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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Industrial Energy Training and Certification

We present compressed air systems, ammonia refrigeration systems, chilled water systems, steam systems, process heating systems, combined heat and power systems, pump systems and fan systems are major industrial energy systems commonly found in manufacturing facilities. Efficiency of these systems contributes significantly to whole facilities' energy performance. On the national, even international level, well-structured training and highly recognized certification programs help develop a highly-skilled and qualified workforce to maintain and improve facilities' energy performance, particularly as technologies within these systems become more advanced. The purpose of this paper is to review currently available training and certification programs focusing on these systems and to identify the gap between market's needs and currently available programs. Three major conclusions are: first, most training programs focus on operations, maintenance, safety and design although some briefly touch the energy performance aspect; second, except CRES by RETA and PSA Certificate and PSAP Master Certification by HI, no other certifications had been found emphasizing on knowledge and skills for improving and maintaining these systems' energy performance; third, developing energy efficiency focused training and ANSI accredited certification programs on these energy systems will fill the gap between market's needs and currently available programs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2019

Estimating Customer Impact of Volt-Watt Using Only Smart Meter Voltage Data

The autonomous inverter control mode known as volt-watt control can be useful as a backstop against high customer voltages outside of the ranges specified in ANSI C84.1 (i.e. above 1.05-1.06 per unit). Volt-watt control mitigates high voltages by directly reducing the active power output of a distributed energy resource based on local voltage measurements. Therefore volt-watt control also can impact the energy produced by the DER (e.g. PV system), especially for customers with persistently high voltages, and in such cases it is difficult to determine exactly how much the DER has been curtailed because it is not generally known exactly how much energy the PV system could have produced. These slides propose a relatively simple method of estimating the DER's energy curtailment using only data from the utility advanced metering infrastructure (AMI) data). The method proves surprisingly accurate when validated against detailed quasi-static time-series simulations and against limited field data.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2019

Impacts of Voltage-Based Grid-Support Functions on Energy Production of PV Customers: Preprint

This paper presents the impact of grid-support utility-interactive inverter functions, such as volt/volt-ampere reactive and volt/watt controls, on quasi-steady-state feeder voltages and on photovoltaic (PV) customer energy production on a real distribution feeder in Oahu, Hawai'i. These autonomous inverter controls provide an effective means to modulate active and reactive power based on local voltage measurements and therefore serve as good candidates for non-wire alternatives to increase PV hosting capacity. However, because the activation of these functions can result in PV energy curtailment, this study addresses the concerns about the impact of these advanced inverter controls on curtailment through detailed quasi-static time series (QSTS) simulations. This study proposes four metrics-maximum and average grid-support function curtailments, average increased generation, and average net generation change-to assess the impact of a given control on PV systems located on customer sites. For representative scenarios modeled in detail, it was found that curtailment of PV production is negligible for customers where peak voltage is within ANSI C84.1 ranges. A reliable relationship between curtailment and peak customer voltage is demonstrated, allowing peak voltage to be used as an indicator of curtailment without the need to measure curtailment directly.

14 SOLAR ENERGY↗
DOE OSTI2019

Methodology for Fast Iterations of Blade Designs Using Thermoplastic Composite Materials: Preprint

Tidal energy is still in the early research and development phases, therefore the ability to quickly manufacture and evaluate prototype blades with new blade designs and materials is critical. This paper investigates using a Stratasys three-dimensional printer to rapidly prototype scale-model turbine blades by printing the blade tooling and using vacuum-assisted resin transfer molding (VARTM) to manufacture blades. This work outlines a methodology for cost effectively designing and manufacturing model-scale tidal turbine blades to be used in testing campaigns, and for evaluating new thermoplastic composite materials for tidal energy applications. Demonstration blades were designed in ANSYS and manufactured using an infusible thermoplastic resin system called Elium(R). The development of scale-model thermoplastic blades enables research into their fatigue performance in realistic conditions at a cost-effective scale, and manufacturing using 3-D printed tooling enables fast and low-cost blade design iterations.

