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DOE OSTI2026

CMS Outer Tracker Module QA

The High Luminosity Large Hadron Collider is a planned upgrade to the LHC that will allow it to take up to 7 times as much data. Upgrades to all detector systems, including the Outer Tracker, are necessary to allow them to handle the increased radiation and pileup. Fermilab has been tasked with assembling modules for the Outer Tracker system. This presentation discusses the QA tests performed on these modules and the integration procedure required to ensure all modules work in sync. The QA tests include sensor IV curves, MaPSA testing, visual inspection, skeleton testing, and module testing. There are additional tests that can only be performed on integrated modules that are working in sync, and developing an understanding of the timing and latency of the modules is necessary to perform this synchronization.

Hobbeheydar, Samuel [Fermilab; Carnegie Mellon U. ↗

DOE OSTI2023

Grid Resilient, Self-Powered, Fuel Flexible, High Efficiency Heating System (Final Report)

The Grid Independent High Efficiency System (GIHES) delivers a heating system that operates free from the power grid and provides ultra-low emissions and high efficiency heating for residential and commercial buildings. The project demonstrated two weeks of continuous grid independent operation of a storage water heater equipped with a powered damper. The Thermoelectric Generator (TEG) integrated GIHES technology revolutionizes heating systems to provide grid resilient hot water production, while delivering significant value to the end user by eliminating impacts of power interruption and enhancing comfort, convenience and productivity. The system maximizes the thermal-to-electric conversion efficiency by optimizing location and orientation of the TEGs and durability while lowering system costs. The TEGs generate enough power to charge a battery and run the storage water heater unit with a powered damper uninterrupted by providing the required parasitic electrical power for start-up, shutdown and during idling. Several TEGs were analytically and experimentally evaluated based on the size, surface area and the power being generated before designing and fabricating a complete multi-TEG assembly for integration with the water heater. The GIHES technology can be extended to boilers, furnaces and tankless water heaters and integrated with heat pump to further increase the overall equipment efficiency. The technology has the potential to reduce the amount of dispatch power and peak power plant operation. An advanced burner was designed, developed and 3D printed for fuel flexible operation. The burner was designed to enable tighter integration with TEGs for potentially higher TEG output, should this be necessary. A bench-scale test rig to perform testing of a 200,000 Btu/h burner and capable of handling up to 10% H2 (by volume) was setup at GTI’s laboratory with appropriate safety and controls to ensure smooth and safe operation. Testing of the 3D burner showed < 5 ppm NOx emissions can be achieved for the entire firing range and with different levels of hydrogen blends with natural gas. The burner will enable a more integrated TEG-burner module design for improved system performance, should this be required in the future. Techno-economic analysis (TEA) of the TEG integrated with the water heaters was performed. The testing data and the power output were used to develop the TEA. The analysis for the storage unit with damper showed that the TEG integrated system costs $95. This is much lower than a one-time charge needed to wire and install dedicated power. Discussions with TEG manufacturers and OEM’s will provide more detailed information and methods to further lower these costs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Can we safely go to 200 °C? An integrated approach to assessing impacts to the engineered barrier system in a high-temperature repository

Abstract. This presentation gives on overview of the complex thermo-hydro-mechanical-chemical (THMC) processes occurring during the disposal of heat-producing high-level radioactive waste in geologic repositories. A specific focus is on the role of compacted bentonite, which is commonly used as an engineered backfill material for emplacement tunnels because of its low permeability, high swelling pressure, and radionuclide retention capacity. Laboratory and field tests integrated with THMC modeling have provided an effective way to deepen our understanding of temperature-related perturbations in the engineered barrier system; however, most of this work has been conducted for maximum temperatures around 100 ∘C. In contrast, some international disposal programs have recently started investigations to understand whether local temperatures in the bentonite of up to 200 ∘C could be tolerated with no significant changes to safety relevant properties. Raising the maximum temperature is attractive for economical and safety reasons but faces the challenge of exposing the bentonite to significant temperature increases. Strong thermal gradients may induce complex moisture transport processes while geochemical processes, such as cementation and perhaps also illitization effects may occur, all of which could strongly affect the bentonite and near-field rock properties. Here, we present initial investigations of repository behavior exposed to strongly elevated temperatures. We will start discussing our current knowledge base for temperature effects in repositories exposed to a maximum temperature of 100 ∘C, based on data and related modeling analysis from a large heater experiment conducted for over 18 years in the Grimsel Test Site in Switzerland. We then show results from coupled THMC simulations of a nuclear waste repository in a clay formation exposed to a maximum temperature of 200 ∘C. We also explore preliminary data from a bench-scale laboratory mock-up experiment, which was designed to represent the strong THMC gradients occurring in a “hot” repository, and we finally touch on a full-scale field heater test to be conducted soon in the Grimsel Test Site underground research laboratory in Switzerland (referred to as HotBENT).

