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DOE OSTI2020

Effect of heating/cooling dynamics in the hysteresis loop and tunable IR emissivity of VO 2 thin films

We experimentally investigate the semiconductor-to-metal transition (SMT) in vanadium dioxide thin films using an infrared thermographic technique. During the semiconductor to metal phase change process, VO 2 optical properties dynamically change and infrared emission undergoes a hysteresis loop due to differences between heating and cooling stages. The shape of the hysteresis loop was accurately monitored under different dynamic heating/cooling rates. In order to quantify and understand the effects of different rates, we used a numerical modelling approach in which a VO 2 thin layer was modeled as metamaterial. The main experimental findings are interpreted assuming that both the rate of formation and shape of metallic inclusions are tuned with the heating/cooling rate. The structural transition from monoclinic to tetragonal phases is the main mechanism for controlling the global properties of the phase transition. However, our experimental results reveal that the dynamics of the heating/cooling process can become a useful parameter for further tuning options and lays out a macroscopic optical sensing scheme for the microscopic phase change dynamics of VO 2 . Our study sheds light on phase-transition dynamics and their effect on the infrared emission spectra of VO 2 thin films, therefore enabling the heating/cooling rate to be an additional parameter to control infrared emission characteristics of thermal emitters. The hysteresis loop represents the phase coexistence region, thus being of fundamental importance for several applications, such as the operation of radiative thermal logic elements based on phase transition materials. For such applications, the phase transition region is shifted for heating and cooling processes. We also show that, depending on the way the phase change elements are heated, the temperature operation range will be slightly modified.

42 ENGINEERING↗

DOE OSTI2025

Experimental Studies on Enhanced Ignition for Improved Pre-Chamber Combustion in Gas Engines

Global efforts to reduce greenhouse gas emissions and mitigate climate change have intensified the demand for cleaner and more efficient combustion technologies. Heavyduty engines, which remain essential for transportation and power generation, must operate with significantly lower emissions while maintaining high efficiency and fuel flexibility. Lean combustion and exhaust gas recirculation (EGR) offer promising pathways to reduce emissions and improve thermal efficiency; however, these strategies impose severe challenges for engine operation, especially for low reactivity gaseous fuels like natural gas and ammonia. Pre-chamber combustion has emerged as a viable approach that uses turbulent jets to accelerate main chamber ignition, but its performance can degrade under high dilution or with hard-to-ignite fuels. These limitations motivate the central focus of this dissertation: understanding passive pre-chambers and improving their performance under challenging conditions.

Dhotre, Akash [Univ. of Minnesota, Minneapolis, MN↗

DOE OSTI2022

Thermal Process Intensification: Transforming the Way Industry Uses Thermal Process Energy (Workshop Report)

The US Department of Energy’s (DOE’s) Advanced Manufacturing Office held the virtual workshop entitled “Thermal Process Intensification: Transforming the Way Industry Uses Thermal Process Energy” in November and December 2020. The workshop brought together participants from universities/laboratories, industries, equipment manufacturers, technology vendors, nongovernmental organizations, and subject-matter experts to discuss transformative technologies and strategies to substantially improve the performance (e.g., energy productivity, thermal efficiency, reduced greenhouse gas [GHG] emissions, reduced number of process steps) of thermal processing systems in the industrial sector. The US industrial sector accounts for 32% of the nation’s primary energy use (including feedstocks), and refining, chemicals, pulp and paper, iron and steel, and food products represent the top energy-consuming sectors. Thermal processing or process heating represents the largest energy use category; it accounts for 63% of all energy use in manufacturing. Additionally, thermal processing is the largest contributor of carbon dioxide (CO2) generation, resulting from combustion of fuels and process related chemical reactions, such as in the case of cement and lime production. The challenge of achieving net-zero industrial GHG emissions is colossal considering the established industrial base that depends mainly on carbon-based processes and energy sources; the time frame and cost to replace carbon-based energy sources and feedstocks; and the long-term outlook for development with large-scale adaptation of alternative non carbon–based technologies. The goals of the DOE Advanced Manufacturing Office Thermal Process Intensification Workshop were as follows: (1) Identify R&D gaps and opportunities to facilitate transformative improvement in industrial thermal processes beyond current technologies and allow for entirely new methods for processing materials; (2) Gain insight into new and innovative approaches to thermally intensify processes, reduce heat demand, harness waste heat, and use fuels and hydrocarbon feedstocks more efficiently; (3) Identify the R&D pathways to thermal process intensification (TPI) with the highest potential for impact and adoption by the industrial sector; (4) Define areas of research, development, and demonstration (RD&D) activities to accelerate development and application of emerging and transformative technologies to intensify thermal processes in industry. The scope and focus of the workshop were defined to meet these goals. Based on the available data for energy use and GHG emissions, the industries that collectively use more than 80% of the total process heating energy consumption were selected as primary focus areas. The chosen industries were combined into the following four groups based on similarities in their thermal processes: high-temperature metal processing (iron and steel industry, alumina-aluminum industry); high-temperature nonmetal and mineral processing (cement and glass industry); medium- to low-temperature thermal processing (food processing and pulp and paper industry as part of forest products sector); and hydrocarbon processing (petroleum refining and chemical industry). Furthermore, all potential TPI technologies associated with the processes defined were considered as part of the workshop. Different types of TPI technologies possible in industrial in the document.

