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NASA NTRS2014

Hardware Design and Testing of SUPERball, A Modular Tensegrity Robot

We are developing a system of modular, autonomous "tensegrity end-caps" to enable the rapid exploration of untethered tensegrity robot morphologies and functions. By adopting a self-contained modular approach, different end-caps with various capabilities (such as peak torques, or motor speeds), can be easily combined into new tensegrity robots composed of rods, cables, and actuators of different scale (such as in length, mass, peak loads, etc). As a first step in developing this concept, we are in the process of designing and testing the end-caps for SUPERball (Spherical Underactuated Planetary Exploration Robot), a project at the Dynamic Tensegrity Robotics Lab (DTRL) within NASA Ames's Intelligent Robotics Group. This work discusses the evolving design concepts and test results that have gone into the structural, mechanical, and sensing aspects of SUPERball. This representative tensegrity end-cap design supports robust and repeatable untethered mobility tests of the SUPERball, while providing high force, high displacement actuation, with a low-friction, compliant cabling system.

Tensegrity↗

NASA NTRS2015

Ames Modular Common Spacecraft Bus

The Ames Modular Common Spacecraft Bus is a lightweight carbon composite structure designed to accommodate launch loads and provide attenuation of impact loads. It is also designed for ease of manufacturing and assembly. The modularity of the design is intended not only for multiple mission configurations,but also parallelism in development and assembly. The system-level components were drawn from low-cost flight-proven product lines.

Common bus↗

DOE OSTI2021

The Fast Modular Reactor (FMR) - Development Plan of a New 50 MWe Gas-cooled Fast Reactor

General Atomics Electromagnetic Systems (GA-EMS) will be developing a new 50-megawatt electric (MWe) fast modular reactor (FMR), under the Department of Energy’s (DOE’s) Advanced Reactor Demonstration Program (ARDP), Advanced Reactor Concepts 2020 (ARC-20) development pathway, that provides safe, carbon free electricity, capable of incremental capacity additions. A modular design allows it to be factory-built and assembled on-site to keep the cost of capital low, while the dry-cooling facilitates siting to complement renewables in nearly any location. GA-EMS is committed to commercialization of the proposed reactor, with a demonstration by 2030, and deployment by the mid-2030s. The ultimate goal of the design is to develop flexible and dispatchable carbon-free power source for the 2035 US electricity market. The GAEMS- led team will verify that simplified characteristics (e.g., inert helium gas coolant, pellet-loaded fuel rod, installation-free of heat sink requirements, small and passive heat removal systems) of the FMR will result in a safe, maintainable, cost-effective, distributed, nuclear energygenerating station. Three key specific project objectives for the next three years include: Development of the conceptual design of the 50- MWe FMR plant, Achievement of Technology Readiness Level (TRL) 4 for key system and component technologies through in-pile tests, out-of-pile tests, and numerical experiments; and Development of robust techno-economic analysis (TEA) and pre-application licensing approach necessary for timely demonstration and eventual commercialization.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2022

A Scalable Method for Decarbonizing Modular Building Solutions: Preprint

The decarbonization movement emphasizes the shift in focus from energy efficiency to directly reducing global-warming impact. Blokable, LLC, a vertically integrated modular builder with an all-electric portfolio, worked with NREL on a roadmap to decarbonize its high-performance building product at a relative cost advantage by utilizing the learning curves of mass production. Previous decarbonization literature focused on either i) lifecycle assessments, or ii) efficiency measures. These decarbonization exercises were bespoke to individual building projects and did not consider positive feedback loops of builder experience or process repetition. Vertically integrated, prefab builders possess the unique ability to leverage learning and repetition to decarbonize their design-build-operate process. This collaboration between Blokable and NREL resulted in a decarbonization strategy utilizing the company's scaling and production efficiencies, on-site renewable energy and storage, and the projected evolution of building components over time based on trends and emerging legislation. The method developed here encompasses a growing business model, lifecycle carbon assessment, and projected changes in product and grid emissions over time due to existing trends and emerging legislation. This methodology incorporates learning-curve efficiencies gleaned from scaled manufacturing, as well as open-source tools integration for energy and carbon accounting. The output projects and compares cost and carbon savings per modular unit as production increases to 10,000 dwelling units annually over 15 years. The resulting roadmap illustrates a path to roughly 60% carbon savings and beyond-net-zero-energy performance at no incremental cost by 2030. The methodology can be mapped to other integrated or productized builders for methodical decarbonization.