Birkholzer, Jens T. (ORCID:0000000279891912)↗

DOE OSTI2024

Deep Learning-Based Dynamic Modeling of Three-Phase Voltage Source Inverters

Inverter-based resource (IBR) models are necessary to analyze modern power system stability and create effective control strategies. Modeling IBRs in converter-rich power systems is crucial, yet challenging due to the lack of commercial information on converter topologies and control parameters. This paper proposes novel convolutional neural network (CNN)–based data-driven techniques for modeling IBRs, addressing adaptability and proprietary concerns without requiring internal system physics knowledge. The proposed method is tested using real grid-tied commercial IBR transient data and demonstrates effectiveness and accuracy. Furthermore, the developed modeling approach is integrated and implemented in the open-source power distribution simulation and analysis tool, GridLAB-D, to illustrate the potentiality of dynamic analysis of large-scale power systems with high IBRs.

deep learning, artificial intelligence↗

DOE OSTI2021

Corrosion Protection and Dissimilar Material Joining for Next Generation Lightweight Vehicles

The Arconic Technology Center working with Honda R&D Americas, LLC and the Ohio State University evaluated the corrosion performance of several multi-material conditions and demonstrated the production worthiness of the Resistance Spot Riveting (RSR™) process. RSR is a new technology being developed by Howmet Fastening Systems (formerly Arconic, Inc.) that employs a fastener that is installed using conventional resistance spot welding equipment to produce multi-material joints. The goal of the 3-year project was to demonstrate the use of RSR to join aluminum to steel and aluminum to carbon fiber composites on a prototype scale. Deployment of this technology would help the automotive industry achieve an additional 10 to 20% weight reduction over high strength steels. These weight-savings to the body in white generally translates to 2.5-5.0% of overall vehicle curb weight. The resulting total weight-savings could provide a 1.5% to 3.0% total improvement in fuel efficiency for vehicles that incorporate RSR for multi-material joining. The RSR technology addresses several production barriers to achieving DOE’s fuel efficiency targets including eliminating the need of additional capital for new joining technologies and the flexibility to process conventional steel and multi-material structures with the same equipment. Additionally, the trend towards ultra-high strength steels limits the availability of conventional joining technologies that can effectively process these multi-material combinations. In order to accomplish these goals, the following program milestones were completed by the team: 1) Developed RSR process parameters, producing multi-material joints for mechanical testing and corrosion assessments. 2) Conducted corrosion evaluation of RSR and baseline joints assembled between automotive type aluminum alloys, steels, and carbon fiber using several corrosion mitigation strategies. 3) Developed a production ready feed system and integrate into a robotic resistance spot welding station to simulate automotive production conditions. 4) Produced demonstration assemblies for testing and evaluation.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Statistical Steady-State Stability Analysis for Transmission System Planning for Offshore Wind Power Plant Integration

This paper presents a statistical steady-state stability analysis for transmission system planning studies in order to identify operational issues inherent in the integration of offshore wind power plants. It includes normal and contingency operation. This study considers the integration of a 1000-MW offshore wind power plant into the FirstEnergy/PJM service territory in the U.S. Great Lakes region as a case study and uses a realistic computer model of the U.S. Eastern Interconnection, a 63,000-bus test system. The results show the utility of this statistical analysis tool and its effectiveness in identification of the operational impacts as a result of the integration of offshore wind power plant.

Sajadi, Amirhossein↗

DOE OSTI2022

Model predictive control for demand flexibility: Real-world operation of a commercial building with photovoltaic and battery systems

Hundreds of studies have investigated Model Predictive Control (MPC) for the optimal operation of building energy systems in the past two decades. However, MPC field tests are still uncommon, especially for small- and medium-sized commercial buildings and for buildings integrated with onsite renewables. This paper describes the implementation and the long-term performance evaluation of an MPC controller in a small commercial building equipped with behind-the-meter photovoltaics and electrochemical batteries. MPC controls space conditioning, commercial refrigeration, and the battery system. We tested two types of demand flexibility applications in the field: electricity bill minimization under time-of-use tariffs and responses to grid flexibility events. Results show that the proposed controller achieves 12% of annual electricity cost savings and 34% peak demand reduction against the baseline, while respecting thermal comfort and food safety. The field tests also demonstrate the ability of the MPC controller to provide a multitude of grid services including real-time pricing, demand limiting, load shedding, load shifting, and load tracking, using the same optimization framework.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2021

