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DOE OSTI2013

Advanced Capabilities in GOMA 6.0 - Augmenting Conditions Automatic Continuation and Linear Stability Analysis

This document describes the form and use of three supplemental capabilities added to Goma during 1998 -- augmenting conditions, automatic continuation and linear stability analysis. Augmenting conditions allow the addition of constraints and auxiliary conditions which describe the relationship between unknowns, boundary conditions, material properties and post-processing extracted quantities. Automatic continuation refers to a family of algorithms (zeroth and first order here, single and multi-parameter) that allow tracking steady-state solution paths as material parameters or boundary conditions are varied. The stability analysis capability in Goma uses the method of small disturbances and superposition of normal modes to test the stability of a steady- state flow, i.e., it determines if the disturbance grows or decays in time.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2019

Continuous Flow Biocatalytic Generation of Green Propellant Fuels

Propulsion technologies have focused on monopropellant hydrazine systems for the past four decades. However, hydrazine is both highly toxic and highly flammable, requiring expensive cold storage and specialized handling and disposal protocols. Alternative propellant fuels for supporting satellites and spacecraft are required, and greener, on-demand approaches for manufacturing denser, less dangerous rocket fuels are essential. This project will ensure that humans in extreme environments such as space can sustainably access renewable fuel resources from biomass waste streams via continuous biocatalytic manufacturing using microfluidic reactor systems. Demonstration of our sustainable and recyclable processes for manufacturing greener propellants from biomass waste will advance further applications in future space missions. There remains a continued need to develop more sustainable, environmentally-responsible pathways for manufacturing fuels in general and propellants in particular. This project, building upon known biocatalytic processes, will provide astronauts with renewable propellant fuel sources that can be manufactured in situ. Thus, “on-demand” access to propellants that perform more efficiently than hydrazine is enabled by this proposed work.

09 BIOMASS FUELS↗

DOE OSTI2019

Systems Biology Towards a Continuous Platform for Biofuels Production

The goal of our project was to develop Bacillus megaterium as a host for continuous biofuel production coupled with in situ product extraction by supercritical (sc) CO 2 stripping. We aimed to develop a system that utilizes supercritical CO 2 (scCO 2 ) to address challenges associated with microbial contamination, product toxicity, and product recovery that currently limit the potential of advanced biofuel and bio-based chemical production. We proposed an interdisciplinary research and development effort involving bioprocess engineering, systems biology, and chemical separation engineering, centered around a recently isolated microorganism that is tolerant to scCO 2 . To this end we pursued a series of Aims and Sub-Aims with the ultimate goals of 1) determining the systems physiology of B. megaterium during growth under scCO 2 (Aim 1); 2) engineering heterologous butanol production pathways for anaerobic and aerobic expression in B. megaterium (Aims 1 & 2); 3) conducting de novo pathway engineering for biosynthesis of longer chain fuels (Aim 2); and 4) developing and modeling a two-phase stripping chemostat for continuous production of biofuels with in situ scCO 2 extraction (Aim 3).

09 BIOMASS FUELS↗

DOE OSTI2020

Cost Efficient and Highly Weather-Resistant Solar Panel Backsheet Produced through Continuous Co-Extrusion Processing

