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DOE OSTI2024

Advanced fuel fusion, phase space engineering, and structure-preserving geometric algorithms

Non-thermal advanced fuel fusion trades the requirement of a large amount of recirculating tritium in the system for that of large recirculating power. Phase space engineering technologies utilizing externally injected electromagnetic fields can be applied to meet the challenge of maintaining non-thermal particle distributions at a reasonable cost. The physical processes of the phase space engineering are studied from a theoretical and algorithmic perspective. It is emphasized that the operational space of phase space engineering is limited by the underpinning symplectic dynamics of charged particles. The phase space incompressibility according to the Liouville theorem is just one of many constraints, and Gromov's non-squeezing theorem determines the minimum footprint of the charged particles on every conjugate phase space plane. In this sense and level of sophistication, the mathematical abstraction of phase space engineering is symplectic topology. To simulate the processes of phase space engineering, such as the Maxwell demon and electromagnetic energy extraction, and to accurately calculate the minimum footprints of charged particles, recently developed structure-preserving geometric algorithms can be used. The family of algorithms conserves exactly, on discretized spacetime, symplecticity and thus incompressibility, non-squeezability, and symplectic capacities. The algorithms apply to the dynamics of charged particles under the influence of external electromagnetic fields as well as the charged particle–electromagnetic field system governed by the Vlasov–Maxwell equations.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

Development of an Efficient Conjugate Heat Transfer Modeling Framework to Optimize Mixing-Limited Combustion of Ethanol in a Diesel Engine

Mixing controlled combustion of alcohol fuels has been identified as a promising technology based on their low propensity for particulate and NOx production, but the higher heats of vaporization and auto-ignition temperatures of these fuels make their direct use in diesel engine architectures a challenge. To realize the potential of alcohol-fueled combustion, a computational fluid dynamics (CFD) modeling framework is developed, validated, and exercised to identify designs that maximize engine thermal efficiency. To evaluate the use of thermal barrier coatings (TBCs), a simplified one-dimensional (1D) conjugate heat transfer (CHT) modeling framework is employed. The addition of the 1D CHT model only increases the computational expense by 15% relative to traditional approaches, yet offers more accurate heat transfer predictions over constant temperature boundary conditions. The validated model is then used to explore a range of injector orientations and piston bowl geometries. Using a design of experiments (DoE) approach, several designs were identified that improved fuel-air mixing, shortened the combustion duration, and increased thermal efficiency. The most promising design was fabricated and tested in a Caterpillar 1Y3700 single-cylinder oil test engine (SCOTE). Engine testing confirmed the findings from the CFD simulations and found that the co-optimized injector and piston bowl design yielded over 2-percentage point increase in thermal efficiency at the same equivalence ratio (0.96) and over 6-percentage point increase at the same engine load (10.1 bar indicated mean effective pressure (IMEP)), while satisfying design constraints for peak pressure and maximum pressure rise rate.

Magnotti, Gina M.↗

DOE OSTI2024

Cyber-informed Engineering Microgrid Analysis Tool

The Cyber-Informed Engineering Microgrid Analysis Tool (CIEMAT) leverages the Department of Energy’s Cyber-Informed Engineering to prompt engineering designers and operators through an analysis of the critical functions to be supported by a microgrid installations, the criticality of those functions, the impacts of denial, disruption or misuse of those functions on the microgrid and dependent functions, and the mitigations which could best prevent impacts to those functions resulting from cyber attack. Through use of this tool, microgrid designers and operators can quickly identify appropriate engineering mitigations to limit impacts from cyber attack and functions where engineering and operational staff can prioritize and guide the application of cybersecurity protections to best support the resiliency of the system.

Wright, VirginiaL [Idaho National Laboratory (INL)↗

DOE OSTI2025

Cyber-informed Engineering Battery Analysis Tool

The Cyber-Informed Engineering Battery Analysis Tool (CIEBAT) leverages the Department of Energy’s Cyber-Informed Engineering to prompt engineering designers and operators through an analysis of the critical functions to be supported by a BESS installation, the criticality of those functions, the impacts of denial, disruption or misuse of those functions within the BESS system, and the mitigations which could best prevent impacts to those functions resulting from cyber attack. Through use of this tool, BESS designers and operators can quickly identify appropriate engineering mitigation opportunities to limit impacts from cyber attack and functions where engineering and operational staff can prioritize and guide the application of cybersecurity protections to best support the resiliency of the system.

