Search NASA⌕ Search

SEARCH · Search NASA

Results for “Process Control”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Securing the Clean Energy Transition with Cyber-Informed Engineering

The Bipartisan Infrastructure Law kick-started a surge in clean energy investments in the United States. Securing these systems and their supporting infrastructure from the outset is imperative, starting from the conceptual design and continuing through the entire engineering lifecycle. Cyber-Informed Engineering is an ideal approach to seamlessly integrate the necessary advanced control capabilities and adaptive protection systems, especially considering the trend towards cloud-based infrastructure and process controls. Learn more about CIE at https://www.energy.gov/ceser/articles/cyber-informed-engineering-bridge-between-cyber-and-critical-infrastructure-securing.

14 SOLAR ENERGY↗
DOE OSTI2023

Startup process for a dual active bridge converter to prevent over-voltage failure and thermal run-away

A system and method for controlling a dual active bridge based DC/DC converter. A controller implements a startup control scheme and DC bus pre-charge routine to prevent damage to the converter upon startup. During startup of the converter, the startup control process can be used to prevent excessive phase-shift and the DC bus pre-charge routine adjusts the pulse width modulated duty cycle by increasing the dead time between signals, resulting in a decreased DC bus capacitor.

Singh, Braj K.↗
DOE OSTI2025

The Role of Dislocations in the Anelasticity of the Upper Mantle

Dislocation‐based dissipation mechanisms potentially control the viscoelastic response of Earth's upper mantle across a variety of geodynamic contexts, including glacial isostatic adjustment, postseismic creep, and seismic‐wave attenuation. However, there is no consensus on which dislocation‐based, microphysical process controls the viscoelastic behavior of the upper mantle. Although both intergranular (plastic anisotropy) and intragranular (backstress) mechanisms have been proposed, there is currently insufficient laboratory data to discriminate between those mechanisms. Here, we present the results of forced‐oscillation experiments in a deformation‐DIA apparatus at confining pressures of 3–7 GPa and temperatures of 298–1370 K. Our experiments tested the viscoelastic response of polycrystalline olivine—the main constituent of the upper mantle—at stress amplitudes from 70 to 2,800 MPa. Mechanical data are complemented by microstructural analyses of grain size, crystallographic preferred orientation, and dislocation density. We observe amplitude‐ and frequency‐dependent attenuation and modulus relaxation and find that numerical solutions of the backstress model match our results well. Therefore, we argue that interactions among dislocations, rather than intergranular processes (e.g., plastic anisotropy or grain boundary sliding), control the viscoelastic behavior of polycrystalline olivine in our experiments. In addition, we present a linearized version of the constitutive equations of the backstress model and extrapolate it to conditions typical of seismic‐wave propagation in the upper mantle. Our extrapolation demonstrates that the backstress model can explain the magnitude of seismic‐wave attenuation in the upper mantle, although some modification is required to explain the weak frequency dependence of attenuation observed in nature and in previous experimental work.

Hein, Diede [Univ. of Minnesota, Minneapolis, MN (↗
DOE OSTI2024

Hybrid metal additive/subtractive machine tools and applications

Additive manufacturing creates parts by depositing a preform, typically layer by layer. Subtractive manufacturing involves removing material from a preform to create parts. Hybrid machine tools combine both additive and subtractive processes in the same workspace. They can be used to create parts that meet functional tolerance and surface finish requirements, or to create features that are difficult to produce using additive or subtractive processes alone. Here, this paper describes hybrid metal additive/subtractive machine tools. It covers design considerations, sensors and controls, process management, programming and software, and the impact on the design space. It also identifies future research challenges.

