Results for “load testing” — Page 4

DOE OSTI2017

Modifications to JLab 12 GeV Refrigerator and Wide Range Mix Mode Performance Testing Results

Analysis of data obtained during the spring 2013 commissioning of the new 4.5-K refrigeration system at Jefferson Lab (JLab) for the 12 GeV upgrade indicated a wide capacity range with good efficiency and minimal operator interaction. Testing also showed that the refrigerator required a higher liquid nitrogen (LN) consumption for its pre-cooler than anticipated by the design. This does not affect the capacity of the refrigerator, but it does result in an increased LN utility cost. During the summer of 2015 the modifications were implemented by the cold box manufacturer, according to a design similar to the JLab 12 GeV cold box specification. Subsequently, JLab recommissioned the cold box and performed extensive performance testing, ranging from 20% to 100% of the maximum capacity, and in various modes of operation, ranging from pure refrigeration, pure liquefaction, half-and-half mix mode and at selected design modes. This testing demonstrated the modifications resulted in a LN consumption significantly lower than the expected design for the nominal and maximum capacity modes and equal to the expected design for the pure refrigeration mode (which is the most demanding). The testing also demonstrated that the refrigerator system has a good and fairly constant performance over this wide capacity range and different modes of operation. Also, a pulsed-load test, similar to what is expected for cryogenic systems supporting fusion experiments, was conducted to observe the response using the Floating Pressure ? Ganni Cycle, which was stable and robust. This paper will discuss the results and analysis of this testing pertaining to the LN consumption, the system efficiency over a wide range of capacity and different modes and the behavior of the system to a pulsed load.

Knudsen, P.↗

DOE OSTI2021

Formulation and calibration of two-dimensional constitutive models for composite structures based on panel tests

Steel Plate Concrete (SC) composite members have been widely adopted because of its cost-efficiency and enhanced structural behavior. While researchers have attempted to study its in-plane shear behavior in the past twenty years, very limited number of large-scale pure shear tests were performed due to the challenge of experimental set-up and the availability of facilities. In this paper, a series of uniaxial loading tests and two full-scale pure shear panel tests of SC members were reported, on which the “mechanics-based Membrane Model of SC elements (MM-SC)” is developed. The MM-SC model is based on the fixed-angle crack formulation and the smeared-crack formulation, in which the experimental-based uniaxial constitutive models are implemented, considering the local buckling of faceplate, the tension stiffening of steel plate, the strength degradation of cracked concrete and the confinement effect of concrete. The proposed MM-SC model is subsequently incorporated into the object-oriented software OpenSEES. Finally, the simulation results of proposed model well predict the SC test observations in terms of critical branch points and structural behaviors, including initial stiffness, cracking strength, post-crack stiffness, yield strength, maximum strength, and failure modes.

42 ENGINEERING↗

DOE OSTI2017

Building America Case Study: High-Velocity Small-Diameter Duct System, Pittsburgh, Pennsylvania

This study tests the performance of a variable airflow small-diameter duct heating, ventilation, and air conditioning (HVAC) system in a new construction unoccupied low-load test house in Pittsburgh, Pennsylvania. The duct system was installed entirely in conditioned space and was operated from the winter through summer seasons. Measurements were collected on the in-room temperatures and energy consumed by the air handler and heat pump unit. Operation modes with three different volumes of airflow were compared to determine the ideal airflow scenario that maximizes room-to-room thermal uniformity while minimizing fan energy consumption. Black felt infrared imagery was used as a measure of diffuser throw and in-room air mixing. Measured results indicate the small-diameter, high velocity airflow system can provide comfort under some conditions. Solar heat gains resulted in southern rooms drifting beyond acceptable temperature limits. Insufficient airflow to some bedrooms also resulted in periods of potential discomfort. Homebuilders or HVAC contractors can use these results to assess whether this space conditioning strategy is an attractive alternative to a traditional duct system. The team performed a cost analysis of two duct system configurations: (1) a conventional diameter and velocity duct system, and (2) the small-diameter duct system. This work applies to both new and retrofit homes that have achieved a low heating and cooling density either by energy conservation or by operation in a mild climate with few heating or cooling degree days. Guidance is provided on cost trade-offs between the conventional duct system and the small-diameter duct system.