42 ENGINEERING↗

DOE OSTI2023

Model predictive control of mixing controlled compression ignition operation for low reactivity fuels

Using gasoline or other low reactivity fuels with a pilot injection or port fuel injection in a compression ignition engine has shown great potential in reducing NOx emissions while keeping high thermal efficiency compared to diesel. However, excessive combustion noise is caused by a high maximum pressure rise rate in the cylinder due to the higher fractions of premixed charge of the low-reactivity fuel. This noise can result in structural damage to engine components and as such, combustion noise limits the range of the operating parameters and makes the control of such engines challenging. In this study, a simulation environment was built up in MATLAB/Simulink leveraging a physics-based zero-dimension combustion model to capture the in-cylinder pressure time traces as well as metrics relevant to thermal efficiency and combustion noise. Here, in order to also facilitate the control of emissions, machine learning models were investigated to capture NOx emissions. A kernel-based extreme learning machine (K-ELM) performed best and had a coefficient of correlation (R-squared) of 0.998. The combustion and NOx emission models are valid for not only conventional gasoline fuel but also oxygenated alternative fuel blends at three different pilot injection strategies. In order to track key combustion metrics while keeping noise and emissions within constraints, a model predictive control (MPC) was applied for a compression ignition engine operating with a range of potential fuels and fuel injection strategies. The MPC is validated under different scenarios, including a load step change, fuel type change, and injection strategy change, with proportional–integral (PI) control as the baseline. The simulation results show that MPC reduces about 26% of ringing intensity in the transient process and 17% at the steady state for E30. Generally, MPC can optimize the overall performance through modifying the main injection timing, pilot fuel mass, and exhaust gas recirculation (EGR) fraction.

42 ENGINEERING↗

DOE OSTI2022

Thermal Process Intensification: Transforming the Way Industry Uses Thermal Process Energy

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Stimulation of isoprene emissions and electron transport rates are a key mechanism of thermal tolerance in the tropical species Vismia guianensis

