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DOE OSTI2024

Feasible Actuator Range Modifier (FARM), a Tool Aiding the Solution of Unit Dispatch Problems for Advanced Energy Systems

Integrated energy systems (IESs) seek to minimize power generating costs in future power grids through the coupling of different energy technologies. To accommodate fluctuations in load demand due to the penetration of renewable energy sources, flexible operation capabilities must be fully exploited, and even power plants that are traditionally considered as base-load units need to be operated according to unconventional paradigms. Thermomechanical loads induced by frequent power adjustments can accelerate the wear and tear. If a unit is flexibly operated without respecting limits on materials, the risk of failures of expensive components will eventually increase, nullifying the additional profits ensured by flexible operation. In addition to the bounds on power variations (explicit constraints),the solution of the unit dispatch problem needs to meet the limits on the variation of key process variables, including temperature, pressure and flow rate (implicit constraints).The FARM (Feasible Actuator Range Modifier) module was developed to enable existing optimization algorithms to identify solutions to the unit dispatch problem that are both economically favorable and technologically sustainable. Thanks to the iterative dispatcher–validator scheme, FARM permits addressing all the imposed constraints without excessively increasing the computational costs. In this work, the algorithms constituting the module are described, and the performance was assessed by solving the unit dispatch problem for an IES composed of three units, i.e., balance of plant, gas turbine, and high-temperature steam electrolysis. Finally, the FARM module provides dedicated tools for visualizing the response of the constrained variables of interest during operational transients and a tool aiding the operator at making decisions. These techniques might represent the first step towards the deployment of an ecological interface design (EID) for IES units.

47 OTHER INSTRUMENTATION↗

DOE OSTI2025

A Review of the Research and Development of Brayton Cycle Technology in Nuclear Power Applications with a Focus on Compressor Technology

This study reviews the integration of Brayton Cycle (BC) systems in nuclear power generation, emphasizing their potential to enhance thermal efficiency and operational flexibility over traditional Rankine Cycle (RC) systems. Key working fluids, such as helium (He), supercritical carbon dioxide (sCO 2 ), nitrogen (N 2 ), and air, are evaluated for their performance, efficiency, and compatibility with nuclear systems. He is recognized for its high thermal conductivity and inertness at elevated temperatures, while sCO 2 demonstrates advantages in compactness and efficiency in midrange temperatures. This article also highlights the importance of compressor designs in optimizing BC performance and reviews, available compressor technologies. Axial and centrifugal compressor designs enable efficient gas compression while managing the thermal and mechanical stresses associated with high-pressure operations in nuclear systems. Combined with variable geometry components and advanced materials, these technologies address the challenges posed by varying load conditions. Despite the promising features of BC systems, several challenges persist, including high leakage rates and material degradation under extreme conditions, which necessitate robust sealing technologies and thorough testing. The insights gained from operational experiences at facilities, such as the Oberhausen II plant and the High-Temperature He Test Facility (HHV), underscore the complexities involved in designing high-temperature gas turbines for nuclear applications. This review concludes that as the nuclear industry evolves, BC systems hold significant promise for contributing to a sustainable energy future, particularly in the context of small modular reactors (SMRs) and microreactors. Further exploration of combined cycle configurations that combine BCs with RCs may enhance overall efficiency and flexibility in power generation.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Theoretical Prediction of Thermal Expansion Anisotropy for Y 2 Si 2 O 7 Environmental Barrier Coatings Using a Deep Neural Network Potential and Comparison to Experiment

