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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.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Thermal Stress Modeling and Analysis of Packed-bed Thermocline Energy Storage Tank for INL Thermal Energy Distribution System (TEDS)

The Thermal Energy Distribution System (TEDS) at Idaho National Laboratory (INL) is a thermal-hydraulic flow loop to support the integration of co-located multiple experimental systems, where a packed-bed thermal energy storage (TES) is installed as a thermal buffer and storage unit for TEDS. The packed-bed TES is adopted in TEDS because of its benefit as a low-cost single-tank storage option compared to the traditional two-tank storage. However, thermal ratcheting is one potential design concern which is caused by the rearrangement of granular filler inside a packed-bed tank during continuous thermal cycling operation of the packed-bed TES tank. If the thermally induced stress exceeds yield strength of the tank wall, it may cause catastrophic consequences like rupture of the thermal storage tank. Thus, it is crucial to understand the phenomenon to ensure the robust operation. Based on the temperature boundary conditions given by transient thermal analyses with computational fluid dynamics (CFD) simulations, the thermal ratcheting analysis is then conducted to evaluate the hoop stress and resultant thermal ratcheting potential of the TES tanks with two different modeling approaches: (1) infinite rigidity model and (2) Drucker-Prager (DP) model. The validity of each modeling method was examined by comparing the numerical simulation with the experimental data obtained from the packed-bed TES tank for Solar One Plant and evaluate the thermal ratcheting potential of the TEDS TES tank.

25 ENERGY STORAGE↗
DOE OSTI2024

Development of Supervisory Control System for Thermal Energy Distribution System

The integrated energy system (IES) refers to the combination of nuclear energy generation with other energy sources to enable the efficiency and reliability of power generations. To create technologically viable and economically competitive systems, supervisory control strategies are critical for optimizing performance and ensuring stability across different energy generation, transportation, and utilization. This work focuses on the control strategies for the thermal energy distribution system (TEDS), which is a cornerstone of the Dynamic Energy Transport and Integration Laboratory at Idaho National Laboratory. TEDS currently relies on operators to coordinate across different components to manage energy storage and ensure efficiency. This work demonstrates the use of model predictive control (MPC) with surrogate models in determining optimal setpoints for major TEDS components. The capability of MPC-based supervisory control system is evaluated by autonomously matching the power outputs from a Dymola-based TEDS with target heat demands.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Thermal Energy Distribution System (TEDS) Startup

The thermal energy distribution system was started to demonstrate preliminary system operability. Some construction and warranty repairs remain before the system can be fully tested and certified for operation.

25 ENERGY STORAGE↗
DOE OSTI2022

Dynamical System Scaling of a Thermocline Thermal Storage System in the Thermal Energy Distribution System (TEDS) Facility

The purpose of this study was to develop a process to convert input signals from one facility into another by reflecting geometric and environmental settings. The Dynamic Energy Transport and Integration Laboratory (DETAIL) is one facility in development that aims to emulate the daily interactions among power production industry systems and be capable of receiving real-time data from those systems as inputs. To convert signals and ensure that the temporal sequences and magnitudes reflect the laboratory settings, the ability to scale and project data is essential. To demonstrate this ability, Dynamical System Scaling (a methodology that enables systems to scale and project or extrapolate datasets to desired environments while conserving the observed transient behavior based on first principles) was applied to DETAIL’s thermocline thermal storage system in the Thermal Energy Distribution System. The thermocline system was successfully scaled and a test case was conducted to generate a doubly accelerated energy charge and discharge in reference to past experimental data from the facility. The accelerated data were determined as able to conserve the amount of energy stored and the associated test boundary conditions were charge line maximum temperature, charge line velocity, and thermocline maximum temperature at 354 °C, 0.458 m/s, and 418 °C, respectively. The research results represented a case that required signals to be accelerated without altering the stored energy.

