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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 181 records · Page 10

Comparing the effect of virtual and in-person instruction on students’ performance in a design for additive manufacturing learning activity

The goal of this work is to compare the outcome of a design for additive manufacturing (DfAM) heuristics lesson conducted in a virtual learning environment to the same in an in-person learning environment. Prior work revealed that receiving DfAM heuristics at different points in the design process impacts the quality and novelty of designs produced afterward, but this work may have been limited by the solely virtual format. In this work, an identical experiment was performed in a face-to-face learning environment. Results indicate that neither learning format presents an advantage over the other when it comes to the quality of designs produced during the intervention. Participants across all experimental groups reported an increase in self-efficacy after the intervention, with improved performance on quiz-type questions. Furthermore, the novelty and variety of the designs produced by the in-person experimental groups were significantly lower than that of the virtual experimental groups. In addition to validating the effectiveness of virtual instruction as a teaching method, these results also support the authors’ hypothesis that the priming effect is stronger in an in-person classroom than in a virtual classroom.

Design for additive manufacturing↗

Autonomous online optimization of a closed-circuit reverse osmosis system

As freshwater becomes increasingly scarce, many industrial and municipal water utilities look at premise-scale water treatment and reuse to meet water demand. Closed-circuit reverse osmosis (CCRO) has been proposed as a promising process design to do so. This sequencing batch process enables operation at higher brine salinity levels by means of a recycle flow. Optimal operation requires that the maximum salinity level at the membrane surface represents an optimal trade-off between brine disposal costs and energy efficiency. This maximum salinity level may change over time as the feed water composition changes and electricity markets fluctuate. In this article, we present the results of the experimental evaluation of an automatic technique for continuous online optimization, known as extremum seeking control. This technique has a long history in the process control community but has received little traction so far in the water industry. We modify this technique to enable its use for online optimization of CCRO, specifically to account for its sequential batch operation. We challenge the optimization schemes through several experimental tests and illustrate the advantages and drawbacks of extremum-seeking control.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Conceptual Fuel Element Design Candidates for Conversion of High Flux Isotope Reactor with Low-Enriched Uranium Silicide Dispersion Fuel

Engineering design studies are underway to assess the feasibility of converting the High Flux Isotope Reactor (HFIR) to operate with low-enriched uranium (LEU) silicide dispersion (U3Si2-Al) fuel. These studies are supported by the U.S. Department of Energy National Nuclear Security Administration’s Office of Material Management and Minimization. A systematic approach employing neutronic and thermal-hydraulic analyses have been performed with the ORNL Shift and HFIR Steady State Heat Transfer Code tools, respectively, to predict reactor performance and thermal safety margins for proposed LEU3Si2-Al fuel designs. The design process was initiated by generating an optimized design with fabrication features identified from previous studies that result in excellent performance and safety metrics. The approach continued by substituting a single fabrication feature anticipated to be difficult to manufacture with another feature expected to perform an analogous function to that of the removed feature. Four conceptual fuel element design candidates, with various fabrication features, for conversion of HFIR with 4.8 gU/cm3 LEU3Si2-Al fuel have been generated and shown to meet pre-defined performance and safety metrics. Results to date indicate that HFIR could convert with the subject fuel system and meet performance and safety requirements if, among other considerations, fabrication of the specific design features are demonstrated and qualification of the fuel is complete under HFIR-specific conditions.

Chandler, David↗

Power Converter Circuit Design Automation using Parallel Monte Carlo Tree Search

The tidal waves of modern electronic/electrical devices have led to increasing demands for ubiquitous application-specific power converters. A conventional manual design procedure of such power converters is computation- and labor-intensive, which involves selecting and connecting component devices, tuning component-wise parameters and control schemes, and iteratively evaluating and optimizing the design. To automate and speed up this design process, we propose an automatic framework that designs custom power converters from design specifications using Monte Carlo Tree Search. Specifically, the framework embraces the upper-confidence-bound-tree (UCT), a variant of Monte Carlo Tree Search, to automate topology space exploration with circuit design specification-encoded reward signals. Moreover, our UCT-based approach can exploit small offline data via the specially designed default policy and can run in parallel to accelerate topology space exploration. Further, it utilizes a hybrid circuit evaluation strategy to substantially reduce design evaluation costs. Empirically, we demonstrated that our framework could generate energy-efficient circuit topologies for various target voltage conversion ratios. Compared to existing automatic topology optimization strategies, the proposed method is much more computationally efficient --- the sequential version can generate topologies with the same quality while being up to 67% faster. Here, the parallelization schemes can further achieve high speedups compared to the sequential version.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Oxy-Combustion System Process Optimization