affordable housing↗

DOE OSTI2022

A Scalable Method for Decarbonizing Modular Building Solutions

affordable housing↗

DOE OSTI2023

Advances in Integral and Separate Effects Experiments for Water Cooled Small Modular Reactors

This paper focuses on the progress being made in water-cooled small modular reactor (SMR) advanced integral effects and separate effects experiments for reactor licensing. SMRs, considered modular in design, are mostly factory-built and then shipped to the reactor site. Of the several types of SMR designs available, water-cooled SMRs are likely to receive regulatory approval faster than others, as most of the technologies involved (e.g., the fuel and coolant technologies) are matured. However, the unique safety systems of SMRs, which depend on specific SMR design features, require integral and separate effects experiments to achieve reactor licensing. Thus, of the many SMR designs being proposed, only a few have successfully undergone licensing and reached the final development and demonstration stage. Many nuclear vendors and newcomer companies are investing millions of dollars to develop integral and separate effects testing facilities for preparing final safety analysis reports to include in licensing applications. Development and analysis of these experimental facilities is costly and takes about four to five years. The unique challenges involved can be reduced when stakeholders synergistically apply lessons learned, knowing the critical role played by advancements in experiments that support the licensing of SMR safety systems. Identification of knowledge/research gaps with the phenomena identification and ranking table (PIRT) and designing experimental facilities focusing on the phenomena of interest (POI) and figures of merit (FOMs) are pivotal to select the critical path to successful design demonstration and licensing application.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2016

Techno-Economic Assessment of the Factory Production of Small Modular Reactor

The demand for electricity continues to grow around the world while pressures remain high to reduce carbon emissions. Nuclear energy provides a strong and reliable baseload power component without a high output of greenhouse gases. Global nuclear energy capacity is increasing with 62 reactors under construction in 14 countries. Nuclear energy will be crucial as energy demands are met with a sustainable and diverse energy portfolio. Small modular reactors (SMRs) are small scale (less than 300 MWe) reactors that incorporate the same advanced technologies included in recent LR nuclear reactor designs. SMRs are designed to include the latest reactor technology including passive safety features. SMRs offer economic advantages over LRs such as lower up-front capital and easier integration into the existing power grid. The modular characteristic of SMRs would allow incremental additions to power plants years after its completion. The cost of constructing SMR power plants will determine their future in the energy industry. Three SMR reactors are in advanced stages of design in the United States; the Westinghouse 225 MWe, mPower 180 MWe and nuScale 45 MWe. SMRs are expected to have lower capital expenses of reactor components due to factory production. Current estimates predict these savings to reduce SMR capital 30-40%. Existing studies have estimated SMR capital using economies of scale and holistic discounts applied to an overall capital expense figure, but do not include the expense of an SMR factory facility. To better understand the actual costs associated with construction of an SMR power plant, capital components will be broken down according to its place in the construction phase. The expense of a factory facility will also be included with SMR capital expenses to determine its significance and benefits to overall capital expenses. Results from this study show that SMRs can compete with LRs in terms of startup costs. The capital cost of building a factory for SMRs was previously overlooked for SMR capital estimates. The annualized capital expenses expected for an SMR factory are very small, but offer significant discounts to the overall capital costs for SMRs. Case 3 shows that factory production can reduce SMR capital expenses to the range of 30%-40% when compared to Case 1 in this study. Factory savings of this magnitude would require factory production of several SMR reactor and generator components including the reactor pressure vessel, control rods, steam generation, and chemical and volume control system, containment, condenser and turbo-generator. SMRs will also benefit from lower indirect expenses due to a much smaller construction duration. It is expected that SMRs will have capital costs competitive with LRs. The differences between Case 2 and Case 3 in this study show that SMRs are heavily dependent on the cost reductions coming from factory production. The factory facility represents a small increase in capital expense, but accounts for a large reduction of cost for factory components. SMRs have the potential to meet growing energy demands in the United States and around the world, but their economic viability is dependent on a factory facility that will lower the capital expenses of reactor and generator components. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2026

Techno-Economic Assessment of Data Center Load Demand Powered by Small Modular Reactors and Distributed Energy Resources

