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DOE OSTI2021

Two Dimensional Topology Optimization of Heat Exchangers with the Density and Level-Set Methods

We design heat exchangers using two topology optimization approaches: the density, i.e. volume fraction and level set methods. Our goal is to maximize the heat exchange between two fluids in separate channels while constraining the pressure drop across each channel. The heat exchanger is modeled with a coupled thermal-flow formulation. The flow is governed by an isothermal and incompressible Stokes-Brinkman equation and the heat transfer is governed by a convection-diffusion equation with high Peclet number. We solve one set of Stokes-Brinkman equations per fluid. Each Brinkman term in the flow equation serves to model the other phase as a solid, thereby preventing mixing. We first represent the solid and fluid phases using a volume fraction variable and apply a SIMP-like penalization in the Brinkman term to drive the optimization to a discrete design. The cost and constraint function derivatives are automatically calculated with the library pyadjoint and the optimization is performed by the Method of Moving Asymptotes. In a second optimization formulation, we use the level set approach to define the interface that separates the two fluids. Pyadjoint calculates the shape derivatives of the cost and constraint functions and the Hamilton-Jacobi advects the interface, allowing for topological changes. We present results in two dimensions and discuss the advantages and disadvantages of each approach.

42 ENGINEERING↗

DOE OSTI2024

Stochastic Optimization and Uncertainty Quantification of Natrium-based Nuclear-Renewable Energy Systems for Flexible Power Applications in Deregulated Markets

Rapid integration of variable renewable energy sources (VRES) has made modeling and stochastic optimization of hybrid energy systems crucial for studying their long-term performance and viability. However, most studies have focused on just historical data, which may be unreliable for capturing short-term fluctuations, rare events, and long-term patterns of energy demand, price, and the variability of renewable energy sources. For this study, optimal synthetic time series models were developed using Wasserstein distance. The models were validated by comparing the key statistical measures against those of the historical data. They were then used to optimize the integrated Natrium-style advanced energy systems and their long-term (30 years) economics. The stochastic model performs bi-level optimization to find the optimal sizes for the balance of plant and thermal energy storage, while also optimizing energy dispatch to achieve the maximum net present value. In studies of two deregulated markets (California ISO and the Electric Reliability Council of Texas), the integrated Natrium-style system performed better in CAISO than in ERCOT, given higher and more consistent electricity prices during peak-demand periods. The potentially enlarged cost associated with the variable operation and maintenance of the TES system also plays a significant role in driving the system sizing, thus its impacts on the system are investigated in detail through comparison against a baseline case. The study also finds that the bi-level optimization results based on stochastic gradient descent closely match the grid search results. The uncertainty quantification of the stochastic signals provides further NPV-related insights and probability distributions for the case studies. The normal standard error of the mean of NPV for the case with and without TES VOM for CAISO were found to be 7.73M (plus-minus sign) 1.09M USD and 104.99M (plus-minus sign) 1.25M USD, respectively based on a 95% confidence. Given the relatively small NPV variance based on 150 samples, the analysis affords the most robust possible prediction of the techno-economic performance of the integrated Natrium-style energy systems.

25 ENERGY STORAGE↗

DOE OSTI2021

Planning for a Resilient Home Electricity Supply System

Resilience of power systems is already a key issue that is getting frequent attention all over the world. It is useful to analyze resilience issues not only for bulk supply, but at all levels including at a customer level. This is because distributed energy resources can play a prominent role in enhancing resilience. Although the literature on planning models, tools and data for bulk supply and distribution systems have expanded in recent years, customer-centric planning, e.g., for an individual household, is yet to receive adequate attention. Although solar PV and battery storage at a household level have been analyzed, how these resources can be optimally combined, together with grid supply, from a resilience perspective is the focus of this study. The study demonstrates how a conceptual framework can be developed to show the trade-off between system costs and resilience including its dimensions such as duration, depth and frequency of service outages. A planning model is developed that incorporates multiple facets of resilience and individual customer preferences. The model considers power system resilience explicitly as a constraint. The model is implemented for a household level case study in Miami, Florida. The results show there are complex trade-offs among different dimensions of resilience. The study demonstrates how combined resilience metrics can be formulated and evaluated using the proposed least-cost planning model at a household level to optimize grid supply together with solar, battery storage and diesel generators. The model allows a planner to directly embed a resilience standard to drive the optimal supply mix. These concepts and the modeling construct can also be applied at other levels of planning, including community level and bulk supply system planning.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRSDate not supplied