42 ENGINEERING↗
DOE OSTI2022

River Organic Carbon Fluxes Modulated by Hydrodynamic Sorting of Particulate Organic Matter

Rivers regulate the global carbon cycle by transferring particulate organic carbon (POC) from terrestrial landscapes to marine sedimentary basins, but the processes controlling the amount and composition of fluvially exported POC are poorly understood. We propose that hydrodynamic sorting processes modify POC fluxes during fluvial transit. We test this hypothesis by studying POC transported along a ~1,200 km reach of the Rio Bermejo, Argentina. Nanoscale secondary ion mass spectrometry revealed that POC was either fine, mineral-associated organic matter, or coarse discrete organic particles. Mineral-associated POC is more resistant to oxidation and has a lower particle settling velocity than discrete POC. Consequently, hydraulic sorting and downstream fining amplify the proportion of fine, mineral-associated POC from ~55% to ~78% over 1,220 km of downstream transit. This suggests that mineral-associated POC has a greater probability of export and preservation in marine basins than plant detritus, which may be oxidized to CO 2 during transit.

58 GEOSCIENCES↗
DOE OSTI2023

Summary report of the 4th IAEA Technical Meeting on Fusion Data Processing, Validation and Analysis (FDPVA)

The objective of the Fourth Technical Meeting on Fusion Data Processing, Validation and Analysis was to provide a platform during which a set of topics relevant to fusion data processing, validation and analysis are discussed with the view of extrapolating needs to next step fusion devices such as ITER. The validation and analysis of experimental data obtained from diagnostics used to characterize fusion plasmas are crucial for a knowledge-based understanding of the physical processes governing the dynamics of these plasmas. This paper presents the recent progress and achievements in the domain of plasma diagnostics and synthetic diagnostics data analysis (including image processing, regression analysis, inverse problems, deep learning, machine learning, big data and physics-based models for control) reported at the meeting. The progress in these areas highlight trends observed in current major fusion confinement devices. A special focus is dedicated on data analysis requirements for ITER and DEMO with a particular attention paid to artificial intelligence for automatization and improving reliability of control processes.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2012

Design and Analysis of a Region-Wide Remotely Controllable Electrical Lock-Out System

Electric utilities have a main responsibility to protect the lives and safety of their workers when they are working on low-, medium-, and high-voltage power lines and distribution circuits. With the anticipated widespread deployment of smart grids, a secure and highly reliable means of maintaining isolation of customer-owned distributed generation (DG) from the affected distribution circuits during maintenance is necessary to provide a fully de-energized work area, ensure utility personnel safety, and prevent hazards that can lead to accidents such as accidental electrocution from unanticipated power sources. Some circuits are serviced while energized (live line work) while others are de-energized for maintenance. For servicing de-energized circuits and equipment, lock-out tag-out (LOTO) programs provide a verifiable procedure for ensuring that circuit breakers are locked in the off state and tagged to indicate that status to operational personnel so that the lines will be checked for voltage to verify they are de-energized. The de-energized area is isolated from any energized sources, which traditionally are the substations. This procedure works well when all power sources and their interconnections are known armed with this knowledge, utility personnel can determine the appropriate circuits to de-energize for isolating the target line or equipment. However, with customer-owned DG tied into the grid, the risk of inadvertently reenergizing a circuit increases because circuit connections may not be adequately documented and are not under the direct control of the local utility. Thus, the active device may not be properly de-energized or isolated from the work area. Further, a remote means of de-energizing and locking out energized devices provides an opportunity for greatly reduced safety risk to utility personnel compared to manual operations. In this paper, we present a remotely controllable LOTO system that allows individual workers to determine the configuration and status of electrical system circuits and permit them to lock out customer-owned DG devices for safety purposes using a highly secure and ultra-reliable radio signal. The system consists of: (1) individual personal lockout devices, (2) lockout communications and logic module at circuit breakers, which are located at all DG devices, and (3) a database and configuration control process located at the utility operations center. The lockout system is a close permissive, i.e., loss of control power or communications will cause the circuit breaker to open. Once the DG device is tripped open, a visual means will provide confirmation of a loss of voltage and current that verifies the disconnected status of the DG. Further the utility personnel will be able to place their own lock electronically on the system to ensure a lockout functionally. The proposed LOTO system provides enhanced worker safety and protection against unintended energized lines when DG is present. The main approaches and challenges encountered through designing the proposed region-wide LOTO system are discussed in this paper. These approaches include: (1) evaluating the reliability of the proposed approach under N-modular redundancy with voter/spares configurations and (2) conducting a system level risk assessment study using the failure modes and effects analysis (FMEA) technique to identify and rank failure modes by probability of occurrence, probability of detection, and severity of consequences. This ranking allows a cost benefits analysis to be conducted such that dollars and efforts will be applied to the failures that provide greatest incremental gains in system capability (resilience, survivability, security, reliability, availability, etc.) per dollar spent whether capital, operations, or investment. Several simulation scenarios and their results are presented to demonstrate the viability of these approaches.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2019