17 WIND ENERGY↗
DOE OSTI2019

EFCOG Best Practice #65 Engineering Calculations

The purpose of this paper is to present guidance for developing engineering calculations to assure that such technical documents meet the quality requirements of 10 CFR 830 and DOE O 414.1C. More specifically, this paper presents guidance related to the following general topics: Development; Design Input/Assumptions; Documentation/Content; Format; Rigor; Review/Verification; Approval; Revisions. Guidance for this paper was also taken from ASME NQA-1, Quality Assurance Requirements for Nuclear Facility Applications and its predecessor ANSI N45.2.11, Quality Assurance Requirements for the Design of Nuclear Power Plants. These standards clearly point to what can be described as a graded approach. This guidance presented in this paper is intended to apply to safety related structures, systems and components (SSCs) whose reliable performance prevents or mitigates accidents that could cause undue risk to the health and safety of the public. Extension beyond this scope to non-safety related SSCs represents good engineering practice.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2018

Numerical modeling of the lifesaver mooring system for deployment at WETS

NUMERICAL MODELING OF THE LIFESAVER MOORING SYSTEM FOR DEPLOYMENT AT WETS: Preliminary designs are described and modeled, of the mooring system that is expected to be deployed with the Fred. Olsen BOLT Lifesaver device during upcoming trails at the WETS 30m berth. Component selection and modeling results obtained from ANSYS Aqwa will be discussed.

16 TIDAL AND WAVE POWER↗
DOE OSTI2019

Evaluation of low heat conductivity rf cables

New potential applications of superconducting radio-frequency can be envisioned with conduction cooling of the cavities using cryocoolers. In this case, the total heat load to the cryocoolers have to be carefully managed to assure sufficient margin to operate the cavity at an acceptable accelerating gradient. The static and dynamic heat load from rf cables connected to the cavity can be a significant contribution to the total heat load. In this contribution we report the results from measurements of the temperature profile at 1.3 GHz for two low heat conductivity rf cables, as a function of the rf power and with one end of the cable in thermal contact with a liquid helium bath at 4.3 K. A parametric model of the two cables was developed with ANSYS to match the temperature profiles and calculate the heat load at the cold end of the cable.

Cheng, G.↗
DOE OSTI2019

RF performance sensitivity to tuning of Nb3Sn coated CEBAF cavities

Nb3Sn has the potential to surpass niobium as the material of choice for SRF applications. The potential of this material stems from a larger superconducting energy gap, which leads to expectations of a higher RF critical field and a lower RF surface resistance. The appeal of better superconducting properties is offset by the relative complexity of producing practical Nb3Sn structures, and Nb3Sn sensitivity to lattice disorder challenges the use of the material for practical applications. Such sensitivity is indirectly probed during SRF cavity development, when the cavity is tuned to match the desired accelerator frequency. In the course of recent experiments we have coated and tuned several multi-cell cavities. Cold RF measurements before and after tuning showed degradation in cavity performance after tuning. The results of RF measurement were compared against strain evolution on Nb3Sn surface during tuning based on CST and ANSYS models.

Eremeev, G. V.↗
DOE OSTI2020

Thermal Insulation for a High Temperature Molten Salt Storage Tank in a CSP Plant: Preprint

A ternary molten chloride has been suggested as a high temperature (550-720 °C) sensible heat storage medium for a two-tank system. An effective thermal insulation is proposed to provide an opportunity for the fabrication of both the hot and cold storage tanks from lower cost metals, e.g. A240-347H, by maintaining the tank wall below 500 °C. To achieve this, the hot storage tank mainly comprises of inner shell (11.4 cm of a refractory brick as liner (KX-99 ®), 30 cm of insulation brick) and outer metal shell, where 5 cm of frozen layer of PCM800 (NaCl), and 5 cm of ceramic wool fill the annular space between the shells. Another layer of ceramic wool was introduced at the outer side of the metal shell to keep the temperature lower than 60 °C. ANSYS Fluent was used for the numerical study of the cool down behavior of the system during idle period when tank is quarter-filled. The heat transfer modes were considered as radiation and natural convection heat transfer from the hot molten salt at 720 °C, conduction through the solid layers and convection heat transfer from the outer shell to the environment at 15 °C. The results showed that the proposed insulation system including a frozen layer of PCM800 maintains the temperature at the metal wall lower than 500 °C, and lower than 60 °C at the outer side of the tank. Apart from the insulation property of the frozen layer of PCM800, it absorbs any leak of hot molten salt, acting as a barrier between salt and the metal shell. The thermal performance analysis provide an insight into the benefits of the multilayer insulation.