Modelling of Wastewater Heat Recovery Heat Pump Systems

Wastewater heat recovery is currently an underutilized technology that could be part of solving the climate crisis. A large portion of the heat that leaves a building in the form of wastewater is potentially recoverable for pre-heating domestic hot water or other service water systems. While there are several different approaches to wastewater heat recovery, this project focused on creating detailed, integrated building models for wastewater heat recovery heat pump systems. EnergyPlus models were developed featuring inputs and assumptions corresponding to manufacturers’ specifications, performance lab test data and feedback from engineering consultants. EnergyPlus’s supervisory control Energy Management System objects were heavily relied upon to overcome modelling challenges. The developed EnergyPlus model was integrated into U.S. Department of Energy New Construction Reference Building models for various climate zones and building types to assess potential energy use, energy cost and greenhouse gas emission reductions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Demonstrate FARM supervisory capabilities for a thermal energy storage problem for the DETAIL facility: IES Simulation Ecosystem Control System Development

The goal of the power dispatch problem for an Integrated Energy System (IES) is to adjust the power output and the heat flow of each component to maximize the profitability of the whole unit. Facilities that can integrate real-time digital signals, mock nuclear power, thermal energy storage and industrial heat use via high-temperature electrolysis were constructed at INL to support the research activities. The Dynamic Energy Technology and Integration Laboratory (DETAIL) houses the Microreactor Agile Non-nuclear Experimental Test Bed (MAGNET) and the Thermal Energy Distribution System (TEDS). In this report, the hierarchical control system architecture proposed in June 2023 milestone for the flexible operation of DETAIL facility is finalized and demonstrated. A brief description of the components and the corresponding Dymola models from the HYRBID repository is first provided. Then, the current control strategy is presented. In particular, the approach for generating the set-point trajectories to be fed to the PI controllers is analyzed, and its limits were identified. To preserve safe operation over both long-time and real-time horizons, the integration of a Supervisory Control layer embedding a modified version of FARM (Feasible Actuator Range Modifier) module is proposed. FARM is a component of the RAVEN-based FORCE framework designed to support HERON module at optimizing the operation of IES units. The proposed control system for DETAIL foresees FARM to be applied twice, i.e., the original version (“FARM-Validator”) aiding the solution of the power dispatch problem, and a modified version (“FARM-Supervisory”) coordinating the PID controllers. Despite the kernel of the two modules is the same, their tasks are quite different. The former intervenes at the beginning of each hour to prevent constraint violations over long time periods, the latter addresses real-time control tasks and monitors the response of constrained variables at a much finer time resolution. A tentative procedure for training the embedded Digital Twins with the experimental data is also proposed. Finally, the capabilities of the designed architecture and the impact of the added Supervisory Control layer are demonstrated by simulating a representative power dispatch scenario.

25 ENERGY STORAGE↗

DOE OSTI2023

Synchronous Wind: Evaluating the Grid Impact of Inverterless Grid-Forming Wind Power Plants

Grid-forming (GFM) control of Type-3 and Type-4 wind turbine generators has attracted substantial attention in power systems research; however, the limited over-current capability of power electronics converters continues to deteriorate the grid strength of the evolving power systems. This paper develops the generic model of synchronous wind power generators, also known as Type-5 wind turbines, for power system integration studies. The Type-5 wind turbine interfaces with the electric grid through a synchronous generator; hence, its operation and consequent grid impacts are similar to a conventional power plant. Based on the developed model, a Type-5 wind power plant is integrated into the IEEE 14-bus test bed to evaluate its control and operation with a bulk power system. Finally, the stability properties of Type-5 wind turbine generators are compared with Type-3 wind turbines in GFM control mode through impedance characterization.

grid strength↗

DOE OSTI2023

Final Design and Analysis of the Superconducting Magnets for the Material Plasma Exposure Experiment

The Material Plasma Exposure eXperiment (MPEX), which has completed its final design, is a new linear plasma device to advance the understanding of plasma-material interactions through the generation and delivery of plasmas as they are expected in future fusion reactor divertors. MPEX will be a steady-state device to study high-fluence exposures of plasma-facing materials and components. The requirements for the magnetic field at the heating stages and the target make the application of superconducting coils necessary. The final designs for the superconducting magnets have been developed using three cryostat designs with warm bore diameters of 65 cm and 156 cm. The large bores are required to for other systems such as vacuum, water cooling, and RF power. There are 19 superconducting coils in MPEX that are contained in six cryostats. Although design, fabrication, and testing for the magnets as stand-alone units are straightforward, challenges will arise during the integration of the system. Various field profiles will be used during operation. The magnetic field where the electron cyclotron heating occurs needs to operate at both 1.25 and 2.50 T. Analyses that have been performed on the final design include designing the coils and determining operating currents to meet field requirements, forces between cryostats, the effects of coil and/or cryostat movement, and quench analysis. To ensure that the magnetic field requirements are met, a plan for monitoring the magnetic field at specified locations has been developed which includes the effect of coil and/or cryostat movement.