Tropical forests absorb large amounts of atmospheric CO 2 through photosynthesis, but high surface temperatures suppress this absorption while promoting isoprene emissions. While mechanistic isoprene emission models predict a tight coupling to photosynthetic electron transport (ETR) as a function of temperature, direct field observations of these phenomenon are lacking in the tropics and are necessary to assess the impact of a warming climate on global isoprene emissions. In this paper, we demonstrate that in the early successional species Vismia guianensis in the central Amazon, ETR rates increased with temperature in concert with isoprene emissions, even as stomatal conductance ($g _s$) and net photosynthetic carbon fixation ($P_n$) declined. We observed the highest temperatures of continually increasing isoprene emissions yet reported (50°C). While $P_n$ showed an optimum value of 32.6 ± 0.4°C, isoprene emissions, ETR, and the oxidation state of PSII reaction centers (q L ) increased with leaf temperature with strong linear correlations for ETR (ρ = 0.98) and q L (ρ= 0.99) with leaf isoprene emissions. In contrast, other photoprotective mechanisms, such as non-photochemical quenching (NPQ), were not activated at elevated temperatures. Inhibition of isoprenoid biosynthesis repressed $P_n$ at high temperatures through a mechanism that was independent of stomatal closure. While extreme warming will decrease $g_s$ and $P_n$ in tropical species, our observations support a thermal tolerance mechanism where the maintenance of high photosynthetic capacity under extreme warming is assisted by the simultaneous stimulation of ETR and metabolic pathways that consume the direct products of ETR including photorespiration and the biosynthesis of thermoprotective isoprenoids. Our results confirm that models which link isoprene emissions to the rate of ETR hold true in tropical species and provide necessary "ground-truthing" for simulations of the large predicted increases in tropical isoprene emissions with climate warming.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Energy migration and scintillation kinetics in compositionally complex (Gd 1/4 Y 1/4 Tb 1/4 Lu 1/4 ) 3 Al 5 O 12 :Ce single crystal scintillator

It is well-established that compositional tuning through binary admixture can improve scintillation performance in several materials systems, including Ce-activated garnets. Although recent work on ternary or quaternary cation admixture shows promise, the impact of this increased compositional complexity on thermal stability and carrier-defect dynamics has not been addressed. Here, we investigate a compositionally complex garnet, (Gd 1/4 Y 1/4 Tb 1/4 Lu 1/4 ) 3 Al 5 O 12 :Ce (GYTLAG), grown by the Czochralski method using temperature-dependent photoluminescence (PL), PL decay, and thermoluminescence (TL). PL and PL decay measurements support a thermally activated Tb 3+ -Ce 3+ energy transfer, where Tb 3+ emission dominates below 60 K, but Ce 3+ emission increases from 20-300 K. Thermal quenching of Ce 3+ emission occurs around T 50 = 508 K, with an activation energy of 0.6 eV. TL and wavelength-resolved TL spectra from 20–500 K show that GYTLAG contains similar trap groups to LuAG but with a broader distribution of glow peaks below room temperature, possibly caused by quaternary cation mixing. A combination of dose dependence, partial cleaning and initial rise, and glow curve fitting to a first order continuous Gaussian distribution model are used to understand the contribution of electronic point defects to scintillation decay and afterglow at room temperature. Furthermore, these results inform how increased compositional complexity influences recombination dynamics in garnet scintillators.

Compositionally complex↗

DOE OSTI2022

An indirect approach to optimize the reaction rates of thermal NO formation for diesel engines

With stringent emission regulations, it has become more important for modern diesel engine manufacturers to accurately predict engine-out nitrogen oxide (NO x ) emissions across a wide range of operating conditions. Thermal NO is the major source of engine-out NO x in modern diesel engines. For thermal NO formation, several earlier studies have recommended the forward and reverse reaction rate coefficients of the rate-limiting reaction (O + N 2 ⇌ NO + N). However, due to deficiencies in sub-models and inadequacies of reduced chemical mechanisms to represent diesel combustion, these recommended values more often than not need to be adjusted in reduced order combustion models to accurately predict engine-out NO x . Hence, in this work a systematic and computationally efficient approach has been proposed to streamline the process of determining the optimum reaction rate coefficients. Here, to develop the optimization approach, four different production diesel engines with different operating conditions in terms of speed, load, and exhaust-gas recirculation have been considered. Numerical simulations have been performed using a detailed zero-dimensional velocity-composition-frequency transported probability density function (0D-VCF-tPDF) model that uses hundreds of notional particles to capture in-cylinder stratification. Four different combinations of hydrocarbon and NO x chemical mechanisms were used to represent chemistry. It was found that for the rate-limiting reaction, the pre-exponent factors (A f1 , A r1 ) and activation energies (E A,f1 , E A,r1 ) of the forward and reverse reaction rates follow a linear band in A f1 - E A,f1 and A r1 - E A,r1 space where predicted engine-out NO x match the measured values closely. By encompassing such bands from different engines and considering constraints on activation energies, a reduced search domain of pre-exponent factors and activation energies was constructed that is expected to be applicable to any diesel engine. Eventually, computationally efficient three-line and one-line search approaches were proposed to determine the optimum values of the pre-exponent factors and activation energies that led to a minimum error between measured and predicted engine-out NO x . Finally, these three-line and one-line NO x optimization approaches were applied to a fifth production diesel engine for which the 0D-VCF-tPDF model showed a very good predictive performance in terms of predicting peak pressure, 50% burn rate, and engine-out NO x when compared to measured and 3D-CFD values.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2021