The efficient generation and delivery of ‘clean energy” through photovoltaic (PV) technology relies heavily on the cost, performance and reliability of solar panels, along with the individual components used in assembly of those panels. In order to continue towards the Department of Energy’s (DOE) goals of driving costs down, the lifetime of high-output power generation equipment (i.e. solar modules) must be extended to reduce costs associated with power output degradation and replacement of failed or degraded panels. One of the major sources of module failures in the past 30 years has been the failure of the solar panel backsheet. Failure of this component causes severe output losses due to oxidation and yellowing of the module while creating safety concerns as the major electrical insulation of the module is compromised. Tomark-Worthen LLC was formed in 2012 with the goal of designing and manufacturing novel PV backsheets and encapsulants that would be produced in the United States of America and exceed expectations of domestic and international module producers. These backsheets would improve upon known backsheet design failures (i.e. Isovoltaic’s AAA backsheet) and create domestic manufacturing jobs in the PV sector. This goal became a reality with a first-generation product in 2018 and now, with the support of the DOE, Tomark-Worthen has launched a second-generation product known as PhotoMark® Reflections™ 205-3 and 360-3. This 2+ year effort began in late 2017 with a screening of potential polymeric materials and backsheet structural designs. Performance evaluations of each material provided the necessary data needed to select the proper material combinations and move forward into the design of the manufacturing process. These decisions were made by teaming with a local university, well-respected government laboratories, and private research organizations who provided the tools necessary to predict long-term performance of these materials in much shorter periods of time. Once the go/no-go criteria were met at the mid-point of the project, the effort transitioned to predicting 30+ year performance, achieving certifications, and improving manufacturing efficiencies designed to lower costs in order to be competitive in a cost-driven market. Major project accomplishments include recognition of the new backsheet by Underwriters Laboratories (UL) and international certification for 1000V and 1500V modules by TUV Sud. Both 1000V and 1500V products have been proven on several module manufacturing lines and initial customer orders have been received by both domestic and international module producers. Accelerated exposure testing has shown that the performance of this backsheet exceeds the prior polyamide-based backsheet known to fail in the field. Cost-models and initial customer orders have shown the ability to produce this backsheet at a cost acceptable to many domestic manufacturers, while International costs for standard backsheet remains extremely low. Tomark-Worthen remains one of the only U.S. companies manufacturing backsheet domestically and this has drawn interest from many domestic module manufacturers looking to improve their material supply logistics by avoiding long lead times and custom’s headaches while avoiding current tariffs on Chinese-made components. Along with the launch of a new PV backsheet, this project has provided a critical deliverable to the PV R&D community. This deliverable is the knowledge that not all polyamide-containing backsheets are doomed to failure as the earlier versions did. There has been a fear amongst the PV community to consider these materials due to the failure of one design. This effort has brought a new level of interest to the scientific community as it has been shown that polyamides can be used successfully in a well-designed backsheet. As we move forward from this project, we are excited to see how backsheet technology and manufacturing in the U.S. will continue to progress and grow.

14 SOLAR ENERGY↗

DOE OSTI2020

Continuous Monitoring and Partial Water Softening for Cooling Tower Water Treatment

Cooling towers are an integral component of many refrigeration systems, providing comfort or process cooling across a broad range of applications. They are the point in the system where heat is dissipated to the atmosphere through the evaporative cooling process. Cooling towers are commonly found in industrial applications and are also often used in water-cooled chilled water plants in medium to large commercial buildings. Continuous monitoring and partial water softening for cooling towers used in medium to large commercial buildings are the focus of this paper. Cooling towers consume large amounts of water. Cooling tower-related water consumption is one of largest potable water loads within buildings in the United States, with substantial building water use associated with heating and cooling. Regional water shortages have highlighted a need to reduce water consumption; the U.S. General Services Administration (GSA) and Executive Order 13834 place priority on reducing water consumption. This priority has fueled interest in the identification, investigation, and potential broad deployment of cost-effective opportunities to reduce water use, such as alternative water treatment (AWT) technologies for cooling towers. Traditional water treatment approaches use chemicals to extend the ability of the water to hold scaling minerals in suspension, minimize corrosion, and prevent biological growth. This treatment protects the chillers and cooling tower equipment; however, even when chemicals are used regularly, a certain percentage of condenser water must be drained and made up with fresh water to maintain system water quality parameters. In addition, the use of chemicals sometimes creates a waste disposal issue and can cause building owners to incur additional fees, such as disposal or wastewater charges. To manage cooling tower water treatment, GSA typically contracts with a company specializing in conventional chemical maintenance for a fixed fee. While there are many types and vendors of AWT systems, this project assesses the effectiveness of one technology provided by Aqualogix. This system is a chilled water plant monitoring and control system aimed at optimizing system performance by reducing the blowdown occurrences used to remove mineral build-up. The technology consists of two components – continuous programmable logic control (PLC) monitoring and side-stream filtration with partial water softening. PLC monitoring calculates cycles of concentration (CoC) and determines the optimum amount of blowdown water required to satisfy all water chemistry requirements. Side-stream filtration removes suspended matter and improves biocide efficacy while precisely dispensing softened water to achieve optimal makeup water hardness. Unlike other AWT systems evaluated by GSA to date, this system does not replace the legacy treatment system but is used in addition to chemical water treatment. The vendor claims their technology will reduce water consumption, water discharge, and maintenance costs. The AWT system evaluated in this demonstration is a commercialized technology. Given its commercialized state, the system evaluated in this report is at a Technology Readiness Level 9 according to National Aeronautics and Space Administration (NASA) definitions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Manufacture of Carbon Foam in Continuous Process at Atmospheric Pressure

