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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

A spatial superstructure approach to the optimal design of modular processes and supply chains

Modularity is a design principle that aims to provide flexibility for spatio-temporal assembly/disassembly and reconfiguration of systems. This design principle can be applied to multiscale (hierarchical) manufacturing systems that connect units, processes, facilities, and entire supply chains. Designing modular systems is challenging because of the need to capture spatial interdependencies that arise between system components due to product exchange/transport between components and due to product transformation in such components. In this work, we propose an optimization framework to facilitate the design of modular manufacturing systems. Central to our approach is the concept of a spatial superstructure, which is a graph that captures all possible system configurations and interdependencies between components. The spatial superstructure is a generalization of the notion of a superstructure and of a p-graph used in process design, in that it encodes spatial (geographical) context of the system components. Here, we show that this generalization facilitates the simultaneous design and analysis of processes, facilities, and of supply chains. Our framework aims to select the system topology from the spatial superstructure that minimizes design cost and that maximizes design modularity. We show that this design problem can be cast as a mixed-integer, multi-objective optimization formulation. We demonstrate these capabilities using a case study arising in the design of a plastic waste upcycling supply chain.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Oxy-combustion process with modular boiler design

A modular boiler system for implementing fuel combustion is provided. The system includes a first boiler and a second boiler of a plurality of boilers, an oxygen input unit, a fuel input unit, a recycled flue gas input unit, and a flue gas separator. The first boiler receives oxygen from the oxygen input unit, fuel from the fuel input unit, and recycled flue gas from the recycled flue gas input unit. The first boiler outputs intra-system flue gas. The flue gas separator separates the intra-system flue gas into a first and second flue gas stream, transfers the first flue gas stream to the second boiler, and transfers the second flue gas stream to a gas cleaning system. The second boiler receives oxygen from the oxygen input unit, fuel from the fuel input unit, and the first flue gas stream from the flue gas separator.

Axelbaum, Richard L.↗
DOE OSTI2015

A modular reactor design for in situ synchrotron x-ray investigation of atomic layer deposition processes

Synchrotron characterization techniques provide some of the most powerful tools for the study of film structure and chemistry. The brilliance and tunability of the Advanced Photon Source allow access to scattering and spectroscopic techniques unavailable with in-house laboratory setups and provide the opportunity to probe various atomic layer deposition (ALD) processes in situ starting at the very first deposition cycle. Here, we present the design and implementation of a portable ALD instrument which possesses a modular reactor scheme that enables simple experimental switchover between various beamlines and characterization techniques. As first examples, we present in situ results for (1) X-ray surface scattering and reflectivity measurements of epitaxial ZnO ALD on sapphire, (2) grazing-incidence small angle scattering of MnO nucleation on silicon, and (3) grazing-incidence X-ray absorption spectroscopy of nucleation-regime Er{sub 2}O{sub 3} ALD on amorphous ALD alumina and single crystalline sapphire.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Design of Modular Test Facility for Particle/sCO2 Heat Exchanger Evaluation

Heliogen has designed a 1.3 MW particle and supercritical carbon dioxide (sCO2) test loop to retire technical and manufacturing risks. The data from this facility will be used to validate near commercial-scale particle heat exchanger modules. The heat exchanger is scaled to capture all features of the full-scale modules. Testing will be conducted with CARBOBEAD HSP 16/30, a larger particle size than other recent testing. The system was designed to ASME codes with the constraint that sCO2 piping and other major components are stainless steels.

14 SOLAR ENERGY↗
DOE OSTI2024

Design Basis Model for Hosting Small Modular Reactors

An aggressive transition from fossil fuels to other types of energy implies the need to construct a large number of nuclear power plants in the near future. However, the real and perceived risks of nuclear energy remain a significant impediment to this transition. This paper describes a comprehensive work process that combines the rigor of model-based systems engineering (MBSE) with 1) the Idaho National Laboratory's (INL) decades of experience with small reactors and with 2) modern project delivery processes. The objective is to reduce the risk of building new facilities or converting existing facilities to nuclear power generation.