Building America↗

DOE OSTI2017

Building America Case Study: High-Velocity Small-Diameter Duct System, Pittsburgh, Pennsylvania

This study tests the performance of a variable airflow small-diameter duct heating, ventilation, and air conditioning (HVAC) system in a new construction unoccupied low-load test house in Pittsburgh, Pennsylvania. The duct system was installed entirely in conditioned space and was operated from the winter through summer seasons. Measurements were collected on the in-room temperatures and energy consumed by the air handler and heat pump unit. Operation modes with three different volumes of airflow were compared to determine the ideal airflow scenario that maximizes room-to-room thermal uniformity while minimizing fan energy consumption. Black felt infrared imagery was used as a measure of diffuser throw and in-room air mixing. Measured results indicate the small-diameter, high velocity airflow system can provide comfort under some conditions. Solar heat gains resulted in southern rooms drifting beyond acceptable temperature limits. Insufficient airflow to some bedrooms also resulted in periods of potential discomfort. Homebuilders or HVAC contractors can use these results to assess whether this space conditioning strategy is an attractive alternative to a traditional duct system. The team performed a cost analysis of two duct system configurations: (1) a conventional diameter and velocity duct system, and (2) the small-diameter duct system. This work applies to both new and retrofit homes that have achieved a low heating and cooling density either by energy conservation or by operation in a mild climate with few heating or cooling degree days. Guidance is provided on cost trade-offs between the conventional duct system and the small-diameter duct system.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2017

Measured Performance of a Varied Airflow Small-Diameter Duct System

This study tests the performance of a variable airflow small-diameter duct heating, ventilation, and air conditioning (HVAC) system in a new construction unoccupied low-load test house in Pittsburgh, Pennsylvania. The duct system was installed entirely in conditioned space and was operated from the winter through summer seasons. Measurements were collected on the in-room temperatures and energy consumed by the air handler and heat pump unit. Operation modes with three different volumes of airflow were compared to determine the ideal airflow scenario that maximizes room-to-room thermal uniformity while minimizing fan energy consumption. Black felt infrared imagery was used as a measure of diffuser throw and in-room air mixing. Measured results indicate the small-diameter, high velocity airflow system can provide comfort under some conditions. Solar heat gains resulted in southern rooms drifting beyond acceptable temperature limits. Insufficient airflow to some bedrooms also resulted in periods of potential discomfort. Homebuilders or HVAC contractors can use these results to assess whether this space conditioning strategy is an attractive alternative to a traditional duct system. The team performed a cost analysis of two duct system configurations: (1) a conventional diameter and velocity duct system, and (2) the small-diameter duct system. This work applies to both new and retrofit homes that have achieved a low heating and cooling density either by energy conservation or by operation in a mild climate with few heating or cooling degree days. Guidance is provided on cost trade-offs between the conventional duct system and the small-diameter duct system.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2017

Measured Performance of a Varied Airflow Small-Diameter Duct System

This study tests the performance of a variable airflow small-diameter duct heating, ventilation, and air conditioning (HVAC) system in a new construction unoccupied low-load test house in Pittsburgh, Pennsylvania. The duct system was installed entirely in conditioned space and was operated from the winter through summer seasons. Measurements were collected on the in-room temperatures and energy consumed by the air handler and heat pump unit. Operation modes with three different volumes of airflow were compared to determine the ideal airflow scenario that maximizes room-to-room thermal uniformity while minimizing fan energy consumption. Black felt infrared imagery was used as a measure of diffuser throw and in-room air mixing. Measured results indicate the small-diameter, high velocity airflow system can provide comfort under some conditions. Solar heat gains resulted in southern rooms drifting beyond acceptable temperature limits. Insufficient airflow to some bedrooms also resulted in periods of potential discomfort. Homebuilders or HVAC contractors can use these results to assess whether this space conditioning strategy is an attractive alternative to a traditional duct system. The team performed a cost analysis of two duct system configurations: (1) a conventional diameter and velocity duct system, and (2) the small-diameter duct system. This work applies to both new and retrofit homes that have achieved a low heating and cooling density either by energy conservation or by operation in a mild climate with few heating or cooling degree days. Guidance is provided on cost trade-offs between the conventional duct system and the small-diameter duct system.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Singleplex, multiplex and pooled sample real-time RT-PCR assays for detection of SARS-CoV-2 in an occupational medicine setting