CFOAM LLC has been manufacturing CFOAM® vitreous carbon foam from coal in panel form for several years. The process is currently set up in batch mode as two steps, where the first step is conducted at very high pressure. In order to reduce cost and increase capacity, a new process for making carbon foam is being developed that can be performed at atmospheric pressure. This advance in turn would enable the development of a continuous manufacturing process, which is also being pursued. Both carbon foam panels and light weight aggregates are being investigate. Progress on the evolution of the pilot scale manufacturing plant and initial results of processing, microstructure, properties and performance of carbon foam products made using this new process will be discussed. This project is being supported by a cooperative agreement with the Department of Energy – National Energy Technology Laboratory (DE-FOA-0002185, Area of Interest 4: Coal-Derived Carbon Foam Produced via a Continuous Process, award number DE-FE-0031992).

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2020

Injection Overmolding of Continuous Carbon Fiber Preforms

This project explored and developed a process to injection overmold continuous carbon fiber preforms fabricated with tailored fiber placement. Much early work was focused on the ability to infuse dry carbon fiber tow, fully wetting out the fibers, in an injection molding process. Various approaches were explored, including using commingled fiber and pre-consolidated flexible preforms. The commingled fiber was a blend of carbon fiber and polymer fiber matching the injecting polymer. This approach showed some merit but required an extremely high quality homogeneous mixing of the polymer fibers with the carbon fibers to wet out the carbon fiber tow. Therefore, the project focused on pre-consolidated preforms. The pre-consolidated preform manufacturing method was first developed using compression molded flat plates that were cut into tensile specimen for testing. Work then progressed to an injection molded simplified corner fitting bracket. It was shown that a viable manufacturing method for overmolding continuous carbon fiber preforms could be developed.

36 MATERIALS SCIENCE↗

DOE OSTI2022

OPEN2018 (continuation of GENSETS effort)

This project has demonstrated the key components and engineering principles to support a residential scale (1 to 2 kWe) recuperated Brayton cycle generator based upon a screw compressor and screw expander. This technical work is a continuation of the previously awarded ‘GENSETS’ program. The product goal has been to achieve a 40% fuel-to-electric LHV efficiency, an 80% overall CHP efficiency, emissions qualified to the California Air Resources Board standards, and at noise levels of 55 dB or less at 1 meter. Further, the product must operate with 8,000 hour service intervals and achieve a mean-time to overhaul of 90,000 hours. Lastly, and possibly most importantly, the product must meet demanding cost targets, exhibiting a factory cost well below $1,500/kWe. After extensive aerodynamic studies under the ‘GENSETS’ program, Brayton concluded that miniature turbomachinery could not achieve an efficiency consistent with the product’s system performance goal. Given compressor and turbine efficiency targets in the range of 78 to 81%, Brayton turned to the rotary screw machines. While the justification for a screw compressor over a conventional centrifugal compressor is well supported by industry experience, the high temperature expander represented the core technology advancement. To meet the extremely high efficiency goals, an all-ceramic rotary screw expander hot section was developed and has now been tested in the laboratory. This first-of-its-kind ceramic screw expander prototype was able to demonstrate aerodynamic efficiency in line with predictions. The test article was successfully run to full stress conditions so has also validated the mechanical design of such a unit. This has opened new avenues for the commercialization of high efficiency, small scale power generation. Interest in the technology has sparked several requests for alternate uses, an invitation to present at a screw machine conference, and continued interest from parties looking to develop a product in the spirit of the original ‘GENSETS’ goals.

42 ENGINEERING↗

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 OSTI2021

Manufacture of Carbon Foam in Continuous Process at Atmospheric Pressure

CFOAM LLC has been manufacturing vitreous carbon foam from coal in panel form for several years. The process is currently set up in batch mode as two steps, where the first step is conducted at very high pressure. In order to reduce cost and increase capacity, a new process for making carbon foam is being developed that can be performed at atmospheric pressure. This advance in turn would enable the development of a continuous manufacturing process, which is also being pursued. Both carbon foam panels and light weight aggregates are being investigate. Progress on the evolution of the pilot scale manufacturing plant and initial results of processing, microstructure, properties and performance of carbon foam products made using this new process will be discussed. This project is being supported by a cooperative agreement with the Department of Energy – National Energy Technology Laboratory (DE-FOA-0002185, Area of Interest 4: Coal-Derived Carbon Foam Produced via a Continuous Process, award number DE-FE-0031992).

