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DOE OSTI2022

Continuous Fiber Bath Treatments at Pilot Scale: A Novel Testbed System

The technical demands on high performance textiles continues to expand, and the research community has answered the call with innovative fiber bath treatments for enhanced properties and sizings for improved composites. However, little translation to greater scale has been demonstrated. To fill this gap, a novel, multifunctional system has been developed to explore polymer fiber treatment methods, the deployment of nanoadditive coatings and other sizings, and smart processing methods at the pilot scale. Continuous tows of fibers can be passed through a temperature-controlled, crossflow bath with an immersion residence time exceeding 2 hours. The modular system is resistant to corrosive solutions, includes additional inline stations for washing and drying after processing, is equipped with a bevy of sensors, pumps, and valves monitored and controlled by a LabView program, and can be fully contained in a standard lab fume hood. This new testbed system, when coupled with high fidelity materials characterization methods, will enable rapid evaluation of new fiber treatment methods at pilot-scale.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Upgrade of Core Conduction Cooldown Test Facility Control System

The CCCTF was designed and installed at ORNL in the 1990s for high-temperature gas-cooled reactor accident simulation. It is located within a modular hot cell housed in the IFEL facility. In 2008 and 2009, modifications were made to the CCCTF in preparation for AGR safety testing. A new airlock was designed and installed to better support periodic exchange of the fission product deposition cups while maintaining the fuel at safety test temperature, and modifications were made to add routines to the existing user interface software for computer-controlled automation of the He sweep gas flow and liquid nitrogen supply to the 85Kr cold traps. However, the furnace control hardware and software remained essentially unchanged. At the conclusion of the AGR-1 and AGR-2 PIE campaigns, continued use of the CCCTF was in question because of the gradual obsolescence of the hardware and software used to control the furnace and ancillary systems that make up the CCCTF. Therefore, an effort was undertaken to replace all the obsolete components with new hardware and update the software to increase system reliability and ensure this capability’s maintenance for future research and fuel qualification efforts. The modifications included creating a new National Instruments (NI) LabVIEW-based control system with a graphical user interface (GUI).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Time-Gated Raman Spectroscopy (Intern Final Report)

Time-gated Raman spectroscopy is a powerful tool for rapid non-destructive analysis of chemical compounds, particularly when combined with other investigative methods. Time-gating the signal obtained from a sample during Raman spectroscopy allows for the removal of background emission and black body radiation, improving clarity and accuracy of scans. The main objectives of this project were to prove the lab’s time-gated Raman spectroscopy system works as proof of concept and to make select improvements to the in-house LabVIEW software used to run the time-gated system. This time-gated system will be added to the CTK’s TAP reactors in the future, but this is out of the scope of this internship project. This research is important, as understanding the mechanisms behind catalysts leads to designing better systems/materials and the perfection of catalysts, and energy-efficient chemical manufacturing is key when designing a greener future. The research for this project was done with samples at both ambient conditions in sample holders and at operando conditions (i.e., high temperature, unsteady-state) inside a small-volume chemical reactor. Numerous spectro-kinetic scans of the catalysts were obtained, but the advanced dynamics of these systems are still being interpreted. There is data that demonstrates that the time-gated system is correctly rejecting emission from samples, and one can observe real-time changes in the signal from the sample, due to coking or changes induced by redox chemistry. Chemical manufacturers and the planet are the main beneficiaries of catalysis research, as better catalysts will reduce carbon emissions.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Commissioning of the trigger system for the ICARUS T600 LAr-TPC detector in SBN Program

The ICARUS experiment at Fermilab is the far detector of the Short Baseline Neutrino Program (SBN), aimed at studing the neutrino oscillation to find a fourth type of neutrino, called sterile neutrino. A key component for this detector is the trigger system, which aims to identify and isolate the physical interactions from the background events. In this framework my internship program was dedicated to the development of trigger logic and trigger inhibit mechanism in order to select the genuine neutrino interaction and to guarantee a correct functioning of the readout system. These two steps, that represent a part of the commissioning of the trigger system, were implemented with LabVIEW Software. The obtained results are a fundamental step towards a succesful activation of the detector in the next few months.