Regenerative ECLSS and Logistics Analysis for Sustained Lunar Surface Missions

Sustained Lunar Campaign: Annual crew missions to the lunar surface with 2 to 4 crewmembers living in a Surface Habitat (SH) and/or a Pressurized Rover (PR) for 30 days or longer. Missions will require annual resupply of logistics to the lunar surface: Logistics include consumables, EVA consumables and spares, carriers, surface system spares and maintenance, and science and utilization. Water and gas (may) dominate the total logistics resupply: Water and gas = a direct function of the level of closure provided by the ECLSS in the Surface Habitat (SH) and the Pressurized Rover (PR). Logistics requirements will drive the number of required resupply landers, launch vehicles, and resupply costs. Goal of Paper: Determine a recommended regenerative ECLSS architecture option to minimize the tradeoff between ECLSS Delivery Mass and Logistics Resupply Mass

ECLSS↗

DOE OSTI2025

Research and Development on Advanced Electrochemical Energy Storage Devices Enabling a Spectrum of Electrified Vehicles

The USABC Advanced Battery development plan had the following three focus areas: 1. Existing technology validation, implementation, and cost reduction 2. Identification of the next viable technology with emphasis on the potential to meet USABC cost and energy density goals. 3. Support high-risk, high-reward battery technology R&D The primary aim of this project was focused on the barriers that most impede wider public adoption of electrification in vehicles-cost, energy density, low-temp performance, calendar life, and improvements in abuse tolerance. The specific objectives are as follows: Cost Reduction: drive to significantly reduce battery cost to be in-line with the $\$$100/kWh or less (by the end of calendar year 2020) DOE cost goals. Additionally, goals of $\$$75/KWh were set for 2023 aligned with fast charge and some offset of energy density. Energy Density Increase: focus on improving the cell-level specific energy and energy densities to >350 watt hours per kilogram (Wh/kg) and >750Wh/L. Low Temperature Performance Increase: strive toward developments that improve the discharge power and eliminate or dramatically reduce the life limiting lithium plating associated with regenerative braking at low temperatures, during the program. Calendar Life Increase: drive to achieve a 15-year calendar life. Abuse Tolerance Improvement: strive to develop improvements in Li-ion abuse tolerance and/or development of electrochemical energy storage technologies with inherently better response to abuse circumstances. Emerging Areas: initiate new programs that address emerging technologies that arise during the contract period.

25 ENERGY STORAGE↗

DOE OSTI2021

A comparative techno-economic analysis of renewable methanol synthesis from biomass and CO 2 : Opportunities and barriers to commercialization

Global demand for methanol as both a chemical precursor and a fuel additive is rising. At the same time, numerous renewable methanol production pathways are under development, which, if commercialized, could provide significant environmental benefits over traditional methanol synthesis pathways. However, it is difficult to compare technologies at different maturity levels, with differing feedstocks, and with significant differences in overall process design. Thus, there is a need to harmonize the analyses of renewable pathways using a consistent techno-economic approach to evaluate the potential for commercialization of various pathways. This analysis uses a novel cross-comparison method to assess near-term and long-term viability of both low- and high-maturity level technologies. Furthermore, the techno-economic assessment considers cost factors critical to market acceptance combined with carbon- and energy-efficiency assessments of three renewable pathways compared with a commercial baseline. We find that biomass gasification to methanol represents a near-term viable pathway with a high technology readiness level and commercially competitive market price. If cost-reducing technological improvements can be realized and scaled up in the CO 2 electrolysis pathways, the potential for higher carbon efficiencies may help drive market adoption of these more modular, direct conversion pathways in future markets as they present an opportunity to better support global decarbonization efforts through efficient waste carbon utilization.

09 BIOMASS FUELS↗

DOE OSTI2023

Deployment Implications of Reaching the DOE Floating Offshore Wind Shot Goal: A Summary of Initial Results and Methods [Slides]

The Floating Offshore Wind Shot is an initiative to help usher in a clean energy future by driving U.S. leadership in floating offshore wind design, development, and manufacturing. Here, we document impact of attaining the Shot cost goal of $45/megawatt-hour by 2035, a reduction of 70% from today's cost levels. We find deployment of 90-120 gigawatt of floating offshore wind by 2050.

