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At least 649 records · Page 36

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DOE OSTI2024

Propulsion Electrification Architecture Selection Process and Cost of Carbon Abatement Analysis for Heavy-Duty Off-Road Material Handler

The heavy-duty off-road industry continues to expand efforts to reduce fuel consumption and CO 2 e (carbon dioxide equivalent) emissions. Many manufacturers are pursuing electrification to decrease fuel consumption and emissions. Future policies will likely require electrification for CO2e savings, as seen in light-duty on-road vehicles. Electrified architectures vary widely in the heavy-duty off-road space, with parallel hybrids in some applications and series hybrids in others. The diverse applications for different types of equipment mean different electrified configurations are required. Companies must also determine the value in pursuing electrified architectures; this work analyzes a range of electrified architectures, from micro hybrids to parallel hybrids to series hybrids to a BEV, looking at the total cost, total CO 2 e, and cost per CO 2 e (cost of carbon abatement, or cost of carbon reduction) using data for the year 2021. This study is focused on a heavy-duty off-road material handler, the Pettibone Cary-Lift 204i. This machine’s specialty application, including events like unloading large oil pipes from a railcar, requires a unique electrified architecture that suits its specific needs. However, the results from this study may be extrapolated to similar machinery to inform fuel savings options across the heavy-duty off-road industry. In this study, a unique electrified architecture is determined for the Cary-Lift. This architecture is informed by multiple rounds of a Pugh matrix decision analysis to select a shortened list of desirable electrified architectures. The shortened list is modeled and simulated to determine CO 2 e, cost, and cost per CO 2 e. A final architecture is determined as a plug-in series hybrid that reduces fuel consumption by 65%, targeting the large fuel and CO 2 e savings that are likely to be required for the future of the heavy-duty off-road industry.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS1943

Operating Temperatures of a Sodium-Cooled Exhaust Valve as Measured by a Thermocouple

A thermocouple was installed in the crown of a sodium-cooled exhaust valve. The valve was then tested in an air-cooled engine cylinder and valve temperatures under various engine operating conditions were determined. A temperature of 1337 F was observed at a fuel-air ratio of 0.064, a brake mean effective pressure of 179 pounds per square inch, and an engine speed of 2000 rpm. Fuel-air ratio was found to have a large influence on valve temperature, but cooling-air pressure and variation in spark advance had little effect. An increase in engine power by change of speed or mean effective pressure increased the valve temperature. It was found that the temperature of the rear spark-plug bushing was not a satisfactory indication of the temperature of the exhaust valve.

FUEL-AIR MIXTURES↗

NASA NTRSDate not supplied

Optimization of a Parametric Lobe Mixer for Internally Mixed Nozzles

The results of the first phase of an optimization study on a parametric procedurally-generated lobe mixer are presented. This mixer is part of a dual-stream plug nozzle system, designed under NASA’s CST project for use in near-term commercial supersonic applications. Data was obtained numerically using NASA’s in-house CFD code FUN3D and analyzed to determine mixer performance. Phase I of the study examined five independently-variable geometric parameters describing the lobe mixer. Methods of Design of Experiments (DoE) were used to obtain a parametric model to quickly evaluate mixer performance and determine an optimum configuration. Mixers that induced strong axial vorticity and shear layers without causing flow separation were found to perform best, with exit temperature variance highly inversely correlated to mixing effectiveness.

Lobe Mixer↗

NASA NTRSDate not supplied

Optimization of a Parametric Lobe Mixer for Internally Mixed Nozzles

Lobe mixer↗

DOE OSTI2024

Reaction Pathways and Energy Consumption in NH 3 Decomposition for H 2 Production by Low Temperature, Atmospheric Pressure Plasma

