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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.

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At least 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

CFD modeling and simulation for corrosive wear of refractory in molten slag

The development of high-wear resistant refractories having minimal production costs is facilitated by characterizing the wear mechanisms associated with their corrosive wear. Static cup testing is a commonly used method for comparing the corrosion resistance performance of two or more refractory materials. Although the static cup test conditions are not as severe as dynamic tests, this study shows that the thermal gradient present within the system during heating and cooling stages serves to generate movement of the slag leading to mechanical wear. The thermal gradient within the refractory, and between the slag and the refractory, occurs during the ramp stage of the test and lasts until the soaking stage is reached bringing the system to a thermal equilibrium. Using computational fluid dynamics (CFD) capabilities embedded within ANSYS software, this study modelled and quantified the convection currents within the slag and associated shear stresses generated on the refractory walls due to the thermal gradient. A traditional ladle furnace was employed as a case study to verify the results of the studied CFD model. The corrosion rate of the refractory lining was found to depend on the mass transfer coefficient of the refractory dissolution into the slag, and a velocity term which governs the extent of corrosion at any given location. This velocity term is a function of slag viscosity, as well as the concentration gradient and/or temperature gradient at the triple points. In this study, wall shear stress was used as a reliable proxy for identifying high-velocity regions prone to excessive corrosive wear. Elevated wall shear stress near the slag/air and slag/molten steel interfaces align with observed corrosion grooves, which reflects the intensified corrosive wear at these locations.

Ramteke, Rajat Rajat Durgesh Ramteke [University o↗
DOE OSTI2024

Early-stage Testing of Thermal Power Dispatch Simulator for Subjective Mental Workload and Evolution Time

The excess thermal energy produced by nuclear power plants (NPPs) during low electricity demands can be utilized in industrial processes, such as hydrogen production, through a thermal power dispatch (TPD) system. Initial testing of the first iteration of a single-train TPD design with a manual control mode at the Idaho National Lab (INL) revealed a high operator workload and degraded control capability. The current study evaluated the impact of an enhanced dual-train TPD design on operators’ subjective mental workload and evolution task-time while completing two operating scenarios in manual and automatic control modes. The results showed no statistically significant difference between participants’ mental workload using both control modes. Evolution time in automatic control mode took a shorter time than in manual control, with participants completing all evolutions in less than the 10-min set as the design specification limit. The shorter evolution time is discussed within the context of plant safety and operational efficiency.

Gideon, Olugbenga↗
DOE OSTI2023

Scaling for Nuclear Reactor System: Overview

A scaling analysis is essential for predicting the behavior of a reactor system under various operating conditions, as well as for ensuring safe and reliable experimentation and adequate dataset generation for supporting the system code model development and assessment in accordance with USNRC guidelines 1.203. Testing and modeling can be carried out at various scales, from small test units to full-scale reactors, to validate the predictions produced by the analysis. However, due to the cost and challenges associated with full-scale testing, the nuclear industry uses scaled test facilities—integral effect test (IET) and separate effect test (SET)—to identify potential design issues and optimize the design to ensure regulatory compliance for safer operation and anticipated accident management. In general, IET facilities are non-nuclear thermal hydraulics test facilities. In contrast, SET facilities can be non-nuclear testing (e.g., steam generator, containment, pump system SETs) and nuclear testing (mostly fuel-material irradiation testing). IETs are used to study the system-level thermal-hydraulic behavior of the reactor coolant system (RCS) under different anticipated operational occurrences (AOOs) and design basis accidents (DBAs) such as loss-of-coolant-accident (LOCA) and loss-of-power (i.e., station blackout) and loss-of-flow (i.e., failure of RCS pump). Several LOCA scenarios could happen in reactor DBAs, such as main steam line break (MSLB), SG tube rapture (SGTR), break in direct vessel injection (DVI), and other small breaks LOCA. Scaling analysis determines the appropriate size and operating conditions for the test facility. This involves analyzing the system's thermal-hydraulic behavior at different scales and identifying the key parameters that affect the thermal-hydraulic behavior of the reactor. These key parameters can be identified so that the scaled facility can replicate the expected conditions in a prototypical setting. The scaled facility can simulate the same flow rates, pressure gradients, heat transfer coefficients, and fluid properties as the prototype. Scaling analysis is used to ensure that the results from these tests can be scaled up to predict the behavior of a full-scale prototype with an acceptable range of scaling distortions.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

