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DOE OSTI2022

Accelerating Optimal Integration of Energy Efficiency Strategies with Industrialized Modular Construction: Preprint

The National Renewable Energy Laboratory's (NREL's) Industrialized Construction Innovation team first introduced the Industrialized Construction Assessment Framework to achieve affordable, net-zero energy (NZE) modular multifamily buildings in the 2020 ACEEE paper "Integrating Energy Efficiency Strategies with Industrialized Construction for our Clean Energy Future." Since then, NREL has continued to drive the ambitious plan to accelerate optimal integration of energy efficiency strategies during industrialized construction with little or no additional cost, labor, and production time. This follow-on paper introduces the Energy in Modular (EMOD) buildings method and presents NREL's research efforts over the last two years in collaboration with industry, including affordable housing partners. NREL has developed an idealized NZE modular multifamily building design that incorporates five energy efficiency strategies well suited for industrialized construction in factories: (1) envelope thermal control, (2) envelope infiltration control, (3) mechanical, electrical, and plumbing systems, (4) smart controls, and (5) solar plus storage. This paper highlights results from leveraging design for manufacturing and assembly principles, testing, and validation pilots with factory partners; demonstrating pod prototypes in test stand at NREL; and performing simulations. Overall, these research efforts address barriers to whole-building system integration, such as poor installation quality of thermal and air barriers; lack of unitized systems for space conditioning, energy recovery and ventilation, and water heating; problematic on-site installation, commissioning, and configuration of controls; and lack of cost-effective integration for grid-friendly design and emerging technologies. Conclusively, the paper delineates next steps for future work with NREL's partners toward developing a transformational pathway for our clean energy future.

affordable housing↗

DOE OSTI2022

Coaxial Ceramic Direct Ink Writing on Heterogenous and Rough Surfaces: Investigation of Core–Shell Interactions

In this work, coaxial conductor–ceramic direct ink writing enables the printing of sensitive or encapsulated materials onto heterogeneous and rough substrates. While encasing the core fluid within a stiff ceramic shell, continuity may be maintained, even while printing onto conventionally challenging substrates. Here, we report the development of a coaxial ceramic direct ink writing suite and explore coflow interrelationships based on microfluidic principles. A coaxial nozzle is designed to facilitate the coextrusion of an alumina shell, whereas indium–tin-oxide inks constitute the core. In this manner, a core–shell ceramic element may be printed onto rough substrates for future high-temperature applications. Colloidal inks are engineered to provide the required rheological and sintering performance. Moreover, flow simulations in conjunction with microfluidic coflow principles are used to explore the coaxial printing processing space, thus controlling the core–shell architectures. Physical modeling is further used to analyze core deformations and eccentricity. As a result, simulations are validated experimentally, and the analyses are used to deposit coaxial ceramic features onto heterogeneous, high-temperature ceramic substrates.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2024

Transport coefficient sensitivities in a semi-analytic model for magnetized liner inertial fusion

Performance of magnetized liner inertial fusion (MagLIF) experiments is highly dependent on transport processes including magnetized heat flows and magnetic flux losses. Magnetohydrodynamic simulations used to model these experiments require a choice of model for the transport coefficients, which are the constants of proportionality relating driving terms, such as temperature gradients and currents, to the associated heat and magnetic field transport. The coefficients have been the subject of repeated recalculation using various methods throughout the years. Using a semi-analytic MagLIF model, we compare models for the transport coefficients. The choice of model modifies magnetic-flux losses caused by the Nernst thermoelectric effect and thermal conduction losses. We present simulated results from parameter scans conducted in order to compare the effects of the different models on parameters of interest in MagLIF. In some regions of parameter space, discrepancies of up to 38% are found in integrated quantities like the fusion yield. These results may serve as a guide for experimental validation of the various models, particularly as laser preheat energies and initial axial field strengths are increased on MagLIF experiments.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2020

Physics-informed neural networks for inverse problems in nano-optics and metamaterials