42 ENGINEERING↗
DOE OSTI2015

Safeguards and Security by Design (SSBD) for Small Modular Reactors (SMRs) through a Common Global Approach

Small Modular Reactors (SMR) with power levels significantly less than the currently standard 1000 to 1600-MWe reactors have been proposed as a potential game changer for future nuclear power. SMRs may offer a simpler, more standardized, and safer modular design by using factory built and easily transportable components. Additionally, SMRs may be more easily built and operated in isolated locations, and may require smaller initial capital investment and shorter construction times. Because many SMRs designs are still conceptual and consequently not yet fixed, designers have a unique opportunity to incorporate updated design basis threats, emergency preparedness requirements, and then fully integrate safety, physical security, and safeguards/material control and accounting (MC&A) designs. Integrating safety, physical security, and safeguards is often referred to as integrating the 3Ss, and early consideration of safeguards and security in the design is often referred to as safeguards and security by design (SSBD). This paper describes U.S./Russian collaborative efforts toward developing an internationally accepted common approach for implementing SSBD/3Ss for SMRs based upon domestic requirements, and international guidance and requirements. These collaborative efforts originated with the Nuclear Energy and Nuclear Security working group established under the U.S.-Russia Bilateral Presidential Commission during the 2009 Presidential Summit. Initial efforts have focused on review of U.S. and Russian domestic requirements for Security and MC&A, IAEA guidance for security and MC&A, and IAEA requirements for international safeguards. Additionally, example SMR design features that can enhance proliferation resistance and physical security have been collected from past work and reported here. The development of a U.S./Russian common approach for SSBD/3Ss should aid the designer of SMRs located anywhere in the world. More specifically, the application of this approach may lead to more proliferation resistant and physically secure design features for SMRs.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2019

Comparison of Multi-Objective Evolutionary Algorithms to Solve the Modular Cell Design Problem for Novel Biocatalysis

A large space of chemicals with broad industrial and consumer applications could be synthesized by engineered microbial biocatalysts. However, the current strain optimization process is prohibitively laborious and costly to produce one target chemical and often requires new engineering efforts to produce new molecules. To tackle this challenge, modular cell design based on a chassis strain that can be combined with different product synthesis pathway modules has recently been proposed. This approach seeks to minimize unexpected failure and avoid task repetition, leading to a more robust and faster strain engineering process. In our previous study, we mathematically formulated the modular cell design problem based on the multi-objective optimization framework. In this study, we evaluated a library of state-of-the-art multi-objective evolutionary algorithms (MOEAs) to identify the most effective method to solve the modular cell design problem. Using the best MOEA, we found better solutions for modular cells compatible with many product synthesis modules. Furthermore, the best performing algorithm could provide better and more diverse design options that might help increase the likelihood of successful experimental implementation. We identified key parameter configurations to overcome the difficulty associated with multi-objective optimization problems with many competing design objectives. Interestingly, we found that MOEA performance with a real application problem, e.g., the modular strain design problem, does not always correlate with artificial benchmarks. Overall, MOEAs provide powerful tools to solve the modular cell design problem for novel biocatalysis.