41 EE - Solar Energy Technologies Office (EE-4S)↗
DOE OSTI2020

DOE-ART HT(G)R R&D Overview

The US Government currently has no plans to finance or build advanced nuclear reactors. Instead, the DOE performs research and development to raise the technological readiness of new concepts, fuels and component materials so that private industrial partners are more likely to design and build plants. Develop technologies that can enable new concepts and designs to achieve greater levels of safety and resilience, flexibility of use, sustainability and construction or operational affordability. Collaborate with industry to identify and conduct essential research to reduce technical risk associated with advanced reactor technologies. Sustain essential technical expertise and capabilities within national laboratories, universities, and industry to perform needed research. Collaborate with the Nuclear Regulatory Commission and Standards Developing Organizations (ASME, ANS, ANSI, etc.) to address gaps in codes and standards to support advanced reactor designs

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

A REDUCED ORDER MODELING APPROACH TO PROBABILISTIC CREEP-DAMAGE PREDICTIONS IN FINITE ELEMENT ANALYSIS

This paper introduces a computationally efficient Reduced Order Modeling (ROM) approach for the probabilistic prediction of creep-damage failure. Component-level probabilistic simulations are needed to assess the reliability and safety of high-temperature components. Full-scale probabilistic creep-damage modeling in finite element (FE) approach is computationally expensive requiring many hundreds of simulations to replicate the uncertainty of component failure. To that end, ROM is proposed to minimize the elevated computational cost while controlling the loss of accuracy. It is proposed that full-scale probabilistic simulations can be completed in 1D at a reduced cost, the extremum conditions extracted, and those conditions applied for lower-cost 2D/3D probabilistic simulations of components that capture the mean and uncertainty of failure. The probabilistic Sine-hyperbolic (Sinh) model is selected which in previous work was calibrated to alloy 304 stainless steel. The Sinh model includes probability density functions (pdfs) for test condition (stress and temperature), initial damage (i.e. microstructure), and material properties uncertainty. The Sinh model is programmed into ANSYS finite element software using the USERCREEP.F material subroutine. First, the Sinh model and FE code are subject to verification and validation to ensure the accuracy of the simulations. Numerous Monte Carlo simulations are executed in a 1D model to generate probabilistic creep deformation, damage, and rupture data. This data is analyzed and the probabilistic parameters corresponding to extreme creep response are extracted. The ROM concept is applied where only the extreme conditions are applied in the 2D probabilistic prediction of a component. The probabilistic predictions between the 1D and 2D geometry is compared to assess ROM for creep. The accuracy of the probabilistic prediction employing the ROM approach will potentially reduce the time and cost of simulating complex engineering systems. Future studies will introduce multi-stage Sinh, stochasticity, and spatial uncertainty for improved prediction.

36 MATERIALS SCIENCE↗
DOE OSTI2018

DESIGN AND EXPERIMENTAL STUDY OF A HIGH PRESSURE AND SUPERCRITICAL METHANE-OXYGEN BURNER

Directly heated supercritical oxy-fuel power cycles have potential to offer a higher thermal efficiency and lower pollutant emissions compared to existing power cycles. Recent thermodynamic analysis of the cycle performed by several groups including the UTEP-Air Liquide research team show that combustion in the vicinity of 300 bar pressure and 1000-1400 K temperature allows for relatively high system efficiencies while operating within the limit of practical combustor materials. However, the realization of directly heated supercritical power cycle requires combustion systems be designed to operate in supercritical conditions and at temperature far below the blowout limit of conventional flames (above 1500 K), where not only the thermodynamic properties but also the combustion properties and kinetics are unexplored. To minimize these knowledge gaps, some intermediate pressure ranges (up to 20 bar) are experimented and modeled using a CFD simulation tool. The knowledge obtained from the high pressure test will assist in understanding the combustion chamber pressurization mechanism, ignition and flame behavior at the elevated pressure. This is a systematic first step in testing at higher pressures of 100 and 300 bar pressures. The primary objective of this dissertation is to perform qualitative analysis on oxy-methane combustion at high pressure (< 20 bar) and compare to CFD model for future scale up to supercritical condition. For modeling of the system, a commercial computational fluid dynamics simulation tool, ANSYS Fluent, is used. The inlet conditions for the CFD analysis are obtained from the experiments. The geometry used for the study is same as the test apparatus and operates at the same power ratings. The expertise gained from this experimental study is important to accurately and safely design combustors at elevated pressures up to 300bar. A high pressure methane-oxygen fuel burner and combustor have been developed to accommodate oxycombustion environment. A detailed CFD analysis is conducted to understand the flame length and cooling phenomenon inside the combustor first at pressures up to 20 bar to compare to experiments then at supercritical pressure. The first part of the dissertation compares CFD results with high pressure burner experiments at pressures up to 20 bar. The test is conducted for 30 s within 150 kW – 250 kW thermal power inputs. Afterwards, based on the simulation results a cooling system is proposed for steady state high pressure combustion experiments. It is observed from the experimental study that the proposed pressurization mechanism able to pressurize the vessel up to 20 bar. It is also determined that the current combustor can operate up to 20 bar for short term. The steady state CFD simulation demonstrates that a cooling system must be incorporated for continuous operation. Additionally, the study focuses on the ignition delay due to added diluent during the combustion process. It is observed that as the carbon dioxide recirculation ratio increases the ignition delay time increases. Later part of the dissertation provides a preliminary guideline for developing a laboratory scale supercritical oxy combustor. The employment of supercritical fluid in gas turbine is fairly a new concept. Hence, there are many questions that need to be answered. During this dissertation study an investigation is performed to understand the impact of equation of state in the supercritical combustion simulation. Finally, a CFD model for developing supercritical oxy-methane burner and the combustor, incorporating real gas model, is presented. Although Lee-Kesler equation of state provides better accuracy than Peng Robinson, due to the computational time Peng Robinson equation of state is used for the simulation. It is found that existing knowledge is not enough to simulate combustion at supercritical phase. Detailed combustion chemistry at the supercritical condition must be developed and should be incorporated to accurately replicate the combustion phenomenon.