Vapor-Deposited Glass Structure Determined by Deposition Rate–Substrate Temperature Superposition Principle

In this article, we show that deposition rate substantially affects the anisotropic structure of thin glassy films produced by physical vapor deposition. Itraconazole, a glass-forming liquid crystal, was deposited at rates spanning 3 orders of magnitude over a 25 K range of substrate temperatures, and structure was characterized by ellipsometry and X-ray scattering. Both the molecular orientation and the spacing of the smectic layers obey deposition rate–substrate temperature superposition, such that lowering the deposition rate is equivalent to raising the substrate temperature. We identify two different surface relaxations that are responsible for structural order in the vapor-deposited glasses and find that the process controlling molecular orientation is accelerated by more than 3 orders of magnitude at the surface relative to the bulk. Finally, the identification of distinct surface processes responsible for anisotropic structural features in vapor-deposited glasses will enable more precise control over the structure of glassy materials used in organic electronics.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Evaluation of a Combined Cyclone and Gas Filtration System for Particulate Removal in the Gasification Process

The Wabash gasification facility, owned and operated by sgSolutions LLC, is one of the largest single train solid fuel gasification facilities in the world capable of transforming 2,000 tons per day of petroleum coke or 2,600 tons per day of bituminous coal into synthetic gas for electrical power generation. The Wabash plant utilizes Phillips66 proprietary E-Gas™ Gasification Process to convert solid fuels such as petroleum coke or coal into synthetic gas that is fed to a combined cycle combustion turbine power generation facility. During plant startup in 1995, reliability issues were realized in the gas filtration portion of the gasification process. To address these issues, a slipstream test unit was constructed at the Wabash facility to test various filter designs, materials and process conditions for potential reliability improvement. The char filtration slipstream unit provided a way of testing new materials, maintenance procedures, and process changes without the risk of stopping commercial production in the facility. It also greatly reduced maintenance expenditures associated with full scale testing in the commercial plant. This char filtration slipstream unit was installed with assistance from the United States Department of Energy (built under DOE Contract No. DE-FC26-97FT34158) and began initial testing in November of 1997. It has proven to be extremely beneficial in the advancement of the E-Gas™ char removal technology by accurately predicting filter behavior and potential failure mechanisms that would occur in the commercial process. After completing four (4) years of testing various filter types and configurations on numerous gasification feed stocks, a decision was made to investigate the economic and reliability effects of using a particulate removal gas cyclone upstream of the current gas filtration unit. A paper study had indicated that there was a real potential to lower both installed capital and operating costs by implementing a char cyclone-filtration hybrid unit in the E-Gas™ gasification process. These reductions would help to keep the E-Gas™ technology competitive among other coal-fired power generation technologies. The Wabash combined cyclone and gas filtration slipstream test program was developed to provide design information, equipment specification and process control parameters of a hybrid cyclone and candle filter particulate removal system in the E-Gas™ gasification process that would provide the optimum performance and reliability for future commercial use. The test program objectives were as follows: 1. Evaluate the use of various cyclone materials of construction; 2. Establish the optimal cyclone efficiency that provides stable long term gas filter operation; 3. Determine the particle size distribution of the char separated by both the cyclone and candle filters. This will provide insight into cyclone efficiency and potential future plant design; 4. Determine the optimum filter media size requirements for the cyclone-filtration hybrid unit; 5. Determine the appropriate char transfer rates for both the cyclone and filtration portions of the hybrid unit; 6. Develop operating procedures for the cyclone-filtration hybrid unit; and, 7. Compare the installed capital cost of a scaled-up commercial cyclone-filtration hybrid unit to the current gas filtration design without a cyclone unit, such as currently exists at the Wabash facility.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2014

