scalable distributed environments have traditionally been decoupled from the underlying file systems, and are often deployed using external databases and indexing services. However, modern data production rates, looming data movement costs, and the lack of metadata, entail revisiting the decoupled file system-data services design philosophy. In this article, we present TagIt, a scalable data management service framework aimed at scientific datasets, which can be integrated into prevalent distributed file system architectures. A key feature of TagIt is a scalable, distributed metadata indexing framework, which facilitates a flexible tagging capability to support data discovery. Furthermore, the tags can also be associated with an active operator, for pre-processing, filtering, or automatic metadata extraction, which we seamlessly offload to file servers in a load-aware fashion. We have integrated TagIt into two popular distributed file systems, i.e., GlusterFS and CephFS. Our evaluation demonstrates that TagIt can expedite data search operation by up to 10× over the extant decoupled approach.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Distribution System State Estimation With High Penetration of Demand Response Enabled Loads

Demand-side operations incentivize utility customers to take part in various grid services. A demand response enabled load (DREL) is a flexible grid asset that schedules electricity consumption in response to a time-of-use (TOU) energy price. Consequently, its energy profile differs from that of a conventional load that is insensitive to price. This difference may cause new challenges for distribution system state estimation (DSSE). It is well known that DSSE often needs to use pseudo-measurements based on historic load profiles to increase system observability. However, historic profiles of conventional loads are not representative of DREL behaviors. Additionally, the inaccuracy impacts DSSE results and other DSSE-dependent operations. In this paper, we propose an online pseudo-measurement generation approach for DSSE with DRELs. We formulate an optimization model to represent DRELs self-adjusting actions. Sampling-based stochastic optimization techniques are proposed to account for uncertainties in DRELs. A set of representative DREL behavior data corresponding to the samples are used to characterize DREL pseudo-measurements. Case studies with modified IEEE 123-bus test system verify the validity of the proposed work.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2026

redis-pvxs-ioc

redis-pvxs-ioc is a standalone PVAccess service for hot-reloadable, Redis-backed EPICS process variables (PV) defined by YAML. The core runtime is PVA-only. It does not load EPICS databases, call iocInit(), or serve Channel Access.

Steinkamp, Derek [Fermi National Accelerator Labor↗
DOE OSTI2026

A GPU-based compressible combustion solver for applications exhibiting disparate space and time scales

High-speed chemically active flows pose significant computational challenges due to their disparate space and time scales, with stiff chemistry often dominating simulation time. While modern scientific computing programs achieve exascale performance by leveraging graphics processing units (GPUs), existing GPU-based compressible combustion solvers face critical limitations in memory management, load balancing, and handling the highly localized nature of chemical reactions. To this end, we present a high-performance compressible reacting flow solver built on the AMReX framework and optimized for multi-GPU settings. Here, our approach addresses three GPU performance bottlenecks: memory access patterns through column-major storage optimization, computational workload variability via a bulk-sparse integration strategy for chemical kinetics, and multi-GPU load distribution for adaptive mesh refinement applications. The solver adapts existing matrix-based chemical kinetics formulations to multi-grid contexts. Using representative combustion applications, including 2D and 3D detonations and a 3D jet-in-crossflow configuration, we demonstrate 1.4–5× performance improvements over initial implementations on an in-house cluster of NVIDIA H100 GPUs, and near-ideal weak scaling on the Frontier supercomputer (Oak Ridge Leadership Computing Facility) with up to 1024 AMD Instinct MI250X GPUs. Roofline analysis reveals substantial improvements in arithmetic intensity for both convection (∼ 10 ×) and chemistry (∼ 4 ×) routines, confirming efficient utilization of GPU memory bandwidth and computational resources.

42 ENGINEERING↗
DOE OSTI2025

Solid State Additive Manufacturing of Oxide Dispersion Strengthened-FeCrAl Alloy Components for High-Temperature Supercritical CO2 Power Cycle Applications

In this research, material extrusion additive manufacturing (MEAM) has been explored as an SSAM method for fabrication of 3-D components using ODS-FeCrAl alloy. MEAM-printed 3-D parts go through a series of process steps, e.g., chemical treatment, thermal treatment etc. in order to create a high density fully metallic part. Final 3-D part quality is associated with various process steps, e.g., filament fabrication, print design, and thermal treatment optimization. In MEAM, a metal powder loaded filament is used for printing 3-D shapes. Composition of the filament is very important since it provides shape retention at low-to-medium temperature. There are a few commercially available metallic alloy filaments. However, FeCrAl alloy filaments are not commercially available. In this project, we came up with a method to fabricate high quality composite FeCrAl filaments that could be used for MEAM printing. Subsequently, we have optimized MEAM print methods to fabricate samples that are larger than 10 mm, by using a modular print design approach. Finally, we have been able to optimize the chemical and high temperature heat treatment steps to achieve very high density (>98%) in sintered MEAM-printed products.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Material Control & Accounting Modeling Developments for a Generic TRISO Fuel Fabrication Facility

The Material Protection, Accounting, and Control Technologies (MPACT) program utilizes modeling and simulation to assess Material Control and Accountability (MC&A) concerns for a variety of nuclear facilities. The Sandia National Laboratories (SNL)-developed Fissile Facility Flow Modeler (F3M) and the Material Accountancy Performance Indicator Toolkit (MAPIT) have historically provided MPACT with the capability to analyze MC&A approaches for nuclear facilities to determine that these facilities meet regulatory requirements. In FY25, improvements on the application of the F3M and MAPIT tools to simulate a generic TRi-structural ISOtropic (TRISO) fuel fabrication facility were successfully completed. The generic TRISO fuel fabrication F3M model captures the entire TRISO fuel fabrication process and is adaptable to any final TRISO fuel form, including spherical pebbles and cylindrical compacts loaded into graphite prismatic blocks. Comprehensive F3M/MAPIT functionality for the generic TRISO fuel fabrication model has been demonstrated. This modeling framework can be applied to support the U.S. Department of Energy and domestic nuclear industry stakeholders in developing MC&A approaches for advanced fuel fabrication facilities via statistical tests that demonstrate compliance to regulatory requirements.

97 MATHEMATICS AND COMPUTING↗