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2022

Manufacture of Carbon Foam in Continuous Process at Atmospheric Pressure

CFOAM LLC has been manufacturing vitreous carbon foam from coal in panel form for several years. The process is currently set up in batch mode as two steps, where the first step is conducted at very high pressure. In order to reduce cost and increase capacity, a new process for making carbon foam is being developed that can be performed at atmospheric pressure. This advance in turn would enable the development of a continuous manufacturing process, which is also being pursued. Both carbon foam panels and light weight aggregates are being investigate. Construction of the pilot scale manufacturing plant has been completed and results of processing, microstructure, properties and performance of carbon foam products made using this new process will be discussed. This project is being supported by a cooperative agreement with the Department of Energy – National Energy Technology Laboratory (DE-FOA-0002185, Area of Interest 4: Coal-Derived Carbon Foam Produced via a Continuous Process, award number DE-FE-0031992).

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2024

58966_TSQP Continuing Learning

This training is established to maintain the knowledge and skills of the Learning Specialist. It aligns with the tasks identified as overtrain and ensures continuity of learning and knowledge within the Learning Specialist Curriculum 409 and the revised curriculums. Completion of the fixed continuing training course is required once every two years for the Learning Specialist to remain in qualification.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗

DOE OSTI2024

Demonstration of a Continuous Motion Direct Air Capture System

Global Thermostat (GT) has developed a process that addresses the primary technical challenges associated with direct air capture (DAC): the ability to process enormous volumetric flowrates of air and provide the energy for regeneration at acceptable cost. However, at current, there is opportunity for improvement in overall capture costs and especially in capital costs. While GT has advanced its base technology to TRL levels supporting commercial deployments, its research strategy includes alternative technology embodiments that enable substantial reductions in the cost per tonne of CO 2 removed. The objective of this project is to advance the most promising of these embodiments, where a DAC plant is operated in a continuous fashion rather than a discrete stepwise fashion (GT’s commercial scale technology approach). The Continuous Motion Direct Air Capture (cDAC) System’s advantages over the GT baseline stepwise DAC platform have been proposed primarily as a reduction in the complexity required for starting and stopping a movement system, relaxing requirements for other components designed for a rapid switching application, and a flattening of the sharp instantaneous fluid flowrates into steady-state mass & energy flows to enable smoother operation and easier heat integration. These advantages can lead to shorter cycle times, greater plant reliability, and lower capital expense. The primary objective of this project is the design, construction, commissioning, and operation of a field-test unit (FTU) at a scale in the range of ~200 tons CO 2 per year. Data generated from the operation campaign would then be used in a prescreening techno-economic analysis (TEA) and life cycle analysis (LCA), allowing this process to be compared to other carbon capture technologies.

42 ENGINEERING↗

DOE OSTI2025

A Data-Agnostic, Continuous Machine Learning Framework for Application in High Energy Physics and Beyond: Phase 1 Final Scientific/Technical Report