Abstract For workplaces which cannot operate as telework or remotely, there is a critical need for routine occupational SARS-CoV-2 diagnostic testing. Although diagnostic tests including the CDC 2019-Novel Coronavirus (2019-nCoV) Real-Time RT-PCR Diagnostic Panel (CDC Diagnostic Panel) (EUA200001) were made available early in the pandemic, resource scarcity and high demand for reagents and equipment necessitated priority of symptomatic patients. There is a clearly defined need for flexible testing methodologies and strategies with rapid turnaround of results for (1) symptomatic, (2) asymptomatic with high-risk exposures and (3) asymptomatic populations without preexisting conditions for routine screening to address the needs of an on-site work force. We developed a distinct SARS-CoV-2 diagnostic assay based on the original CDC Diagnostic Panel (EUA200001), yet, with minimum overlap for currently employed reagents to eliminate direct competition for limited resources. As the pandemic progressed with testing loads increasing, we modified the assay to include 5-sample pooling and amplicon target multiplexing. Analytical sensitivity of the pooled and multiplexed assays was rigorously tested with contrived positive samples in realistic patient backgrounds. Assay performance was determined with clinical samples previously assessed with an FDA authorized assay. Throughout the pandemic we successfully tested symptomatic, known contact and travelers within our occupational population with a ~ 24–48-h turnaround time to limit the spread of COVID-19 in the workplace. Our singleplex assay had a detection limit of 31.25 copies per reaction. The three-color multiplexed assay maintained similar sensitivity to the singleplex assay, while tripling the throughput. The pooling assay further increased the throughput to five-fold the singleplex assay, albeit with a subtle loss of sensitivity. We subsequently developed a hybrid ‘multiplex-pooled’ strategy to testing to address the need for both rapid analysis of samples from personnel at high risk of COVID infection and routine screening. Herein, our SARS-CoV-2 assays specifically address the needs of occupational healthcare for both rapid analysis of personnel at high-risk of infection and routine screening that is essential for controlling COVID-19 disease transmission. In addition to SARS-CoV-2 and COVID-19, this work demonstrates successful flexible assays developments and deployments with implications for emerging highly transmissible diseases and future pandemics.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2023

Mechanical behavior analysis using small-size graphite disc compression testing with digital image correlation methods

The ASTM International Standard Test Method for Tensile Stress-Strain of Carbon and Graphite (ASTM C749) requires dog-bone shaped specimens. Unfortunately, specimen sizes required in ASTM C749 are much too large for irradiation within a test reactor and are incompatible with irradiation capsule volumes, molten salt degradation facilities, or oxidation apparatus. The ASTM International Standard Test Method for Tensile Strength Estimate by Disc Compression of Manufactured Graphite (ASTM D8289) was developed as an alternative that provides a means for testing tensile properties using smaller specimens when geometric constraints are present. However, the important stress–strain relation throughout the test loading history that could be recorded using ASTM C749 is lost by using ASTM D8289 because of the difficulties involved with using traditional strain gauges or extensometers on such a small specimen. In this work, a digital image correlation (DIC) method, which uses a full-field noncontact surface displacement measurement technique, was applied along with the ASTM D8289 splitting tensile test on eight small samples of graphite grade Mersen 2114 to track their deformation during compressive loading. Initial results showed that the DIC technique can measure the surface displacement/strain on these small (Ø6 × 3 mm) graphite specimens with high accuracy and good repeatability, indicating that the DIC technique, combined with the small-disc splitting tensile test in ASTM D8289, can capture the strain evolution in the test. In conclusion, further comparison of measured strains with analytical and numerical simulation results provides additional understanding of the mechanical behaviour of this nuclear graphite material in complex stress states.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Observed Temperature Effects on Load Cells

Researchers at Oak Ridge National Laboratory subjected load cells to a range of temperatures beyond their compensated range to characterize the temperature effect on the minimum dead load output over their entire operating temperature range. In modern front-end nuclear fuel cycle facilities, load cells are often used in UF6 feed and withdrawal stations to monitor the material being fed to or withdrawn from the cylinders. Load cells exhibit some temperature dependence; however, manufacturers try to minimize temperature effects by compensating load cells over a range of temperatures (typically from -10 °C to +40 °C (+14 °F to +104 °F)). Load cells in modern UF6 feed and withdrawal stations tend to operate beyond this range: down to -25 °C and up to 80 °C (-13 °F to 176 °F). While load cell data sheets often include specifications for the temperature effect on the minimum dead load output and the sensitivity over the compensated range, they do not include specifications for expected effects outside of this range. In this paper, we discuss our test setup and preliminary results of testing load cells representative of those that may be used in UF6 feed and withdrawal stations.