The rapid increase in data center energy demand, driven by AI and large-scale data processing, poses significant challenges to global energy infrastructure. Data centers require substantial and reliable energy for continuous operations and high-performance computing. Current electrical grids face issues such as transmission bottlenecks and aging infrastructure, making it difficult to meet these demands. Integrating inverter-based-resources (IBRs) like solar and wind presents both opportunities and challenges due to their intermittent nature. Small Modular Reactors (SMRs) offer a promising solution with their enhanced safety, modularity, reliability, and scalability, providing consistent base load power ideal for data center operations. This study presents a comprehensive techno-economic assessment of powering data center load demand using a combination of SMRs and IBRs with grid-connected and islanded mode. This study utilized Idaho National Laboratory’s (INL) HPC data center hourly load profiles and Xendee microgrid optimization platform to conduct the analysis. In this configuration, SMRs serves as the primary base load power source, consistently providing a steady supply of electricity necessary to meet the minimum load demand of the data center with support from the IBRs. Key performance indicators such as Levelized Cost of Electricity (LCOE), Net Present Value (NPV) has been calculated to assess the economic feasibility. The findings from this research will underscore the strategic benefits of integrating SMR plant with DERs – particularly for critical infrastructure load such as data centers.

14 - SOLAR ENERGY↗

DOE OSTI2024

Tailorable Multi–Modular Pore–Space–Partitioned Vanadium Metal–Organic Frameworks for Gas Separation

Currently, few porous vanadium metal-organic frameworks (V-MOFs) are known and even fewer are obtainable as single crystals, resulting in limited information on their structures and properties. Here this work demonstrates remarkable promise of V-MOFs by presenting an extensible family of V-MOFs with tailorable pore geometry and properties. The synthesis leverages inter-modular synergy on a tri-modular pore-partitioned platform. New V-MOFs show a broad range of structural features and sorption properties suitable for gas storage and separation applications for C 2 H 2 /CO 2 , C 2 H 6 /C 2 H 4 , and C 3 H 8 /C 3 H 6 . The c/a ratio of the hexagonal cell, a measure of pore shape, is tunable from 0.612 to 1.258. Other tunable properties include pore size from 5.0 to 10.9 Å and surface area from 820 to 2964 m 2 g –1 . With C 2 H 2 /CO 2 selectivity from 3.3 to 11 and high uptake capacity for C 2 H 2 from 65.2 to 182 cm 3 g –1 (298K, 1 bar), an efficient separation is confirmed by breakthrough experiments. The near-record high uptake for C 2 H 6 (166.8 cm 3 g –1 ) contributes to the promise for C 2 H 6 -selective separation of C 2 H 6 /C 2 H 4 . The multi-module pore expansion enables transition from C 3 H 6 -selective to more desirable C 3 H 8 -selective separation with extraordinarily high C 3 H 8 uptake (254.9 cm 3 g –1 ) and high separation potential (1.25 mmol g –1 ) for C 3 H 8 /C 3 H 6 (50:50 v/v) mixture.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Operability and control in process intensification and modular design: Challenges and opportunities

Abstract In this article, the importance of considering operability and control criteria in the analysis and design of intensified and modular processes is discussed. We first analyze the impact on operability of key factors including: (i) degrees of freedom, (ii) process constraints, (iii) numbering up vs. scaling up, and (iv) dynamic/periodic operation. Comparative examples are presented to showcase the pros and cons in intensified/modular systems vs. their conventional counterparts from operability and control aspects. Then we look into metrics and tools to address these challenges such as: (i) flexibility analysis, (ii) operability‐based design, and (iii) advanced model‐based control. Considering different conceptual design stages as synthesis intensification, steady‐state design, and dynamic operational optimization, we highlight the need to incorporate different levels of operability considerations. Future research opportunities and perspectives are also identified, particularly emphasizing the importance of a holistic strategy for integrated design, operability, and control of intensified and modular process systems.

Pistikopoulos, Efstratios N.↗

DOE OSTI2019

Modular–scale ethane to liquids via chemical looping oxidative dehydrogenation: Redox catalyst performance and process analysis