In this paper, we employ the emerging paradigm of physics-informed neural networks (PINNs) for the solution of representative inverse scattering problems in photonic metamaterials and nano-optics technologies. In particular, we successfully apply mesh-free PINNs to the difficult task of retrieving the effective permittivity parameters of a number of finite-size scattering systems that involve many interacting nanostructures as well as multi-component nanoparticles. Our methodology is fully validated by numerical simulations based on the finite element method (FEM). The development of physics-informed deep learning techniques for inverse scattering can enable the design of novel functional nanostructures and significantly broaden the design space of metamaterials by naturally accounting for radiation and finite-size effects beyond the limitations of traditional effective medium theories.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2026

Autonomous Ion Mass Spectrometer Sentry (AIMSS)

Satellite measurements of plasma density and temperature help predict the intensity of geomagnetic storms, which can impact satellites, communications, and power systems. Accurate forecasting requires knowledge of plasma composition. However, typical orbital mass spectrometers have difficulty distinguishing between nitrogen (N+) and oxygen (O+) ions due to their similar masses. This limitation makes it difficult to validate modern space weather models, which depend on accurate knowledge of ion composition in near-Earth space. N+ and O+ ions behave differently in space due to differences in their origin, transport, and loss mechanisms. Improving our ability to distinguish between these ions is critical for understanding and predicting space weather.

47 OTHER INSTRUMENTATION↗

DOE OSTI2020

Design and Implementation of Full-Scale Industrial Control System Test Bed for Assessing Cyber-Security Defenses

In response to the increasing awareness of the Ethernet-based threat surface of industrial control systems (ICS), both the research and commercial communities are responding with ICS-specific security solutions. Unfortunately, many of the properties of ICS environments that contribute to the extent of this threat surface (e.g. age of devices, inability or unwillingness to patch, criticality of the system) similarly prevent the proper testing and evaluation of these security solutions. Production environments are often too fragile to introduce unvetted technology and most organizations lack test environments that are sufficiently consistent with production to yield actionable results. Cost and space requirements prevent the creation of mirrored physical environments leading many to look towards simulation or virtualization. Examples in literature provide various approaches to building ICS test beds, though most of these suffer from a lack of realism due to contrived scenarios, synthetic data and other compromises. In this paper, we provide a design methodology for building highly realistic ICS test beds for validating cybersecurity defenses. We then apply that methodology to the design and building of a specific test bed and describe the results and experimental use cases.

Gillen, Rob↗

DOE OSTI2023

Field Validation of Air-Source Heat Pumps for Cold Climates

Heating energy is the largest end-use for U.S. residential buildings accounting for approximately one-third of residential building energy consumption (EIA 2021). Historically, air-source heat pumps have been limited to temperate climates because of subpar performance at extremely cold outdoor air temperatures. However, recent advances to cold-climate air-source heat pump technology, which typically rely on inverter-driven, variable-speed compressors and variable-speed fans, have significantly improved low-temperature heat pump performance enabling the technology to save energy for many homes in cold climates. The primary objective of this project was to measure in-field performance of centrally ducted, variable-capacity air-source heat pumps in cold climates to validate performance and develop field-based performance maps. The project focused on quantifying heat pump performance at cold temperatures. The sites identified for the study were primarily located in the Northwest United States since homes in the region tend to have all-electric space heating systems and high-efficiency heat pumps have been incentivized in the region for several years. NREL partnered with Ecotope, Inc., a small energy consulting firm located in Seattle, WA, for site recruitment, monitoring equipment installation, data quality management. All the sites included in the study had previously installed a high-efficiency, central heat pump system. One site was in a Denver, CO suburb, which was the only dual fuel heat pump in the study. We used airside and power measurements, collected at 5-second intervals, to quantify heat pump capacity, coefficient of performance (COP), and auxiliary heater energy consumption. We developed algorithms to automatically determine the heat pump operating mode including defrost and auxiliary heating operation. A whole-house thermal and duct audit was completed during the initial site visit to estimate winter heating loads and assess heat pump sizing. Whole-home heating design loads were calculated at ASHRAE 99% design temperatures and compared to manufacturer-reported maximum capacities to assess the heat pump sizing at each site.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Combining Theory and Experiment to Map the Atomic-Level Structure–Energy Pathways of Adsorbate-Mediated Phase Changes in a Cooperatively Flexible Metal–Organic Framework