Yoshiura, Ramon (ORCID:0000000319781313)↗
DOE OSTI2022

Thermal Modeling and Simulation of the Packed-bed Thermal Energy Storage Combined with INL Thermal Energy Distribution System

Dynamic Energy Transport and Integration Lab (DETAIL) at Idaho National Laboratory is to support experimental demonstration and validation research on Nuclear-Renewable Hybrid Energy System [1]. The Thermal Energy Distribution System (TEDS) is a thermal-hydraulic flow loop in DETAIL with its own dedicated control system to support the integration of co-located multiple experimental systems, where a packed-bed thermal energy storage (TES) is installed as a thermal buffer and storage unit. Among various TES options, the packed-bed TES is adopted in TEDS because it offers a low-cost single-tank thermal storage option compared to the traditional two-tank TES. However, since the TES tank is filled with granular fillers having different thermophysical properties from those of TES tank wall, there is a potential thermo-mechanical issue to be carefully addressed like thermal ratcheting which may pose a significant design concern for the packed-bed TES tank. Thermal ratcheting is a thermomechanical process caused by the repeated rearrangement of granular filler inside a TES tank during continuous thermal cycling operation of the packed-bed TES system. If the thermally induced stress exceeds the yield strength of a TES tank wall, catastrophic consequences may happen like rupture of the TES tank. Thus, it is important to understand the phenomenon to ensure the robust operation of the packed-bed TES tank. Given that thermal ratcheting is caused by complex interaction of thermal transport in the porous bed and solid mechanics, the accurate prediction of transient thermal behavior of the packed-bed TES tank, which is the focus of this paper, is critical to the reliable thermal ratcheting analysis. This paper discusses the numerical modeling, simulation, and validation studies that are ongoing at INL to investigate the transient thermal behavior of the packed-bed TES. Of particular concern is the transient thermal process occurring in the packed-bed TES unit that is operated in conjunction with the INL TEDS. The main goal of this research is three-fold: (i) provide preliminary insights into the transient thermal behavior of the TEDS TES tank, (ii) support the thermal measurement and validation plan for TEDS experiment, and (iii) provide transient thermal boundary conditions to support the reliable thermal ratcheting analysis of the TEDS TES tank. For the transient thermal modeling and analysis, a CFD model was developed, and the validity of the modeling approach was examined via comparing the numerical simulation results with the experimental data obtained from various design characteristics of packed-bed TES tanks. Then, the present modeling method was applied for the transient thermal analysis of the TEDS TES tank, and the results are discussed along with the potential improvement of data acquisition strategy for the future TEDS experiments for more precise validation study.

25 ENERGY STORAGE↗
DOE OSTI2023

Thermal Energy Distribution System (TEDS) Operating Modes and Control Strategies

A Thermal Energy Delivery System was constructed at the Idaho National Laboratory for demonstrating distribution of thermal energy to and from co-located systems sited in the INL Dynamic Energy Transport and Integration Laboratory (DETAIL). DETAIL includes a flow loop simulating a pressurized water reactor, a high-temperature steam electrolysis unit and a thermal energy storage system. This report discusses the various operating modes and control strategies for enabling simultaneous, flexible and efficient transfer of heat from thermal energy sources to end users.

25 ENERGY STORAGE↗
DOE OSTI2025

Uncertainty quantification of a physics-informed model based on sparse identification of a Thermal Energy Distribution System