This Phase 1 effort has focused on the development of continual learning frameworks for use in machine learning, specifically in the applied context of High Energy Physics (HEP). Machine learning (ML) is a transformative technology by which computers, typically through the use of neural networks, are able to perform tasks with proficiency that rivals or surpasses that of human users. Model Degradation & Catastrophic Forgetting are two undesired phenomena which can occur in ML where the performance of a model degrades when either deployed on novel data streams, or trained on novel data which are sufficiently different than the data the models were initially trained on. A natural example where these sorts of effects can be observed is in the performance of detectors in harsh environments, where the detector signature may change over the lifetime of the detector as it ages and deteriorates — precisely what occurs in the experiments conducted in HEP. Real world HEP data is therefore an excellent test-ground and use-case for Continual Learning paradigms, which are techniques used in ML to counteract these problems. Ensemble learning is one such technique, where multiple smaller models are trained on subsets of the overall data and are ensembled together during inference. The intuition behind this technique is that, although there are shifts in the distributions which govern the incoming data streams, these shifts are not expected to be homogeneous or global. If a sufficient diversity in solutions within the various sub-models has been achieved, then at least one sub-model is expected to retain its performance within the overall ensemble. One further strength of this approach is that the architectures of the various models do not need to be identical, and in fact even different modalities of data can naturally be combined in this way. This work focused on applying ensemble learning techniques to derive results using two main datasets, anomaly detection in HEP data & time-series forecasting in semiconductor manufacturing data. Semiconductor manufacturing involves data with surprising similarity to that of HEP (e.g. wafer maps look very similar to digi-occupancy maps) and Cerium Lab’s prominence within the semiconductor industry makes semiconductor manufacturing a natural opportunity for commercialization of this work. Our efforts have led to two strong results. The first is that we evaluated the proposed ensembling techniques using previously proposed machine learning architectures for use in anomaly detection, namely AutoEncoder based models and their derivatives. We also developed new architectures which have not been evaluated in this context before. In fact, this work marks the first use of Vision Transformers for anomaly detection in HEP. Second, we demonstrated that ensemble learning significantly improves model performance in scenarios prone to degradation, validating its effectiveness across both HEP and semiconductor datasets. These results further support ensemble learning as a powerful strategy for mitigating catastrophic forgetting and maintaining robust performance in evolving data environments.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2024

The hygrothermal performance of continuous and cavity wood fiber insulation

Wood fiber insulation is an emerging material known for its effective thermal performance and moisture management properties, making it a compelling alternative to conventional insulation. Its vapor permeability and ability to regulate indoor humidity contribute to improved building durability and comfort, particularly in varying climate conditions. The goal of this project is to characterize the hygrothermal performance of a new wood fiber insulation product line in U.S. climate zones and to facilitate the design and construction of the product in residential and light commercial building envelopes. This study investigates the thermal and hygrothermal performance of wood fiber insulation, both as continuous and cavity insulation. The research employs an exhaustive simulation task and an environmental chamber test of a wood fiber insulation. Over 400 simulations were conducted to study the hygrothermal characteristics of bio-based wood fiber insulation in various building envelope configurations across four climate zones. Environmental chamber tests were conducted under controlled winter conditions representative of Climate Zone 5A (Chicago, IL) to complement the simulation results. The chamber tests focused on the hygrothermal performance of the wood fiber insulation and the sheathing board to assess the insulation's ability to manage moisture in a cold climate. Simulation and environmental chamber test results were analyzed to evaluate the insulation's consistency and efficacy across diverse climatic zones. Results show that with a proper moisture control strategy, both cavity and continuous wood fiber insulation can work properly in both new and retrofit constructions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

The Hygrothermal Performance of Continuous and Cavity Wood Fiber Insulation

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Continuous Baseline Microphysical Retrieval (MICROBASE) Value-Added Product Report

This technical report describes the Continuous Baseline Microphysical Retrieval (MICROBASE) Value-Added Product (VAP) produced operationally by the U.S. Department of Energy Atmospheric Radiation Measurement (ARM) User Facility. MICROBASE provides a continuous estimate of cloud microphysical properties at ARM fixed observatories and ARM Mobile Facility (AMF) sites. It is designed to run operationally and provide data to the ARM Data Center for scientific distribution. This technical report presents an overview of the VAP as a resource for data users and ongoing records for major updates to these products.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

Continual Learning for Particle Accelerators

Particle accelerators operate under dynamically changing conditions, which often lead to data distribution drifts. These drifts pose significant challenges for Machine Learning (ML) models, which typically fail to maintain performance when faced with such non-stationary data. In particle accelerators, the primary sources of these data drifts include changes in accelerator settings and non-measured parameters such as machine degradation and environmental factors. Previous research has proposed conditional models to handle multiple beam configurations effectively; however, it is challenging to train the ML models on all possible configuration settings. Additionally, conditional models alone can not address performance degradation caused by drifts due to non-measured factors. These limitations contribute to a significant gap between ML development and its deployment in real-world operational settings. To bridge this gap, in this paper, we identify some of the key areas within particle accelerators where continual learning can help mitigate drift-induced performance degradation. In addition, we present a practical use case where a conditional Auto-Encoder model coupled with memory-based continual learning has been employed to demonstrate stable performance even when underlying data drifts.

Schram, Malachi [Thomas Jefferson National Acceler↗