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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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At least 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Pre- and post-launch operation of the Resolve soft X-ray spectrometer onboard the XRISM satellite

Resolve is a high-resolution X-ray spectrometer onboard the X-Ray Imaging and Spectroscopy Mission (XRISM), launched on September 6 (UT), 2023. The Resolve has performed better than its required spectral resolution (7 eV at full width at half maximum at 6 keV), both on the ground and in orbit, and has been confirmed to have comparable performance to the soft X-ray spectrometer onboard the ASTRO-H (Hitomi) satellite. The focal plane is composed of an array of microcalorimeter detectors operated at 50 mK to achieve the required energy resolution, and the cooling system is designed to satisfy the lifetime requirement of over 3 years. The focal plane and cooling system are contained in a vacuum-insulated dewar. The cooling system is equipped with a two-stage adiabatic demagnetization refrigerator (ADR) that uses superfluid liquid helium (LHe) as its heat sink. The system includes a third ADR stage that can be used to provide the heat sink when the helium is exhausted. A Joule–Thomson cooler and several two-stage Stirling coolers are used to reduce the heat load on the LHe. During pre-launch operations, we carried out a superfluid LHe top-off operation. The resultant amount of LHe onboard Resolve was over 35 L before launch, which is sufficient to meet the lifetime requirement. During post-launch operation, the LHe vent valve was opened 5 min after launch during rocket acceleration, and the cryocoolers were turned on after several orbits, as planned, which established stable cooling within the dewar. Pre- and post-launch operations for the Resolve instrument were planned around multiple constraints from launch vehicle operations; all were successfully completed, and the launch requirements were fully met.

X-Ray Imaging and Spectroscopy Mission↗
DOE OSTI2024

Process and control variables from the mercury loop at the SNS's mercury target

Set of process and control variables corresponding to the mercury process loop at the Spallation Neutron Source's (SNS) mercury target. The data corresponds to 36 measurement signals (pressure, temperature, flows, valve position, etc.) spanning from 2017/01/01 to 2023/12/31. Each signal is broken intro three-month intervals, resulting in a total of 28 files per signal during the aforementioned period of time.

mercury loop↗
DOE OSTI2024

Monitoring Helium Cryogen Usage with iFix Software at IB1 Test Facility

At the IB1 facility of the Applied Physics and Superconducting Technology Directorate within the Cryogenic Division at Fermilab, liquid helium is essential to the testing activities. The test stands used require large amounts of Helium to test the thermal and superconducting cavities and magnets. The liquid helium that enters the test stand is monitored through a series of valves and controls to determine the start and stop for monitoring time. There are 3 phases of cryogen usage that must be considered for each stand, cooldown, warming and overnight mode. With a new system in place, cold hour tracking will be more objective and precise within each test stand ensuring better calculations for user s fees that will provide funding for the replenishment of helium and continual operation at IB1.

Trillo, Angelica↗
DOE OSTI2024

Liquid Piston with Spray Cooling Near-Isothermal Compressor

The goal of this project was to prototype and characterize the performance of a liquid-piston spray-cooled gas compressor. The working principle of the compressor enables optimized high-efficiency operation over a very wide range of operating conditions, unlike conventional compressors that are optimized for a narrow range of operating conditions. The compressor technology is suitable for many applications, such as gas pipeline transport, gas storage, and commercial and residential heat pumps. Both physical testing and computational fluid dynamics (CFD) modeling of the processes using the Oak Ridge National Laboratory high-performance computing center were completed. The experimental and CFD studies focused on a near-isothermal liquid-piston compressor (LPC) that uses propylene glycol to compress CO 2 . The first prototype demonstrated isothermal operation during several sequentially executed cycles of CO 2 compression and raised the temperature of the compressed CO 2 by only 2 K, compared with approximately 6 K when the gas was compressed non-isothermally. Isothermal operation was demonstrated at CO 2 flow rates of up to 2 L/min. The second prototype was designed with two compression chambers to allow continuous flow of high-pressure CO 2 . However, the design of the valve train to direct flow between the compression chambers was not sufficient to allow demonstration of CO 2 compression. Numerical simulations of the LPC in which the compression chamber was filled with propylene glycol injected from the bottom inlet were performed using large eddy simulation (LES) with the wall-adapting local eddy-viscosity subgrid-scale model coupled with the multiphase volume of fluid (VOF) model to simulate the transient interface between gas and liquid and to capture the heat and mass transfers within the compression chamber. In this effort, the effects of boundary conditions applied to the LES-VOF calculations (i.e., no wall, an adiabatic wall, and a wall with a heat flux subscribed) on the overall pressure and temperature of the CO 2 gas as well as the transient evolution of flow and heat transfer within the compression chamber were investigated and are discussed in this report. The LES calculation with no wall showed no dynamical flow patterns, and the volume-averaged temperature of CO 2 increased from 305 to 392.7 K, whereas LES calculations with a constant wall temperature or a wall heat flux had similar increases of CO 2 temperatures. The results of the LES simulation using a wall heat flux showed different stages in the compression process and revealed dynamical formation and interaction of CO 2 gas layers and circulation flow patterns within the chamber that contributed to the overall heat transfer between the solid wall, gas, and liquid surface in the compressor. Though an industrial partnership for commercializing the compressor was not secured, the technology was attractive for an industrial partner to use in two research proposals in response to US Department of Energy funding opportunity announcements.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Methane Leak Detection from Natural Gas Power Plants