Integrated energy systems (IES)s are crucial for enhancing the economy and efficiency of power generation sources (e.g., nuclear energy) necessary to unleash American energy dominance. These systems can be integrated with thermal energy storage (TES) and intermittent renewable energies to optimize overall energy use, peak-load regulation, and demand-side responses. However, the stabilization of energy generation, transport, and utilization introduces operational complexities that exceed the challenges of managing each sub-component individually. Currently, though IESs rely on human operators for efficiency and stability, reducing human error risk and enhancing performance through automation is highly desirable. Recent advances at Idaho National Laboratory have demonstrated successful control of the Thermal Energy Distributed System (TEDS). However, the automatic control system depends on a deterministic Sparse Identification of Nonlinear Dynamics with Control (SINDyC) model, which are trained based on simulation data from physics-based simulations. Because of uncertainties in physics-based simulation, SINDyC model results in large discrepancies against experimental data and cannot be reliably used in automatic control. In this paper, we present an innovative approach to address these discrepancies by quantifying uncertainties and developing a more robust model. We first generated trajectories by using first-principles physics codes to encapsulate the experiment. Next, we trained thousands of models by randomly sampling these trajectories. We then collapsed all those models into one probabilistic SINDyC by fitting a multivariate Gaussian distribution onto the resulting coefficient’s distribution. Despite its simplicity, our approach successfully produced 95% confidence intervals that captured the experimental trajectories. It even did so with a higher probability and better U-pooling score across six of the seven relevant quantities of interest (QoIs), as compared to other classical approaches. In conclusion, ongoing research is focusing on generating new experimental trajectories to validate this approach, and on employing Bayesian calibration to refine parametric uncertainties and guide future model development efforts.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Modifications to the Thermal Energy Distribution System (TEDS)

INL installed a new controls system and a flame detection system on TEDS as part of upgrades that will eventually allow unattended operation and integration with accessory systems, such as digital twins, or facilities in other locations. These upgrades resolve some corrective actions that came about when oil was spilled from a high-point vent during system startup testing.

42 ENGINEERING↗
DOE OSTI2022

Thermal Ratcheting Analysis of TEDS Packed-bed Thermocline Energy Storage Tank - Modeling Methodology and Data Validation

This report investigates numerical modeling methods for thermal ratcheting analysis of packed-bed thermal energy storage (TES) tank and discusses the validation results via comparison with experimental data. The experimental data obtained from various design characteristics of packed-bed thermocline tanks, including the Thermal Energy Distribution System (TEDS) TES tank at Idaho National Laboratory (INL), were used to validate thermal and mechanical models developed in this study to evaluate the thermal ratcheting potential. The thermal model was shown to predict the transient thermal propagation through the packed-bed thermocline tanks generally well. However, a larger discrepancy was observed during the comparison with the data from TEDS, presumably due to the uncertainty of boundary conditions given from the experiment. Based on the comparative study between the thermal model predictions and experimental data of various packed-bed thermocline tanks, potential improvements were suggested for the future TEDS experiments for more precise validation study. For mechanical (thermally induced stress) analysis, two different modeling approaches were tested to evaluate hoop stress applied to the packed-bed TES tank wall, which is a major cause of thermal ratcheting process: (i) infinite rigidity model and (ii) Drucker-Prager (DP) model. The ‘model (i)’ is a conservative method with infinite rigidity assumption of granular filler inside a TES tank, whereas the ‘model (ii)’ is a method that takes into account more realistic processes such as thermal expansion of filler and tank wall as well as inter-particle interactions during the cyclic operation of a packed-bed TES tank. The validity of each modeling method was examined by comparing the numerical simulation with the experimental data obtained from the packed-bed TES tank for Solar One pilot plant. Then, the effects of various model parameters were discussed to evaluate the thermal ratcheting potential of the TEDS TES tank. The preliminary thermal ratcheting analysis implies that the TEDS TES tank will hold its structural integrity during the normal operation cycles.