Environmental barrier coatings (EBCs) are an enabling technology for silicon carbide (SiC)-based ceramic matrix composites (CMCs) in extreme environments such as gas turbine engines. However, the development of new coating systems is hindered by the large design space and difficulty in predicting the properties for these materials. Density Functional Theory (DFT) has successfully been used to model and predict some thermodynamic and thermo-mechanical properties of high-temperature ceramics for EBCs, although these calculations are challenging due to their high computational costs. In this work, we use machine learning to train a deep neural network potential (DNP) for Y 2 Si 2 O 7 , which is then applied to calculate the thermodynamic and thermo-mechanical properties at near-DFT accuracy much faster and using less computational resources than DFT. We use this DNP to predict the phonon-based thermodynamic properties of Y 2 Si 2 O 7 with good agreement to DFT and experiments. We also utilize the DNP to calculate the anisotropic, lattice direction-dependent coefficients of thermal expansion (CTEs) for Y 2 Si 2 O 7 . Molecular dynamics trajectories using the DNP correctly demonstrate the accurate prediction of the anisotropy of the CTE in good agreement with the diffraction experiments. In the future, this DNP could be applied to accelerate additional property calculations for Y 2 Si 2 O 7 compared to DFT or experiments.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Development of A Multi-Spectral Pyrometry Sensor for High-Speed Transient Surface-Temperature Measurements in Combustion-Relevant Harsh Environments

Accurate and high-speed transient surface-temperature measurements of combustion devices including internal combustion (IC) engines, gas turbines, etc., provide validation targets and boundary conditions for computational fluid dynamics models, and are broadly relevant to technology advancements such as performance improvement and emissions reduction. Development and demonstration of a multi-infrared-channel pyrometry-based optical instrument for high-speed surface-temperature measurement is described. The measurement principle is based on multi-spectral radiation thermometry (MRT) and uses surface thermal radiation at four discrete spectral regions and a corresponding emissivity model to obtain surface temperature via non-linear least squares (NLLS) optimization. Rules of thumb for specifying the spectral regions and considerations to avoid interference with common combustion products are developed; the impact of these along with linear and non-linear MRT analysis are assessed as a function of temperature and signal-to-noise ratio. A multi-start method to determine the MRT-solution global optimum is described and demonstrated. The resulting multi-channel transient pyrometry instrument is described along with practical considerations including optical-alignment drift, matching intra-channel transient response, and solution-confidence indicators. The instrument demonstrated excellent >97% accuracy and >99% 2-sigma precision over the 400–800 °C range, with ~20 µs (50 kHz, equivalent to 0.2 cad at 2000 RPM IC-engine operation) transient response in the bench validation.

47 OTHER INSTRUMENTATION↗

DOE OSTI2026

SuperLab 2.0 Showcase: Connecting Five Labs to Tackle Grid Complexity and Unlock Unique Grid Asset Potential

SuperLab 2.0 (5-Lab Demo) is a collaborative, national-scale experiment showcasing the coordination of geographically distributed energy assets in real time. The demonstration integrates 25 physical and digital assets, spanning wind, PV, batteries, electrolyzers, DC fast chargers, microgrid controllers, building automation systems, small modular reactor (SMR), control centers, and gas turbines, across five DOE national laboratories-NLR, INL, NETL, LBNL, and SNL. These assets are unified using Energy Sciences Network (ESnet), a low-latency, high-performance U.S. Department of Energy's (DOE) network, and controlled via a centralized energy controller hosted at NLR's ARIES facility. The demonstration validates the ability to stress-test hybrid energy systems under dynamic scenarios to de-risk advanced control strategies for greater resilience and flexibility. SuperLab 2.0 (5-Lab Demo) showcased a major advancement in federated national laboratory collaboration, enabling real-time, cross-laboratory experimentation to coordinate geographically dispersed distributed energy resources (DERs) using various communication protocols and networks. SuperLab 2.0 (5-Lab Demo) built on previous demonstrations conducted between NLR-PNNL and NLR-INL connecting diverse assets including distant protection devices, a SMR simulator, and a high temperature electrolyzer (HTE). Previous demos were based on a single connection between two labs with minimal coordination challenges. The 5-Lab demo with a centralized controller, distributed testbeds across different geographical locations, and use of protocols-based communication represents a scenario closer to real-world grid operations that coordinate resources across a region to meet system needs. This experiment studied how local DER controllers interact with a centralized energy controller during normal and abnormal events to maintain reliability. The SuperLab team across the five labs implemented a notional power system model equivalent of transmission and distribution lines, represented by the data networks interconnecting the labs. Each lab continuously exchanged local parameters (such as P and Q) from its Hardware-In-Loop (CHIL) and Power Hardware-In-Loop (PHIL) assets through centralized energy controller at NLR, enabling real-time interaction and coordination across sites. By leveraging ESnet as the communication backbone, the team successfully operated the distributed assets as a unified power system, with each bus represented by a different laboratory. This setup mirrors how assets interact in real-world power systems across dispersed locations with various protocols and latencies. At each lab site, assets were operated using their own local controllers which were coordinated through an overarching operation and control layer of centralized energy controller, equivalent to how an energy management system (EMS) orchestrates assets across a regional or national grid. SuperLab's federated connectivity utilized a Digital Real-Time Simulators (DRTS)-type gateway to connect Controller Hardware-In-Loop (CHIL) and PHIL assets between labs. To enable this federated connection through ESnet, a deterministic network was established where latency variations were consistent. This consistency allowed the development of digital filters for the power system assets across CHIL and PHIL interfaces to avoid unstable and unreliable grid conditions. This report provides an overview of the cross-laboratory configuration and offers insights into interconnecting geographically distributed research assets to test them as if they were co-located. This experiment represents a step toward linking nine DOE national laboratories, enabling nation-wide simulations that can address utility-driven challenges with grid resilience, flexibility, and modernization.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2020