17 WIND ENERGY↗

DOE OSTI2021

Simulations of Grid-Responsive HVAC Cooling Measures via Ice/PCM storage

This study uses EnergyPlus building energy simulations to assess grid-responsive HVAC cooling measures during peak hours having high electricity price, including: lock the high capacity of a two-speed cooling coil during grid-response hours; and use ice/PCM energy storage to drive a chilled water coil and meet the cooling load, when shut off the main electric cooling coil. Here, the impacts on peak power reductions, energy and utility cost savings, and comfort levels in residential buildings of two U.S. cities were revealed.

Shen, Bo↗

NASA NTRS2012

The Effect of Rotor Cruise Tip Speed, Engine Technology and Engine/Drive System RPM on the NASA Large Civil Tiltrotor (LCTR2) Size and Performance

A multi-year study was conducted under NASA NNA06BC41C Task Order 10 and NASA NNA09DA56C task orders 2, 4, and 5 to identify the most promising propulsion system concepts that enable rotor cruise tip speeds down to 54% of the hover tip speed for a civil tiltrotor aircraft. Combinations of engine RPM reduction and 2-speed drive systems were evaluated. Three levels of engine and the drive system advanced technology were assessed; 2015, 2025 and 2035. Propulsion and drive system configurations that resulted in minimum vehicle gross weight were identified. Design variables included engine speed reduction, drive system speed reduction, technology, and rotor cruise propulsion efficiency. The NASA Large Civil Tiltrotor, LCTR, aircraft served as the base vehicle concept for this study and was resized for over thirty combinations of operating cruise RPM and technology level, quantifying LCTR2 Gross Weight, size, and mission fuel. Additional studies show design sensitivity to other mission ranges and design airspeeds, with corresponding relative estimated operational cost. The lightest vehicle gross weight solution consistently came from rotor cruise tip speeds between 422 fps and 500 fps. Nearly equivalent results were achieved with operating at reduced engine RPM with a single-speed drive system or with a two-speed drive system and 100% engine RPM. Projected performance for a 2025 engine technology provided improved fuel flow over a wide range of operating speeds relative to the 2015 technology, but increased engine weight nullified the improved fuel flow resulting in increased aircraft gross weights. The 2035 engine technology provided further fuel flow reduction and 25% lower engine weight, and the 2035 drive system technology provided a 12% reduction in drive system weight. In combination, the 2035 technologies reduced aircraft takeoff gross weight by 14% relative to the 2015 technologies.

Robuck, Mark↗

NASA NTRS1999

Reinventing The Design Process: Teams and Models

The future of space mission designing will be dramatically different from the past. Formerly, performance-driven paradigms emphasized data return with cost and schedule being secondary issues. Now and in the future, costs are capped and schedules fixed-these two variables must be treated as independent in the design process. Accordingly, JPL has redesigned its design process. At the conceptual level, design times have been reduced by properly defining the required design depth, improving the linkages between tools, and managing team dynamics. In implementation-phase design, system requirements will be held in crosscutting models, linked to subsystem design tools through a central database that captures the design and supplies needed configuration management and control. Mission goals will then be captured in timelining software that drives the models, testing their capability to execute the goals. Metrics are used to measure and control both processes and to ensure that design parameters converge through the design process within schedule constraints. This methodology manages margins controlled by acceptable risk levels. Thus, teams can evolve risk tolerance (and cost) as they would any engineering parameter. This new approach allows more design freedom for a longer time, which tends to encourage revolutionary and unexpected improvements in design.