The results of a literature review around leak detection at NG-fueled power plants are presented. The results show that leak detection methods between plants are highly variable and mostly qualitative. Flanged connections and valves are the most common leak points. Plant analytics show a correlation between vibration and %LEL. No other variables show a significant correlation.

Boeke, Seth↗
DOE OSTI2024

FY-24 Progress on Computational Modeling of the Water Based NSTF

This report summarizes the computational modeling of the Natural Convection Shutdown Heat Removal Test Facility (NSTF) completed in FY24. This year’s modeling campaign focuses on the continual testing of the RELAP5 model against experimental data. Several fault cases were simulated with the RELAP5 model in FY23 to study the accuracy of the model under complex flow conditions. Similarly, in FY24, a case is simulated where the chimney outlet is throttled with a valve while the flow is undergoing two-phase oscillations. The purpose of this case is to study the effects of increasing pressure drop in the two-phase region on the system behavior. Even though the model is able to capture the experimental data qualitatively, it overpredicts the pressure drops experienced by the flow in the two-phase regime. Nevertheless, the model and the experiment show that oscillations are stabilized with increased pressure drop in the two-phase region.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Cyber-Physical Simulation of the Cold Startup of Solid Oxide Fuel Cell – Gas Turbine (SOFC-GT) Hybrid Systems

This work introduces experimental studies for the cold startup process (CPS) of the SOFC-GT hybrid system using the cyber-physical simulation approach. The physical gas turbine is coupled with a cyber-physical SOFC stack, which is represented using the integration of a real time dynamic SOFC model with physical components (e.g., pressure chamber, natural gas burner, etc.). Different ramp rates of the turbine speed were tested out during the startup processes. Bypass valves were also used to manipulate the airflow during SOFC-GT hybrid system start-up process. Different ramp rates enable the rapid start-up of the turbine to avoid surge and stall, meanwhile enable acceptable warm rate of the fuel cell stack without damaging the cell material. CPS can enable dynamic characterizations of highly integrated systems at lower cost.

Zhou, Nana↗
DOE OSTI2024

Report on Initial Sodium Testing on the Thermal Hydraulic Experimental Test Article (THETA) (Fiscal Year 2024 Final Report)

The Thermal Hydraulic Experimental Test Article (THETA) is a facility that is used to develop sodium components and instrumentation as well as to acquire experimental data for validation of reactor thermal hydraulic and safety analysis codes. The facility simulates nominal thermal hydraulic conditions as well as protected/unprotected loss of flow accidents in a sodium-cooled fast reactor (SFR). High fidelity distributed temperature profiles of the developed flow field may be acquired with Rayleigh backscatter based optical fiber temperature sensors. The facility was designed in partnership with systems code experts to tailor the experiment to ensure the most relevant and highest quality data for code validation. THETA is comprised of a traditional primary coolant and secondary coolant system. The primary system is submerged in the pool of sodium and consists of a pump, electrically heated core, intermediate heat exchanger, and connected piping and thermal barriers (redan). The secondary system, located outside of the sodium pool, consists of a pump, sodium to air heat exchanger, and connected piping and valves. In fiscal year 2023, thermal stratification tests were completed with the primary system online, while the secondary system was being constructed [1]. These tests had shown that the core barrel and intermediate heat exchanger (IHX) outlet required increased thermal insulation. The THETA primary system was removed from METL, cleaned, thermal insulators installed, and then inserted into METL Test Vessel 4. At the time of this writing the THETA primary and secondary system are operational. During this fiscal year 100+ hours of testing was completed to characterize thermal hydraulic phenomena associated with steady state and transient conditions in a pool type liquid metal cooled reactor. A majority of the testing campaign was completed to satisfy the experimental data acquisition requirements for the GAIN Voucher with Oklo, CRADA 2021-21121. THETA is still operational at the time of this publication and future testing is planned for fiscal year 2025. Work is underway to publish existing and future data to an online database to facilitate collaboration with SFR engineers looking to validate their systems code or computational fluid dynamics models.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Heat load measurements for the PIP-II pHB650 cryomodule