Lampe, BenjaminR [Idaho National Laboratory (INL),↗

DOE OSTI2023

Physically-based control-oriented modeling for turbocharged stoichiometric spark-ignited engine with cooled EGR and flexible VVT systems

Accurate estimation and prediction of engine gas exchange system and in-cylinder conditions are critical for spark-ignited engine control and diagnostic algorithm development. In this paper, a physically-based, control-oriented model for a 2.8 l turbocharged, variable valve timing (VVT) and low pressure (LP) exhaust gas recirculation (EGR)-utilizing SI engine was developed. The model includes the impact of modulation to any combination of 10 actuators, including the throttle valve, compressor bypass valve, fueling rate, waste-gate, LP EGR valve, number of deactivated cylinders, intake valve open (IVO) timing, intake valve close (IVC) timing, exhaust valve open (EVO) timing and exhaust valve close (EVC) timing. The accuracy of the model in capturing engine dynamics was demonstrated by validating it against high-fidelity engine GT-Power simulation results for various drive cycles, particularly emphasizing elevated loads. In comparison to the open literature, novel contributions of the effort described in this paper includes in-cylinder gas composition modeling and turbine-out pressure estimation.

Zhang, Xu↗

DOE OSTI2020

A High Specific Output Gasoline Low Temperature Combustion Engine

This report summarizes activities conducted in support of the project “A High Specific Output Gasoline Low Temperature Combustion Engine” under COOPERATIVE AGREEMENT NUMBER DE-EE0007788. This cooperative agreement was structured as a 51%/49% recipient/DOE NETL cost share with two Go / no-Go decision gates spanning three budget periods. The primary objective of the program is the development and demonstration of a downsized boosted, lean, low temperature gasoline combustion engine system capable of demonstrating a 15-17% fuel economy improvement relative to a contemporary naturally aspirated stoichiometric combustion engine consistent with relevant emissions constraints and the use of marketplace gasolines. The program focused on maximizing internal combustion engine fuel economy potential by combining the benefits of downsized boosted engine technology with next generation gasoline lean-burn, low temperature combustion and novel low temperature plasma ignition. The project achieved a 20.5% improvement from hot FTP cycle test and 18.9% improvement from cold FTP cycle test while meeting stringent SULEV30 emissions regulation for both test cycles (HOT FTP: 15.37 mg of NOx+HC; 0.16 g/mile of CO, COLD FTP: 23.1 mg of NOx+HC; 0.33 g/mile of CO).

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2021

Research software engineering: Professionalization, roles, and identity

This report summarizes the results of a study of research software professionals based on 17 interviews conducted at U.S. national laboratories and academic institutions. The study focuses on understanding the emerging professional role of research software engineer (RSE) and examining how the history of software engineering might be relevant to the emergence of research software engineering as a professional movement. The report first uses interview data to identify several models of professional identity for research software professionals. These include dominance models in which a person strongly identifies with a single professional identity (such as RSE), and multiplicity models in which an individual sees an identity like RSE as just one facet of their overall professional role. Next, it identifies three types of work situations for software professionals at national laboratories, covering those who work in dedicated RSE organizations, those who play an integral role in large multiphysics code projects, and those who work in a more isolated capacity to provide software development support for less computationally intensive research projects. It then reviews some key ideas from the sociology of professions in the context of the software engineering profession, suggesting parallels between the current RSE professional movement and aspects of the history of software engineering. It concludes by suggesting some potential practical implications of these findings for the RSE movement and professional organizations.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2023

Development and testing of residential micro-CHP powered by opposed piston engine (CRADA Final Report)

A micro–combined heat and power (mCHP) prototype powered by innovative opposed piston engine technology was developed to simultaneously provide electricity and heat to residential or light commercial buildings. The mCHP prototype targeted at residential applications includes an opposed-piston four-stroke (OP4S) engine, generator, rectifier, inverter, battery energy storage system, 52 gal water tank, and application accessories for hot water supply and space heating. The OP4S engine can use renewable or regular natural gas, as well as hydrogen, to generate mechanical power and waste heat in form of hot coolant and exhaust gas simultaneously. The waste heat is recovered and stored in the water tank and can be used as a regular hot water supply and/or for space heating application. The tests show that the mCHP prototype enabled power outputs in the range of 3.2 –7.4 kW with up to 26.4% of AC electricity efficiency and up to 93.1% of the overall mCHP efficiency under stoichiometric combustion modes λ=~1.0. The mCHP was also run under lean combustion mode conditions at λ=~1.3. The lean mode operation enables more than 30% improvement in electrical energy efficiency. The maximum AC efficiency of the lean combustion mode attained was 35.2%, with the engine efficiency is approaching 40%. The exceptional electrical efficiency breaks the typical upper boundary of 30% for ICE-based mCHP. The engine exhaust temperatures in the lean modes are substantially less than in the stoichiometric modes. Moreover, the lean cases achieve high overall mCHP efficiencies: the overall mCHP efficiencies are all greater than 93%. Considering the mCHP prototype can achieve low-cost, flexible matching of thermal and electrical loads through reducing the complexity of distribution and installation, and high efficiency the novel technology will promote mCHP acceptance in the US residential and light commercial markets.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Advances in S. cerevisiae Engineering for Xylose Fermentation and Biofuel Production: Balancing Growth, Metabolism, and Defense