Crystallization In High Level Waste (HLW) Glass Melters: Operational Experience From The Savannah River Site

processing strategy for the Hanford Tank Waste Treatment and Immobilization Plant (WTP). The basis of this alternative approach is an empirical model predicting the crystal accumulation in the WTP glass discharge riser and melter bottom as a function of glass composition, time, and temperature. When coupled with an associated operating limit (e.g., the maximum tolerable thickness of an accumulated layer of crystals), this model could then be integrated into the process control algorithms to formulate crystal tolerant high level waste (HLW) glasses targeting higher waste loadings while still meeting process related limits and melter lifetime expectancies. This report provides a review of the scaled melter testing that was completed in support of the Defense Waste Processing Facility (DWPF) melter. Testing with scaled melters provided the data to define the DWPF operating limits to avoid bulk (volume) crystallization in the un-agitated DWPF melter and provided the data to distinguish between spinels generated by K-3 refractory corrosion versus spinels that precipitated from the HLW glass melt pool. This report includes a review of the crystallization observed with the scaled melters and the full scale DWPF melters (DWPF Melter 1 and DWPF Melter 2). Examples of actual DWPF melter attainment with Melter 2 are given. The intent is to provide an overview of lessons learned, including some example data, that can be used to advance the development and implementation of an empirical model and operating limit for crystal accumulation for WTP. Operation of the first and second (current) DWPF melters has demonstrated that the strategy of using a liquidus temperature predictive model combined with a 100 °C offset from the normal melter operating temperature of 1150 °C (i.e., the predicted liquidus temperature (TL) of the glass must be 1050 °C or less) has been successful in preventing any detrimental accumulation of spinel in the DWPF melt pool, and spinel has not been observed in any of the pour stream glass samples. Spinel was observed at the bottom of DWPF Melter 1 as a result of K-3 refractory corrosion. Issues have occurred with accumulation of spinel in the pour spout during periods of operation at higher waste loadings. Given that both DWPF melters were or have been in operation for greater than 8 years, the service life of the melters has far exceeded design expectations. It is possible that the DWPF liquidus temperature approach is conservative, in that it may be possible to successfully operate the melter with a small degree of allowable crystallization in the glass. This could be a viable approach to increasing waste loading in the glass assuming that the crystals are suspended in the melt and swept out through the riser and pour spout. Additional study is needed, and development work for WTP might be leveraged to support a different operating limit for the DWPF. Several recommendations are made regarding considerations that need to be included as part of the WTP crystal tolerant strategy based on the DWPF development work and operational data reviewed here. These include: Identify and consider the impacts of potential heat sinks in the WTP melter and glass pouring system; Consider the contributions of refractory corrosion products, which may serve to nucleate additional crystals leading to further accumulation; Consider volatilization of components from the melt (e.g., boron, alkali, halides, etc.) and determine their impacts on glass crystallization behavior; Evaluate the impacts of glass REDuction/OXidation (REDOX) conditions and the distribution of temperature within the WTP melt pool and melter pour chamber on crystal accumulation rate; Consider the impact of precipitated crystals on glass viscosity; Consider the impact of an accumulated crystalline layer on thermal convection currents and bubbler effectiveness within the melt pool; Evaluate the impact of spinel accumulation on Joule heating of the WTP melt pool; and Include noble metals in glass melt experiments because of their potential to act as nucleation sites for spinel crystallization.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2019

Uncertainty Quantification of Environmentally Assisted Stress Corrosion Cracking in Used Fuel Canisters (Status Report)