43 PARTICLE ACCELERATORS↗

DOE OSTI2023

Development of a hardware-in-the-loop testbed for laboratory performance verification of flexible building equipment in typical commercial buildings

The goals of reducing energy costs, shifting electricity peaks, increasing the use of renewable energy, and enhancing the stability of the electric grid can be met in part by fully exploiting the energy flexibility potential of buildings and building equipment. The development of strategies that exploit these flexibilities could be facilitated by publicly available high-resolution datasets illustrating how control of HVAC systems in commercial buildings can be used in different climate zones to shape the energy use profile of a building for grid needs. This article presents the development and integration of a Hardware-In-the-Loop Flexible load Testbed (HILFT) that integrates physical HVAC systems with a simulated building model and simulated occupants with the goal of generating datasets to verify load flexibility of typical commercial buildings. Compared to simulation-only experiments, the hardware-in-the-loop approach captures the dynamics of the physical systems while also allowing efficient testing of various boundary conditions. The HILFT integration in this article is achieved through the co-simulation among various software environments including LabVIEW, MATLAB, and EnergyPlus. Although theoretically viable, such integration has encountered many real-world challenges, such as: 1) how to design the overall data infrastructure to ensure effective, robust, and efficient integration; 2) how to avoid closed-loop hunting between simulated and emulated variables; 3) how to quantify system response times and minimize system delays; and 4) how to assess the overall integration quality. Lessons-learned using the examples of an AHU-VAV system, an air-source heat pump system, and a water-source heat pump system are presented.

Chen, zhelun↗

DOE OSTI2022

Demonstration of a fault impact reduction control module for wind turbines

Abstract. Traditionally, wind turbines in distributed applications make control decisions as isolated systems. They generally provide maximum power output during operation and manage internal faults with little consideration of the rest of the power system. Although fault detection and tolerance schemes are widely researched and implemented, controls to ameliorate such faults are uncommon in research and industry. The rapid shutdown of a wind turbine in a large transmission-connected wind plant will have a minimal impact on a large power system, but in a microgrid or isolated grid context the abrupt loss of a single wind turbine may cause grid instability and high stress on the system. This paper demonstrates a fault impact reduction control (FIRC) module for a wind turbine, which implements wider warning thresholds around fault thresholds. When the turbine crosses a warning threshold, the controller sends its predicted action to the grid controller, which facilitates the grid operator’s response to a potential wind turbine fault and then takes appropriate action to ameliorate the fault. Various test cases demonstrate the controller action under a variety of faults, and various scenarios demonstrate the grid benefit of an FIRC in both microgrid- and grid-connected contexts. The FIRC maximizes wind turbine generation and eases generation transition under a variety of fault scenarios. The FIRC module is easy to integrate with most existing controllers, just requiring derate capability, and can be easily modified to include the various warnings and thresholds that the user desires. This analysis is mainly performed in a MATLAB-Simulink-based research wind turbine model and is also implemented in the existing LabVIEW-based controller of the same research turbine at NREL.

17 WIND ENERGY↗

DOE OSTI2025

ExINP NSA Ice Nucleating Particle Concentrations

This data set comprises cumulative ambient ice-nucleating particle (INP) concentrations measured at the National Oceanic and Atmospheric Administration's (NOAA’s) Barrow Atmospheric Baseline Observatory (71.3230° N, 156.6114° W, “BRW” hereafter), next to the Atmospheric Radiation Measurement (ARM) North Slope of Alaska (NSA) site and ~ 6 km northeast of the town of Utqiaġvik. Our INP abundance data were generated using a combination of online instrument, the Portable Ice Nucleation Experiment chamber ver. 3 (PINE-03), and an offline cold stage, the West Texas Cryogenic Refrigerator Applied to Freezing Test system (WT-CRAFT). Our online INP data are all from the Examining the Ice-Nucleating Particles from NSA (ExINP-NSA) campaign conducted from October 19, 2021 to May 24, 2024. The offline INP concentration analysis was performed at West Texas A&M University for aerosol particle samples collected on polycarbonate filters (with 0.2-micron diameter pores). The PINE-03 measurements, as well as sampling activities for offline INP measurements, were conducted using the BRW site. An inset laminar sampling stack was mounted to the instrument platform, allowing PINE-03 to intake particle-laden air. For most of the campaign period, the semi-autonomous PINE-03 chamber was remotely controlled from West Texas A&M University using the LabView interface through the BeyondTrust remote-access console. PINE-03 was set to conduct an immersion freezing expansion experiment (i.e., simulated adiabatic cooling along with RHw at or above 100%). Except during the scheduled maintenance periods, the time resolution of each expansion experiment was approximately 12 minutes. PINE-03 continuously measured INP concentrations during the entire campaign without any substantial breaks. For most of the campaign period, PINE scanned its set-point vessel air temperatures from -14 °C to -31 °C and back to -14 °C about every 120 minutes.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