An important subclass of metal–organic frameworks (MOFs) exhibits cooperative flexibility, wherein individual crystallites undergo global structural phase changes in response to external stimuli. Where cooperative flexibility results in reversible changes between crystalline states of distinct accessible porosity, these frameworks can exhibit rare yet desirable behaviors that cannot be explained by local dynamics alone. Yet, the chemical and structural origins of cooperative flexibility and how frameworks undergo these reversible phase changes at the atomic level remain poorly understood. Deliberate design for specific applications is therefore exceedingly difficult, and there is great impetus to develop a fundamental understanding of this phenomenon. Here, an effective and widely accessible computational approach is developed, which is designed to provide microscopic resolution via direct comparison to experimental data along the desorption-guided pathway. The strategy is applied to explain the desorption-induced phase change in an experimentally well-characterized framework, CdIF-13 (sod-Cd(benzimidazolate)2), where experiment alone was unable to resolve the atomistically detailed phase change landscape. Our findings reveal that the cooperative phase change pathways are adsorbate dependent with thermodynamics of intermediate structural states dictated by a nuanced interplay of ligand orientation, skeletal symmetry, and modes of surface adsorption. The results reveal that this isotropically flexible framework is “chaperoned” through a complex energy landscape by specific adsorbates, revealed by the reported computational approach with atomic-level insight and validated by experimentally determined structures. Thus, this work facilitates both understanding and future design of flexible materials for applications in gas storage, transport, delivery, and separation technologies.

03 NATURAL GAS↗

DOE OSTI2024

Energetic Particles - microturbulence interaction thrust (EP SIWG white paper)

This white paper outlines a strategic approach to Energetic Particle (EP) research, aimed at applying the results to the future burning devices such as ITER. Our goal is to deepen the understanding of the interplay between plasma background microturbulence and diverse species of energetic ions in burning plasma devices. This strategy is poised to advance our knowledge in this crucial area of fusion science, paving the way for significant breakthroughs in plasma physics and fusion energy research. We consider the confinement of energetic ions such as auxiliary heating beams, minority ions from ICRH, and fusion product alpha particles. Recent studies have underscored the potential of EP/microturbulence interaction to enhance fusion plasma performance by stabilizing microturbulence. However, it also poses risks, such as exacerbating Alfvénic eigenmode (AE) instabilities, which could compromise the sustainability of plasma discharge by causing EP losses. The interplay between EPs and background microturbulence is evident in the phenomenon of effective pitch angle scattering, a crucial aspect of the quasilinear (QL) theory. This theory is integral to developing numerically-efficient yet comprehensive and self-consistent approaches, recently employed to investigate the relaxation of energetic particle populations in the holistic modeling of fusion-grade plasmas. The primary objectives of this white paper thrust encompass a dual focus. First is that we need to delve into the mechanisms through which microturbulence engenders effective pitch angle scattering. This investigation will entail the examination of the presence of known or self-consistently predicted spectra of modes accountable for microturbulence. In these explorations, electrostatic microturbulence serves as a logical initial stride towards achieving the trust's objectives. This endeavor is anticipated to yield formulations expressing the parametric dependencies of the effective pitch angle scattering frequency on variables such as thermal plasma electron and/or ion temperatures, as well as their respective thermal conductivities. In our second objective, we aim to delve into the intricate formation of zonal flow (ZF) structures amidst the complex interplay of microturbulence and Alfvenic eigenmodes (AEs). This endeavor poses greater challenges as we seek to unravel the macroscopic manifestations influenced by microturbulence, termed as zonal structures (ZS), stemming from microturbulence-induced ZF. Drawing from this understanding, we anticipate employing a QL approach to yield comprehensive insights into the distribution function of energetic particles (EP) within phase space. This method entails resolving the dominant multidimensional phase space diffusion processes while effectively averaging over the rapid ballistic responses. Nevertheless, substantial strides remain imperative to realize a comprehensive whole-device modeling framework. This entails meticulous verification and validation exercises against experimental observations, as well as rigorous benchmarking against theoretical frameworks and numerical simulations.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2020