Pathways for NH 3 decomposition to N 2 and N 2 H 4 by atmospheric pressure nonthermal plasma are analyzed using a combination of molecular beam mass spectrometry measurements and zero-dimensional kinetic modeling. Experimental measurements show that NH 3 conversion and selectivity towards N 2 formation scale monotonically with the specific energy input into the plasma with ~ 100% selectivity to N 2 formation achieved at specific energy inputs above 0.12 J cm −3 (3.1 eV (molecule NH 3 ) −1 ). The kinetic model recovers these trends, although it underpredicts N 2 selectivity at low specific energy input. These discrepancies can be explained by the underestimation of reaction rate coefficients for reactions that consume N 2 H x species in collisions with H radicals and/or radial nonuniformities in power deposition, gas temperature, and species concentrations that are not represented by the plug flow approximation used in the model. The kinetic model shows that N 2 formation proceeds through N 2 H x decomposition pathways rather than NH x decomposition pathways in low temperature, atmospheric pressure plasma. Higher selectivity toward N 2 production can be achieved by operating at higher NH 3 conversion and with a higher gas temperature. Furthermore, the high energy cost of NH 3 decomposition by atmospheric pressure nonthermal plasma found in this work (25–50 eV (molecule NH 3 converted) −1 ; 17–33 eV (molecule H 2 formed) −1 ) is a result of the energy requirement for electron-impact dissociation of NH 3 and the significant re-formation of NH 3 by three-body recombination reactions between NH 2 and H.

Nonthermal plasma↗

DOE OSTI2025

The effective number of parameters in kernel density estimation

We devise a new formula for measuring the effective degrees of freedom (EDoF) in kernel density estimation (KDE). Starting from the orthogonal polynomial sequence (OPS) expansion for the ratio of the empirical to the oracle density, we show how convolution with the kernel leads to a new OPS with respect to which one may express the resulting KDE. The expansion coefficients of the two OPS systems can then be related via a kernel sensitivity matrix, which leads to a natural oracle definition of EDoF through the trace operator. Asymptotic properties of the (empirical) plug-in EDoF are worked out through influence functions, and connections with other empirical EDoFs are established. Minimization of Kullback-Leibler divergence is investigated as an alternative to integrated squared error based bandwidth selection rules, yielding a new normal scale rule. The methodology, which arises from a proper oracle formulation and is not restricted to convolution kernels, suggests the possibility of a new bandwidth selection rule based on an information criterion such as AIC.

bandwidth selection↗

DOE OSTI2025

Thermo-hydraulic steam pipe models for district heating simulations: Simplifications to balance accuracy and simulation speed

Steam piping networks are essential for optimizing performance in industrial processes and district heating systems. However, dynamic models that balance thermo-hydraulic accuracy with computational efficiency remain limited. In response, this paper presents a new discretized steam pipe model based on the plug flow approach, capturing key thermo-hydraulic behaviors while simplifying steam phase change processes. Implemented in Modelica, the model accurately calculates temperature and pressure distributions along steam pipelines. To improve computational efficiency for district-scale simulations, five model simplifications are introduced: lumped thermo-hydraulic functions, empirical correlations, fluid state approximations, steady-state dynamics and inclusion of flow derivatives. These simplified models achieve 85%-98% accuracy in predicting pressure drop and condensation losses, including dynamic condensate behavior during pipe warm-up—a factor often overlooked in existing models. The models support diverse network configurations, scaling effectively to systems with multiple distribution pipes and connected building loads. Discrete models provide detailed insights but exhibit a cubic increase in simulation time as the network scales by N connected building O(N 2.42 ). In contrast, lumped models simulate 10–28 times faster than discrete, offering quadratic scaling of simulation time O(N 1.73 ). However, they still require 6 times more computation time than a lossless network, highlighting the inherent computational challenges of modeling compressible fluid flow. In conclusion, the steady-state lumped variant, with its near-linear scalability in computational time O(N 1.01 ), emerges as an efficient solution for preliminary design evaluations and extensive parametric studies.

15 GEOTHERMAL ENERGY↗

DOE OSTI2024

Mitigating municipal solid waste fouling in biofuel conversion via screw surface modifications

Here, municipal solid waste (MSW)'s 40–60 % carbon content makes it a feedstock for biofuel production via pyrolysis. One challenge in the conversion process is MSW fouling due to thermal decomposition. The accumulated deposit on the injection screw often leads to plugging and constriction. This study examined the morphology and composition of the MSW fouling deposit and conducted a thermal simulation to understand the temperature gradience of the injection screw. Surface modifications including smoothening and anti-adhesion coating were proposed for the injection screw to address the deposit problem. For evaluating the candidate mitigations, a bench-scale fouling test was developed with the gas environment, temperature, and sliding speed relevant to the contact interface between the MSW particles and the screw. Results suggested that a smoother screw surface could reduce the grip and a non-metallic coating with a lower surface energy could decrease adhesion, consequently leading to less fouling. Specifically, reducing the roughness from 2 to 0.6 and then to 0.2 μm proportionally decreased the amount of deposit, and the diamond-like-carbon, CrN, and NiCr–CrC composite coatings effectively hindered the fouling process. This study provides fundamental insights into the MSW fouling and proof-of-concept of potential mitigations through the screw surface modification.