Mattingly, Gavin↗

DOE OSTI2023

Bio-fuel effects and seasonal fuel property variations related to abnormal combustion occurrences observed in the field

Since 2015, the automotive industry has regularly observed sharp increases in customer complaints of poor driveability and increased warranty claims during the months of September and October. These persistent seasonal complaint increases have been tracked to occur from increased abnormal combustion events that coincide with the seasonal transition from summer to winter fuel volatility, beginning on September 15th annually. The Reid Vapor Pressure (RVP) of gasoline during this seasonal transition has been found to be the primary property attributed to this annual issue. It’s hypothesized that an increase in volatile butanes and pentanes from advanced petroleum recovery techniques and hydrofracking production has hastened the transition from summer to winter fuel volatility in the marketplace, rather than the gradual increase of the RVP over time as historically intended. At worst, mid-winter fuel, with an RVP ranging from 12 to 16 psi, depending on location in the U.S., enters the market while ambient temperatures can still be above average for the winter season. This combination of high volatility fuel with unseasonably warm weather will increase fuel system flash boiling, injector spray cavitation, and spray collapse inside the engine’s combustion chamber, ultimately linking fuel property variations to abnormal engine combustion processes. This CRADA program will investigate these known knowledge gaps by coupling with two national laboratories, Oak Ridge National Laboratory, and the National Renewable Energy Laboratory to employ both unique tools and expertise throughout the industry to provide the insight, knowledge, and data critical to understand the observed interactions. Overall findings of this work are that fuel wall retention increased SPI proportionally, and fuels with an increased distillation (i.e. energy fraction) above the wall temperature increased fuel retention. Likewise fuels with increased enthalpy of vaporization (HoV) increased fuel retention proportional to the temperature reduction from the HoV (~13K reduction in this work). Thus, fuel with increased HoV and increased fuel distillation above the linear temperature also exhibited increased SPI rates. Fuel with high RVP did exhibit increased fuel spray collapse form spray imaging measurements, but in SPI testing the high volatility of these fuels at the tested conditions did not necessarily increase SPI rates despite exhibiting increased spray collapse in injector imaging and increased spray-wall impingement measured in fired engine testing. It was also found that spray imaging showed collapse was possible at throttled conditions, but this was not relevant to high boost pressures relevant to SPI conditions, however, under transient load and or speed encountered in real-world operation fuel spray collapse could affect fuel retention and real-world SPI that were not probed in the automated high load test sequence of this work.

09 BIOMASS FUELS↗

DOE OSTI2015

Grain size dependence of dynamic mechanical behavior of AZ31B magnesium alloy sheet under compressive shock loading

The effects of grain size on the dynamic deformation behavior of rolled AZ31B alloy at high strain rates were investigated. Rolled AZ31B alloy samples with grain sizes of 6, 18 and 37 μm, were subjected to shock loading tests using Split Hopkinson Pressure Bar at room temperature and at a strain rate of 1100 s{sup −} {sup 1}. It was found that a double-peak basal texture formed in the shock loaded samples. The strength and ductility of the alloy under the high strain-rate compressive loading increased with decreasing grain size. However, twinning fraction and strain hardening rate were found to decrease with decreasing grain size. In addition, orientation imaging microscopy showed a higher contribution of double and contraction twins in the deformation process of the coarse-grained samples. Using transmission electron microscopy, pyramidal dislocations were detected in the shock loaded sample, proving the activation of pyramidal slip system under dynamic impact loading. - Highlights: • A double-peak basal texture developed in all shock loaded samples. • Both strength and ductility increased with decreasing grain size. • Twinning fraction and strain hardening rate decreased with decreasing grain size. • ‘g.b’ analysis confirmed the presence of dislocations in shock loaded alloy.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Enhancing Distribution System Resiliency through a Novel Transactive Energy Systems Framework

Restoration of end-use loads during bulk transmission system outages is a key challenge for electric utilities. During those outages, utilities often do not have enough resources to fully restore the end-use loads. Additionally, not all available switching options are feasible due to voltage and load limits. Incentivizing non-utility flexible assets to provide their flexibility during resiliency events is a potential solution to improve resiliency. This paper presents a new transactive energy system framework (TESF) to incentivize distributed energy resources (DERs) to provide reactive power for supporting the self-healing functions of distribution management system (DMS). TESF engages non-utility DERs during resiliency events by incentivizing them through transactive signals computed using marginal cost of producing reactive power and marginal benefit of additional switching operations. TESF calculates additional switching options, which DMS then leverages to identify new optimal switching plans to restore additional loads. Test system consisting of multiple IEEE-13 node distribution feeders is used to demonstrate the performance of the proposed method. For the given system configuration and use-case, TESF results in 24.82 % additional load restoration and one additional switching operation.