The difficulties in the liquefaction and transportation of ethane in shale gas has led to significant rejection, via reinjection or flaring, of this valuable hydrocarbon resource. Upgrading this low–value, isolated ethane into easily transportable liquid fuels is a promising solution to this supply glut. In this study, we present a modular system that can potentially be operated economically at geographically isolated gas–processing facilities. The modular ethane–to–liquids (M–ETL) system uses a chemical looping–oxidative dehydrogenation (CL–ODH) technology to efficiently convert ethane and natural gas liquids into olefins (primarily ethylene) via cyclic redox reactions of highly effective redox catalyst particles. The resulting olefins are then converted to gasoline and mid–distillate products via oligomerization. CL–ODH eliminates air separation and equilibrium limitations for olefin generation. It also simplifies the process scheme and reduces energy consumption. Here, we present experimental proof–of–concept data on CL–ODH conversion of ethane to ethylene. Using the CL–ODH performance data at 750°C, we show that a simple, single–pass configuration can be economically viable at distributed sites. We identify that economic factors such as the capital cost, price of ethane feed, and value of electricity byproduct have strong effects on the required selling price of the liquids. It is also noted that the economic viability of the M–ETL system is relatively insensitive to the liquid yield under a low ethane price scenario. In conclusion, the demand and value of electricity at distributed locations, on the other hand, can play an important role in the optimal process configuration and economics.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Specialty chemicals production case study: Economic analysis of modular chemical process intensification versus conventional stick‐built approaches

Abstract The beneficial synergies of chemical process intensification and plant modularization present a unique step‐wise advancement opportunity for many chemical manufacturers, but economic case studies are needed to raise awareness of such opportunities. The primary objective of this case study is to better understand the business case economics of a specialty chemical plant using modular chemical process intensification (MCPI), by comparing it with that of a conventional stick‐built (CSB) plant that produces the same product at the same production capacity. When comparing MCPI against CSB approaches for a plant project strategy decision, analysts should thoroughly understand and model the differences and similarities in scope bases. The MCPI approach for this case study benefitted from dramatic reductions in capital expenditures (CAPEX). A sizeable reduction in plant spatial volume likely explains some of these reductions. Sizeable operational expenditure (OPEX) reductions with the MCPI plant appear to be associated with the reduced operator staffing required from converting a labor‐intensive batch process into an automated, continuous flow process. Traditional project investment economic measures strongly favored the MCPI case for the design, construction, and operation of the specialty chemical plant. The net present value for the MCPI case was nearly twice that for the CSB case over a ten‐year period, and the payback period for the CSB case was nearly five times longer than that of the MCPI case. The opinion‐based perspective of the study participant identified significant contributors to superior MCPI economic performance for this case study. With the two conditions of low MCPI CAPEX and high product profit margin, economic analysis indicates that incorporation of a backup MCPI train, for operational redundancy when downtime occurs, is a very beneficial strategy.

O'Connor, James T.↗

DOE OSTI2017

BeamDyn: a high-fidelity wind turbine blade solver in the FAST modular framework

Here, this paper presents a numerical implementation of the geometrically exact beam theory based on the Legendre-spectral-finite-element (LSFE) method. The displacement-based geometrically exact beam theory is presented, and the special treatment of three-dimensional rotation parameters is reviewed. An LSFE is a high-order finite element with nodes located at the Gauss-Legendre-Lobatto points. These elements can be an order of magnitude more computationally efficient than low-order finite elements for a given accuracy level. The new module, BeamDyn, is implemented in the FAST modularization framework for dynamic simulation of highly flexible composite-material wind turbine blades within the FAST aeroelastic engineering model. The framework allows for fully interactive simulations of turbine blades in operating conditions. Numerical examples are provided to validate BeamDyn and examine the LSFE performance as well as the coupling algorithm in the FAST modularization framework. BeamDyn can also be used as a stand-alone high-fidelity beam tool.

17 WIND ENERGY↗

DOE OSTI2023

Analyticity of replica correlators and modular ETH

We study the two point correlation function of a local operator on an n -sheeted replica manifold corresponding to the half-space in the vacuum state of a conformal field theory. In analogy with the inverse Laplace transform, we define the Renyi transform of this correlation function, which is a function of one complex variable w, dual to the Renyi parameter n . Inspired by the inversion formula of Caron-Huot, we argue that if the Renyi transform ƒ(w) has bounded behavior at infinity in the complex w plane, the discontinuity of the Renyi transform disc ƒ(w) provides the unique analytic continuation in n of the original replica correlation function. We check our formula by explicitly calculating the Renyi transform of a particular replica correlator in a large N holographic CFT d in dimensions d > 2. We also discover that the discontinuity of the Renyi transform is related to the matrix element of local operators between two distinct eigenstates of the modular Hamiltonian. We calculate the Renyi transform in 2 d conformal field theories, and use it to extract the off-diagonal elements of (modular) ETH. We argue that in 2 d , this is equivalent to the off-diagonal OPE coefficients of a CFT and show that our technique exactly reproduces recent results in the literature.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2021