Genetically engineering microorganisms to produce chemicals has changed the industrialized world. The budding yeast Saccharomyces cerevisiae is frequently used in industry due to its genetic tractability and unique metabolic capabilities. S. cerevisiae has been engineered to produce novel compounds from diverse sugars found in lignocellulosic biomass, including pentose sugars, like xylose, not recognized by the organism. Engineering high flux toward novel compounds has proved to be more challenging than anticipated since simply introducing pathway components is often not enough. Several studies show that the rewiring of upstream signaling is required to direct products toward pathways of interest, but doing so can diminish stress tolerance, which is important in industrial conditions. As an example of these challenges, we reviewed S. cerevisiae engineering efforts, enabling anaerobic xylose fermentation as a model system and showcasing the regulatory interplay’s controlling growth, metabolism, and stress defense. Enabling xylose fermentation in S. cerevisiae requires the introduction of several key metabolic enzymes but also regulatory rewiring of three signaling pathways at the intersection of the growth and stress defense responses: the RAS/PKA, Snf1, and high osmolarity glycerol (HOG) pathways. The current studies reviewed here suggest the modulation of global signaling pathways should be adopted into biorefinery microbial engineering pipelines to increase efficient product yields.

59 BASIC BIOLOGICAL SCIENCES↗

NASA NTRS1972

Integrated engine-generator concept for aircraft electric secondary power

The integrated engine-generator concept of locating an electric generator inside an aircraft turbojet or turbofan engine concentric with, and driven by, one of the main engine shafts is discussed. When properly rated, the generator can serve as an engine starter as well as a generator of electric power. The electric power conversion equipment and generator controls are conveniently located in the aircraft. Preliminary layouts of generators in a large engine together with their physical sizes and weights indicate that this concept is a technically feasible approach to aircraft secondary power.

Secunde, R. R.↗

NASA NTRS1972

Integrated engine generator for aircraft secondary power

An integrated engine-generator for aircraft secondary power generation is described. The concept consists of an electric generator located inside a turbojet or turbofan engine and both concentric with and driven by one of the main engine shafts. The electric power conversion equipment and generator controls are located in the aircraft. When properly rated, the generator serves as an engine starter as well as a source of electric power. This configuration reduces or eliminates the need for an external gear box on the engine and permits reduction in the nacelle diameter.

Secunde, R. R.↗

NASA NTRS1972

TF-34 turbofan quiet engine study

A study of high bypass turbofan engines in heavily sound-suppressed nacelles based on the TF-34 engine. The four-engine noise objective was 95 PNdb at four locations typical of takeoff and landing. Three engines were studied; these had fan pressure ratios, bypass ratios, and fan tip speeds respectively of 1.48/6.5/404 m/sec (1327 ft/sec), 1.25/13/305 (1000), 1.25/13/366(1200). The bypass 13 engines had a variable pitch fan, direct- and gear-driven. Noise suppressive treatment was identified which met 95 PNdb objective except for sideline liftoff at 6.5 bypass, full power, which was 2 PNdb noisier; at 90% power, 95 PNdb was achieved.

Edkins, D. P.↗

NASA NTRS1972

Design studies of lift fan engines suitable for use in civilian VTOL aircraft.

Preliminary engine design studies have been made of two general types of low-pressure-ratio lift fan engines that are receiving increasing attention as a means to provide low-speed lift for large civilian VTOL transports. The two engine types are integral fans and remote powered fans. A portion of the results of these design studies is summarized, including the crucial engine requirements, and some of the characteristics of the emerging engine designs of each type.

