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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 199 records · Page 11

Control and Grid Support Function Evaluation for a Three-Phase Back-to-Back Modular Multilevel Converter System

This paper focuses on the evaluation of advanced inverter controls for a 500kW back-to-back (B2B), silicon carbide, multilevel modular converter (MMC) used as a direct-connected medium-voltage grid intertie. A decentralized hierarchical controller architecture for the MMC system is presented, which uses the main controller to implement higher level grid interconnection functions per the IEEE 1547–2018 standards and the local controllers to execute lower level closed-loop functionality of the MMC stages. This paper presents and elaborates on the grid functionalities are elaborated and presented. The back-to-back converter system is equipped with local controllers and their corresponding functionalities are presented. Case study results for the corresponding functionalities presented show the effectiveness of the proposed architecture. To enhance the operation capabilities of the system, a parameter update scheme has been implemented and utilized in unison with the controller.

decentralized control↗

Describing Function Analysis of Transformer Magnetizing Inductance for Direct Power Control of Back-to-Back Modular Multilevel Converters with Advanced Grid Support

This paper provides a detailed investigation into the application of describing function-based analysis for assessing transformer magnetizing inductance and its impact on system performance. The focus is on a back-to-back modular multilevel converter architecture, designed to interconnect systems operating at different frequencies. The study explores the implementation of a Direct Power Control strategy, examining its effects on transformer magnetizing inductance saturation and offering effective mitigation techniques. Furthermore, the integration of advanced grid support functionalities is highlighted, demonstrating how these enhancements bolster the converter's ability to improve grid stability and power quality, positioning it as a robust solution for modern power systems. The proposed approach is validated through extensive computer simulations based MAT LAB/Simulink domain, supported by significant case study results, confirming its practical effectiveness.

back-to-back modular multilevel converters (B2B- M↗

Analysis of Transformer Magnetizing Reactance Using Describing Function in Direct Power Control of Back-to-Back Modular Multilevel Converter with Advanced Grid Support

This paper presents a Port Controlled Hamiltonian based direct power control architecture for a back-to-back modular multilevel converter system connecting two ac sources at different frequencies. The system features advanced grid support functionalities based on IEEE 1547-2018, implemented on the inverter side. The rectifier side controller ensures reference following for active and/or reactive powers and maintains the commanded dc bus voltage. The inverter side controller ensures power command following for active and reactive powers.The proposed control architecture is designed to suppress second harmonic oscillations in powers during unbalanced grid voltage sags by dynamically adjusting the currents on each ac side. This also ensures effective elimination of any second harmonic oscillations in the equivalent dc bus voltage. Validation is performed on an OPAL-RT real-time platform with case studies on unbalanced and balanced sags, demonstrating the controller's effectiveness during real time implementation. A reduced-scale laboratory prototype further verifies these case studies, with experimental results for balanced sags due to grid simulator limitations. The results confirm the robustness and efficiency of the proposed control strategy in ensuring stable and reliable operation under various grid conditions.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Multiscale Electrothermal Design of a Modular Multilevel Converter for Medium-Voltage Grid-Tied Applications

As a key feature of modular multilevel converters (MMCs), a large number of semiconductor devices are employed in the converter and distributed over a stack of submodules. Each submodule has a strict temperature limit that imposes constraints on the operating range of the converter. Different loading conditions/losses in the submodules lead to unavoidable temperature variations inside the MMC, which consequently affect the system-level performance and reliability. This paper is focused on the electrothermal analysis and design of a medium-voltage silicon carbide (SiC)-based MMC system, from submodule power semiconductors to the overall MMC system integration of multiple submodules, for grid-connected applications. Loss calculations are performed to estimate the cooling requirements and aid thermal design at different levels. The performance of a forced-air cooling approach is analyzed within a numerical modeling framework. Maximum temperature of the SiC power modules is predicted using numerical tools. Thermal design of the MMC cabinet with various arrangements of air inlet(s) and outlet(s) is investigated and compared from a cooling performance perspective. A fully resolved model of the arrangement that yields optimal results is developed to accurately predict the temperature profile of the essential components in the submodules.