HOLISTIC ENERGY EFFICIENCY ANALYSIS OF ELECTRIFIED OFF-HIGHWAY MATERIAL HANDLER: FROM DRIVE CYCLE CHARACTERIZATION TO POWERTRAIN, HYDRAULIC, AND THERMAL SYSTEM PERFORMANCE

Three complexities surrounding the operation and testing of hybrid electric, heavy-duty nonroad machines have been addressed experimentally and using 1D simulation. Their resolutions have been intertwined with the development of a prototype machine that was proven to reduce fuel consumption in excess of 20%. A real-world drive cycle that leveraged hydraulic cylinder position was developed and utilized to ensure accurate reproduction of hydraulic work between the baseline and hybrid machines, while simultaneously maintaining less than 5% RMS error in position for main load handling functions. The newly developed, machine-specific drive cycle also contributed towards making equivalent comparisons in energy consumption between machine types through composite performance metrics that were extrapolated over a typical shift duration. Lastly, this work addressed thermal management energy consumption, a topic of increasing popularity when discussing electrified vehicles, by proposing a 1.4% energy savings through special mechanization and control of cooling system components.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Thermal Management for FPGA Nodes in HPC Systems

The integration of FPGAs into large-scale computing systems is gaining attention. In these systems, real-time data handling for networking, tasks for scientific computing, and machine learning can be executed with customized datapaths on reconfigurable fabric within heterogeneous compute nodes. At the same time, thermal management, particularly battling the cooling cost and guaranteeing the reliability, is a continuing concern. The introduction of new heterogeneous components into HPC nodes only adds further complexities to thermal modeling and management. The thermal behavior of multi-FPGA systems deployed within large compute clusters is less explored. Here, we first show that the thermal behaviors of different FPGAs of the same generation can vary due to their physical locations in a rack and process variation, even though they are running the same tasks. We present a machine learning–based model to capture the thermal behavior of each individual FPGA in the cluster. We then propose two thermal management strategies guided by our thermal model. First, we mitigate thermal variation and hotspots across the cluster by proactive thermal-aware task placement. Under the tested system and benchmarks, we achieve up to 26.4° C and on average 13.3° C system temperature reduction with no performance penalty. Second, we utilize this thermal model to guide HLS parameter tuning at the task design stage to achieve improved thermal response after deployment.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

MSTL Re-Start Phase 1.5 Project Final Report

This document provides an overview of re-start efforts at Sandia National Laboratories (SNL), National Solar Thermal Test Facility (NSTTF), for the SNL Molten Salt Test Loop (MSTL). MSTL is one of the world’s only industrial-scale molten salt test systems, capable of testing commercial-scale thermal hydraulic equipment at an industrial scale, required for confident bankability of products. This work was facilitated as part of the Phase 1 re-start effort for facilitating forensics assessments to inform final refurbishments and upgrades costs and schedule information for revitalizing MSTL for use during a separate Phase 2 effort. This work was facilitated to further de-risk a Phase 2 effort pertaining to the tank and the pump, which were considered during Phase 1 to be high-risk items for a successful re-start. Impact from a successful re-start will allow SNL and other industrial molten salt systems companies, such as those in the Market Utilization Report provided in the Phase 1 submission package. An objective of this document is to also ensure longevity of utilization of MSTL after re start.

14 SOLAR ENERGY↗
DOE OSTI2025

Cryogenic Gear System for ADMX Tuning Cavity

The Axion Dark Matter Experiment (ADMX) searches for axions by converting them into detectable photons using resonant microwave cavities at cryogenic temperatures. A precise tuning system is needed to adjust cavity frequency without adding thermal load or electromagnetic interference. This project developed and tested a 1000 to 1 gear reduction system made from PEEK, a low thermal conductivity plastic with good dimensional stability and self lubrication at low temperatures. A compound gear train design of five 3 to 1 stages and one 4 to 1 stage achieves high reduction within a 40 mm diameter compact housing. Prototypes were 3D printed and later CNC machined in PEEK using Fusion 360 and Bantam Tools to confirm manufacturability. Prototype testing showed smooth gear engagement and no slipping. The final gearbox improves cavity tuning precision for axion searches while protecting cryogenic conditions.