Atomic-Level, Energy-Conversion Heat Transfer

Abstract Heat is stored in quanta of kinetic and potential energies in matter. The temperature represents the equilibrium and excited occupation (boson) of these energy conditions. Temporal and spatial temperature variations and heat transfer are associated with the kinetics of these equilibrium excitations. During energy-conversion (between electron and phonon systems), the occupancies deviate from equilibria, while holding atomic-scale, inelastic spectral energy transfer kinetics. Heat transfer physics reaches nonequilibrium energy excitations and kinetics among the principal carriers, phonon, electron (and holes and ions), fluid particle, and photon. This allows atomic-level tailoring of energetic materials and energy-conversion processes and their efficiencies. For example, modern thermal-electric harvesters have transformed broad-spectrum, high-entropy heat into a narrow spectrum of low-entropy emissions to efficiently generate thermal electricity. Phonoelectricity, in contrast, intervenes before a low-entropy population of nonequilibrium optical phonons becomes a high-entropy heat. In particular, the suggested phonovoltaic cell generates phonoelectricity by employing the nonequilibrium, low-entropy, and elevated temperature optical-phonon produced population—for example, by relaxing electrons, excited by an electric field. A phonovoltaic material has an ultranarrow electronic bandgap, such that the hot optical-phonon population can relax by producing electron-hole pairs (and power) instead of multiple acoustic phonons (and entropy). Examples of these quanta and spectral heat transfer are reviewed, contemplating a prospect for education and research in this field.

Engineering↗

DOE OSTI2020

Frequency-domain hot-wire sensor and 3D model for thermal conductivity measurements of reactive and corrosive materials at high temperatures

High temperature solids and liquids are becoming increasingly important in next-generation energy and manufacturing systems that seek higher efficiencies and lower emissions. Accurate measurements of thermal conductivity at high temperatures are required for the modeling and design of these systems, but commonly employed time-domain measurements can have errors from convection, corrosion, and ambient temperature fluctuations. Here, we describe the development of a frequency-domain hot-wire technique capable of accurately measuring the thermal conductivity of solid and molten compounds from room temperature up to 800 °C. Therefore, by operating in the frequency-domain, we can lock into the harmonic thermal response of the material and reject the influence of ambient temperature fluctuations, and we can keep the probed volume below 1 µl to minimize convection. The design of the microfabricated hot-wire sensor, electrical systems, and insulating wire coating to protect against corrosion is covered in detail. Furthermore, we discuss the development of a full three-dimensional multilayer thermal model that accounts for both radial conduction into the sample and axial conduction along the wire and the effect of wire coatings. The 3D, multilayer model facilitates the measurement of small sample volumes important for material development. A sensitivity analysis and an error propagation calculation of the frequency-domain thermal model are performed to demonstrate what factors are most important for thermal conductivity measurements. Finally, we show thermal conductivity measurements including model data fitting on gas (argon), solid (sulfur), and molten substances over a range of temperatures.

47 OTHER INSTRUMENTATION↗

DOE OSTI2022

Relativistic non-thermal particle acceleration in two-dimensional collisionless magnetic reconnection

Magnetic reconnection, especially in the relativistic regime, provides an efficient mechanism for accelerating relativistic particles and thus offers an attractive physical explanation for non-thermal high-energy emission from various astrophysical sources. I present a simple analytical model that elucidates key physical processes responsible for reconnection-driven relativistic non-thermal particle acceleration in the large-system, plasmoid-dominated regime in two dimensions. The model aims to explain the numerically observed dependencies of the power-law index $p$ and high-energy cutoff $\gamma _c$ of the resulting non-thermal particle energy spectrum $f(\gamma )$ on the ambient plasma magnetization $\sigma$ , and (for $\gamma _c$ ) on the system size $L$ . In this self-similar model, energetic particles are continuously accelerated by the out-of-plane reconnection electric field $E_{\rm rec}$ until they become magnetized by the reconnected magnetic field and eventually trapped in plasmoids large enough to confine them. The model also includes diffusive Fermi acceleration by particle bouncing off rapidly moving plasmoids. I argue that the balance between electric acceleration and magnetization controls the power-law index, while trapping in plasmoids governs the cutoff, thus tying the particle energy spectrum to the plasmoid distribution.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Solution-Processed Temperature-Adaptive Radiative Paint as a Thermal Imaging Sensitizer

