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DOE OSTI2021

Employing Fracture Statistics to Track Cell Reliability Through Module Fabrication

In this work we demonstrate how fracture statistics may be employed to track cell reliability through module fabrication steps. We were able to detect how cell cutting equipment could reduce cell fracture strain by 25 % as well as increase its variability. A smaller reduction was found to result from the ribbon soldering operation, and all cells measured were weaker when strained in an orientation perpendicular to the gridlines. Cell fracture measurements were found to be consistent with the number of cracked cells experienced in full sized modules exposed to mechanical loading. A structural mechanics model was created to elucidate how the requisite fracture strain is developed in a cell encapsulated within a PV module and demonstrates that this strain decreases more than 50 % from its center to edge when placed within the inner loading span of four-point flexure. The associated implications on the apparent cell strength is examined with an effective volume treatment.

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

DOE OSTI2022

Rotational flexural strength of cylindrical brittle specimens

Conventional static flexural strength testing of brittle cylindrical rods only subjects a small fraction of the entire specimen's area or volume to the maximum tensile stress. Thus, a nonconservative measured strength likely results since most flaws on the surface or in the bulk are not subjected to a sufficiently high tensile stress that can cause fracture. Here, to mitigate this, a rotational flexural tester and corresponding test method were developed whereby rotation and monotonically increasing three-point flexure were superimposed to investigate fracture response of solid glass cylinders. This combination of rotation and flexure subjects more area and volume of a cylindrical test specimen to tensile stress than a standard static (nonrotating) flexural test. As anticipated, failure stresses were lower for the rotational flexural test. Expressions for effective area and volume are provided for rotating solid rods and tubes subjected to three-point, four-point, uniform, and uniformly distributed load bending configurations.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Benchmarking Demand Flexibility in Commercial Buildings and Flattening the Duck – Addressing Baseline and Commissioning Challenges

With the transition from our traditional electric grid to a cleaner grid with renewable power generation, there is a need to enable building loads to be flexible. Load shedding and shifting will be essential for flattening the “Duck” for decarbonization. This paper explored the trend in the timing of DR events as a reflection of the grid’s needs using recent four years of event data from 203 retail stores in 11 states. The events are becoming significantly shorter with 2-hour duration being the most popular; shifting to late afternoon and early evening is another trend beyond California. Benchmarking will be essential for accounting DF as a reliable grid resource. This paper addresses a challenging aspect of benchmarking – inaccuracies in counterfactual baseline methods can introduce significant DF metrics variations in addition to weather and building characteristics related factors. The conventional “10/10” with adjustment baseline method has inherent limitation by design for load shifting applications. Therefore, it is imperative to identify alternative methods. This study compared three hourly regression baseline methods with “10/10” methods using two groups of commercial buildings that participated in DR programs: (1) 121 big-box retail stores, and (2) 11 office buildings in CA. The 14-day hourly outdoor temperature regression method was found to produce least error in the tested datasets and is promising for load shifting. The paper also pointed out that commissioning issues can also be a significant barrier for achieving consistent DF performance, which building managers and utilities should be aware of.

Liu, Jingjing↗

DOE OSTI2021

Employing Fracture Statistics to Track Cell Reliability Through Module Fabrication

14 SOLAR ENERGY↗

DOE OSTI2025

Nuclear microreactor transient and load-following control with deep reinforcement learning

The economic feasibility of nuclear microreactors will depend on minimizing operating costs through advancements in autonomous control, especially when these microreactors are operating alongside other types of energy systems (e.g., renewable energy). This study explores the application of deep reinforcement learning (RL) for real-time drum control in microreactors, exploring performance in regard to load-following scenarios. By leveraging a point kinetics model with thermal and xenon feedback, we first establish a baseline using a single-output RL agent, then compare it against a traditional proportional–integral–derivative (PID) controller. This study demonstrates that RL controllers, including both single- and multi-agent RL (MARL) frameworks, can achieve similar or even superior load-following performance as traditional PID control across a range of load-following scenarios. In short transients, the RL agent was able to reduce the tracking error rate in comparison to PID by one half to one third. Over extended 300-minute load-following scenarios in which xenon feedback becomes a dominant factor, PID maintained better accuracy, but RL still remained within a 1% error margin despite being trained only on short-duration scenarios. This highlights RL’s strong ability to generalize and extrapolate to longer, more complex transients, affording substantial reductions in training costs and reduced overfitting. Furthermore, when control was extended to multiple drums, MARL enabled independent drum control as well as maintained reactor symmetry constraints without sacrificing performance---an objective that standard single-agent RL could not learn. We also found that, as increasing levels of Gaussian noise were added to the power measurements, the RL controllers were able to maintain lower error rates than PID, and to do so with at least 10% and upwards of 150% less control effort. These findings illustrate RL's potential for autonomous nuclear reactor control, laying the groundwork for future integration into high-fidelity simulations and experimental validation efforts.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