computational fluid dynamics↗

A Novel Voltage Balancing Control With dv/dt Reduction for 10-kV SiC MOSFET-Based Medium Voltage Modular Multilevel Converter

Using high voltage (HV) silicon carbide (SiC) power semiconductors in a modular multilevel converter (MMC) is promising because it results in fewer submodules and lower switching loss compared to conventional Si based solutions. The nearest level pulsewidth modulation (NL-PWM) is commonly used in the MMC for medium voltage applications. However, with the NL-PWM and existing voltage balancing control, there are many submodules that switch their modes in a control cycle, resulting in a high dv/dt during the deadtime of the power semiconductor, which could be multiple times of the dv/dt of the single device. This poses great challenges on the noise immunity and insulation design in the MMC using HV SiC devices, which have very fast switching speed. A novel voltage balancing control, which ensures only two submodules switch their modes in a control cycle, is proposed in this article, limiting the maximum dv/dt to the dv/dt of a single power semiconductor and also maintaining the voltage balance performance. Furthermore, the proposed voltage balancing control is experimentally validated in a 10-kV SiC mosfet based MMC with four submodules per arm.

42 ENGINEERING↗

Capacitor Voltage Ripple Estimation and Optimal Sizing of Modular Multi-Level Converters for Variable-Speed Drives

This article deals with the sizing of submodule capacitors for modular multilevel converters (MMCs) used for variable speed drives for medium voltage and high voltage electric machines. Variable speed drives are required to run over a wide frequency range from zero to a few hundred Hz or even over 1 kHz. Under low frequency operation (<30 Hz), a large current ripple flowing through the MMC submodule capacitors will cause significant capacitor voltage fluctuation. This article proposes an optimal submodule capacitor selection method based on the common-mode voltage injection. The proposed sizing model includes two functions: 1) accurately estimating the capacitor voltage ripple based on the drive system parameters; and 2) identifying the minimum capacitance of the submodule capacitors based on the allowed maximum capacitor voltage fluctuations. Simulation and experimental results show that the error between the actual and estimated values of the voltage fluctuation is within 3% using the proposed model.

42 ENGINEERING↗

Modular Multilevel Converter (MMC) Modeling Considering Submodule Voltage Sensor Noise

The modular multilevel converter (MMC) is a popular topology in medium- and high-voltage applications, and many efforts have been spent on MMC modeling. However, the impact of submodule voltage sensor noise (SVSN), which becomes more severe due to increasing switching speed of power semiconductors and compact submodule design, has not been considered in conventional models. In this letter, the SVSN is introduced by coupling capacitances between the sensor and power stage in an MMC switching model. Furthermore, the SVSN impact is considered in an MMC average model based on derivation of the relationship between the SVSN and the duty cycle. Here, the proposed MMC switching model and average model considering the SVSN are validated by comparing simulations with experimental results in an MMC prototype using 10-kV SiC MOSFETS.

47 OTHER INSTRUMENTATION↗

Modeling and ZVS Operation of the Isolated Modular Multilevel DC–DC Converter With a Unified Trapezoidal Wave Modulation