Wall, Stephen D.↗

NASA NTRS2015

Direct Drive Solar-Powered Arcjet Thruster

Electric thrusters typically require a power processing unit (PPU) to convert the spacecraft-provided power to the voltage and current that a thruster needs for operation. NASA Marshall Space Flight Center has initiated fundamental studies on whether an arcjet thruster can be operated directly with the power produced by solar arrays without any additional conversion. Elimination of the PPU significantly reduces system-level complexity of the propulsion system, and lowers developmental cost and risk. The proposed work will aim to refine the proof-of-concept presently being assembled and begin to identify and address technical questions related to power conditioning and noise suppression in the system, and heating of the thruster in long-duration operation. The apparatus proposed for investigation has a target power level of 400 to 1,000 W. The proposed direct-drive arcjet is potentially a highly scalable concept, applicable to spacecraft with up to hundreds of kilowatts and beyond. The design of the arcjet built for this effort was based on previous low power (1 kW class) arcjets.1-3 It has a precision machined 99.95% pure tungsten anode that also serves as the nozzle with a 0.040-in- (1-mm-) diameter, 0.040-in-long constrictor region. An additional anode with a 0.020-in- (0.5-mm-) diameter, 0.020-inlong constrictor region was purchased, but has not yet been used. The cathode is a 0.125-in-diameter tungsten welding electrode doped with lanthum-oxygen; its tip was precision ground to a 308deg angle and terminates in a blunt end. The two electrodes are separated by a boron-nitride insulator that also serves as the propellant manifold; it ends in six small holes which introduce the propellant gas in the diverging section of the nozzle, directly adjacent to the cathode. The electrodes and insulator are housed in a stainless-steel outer body, with a Macor insulator at the mid-plane to provide thermal isolation between the front and back halves of the device. The gas seals were made using Grafoil gaskets. Figure 1(a) shows the assembled thruster; figure 1(b) shows the thruster in the vacuum chamber with electrical and propellant connections.

Polzin, Kurt↗

NASA NTRS1993

Proposed system safety design and test requirements for the microlaser ordnance system

Safety for pyrotechnic ignition systems is becoming a major concern for the military. In the past twenty years, stray electromagnetic fields have steadily increased during peacetime training missions and have dramatically increased during battlefield missions. Almost all of the ordnance systems in use today depend on an electrical bridgewire for ignition. Unfortunately, the bridgewire is the cause of the majority of failure modes. The common failure modes include the following: broken bridgewires; transient RF power, which induces bridgewire heating; and cold temperatures, which contracts the explosive mix away from the bridgewire. Finding solutions for these failure modes is driving the costs of pyrotechnic systems up. For example, analyses are performed to verify that the system in the environment will not see more energy than 20 dB below the 'No-fire' level. Range surveys are performed to determine the operational, storage, and transportation RF environments. Cryogenic tests are performed to verify the bridgewire to mix interface. System requirements call for 'last minute installation,' 'continuity checks after installation,' and rotating safety devices to 'interrupt the explosive train.' As an alternative, MDESC has developed a new approach based upon our enabling laser diode technology. We believe that Microlaser initiated ordnance offers a unique solution to the bridgewire safety concerns. For this presentation, we will address, from a system safety viewpoint, the safety design and the test requirements for a Microlaser ordnance system. We will also review how this system could be compliant to MIL-STD-1576 and DOD-83578A and the additional necessary requirements.

Stoltz, Barb A.↗

NASA NTRS2009

Review of the Constellation Level II Safety, Reliability, and Quality Assurance (SR&QA) Requirements Documents during Participation in the Constellation Level II SR&QA Forum

At the request of the Exploration Systems Mission Directorate (ESMD) and the Constellation Program (CxP) Safety, Reliability; and Quality Assurance (SR&QA) Requirements Director, the NASA Engineering and Safety Center (NESC) participated in the Cx SR&QA Requirements forum. The Requirements Forum was held June 24-26; 2008, at GRC's Plum Brook Facility. The forums purpose was to gather all stakeholders into a focused meeting to help complete the process of refining the CxP to refine its Level II SR&QA requirements or defining project-specific requirements tailoring. Element prime contractors had raised specific questions about the wording and intent of many requirements in areas they felt were driving costs without adding commensurate value. NESC was asked to provide an independent and thorough review of requirements that contractors believed were driving Program costs, by active participation in the forum. This document contains information from the forum.