The overall objective of this work is to develop a new chemical absorbent-based, high pressure, CO 2 purification system to remove the residual oxygen that currently contaminates the recovered CO 2 , and to optimize the Pressurized Oxy-Combustion (POxC) process to minimize the Cost of Electricity (COE) generated in this advanced combustion process. TDA developed and validated the performance of the oxygen removal system for CO 2 purification. In collaboration with the Advanced Power & Energy Program (APEP) of University of California, Irvine (UCI), we optimized the POxC process, including thermal management, heat integration, and power cycle optimization using process design and modeling supported with Aspen Plus® process simulations. The techno-economic analysis results indicate that the pressurized oxycombustion coal power plant with Ion-transport membrane (ITM) air separation unit (ASU) (Case 2 – 30.55%) does not show an advantage over a cryogenic ASU (Case 1 – 31.24%) while TDA’s sorption-based ASU (Case 4 - 32.61%) shows a significant advantage over the cryogenic ASU (Case 1 – 331.24%). The specific plant costs show a wide range with a low of $2544/kW for Case 11C (TDA ASU, co-sequestering the SO x , and ultra-supercritical steam cycle) to a high of $2975/kW for Case 12A (cryogenic ASU and sCO 2 cycle). In general, the ITM ASU based cases have lower specific plant costs than the corresponding cryogenic ASU based cases while the TDA ASU based cases show the lowest specific plant costs. The main reason for lowering these costs is the higher overall plant thermal efficiency which decreases the plant cost on a $ per kW basis. Next comparing the cases with different power cycle working fluid conditions in terms of temperature and pressure while all utilizing steam, similar trends as the plant costs may be observed. However, with the supercritical CO 2 (sCO 2 ) cycle, the increase in thermal efficiency of the sCO 2 cycle was not able to offset its increase in plant cost making the plant costs higher than those of the corresponding steam cycle cases. The Cost of Electricity (COE) again shows similar trends as the specific plant costs. The COE for Case 11C at $110.1/MWh is also the lowest, but among all cases that do not co-sequester the SO x , Case 12C (TDA ASU and sCO 2 cycle) has the lowest COE at $\$$117.5/MWh while the highest is for Case 8A (cryogenic ASU and supercritical steam cycle) at $130.4/MWh.

20 FOSSIL-FUELED POWER PLANTS↗

Design and Performance Analysis of a Highly Efficient Polychromatic Full Stokes Polarization Modulator for the CRISP Imaging Spectrometer

We present the design and performance of a polychromatic polarization modulator for the CRisp Imaging SpectroPolarimeter (CRISP) Fabry–Perot tunable narrow-band imaging spectropolarimer at the Swedish 1 m Solar Telescope (SST). We discuss the design process in depth, compare two possible modulator designs through a tolerance analysis, and investigate thermal sensitivity of the selected design. The trade-offs and procedures described in this paper are generally applicable in the development of broadband polarization modulators. The modulator was built and has been operational since 2015. Its measured performance is close to optimal between 500 and 900 nm, and differences between the design and as-built modulator are largely understood. We show some example data, and briefly review scientific work that used data from SST/CRISP and this modulator.

42 ENGINEERING↗

LOTO Training Flow Simulator Design

The LOTO Training Flow Simulator Design poster discusses the intended purpose of the simulator along with the steps taken in the design process. It highlights the two main systems designed in the primary flow loop and the bubbler system, along with a brief description of the flow calculations made to ensure the functionality of the system.

42 - ENGINEERING↗

Multi-objective Bayesian alloy design using multi-task Gaussian processes

In design applications, correlations among material properties (such as the tendency for stronger materials to be less ductile) are often neglected. This approach is echoed in multi-objective optimization techniques which treat each performance characteristic as an independent objective, aiming to optimize scalar functions and find optimal Pareto fronts. However, this overlooks the statistical relationships between performance characteristics inherent in a material system. To address this, we propose the use of Bayesian optimization, a highly efficient black-box optimization algorithm known for constructing Gaussian processes (GPs) – uncorrelated surrogates - to model objective functions. Rather than evaluating multiple GPs for each objective function separately, we argue for a shift towards jointly modeling these objective functions, considering their statistical correlations. This integrated approach utilizes naturally occurring relationships among material properties, providing additional information to enhance the performance of the design framework. This requires the replacement of multiple independent GPs with a single multi-task GP, employing a correlation matrix to construct a multi-task kernel function, wherein each task corresponds to a single objective function. Here, we anticipate this refined methodology will better leverage material correlations, improving design optimization results.