09 BIOMASS FUELS↗

DOE OSTI2025

Enhancing the flowability of woody biomass slurries in wet biorefineries

Feeding wet lignocellulosic biomass (e.g., softwood and hardwood) slurries into high-pressure, high-temperature reactors at an industrially relevant scale presents significant challenges, such as process equipment plugging. Here, in this study, we investigate the possibility of improving the flowability of biomass slurries in an industrial scale wet biorefinery by tuning the physical and chemical characteristics of the biomass particles. To understand the effects of the chemical characteristics of woody biomass on flowability, cellulose pulp particles are produced from pulp sheets via knife milling, pelletizing, and crumbling. These cellulose pulp particles are processed for acid hydrolysis dehydration (AHDH) at one –tonne-per day pilot scale. The levulinic acid yield (a product of cellulose AHDH) and the flowability of the biomass particles are compared using market pulp, 1 mm crumbled pine softwood, a blend of 2 mm hammer-milled pine softwood with 10 wt.% bark, and 2 mm hammer-milled hardwood material with 10 wt.% bark (to represent forest residues). The results indicate that the presence of hemicellulose and lignin influences the flowability of lignocellulosic feedstocks. Crumbled wood particles show poor flowability at the pilot scale, while the presence of fine materials (less than 0.7 mm) and bark improves the flowability of biomass slurries without affecting the organic acid yields (based on C6 carbohydrate content).

09 - BIOMASS FUELS↗

DOE OSTI2024

An integrated modeling framework with open architecture for phase field simulation of multi-component alloys

An integrated modeling framework (PanPhaseField) has been developed, which enables a direct and fast coupling between CALPHAD calculations and large-scale phase field simulations for multi-component alloys. Further, it adopts an open architecture allowing for integration of user-defined phase field models in a plug-and-play manner by taking full advantage of the user-friendly graphical interface of Pandat software. The developed modeling platform becomes an enabling tool that can be used to simulate the evolution of spatially varying microstructures of industrial complex alloys for various engineering applications.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Dynamic flux surrogate-based partitioned methods for interface problems

Loosely coupled partitioned methods for multiphysics problems treat each subproblem as a separate entity and advance them independently in time. In so doing these methods enable code reuse, increase concurrency and provide a convenient framework for plug-and-play multiphysics simulations. However, mathematically loosely coupled schemes are equivalent to a single step of an iterative solution method, which can compromise their accuracy and stability. We present a new data-driven partitioned method for coupled parametric PDEs that can improve upon the accuracy of traditional loosely coupled methods without incurring a performance penalty. To that end, we replace conventional field transfers across the interface by a surrogate for the dynamics of the interface flux exchanged between the subdomains. To develop this surrogate we apply dynamic mode decomposition to a non-standard staggered-in-time state, comprising the interface flux and small solution patches near the interface. The new approach shifts the main computational burden to an offline training phase, whereas application of the surrogate in the online phase amounts to a single matrix–vector multiplication. In conclusion, we provide stability analysis of the surrogate-based partitioned scheme and include numerical results that demonstrate its potential.

Dynamic mode decomposition (DMD)↗

DOE OSTI2024

NeuroSEM: A hybrid framework for simulating multiphysics problems by coupling PINNs and spectral elements