This study was initiated to quantify and characterize the uncertainty associated with the degradation mechanisms impacting normal dry storage operations for used nuclear fuel (UNF) and normal conditions of transport in support of the Spent Fuel and Waste Science & Technology Campaign (SFWST) and its effectiveness to rank the data needs and parameters of interest. This report describes the technical basis and guidance resulting from the development of software to perform uncertainty quantification (UQ) by developing and describing a holistic model that integrates the various processes controlling Atmospheric Stress Corrosion Cracking (ASCC) in the specific context of Interim Spent Fuel Storage Installations (ISFSIs). These processes include the daily and annual cycles of temperature and humidity associated with the environment, the deposition of chloride-containing aerosol particles, pit formation, pit-to-crack transition, and crack propagation.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2015

Controlled exciton transfer between quantum dots with acoustic phonons taken into account

A system of excitons in two quantum dots coupled by the dipole–dipole interaction is investigated. The excitation transfer process controlled by the optical Stark effect at nonresonant frequencies is considered and the effect of the interaction between excitons and acoustic phonons in a medium on this process is taken into account. The system evolution is described using quantum Heisenberg equations. A truncated set of equations is obtained and the transfer dynamics is numerically simulated. High-efficiency picosecond switching of the excitation transfer by a laser pulse with a rectangular envelope is demonstrated. The dependence of picosecond switching on the quantum-dot parameters and optical-pulse length is presented.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Evaluation of the Hanford 200 West Groundwater Treatment System: Fluidized Bed Bioreactor

A fluidized bed reactor (FBR) in the 200W water treatment facility at Hanford is removing nitrate from groundwater as part of the overall pump-treat-reinject process. Control of the FBR bed solids has proven challenging, impacting equipment, increasing operations and maintenance (O&M), and limiting the throughput of the facility. In response to the operational challenges, the Department of Energy Richland Office (DOE-RL) commissioned a technical assistance team to facilitate a system engineering evaluation and provide focused support recommendations to the Hanford Team. The DOE Environmental Management (EM) technical assistance process is structured to identify and triage technologies and strategies that address the target problem(s). The process encourages brainstorming and dialog and allows rapid identification and prioritization of possible options. Recognizing that continuous operation of a large-scale FBR is complex, requiring careful attention to system monitoring data and changing conditions, the technical assistance process focused on explicit identification of the available control parameters (“knobs”), how these parameters interact and impact the FBR system, and how these can be adjusted under different scenarios to achieve operational goals. The technical assistance triage process was performed in collaboration with the Hanford team.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2026

Towards High-Speed friction stir welding of 25 mm Thick AA2139-T8: tool innovation and process development

Joining thick plates (≥ 12 mm) of aluminum (Al) alloys is challenging due to high tool forces, uneven material flow, and non-uniform heat distribution through the material’s thickness. Recent advancements in tool design and welding parameters for friction stir welding (FSW) in thick plates butt joining have encountered a developmental plateau, highlighting the need for innovative approaches to overcome existing limitations. Here, this study focuses on the systematic development of single-pass and double-pass FSW processes for high-strength aluminum alloy AA2139-T8, to improve joint efficiency and enable high-speed welding capabilities. Experimental evidence is presented for a novel tool design with opposing pin threads, enabling high-speed (178 mm/min) single-pass friction stir butt welding of 25 mm thick AA2139-T8. A series of FSW trials was conducted both in air and with a trailing water spray, using steel backing plates (BPs) to investigate the impact of quenching and cooling rates on process response and joint performance. A joint efficiency of 83% was attained using the novel tool features and effectively controlling process forces and thermal boundary conditions.

AA2139-T8↗
DOE OSTI2018

Accelerated Nutrient Cycling and Increased Light Competition Will Lead to 21st Century Shrub Expansion in North American Arctic Tundra