Simulation of Reverse Osmosis Membrane Compaction Using Material Point Method (MPM)

Access to fresh drinking water in the future requires effective management of industrial wastewater and water purification from available resources. In this study, we present the simulation methodology and the analysis of a Reverse Osmosis (RO) membrane under various pressure conditions using the Material Point Method (MPM). In contrast to other numerical methods, MPM solves the continuum governing equations on material points in a Lagrangian framework. The method does not require a grid connecting the material points hence making it suitable to simulate large deformations during membrane compaction. The time integration is carried out using the explicit Euler method, while the spatial discretization is performed using linear or cubic-spline shape functions. A series of planar images containing detailed pore structures obtained from X-ray tomography experiments is converted to a three-dimensional collection of material points to simulate the membrane. Compressive loads are applied to the top layer of the membrane to simulate the experiments. The membrane deformation and pore size distribution before and after load application are reported and compared with the experimental measurements. The presentation discusses the numerical methods used, the performance of the solver on high-performance computing machines, and the results of membrane compaction in detail.

ENGINEERING,MATHEMATICS AND COMPUTING↗

DOE OSTI2021

Solvent Impregnated Polymers Loaded with Liquid-Like Nanoparticle Organic Hybrid Materials for Enhanced Kinetics of Direct Air Capture and Point Source CO 2 Capture

Hybrid CO 2 capture materials, solvent impregnated polymers (SIPs), are developed based on a simple and scalable encapsulation technique to enhance CO 2 capture kinetics of water-lean solvents with high viscosity. Liquid-like nanoparticle organic hybrid materials functionalized with polyethylenimine (NOHM-I-PEI) are incorporated into a shell material and UV-cured to produce gas-permeable solid sorbents with uniform NOHMs loading (NPEI-SIPs). The CO 2 capture kinetics of NPEI-SIPs show a remarkable 50-fold increase compared to that of neat NOHM-I-PEI due to a large increase in the NOHMs-CO 2 interfacial surface area provided by the SIP design. The optimum NOHM-I-PEI loading and sorption temperature are found to be ≈49 wt% and 50 °C, respectively, and NPEI-SIPs exhibit great thermal stability over 20 CO 2 capture/sorbent regeneration temperature swing cycles. The pseudoequilibrium CO 2 loadings of NPEI-SIPs under humid conditions are as high as 3.1 mmol CO 2 g -1 NPEI - SIPs for 15 vol% CO 2 (postcombustion capture) and 1.7 mmol CO 2 g -1 NPEI - SIPs for 400 ppm (direct air capture). Overall, these findings suggest that NPEI-SIPs can effectively capture CO 2 from a wide range of CO 2 concentrations including direct air capture while allowing the flexible design of CO 2 capture reactors by combining the benefits of liquid solvents and solid sorbents.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Impacts of Control Set-Points on Battery Energy Storage Performance for Peak Shaving Application

This article presents the impact of battery energy storage system’s (BESS) control triggers on its performance during peak shaving application. With the increasing deployment of BESS for load leveling and grid capacity relief, the sensitivity of BESS performance to its set-points is yet to be investigated. Most utilities have defined thresholds for activating BESS control during peak demand leveling and baseload BESS charging. However, this study shows that without using optimal setpoints for control applications, the BESS can be under-utilized. Simulations results of the peak shaving algorithm implementation in 30-minute time step over a period of 10 years show the impact of different set-points on distribution transformer loading, line and system losses.

battery energy storage system↗

DOE OSTI2023

Infusible Thermoplastic Composites for Wind Turbine Blade Manufacturing: Fatigue Life of Thermoplastic Laminates under Ambient and Low-Temperature Conditions

Traditionally, thermoset resins such as polyesters (PE) and epoxies are used as the polymer matrix for construction of wind turbine blades. However, concern about their end-of-life treatment garners interest to use thermoplastics for increased recyclability. However, the high viscosity of molten thermoplastics inhibits their use in manufacturing wind turbine blades with injection or compression molding. A recently developed, infusible, reactive thermoplastic resin overcomes this technological barrier. Toward verifying that this recyclable resin is suitable for use in wind turbine blades, a dataset of R?=?0.1 and R?=?10 fatigue data for glass fiber-reinforced acrylic composites is provided and equal fatigue life to industry standard epoxy and unsaturated PE resin systems is demonstrated. Specifically, R?=?0.1 fatigue data for acrylic composites at room temperature and -30?degrees C for verification of low-temperature performance are tabulated. To elucidate failure mechanisms, in situ mechanical testing with X-ray computed tomography demonstrates that damage accumulation occurs by crack propagation along the fiber-matrix interface under cyclic loading. Infrared (IR) thermography predicts failure points in composites specimens with porosity defects introduced from nonideal manufacturing processes. Furthermore, these manufacturing defects are shown to compromise the fatigue life of the acrylic laminates by an order of magnitude.