Multiphysics problems that are characterized by complex interactions among fluid dynamics, heat transfer, structural mechanics, and electromagnetics, are inherently challenging due to their coupled nature. While experimental data on certain state variables may be available, integrating these data with numerical solvers remains a significant challenge. Physics-informed neural networks (PINNs) have shown promising results in various engineering disciplines, particularly in handling noisy data and solving inverse problems in partial differential equations (PDEs). However, their effectiveness in forecasting nonlinear phenomena in multiphysics regimes, particularly involving turbulence, is yet to be fully established. Here, this study introduces NeuroSEM, a hybrid framework integrating PINNs with the highfidelity Spectral Element Method (SEM) solver, Nektar++. NeuroSEM leverages the strengths of both PINNs and SEM, providing robust solutions for multiphysics problems. PINNs are trained to assimilate data and model physical phenomena in specific subdomains, which are then integrated into the Nektar++ solver. We demonstrate the efficiency and accuracy of NeuroSEM for thermal convection in cavity flow and flow past a cylinder. The framework effectively handles data assimilation by addressing those subdomains and state variables where the data is available. We applied NeuroSEM to the Rayleigh-B´enard convection system, including cases with missing thermal boundary conditions and noisy datasets. Finally, we applied the proposed NeuroSEM framework to real particle image velocimetry (PIV) data to capture flow patterns characterized by horseshoe vortical structures. Our results indicate that NeuroSEM accurately models the physical phenomena and assimilates the data within the specified subdomains. The framework’s plug-and-play nature facilitates its extension to other multiphysics or multiscale problems. Furthermore, NeuroSEM is optimized for efficient execution on emerging integrated GPU-CPU architectures. This hybrid approach enhances the accuracy and efficiency of simulations, making it a powerful tool for tackling complex engineering challenges in various scientific domains.

42 ENGINEERING↗

DOE OSTI2025

An economic and technical feasibility analysis of a dual-source heat pump using both the air and the ground

The study investigates the economic and technical performance of a novel dual-source heat pump (DSHP) compared with that of air-source heat pumps (ASHPs) and ground-source heat pumps (GSHPs). The DSHP can use both ambient air and the ground as a heat source or heat sink. It uses ambient air when its temperature is favorable for efficient heat pump operation. When the ambient temperature is too hot or cold, the ground source is used to retain high-efficiency heat pump operation. Since the DSHP can alternately use either the ground heat exchanger (GHE) or ambient air to meet the thermal load, the required size of GHE can be smaller than those of GSHPs. This study models the DSHP using a whole building energy simulation tool (EnergyPlus) coupled with a Python plug-in and Heat Pump Design Model (HPDM) to simulate its heating and cooling performance for a typical single-family home in 15 US climate zones. The required GHE size of the DSHP system is determined through simulations and compared with that of GSHPs. DSHP deployment can reduce electricity use compared to ASHPs, especially in cold climates where it shows a reduction of around 50%. When compared to GSHPs, DSHPs use 20%–40% more electricity in warm climates but consume around the same amount in moderate and colder climates. Since the DSHP can use air source when the ambient temperature is mild, the GHE size needed for the DSHP is about 40% less than that needed for GSHPs in hot climates and about 25% less in cold climates. In conclusion, the life cycle cost analysis shows that the DSHP is economically more feasible than ASHPs in colder regions and economically more feasible than GSHPs in hot and cold regions.

Dual-source heat pumps↗

DOE OSTI2025

Understanding the impacts of inorganic species in woody biomass for preprocessing and pyrolysis–A review

Woody biomass represents an abundant resource for sustainable biofuels, biochemicals, and bioproducts. Technologies for converting woody biomass have been established for decades, and research consistently highlights the critical role of inorganic species and ash plays in feedstock handling and conversion processes, including equipment plugging, corrosion, and catalyst deactivation. A thorough understanding of the variability, transport behavior, and downstream impact of inorganic species in woody biomass is essential for defining feedstock quality specifications and developing effective management strategies for conversion processes. This review compiles critical information in five main sections: 1) inorganic species concentration in woody biomass, based on anatomical fractions and their sources of variability; 2) technique features for quantifying inorganic elemental chemical analysis; 3) impacts of inorganic species on biomass preprocessing; 4) impacts of inorganic species on pyrolysis, and 5) mitigation strategies. Additionally, this review explores future challenges and opportunities in addressing the impacts of inorganic species on biomass quality. These insights aim to support the sustainable development of the biomass-to-bioenergy pipeline and ensure high-quality lignocellulosic feedstocks for efficient downstream conversions. The findings offer valuable guidance to policy makers, industry stakeholders, and researchers in developing effective strategies for managing inorganic species in woody biomass and fostering the sustainable processes for lignocellulosic biorefineries.