Distribution system, reconfiguration, resiliency, ↗

DOE OSTI2015

Chemical Free Surface Processing for High Gradient Superconducting RF Cavities

Chemical treatment such as buffered chemical polishing (BCP) or electro polishing (EP) followed by high pressure rinsing (HPR) of niobium (Nb) superconducting RF (SRF) cavities is expensive and complex multistep process. Furthermore, the cavity RF surfaces after the treatment still have numerous bubbles and pits that result from welding. These quench-producing weld defects together with the particulate contamination, result in significant scatter of the multi-cell Nb SRF cavities performance characteristics. This scatter is the major problem in the current manufacturing of the Nb SRF cavities. When developed the chemical free surafce processing using IEB will benefit first J-lab's CEBAF and Fermilab's Project X. Also, light sources, require 1.3 - 1.5 GHz SRF structures. Furthermore, IEB will produce much broader impact because it can be implemented into manufacturing of many other types of RF devices including both superconducting as well as normal conducting RF cavities. This program will develop a new process that will enhance quality of the superconducing radio-frequency cavities and allow acceleration of charged particles to much higher energies. The process also will improve the cavity manufacturing and result in substantial cost reduction of superconducting radio-frequency high-energy particle accelerators. Niobium samples were successfully processed by a DC electron beam to a degree that is suitable for the interior surface of an SRF cavity. To accomplish this, a complete system was developed from the ground up. A vacuum chamber system was acquired and adapted to act as the vessel for performing the Nb processing experiments. An extremely robust high voltage power supply was developed and manufactured to provide the power necessary to drive the multi-kW DC electron gun. A high voltage isolation filament transformer was also designed and manufactured to provide the necessary current to drive the filament within the electron gun. Finally, a beam melt characterization DC electron gun was created. This gun was used to explore the parameter space of interest for processing Nb SRF cavities. The beam melt characterization tests concluded that multiple quick passes at moderate beam power provided the most ideal melt zone characteristics Nb surfaces. It was also found that excellent melt and polish results could be achieved at lower voltages than originally conceived, getting the great results at a beam voltage of 20kV versus the 50kV used in the initial Phase I testing at Jefferson Laboratory. Operating at 20kV will also greatly reduce the challenges of designing a compact DC electron gun for processing of complete Nb SRF cavities, which will be done in Phase III. This final report is divided in eight parts which cover the major investigation work and results which have been performed and achieved. The first part addresses the design, fabrication and testing of the vacuum chamber. In the second part, the DC power supply output circuit design is presented for providing an operating space of 50-60kV with currents from 20-160mA and short and open circuit fault modes are considered and resolved. The third section covers testing and commissioning of the high voltage step up transformer and 150kV isolation transformer. Section four covers the design, construction and performance for a 100kV high voltage bushing. Section number five treats the filament design and load testing. Section number six covers electron gun design and simulation of electron beam melting. Section seven presents the beam target design, assembly and testing and test gun with solenoid magnet, design, fabrication and testing. Finally, section eight demonstrates electron beam melting and polishing of Nb, Cu and SS samples.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2023