25 ENERGY STORAGE↗
DOE OSTI2022

DETAIL Component Scaling and Methodology Comparison

The purpose of this study was to develop a process to convert input signals from one facility into another by reflecting geometric and environmental settings. The Dynamic Energy Transport and Integration Laboratory (DETAIL) is a research facility in development. Its aim is to emulate the daily interactions among power production industry systems and receive real-time data from those systems as inputs. To convert signals and ensure that the temporal sequences and magnitudes reflect laboratory settings, the ability to scale and project data is essential. To demonstrate this ability, Dynamical System Scaling (DSS) and Hierarchical Two-Tiered Scaling (H2TS) (methodologies that enable systems to scale and project or extrapolate data sets to desired environments while conserving the observed behavior based on first principles) were applied to DETAIL’s thermocline thermal storage system in the Thermal Energy Distribution System (TEDS) facility and solid-oxide electrolysis cell in the High Temperature Hydrogen Electrolysis (HTHE) facility. Both thermocline and electrolysis cell systems were successfully scaled, and test cases were conducted to generate a doubly accelerated energy charge and discharge in reference to past experimental data from the facilities. The research results represented a case for the thermocline system that required signals to be accelerated without altering the stored energy. To enhance the quality of the accelerated data, error propagation analyses were conducted on DSS post-processing terms to determine the consequences of raw-data-associated errors.

08 HYDROGEN↗
DOE OSTI2022

HYBRID Modeling of DETAIL Experimental Facility

Idaho National Laboratory continues to be at the forefront of advanced reactor systems and integrated energy systems research. Through the Thermal Energy Distribution System (TEDS) and Microreactor Agile Non-nuclear Test Bed (MAGNET) experiments in the Dynamic Energy Transport and Innovation Laboratory (DETAIL) within the Engineering Systems Laboratory, a mix of digital and physical testing systems can explore the operation of thermally and electrically integrated systems. Modeling of these systems has been done using the HYBRID modeling repository of the Integrated Energy Systems program. DETAIL also contains high temperature steam electrolysis (HTSE) units to produce hydrogen and generate the load imposed on MAGNET and TEDS. The dynamic modeling capabilities within the IES program describe the DETAIL components as-built and can be used to evaluate controls, process flows, and overall system conditions.

08 HYDROGEN↗
DOE OSTI2023

Engineering-Scale Integrated Energy System Data Projection Demonstration via the Dynamic Energy Transport and Integration Laboratory

The objective of this study is to demonstrate and validate the Dynamic Energy Transport and Integration Laboratory (DETAIL) preliminary scaling analysis using Modelica language system-code Dymola. The DETAIL preliminary scaling analysis includes a multisystem integral scaling package between thermal-storage and hydrogen-electrolysis systems. To construct the system of scaled equations, dynamical system scaling (DSS) was applied to all governing laws and closure relations associated with the selected integral system. The existing Dymola thermal-energy distribution system (TEDS) facility and high-temperature steam electrolysis (HTSE) facility models in the Idaho National Laboratory HYBRID repository were used to simulate a test case and a corresponding scaled case for integrated system HYBRID demonstration and validation. The DSS projected data based on the test-case simulations and determined scaling ratios were generated and compared with scaled case simulations. The preliminary scaling analysis performance was evaluated, and scaling distortions were investigated based on data magnitude, sequence, and similarity. The results indicated a necessity to change the normalization method for thermal storage generating optimal operating conditions of 261 kW power and mass flow rate of 6.42 kg/s and the possibility of reselecting governing laws for hydrogen electrolysis to improve scaling predictive properties. To enhance system-scaling similarity for TEDS and HTSE, the requirement for scaling validation via physical-facility demonstration was identified.

08 HYDROGEN↗
DOE OSTI2023

Validation and Verification of TEDS Facility HYBRID Modeling

The HYBRID modeling repository is an in-house developed library of models for selected integrated energy systems (IES) modelling. HYBRID models have been developed since 2015 to describe the physical operation of tightly coupled thermal systems including power generators, thermal transport systems, thermal storage, thermal-to-electric conversion systems, and other thermal applications. Here, validation and verification (V&V) capabilities are demonstrated using the Thermal Energy Distribution System (TEDS) at INL. Building upon prior work, the TEDS model has been updated and verified so that it better represents the installed system configuration and the operating control system. The model control system was changed to allow replication of actual experimental procedures. Experimental operations focusing primarily on thermocline tank performance were devised and performed. Several anomalies were found in the operation data of the experiment facility. V&V activities calibrating a selected input parameter are demonstrated on a single component as well as with a single parameter within the thermocline. Calibrating is then demonstrated on multiple components and a multi-parameter metric for the entire system. The validation methodology is successfully applied to validate the model with experimental data. It is also used to confirm a hypothesis behind one of the anomalies in experimental performance.