This study presents a brief overview of the 1st and 2nd phases and an in-depth analysis of the 3rd phase heat load testing performed on the pHB650 (prototype High Beta 650 MHz) cryomodule at PIP2IT (PIP-II Injector Test Facility), with a focus on both the results and the methodological advancements that have improved testing efficiency and accuracy. A key challenge identified in the testing campaign is the higher-than-expected heat loads observed in the first PIP-II (Proton Improvement Plan II) prototype cryomodules (pSSR1 and pHB650) tested at PIP2IT. Elevated heat loads are concerning given the fixed capacity of the PIP-II cryoplant that is currently being installed at Fermilab. However, understanding the sources of these elevated heat loads offers a critical opportunity to implement effective heat load mitigations on upcoming PIP-II cryomodules to stay within the available capacity of the PIP-II cryoplant. The study includes a summary of test results, descriptions of measurement procedures, and key observations on parameters directly and indirectly related to heat load measurements. Direct observations include measured heat loads and the effectiveness of JT heat exchanger under varying conditions, while indirect observation analyze factors such as the temperature distribution on the two-phase pipe and relief piping under varying conditions. Thermal acoustic oscillations (TAO) were identified during testing, which was mitigated by replacing the original G10 stem with a stainless steel stem equipped with wipers for the cryomodule cooldown valve. A major innovation during pHB650 Phase 3 testing was the development of an automated Python script to streamline data acquisition, analysis, and reporting of heat load results. This script automatically retrieved data from ACNET (Accelerator Control Network), performed heat load calculations, and generated detailed reports featuring plots and tables. This advancement significantly reduced manual labor and enhanced the thoroughness of data analysis compared to earlier campaigns. The heat load test reports were promptly uploaded to the electronic logbook shortly after each test, enabling rapid feedback and collaboration between the SRF and cryogenic teams. The heat load measurements included various components: HTTS (high-temperature thermal shield), LTTS (low-temperature thermal shield), 2K isothermal and non-isothermal heat loads. Results were recorded both within the cryomodule and between the bayonet can supply and return. Measurements were conducted under different operating conditions such as "standard", "linac", and "simulated dynamic". Additionally, HTTS and LTTS heat loads were calculated in real time, allowing for the tracking of thermal stability and identification of changes during testing, both in steady-state and transient conditions. The results of this testing campaign not only provide valuable insights into the performance of the pHB650 cryomodule but also highlight best practices and lessons learned that will inform future cryomodule testing at PIP2IT. These include adopting automated tools for data analysis, refining real-time measurement capabilities, and emphasizing detailed pre-test planning. The framework established in this campaign aims to set an improved standard for cryomodule testing and heat load reporting in future cryomodule test campaigns.

Porwisiak, D. [Fermilab; Wroclaw Tech. U.]↗
DOE OSTI2025

Fermilab PIP-II CDS & CM Cryogenic Controls System

Details on Final design for Cryogenic Electrical & Controls System for Fermilab' s next-gen particle accelerator PIP-II. Electrical Controls System includes instrumentation and controls of Cryogenics Distribution System and Cryomodules. Design includes Siemens PCS7 Controls System with 26 Remote IO Rittal Cabinets and 48 Relay Racks for Temperature Readouts, Valve Positioners, Level, Heater Controls etc. Electrical Drawings and Design have been completed with focus now on fabrication of the 26 Rittal Cabinets and 48 Relay Racks. All materials have been procured. EPICS will be used as a SCADA system communicating to S7 Controllers via OPC UA.