ExINP NSA Ice Nucleating Particle Concentrations

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

Digital Engineering & Data Acquisition

This is an Intern Poster submission regarding my research in the digital engineering team. My task was to create a software adapter to communicate between a data acquisition system (LabVIEW) and a data warehouse (Deep Lynx) as described in the poster.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2022

Development of a water source heat pump hardware-in-the-loop (HIL) testing facility for smart building applications

Over the last decade, the global fight against climate change through electrification has led to an increase in research on building heating, ventilation, and air conditioning (HVAC) systems that utilize intelligent control algorithms to provide demand-side grid service while maintaining the thermal comfort of building occupants. As the pivotalpoint between building electricity consumption and indoor thermal comfort, high-efficiency electrical heatpumps are at the center of these emerging studies, and various grid-interactive and occupant-comfort control algorithms have been developed for them. The impact of these algorithms on the heatpump operation andperformance under different weather, building load, and grid requests calls for investigation and verification via experimental tests with actual heat pumps integrated with real-time building and grid responses. This study presents a Water-Source Heat Pump Hardware-in-The-Loop (HIL) Test Facility developed with the capability to perform such tests. The hardware configuration for this testfacility introduces a hydronic system that emulates the conditions for the heat pump water-side, and a duct system that emulates conditions for the heat pump airside. Both data acquisition and emulator control are implemented through the National Instruments (NI) LabVIEW software running on an NI PXIplatform. The HIL mechanism based on the hardware-software integration that allows the testbed to communicate with a generic simulation environment is also discussed. Currently, the test facility setup includes a single heatpump and virtual building model in EnergyPlus coupled with an occupant behavioral model in MATLAB. Preliminary test results of the current setup demonstrate the building load emulator's ability to track the simulated gone temperature with a Root Mean Square Deviation (RSME) below 0.12°C (0.216°F). An uncertainty analysis based on sensor accuracies shows that the heat pump coefficient of performance (COP) can be measured with a relative uncertainty of 10.4% in cooling and 3.7% in heating. Apartfrom the current testing on a single heat pump, the test facility also provides the flexibility to include additional heat pumps to form a heat pump cluster, as well as coupling the heat pump with active thermal storage to provide enhanced demandflexibility.

Calfa, Caleb↗

DOE OSTI2025

Toluene Adsorption and TPD

Raw data for toluene adsorption and TPD experiments on two different adsorbents using a custom flow-through, bench-top reactor capable of controlling gas compositions and temperature.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Multi-Sensor Data Acquisition System for Process Monitoring

Idaho National Laboratory is building a new nuclear fuel cycle test bed. This fuel cycle test bed named “Beartooth” will give researchers the opportunity to study the nuclear fuel cycle process. The process operations include the use of centrifugal contactors and process flow for the purification of special nuclear material recovery in used fuel. This new research facility has the need to use non-traditional measurement sensors to determine the state-of-health of the solvent extraction process. These non-traditional sensors can also enhance nuclear nonproliferation supervision and other activities. The non-traditional sensors include accelerometers, acoustic, current, flow, colorimetric, temperature, pH and conductivity. The challenge behind deploying all these sensors, is the need for fast and reliable data collection. The data acquisition system (DAQ) needs to be capable of recording up to 12 accelerometers and/or acoustic microphones simultaneously at rates up to 12.8 kSamples/second/channel. This requires the need for a strong architecture and data collection solution. This summary identifies the system architecture, DAQ, and sensors needed to support non-traditional measurements in a solvent extraction process.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Color Sensor Comparison for Solvent Extraction Processes

Idaho National Laboratory is building Beartooth, a test bed to advance research into nuclear fuel cycle reprocessing. This test bed will give researchers the opportunity to study solvent extraction processes. Beartooth extraction operations will include the use of centrifugal contactors designed for the recovery and purification of special nuclear material from spent fuel. This new test bed facility provides researchers with the opportunity to study innovative technologies. As part of that initiative, this project will integrate non-traditional (atypical to a solvent extraction process) measurement sensors into a system of contactors to determine the state-of-health. These non-traditional sensors have the potential to enhance nuclear safeguarding efforts and other process activities. The non-traditional sensors include accelerometers, acoustic microphones, colorimetric, pH, conductivity, viscosity, density, and infrared cameras. This report documents the testing and evaluation of two different colorimetric RGB sensors.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