Garcia, Sergio (ORCID:000000023998986X)↗
DOE OSTI2023

Preliminary Neutronics Design and Analysis of the Fast Modular Reactor

General Atomics is developing a new 100-MW(thermal) fast modular reactor (FMR) that provides safe, carbon-free electricity and is capable of incremental capacity additions. The modular design allows it to be factory built and assembled onsite to keep the capital cost low, while the use of dry cooling facilitates siting to complement renewables in nearly any location. The FMR uses high-assay low-enriched uranium-dioxide fuel encapsulated by recognized irradiationresistant silicon carbide composite (SiGA®) cladding that is derisked in the current accident-tolerant fuel program. The FMR fuel assembly is a hexagonal fuel bundle of 120 fuel rods. The total length of the fuel assembly is less than 4 m, with an active fuel length of 1.8 m. The fuel assemblies are configured in an annular core that is located and supported by the reactor internals. The coolant material is helium at a normal operating pressure of 7 MPa. The core is surrounded by zirconium silicide (Zr 3 Si 2 ) and graphite reflector blocks. The fuel, coolant, internals, and reflectors are contained within a reactor pressure vessel. Here, the preliminary nuclear design and analysis established the arrangement of the active core and reflector blocks. The nuclear design analyses of the FMR defined the design parameters, such as fuel enrichments, excess reactivity, fueling scheme, fuel cycle, power distribution, and control rod worth. The preliminary conceptual design determined the three-batch fueling scheme with the allowable total power peaking factor of 1.5. The average discharge burnup is 100 GW days per ton of uranium.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

A Modular Integration Design of LCL Circuit Featuring Field Enhancement and Misalignment Tolerance for Wireless EV Charging

One of the major challenges of high-order wireless charging circuit is to reduce the system volume and cost induced by its additional components. Based on an LCL-S circuit, this paper proposes a modular integration design, in which an identical compensation inductor and transmitter are closely coupled. A new compensation method is derived to enable zero phase angle (ZPA) and constant current (CC) output. Identical currents are fed into the same reference terminals of both inductors to enable transmission field enhancement and to eliminate reactive power flow between the inductors. A misalignment tolerant coil is used to improve the output power stability under random parking imperfection. The proposed integration design achieves enhanced transmission capacity. Experiments are carried out to verify the proposed design.

Zhang, Pengcheng↗
DOE OSTI2022

Module-Fluidics: Building Blocks for Spatio-Temporal Microenvironment Control

Generating the desired solute concentration signal in micro-environments is vital to many applications ranging from micromixing to analyzing cellular response to a dynamic microenvironment. We propose a new modular design to generate targeted temporally varying concentration signals in microfluidic systems while minimizing perturbations to the flow field. The modularized design, here referred to as module-fluidics, similar in principle to interlocking toy bricks, is constructed from a combination of two building blocks and allows one to achieve versatility and flexibility in dynamically controlling input concentration. The building blocks are an oscillator and an integrator, and their combination enables the creation of controlled and complex concentration signals, with different user-defined time-scales. We show two basic connection patterns, in-series and in-parallel, to test the generation, integration, sampling and superposition of temporally-varying signals. All such signals can be fully characterized by analytic functions, in analogy with electric circuits, and allow one to perform design and optimization before fabrication. Such modularization offers a versatile and promising platform that allows one to create highly customizable time-dependent concentration inputs which can be targeted to the specific application of interest.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

Identifying Parameter Space for Robust Stability in Nonlinear Networks: A Microgrid Application

As modern engineering systems grow in complexity, attitudes toward a modular design approach become increasingly more favorable. A key challenge to a modular design approach is the certification of robust stability under uncertainties in the rest of the network. In this paper, we consider the problem of identifying the parametric region, which guarantees stability of the connected module in the robust sense under uncertainties. We derive the conditions under which the robust stability of the connected module is guaranteed for some values of the design parameters, and present a sum-of-squares (SOS) optimization-based algorithm to identify such a parametric region for polynomial systems. Using the example of an inverter-based microgrid, we show how this parametric region changes with variations in the level of uncertainties in the network.