Chowdhury, ASM Arifur Rahim↗
DOE OSTI2022

Recent Developments in the WEC-Sim Open-Source Design Tool: Preprint

WEC-Sim (Wave Energy Converter SIMulator) is an open-source code for simulating wave energy converters, which has been actively developed and applied to simulate a wide variety of device archetypes and has become a popular tool since its initial release in 2014. WEC-Sim is developed jointly by the National Renewable Energy Laboratory (NREL) and Sandia National Laboratories (SNL) within the MATLAB/SIMULINK environment. Figure 1 illustrates a general wave-to-wire model which begins with a deployment site resource characterization, which is used to complete the hydrodynamic simulation of a single WEC (or array), with the power generation profile imported to a grid simulator to understand the influence on the local electrical network. While modelling the entire wave-to-wire is difficult and encompass multiple time scales and physics, WEC-Sim is focused on the hydrodynamics simulation to predict, analyze and optimize WEC dynamics and power performance. WEC-Sim simulations are performed in the time domain based on the radiation and diffraction method using hydrodynamics coefficients derived from boundary element method (BEM) based-frequency-domain potential flow solvers (e.g., WAMIT, NEMOH, Capytaine, or ANSYS-AQWA). Within this level of modeling fidelity, WEC-Sim can handle floating body hydrodynamics, mechanical and electrical power generation methods, advanced control implementation, mooring systems, and other unique applications such as desalination. Table 1 lists additional WEC-Sim functionalities, which are created using prebuilt Simulink blocks and MATLAB scripts that can simulate a wide range of floating systems and the corresponding auxiliary subsystems.

hydrodynamics modeling↗
DOE OSTI2022

316L Stainless Steel Wire Arc Additive Manufacturing and Characterization for Potential SNF Canister Production

In this paper, 316L stainless steel (316L SS) straight walls, curved walls, and vessels were printed by wire arc additive manufacturing (WAAM) using the 316L SS welding wire, to demonstrate the feasibility of spent nuclear fuel (SNF) canisters using this advanced manufacturing technique. Helium leak test with leak tight criteria of 1 × 10-7 ref-cc/s were performed on printed vessels with various wall thickness, and testing pressures were from 0.345 MPa (50 psi) to 1.724 MPa (250 psi). Printed wall microstructures were characterized using optical microscopy (OM) and scanning electron microscopy (SEM). Tensile specimens were machined out from printed walls along the length, height, and thickness directions, respectively, and tested at different temperature conditions, room temperature, 80 °C, 150 °C and 250 °C, respectively. Results showed t hat, all five WAAM-printed canisters with different thickness passed the helium leaktight criteria of radioactive materials containers by the ANSI N14.5; Dispersed micrometer-level size inclusions/voids were observed at printed wall cross sections, dendritic microstructures were found with grain size variation through the welding torch shifting direction, and very small amount of δ-ferrite and σ-phase were also observed in those cross sections; The printed walls were ductile, all tensile specimens broke with large plastic deformation/elongation and without brittle failure, and printed specimens yield strengths and tensile strengths under room temperature and 80 °C conditions are higher than minimum values of 316L SS for pressure vessels and for general applications at room temperature required by the ASTM standard, respectively.