Performance of Windows in Walls With Continuous Insulation

Window openings in walls are a significant contributor to poor thermal performance because of thermal bridging through the framing members (e.g., studs, joists, plates, bracing) and because windows lack the thermal properties of insulation. Window installation guidance for walls with continuous insulation (CI) is critical for continued market growth of this energy efficiency technology. This research project offers window manufacturers a starting point and a potential path toward developing installation instructions for windows over CI. The objectives of the research include evaluating the common method for installing windows in walls with CI, as well as establishing acceptance criteria for evaluating the performance of windows installed in walls with and without CI. The research measures: 1. The performance characteristics (e.g., water management, structural integrity) of windows in walls without CI. 2. The performance of different thicknesses and types of CI used in walls. 3. The performance of different types of window assemblies (e.g., double-hung windows, mulled double-hung windows, mulled casement windows, and slider windows) installed over CI. 4. The performance of window flange types (e.g., rigid mounting and less robust flanges) installed over CI. 5. Installing windows over CI using baseline installation instructions versus window manufacturer installation instructions. The project’s sequential testing protocol consists of the following: • A water penetration resistance testing adapted from two ASTM standards: E331 (uniform static air pressure in four steps) and E547 (cyclic static air pressure) • A temperature cycling adapted from ASTM E2264 Method B (convective hot air) • A service condition wind loading test adapted from ASTM E330 • A six-month vertical displacement observation phase prior to the structural performance testing • A final water penetration resistance test after vertical displacement observation • A structural performance test adapted from ASTM E330. Key research findings include: • The criterion for passing a water penetration resistance test is that there is no water overflowing at the interior face of the studs. If there is any bubbling or slight pooling of water at the sill, then it must recede after the pressure is removed. Excessive leakage and/or water leaking to the interior face of the framing around the window constitutes a failure. • All single double-hung windows installed directly to lumber or over oriented strand board passed all test protocols. • For most wall specimens, the test results showed that the use of foam sheathing did not affect the performance of the window for water leakage. • All wall specimens underwent temperature cycling. The results indicated that temperature cycling had little to no effect on windows installed over foam sheathing. • For wall specimens that underwent six-month vertical displacement monitoring, the results showed that windows installed over foam sheathing do not sag over time. • The single-hung and double-hung windows installed using window manufacturer installation instructions passed the structural performance test, compared to failures observed in windows that were installed using generic installation instructions. The generic and manufacturer installation methods differed on the following construction details: type of fasteners, fastening patterns on the flanges, and window shimming details. • Additional testing is required to determine methods to improve structural pressure performance of slider windows. Potential solutions that would require additional testing may include fastener spacing, different types of fasteners, masonry window clips, construction adhesive, foam sealant, stronger window flange material, and/or straps.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2018

Coupled aging effects in nanofiber-reinforced siloxane foams

Here, this study investigates the combined effects of ionizing radiation and thermal treatments on the aging of siloxane foams containing small amounts of carbon nanofibers. Our siloxane foams were exposed to accelerated aging conditions for more than two years, resulting in very low dose rates. In addition, foams were aged under compressive load to evaluate the strength of the porous microstructure. Samples were characterized by differential scanning calorimetry (DSC), thermogravimetric analysis (TGA), Fourier transform infrared spectroscopy (FTIR), nuclear magnetic resonance spectroscopy (NMR), Mössbauer, mass spectroscopy, electron paramagnetic resonance spectroscopy (EPR), solvent swelling, imaging techniques, uniaxial compressive load testing and tear testing. No significant changes in thermal stability or chemistry of the accelerated aged foam were observed, although gas evolution was detected. Changes in crystallization levels at low temperatures, microstructure, and mechanical properties were observed for foams with and without carbon nanofibers. In particular, foams aged under compressive load showed irreversible deformation of the porous microstructure. This study demonstrates that aging effects were enhanced when thermal and radiolysis were coupled together and that the addition of carbon nanofibers did not improve aging effects.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Laser Welded Edge Seals for Polymer-Free Glass/Glass Modules

This presentation covers fs lasers which enable crack-free and stress-free glass/glass welds. Welds are nearly as strong as the glass (KI, weld ~ KI, glass) and static load test passed, enabling: 1) polymer-free; 2) hermetically sealed; and 3) recyclable modules. Next steps are: 1) follow-on funding; 2) develop feed throughs (metal/glass welds already achieved for other devices); and 3) weld mini modules for further IEC module testing.

DuraMAT↗

DOE OSTI2019

Production of Hydrogel Microneedles from Fish Scale Biopolymer

This work presents for the first time, a scalable, low cost method for producing hydrogel microneedles from fish scales derived biopolymer using a modified low temperature press method. The microneedles are made from cross-linked hydrolyzed collagen (HC). The suitability of the microneedles for drug loading were tested by loading with Ferrous gluconate. Force analysis carried out in compression mode showed that the microneedles could withstand up to 0.136 N per microneedle before fracture which is sufficient strength to pierce the skin. The cross-linked microneedles swelled to 340% of their original mass in PBS and within 24 h released 34.5% of the loaded drug, while the non cross-linked microneedles dissolved within minutes. Chemical testing of the released drug confirmed that the drug released retained its chemical structure by forming colored complex with acetylsalicylic acid and UV spectrometry was used to quantify the concentration released. FTIR analysis confirmed the modified structure of the polymer when cross-linked. This proposed method allows cross-linking at room temperature using a thermal press method which can be easily scaled up.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2017