Opinion: Lighting Research During and After the Pandemic

For many lighting researchers, the recent restrictions related to COVID-19 have paused most in-person laboratory or field experiments. In certain countries, regulatory institutions have allowed such experiments to resume but issued safety recommendations like pre-checking participants for disease symptoms and excluding those that are especially vulnerable. To avoid potential complications and delays, researchers are likely to resort to other research designs that enable remote research — eliminating the need for the experimenter and subjects to be in the same room. While unanticipated, this shift to remote research methods is an opportunity to revisit and further develop remote experimental techniques, which can have beneficial long-lasting implications on lighting research during and after the pandemic. Perhaps the most common type of remote research is online experiments; which can greatly benefit from improved techniques to allow for greater control or characterization of experimental conditions, like those proposed by Villa and Labayrade . These techniques require validation specific to the type of response collected and context, e.g. space type and attributes. New research techniques continue to emerge and will enable remote collection of objective measures such as gaze direction and high dynamic range images (HDRIs) without specialized equipment. In fact, many of these methods and techniques are commonly used in other disciplines, like vision science and psychology, and can be adapted for lighting research. Not all lighting studies can be conducted online, but in the age of ubiquitous and connected technologies, there is a largely missed opportunity to utilize crowdsourced responses to lighting conditions in real environments where people live and go about their daily lives without the research being limited to a certain time and laboratory locations. For instance, outdoor street luminaires can be rated by passersby using ecological momentary assessments on mobile phones. While this approach does not provide laboratory-level control over experimental conditions, it can provide more contextual responses resulting from ‘normal’ dynamic gaze, behavior, and interactions. Further, it can also reduce bias related to the experimental setting. Further development of remote research methods and their use in lighting research can improve the quality of lighting research. Given that sample sizes in most lighting research are relatively small, remote research can substantially increase sample sizes, reduce research costs, and shorten study duration, all while reducing interaction between experimenter and subjects. Another benefit is reaching a wider audience and including under-represented individuals who typically are not reachable using common recruitment methods. The pandemic has set back our plans for in-lab experiments, but can it inspire us to think of new and creative ways to expand lighting research?

Abboushi, Belal K.↗

DOE OSTI2023

Tangent functional connectomes uncover more unique phenotypic traits

Functional connectomes (FCs) containing pairwise estimations of functional couplings between pairs of brain regions are commonly represented by correlation matrices. As symmetric positive definite matrices, FCs can be transformed via tangent space projections, resulting into tangent-FCs. Tangent-FCs have led to more accurate models predicting brain conditions or aging. Motivated by the fact that tangent-FCs seem to be better biomarkers than FCs, we hypothesized that tangent-FCs have also a higher fingerprint. We explored the effects of six factors: fMRI condition, scan length, parcellation granularity, reference matrix, main-diagonal regularization, and distance metric. Our results showed that identification rates are systematically higher when using tangent-FCs across the “fingerprint gradient” (here including test-retest, monozygotic and dizygotic twins). Highest identification rates were achieved when minimally (0.01) regularizing FCs while performing tangent space projection using Riemann reference matrix and using correlation distance to compare the resulting tangent-FCs. Such configuration was validated in a second dataset (resting-state).

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2020

A multiscale cohesive law for carbon fiber networks

Better predictive models of mechanical failure in low-weight heat shield composites would aid material certification for missions with aggressive atmospheric entry conditions. In this study, we develop such a model for the rapid engineering analysis of the failure limits of phenolic impregnated carbon ablator (PICA) - a leading heat shield material whose structural component is a carbon fiber network. We hypothesize inelastic deformation failure mechanisms and model their behavior using molecular dynamics simulations to calculate the binding energy. We then upscale this binding energy to the macroscale using a renormalization argument. The approach delivers insightful and reasonably accurate macroscale predictions that compare favorably to experiments. In application, the model is validated for a particular variety of PICA by comparison to experiment and would then be used to study design scenarios in different entry conditions.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Improvements in Optical Surface Measurement Using Reflected Computer Vision Targets