Tang, Wei↗
DOE OSTI2023

PRINTED, PLANAR MICROWAVE CONNECTOR WITH MULTIPLE SIGNAL LINES

Microwave connectors with a planar geometry have been demonstrated using additive manufacturing techniques. This planar form factor is expected to enable connectors to be integrated directly with other components onto a printed circuit board. The connectors were developed with multiple signal lines that will increase the density of signal connections to PCBs, eliminating the physical constraints of single-signal COTS microwave connectors. This work developed electromagnetic models (using Ansys HFSS) of these planar connectors to predict performance and optimize connector design. Materials and printing processes were developed to fabricate the connectors based on high-temperature PEEK thermoplastics. The multiple signal connectors were designed to operate over the 1-6GHz band and are built upon the single signal printed planar geometry connector introduced in a previous paper [1].

Additive Manufacturing↗
DOE OSTI2023

New Developments and Capabilities Within WEC-Sim: Preprint

WEC-Sim is an open-source software for simulating wave energy converters, which has been actively developed and applied since its initial release in 2014 to simulate a wide variety of device archetypes. WEC-Sim is developed jointly by the National Renewable Energy Laboratory (NREL) and Sandia National Laboratories (Sandia) within the MATLAB/SIMULINK environment. A general wave-to-wire model begins with a deployment site resource characterization, which is used to complete the hydrodynamic simulation of wave energy converters (WEC), with the power generation profile imported to a grid simulator to understand the influence on the local electrical network. While modeling the entire wave-to-wire is difficult and encompasses multiple time scales and physics, WEC-Sim is focused on the hydrodynamics simulation to predict, analyze, and optimize WEC dynamics and power performance. WEC-Sim simulations are performed in the time domain based on the radiation and diffraction method using hydrodynamics coefficients derived from boundary element method (BEM)-based frequency-domain potential flow solvers (e.g., WAMIT, NEMOH, Capytaine, or ANSYS-AQWA). With this level of modeling fidelity, WEC-Sim can handle floating body hydrodynamics, mechanical and electrical power generation methods, advanced control implementation, mooring systems, and other unique applications such as desalination. Additional WEC-Sim functionalities include pre-built Simulink blocks and MATLAB scripts that can simulate a wide range of floating systems and the corresponding auxiliary subsystems. The developers of WEC-Sim continue to release new versions of the software, at least annually, with our latest release in September 2022. These releases include bug fixes, updates to software documentation, as well as new features to expand WEC-Sim's capabilities to model a wide range of WEC concepts. This publication will highlight the new features added to WEC-Sim between versions 4.1.0 to 5.0.1 which spans over a two year period from June 2020 to September 2022. New features to be described will include topics such as continuous integration checks, revised Morison Element and nonlinear hydro implementations, run directly from Simulink (required for hardware-in-the-loop execution), BEMIO updates to import Capytaine BEM hydrodynamics, addition of cable blocks, and new wave visualization features.

TIDAL AND WAVE POWER↗
DOE OSTI2011

Design and development of a 6 MW peak, 24 kW average power S-band klystron

A 6 MW peak, 24 kW average power S-band Klystron is under development at CEERI, Pilani under an MoU between BARC and CEERI. The design of the klystron has been completed. The electron gun has been designed using TRAK and MAGIC codes. RF cavities have been designed using HFSS and CST Microwave Studio while the complete beam wave interaction simulation has been done using MAGIC code. The thermal design of collector and RF window has been done using ANSYS code. A Gun Collector Test Module (GCTM) was developed before making actual klystron to validate gun perveance and thermal design of collector. A high voltage solid state pulsed modulator has been installed for performance valuation of the tube. The paper will cover the design aspects of the tube and experimental test results of GCTM and klystron. (author)

43 PARTICLE ACCELERATORS↗
DOE OSTI2012

CFD modeling of debris melting phenomena during late phase Candu 6 severe accident

The objective of this paper was to study the phase change of the debris formed on the Candu 6 calandria bottom in a postulated accident sequence. The molten pool and crust formation were studied employing the Ansys-Fluent code. The 3D model using Large Eddy Simulation (LES) predicts the conjugate, radiative and convective heat transfer inside and from the corium pool. LES simulations require a very fine grid to capture the crust formation and the free convection flow. This aspect (fine mesh requirement) correlated with the long transient has imposed the use of a slice from the 3D calandria geometry in order not to exceed the computing resources. The preliminary results include heat transfer coefficients, temperature profiles and heat fluxes through calandria wall. From the safety point of view it is very important to maintain a heat flux through the wall below the CHF assuring the integrity of the calandria vessel. This can be achieved by proper cooling of the tank water which contains the vessel. Also, transient duration can be estimated being important in developing guidelines for severe accidents management. The debris physical structure and material properties have large uncertainties in the temperature range of interest. Thus, further sensitivity studies should be carried out in order to better understand the influence of these parameters on this complex phenomenon. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