Patel, Pratik [Fermilab]↗
DOE OSTI2025

Tritium Containment Vessel Response to Thermal and Mechanical Abuse Environments for Fire Safety Assessments

This report evaluates leakage behavior from tritium containment vessels under thermal abuse and combined thermal-mechanical abuse conditions to better understand safety implications for releases occurring in a fire scenario. Surrogate gases were used for all tests in this report. Leakage through the valves from thermal pressurization was observed when heating rates >0.8°C/s were sustained to >300°C. Gas plumes were visualized from vessels that were heated above 260°C and then dropped.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Safety Hazards of Batteries and Hydrogen Storage Systems in Proximity

This report addresses the safety concerns and mitigations for battery failures and their impact on hydrogen storage systems. Through an analysis of failure modes, this report highlights the risks posed by thermal runaway and chemical emissions caused by batteries. Although rare, battery thermal failure events may prompt the opening of the relief valve on the hydrogen tank. Strategies such as battery management systems, thermal management systems, and multiple thermally activated pressure relief devices can mitigate these risks. Potential simulations and experiments to better quantify the unique risks posed by lithium-ion batteries near tanks are suggested. Improving safety standards will enable integration of batteries and hydrogen storage systems in various energy storage technologies.

08 HYDROGEN↗
DOE OSTI2025

Lessons Learned: Summary of Insights From the HERO WEC and Waves to Water Deployments Between 2022 and 2024

In 2020, a team from the National Renewable Energy Laboratory (NREL) partnered with the East Carolina University Coastal Studies Institute to develop a small, modular, wave-powered point absorber desalination prototype. That prototype, known as the hydraulic and electric reverse osmosis wave energy converter (HERO WEC), was intended to de-risk the installation activities planned for the Waves to Water Prize sponsored by the Water Power Technologies Office. The NREL team was given approximately 18 months to design, build, bench test, and deploy the HERO WEC prototype. Since the initial HERO WEC development, it has been used for two in-lab test programs and three ocean deployments. The first in-lab test program focused on ensuring that the overall operation of the device occurred as expected and on validating the operation of safety systems such as pressure relief valves or electrical breakers for load mitigation. The second in-lab test program was the first time the NREL team leveraged NREL’s large-amplitude motion platform to characterize the performance of the HERO WEC. Of the three in-water deployments, the first deployment was effectively an installation and recovery practice with no meaningful wave activity during the time that it was installed. The second deployment was a 2-week effort that enabled both the electric and hydraulic configurations of the device to be in the water for approximately 5 days each. This deployment was also the first time that the team had the opportunity to perform a drivetrain swap on the Coastal Studies Institute research vessel. The third deployment had to be split into two separate installations due to minor damage incurred from the WEC spinning during the initial installation. This report summarizes the deployments, the challenges encountered with each deployment, and the lessons learned for future work.

16 TIDAL AND WAVE POWER↗
DOE OSTI2026

Autonomous Hydrogen Fueling Station

This project “Autonomous Hydrogen Fueling Station” covered the autonomous refueling with both gaseous hydrogen and liquid hydrogen. The part on gaseous hydrogen focused on the development of an autonomous robotic fueling arm that would couple to a fuel cell engine for hydrogen refueling without guidance from the forklift operator and budget period. Research was also covered for the robotic fueling with a commercial vehicle. The second phase of the project created the baseline for an autonomous liquid hydrogen transfer system that would minimize boil off losses by operating at thermodynamically efficient state points. For the development of the robotic fueling arm, testing was conducted to establish a baseline measurement of the accuracy and repeatability of a human operator positioning a lift truck in front of a dispenser. The goal was to establish the range of motion required for an autonomous fueling mechanism to mate a hydrogen nozzle with a receptacle on a fuel cell system installed in a forklift. The final design comprised a selective compliance articulated robot arm (SCARA)-type mechanism with two arms for horizontal motion and a ball screw for vertical movement and color and LIDAR cameras were used for marker identification and proximity awareness to guide the robotic arm to its target receptacle. Initial tests resulted in 199 out of 200 successful attempts at autonomous coupling of the dispensing coupler and a fuel cell engine, without hydrogen. The dispenser prototype was modified to include tubing for both hydrogen fuel and air purge lines, but subsequent tests were confounded by the shoulder motor over current errors which limited the robot from getting to the fully inserted position to achieve a positive latch. Robotic hydrogen refueling was successfully demonstrated over 1.5 hours of testing, Plug completed 29 successful latches with an average number of 4 sequential latches before failure. However, a robot capable of placing the nozzle with more force is required for higher reliability. For budget period two, a small scale (10 kg / transfer) automated control system was designed that would operate valves to control pressure and flow of liquid nitrogen between a source and receiving tank with an aim to minimize boil off losses by operating at the most thermodynamically efficient state points. Control system logic flow and a P&ID were developed prior to system safety characterization via HAZOP. A control narrative and system state points were defined. Delays in approval for a change of project objective and procurement issues precluded the construction and test of the final prototype system.