09 BIOMASS FUELS↗

DOE OSTI2025

Scalability and Effectiveness of Smart Charge Management

The rise in electric vehicle (EV) adoption presents growing challenges for power grids, particularly from simultaneous residential charging, which can cause voltage fluctuations and increase feeder peak loads. Baltimore Gas and Electric (BGE), with support from the U.S. Department of Energy, initiated a pilot program to evaluate managed residential EV charging through Smart Charge Management (SCM). This study analyzes real-world charging behavior data from the pilot and feeder-level base loads from BGE to simulate residential charging scenarios through 2035 across the Washington, DC–Baltimore region. Grid impacts under unmanaged charging are compared to three SCM strategies: TOU-immediate, TOU-distributed, and Load Balancing. Results show that the magnitude of peak reduction is highly feeder-dependent. Some feeders achieve reductions of more than 40% at high enrollment levels, while others show improvements closer to 10–15%. This heterogeneity reflects differences in baseline feeder load shapes, EV penetration, and plug-in behavior across customers. Results also highlight trade-offs between shifting load away from peak periods and minimizing secondary demand peaks, offering practical insights for future utility program design.

Electric vehicle↗

DOE OSTI2024

Understanding drivers of oil and gas well integrity issues in the greater wattenberg area of Colorado

Well integrity is critically important to maintain to minimize the environmental impacts of oil and gas development and other subsurface energy operations. The Wattenberg Field of Colorado—a top producing field with >40,000 wells—has one of the most robust publicly reported well integrity programs in the country. Here, in this study, we analyzed annular pressure and annular-fluid geochemical test results collected from Wattenberg wells through the end of 2019 to characterize the frequency and spatial variability of integrity issues in the field and understand their drivers. Estimated frequencies of integrity issues among tested wells were 8.2-17.1% between 1955 and 2019 and 6.1-11.4% in 2019 alone. The frequency of integrity issues was nearly four times greater in wells located above the Longmont Wrench Fault Zone. Potential drivers of integrity issues were identified using ensemble decision tree models trained with a broad set of relevant information. Models show that well integrity issues are spatially clustered on regional and sub-regional scales and suggest the relatively high frequency of integrity issues observed is likely attributed to geologic factors. These findings are valuable for regulatory agencies and operators seeking to inform well integrity monitoring, plugging, and emissions reduction efforts and design future subsurface energy projects.

03 NATURAL GAS↗

DOE OSTI2026

Propagation method and planting density influence canopy developmental transition and biomass productivity in Miscanthus × giganteus

Understanding how establishment practices influence the mechanisms underlying Miscanthus × giganteus (miscanthus) productivity and canopy development is critical for optimizing management. Data was collected during the juvenile (2011–2013) and mature (2024) phases of a long-term field experiment established in Urbana, Illinois, to evaluate the effects of propagation method (plug propagation [PP] and rhizome propagation [RP]), planting density (1.0, 0.75, and 0.25 plants m⁻²), and nitrogen application (0 and 67 kg N ha⁻¹) on end-of-season biomass yield, tiller mass, tiller density, and tiller height. Linear regression models identified the dominant predictors of yield across stand ages and management regimes. Planting density, nitrogen (N) application, and propagation method significantly influenced early yield and canopy development. During the juvenile phase, biomass yield was driven by tiller density due to canopy expansion; in the mature phase, yield became driven by tiller mass. The PP plots produced higher tiller density than the RP plots, resulting in faster canopy closure and higher juvenile-phase yields. Rhizome-propagated (RP) plots produced lower tiller density, but individual tillers were 3.3–6.4 g tiller −1 heavier than PP tillers. After the canopy reached equilibrium, the PP and RP yields were similar because greater RP tiller mass compensated for its lower tiller density. Higher planting density resulted in greater yield and tiller density during the second year (2012), but this effect was absent from the third year (2013) onward. In the juvenile phase, N fertilization enhanced yield by 1.6–3.4 Mg ha −1 . Initiating fertilization in 2013 on unfertilized plots produced biomass similar to that in fertilized plots, suggesting yield recovery in the mature phase. These findings revealed that establishment strategies, including propagation method and planting density, influence juvenile miscanthus canopy development and productivity, transitioning from tiller-density- to mass-dominated yields, but not mature phase productivity.

09 BIOMASS FUELS↗

DOE OSTI2025

UQpy Version 4.2: Uncertainty quantification with Python

We introduce a new module for the UQpy software package which extends its capabilities into the field of Scientific Machine Learning. This module builds on PyTorch to create a flexible and robust platform for uncertainty quantification in machine learning. The scientific machine learning module of UQpy introduces custom layers, neural networks, and neural network trainers that are compatible with torch version 2.2.2 and allow for “plug and play” integration into existing torch code.

Neural networks↗