effect of defects↗

DOE OSTI2021

Multi-Core Microcontroller Hardware In the Loop System for Electric Machine Control

Hardware in the Loop (HIL) is a simulation technique used to reduce the software development cycle and test control systems in a non-destructive environment. This work describes a cost effective HIL simulator on a dual core microcontroller in which one core acts as a controller and the other emulates the system under control. The emulator runs one step per Pulse Width Modulation (PWM) period in real time. To handle the computational burden and prioritize execution of simulation and control tasks, an interrupt-based software architecture with task prioritization has been developed. As a demonstration, the HIL has been implemented on a Texas Instruments TMS320F28379D dual core microcontroller, which emulates a Permanent Magnet Synchronous Machine (PMSM) with resolver feedback. Hardware peripherals are developed and tested concurrently with the control system, providing higher confidence in the software. By using the peripherals in the HIL development, the controller exercises either the HIL emulation or a pin compatible PMSM testbench. To quantify performance and validate the processor based emulator, the HIL results are compared to the preexisting testbench for accuracy benchmarking at no-load and under load for a range of operating points.

33 ADVANCED PROPULSION SYSTEMS↗

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 OSTI2022

Noble Gas Management: SBMOF 1 vs. NUCON Carbon

Pacific Northwest National Laboratory (PNNL), in collaboration with Flibe Energy, Inc., demonstrated the fabrication of metal organic frameworks (MOFs) into engineered beads to manage off-gases released from molten salt reactors. Among the many MOF options, SBMOF 1 was selected as an ideal sorbent to manage off-gases released from a molten salt reactor because its pore size is optimal. The SBMOF 1 was synthesized and fabricated into engineered particles using three different methods, with and without polymers. All the engineered particles were exposed to Co-60 radiation (1,000 kGy) to demonstrate their radiation stability. Single column breakthrough experiments were performed at different temperatures, activation conditions, flow rates, and off-gas compositions to optimize the Xe capacity at the breakthrough point and at saturation. The Xe loading in SBMOF 1 was compared with that of standard solid sorbent (Nucon carbon) under identical conditions. Based on the single column experiments, SBMOF 1 outperforms the Nucon carbon at all the temperatures and reduces the mass (to as little as 55%) of sorbent needed to achieve the same performance as carbon. The bed volume is also reduced, down to 48% of that of Nucon carbon, when the MOF is used. These results clearly demonstrate improvement in the amount of adsorbent needed and show a reduction in bed volume compared to traditional sorbent material.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Energy impacts of nationwide window upgrades in commercial buildings

This report presents comprehensive estimates of the energy impacts of nationwide commercial building window upgrades in the United States, using a conservative approach. Windows play a substantial role in determining building energy use and occupant experience. Estimates point to commercial building windows impacting loads that represent more than 6 quads (approximately 6%) of annual primary energy use in the U.S. (Harris, 2022). Beyond heating and cooling loads, windows also have effects on lighting and occupant comfort. The fastest route to improving the energy efficiency of windows in U.S. buildings is upgrading or replacing windows in existing buildings. This is due to poor performance of windows in older existing buildings compared to most new construction, low levels of window replacement, and long window service life compared to energy-using building components. Nationwide window upgrades were considered using the following technologies: • Secondary glazing systems • Double pane (clear and tinted) • Triple pane (clear and tinted) • Electrochromic glazing Nationwide upgrades provide on the order of 4%–6% site energy savings in typical buildings, or up to 26% in buildings with the highest savings potential. Electrochromic windows, with their ability to adapt dynamically to environmental conditions, can provide additional benefits, ranging from median savings of 7.2% in buildings with window to wall ratio (WWR) greater than 10% and up to 28% for some buildings. Savings increase substantially for buildings with higher WWR. This study’s approach focused on isolating the direct energy benefits from improvement in window performance, and does not take into account the following additional benefits from window retrofits, which are likely to be substantial: • Managing peak demand and enabling HVAC equipment downsizing. • Energy savings from customizing upgrades to building type and climate. • Energy savings and comfort improvements resulting from post-retrofit reductions in air leakage. • Non-energy benefits, such as occupant comfort and resilience during extreme weather.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

A Scalable, Distribution Network-Aware, Customer Privacy-Preserving Framework for Operation of Virtual Power Plants