Thermography detects mid-infrared radiation from surfaces based on the Stefan-Boltzmann law, mapping surface temperatures and potentially revealing subsurface thermal activity. Recent developments offer an alternative strategy to traditional camera-based improvements: a thermal imaging sensitizer (TIS) coating whose emissivity increases sharply with local temperature, amplifying small thermal variations into high-contrast signals. Existing TIS structures are nanofabricated solid membranes and face significant challenges in fabrication complexity. Here, in this study, we present a solution-processed, liquid form of TIS, termed temperature-adaptive radiative paint (TARP), to address these limitations. TARP offers drastically reduced fabrication costs, scalability to large areas, applicability to curved surfaces, and an extended operating temperature range, while maintaining the function of temperature amplification. Application of TARP enhances small temperature contrast by more than 3 times, substantially improving ambient thermography and enabling broader applications such as detection of structural defects and hot spots in electronic components.

paint↗

DOE OSTI2020

An expanded kinetics model describing injector region desorption

During the initial stages of electron beam injection, absorbed or entrained material can be released into the nascent beam pulse by thermal desorption or electron beam impact. These processes, and subsequent ionization and dissociation, are examined assuming a prototypical temporal beam pulse. An expanded set of kinetic equations that includes thermal desorption, electron-stimulated ion emission, electron impact dissociation, electron impact ionization, and thermal decomposition of adsorbed water molecules is developed. Estimates of the three most important ionized species H 2 O + , H + and OH + are provided for typical injector conditions. Electron impact dissociative ionization of neutral H 2 O is the dominant source of H + under these conditions. Since the abundance of thermally desorbed neutral H 2 O has an exponential rate, the production of H+ is likewise controlled by this exponential desorption rate. Thus thermal management of the confining walls could suppress proton production in the injector region. Thermal decomposition of H 2 O will not be a contributing physical process in the injector region on time scales less than a μs. The formalism is sufficiently flexible to include entrained hydrogen.

42 ENGINEERING↗

DOE OSTI2024

The Experimental and Numerical Investigation of Internal Heat Transfer for Supercritical Carbon Dioxide Cooling in a Staggered Pin Fin Array and Single-Jet Impingement

Over the past decade, the drive to reduce greenhouse gas emissions and to increase thermal efficiency for turbomachinery has invigorated the application of supercritical carbon dioxide (sCO2) power cycles for energy generation. Compared to the industry standard air cycles, sCO2 applications hold the potential for several advantages, including higher efficiencies, smaller footprints, and zero greenhouse gas emissions. However, like any turbomachinery application, the turbine inlet temperature must increase to increase thermal efficiency. This introduces the need for internal cooling features to avoid material failure as operating conditions rise. Two standard features include pin fin turbulators in the trailing edge and jet impingement in the airfoil's leading edge. Over the past several decades, these features have been the subject of extensive research. However, the move to the sCO2 operating environment creates the need to re-visit these features to quantify the heat transfer capabilities within this supercritical cooling environment. The first objective of this paper is to discuss the development of the experimental demonstration for internal heat transfer testing at 200 bar and 400 Celsius, which sits well within the CO2 supercritical region. Next, the heat transfer for pin fin turbulators and single-jet impingement in the sCO2 environment is compared to existing air data-derived correlations to quantify any deviations from literature correlations. Finally, the experimental process aims to validate internal cooling conjugate heat transfer numerical simulations for sCO2 turbines.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2025

Mechanically induced thermal runaway severity analysis of Li-ion batteries and continuous energy release monitoring