4-manifolds and topological modular forms

We build a connection between topology of smooth 4-manifolds and the theory of topological modular forms by considering topologically twisted compactification of 6d (1, 0) theories on 4-manifolds with flavor symmetry backgrounds. The effective 2d theory has (0, 1) supersymmetry and, possibly, a residual flavor symmetry. The equivariant topological Witten genus of this 2d theory then produces a new invariant of the 4-manifold equipped with a principle bundle, valued in the ring of equivariant weakly holomorphic (topological) modular forms. We describe basic properties of this map and present a few simple examples. As a byproduct, we obtain some new results on ’t Hooft anomalies of 6d (1, 0) theories and a better understanding of the relation between 2d (0, 1) theories and TMF spectra.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2015

Metastring theory and modular space-time

String theory is canonically accompanied with a space-time interpretation which determines S-matrix-like observables, and connects to the standard physics at low energies in the guise of local effective field theory. Recently, we have introduced a reformulation of string theory which does not rely on an a priori space-time interpretation or a pre-assumption of locality. This metastring theory is formulated in such a way that stringy symmetries (such as T-duality) are realized linearly. In this paper, we study metastring theory on a flat background and develop a variety of technical and interpretational ideas. These include a formulation of the moduli space of Lorentzian worldsheets, a careful study of the symplectic structure and consequently consistent closed and open boundary conditions, and the string spectrum and operator algebra. What emerges from these studies is a new quantum notion of space-time that we refer to as a quantum Lagrangian or equivalently a modular space-time. This concept embodies the standard tenets of quantum theory and implements in a precise way a notion of relative locality. The usual string backgrounds (non-compact space-time along with some toroidally compactified spatial directions) are obtained from modular space-time by a limiting procedure that can be thought of as a correspondence limit.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2024

Modular flow in JT gravity and entanglement wedge reconstruction

It has been shown in recent works that JT gravity with matter with two boundaries has a type II ∞ algebra on each side. As the bulk spacetime between the two boundaries fluctuates in quantum nature, we can only define the entanglement wedge for each side in a pure algebraic sense. As we take the semiclassical limit, we will have a fixed long wormhole spacetime for a generic partially entangled thermal state (PETS), which is prepared by inserting heavy operators on the Euclidean path integral. Under this limit, with appropriate assumptions of the matter theory, geometric notions of the causal wedge and entanglement wedge emerge in this background. In particular, the causal wedge is manifestly nested in the entanglement wedge. Different PETS are orthogonal to each other, and thus the Hilbert space has a direct sum structure over sub-Hilbert spaces labeled by different Euclidean geometries. The full algebra for both sides is decomposed accordingly. From the algebra viewpoint, the causal wedge is dual to an emergent type III 1 subalgebra, which is generated by boundary light operators. To reconstruct the entanglement wedge, we consider the modular flow in a generic PETS for each boundary. We show that the modular flow acts locally and is the boost transformation around the global RT surface in the semiclassical limit. It follows that we can extend the causal wedge algebra to a larger type III 1 algebra corresponding to the entanglement wedge. Within each sub-Hilbert space, the original type II ∞ reduces to type III 1 .

2D Gravity↗

DOE OSTI2024

Relational bulk reconstruction from modular flow

Abstract The entanglement wedge reconstruction paradigm in AdS/CFT states that for a bulk qudit within the entanglement wedge of a boundary subregion$$ \overline{A} $$ A ¯ , operators acting on the bulk qudit can be reconstructed as CFT operators on$$ \overline{A} $$ A ¯ . This naturally fits within the framework of quantum error correction, with the CFT states containing the bulk qudit forming a code protected against the erasure of the boundary subregionA. In this paper, we set up and study a framework for relational bulk reconstruction in holography: given two code subspaces both protected against erasure of the boundary regionA, the goal is to relate the operator reconstructions between the two spaces. To accomplish this, we assume that the two code subspaces are smoothly connected by a one-parameter family of codes all protected against the erasure ofA, and that the maximally-entangled states on these codes are all full-rank. We argue that such code subspaces can naturally be constructed in holography in a “measurement-based” setting. In this setting, we derive a flow equation for the operator reconstruction of a fixed code subspace operator using modular theory which can, in principle, be integrated to relate the reconstructed operators all along the flow. We observe a striking resemblance between our formulas for relational bulk reconstruction and the infinite-time limit of Connes cocycle flow, and take some steps towards making this connection more rigorous. We also provide alternative derivations of our reconstruction formulas in terms of a canonical reconstruction map we call the modular reflection operator.

Physics↗