Advanced high temperature environmental barrier coating for SiC/SiC ceramic matrix composites

Advanced environmental barrier coating bond coat systems with higher temperature capabilities and environmental resistance are disclosed. These bond coat systems can be applied to ceramic substrates such as SiC/SiC ceramic matrix composite substrates, and can provide protection from extreme temperature, mechanical loading and environmental conditions, such as in high temperature gas turbines. Example bond coat systems can include either an advanced silicon/silicide component, an oxide/silicate component, or a combination thereof.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Individual Wave Detection and Tracking within a Rotating Detonation Engine through Computer Vision Object Detection applied to High-Speed Images

Known for their simplistic design and continuous detonation, rotating detonation engines (RDEs) constitute a majority of current pressure gain combustion (PGC) research efforts. Experimental RDE operation times have been continuously extended through the use of rig cooling techniques. As the window of observable behavior is expanded, and as the technology matures toward eventual integration within gas turbines, monitoring techniques must evolve to better match industrial diagnostics. High-speed image analysis techniques prove useful to capture and evaluate the unsteady detonation behavior within the RDE. Traditional image analysis techniques, however, require extensive processing times which prohibit simultaneous monitoring. To better address this problem, a computer vision object detection methodology is proposed to quickly detect individual detonation waves within a single down-axis image. Detonation waves are detected in individual images by the implemented computer vision method You Only Look Once (YOLO) object detection network. In order to detect detonation waves, the network must first be trained using RDE images of interest, for which each required phase of network development is outlined. Detection of waves is improved through proper treatment of the collected image set, variation of Intersection over Union (IoU) and confidence thresholding, and through a parametric study of annotation dimensions. Each detected wave is described by its location and rotational direction, and locations are tracked to calculate wave velocity across each frame, leading to a timestep resolution of 20 µs. Wave velocities are also calculated through a series of frames, leading to a suitable average velocity estimation using as few as 10 frames. Uncertainty analysis accounting for variation in camera framerate, pixel width and annotation centroid locations estimates a total uncertainty of ±4.3% for velocity calculations, using the smallest annotation boxes. This method offers great reductions in processing times, as a step toward real-time monitoring of detonation waves within an RDE. Improving on previous studies, this technique is impartial to wave modes not included in the original training set and calculates wave velocities independent of high-speed pressure data. The ability to isolate waves within predicted bounding boxes will likely facilitate analysis of pixel intensity variation as an estimation of wave strength in future work.