Energy Efficient Clothes Dryer with IR Heating and Electrostatic Precipitator

The project goal was to develop a revolutionary energy saving technology for residential clothes drying. The team developed an IR (infrared) heating system and NESP (Nebulizer and Electro-Static Precipitator) for integration into a ventless clothes dryer. The proposed technology addresses two of the major inefficiencies in current electric vented dryers by providing effective energy transfer for the removal of the water and recapture of the vapor latent heat. The IR heaters operating in the mid wave (2.5-10um) are very efficient as they target the 3-micron peak absorption of the water molecule. This allows direct energy absorption, unlike conventional element heaters where heat is transferred by convection. The low power NESP removes water vapor from the exhausted stream and recaptures the latent heat in the ESP (Electro-Static Precipitator) exchanger section. This allows the warm dry air to be recirculated back into the drum for additional efficiency savings. The remaining majority of the dryer hardware stays the same. Summing the efficiency gain from the two subcomponents we anticipated the EF (Efficiency Factor) to exceed the goal of 4.04. EF is obtained by dividing the weight (lbs) of water removed by the energy (kWhr) used, where the test load size is 8.45 lbs of bone dry clothing wetted to 57.5% or 4.8lbs of water, and dried to a remaining moisture content of 2.5-5%. Additional benefits include not having to recondition (heat or cool) the large amounts of make-up air to replace the air exhausted by a vented dryer. It was anticipated that the NESP/heat exchanger would be the most challenging and highest risk element in the program. Therefore, the team focused their efforts during Phase 1 of the program on the design, construction, testing, and optimization of the NESP/heat exchanger. At the end Phase 1, the team compared the performance of the NESP/heat exchanger with the system level requirements and made a Go/No-Go decision on proceeding with the second portion of the program. Phase 2 of the program was structured to develop the IR heating system and then integrate it and the NESP/heat exchanger into a residential clothes dryer prototype for final testing. The proposed technology utilizes heat recovery which is known to have the biggest impact on dryer efficiency. The two current mainstream recovery approaches are air to air exchangers and heat pump condenser systems. Air to air exchanges can be very efficient but require large surface areas which are prone to fouling from uncaptured lint. Dryers based on heat pump condenser recovery systems have shown efficiency improvements of 20–60% and are commercially available. The issue with a heat pump condenser approach is the added cost, as typical prices are twice that of standard vented dryers and they are only available in small to medium capacities. The energy factor (EF) for these systems is 5.50 to 6.88 pounds/kWh compared to conventional dryers at 2.75 to 3.67 pounds/kWh. The efficiency improvements for the proposed technology come from the use of IR heating and the NESP. As the concept is in its infancy, and these improvements were difficult to predict without experimental data, assumptions were made based on available literature. IR radiant drying times, when compared to convection, are typically 30% less. This is a result of the fact that radiant energy heats directly and is absorbed at and below the surface, unlike convection heating, that must conduct the heat through the boundary film of air at the clothes surface and rely on wicking of the moisture to the surface. The second area of improvement comes from the NESP. The NESP operation is as follows: 1. Highly charged, micron sized, droplets of water are injected into the dryer exhaust by the Nebulizer. 2. These charged droplets attract water molecules and continue to grow in size, until losing their charge. During this process, latent heat is rejected back into the air stream. 3. The large droplets enter the ESP, where they are recharged and drawn to the ESP wall, to be extracted at the bottom of the ESP. The warm dry air is then recirculated back into the dryer. The proposed technology, at the time of the proposal submission was estimated to have an EF of 4.79. At program completion we have designed, built, tested, integrated and optimized the proposed technologies into a prototype “high efficiency” residential clothes dryer. Testing of the integrated prototype dryer provided insight into the technical effectiveness and economic feasibility of the proposed technologies. The program has the potential of greatly impacting energy savings. The predicted EF of the proposed technology is 4.79, yielding an energy savings of 42% when compared to conventional electric vented dryers. Given there are approximately 84 million dryers in the US consuming ~64 billion kWh per year, a net savings of 27 billion kWh per year or 0.092 quads could be realized. Since the dryer is not vented, make up air from the room is not needed, adding an additional savings of ~1kWh per load, or 23.8 billion kWh per year. In addition, it is envisioned that the proposed ESP, when successful, would potentially find applications in industrial and residential dehumidification.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