Kundu, Soumya↗
DOE OSTI2016

An advanced materials irradiation facility for materials and fuels irradiations at the high flux isotope reactor

The High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory (ORNL) is a pressurized, light-water-cooled and -moderated, beryllium-reflected, 85 MW research reactor fueled by Highly enriched {sup 235}U. The Materials Irradiation Facility (MIF) at HFIR) is one of the two experimental platforms in the US that can host fully instrumented and monitored experiments in a high-neutron-flux environment. The unique advantage of instrumented capsules is that the researcher can monitor and acquire in situ data and change capsule operating conditions in real time during the irradiation. Recently ORNL funded a Laboratory-Directed Research and Development (LDRD) project to strategically enhance the capabilities of MIF and provide researchers with a more flexible experimental platform. MIF comprises 4 systems: a gas supply system, a supervisory control system, an effluent system, and a standard gas routing system. The first 3 systems have common functionality for all types of experiments. The gas routing system provides the correct gases and gas mixtures for individual experiments and is unique to each experiment. MIF improvements include an updated and more sophisticated experiment monitoring system, a modular design allowing easier addition of simultaneous experiments, and features that allow rapid incorporation of additional instrumentation. The new design is both modular and re-configurable. It calls for a standard gas routing system module that can be configured with software to allow for easy expansion to multiple experiments. The ability to monitor the effluent activity during fissile material irradiation is a much needed enhancement for detecting fuel failures or determining fission product release. A gamma-ray spectrometry will be installed in a bypass gas line off the effluent main stream. The gas will flow through the detector for continuous detection of the particles of interest.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2024

De novo design of modular protein hydrogels with programmable intra- and extracellular viscoelasticity

Relating the macroscopic properties of protein-based materials to their underlying component microstructure is an outstanding challenge. Here, we exploit computational design to specify the size, flexibility, and valency of de novo protein building blocks, as well as the interaction dynamics between them, to investigate how molecular parameters govern the macroscopic viscoelasticity of the resultant protein hydrogels. We construct gel systems from pairs of symmetric protein homo-oligomers, each comprising 2, 5, 24, or 120 individual protein components, that are crosslinked either physically or covalently into idealized step-growth biopolymer networks. Through rheological assessment, we find that the covalent linkage of multifunctional precursors yields hydrogels whose viscoelasticity depends on the crosslink length between the constituent building blocks. In contrast, reversibly crosslinking the homo-oligomeric components with a computationally designed heterodimer results in viscoelastic biomaterials exhibiting fluid-like properties under rest and low shear, but solid-like behavior at higher frequencies. Exploiting the unique genetic encodability of these materials, we demonstrate the assembly of protein networks within living mammalian cells and show via fluorescence recovery after photobleaching (FRAP) that mechanical properties can be tuned intracellularly in a manner similar to formulations formed extracellularly. We anticipate that the ability to modularly construct and systematically program the viscoelastic properties of designer protein-based materials could have broad utility in biomedicine, with applications in tissue engineering, therapeutic delivery, and synthetic biology.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Design of a Modular E-Core Flux Concentrating Axial Flux Machine

In this paper a novel E-Core axial flux machine is proposed. The machine has a double stator-single rotor configuration with flux concentrating ferrite magnets, and pole windings across each leg of an E-Core stator. E-Core stators with the proposed flux-concentrating rotor arrangement result in better magnet utilization and higher torque density. The machine also has a modular structure facilitating simpler construction. This paper presents a single phase and a three-phase version of the E-Core machine. Case study for a 1.1 kW, 400 rpm machine for both the single phase and three-phase axial flux machine is presented. The results are verified through 3D finite element analysis.