Johnson, Kristyn↗

DOE OSTI2020

Advanced high temperature environmental barrier coating systems for SiC/SiC ceramic matrix composites

36 MATERIALS SCIENCE↗

DOE OSTI2020

Segmented annular combustion system with dual fuel capability

A segmented annular combustion system with dual fuel capability includes an alternating arrangement of fuel injection modules and integrated combustor nozzles. The fuel injection module includes a bundled tube fuel nozzle portion and fuel injection lances, which are fluidly coupled via conduits to respective fuel plenums. A liquid fuel cartridge is disposed within the bundled tube fuel nozzle portion, within one of the plurality of fuel injection lances, or within both the bundled tube fuel nozzle portion and one of the plurality of fuel injection lances. A gas turbine having the segmented annular combustion system is also provided.

Berry, Jonathan Dwight↗

DOE OSTI2021

ACCELERATED CREEP TEST (ACT) QUALIFICATION OF CREEP RESISTANCE USING THE WCS CONSTITUTIVE MODEL AND STEPPED ISOSTRESS METHOD (SSM)

In this study, a qualification of accelerated creep-resistance of Inconel 718 is assessed using the novel Wilshire-Cano-Stewart (WCS) model and the stepped isostress method (SSM) and predictions are made to conventional creep data. Conventional creep testing (CCT) is a long-term continuous process, in fact, the ASME B&PV III requires that 10,000+ hours of experiments must be conducted to each heat for materials employed in boilers and/or pressure vessel components. This process is costly and not feasible for rapid development of new materials. As an alternative, accelerated creep testing techniques have been developed to reduce the time needed to characterize the creep resistance of materials. Most techniques are based upon the time-temperature-stress superposition principle (TTSSP) that predicts minimum-creep-strain-rate (MCSR) and stress-rupture behaviors but lack the ability to predict creep deformation and consider deformation mechanisms that occur for experiments of longer duration. The stepped isostress method (SSM) has been developed which enables the prediction of creep deformation response as well as reduce the time needed for qualification of materials. The SSM approach has been successful for polymer, polymeric composites, and recently has been introduced for metals. In this study, the WCS constitutive model, calibrated to SSM test data, qualifies the creep resistance of Inconel 718 at 750°C and predictions are compared to CCT data. The WCS model has proven to make long-term predictions for stress-rupture, minimum-creep-strain-rate (MCSR), creep deformation, and damage in metallic materials. The SSM varies stress levels after time interval adding damage to the material, which can be tracked by the WCS model. The SSM data is calibrated into the model and the WCS model generates realistic predictions of stress-rupture, MSCR, damage, and creep deformation. The calibrated material constants are used to generate predictions of stress-rupture and are post-audit validated using the National Institute of Material Science (NIMS) database. Similarly, the MCSR predictions are compared from previous studies. Finally the creep deformation predictions are compared with real data and is determined that the results are well in between the expected boundaries. Material characterization and mechanical properties can be determined at a faster rate and with a more cost-effective method. This is beneficial for multiple applications such as in additive manufacturing, composites, spacecraft, and Industrial Gas Turbines (IGT).

36 MATERIALS SCIENCE↗

DOE OSTI2021

MACHINE LEARNING BASED CHEMICAL EXPLOSIVE MODE ANALYSIS (ML-CEMA)

The software consists of a Machine Learning based Chemical Explosive Mode Analysis (ML-CEMA) tool for advanced computational flame diagnostics. CEMA, originally based on eigen-analysis of the local thermochemical system, is capable of identifying reaction fronts and limit phenomena such as auto-ignition and extinction in practical combustion systems, such as internal combustion engines and gas turbine combustors. However, the original CEMA is computationally expensive for large reaction mechanisms that are typically needed to describe fuel chemistry of practical large-hydrocarbon fuels. This novel ML-CEMA tool employs a ML technique to accelerate the eigen-analysis of the basic CEMA approach by orders of magnitude, thus making it suitable for practical fuels. In ML-CEMA,zero-dimensional (0D) reactors and one-dimensional (1D) premixed flames are first used to generate a large number of data points for neural network based ML training. The trained ML model is then used to perform CEMA prediction. This ML-CEMA tool has been demonstrated in canonical 0D and 1D configurations as well as highly-transient three-dimensional spray flames exhibiting multi-mode turbulent combustion, showing promising results. ML-CEMA, as a standalone tool, can be used for computationally-efficient diagnostics of massive datasets generated from both experiments and simulations. For example, based on spatially resolved measurements of a small set of reactive scalars(such as temperature, hydroxyl radical and formaldehyde), ML-CEMA can effectively identify flame fronts and rare events. ML-CEMA also provides a robust online or offline flame feature detection tool. When used for on-the-fly simulations, ML-CEMA further enables zone-adaptive combustion modeling, in which the predicted eigenvalue is used as a robust mode indicator for judicious assignment of locally-valid combustion models. This ML-CEMA based zone-adaptive model can lead to substantial computational cost savings when used for large-scale simulations of multi-mode combustion systems. Third Party Code Web Page to Download Code Web Page Location of Third Party License