36 MATERIALS SCIENCE↗

Cost of Using Laser Powder Bed Fusion to Fabricate a Molten Salt-to-Supercritial Carbon Dioxide Heat Exchanger for Concentrating Solar Power

Advances in manufacturing technologies and materials are crucial to the commercial deployment of energy technologies. We present the case of concentrating solar power (CSP) with molten salt (MS) thermal storage, where low-cost, high-efficiency heat exchangers (HXs) are needed to achieve cost competitiveness. Here, the materials required to tolerate the extreme operating conditions in CSP systems make it difficult or infeasible to produce them using conventional manufacturing processes. Although it is technically possible to produce HXs with adequate performance using additive manufacturing, specifically laser powder bed fusion (LPBF), here we assess whether doing so is cost-effective. We describe a process-based cost model (PBCM) to estimate the cost of fabricating a MS-to-supercritical carbon dioxide HX using LPBF. The PBCM is designed to identify modifications to designs, process choices, and manufacturing innovations that have the greatest effect on manufacturing cost. Our PBCM identified HX design and LPBF process modifications that reduced projected HX cost from $\$750$ per kilo-Watt thermal (kW-th) ($\$8$ /cm 3 ) to $\$350$ /kW-th ($\$6/$ cm 3 ) using currently available LPBF technology, and down to $\$220$ /kW-th ($\$4$ /cm 3 ) with improvements in LPBF technology that are likely to be achieved in the near term. The PBCM also informed a redesign of the HX design that reduced projected costs to $\$140$ –160/kW-th ($\$3$ /cm 3 ).

36 MATERIALS SCIENCE↗

Small Modular Reactor and Microreactor Security-by-Design Lessons Learned: Integrated PPS Designs

U.S. nuclear power facilities face increasing challenges in meeting dynamic security requirements caused by evolving and expanding threats while keeping costs reasonable to make nuclear energy competitive. The past approach has often included implementing security features after a facility has been designed and without attention to optimization, which can lead to cost overruns. Incorporating security into the design process can provide robust, cost-effective, and sufficient physical protection systems. The purpose of this report is to capture lessons learned by the Advanced Reactor Safeguards and Security (ARSS) program that may be beneficial for other advanced and small modular reactor (SMR) vendors to use when developing security systems and postures. This report will capture relevant information that can be used in the security-by-design (SeBD) process for SMR and microreactor vendors.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

LBNF CMGC Delivery Method: ICE Process

The Construction Manager/General Contractor (CM/GC) delivery method is intended to benefit the design process, value engineering, risk mitigation, and schedule optimization while promoting construction and design innovation. This delivery method is particularly suited for complex projects that require significant consideration of contractor means and methods. Fermilab’s Far Site Conventional Facilities proceeded with a CM/GC delivery method to account for the unique conditions of excavating over 300,000 cubic yards of rock in tunnels and caverns that will be constructed approximately 5000-ft deep in the repurposed Homestake Mine in Lead, SD. The experiences of the Independent Cost Estimating (ICE) process are presented.

Pelletier, Douglas↗

Designing a Magnetic Measurement Data Acquisition and Control System With Reuse in Mind: A Rotating Coil System Example

Accelerator magnet test facilities frequently need to measure different magnets on differently equipped test stands and with different instrumentation. Designing a modular and highly reusable system that combines flexibility built-in at the architectural level as well as on the component level addresses this need. Specification of the backbone of the system, with the interfaces and dataflow for software components and core hardware modules, serves as a basis for building such a system. The design process and implementation of an extensible magnetic measurement data acquisition and control system are described, including techniques for maximizing the reuse of software. The discussion is supported by showing the application of this methodology to constructing two dissimilar systems for rotating coil measurements, both based on the same architecture and sharing core hardware modules and many software components. The first system is for production testing 10 m long cryo-assemblies containing two MQXFA quadrupole magnets for the high-luminosity upgrade of the Large Hadron Collider and the second for testing IQC conventional quadrupole magnets in support of the accelerator system at Fermilab.

43 PARTICLE ACCELERATORS↗

Wood-to-Fuel Demonstration Project for California's Transportation Sector using Autothermal Pyrolysis (Non-Proprietary Summary Process Hazard Assessment)