Here, this article introduces a unified trapezoidal wave (UTW) modulation scheme for the isolated modular multilevel dc–dc (IM2dc) converter, which consolidates multiple existing modulation strategies for the IM2dc converter, including the quasi-square wave (QSW) modulation, trapezoidal wave modulation, and sinusoidal wave modulation, into a unified framework. Furthermore, this article introduces the harmonic state-space (HSS) equations to model the IM2dc converter based on the UTW modulation method. The HSS model operates in the frequency domain, enabling it to circumvent the complexities associated with time-domain analysis and seamlessly integrate with the UTW modulation. This article proceeds to analyze the real and reactive power transfer characteristics of the IM2dc converter, as well as the power factor, considering the influence of multiple modulation parameters. Subsequently, it delves into the examination of zero voltage switching (ZVS) conditions for the IM2dc converter based on the UTW modulation and the HSS model. The complete ZVS boundaries of the IM2dc converter, taking various voltage ratios into account, are derived. This article also illustrates the effects of including harmonic orders in the modeling process, modulation parameters, and internal harmonic ripples on the ZVS boundaries. Finally, experimental validation of the analyses is conducted on a down-scaled prototype.

42 ENGINEERING↗

Modular Power Electronics Approach for High Power Dynamic Wireless Charging System

Dynamic wireless power transfer (DWPT) can provide energy to EVs in motion and extend the drive range. Upscaling the charging power to 200 kW (High Power DWPT) reduces the percentage of electrified roadway required, and the solution becomes cost-effective. To smooth the power at the battery and grid, a secondary regulation stage must be added. The DWPT system therefore relies on power electronics to interface with the coils and regulate the power flow. Designing this high power system using wide bandgap devices makes ensuring high efficiency, small size, and reliable operation very challenging, and significant engineering effort is required to build such complicated systems for large-scale installation and deployment. Here, this paper describes a modular design approach for the power electronics to achieve the 200 kW wireless power transfer. As described, the SiC power electronics building block is designed, simulated, and characterized. The approach is validated in the DWPT system to build the inverter, the rectifier, and the DC/DC converter, which demonstrated high performance and reliable operation with 188 kW power.

42 ENGINEERING↗

Hardware Design of Medium Voltage SiC-Based Modular Multilevel Converters for Grid-Tied Applications

This paper presents a design of a 10 kV silicon carbide (SiC) MOSFET based modular multilevel converter (MMC). The MMC functions as the interconnection between a 24 kV dc bus and a 13. SkV distribution grid. This paper focuses on the hardware design of the MMC and its submodules. The gate driver, auxiliary power supply and bus bur in submodules are major components that need to meet high dv/dt immunity and high insulation voltage requirements. The gate driver achieves over 200 kV/us common mode transient immunity (CMTI). Its associated auxiliary power supply is based on an on-board transformer with over 30 kV insulation capability and 1.4 pF barrier capacitance. The busbar achieves less than 11 kV/cm electric field in the air to avoid partial discharges. Validation tests of the MMC submodule were performed by double pulse tests at 5 kV and buck converter tests at3 kV, 52A (peak). Reliable operations were achieved in validation tests.

auxiliary power supply↗

Coupled Heat Power Operation of Smart Buildings via Modular Pumped Hydro Storage

In the United States, building sector is responsible for around 40% of total energy consumption and contributes about 40% of carbon emissions since 2012. Within the past several years, various optimization models and control strategies have been studied to improve buildings’ energy efficiency and reduce operational expenses under the constraints of satisfying occupants’ comfort requirements. However, the majority of these studies consider building electricity demand and thermal load being satisfied by unidirectional electricity flow from the power grid or on-site renewable energy generation to electrical and thermal home appliances. Opportunities for leveraging low-grade heat for electricity have largely been overlooked due to impracticality at small scale. In 2016, a modular pumped hydro storage technology was invented in Oak Ridge National Laboratory, named Ground Level Integrated Diverse Energy Storage (GLIDES). In GLIDES, employing high-efficiency hydraulic machinery instead of gas compressor/turbine, liquid is pumped to compress gas inside high-pressure vessel creating head on ground level. This unique design eliminates the geographical limitation associated with the existing state-of-the-art energy storage technologies. It is easy to be scaled for building level, community level, and grid level applications. By using this novel hydro-pneumatic storage technology, opportunities for leveraging low-grade heat in building can be economical. In this research, the potential of utilizing low-grade thermal energy to augment electricity generation of GLIDES is investigated. Since GLIDES relies on gas expansion in the discharge process and the gas temperature drops during this non-isothermal process, available thermal energy, e.g., from thermal storage, combined cooling, heat and power system (CCHP), can be utilized by GLIDES to counter the cooling effect of the expansion process and elevate the gas temperature and pressure and boost the roundtrip efficiency. Here, several groups of comparison experiments have been conducted, and the experimental results show that a maximum 12.9% cost saving could be achieved with unlimited heat source for GLIDES, and a moderate 3.8% cost improvement can be expected when operated coordinately with CCHP and thermal energy storage in a smart building.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Automotive Silicon Carbide Power Module Cooling With A Novel Modular Manifold And Embedded Heat Sink