Burkhardt, Earle↗

DOE OSTI2020

Advanced control sequences and FDD technology. Just shiny objects, or ready for scale?

Innovations in commercial building control sequences (ASHRAE guideline 36) and fault detection and diagnostics (FDD) technology have the potential to transform existing building operational efficiency by realizing whole-building level savings on the order of 15% and higher. However, several technical and market barriers related to up-front estimation of achievable savings, verifying implementation, and ensuring persistence are slowing down their adoption as a core offering through diverse owner-funded initiatives and rate-payer funded programs. This paper describes a suite of solutions to overcome these barriers to program delivery of advanced HVAC controls integrated with FDD energy management and information system (EMIS) technology. First, the Guideline 36 conformance test offers an automated method to confirm correct sequence implementation by the manufacturer, before field deployment. A successful test of a controller was conducted using a new manufacturer-independent hardware-in-the-loop testbed demonstrating the viability and scalability of this approach. Second, the Guideline 36 energy savings calculator uses modeling paired with high-level user inputs to estimate building-specific savings potential, target cost effective implementation and minimize uncertainty. Initial results indicate the baseline control sequences significantly impact energy savings, however, as much as 50% savings may be possible for the worst-case baseline scenario. Third, a functional specification provides minimum recommended EMIS-FDD capabilities, and best practices to integrate the technology into organizational practice and ensure that advanced control sequences provide persistent savings.

Pritoni, Marco↗

DOE OSTI2022

Scalability Testing Approach for Internet of Things for Manufacturing SQL and NoSQL Database Latency and Throughput

The proliferation of low-cost sensors and industrial data solutions has continued to push the frontier of manufacturing technology. Machine learning and other advanced statistical techniques stand to provide tremendous advantages in production capabilities, optimization, monitoring, and efficiency. The tremendous volume of data gathered continues to grow, and the methods for storing the data are critical underpinnings for advancing manufacturing technology. This work aims to investigate the ramifications and design tradeoffs within a decoupled architecture of two prominent database management systems (DBMS): sql and NoSQL. A representative comparison is carried out with Amazon Web Services (AWS) DynamoDB and AWS Aurora MySQL. The technologies and accompanying design constraints are investigated, and a side-by-side comparison is carried out through high-fidelity industrial data simulated load tests using metrics from a major US manufacturer. The results support the use of simulated client load testing for comparing the latency of database management systems as a system scales up from the prototype stage into production. As a result of complex query support, MySQL is favored for higher-order insights, while NoSQL can reduce system latency for known access patterns at the expense of integrated query flexibility. Here, by reviewing this work, a manufacturer can observe that the use of high-fidelity load testing can reveal tradeoffs in IoTfM write/ingestion performance in terms of latency that are not observable through prototype-scale testing of commercially available cloud DB solutions.

AWS↗

DOE OSTI2026

Captan+X Data Converter Integration

Fermi National Accelerator Laboratory's CAPTAN (Compact And Programmable daTa Acquisition Node) series provides a flexible hardware platform for data acquisition across a range of experiments and facilities. The latest iteration, CAPTAN+X, is built around a Kintex-7 FPGA supporting four FPGA Mezzanine Card (FMC) connections. As part of a broader laboratory effort to bring facility systems under a Model-Based Systems Engineering (MBSE) framework, CAPTAN+X is one of several systems slated to be incorporated into this modeling environment in the near term. A necessary step toward that goal is incorporating the platform's core functionality, which centers on integration with the LXD31K4 FMC, a data converter module combining dual AD9652 analog-to-digital converters and dual AD9142A digital-to-analog converters. Achieving compatibility required resolving pin-mapping conflicts between the LXD31K4's High Pin Count connector and the CAPTAN+X's available pin types, adapting a Board Support Project originally written for an UltraScale-class evaluation board to the Kintex-7 architecture, replacing incompatible primitives, restructuring clock distribution, and manually configuring chip initialization in place of an unsupported soft-processor-based approach. Functional verification of the ADC and DAC channels, followed by closed-loop testing combining both converters with real-time filtering, confirmed correct operation of the integrated system. These results establish a working hardware and firmware baseline for the CAPTAN+X platform, positioning it for future inclusion in the laboratory's growing MBSE modeling effort.