Frontline has prioritized personnel safety, equipment preservation, and environmental protection throughout the design process of the autothermal pyrolysis unit. To facilitate a safe design, Frontline completed an informal hazards and operability (HAZOP) study and a formal HAZOP study, and employ management of change procedures. The result of these safety procedures is a plant that will function in a safe manner with a limited and acceptable amount of risk. Frontline took an approach it used in previous projects to execute a preliminary, internally facilitated hazards and operability (HAZOP) study. While this HAZOP study was performed without any subsequent change tracking, it enables a group of well-trained engineers to consider the safety implications of each part of the plant in a thorough and methodical manner. Frontline chose to bring in a pyrolysis consultant (Daren Daugaard of Burning Oak Energy) to participate in the review. Following the preliminary HAZOP and once the detailed design work was nearing completion, Frontline performed a formal HAZOP with a third-party facilitator, Jason Stittleburg of Novetus Engineering. Although the plant is not subject to process safety management (PSM) requirements, this formal HAZOP was performed in accordance with OSHA regulations deemed reasonable for PSM. Finally, after the formal HAZOP was conducted, Frontline maintained a safe system by implementing and following management of change procedures on each substantial change to the process. Frontline has kept a record of each subsequent change made to the formal HAZOP P&IDs. The process hazard assessment process allowed Frontline to find and correct several unacceptable configurations within the plant.

09 BIOMASS FUELS↗

Artificial Intelligence Designer of Materials and Processes for Advanced Power Generation

In this presentation, ‘deep-freeze’ graphs, ‘convoluted filtering’ networks, ‘mirror-image’ graphs, and adversarial ensemble methods are utilized to support inversion modeling for optimization of the complex compositions and complex processes in design of high-performing alloys, with their properties tailored to the energy application specifications.

Romanov, Vyacheslav↗

Bridging Python to Silicon: The SODA Toolchain

Systems performing scientific computing, data analysis, and machine learning tasks have a growing demand for application-specific accelerators that can provide high computational performance while meeting strict size and power requirements. However, the algorithms and applications that need to be accelerated are evolving at a rate that is incompatible with manual design processes based on hardware description languages. Agile hardware design tools based on compiler techniques can help by quickly producing an application-specific integrated circuit (ASIC) accelerator starting from a high-level algorithmic description. Here, we present the software-defined accelerator (SODA) synthesizer, a modular and open-source hardware compiler that provides automated end-to-end synthesis from high-level software frameworks to ASIC implementation, relying on multilevel representations to progressively lower and optimize the input code. Our approach does not require the application developer to write any register-transfer level code, and it is able to reach up to 364 giga floating point operations per second (GFLOPS)/W efficiency (32-bit precision) on typical convolutional neural network operators.

97 MATHEMATICS AND COMPUTING↗

Deep-Learning-Based Koopman Modeling for Online Control Synthesis of Nonlinear Power System Transient Dynamics

Power system stability and control have become more challenging due to the increasing uncertainty associated with renewable generation. Here, the performance of conventional control is highly driven by the physics-based offline-developed dynamic models that can deviate from the actual system characteristics under different operating conditions and/or configurations. Data-driven approaches based on online measurements can be a better solution to addressing these issues by capturing real-time operation conditions. This article describes a novel fully data-driven probabilistic framework to derive a linear representation of postcontingency grid dynamics and online prescribe control based on the derived model to enhance transient stability. The complex nonlinear power system dynamics is approximated by a linear model by using multiple neural network modules that infer distributions of the observations and introducing a Koopman layer to sample possible Koopman linear models from the inferred distributions. The trained model features linearity that can be easily incorporated into the existing linear control design paradigm and ease the controller design process. The effectiveness of Koopman-based control designs is validated through comparative case studies, which demonstrate increased prediction accuracy and control performance when applied to a power system with heterogeneous generator dynamics.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Recovery of High Purity Rare Earth Elements (REE) from Coal Ash via a Novel Electrowinning Process (Final Report)

The goal of this project was to produce a high purity, separated (>90%) rare earth oxide (REO) product from coal-based sources. This product was achieved using the following three steps: 1. Battelle’s ADP: The ADP process involves pretreatment of ash (milling and caustic leaching), leaching of pretreated ash with nitric acid, roasting of loaded acid solution containing REE, and water leaching of residual from roasting step, resulting in a REE pregnant solution. 2. Solvent Extraction (SX) Upgrading: The SX involves the extraction of REE from a pregnant REE solution using an organic extractant (note after extraction, the aqueous phase was a residual solution and the organic phase contained REE), and stripping of REE from the organic phase product obtained from the extraction using an acid solution (the stripped solution was the final purified product containing REE, organic traces, and traces of other metals for further separation in the electrowinning process). 3. Rare Earth Salts’ (RES) Electrochemical Separation and Purification Process: The staged electrochemical process was separated REO products from the mixed REE solution. Testing by RES was also included in the investigation of options to minimize the solvent extraction steps. This report covers laboratory testing, production of a high purity coal-based REO, process design of the overall REE recovery and purification process, technoeconomic assessment (TEA), and a commercialization plan discussing the overall REE recovery and purification process.

01 COAL, LIGNITE, AND PEAT↗