17 WIND ENERGY↗
DOE OSTI2024

Progress in Fast Modular Reactor Conceptual Design

The Fast Modular Reactor (FMR) is a 100-MW(thermal) gas-cooled fast reactor being developed by General Atomics Electromagnetic System with the goal of developing a FMR for flexible and dispatchable power to the U.S. electricity market in the mid-2030s. The conceptual design aims to develop and verify simplified design features. These include an inert helium gas coolant, pellet-loaded fuel rods, installations with air cooling as ultimate heat sink, and small and passive heat removal systems. The goal is to ensure the development of a safe, maintainable, cost-effective, and distributed nuclear energy-generating station. The baseline technologies selected to achieve this goal are a helium coolant that is an inert gas with no chemical reaction with structural components, not activated, single phase, enabling high-temperature operation and a high thermal efficiency Brayton cycle; conventional uranium dioxide (UO 2 ) fuel, which is the most widely used and well-known fuel material, capable of high burnup (100 MWd/kg) and a long fuel life; and silicon carbide composite (SiGA®) cladding and internal structures that are chemically inert in the helium environment, exceptionally radiation tolerant, and being derisked by accident tolerant fuel technology development. Further, the reactor was specifically designed with passive safety features, including high-temperature in-core materials and a reactor vessel cooling system consisting of cooling panels of naturally circulating water. The passive safety of the core was confirmed for the depressurized loss-of–forced cooling accident, which showed the peak cladding temperature at ~1600°C during the transient, which is below the current design limit of 1800°C. The conceptual design of the FMR has been conducted for the reactor system, vessel system, generator and turbomachine, instrumentation and control, residual heat removal system, plant service system, and containment, as well as pre-application licensing documents.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

Conceptual design of the modular detector and readout system for the CMB-S4 survey experiment

We present the conceptual design of the modular detector and readout system for the Cosmic Microwave Background – Stage four (CMB-S4) ground-based survey experiment. CMB-S4 will map the cosmic microwave background (CMB) and the millimeter-wave sky to unprecedented sensitivity, using 500,000 superconducting detectors observing from Chile and Antarctica to map over 60% of the sky. The fundamental building block of the detector and readout system is a detector module package operated at 100 mK, which is connected to a readout and amplification chain that carries signals out to room temperature. It uses arrays of feedhorn-coupled orthomode transducers (OMT) that collect optical power from the sky onto dc-voltage-biased transition-edge sensor (TES) bolometers. The resulting current signal in the TESs is then amplified by a two-stage cryogenic Superconducting Quantum Interference Device (SQUID) system with a time-division multiplexer to reduce wire count, and matching room-temperature electronics to condition and transmit signals to the data acquisition system. Sensitivity and systematics requirements are being developed for the detector and readout system over wide range of observing bands (20 to 300 GHz) and optical powers to accomplish CMB-S4’s science goals. While the design incorporates the successes of previous generations of CMB instruments, CMB-S4 requires an order of magnitude more detectors than any prior experiment. This requires fabrication of complex superconducting circuits on over 10 m2 of silicon, as well as significant amounts of precision wiring, assembly and cryogenic testing

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

VirSorter2: a multi-classifier, expert-guided approach to detect diverse DNA and RNA viruses

Abstract Background Viruses are a significant player in many biosphere and human ecosystems, but most signals remain “hidden” in metagenomic/metatranscriptomic sequence datasets due to the lack of universal gene markers, database representatives, and insufficiently advanced identification tools. Results Here, we introduce VirSorter2, a DNA and RNA virus identification tool that leverages genome-informed database advances across a collection of customized automatic classifiers to improve the accuracy and range of virus sequence detection. When benchmarked against genomes from both isolated and uncultivated viruses, VirSorter2 uniquely performed consistently with high accuracy (F1-score > 0.8) across viral diversity, while all other tools under-detected viruses outside of the group most represented in reference databases (i.e., those in the order Caudovirales ). Among the tools evaluated, VirSorter2 was also uniquely able to minimize errors associated with atypical cellular sequences including eukaryotic genomes and plasmids. Finally, as the virosphere exploration unravels novel viral sequences, VirSorter2’s modular design makes it inherently able to expand to new types of viruses via the design of new classifiers to maintain maximal sensitivity and specificity. Conclusion With multi-classifier and modular design, VirSorter2 demonstrates higher overall accuracy across major viral groups and will advance our knowledge of virus evolution, diversity, and virus-microbe interaction in various ecosystems. Source code of VirSorter2 is freely available ( https://bitbucket.org/MAVERICLab/virsorter2 ), and VirSorter2 is also available both on bioconda and as an iVirus app on CyVerse ( https://de.cyverse.org/de ).

59 BASIC BIOLOGICAL SCIENCES↗