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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 OSTI2024

High Fidelity Simulations of Air-Cooled Reactor Cavity Cooling System

High Temperature Gas Reactor (HTGR) designs incorporate passive safety systems (e.g., the Reactor Cavity Cooling System [RCCS]) that utilize natural principles to manage heat dissipation from the reactor pressure vessel (RPV) during accidents or routine shutdowns. The industry community is experiencing a pressing need for advanced simulation tools that can accurately assess the performance of these types of systems. In the literature, a knowledge gap exists concerning high-fidelity data for the RCCS, and this gap is one of the areas of focus of the present study. This research focuses on a specific RCCS designed for General Atomics' Modular High-Temperature Gas Reactor (GA-MHTGR). Experimental studies on a scaled version (can be seen in Figure 1) of the air-cooled RCCS used in GA-MHTGR were conducted by the University of Wisconsin-Madison (UW-Madison). This work contributes to a broader initiative aimed at establishing a numerical benchmark based on the UW-Madison experiments.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Experimental Study of Thermal Management and Enhancement of Adsorption-Based Onboard Hydrogen Storage System

Abstract Although hydrogen has one of the highest specific energies, its energy density in terms of volume is very poor compared to liquid fuels. Thus, to achieve attractive energy density for hydrogen, either high-pressure compression or a storage method is needed. For onboard (vehicles) hydrogen storage, up to 700 bars are needed for commercial fuel cell vehicles. This creates extreme requirements for material strength and thus safety concerns. A new metal-organic framework 5 (MOF-5) was selected as the adsorbent for H2 storage, as it provides promising storage capacity and is commercially available. Under the same H2 storage capacity and tank volume, the adsorption system is expected several folds reduction in pressure. Under the current study, a unique thermal management design using Modular Adsorbing Tank Insert (MATI) is paired with conduction-enhanced compressed MOF-5 beds. Compared to bare beds without conduction enhancement, all beds with conduction enhancement using either aluminum pins or expanded natural graphite (ENG) have shown various levels of improvement on bed thermal response, which can potentially help expedite system charge and discharge cycle times for real applications.

Electrochemistry↗
DOE OSTI2025

Leveraging Radiofrequency Identification Success Beyond Hazardous Material Inventory Management at a National Laboratory

Effective inventory management can be overshadowed by conflicting priorities in organizational procedures, particularly in research-focused institutions such as national laboratories that handle expensive, delicate, and hazardous materials. Here, this study investigated the potential of radiofrequency identification (RFID) technology, currently used for hazardous chemical inventory, in applications with higher metal interference and absorption, specifically pressure release device (PRD) compliance and nuclear container management, at Lawrence Livermore National Laboratory (LLNL). This study was done to document best practices to enhance inventory identification speeds for inventory reconciliation and inventory recall and to explore optimal configurations for RFID implementation compared to traditional manual methods of equipment management. Tests were conducted to determine the ideal RFID tag orientation (read at angles of 0°, 90°, and 270°), various container layouts (linear, separated, curved, operational), and ID methods such as manual, barcode, and RFID performing three trials per method per orientation. Results indicated that 0° was the optimal read angle for minimizing metallic interference, and the operational and curved arrangements significantly outperformed the linear and separated configurations in read speed. 3D printed mounts were developed and tested, increasing the read range of the RFID reader by up to 235% in cases of high metallic interference. The RFID technology demonstrated an average speed increase of 65% over a simplified manual identification, which supports the conclusion that RFID is a more efficient method for large hazardous inventory management and equipment reconciliation. Additionally, capturing meta-data, such as location and date, can be used to query for inventory recall and automated updating of record information.

42 ENGINEERING↗
DOE OSTI2023

Enhanced internal condensation of R1233zd(E) on micro- and nanostructured copper and aluminum surfaces

In-tube condensation of refrigerants is an important process which affects thermal efficiency in many applications, ranging from refrigeration and air conditioning to electronics thermal management. In-tube heat transfer and pressure drop are important to heat exchanger sizing and design. Here, in this work, micro- and nanostructured surfaces are applied to the internal wetted areas of copper and aluminum mini-channels to enhance the condensation heat transfer coefficient of hydrofluorocarbon R1233zd(E) refrigerant. To achieve scalable nanomanufacturing, surfaces were uniformly structured by relying on hydrochloric acid etching of aluminum and chemical oxidation of copper. The etched aluminum surfaces exhibited a 150% increase in heat transfer coefficient compared to smooth aluminum channels at specific qualities, with a 66% heat transfer coefficient improvement for complete phase change from saturated vapor to saturated liquid. Copper oxide structures showed no discernable difference in thermal-hydraulic performance when compared to smooth copper channels. Critical dimensionless parameters governing the heat transfer enhancement were identified by varying the tube internal diameter (2.3 mm to 4.7 mm), refrigerant mass flux (50 to 300 kg/(m 2 ·s)), and refrigerant quality (0 to 1). The dimensionless parameters include the Bond number normalized to the condensate film thickness, and the Weber number modified by the vapor friction factor. The relatively small increase in pressure drop (< 10%) associated with these surface enhancements further supports the promise of this method. The scalable and cost-effective techniques used to create these aluminum microstructures may reduce manufacturing cost when compared with current enhancement approaches such as extrusion, drawing, and welding.