Roelke, R. J.↗

NASA NTRS1973

Operation of small rocket engines in the JPL high-vacuum molecular space simulator (Molsink)

The feasibility of operating small rocket engines in the Molsink facility was demonstrated. A 0.44-N (0.1-lbf) hydrazine engine and a 0.18-N (0.04-lbf) thruster using cold gas from a hydrazine plenum system were operated for both flight duty cycles and off-nominal conditions. The exhaust gases from these thrusters contain NH3, N2, and H2. The chamber was also calibrated for larger bipropellant engines using nitrogen tetroxide/monomethyl hydrazine (NTO/MMH). The exhaust products of these engines contain CO2, CO, H2, H2O, and H2. A mixture of cold gases simulating the engine exhaust was injected through a nozzle under conditions simulating thrust levels up to 26.7-N (6 lbf). Pulsing and continuous operations were investigated. The chamber background pressure traces were compared with the traces obtained for the same thrusters operated with pure nitrogen at approximately equivalent thrust. Satisfactory recuperation times were encountered in all the pulsing modes. Test times greater than 20s were obtained in steady state operation before the vacuum chamber back pressure climbed to prohibitive values.

Chirivella, J. E.↗

NASA NTRS1973

Wind tunnel investigation of a large-scale upper surface blown-flap transport model having two engines

An investigation has been conducted to determine the aerodynamic characteristics of a large-scale subsonic jet transport model with an upper surface blowing flap system that would augment lift. The model had a 25 deg swept wing of aspect ratio 7.89 and two turbofan engines with the engine centerline located at 0.256 of the wing semispan. The lift of the flap system was augmented by turbofan exhaust impingement on the Coanda surface. Results were obtained for several flap deflections and engine nozzle configurations at jet momentum coefficients from 0 to 4.0. Three-component longitudinal data are presented with two engines operating. Limited longitudinal and lateral data are presented with an engine out. In addition, limited exhaust and flap pressure data are presented.

Aoyagi, K.↗

NASA NTRS1972

Aircraft engine pollution reduction.

The effect of engine operation on the types and levels of the major aircraft engine pollutants is described and the major factors governing the formation of these pollutants during the burning of hydrocarbon fuel are discussed. Methods which are being explored to reduce these pollutants are discussed and their application to several experimental research programs are pointed out. Results showing significant reductions in the levels of carbon monoxide, unburned hydrocarbons, and oxides of nitrogen obtained from experimental combustion research programs are presented and discussed to point out potential application to aircraft engines. An experimental program designed to develop and demonstrate these and other advanced, low pollution combustor design methods is described. Results that have been obtained to date indicate considerable promise for reducing advanced engine exhaust pollutants to levels significantly below current engines.

Rudey, R. A.↗

NASA NTRS1973

Acoustic characteristics of a large-scale wind tunnel model of an upper-surface blown flap transport having two engines

The upper-surface blown (USB) flap as a powered-lift concept has evolved because of the potential acoustic shielding provided when turbofan engines are installed on a wing upper surface. The results from a wind tunnel investigation of a large-scale USB model powered by two JT15D-1 turbofan engines are-presented. The effects of coanda flap extent and deflection, forward speed, and exhaust nozzle configuration were investigated. To determine the wing shielding the acoustics of a single engine nacelle removed from the model were also measured. Effective shielding occurred in the aft underwing quadrant. In the forward quadrant the shielding of the high frequency noise was counteracted by an increase in the lower frequency wing-exhaust interaction noise. The fuselage provided shielding of the opposite engine noise such that the difference between single and double engine operation was 1.5 PNdB under the wing. The effects of coanda flap deflection and extent, angle of attack, and forward speed were small. Forward speed reduced the perceived noise level (PNL) by reducing the wing-exhaust interaction noise.

Falarski, M. D.↗

NASA NTRS1974

Digital integrated control of a Mach 2.5 mixed-compression supersonic inlet and an augmented mixed-flow turbofan engine

A digitally implemented integrated inlet-engine control system was designed and tested on a mixed-compression, axisymmetric, Mach 2.5, supersonic inlet with 45 percent internal supersonic area contraction and a TF30-P-3 augmented turbofan engine. The control matched engine airflow to available inlet airflow. By monitoring inlet terminal shock position and over-board bypass door command, the control adjusted engine speed so that in steady state, the shock would be at the desired location and the overboard bypass doors would be closed. During engine-induced transients, such as augmentor light-off and cutoff, the inlet operating point was momentarily changed to a more supercritical point to minimize unstarts. The digital control also provided automatic inlet restart. A variable inlet throat bleed control, based on throat Mach number, provided additional inlet stability margin.

Batterton, P. G.↗