Since 2021, NREL has been developing a system to measure heliostats by measuring the deflection of printed computer vision targets, called the Reflected Target Non-intrusive Assessment (ReTNA) [6], [7]. While this system will have lower resolution than a fringe deflectometry system, it has several important advantages that make it a complimentary technology: 2D surface slope measurement can be generated from a single image, it can operate in ambient lighting, target points can be directly located in 3D space with photogrammetry allowing for a non-flat target, and it's well suited to using a smaller target, and multiple images to measure larger optical surfaces. ReTNA has undergone several significant changes and improvements, described below. This talk will summarize new system layouts designed for commercial use, new computer vision algorithms used to automate the analysis process and validation campaigns for the ReTNA software.

computer vision↗

DOE OSTI2023

Enabling residential heating decarbonization through hydronic low-temperature thermal distribution using forced-air assistive devices

Space heating represents approximately one-tenth of the United States’ energy use and has a breadth of potential for emission reduction. An element of space heating, hydronic heat distribution methods, use water supply temperatures up to 82.2 °C (180 °F). However, this operating temperature can be incompatible with high-efficiency heat generation systems, which typically provide heating temperatures of up to 60 °C (140 °F). In this work, a low-cost retrofit solution is developed using experimentally validated computational tools by incorporating an airflow distributor that preferentially directs the airflow from a fan to enhance heat transfer over the finned-tube heat exchanger found in conventional baseboards. The same heat output of traditional baseboard heat distribution systems operating at higher water supply temperatures (71.1 – 82.2 °C) can also be achieved at lower temperatures (≤60 °C). Specifically, results indicate that the technology can produce more than a 46.7% improvement in the heat transfer output at temperatures as low as 60 °C (140 °F), effectively matching the same output range achieved by 71.1 – 82.2 °C (160–180 °F) water supply temperatures. An important benefit of this solution is that it utilizes the existing infrastructure as opposed to requiring the replacement of the entire distribution system. Additionally, this technology enables existing building infrastructure to be coupled with newer, high-efficiency heating systems such as condensing boilers, solar-thermal systems, and geothermal/air-to-water heat pumps that may produce lower water supply temperatures (60 °C). A geospatially resolved techno-economic and environmental analysis is completed and presented to further understand the equivalent carbon footprint of enabling higher efficiency heat generation systems with the improved efficiency heat distribution system disclosed. Using 2021 grid-average emission factors, an emission reduction of up to a 67.5% decrease (2658 kgCO 2 /yr) for a single-family home, depending on state and climate region, could be realized by replacing a traditional natural gas-fired boiler with an air-to-water heat pump coupled to the same high-temperature heat distribution system along with the low-cost retrofit solution. A complete CO 2 emission reduction of 6688 kgCO 2 /yr, depending on state and climate region, could be realized if all electricity is further renewably sourced. Thus, this study provides a possible pathway towards enabling the reduction of operational emissions in space heating.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Engine-in-the-Loop Study of a Hierarchical Predictive Online Controller for Connected and Automated Heavy-Duty Vehicles

This paper presents a cohesive set of engine-in-the-loop (EIL) studies examining the use of hierarchical model-predictive control for fuel consumption minimization in a class-8 heavy-duty truck intended to be equipped with Level-1 connectivity/automation. This work is motivated by the potential of connected/automated vehicle technologies to reduce fuel consumption in both urban/suburban and highway scenarios. The authors begin by presenting a hierarchical model-predictive control scheme that optimizes multiple chassis and powertrain functionalities for fuel consumption. These functionalities include: vehicle routing, arrival/departure at signalized intersections, speed trajectory optimization, platooning, predictive optimal gear shifting, and engine demand torque shaping. The primary optimization goal is to minimize fuel consumption, but the hierarchical controller explicitly accounts for other key objectives/constraints, including operator comfort and safe inter-vehicle spacing. This work is experimentally experimentally validated via a sequence of EIL studies intended for evaluating the computational costs and fuel savings associated with these algorithms. These EIL studies involve the closed-loop validation of the proposed control strategies, both individually and combined. These studies show that this hierarchy of algorithms is capable of running online, with the round-trip communication delay inherent in EIL simulation being one of the key factors affecting the EIL results. Moreover, the EIL studies are encouraging, both in terms of the successful hierarchical integration of the underlying algorithms and also in the resulting fuel savings seen in the EIL tests. In particular, the EIL results suggest that an aggressive overall goal of reducing vehicle fuel consumption by 15-20% or more is potentially achievable, especially in urban/suburban scenarios.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2020