We present that recent changes in species composition, and increases in shrub abundance in particular, have been reported as a result of warming in Arctic tundra. Despite these changes, the driving factors that control shrubification and its future trajectory remain uncertain. Here we used an ecosystem model, ecosys, to mechanistically represent the processes controlling recent and 21st century changes in plant functional type using RCP8.5 climate forcing across North American Arctic tundra. Recent and projected warming was modeled to deepen the active layer (spatially averaged by ~0.35 m by 2100) and thereby increase nutrient availability. Shrub productivity was modeled to increase across much of the tundra, particularly in Alaska and tundra-boreal ecotones. Deciduous and evergreen shrubs increased from ~45% of total tundra ecosystem net primary productivity (NPP) in recent decades to ~70% by 2100. The increased canopy cover of shrubs reduced incoming shortwave radiation for low-lying plants, causing declines in graminoids NPP from a current 35% of tundra NPP to 18%, and declines in nonvascular plants from 20% to 12%. The faster-growing deciduous shrubs modeled with less efficient nutrient conservation dominated much of the low Arctic by 2100 where nutrient cycling became more rapid, while the slower-growing evergreen shrubs modeled with more efficient nutrient conservation dominated a wider latitudinal range that extended to the high Arctic where nutrient cycling remained slower. Lastly, we conclude that high-latitude vegetation dynamics over the 21st century will depend strongly on soil nutrient dynamics, diversity in plant traits controlling nutrient uptake and conservation, and light competition.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2014

Economic model predictive control of nonlinear process systems using empirical models

Economic model predictive control (EMPC) is a feedback control technique that attempts to tightly integrate economic optimization and feedback control since it is a predictive control scheme that is formulated with an objective function representing the process economics. As its name implies, EMPC requires the availability of a dynamic model to compute its control actions and such a model may be obtained either through application of first principles or through system identification techniques. In industrial practice, it may be difficult in general to obtain an accurate first‐principles model of the process. Motivated by this, in the present work, Lyapunov‐based EMPC (LEMPC) is designed with a linear empirical model that allows for closed‐loop stability guarantees in the context of nonlinear chemical processes. Specifically, when the linear model provides a sufficient degree of accuracy in the region where time varying economically optimal operation is considered, conditions for closed‐loop stability under the LEMPC scheme based on the empirical model are derived. The LEMPC scheme is applied to a chemical process example to demonstrate its closed‐loop stability and performance properties as well as significant computational advantages. © 2014 American Institute of Chemical Engineers AIChE J , 61: 816–830, 2015

Alanqar, Anas↗
DOE OSTI2021

Catalysts by pyrolysis: Direct observation of chemical and morphological transformations leading to transition metal-nitrogen-carbon materials

Transition metal-nitrogen-carbon materials (M-N-C catalysts) are promising electrocatalysts in polymer electrolyte fuel cells (PEFCs) and electrolyzer applications. High temperature treatment in inert atmosphere (pyrolysis) is the essential, most common method for the synthesis of M-N-C catalysts and critical to achieve high electrocatalytic activity and electronic conductivity. To this day, despite many uses and successful implementations in materials manufacturing, pyrolysis has been an entirely empirical technology, with process control and optimization relying exclusively on “Edisonian” approach. The knowledge gap in the mechanism about how the precursor is being transformed into catalysts hinders further development of the M-N-C catalysts regardless of the precursor class and processing protocols. In this work, we probed the morphological evolution and chemical transformation of a nitrogen-containing charge transfer organic salt, mixed with transition metal (iron) salt and amorphous silica powder (precursor) during the pyrolysis process via a combination of in situ synchrotron and laboratory-based diagnostic techniques. The pyrolysis process is found to be divided into three stages. During a controlled temperature ramp, the selected organic N-C precursor (nicarbazin) began melting and decomposing just below 400 °C, forming a certain number of micrometer-scale pores and pathways. With increase in temperature from 400 °C to 900 °C, amorphous carbon domains started forming, and reduced (metallic) iron nanoclusters appeared, being dispersed uniformly throughout the carbonaceous matrix. When temperature advanced above 900 °C, graphitization of carbon commenced, associated with appearance and evolution of atomically dispersed metal-nitrogen moieties in the carbonaceous matrix. As the graphitization advanced further, a secondary process of agglomeration of metal nanoparticles occurred. Multi-analytical technique observations conducted here provide a base for rational design and optimization of M-N-C electrocatalysts via pyrolysis.

36 MATERIALS SCIENCE↗