The next generation of integrated power electronics packages will implement wide-bandgap devices with ultrahigh device heat fluxes. Although jet impingement has received attention for power electronics thermal management, it is not used in commercial electric vehicles (EVs) because of the associated pressure drop and reliability concerns. Here, in this paper, we present a modular thermal management system designed for automotive power electronics. The system achieves superior thermal performance to benchmarked EVs, while adhering to reliability standards and with low pumping power. The system utilizes a low-cost and lightweight plastic manifold to generate jets over an optimized heat sink, which is embedded in the direct-bonded-copper (DBC) substrate. The embedded heat sink concept leverages additive manufacturing to add elliptical pin fins to the DBC substrate. The heat sink geometry is optimized for submerged jet impingement using a unit-cell model and an exhaustive search algorithm. The model predictions are validated using unit-cell experiments. A full-scale power module model is then used to compare the DBC-embedded heat sink against direct DBC cooling and baseplate-integrated heat sinks for single-sided (SS) and double-sided (DS) cooling concepts. Using the SS and DS DBC-embedded cooling concepts, the models predict a thermal resistance that represents a reduction of 75% and 85% compared to the 2015 BMW i3, respectively, for the same water-ethylene glycol inverter flow rate. We have shown that an inverter with a 100-kilo-Watt-per-liter power density is achievable with the proposed design.

33 ADVANCED PROPULSION SYSTEMS↗

Development of Principal Design Criteria of the Fast Modular Reactor

General Atomics Electromagnetic Systems (GA-EMS) is developing a 50-megawatt electric (MWe) helium-cooled Fast Modular Reactor (FMR). The project has been selected by the U.S. Department of Energy (DOE) for Advanced Reactor Concepts-20 (ARC-20). The long-term goal of the project is to design, license, and commercialize the FMR plant by the mid-2030s. Early engagement with the U.S. Nuclear Regulatory Commission (NRC) is an important step for the developers to license the advanced reactors including the FMR. As an effort to support the design and the preapplication regulatory engagement plan, GA-EMS is developing Principal Design Criteria (PDC) applicable to the FMR design.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Modular RivGen LCOE Content Model

The Modular RivGen LCOE Content Model contains estimates of levelized cost of energy (LCOE) for three array configurations operating in a theoretical river environment. The LCOE is distinguished by the CapEx, OpEx, and annual energy production and capture for each river environment.