Process-based balance of system cost modeling for offshore wind power plants in the United States

This paper describes the development of a process-based and open-source balance of system cost model that provides the capability to evaluate both existing and novel offshore wind technologies. Individual design and installation steps are represented with bottom-up engineering models that compute times and costs associated with the process; furthermore, operational constraints are assigned to each process so that delays caused by weather and presence of marine mammals may be accounted for in the overall project timeline. The model structure, assumptions, inputs, and results are vetted with industry partners and compared against actual projects for validation. Installation times show reasonable agreement with real data. Project cost sensitivities are investigated to compute the system-level impact of different design choices. First, individual vessel efficiencies are computed for varying numbers of installation vessels and weather time series to show the diminishing returns of more than two feeder barges. Then, array cable capital costs and installation times are determined for a representative project with different turbine sizes. These values quantify the cost-benefit tradeoffs and show a net-cost savings of decreasing numbers of turbines, increased turbine spacing, and fewer turbine terminations. These results demonstrate that the balance of system model features the accuracy, functionality, and accessibility to serve as the foundation for a wide range of analyses to identify cost reduction potentials for offshore wind energy in the United States.

17 WIND ENERGY↗

DOE OSTI2020

I 2 S-LWR microchannel heat exchanger design and experimental validation

The Integral Inherently Safe Light Water Reactor (I 2 S-LWR) includes primary-to-secondary coolant heat exchangers located in the downcomer of the reactor pressure vessel. A microchannel heat exchanger (MCHX) configuration is selected to meet the limited available volume and high heat duty requirements. The design, modeling, and optimization of the liquid-liquid MCHX is outlined. In addition, the performance of a MCHX test section representative of the I 2 S-LWR MCHX design is validated experimentally. Experimental results show that heat transfer and pressure drop correlations developed for larger, macroscale channels lead to accurate predictions of performance. Additionally, this study shows that an MCHX can deliver the required heat duties within the available space and pressure drop constraints of the overall I2 S-LWR design.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2025

Localized material compression to correct distortion in wire arc additive manufacturing

Wire Arc Additive Manufacturing (WAAM) is an advanced manufacturing technology which utilizes welding systems to generate three dimensional geometries in a layer-by-layer fashion. Distortion or warping of a print substrate and WAAM components due to thermally induced residual stresses is an ongoing challenge limiting the widespread adoption of WAAM technologies for producing components. In this manuscript, a novel approach is described to address thermal distortion in deposited components by applying lateral compressions along the length of the deposited material. To demonstrate this method, a series of single-track walls were printed and compressed at evenly spaced intervals using a modified hydraulic cutter tool. The jaws of the tool were modified to compress material rather than to shear it. A mathematical model was developed to relate the curvature of the deposited material to the volume of compression required to eliminate this distortion. Validation of this model was performed using 3D scan data to compare the change in wall curvature induced by compression to the volume of the applied compressions. Substrate deflection was also compared against a control wall, and implementation of wall compression reduced maximum deflections by 93% across a series of four depositions and subsequent compressions. Wall cross sections were also analyzed to determine the impact of compression on material hardness and grain structure. The results demonstrate that successively placed lateral compressions can effectively control and potentially eliminate bending distortion in printed parts. This methodology can be further developed to form a robust model for correction of thermally-induced distortion in WAAM components.

Additive manufacturing↗