Espinoza, David [Illinois U., Urbana (main)]↗

DOE OSTI2026

CAPTAN+X Data Converter Integration

Espinoza, David [Illinois U., Urbana (main)]↗

DOE OSTI2024

Development of a Distribution Optimal Power Flow Federate for Open-Source OEDI-SI Platform

Increasing numbers of distributed generators in the electric power distribution networks require developing a control strategy to optimize solutions in real time. Linearized optimal distribution flow development has seen growth and acceptance in the distribution systems literature for efficiently modeling the \glspl{opf} for distribution systems. This paper examines the implementation and integration procedure for linearized optimal distribution flow federate to \gls{oedisi} platform. Specifically, we discuss i) the usage of the \gls{oedisi} platform, ii) obtaining a tractable solution using developed \gls{opf} federate, and iii) validation of solutions and bench-marking the \gls{oedisi} platform with developed \gls{opf} federate using OpenDSS. In brief, we demonstrate how a general linearized optimal distribution flow federate can be developed and integrated with a co-simulation environment to mimic real-world examples. The efficacy of the proposed method is demonstrated using the IEEE 123-bus test system under different scenarios to obtain a tractable solution and compare its results.

Sadnan, Rabayet↗

DOE OSTI2025

Selection of solvents for integrated CO 2 absorption and electrochemical reduction systems

Abstract Solvent‐based electrochemical CO 2 reduction (CO 2 R) enables the production of chemicals or fuels using CO 2 from a preceding absorption process. Employing previously tested CO 2 capture solvents does not ensure their suitability for either CO 2 R or integrated CO 2 absorption‐reduction. We propose solvent selection criteria that include the CO 2 solubility, kinetic constant, ionic conductivity, concentration of the bicarbonate, carbamate, and solvent cation in the CO 2 ‐loaded solution, and sustainability indicators. They are implemented for solvent selection (a) from novel, aqueous mixtures of N ‐methylcyclohexylamine (MCA) with piperazine (PZ), 2‐amino‐2‐methyl‐1‐propanol (AMP), potassium hydroxide (KOH), and potassium chloride (KCl) and (b) from aqueous monoethanolamine (MEA), AMP, KOH, MCA, and PZ solutions. Versions of a modified Kent‐Eisenberg model for strong bases, carbamate, and non‐carbamate‐forming amine solutions are developed and parameterized through experimental equilibrium measurements. CO 2 R experimental results are presented for solutions of KOH and MCA + KOH, as these indicate desired trade‐offs for CO 2 absorption and reduction.

Amines↗

DOE OSTI2023

Bovine Rectoanal Junction In Vitro Organ Culture Model System to Study Shiga Toxin-Producing Escherichia coli Adherence

Studies evaluating the interactions between Shiga toxin-producing Escherichia coli O157:H7 (O157) and the bovine recto–anal junction (RAJ) have been limited to either in vitro analyses of bacteria, cells, or nucleic acids at the RAJ, providing limited information. Alternatively, expensive in vivo studies in animals have been conducted. Therefore, our objective was to develop a comprehensive in vitro organ culture system of the RAJ (RAJ-IVOC) that accurately represents all cell types present in the RAJ. This system would enable studies that yield results similar to those observed in vivo. Pieces of RAJ tissue, obtained from unrelated cattle necropsies, were assembled and subjected to various tests in order to determine the optimal conditions for assaying bacterial adherence in a viable IVOC. O157 strain EDL933 and E. coli K12 with known adherence differences were used to standardize the RAJ-IVOC adherence assay. Tissue integrity was assessed using cell viability, structural cell markers, and histopathology, while the adherence of bacteria was evaluated via microscopy and culture methods. DNA fingerprinting verified the recovered bacteria against the inoculum. When the RAJ-IVOC was assembled in Dulbecco’s Modified Eagle Medium, maintained at a temperature of 39 °C with 5% CO 2 and gentle shaking for a duration of 3–4 h, it successfully preserved tissue integrity and reproduced the expected adherence phenotype of the bacteria being tested. The RAJ-IVOC model system provides a convenient method to pre-screen multiple bacteria-RAJ interactions prior to in vivo experiments, thereby reducing animal usage.

59 BASIC BIOLOGICAL SCIENCES↗