Cameron, Kenneth D.↗

DOE OSTI2022

Scout Benchmark Scenarios for U.S. Building Energy and CO2 Emissions to 2050

Overview and Intended Use Cases: These scenarios establish a range of futures for U.S. buildings sector energy use and CO2 emissions to 2050 using Scout (scout.energy.gov), a reproducible and granular model of U.S. building energy use, emissions, and consumer costs developed by the U.S. national labs for the U.S. Department of Energy's Building Technologies Office (BTO). Scout benchmark scenario data are suitable for the following example use cases: setting high-level policy goals for the U.S. buildings sector to 2050 (e.g., X% building CO2 emissions reductions vs. 2005 levels by 2030, Y% reductions vs. 2005 levels by 2050); exploring the effects of key dynamics driving U.S. buildings sector energy and CO2 emissions to 2050 that could be affected by policy levers (e.g., raising minimum technology performance levels; accelerating electrification and/or retrofit rates; introducing breakthrough technologies to the market); determining priority segments (regions, building types, and end use/technology types) and sequencing of U.S. buildings sector energy and CO2 emissions reductions to 2050 under a given set of assumptions; and/or identifying the energy and emissions impacts or cost effectiveness of specific technologies or operational approaches of interest—in isolation or after considering competition with other measures in a scenario portfolio. Scenario Summary: A total of 8 scenarios explore the effects of changes across both the demand- and supply-side of building energy use on annual U.S. building energy use and CO2 emissions from 2022–2050. Scenarios are organized into three groups representing low, moderate, and best-case potentials for building decarbonization, respectively.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

NASA NTRS2023

NASA Kennedy Space Center Swamp Works: Innovation Methods for Advanced Research & Technology Development

Kennedy Space Center’s (KSC) Swamp Works, provides government and commercial space ventures with the technologies required for working and living on the surfaces of the Moon or other planets and bodies in our solar system. The Swamp Works team establishes agile, innovative and cost effective exploration mission solutions through leveraging of partnerships across NASA, industry and academia. Concepts start small and build up efficiently, with lean development processes and a hands on approach. Testing is performed in early stages to drive design improvements and progressively increase Technology Readiness Levels (TRL). Swamp Works provides concepts, architecture studies and trades, designs, data, technology development, technology demonstration hardware, flight hardware, testing, flight support and knowledge in support of the development of surface systems. This paper will summarize the state of the art in innovation methods, and it will compare the various other methods to how innovation is accomplished at the NASA KSC Swamp Works. Since 2013, Swamp Works has developed a wide variety of technologies, and has demonstrated viable methods for innovation while also collaborating with other government agencies, industry and academia to support space exploration. These methods focus on agile design, test, build iterations where each cycle of prototyping results in improved knowledge and designs. Failures are tole rated in the early stages of these iterations, since the overall development cycle is shorter more efficient and cost effective by retiring risk early in the cycle. Momentum is maintained and the development teams remain highly motivated by the high level of team work, technical excellence, engagement and creative freedom.

Robotic Mining↗

NASA NTRS1976

Recent progress on new facilities at the NASA Langley Research Center

A new fan-driven high Reynolds number transonic cryogenic tunnel the National Transonic Facility is being planned for the United States. This tunnel will provide an order of magnitude increase in Reynolds number capability over existing tunnels. Theoretical studies and experience with the Langley 1/3 Meter Transonic Cryogenic Tunnel indicate that the cryogenic concept allows the attainment of full-scale Reynolds number at reasonable levels of dynamic pressure. The unique modes of operation which are available only in a cryogenic tunnel make possible the separation of Mach number, Reynolds number possible the separation of Mach number, Reynolds number, and aeroelastic effects. By reducing the drive power requirements to a level where a conventional fan drive system may be used, the cryogenic concept makes possible a tunnel with high productivity and run times sufficiently long to allow for all types of tests at reduced capital costs and, reduced total energy consumption.

Kilgore, R. A.↗

NASA NTRS1976

The cryogenic wind tunnel

Based on theoretical studies and experience with a low speed cryogenic tunnel and with a 1/3-meter transonic cryogenic tunnel, the cryogenic wind tunnel concept was shown to offer many advantages with respect to the attainment of full scale Reynolds number at reasonable levels of dynamic pressure in a ground based facility. The unique modes of operation available in a pressurized cryogenic tunnel make possible for the first time the separation of Mach number, Reynolds number, and aeroelastic effects. By reducing the drive-power requirements to a level where a conventional fan drive system may be used, the cryogenic concept makes possible a tunnel with high productivity and run times sufficiently long to allow for all types of tests at reduced capital costs and, for equal amounts of testing, reduced total energy consumption in comparison with other tunnel concepts.

Kilgore, R. A.↗

NASA NTRS2019

Reliability Estimation for Mission Extension NASA Approach/Recommendations

Present NASA's current and recommended concepts for Mission Extension and De-orbit reliability Methodologies. NASA's current and recommended approaches ensuring de-orbit requirements are not unnecessarily driving mission design efforts or adding incresed costs or risks to manufacturing solutions without providing benefit to missionsand will assist in moving reliability estimation from piece part performance estimates to component history and system-level testing based estimations.

SMA↗