25 ENERGY STORAGE↗
DOE OSTI2023

Data Projection of the High Temperature Electrolysis System in the Dynamic Energy Transport and Integration Laboratory using Dynamic System Scaling

For nuclear power to be flexible in a functioning Integrated Energy System (IES), excess produced heat must be stored or utilized during times of low power demand to ensure a load factor of 1 while load balancing. The Dynamic Energy Transport and Integration Laboratory (DETAIL) is one facility that is under development to emulate IES conditions on the engineering-scale, planned to conduct virtual real time operations with industry-scale facilities, and is currently testing thermal storage and high temperature electrolysis. As part of the study to develop a method to preprocess input signals or postprocess output signals between systems of different scales via Dynamical System Scaling (DSS), the current research is one of the continued efforts branching from the data projection activity conducted for the Thermal Energy Distribution System and currently engages the High Temperature Electrolysis (HTE) System in DETAIL. The HTE SOEC electrical, fluid, and thermal dynamics Figure of Merits (FOM) were identified, governing equations and closure relations were successfully scaled, and relations between FOM scaling ratios were determined. Setting the scaling objectives to reform existing data to project a data set that doubly accelerated the electrolysis process while preserving the produced amount of hydrogen was generated for the full transient. The calculated boundary conditions were inlet temperature, stack current, and inlet steam mass flow rate at 1470 K, 121.1 A, and 1.886 g/s, respectively. The research outcomes demonstrated an output signal postprocessing case accelerating the hydrogen production without changing geometry, number of cells, and partial pressures.

08 HYDROGEN↗
DOE OSTI2023

Thermal Integration of DETAIL Systems

A thermal connection between the Microreactor AGile Non-nuclear Experimental Testbed (MAGNET) and the thermal energy distribution system (TEDS) has been a key part of the Dynamic Energy Transport and Integration Laboratory (DETAIL) plan since the development of the Integrated Energy Systems Roadmap in 2020. This connection provides an expanding demonstration capability for integrated system operations. The thermal connection between MAGNET and TEDS required the selection of a heat exchanger and valves to isolate flow. Research staff within the NEET Crosscutting Technology Development program selected equipment after receiving proposals from multiple vendors. A helical coil heat exchanger from Graham Corporation was selected for its small volume relative to its heat transfer surface area to fit in the limited space available. Triple offset butterfly valves with pneumatic actuators from Flowserve were selected to isolate and/or control flow of the hot gas through the heat exchanger. Staff from Idaho National Laboratory’s (INL) Facilities and Site Services Engineering department designed the piping and structural support. A mechanical construction firm was contracted to install the system. This report documents the design and construction of this thermal connection.

25 ENERGY STORAGE↗
DOE OSTI2024

Performance Validation of a Thermally Integrated 50 kW High Temperature Electrolyzer System

In the proposed project, INL and OxEon seek to improve the value proposition of hydrogen production by integrating reversible fuel cell operations at relatively small scale for distributed energy applications. This goal will be accomplished by converting a 50 kW solid oxide electrolysis cell or SOEC system into a reversible system that operates at 30 kW in electrolysis mode and approximately 10 kW in fuel cell mode. The reversible SOC system will be operated for over 3,000 hours using an improved catalyst in the fuel electrode. Steam for the electrolysis will come from an electric boiler Thermal Energy Distribution System that will be configured to mimic an industrial source of low-grade heat. Thermodynamic analysis will be performed to demonstrate the potential of the system to achieve >85% system efficiency in electrolysis mode. Finally, a technoeconomic analysis will be completed to show potential to produce hydrogen at a cost of $2/kg. The figure at the right indicates a target cost breakdown to achieve that goal.

08 HYDROGEN↗