Ortega, Giancarlo [Marquette U.]↗
DOE OSTI2023

Integrated solid-state rapid thermo-cycling system

Techniques, systems, and devices are disclosed for implementing a portable lab system for PCR testing. An example method for operating an integrated thermal cycling system includes depositing samples into the integrated thermal cycling system that includes a thermal cycling device and an electronic interface. The thermal cycling device includes multiple wells to receive the samples to be thermally cycled, a thermoelectric cooling (TEC) element connected to the multiple wells, a substrate on which the TEC element is positioned, and a controller coupled to the TEC element. The multiple wells are positioned within the substrate that includes a thermally conductive ground positioned between adjacent wells. Supplying power to the integrated thermal cycling system, via the electronic interface, allows the multiple wells to exchange heat with the substrate and for each well to operate independently from other wells.

Beer, N. Reginald↗
DOE OSTI2021

Impact of Lateral Alignment for Cooling Airflow during Heavy-Truck Platooning

A truck platooning system was tested using two heavy-duty tractor-trailer trucks on a closed test track to investigate the thermal control/heat rejection system sensitivity to intentional lateral offsets over a range of intervehicle spacings. Previous studies have shown the following vehicle can experience elevated temperatures and reduced airflow through the cooling package as a result of close-formation platooning. Four anemometers positioned across the grille of the following trucks as well as aligned and multiple offset positions are used to evaluate the sensitivity of the impact. Straight sections of the track are isolated for the most accurate airflow impact measurements and to be most representative of on-highway driving. An intentional lateral offset in truck platooning is considered as a controls approach to mitigate reduced cooling efficacy at close following scenarios where the highest platoon savings are achieved. The truck platooning system was tested at four gap distances from 9 to 23 meters and the following truck was either aligned with the lead or offset with a 25% width (0.65 m) or 50% width (1.3 m) lateral distance. The experimental results clearly show that offset driving is effective at bringing cooling airflow from 56% with an aligned platoon back up to 75%-80% with minimal impact to fuel savings. In addition, the offset driving can also reduce the trailing truck’s engine coolant temperature by 2°C and the corresponding underhood temperature rise by 10°C. The test outcomes indicate a plausible controls strategy to mitigate reduced cooling flow during hot-weather truck platooning while still enabling the highest-energy-saving, close-following scenarios.

27 ARPA - Advanced Research Projects Agency-Energy↗
DOE OSTI2022

Tabulated Fluid Properties Research Report

The Multiphysics Object-Oriented Simulation Environment (MOOSE) enables a wide range of advanced nuclear reactor simulations.[6] Under the guidance of MOOSE’s Thermal Hydraulics Team,I worked to expand the capabilities of Tabulated Fluid Properties (TFP) in the fluid properties module. The fluid properties module allows the user to determine a variety of fluid properties by interpolating points between tabulated data. I implemented the ability to use bilinear interpolation instead of bicubic interpolation for interpolating tabulated data. I also changed the method of variable set inversions to use a 2-dimensional Newton’s Method utility that I created. Variable set inversions are often done from (v,e) to (p,T), where v is specific volume, e is specific internal energy, p is pressure and T is temperature. New routines have also been added into TFP such that it can be used with more applications, such as the Navier Stokes and Thermal Hydraulics modules in MOOSE for Pronghorn[5] and RELAP-7[1] respectively. This work was spurred by interest from NASA in testing a Nuclear Thermal Propulsion (NTP) engine system. NTP engines have drastically different fluid properties throughout the engine and Tabulated Fluid Properties provides the flexibility needed to properly simulate and test these engines.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