Xu, Chao↗

DOE OSTI2021

Transactive Energy Rationing in an Islanded Electric Power System

A battery energy storage system (BESS) has been installed on Nantucket Island to provide service continuity during the N-1 contingency of partial electricity supply interruption from the mainland. During the N-2 contingency of complete interruption from the mainland, most of the loads will have to be disconnected so that a combustion gas turbine (CTG) can supply critical facilities. This work proposes an alternative transactive rationing mechanism that would provide some service to all of the loads, and still fully serve the critical loads, through market-based control during the N-2 contingency. A BESS operating strategy is proposed that would enhance the transactive rationing mechanism. The necessary enabling changes to communication systems, controls and utility tariffs are discussed, along with some ancillary benefits.

transactive energy, power distribution, energy sto↗

DOE OSTI2021

A hub and spoke approach to optimizing energy wheeling of renewable resources

The deployment of zero carbon renewable energy sources needs to increase significantly to support the goal of net zero greenhouse gas emissions by 2050. At the same time energy end use needs to decarbonize. This will change both energy supply and energy demand patterns, requiring the energy delivery infrastructure (grid-based transmission circuits) to become increasingly flexible to maintain security of supply everywhere and always. The integration of zero carbon renewable energy requires cross-border and cross energy system coupling and a fit-for-purpose design. Nowadays, energy systems are planned, designed and operated in silos with a strong national focus. However, large-scale offshore wind production needs to be transported to deep inland locations, across country borders. The increased peak generation capacity of renewable energy sources will, at times, significantly exceed demand (Matthew Langholtz, 2020). The traditional solution of continuously reinforcing and extending the electricity grid is not sustainable from a cost and societal perspective. This paper will, however, propose a deterministic approach on how networked (interconnected grid) Points of receipt (POR) to Points of Delivery (POD) can be optimized for wheeling renewable energy resources while minimizing energy cost with a hub and spoke approach. The statistical approach will be done via using existing daily energy market clearing prices, available transmission capacity and firm daily transmission prices in open access energy markets. Renewable energy targets, including specific offshore wind targets, need to be in line with the ramp-up as implied by the Paris Agreement. These targets are required to provide industry with a secure market outlook that allows them to build up supply chains accordingly. Optimizing wheeled energy paths from carbon neutral resources such as renewables make them not only cost competitive on the unit commitment stack, but also more accessible on the dispatch stack to other carbon heavy forms of generation such as coal and natural gas turbines (Matthew Langholtz, 2020). This correlates to maximizing renewable resource inertia (wind, solar, biomass) within an interconnected grid without having to consider additional expansion of resources via land purchases and de-forestation.

Mukherjee, Srijib↗

DOE OSTI2022

(Towards) DNS of a Laboratory Lean CH4/H2 Low-Swirl Flame Impinging on an Inclined Wall