08 HYDROGEN↗
DOE OSTI2026

Cost Analysis of Heavy-Duty Vehicle Proton Exchange Membrane Fuel Cell Stationary Power Plants

Heavy-duty PEM fuel cells could be a low-cost, low emission alternative to combustion turbines for re-electrifying hydrogen if used as part of a long duration grid energy storage systems. Many studies expect heavy duty PEM fuel cell production costs to reduce as manufacturing volumes ramp up and their expected durability of 25,000-30,000 hours aligns well with a 30-year life for hydrogen seasonal energy storage plants that would likely operate less than 10% of the year. The labor, material, and equipment costs associated with installing PEM fuel cells and their required balance of plant for stationary applications have not been thoroughly explored, however. This study performs a detailed design and cost analysis of a 100 MW stationary PEM fuel cell power plant, capturing costs such as cooling, power electronics, pipes, valves, fittings, cabling, conduit, concrete foundations, buildings, and land. It employs methods consistent with NLR's solar PV benchmarking cost analysis and annual technology baseline to derive the total installed costs of stationary PEM fuel cell plants that utilize heavy duty PEM fuel cells.

08 HYDROGEN↗
DOE OSTI2025

Conceptual Design of a Water Tank Critical Facility for SPARC

Critical experiments, sometimes referred to zero-power reactors, are crucial tools in developing and validating nuclear physics predictions and thus an indispensable capability to ensure criticality safety during all parts of the nuclear fuel cycle and in reducing uncertainties in reactor physics predictions toward optimizing nuclear energy production. The System Physics Advanced Reactor Facility (SPARC) project was recently initiated to enable large-scale criticality experiments using a horizontal split table machine well suited toward solid core materials systems (fuel, moderator, reflector). The facility selected for this mission was a former pool-type research reactor building and thus also well suited toward a second critical experiment capability able to house full-size light-water reactor (LWR) fuel bundles. A conceptual design study was undertaken to review past water tank critical experiments used for LWR physics experiments and to develop an early engineering design for a new critical assembly tank (CAT). The work described here shows that a relatively simple CAT concept can be constructed and deployed in the SPARC facility to meet the urgent demands for new critical experiments on advanced LWR fuel bundles designs. The SPARC facility layout is conducive to the receipt and upending of LWR fuel bundles using existing containers and equipment from the LWR industry. The facility’s overhead crane can then be used to handle fuel bundles and place them in a vertical storage rack or in the CAT for critical experiments, both of which fit within the building’s “open basement” alongside other equipment planned for SPARC and the horizontal split table. A slightly lower area in the basement can serve as a large drain tank so that fail-safe valves drain the CAT reactor tank for safe shutdown. Neutronic configurations were determined where a 3 × 3 array of fuel bundles can be surrounded by full-length “loose rods” to adjust reactivity so that critical is achieved when the bundles are fully submerged. Viable configurations were determined for both pressurized- and boiling-water-reactor-type fuel bundles. This design concept was used to develop an early planning basis for establishing the CAT capability alongside the otherwise planned SPARC project in order to help streamline the process. Recent presidential executive orders have highlighted the need to achieve power uprates in LWR plants and the CAT capability will be a crucial element of these initiatives. Based on the work described herein, it is recommended that an earnest and timely project begin in order to establish this urgently needed capability.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Ultra Wide Bandgap Laser Addressable Photoconductors

Wide Band Gap (WBG) and Ultra Wide Band Gap (UWBG) photoconductors have the potential to meet several critical mission needs for LLNL and the broader USG due to their exceptional characteristics related to large critical electric field. In particular, high energy laser systems such as the National Ignition Facility would benefit from the development of new materials for active optical devices such as the Optically Addressable Light Valve (OALV) used in the Programmable Spatial Shaper System. Missions in Global Security would benefit from higher performance Photoconductive Semiconductor Switches for pulsed power and radiofrequency amplifiers. This project examined the suitability of both commercially available and custom synthesized semi insulating WBG and UWBG materials for several of these applications. We developed high laser damage threshold OALVs for optical systems based on several of these materials as well as new RF, pulsed power, and power electronics devices based on the same. These devices show superior power handling in terms of laser damage threshold, electric field, and power output. A number of the technologies developed have been transitioned to both internal and external customers.

42 ENGINEERING↗