16 TIDAL AND WAVE POWER↗

Basic Design Layout of a Modular Pumped Hydro Teaching Unit

This work was originally completed in July 2015 as a proposal to Santa Fe Community College (SFCC) for their engineering program and a follow up to a feasibility study completed for the Community College the year earlier as indicated below. The work was ahead of its time and funding was hard to obtain to implement a project. This work is now being formally released for distribution to a wider audience based on the evolving circumstances in greater society that now favor this approach with funding more readily available. Due to the distribution outside of SFCC, specific architectural drawing sets of the pertinent buildings called out in the design have been removed. No changes to the design have been made. The design layout utilizing a building is not meant to limit the implementation of the design. The elevation difference required may be obtained with a building, a small hill, jacking up the upper tank, or similar means. The design presented is a basic design, identifying major components and how they are connected together. The user may change components under their own liability. All local applicable codes and standards must be followed when building an actual unit, under the authority of a responsible engineer or owner. Appropriate measures must be followed to protect people from hazards such as electricity, water pressure, and general construction. A leak test to verify water tightness of the system should be conducted prior to any operations. The vision of this design is to allow a class of 10 to 15 students to construct the assembly within a month or so time period, and then learn to operate the assembly at their school location under the guidance of their instructor. This will allow the students to learn about the practical concept of storing electricity with water, and gain a hands on experience of the real world challenges faced with full Modular Pumped Hydro Projects.

13 HYDRO ENERGY↗

Advanced Syngas Cleanup Using Radically Engineered Modular Systems

The overall objective of this project was to address key knowledge gaps and develop modular sorbent-based warm syngas cleanup designs that will enable 1- to 5-MW REMS-based plants to be cost-competitive with large state-of-the-art commercial plants utilizing all of our abundant domestic coal reserves. We proposed to develop two potential new desulfurization process designs specifically targeted for REMS plants for combined heat and power or polygeneration from coal gasification. The first design is a modification of our commercially offered dual transport reactor design based Warm-gas Desulfurization Process (WDP) where the transport-reactor regenerator is replaced with a fluidized-bed regenerator. This design leverages the learnings obtained from our pre-commercial demonstration testing of the WDP technology for over 3,000 hours and conclusions from the lessons learned workshop. The second design is a fixed-bed process that leverages the successful composition and chemistry of our WDP sorbent to develop an effective fixed-bed sorbent formulation and fixed-bed process design. These two potential desulfurization process designs have a strong technical likelihood of success and offer the best opportunity to effectively employ design standardization, mass production and advanced manufacturing techniques to enable cost competitiveness for syngas cleanup at smaller scale.

01 COAL, LIGNITE, AND PEAT↗

Prefabricated Standard Modular Hydropower Installations for Low-cost Small Hydropower

The goal of the present project was to investigate the potential savings in greenfield hydropower project costs across sites having vastly different characteristics. Littoral Power Systems, Inc. (LPS) undertook the project described herein to explore the promise of Standard Modular Hydropower (SMH) to transform the processes of site identification, conceptual design, detailed design, and construction planning to support low- cost, environmentally attractive development of small hydropower facilities at new stream- reaches. This report includes descriptions of the work to develop these processes, the resulting facility designs achieved using these processes and the projected economics. Installation cost estimates for the resulting conceptual greenfield facility design at two different locations come in at $\$3,419$/kW for Balcony Falls and $\$2,124$/kW for LPS 566. The installation time from site preparation to commissioning-ready is estimated to be 58 weeks for the conceptual facility at Balcony Falls and 42 weeks for the conceptual facility at LPS 566. A real challenge to any hydropower facility – not only the two cases studied here – is that environmental and social conditions can change, and as such, the facility may be required to change. The h-Modulor modules connect uniquely and are structurally independent, enabling site configurations to be changed on the fly, as needed. These results show that LPS's h-Modulor SMH approach delivers an attractive balance between efficiency, economics, and environmental sustainability for small hydro greenfield sites.

13 HYDRO ENERGY↗

How the Modular Construction Industry Is Changing the Construction Workforce [Slides]

564,000 - that's the number of construction workers the United States lacked in 2023. This is not a new or unfamiliar problem, but high interest rates, housing shortages, and an aging workforce are amplifying the pressure to build faster and recruit new talent. Panelized and modular construction are often touted as a solution to this workforce challenge and have seen year over year increases in market share. While research confirms industrialized construction can increase building efficiencies, researchers at the National Renewable Energy Laboratory (NREL), RMI, Washington State University, Dodge Construction Network and Guidehouse were curious how workers are being impacted both on construction sites, at factories, and all the stages in between.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