Due to downsizing trends, flame-wall interaction (FWI) is increasingly prominent in gas turbines (GTs). FWI has direct consequences on flame stabilization and pollutant emissions, but it is not well understood in turbulent flows representative of GTs. We present results from a direct numerical simulation (DNS) of a turbulent CH4/H2 model GT low-swirl laboratory-scale flame interacting with an inclined wall. The results from the laboratory flame include simultaneous measurements of velocity using stereo particle imaging velocimetry and OHxCH2O planar laser induced fluorescence. The adaptive-mesh refinement solver PeleLMeX is used, with 24-species, 105-reaction reduced Aramco chemical kinetics mechanism. The premixed fuel-air mixture consists of hydrogen-enriched methane with 70% hydrogen volume fraction and 0.4 equivalence ratio. The inflow is prescribed to match experimental measurements at the burner exit. Karlovitz and turbulent Reynolds numbers are 300 and 400, respectively. The simulation and experimental results show excellent agreement. The flame features a bowl-shape stabilization, with a corrugated, continuous flame front at the leading edge, followed by fragmented reaction zones downstream. A large diffuse cloud of CH2O is formed downstream of the quenching point. The simulation results indicate that the cloud of CH2O is the result of incomplete methane combustion, with CH2O "leaking" from the locally quenched reaction zones.The DNS provides fine-grain resolution of turbulence-flame-wall interaction that cannot be captured with experimental measurements. With access to the entire solution vector at each cell of the computational domain, the local quenching.

flame-wall interactions↗

DOE OSTI2022

Concentrated solar power generation using solar receivers

Inventive concentrated solar power systems using solar receivers, and related devices and methods, are generally described. Low pressure solar receivers are provided that function to convert solar radiation energy to thermal energy of a working fluid, e.g., a working fluid of a power generation or thermal storage system. In some embodiments, low pressure solar receivers are provided herein that are useful in conjunction with gas turbine based power generation systems.

Anderson, Bruce N.↗

DOE OSTI2022

Fluid mixing apparatus using liquid fuel and high- and low-pressure fluid streams

A fluid mixing apparatus includes mixing conduits that extend through a fluid plenum. The fluid plenum, which surrounds a first wall defining a main passage fluidly coupled to a low-pressure fluid source, is surrounded itself by a second wall defining a high-pressure plenum fluidly coupled to a high-pressure fluid source. An insulated tube disposed at the inlet of the first wall delivers a third fluid. The mixing conduits fluidly couple the high-pressure plenum to the main passage, where the high-pressure fluid is mixed with low-pressure fluid and the third fluid. Optionally, the fluid plenum may house a fourth fluid that is injected through injection holes in the mixing conduits. The fluid mixing apparatus may be used to mix one or more fuels with high- and low-pressure air in a gas turbine combustor. Alternately, the fluid mixing apparatus may mix a fluid with high- and low-pressure water streams.

Berry, Joseph Jonathan↗

DOE OSTI2022

Coolant delivery via an independent cooling circuit

An embodiment of an independent cooling circuit for selectively delivering cooling fluid to a component of a gas turbine system includes: at least one coolant feed channel fluidly coupled to a supply of cooling fluid; and an interconnected circuit of cooling channels, including: an interconnected circuit of cooling channels embedded within an exterior wall of the component; an impingement plate; and a plurality of feed tubes connecting the impingement plate to the exterior wall of the component and fluidly coupling a supply of cooling fluid to the interconnected circuit of cooling channels; wherein the cooling fluid flows through the plurality of feed tubes into the interconnected circuit of cooling channels only in response to a formation of a breach in the exterior wall of the component that exposes at least one of the cooling channels.

42 ENGINEERING↗

DOE OSTI2022

Coolant delivery via an independent cooling circuit

An embodiment of an independent cooling circuit for selectively delivering cooling fluid to a component of a gas turbine system includes: a plurality of independent circuits of cooling channels embedded within an exterior wall of the component, wherein the plurality of circuits of cooling channels are interwoven together; an impingement plate; and a plurality of feed tubes connecting the impingement plate to the exterior wall of the component and fluidly coupling each of the plurality of circuits of cooling channels to at least one supply of cooling fluid, wherein, in each of the plurality of circuits of cooling channels, the cooling fluid flows through the plurality of feed tubes into the circuit of cooling channels only in response to a formation of a breach in the exterior wall of the component that exposes at least one of the cooling channels of the circuit of cooling channels.

Hafner, Matthew Troy↗