A Survey of Multizone Airflow Simulation Software

H-Canyon simulates the building and process ventilation to ensure positive contamination control for any modifications as well as evaluating off-normal conditions. Simulations can also be used to identify air quality of personnel occupied areas. The models can be classified into two groups, single and multi-zone models. As the name states, a single zone model assumes that the building can be described by a single, well-mixed zone. Whereas large buildings have structures that must be described as multizone. Multizone airflow models deal with the difficulty of flows in a building by distinguishing the effects of internal flow restrictions. Several models have been developed that take internal partitions into account. CONTAM (currently used) is a multizone airflow program created by NIST to determine airflows including infiltration, exfiltration, wind pressures acting outside the building, buoyancy effects caused by the indoor and outdoor air temperature difference. COMIS is a multizone air infiltration, ventilation, and contaminant transport model that was developed at Lawrence Berkeley National Laboratory. COMIS deals with applied pressure distribution, airflow components, HVAC systems, schedules, and contaminant transport. EnergyPlus is designed by DOE. It supports flexible component level configuration of HVAC models and simulates sub-hourly time steps to control fast dynamic systems. The program features include providing accurate environmental performance data including energy consumption and carbon emissions, and reporting solar gains on surfaces. Heavent is used to model industrial ventilation systems to control airborne contaminants. It's designed based on the American Conference of Governmental Industrial Hygienists (ACGIH) Ventilation manual. DesignBuilder is the most recognized and advanced user interface to EnergyPlus. It gives access to all of the most frequently required simulation capabilities covering building fabric, thermal mass, glazing, shading renewables, and HVAC analysis. The objective of this study is to identify all relevant software available including commercially licensed, freely licensed, and open source, that can be used to simulate large, complex process facility ventilation systems. All discovered software tools are evaluated for salient features and compared to the software tool currently used to simulate the H-Canyon ventilation system. The design criteria of a ventilation system has two basic requirements: Supplying fresh air for the occupants and changing the air in the room sufficiently; therefore, the smells, fumes, and contaminants will be removed. In this study, first, whether the software simulates airflow (infiltration, natural ventilation, and interzonal) or considers them to be inputs is discussed. Second, if indoor contaminant levels are considered; and finally suggestions on how airflow analysis can be more appropriately accounted for when performing airflow simulation of a building. All of the airflow software reviewed for this study can account for constant infiltration and natural ventilation rates that are not affected by changes in indoor and outdoor conditions. Modelling infiltration in EnergyPlus or DesignBuilder are applicable for small buildings and not appropriate for larger buildings like the H-Canyon. The effect of wind on external pressures, infiltration, and natural and mechanical ventilation, can also be calculated using all of these software. These programs have control options to switch between natural to mechanical ventilation modes or both (hybrid). Interzonal airflow can be applied which means one zone can be specified to receive a fixed amount of air from another zone. The following ventilation modeling software is recommended for further testing: CONTAM, COMIS, Heavent. The next step in evaluating the software will consist of creating test facility simulations using evaluation copies of the software.

42 ENGINEERING↗
DOE OSTI2026

Pilot Development Progress to Demonstrate Electric Thermal Energy Storage (ETES) Using Low-Cost Particles

The rapid growth of future energy demand increases the need to economically store electrical energy over durations up to several days in long-duration energy storage (LDES) applications. LDES can reduce the grid stress for improving the resilience of the grid. The integration of renewable power and storage has several significant and positive impacts including expanding the renewable energy portion of electricity generation, meeting peak-load demand, and coordinating supply and demand. Several energy storage approaches including mechanical, chemical and electrochemical methods are currently deployed or under development. However, LDES requirements pose unique challenges for scalability, energy capacity, and cost. Thermal energy storage (TES) has the ability to store a large capacity of energy with improved site flexibility compared to incumbent LDES technologies (i.e., pumped hydro) and has attracted significant interest. Our development in TES technology using solid particles as the storage medium has shown feasibility and potential in serving LDES purposes. Particle TES has various advantages over commercialized molten nitrate salt TES and has emerged as a promising storage technology originating from Generation 3 concentrating solar power (CSP) development. Stable, inexpensive silica sand produced in the Midwestern U.S. was identified as a suitable storage medium and has been validated through lab heating and cycling tests. We have successfully developed particle TES for bidirectional electric energy storage to broaden the applications for TES beyond CSP technologies and into standalone electric-thermal energy storage (ETES) systems. Key component designs and performance were verified with prototype testing and model simulations. The ETES system uses high-temperature, low-cost particle thermal energy storage coupled with a unique pressurized fluidized bed heat exchanger that supports a high-efficiency, air-Brayton combined power cycle. At times of low energy demand or high renewable production, an electric particle heater heats large quantities of solid particles to high temperatures in excess of 1100 degrees C. The particles are stored in internally insulated silos. At times of high electricity demand, the hot particles are gravity-fed through the heat exchanger where stored thermal energy is transferred to the power cycle working fluid to drive the gas turbine power generation system, thereby converting the thermal energy back into electricity for the grid. The cold particles leaving the heat exchanger are returned to the storage silos by a well-insulated particle conveyor. This ETES technology using particle TES can be sited anywhere and is predicted to be economic and efficient. Moreover, this ETES technology could be co-located with a retired coal or gas plant to leverage existing power generation and grid infrastructure. Our work has focused on the development of each of the key components (e.g., the electric particle heater, particle storage silos, and the particle-to-gas pressurized fluidized bed heat exchanger) through conceptual designs, prototype testing, and computational modeling. These developments demonstrate technological feasibility and are an important step towards the next phase of development of this promising LDES technology. This presentation will show the progress in developing a pilot demonstration of the ETES system on a commercially relevant scale.