This poster presents a hierarchical control framework for a virtual power plant that leverages behind-the-meter resources for grid services while maintaining customer privacy during setpoint disaggregation. Unlike many existing approaches, the virtual power plant model uses a hierarchical control strategy and an iterative approach to determine the optimal set point dis-aggregation without direct load control while maintaining system-level power flow and voltage constraints. The proposed approach is numerically validated on a synthetic distribution feeder in San Francisco, demonstrating the ability of the framework to provide privacy-preserving virtual power plant services.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2023

Verification Problems for Smooth Step Amplitude Load Curves in DYNA3D/Paradyn

This report documents the addition of three new verification tests in the LOADCURVE directory of the DYNA3D/Paradyn Software Quality Assurance test suite. Each test consists of a single element, where the velocities of each node are specified by either the newly added smooth step tabular load curve or another load curve option. The first test assesses the initialization and interpolation of the newly inputted load curve option through tabulated abscissa-ordinate pairs of data. The second test uses the same set of abscissa-ordinate data points and applies offset and scaling parameters available within the load curve definition. The third test defines the smooth step load curve in an original input deck, and assesses its correct redefinition using a restart file. The simulation velocities are compared to their true values at discrete points in time, and each test is verified up to numerical precision. These results confirm that the smooth step load curve option is functioning correctly and as intended.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2020

Investigating Core Gaps and the Development of Subcomponent Validation Methods for Wind Turbine Blades: Preprint

Core gaps are a common manufacturing defect observed in wind blade composite sandwich constructions, which occur when sheets of core material are not properly butted up against each other in the mold. The aim of this study was to characterize core gaps in composite sandwich constructions at the coupon scale. This was to gain an initial understanding of the defect before developing appropriate methodologies for more complex subcomponents as part of a much broader wind blade structural validation and damage tolerance program. Long beam flexure in 4-point-bending was chosen as the most appropriate loading scenario. Beam specimens were characterized with and without 10 mm core gaps in fiberglass/balsa sandwich beams. The core gaps were characterized with two separate resin systems; a Hexion epoxy and Arkema's Elium resins system (a novel, infusible thermoplastic). Results showed that the Elium beams without the core gaps were had a 15% lower static strength than their epoxy counterparts. The introduction of the core gap to the epoxy beams reduced their static strength by 35%. The Elium beams, however, exhibited negligible strength reductions with the inclusion of the core gap. Overall, this characterization study provided pertinent information with regards to core gaps as a manufacturing defect to allow for continued development of damage tolerance and subcomponent validation methodologies with the inclusion of manufacturing defects.

17 WIND ENERGY↗

DOE OSTI2021

Discrete Empirical Interpolation Method Based Dynamic Load Model Reduction

Dynamic load models add significant complexity to bulk power system time-domain simulations. The complexity is due to the large number of ordinary differential equations (ODEs) introduced by the dynamic load components such as induction motors. It is challenging to derive reduced-order models (ROMs) for dynamic loads due to the nonlinear functions in their governing equations. This paper applies the discrete empirical interpolation method enhanced proper orthogonal decomposition (DEIM-POD) to approximate the full dynamic load model with the ROM that minimizes the projection error of the nonlinear functions in dynamic load ODEs onto their dominant modes. This approach only requires evaluation of nonlinear functions at selected observation points. The observation points selected by DEIM also provide information for screening critical load buses where dynamic load model parameters contribute the most to the accuracy of ROM across multiple contingencies. The proposed approach is validated on IEEE 9-bus, WECC 179-bus and 2384-bus Polish systems.

bulk power system↗

DOE OSTI2024

Short-Term Load Forecasting Considering EV Charging Loads with Prediction Interval Evaluation

Short-term load forecasting plays a critical role in power system planning and operation. Along with the electrification of various loads, electricity demands are becoming increasingly hard to predict. Notably, the recent rise in electric vehicles (EVs) has further contributed to this unpredictability. To address this issue, this paper proposes a probabilistic load forecasting strategy utilizing Gaussian process regression, structured in a day-ahead manner. While many works focus on deterministic prediction, probabilistic forecasting offers additional insights into variability and uncertainty, enabling more flexible and reliable operation for power systems. To enhance the accuracy of the load forecasting model, the inputs include features related to EV charging habits as well as commonly used weather information. The load forecasting results are evaluated using various metrics, including conventional ones that assess the accuracy of point forecasts, as well as additional metrics that test the reliability of prediction intervals. The proposed load forecasting method is finally tested on real residential power consumption data and EV charging data sampled from real-world sources. The results prove that the new features can greatly improve the performance of the load forecasting method.

electrical vehicle↗