The large-scale deployment of Li-ion batteries in stationary energy storage and electrical vehicle applications demands a strong focus on safety, particularly on the thermal runaway risk and severity evaluation. A standardized single-side mechanical indentation test protocol was developed to induce an internal short-circuit (ISC) and evaluate cells' thermal runaway severity at different state of charge (SOC). The observed hazard severity (OHS in five categories) and evaluated scores in this work have a comprehensive consideration of each cell's capacity, initial voltage, SOC, temperature and voltage change, allowing a better evaluation of the cells' thermal runaway potential. This method was applied to about 200 Li-ion batteries in order to build an extensive thermal runaway database covering various SOCs, capacities and chemistries. In this study, we monitored the transitions of stored electrochemical energy and applied mechanical energy into both thermal energy and acoustic emissions (AE). The surface temperature and mechanical failures were monitored by infrared imaging and AE to capture critical events within battery cells throughout the mechanical indentation tests. Furthermore, the initial temperature maps can predict two types of follow-up events: thermal runaway or gradual heat release via conduction. Analyzing each cell's severity, AEs, and leveraging the evolving database offer insights into predicting occurrences of thermal runaway. The test method, thermal runaway severity evaluation and prediction, and the corresponding database provide battery designers, manufacturers, and end-users a clear overview of Li-ion batteries' thermal runaway potential under mechanical abuse, advancing the safety design of Li-ion batteries.

Acoustic emission↗

DOE OSTI2022

Carbon emission responsive building control: A case study with an all-electric residential community in a cold climate

In the United States, buildings account for 35% of total energy-related carbon dioxide emissions, making them important contributors to decarbonization. Carbon intensities in the power grid are time-varying and can fluctuate significantly within hours, so shifting building loads in response to the carbon intensities can reduce a building’s operational carbon emissions. This paper presents a rule-based carbon responsive control framework that controls the setpoints of thermostatically controlled loads responding to the grid’s carbon emission signals in real time. Based on this framework, four controllers are proposed with different combinations of carbon accounting methods and control rules. To evaluate their performance, we performed simulation studies using models of a 27-home, all-electric, net zero energy residential community located in Basalt, Colorado, United States. The carbon intensity data of four future years from the Cambium data set are adopted to account for the evolving resource mix in the power grid. Various performance metrics, including energy consumption, carbon emission, energy cost, and thermal discomfort, were used to evaluate the performance of the controllers. Sensitivity analysis was also conducted to determine how the control thresholds and intervals affect the controllers’ performance. Simulation results indicate that the carbon responsive controllers can reduce the homes’ annual carbon emissions by 6.0% to 20.5%. However, the energy consumption increased by 0.9% to 6.7%, except in one scenario where it decreased by 2.2%. Compared to the baseline, the change in energy cost was between –2.9% and 3.4%, and thermal discomfort was also maintained within an acceptable range. The little impact on energy cost and thermal discomfort indicates there are no potential roadblocks for customer acceptance when rolling out the controllers in utility programs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Development of a Framework for Coupled Thermal, Hydrologic, and Biogeochemical Modeling to Predict Permafrost Methane Emissions.

Abstract not provided.

Nole, Michael↗

DOE OSTI2023

Heat transfer augmentation of natural convection heat sink through notched fin design

A novel notched fin heat sink with a central opening is proposed in the present study to augment the heat transfer performance of the natural convection heat sink under horizontal configuration. Thermal and airflow behavior in the heat sinks were studied using both experimental and numerical methods. The results showed that the performance of the conventional heat sink can be enhanced by optimizing its fin design. The basic heat sink model provided a 17% reduction in thermal resistance when its fin height and fin spacing were doubled, and it was accompanied by a 21% increase in surface area. The heat sink with a notched fin design with a less surface area offered a 13% lower thermal resistance compared to the basic model by entraining more airflow into the interior fin region. Providing a central opening in the notched fin heat sink can further reduce the thermal resistance by about 13%. Further, this study also analyzed the influence of emissivity of the heat sink on natural convection conditions. The findings demonstrated that the heat sink with an emissivity of 0.9 can reduce the thermal resistance by nearly 23% compared to one with an emissivity of 0.15.

42 ENGINEERING↗