25 ENERGY STORAGE↗
DOE OSTI2021

CRADA Number NFE1706843 with SkyNano LLC (CRADA Final Report)

Cooperative Research and Development Agreement (CRADA) NFE-17-06843 between Oak Ridge National Laboratory (ORNL) and SkyNano LLC focused on studying and developing a better fundamental understanding of SkyNano’s technology to capture and convert CO 2 into solid carbon nanostructures, including carbon nanotubes (CNTs), using electrochemistry at elevated temperatures in molten salts. The project focused on developing a fundamental scientific understanding of how electrochemistry influences the dynamic catalytic processes that drive the formation of CNTs on electrodes, while developing synthesis and processing technology relevant to implementation of the technology – including chemical engineering to aid in recapturing the lithium carbonate electrolyte essential to the process, and the modeling and testing of systems with the required thermal management at practical scales.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Cost-Effective Thermally Activated Building Systems to Support a Power Grid System With High Penetrations Of As-Available Renewable Energy Resources

With a goal to reduce the energy cost for building operation as well as to support renewable energy sources (RES) for the power grid reliability, quality, resilience, and dispatchability, this project developed and demonstrated a novel thermally activated building envelope system that integrates Phase Change Material (PCM)-based Thermal Energy Storage (TES) and the hydronic activation into the building envelope. The main objectives of this study are: 1) to design and laboraorty-test a novel thermally activated building envelope system that integrate PCM-based TES and the hydronic activation into building envelope, and 2) to exploit this new system to significantly reduce the energy cost of operating buildings and manage and support renewable energy sources (RES), e.g., solar and wind for the power grid reliability, quality, resilience, and dispatchability. To achieve the project objectives, a new low-cost, fire-retardant PCM packaging technology (CenoPCM) was developed specifically for high-volume building applications.

25 ENERGY STORAGE↗
DOE OSTI2021

Development and Demonstration of a Reduced-Order PWR Power Dispatch Simulator

This report describes the development, modeling, and results of a reduced-order thermal power dispatch pressurized water reactor (RO-TPD-PWR) power plant simulator that incorporates coupled electrical and thermal power dispatch to an industrial process. The simulator is built on models that have been developed in previous work, including a Rancor Microworld model previously developed by INL and the University of Idaho [Ref] and reactor core and secondary system models that have been published previously [Ref]. The simulator also includes a scalable model of a high temperature electrolysis (HTE) system that has been developed at INL. A particular benefit of the Rancor Microworld model is that it is compatible with a human-system interface (HMI) that has already been developed by the Human System Simulation Laboratory (HSSL) at INL that can emulate the control room of a PWR for realistic human-in-the-loop studies with mock nuclear power plant operating procedures. The results of these human-in-the-loop tests will be compared with similar tests using a commercial full-scope generic PWR (GPWR) simulator that has been modified to include thermal power dispatch, referred to as the TPD-GPWR [ , ]. The simplicity of the RO-TPD-PWR helps to better understand and verify the results of the TPD-GPWR, which employs >1,000 variables and has much greater complexity. A second key purpose of the RO-TPD-PWR simulator is that its relative simplicity allows it scale between lab-size equipment (~100 kW) and full-scale nuclear power plants (~1 GW) by adjusting only a few parameters in the models, such as fluid masses and heat exchanger areas. The RO-TPD-PWR simulator will be used to guide the controls of lab tests, so that equipment in those tests, such as the Thermal Energy Distribution System (TEDS) and pilot-scale high temperature electrolysis (HTE) units at scales of 50-250 kW, may operate in a manner that is relevant to full-scale PWR operations.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2024

Greybox Thermal Parameter Identification of Electric Machine Stators

The parameters of electric machine thermal equivalent circuit networks are difficult to predict due to material and manufacturing uncertainties. In this paper, a Greybox system identification approach is used to identify parameters of electric machine stator lumped parameter thermal networks (LPTNs). LPTNs provide a low order, computationally efficient, dynamic model of temperatures at specific locations. Second and third order LPTN model structures are defined as state space equations with stator thermal parameters to be identified. To test the Greybox electric machine stator thermal system identification, five stator motorette prototypes were constructed with controlled variations in slot fill and slot liner thickness. The variation in the motorette thermal parameters and thermal time constants are detected using the Greybox identification. Special attention is given to the impact of sampling rate and Greybox data record length on parameter estimation accuracy.

33 ADVANCED PROPULSION SYSTEMS↗