42 ENGINEERING↗
DOE OSTI2023

Automotive Silicon Carbide Power Module Cooling With A Novel Modular Manifold And Embedded Heat Sink

The next generation of integrated power electronics packages will implement wide-bandgap devices with ultrahigh device heat fluxes. Although jet impingement has received attention for power electronics thermal management, it is not used in commercial electric vehicles (EVs) because of the associated pressure drop and reliability concerns. Here, in this paper, we present a modular thermal management system designed for automotive power electronics. The system achieves superior thermal performance to benchmarked EVs, while adhering to reliability standards and with low pumping power. The system utilizes a low-cost and lightweight plastic manifold to generate jets over an optimized heat sink, which is embedded in the direct-bonded-copper (DBC) substrate. The embedded heat sink concept leverages additive manufacturing to add elliptical pin fins to the DBC substrate. The heat sink geometry is optimized for submerged jet impingement using a unit-cell model and an exhaustive search algorithm. The model predictions are validated using unit-cell experiments. A full-scale power module model is then used to compare the DBC-embedded heat sink against direct DBC cooling and baseplate-integrated heat sinks for single-sided (SS) and double-sided (DS) cooling concepts. Using the SS and DS DBC-embedded cooling concepts, the models predict a thermal resistance that represents a reduction of 75% and 85% compared to the 2015 BMW i3, respectively, for the same water-ethylene glycol inverter flow rate. We have shown that an inverter with a 100-kilo-Watt-per-liter power density is achievable with the proposed design.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

DEDUPKV: A Space-Efficient and High-Performance Key-Value Store via Fine-Grained Deduplication

Log-Structured Merge Tree (LSM-tree) based key-value stores excel in write-intensive environments but suffer from data duplication, consuming up to 49% of storage space in LSM-tree-based key-value store deployments. Traditional solutions like compression and coarse-grained file system-level deduplication introduce overhead or have limited effectiveness. In this study, we propose DedupKV, a fine-grained deduplication framework tailored for LSM-tree, maximizing data reduction efficiency while minimizing write stalls and read overheads. DedupKV features three key innovations: (1) FLUSH-integrated inline deduplication, which removes duplicates during memory-to-storage writes; (2) WAL file-based offline deduplication, repurposing write-ahead logs to avoid double writes; and (3) elastic execution, dynamically balancing inline and offline deduplication based on memory pressure and workload intensity. Additionally, dynamic granularity management reduces deduplication metadata overhead. We implemented these four ideas in RocksDB for the first time and conducted experiments in a Linux environment. Our evaluation shows that WAL file-based offline deduplication and DedupKV outperform BlobDB by 33% and 23%, respectively, in write-heavy workloads, while reducing write amplification by 1.2 ×, 2 ×, and 1.6 × for real KV datasets.

Jamil, Safdar [Sogang University]↗
DOE OSTI2024

Multi-physics Modeling of Radiative Heat Transfer and Fluid Flow for the Reactor Cavity Cooling System

High-temperature gas-cooled reactors (HTGRs) are notable for their high thermal efficiency and potential for combined heat and power applications. These reactors are particularly appealing due to their advanced passive safety features. HTGRs utilize passive safety systems that function without requiring active components like pumps or compressors during emergencies. These reactor designs depend on a Reactor Cavity Cooling System (RCCS) to manage decay heat removal from the reactor pressure vessel (RPV) during accident conditions. The RCCS consists of vertical rectangular channels known as "risers" or riser ducts positioned around the RPV. These risers receive heat from the RPV through both convective and radiative heat transfer mechanisms. Understanding the interplay of multiple physical phenomena, such as fluid dynamics, heat transfer, and neutron interactions, is essential for the effective design and operation of nuclear reactors, particularly for systems like the RCCS. Multi-physics simulations provide a comprehensive approach to studying these interactions, offering detailed insights and enhancing accuracy. They are especially important in RCCS designs, where the interaction between radiative and convective heat transfer can significantly impact system performance. By leveraging multi-physics simulations, complex reactor behaviors can be modeled without compromising the fidelity of the underlying physical processes. This work aims to establish a robust methodology for coupling multiple physical processes in an air-cooled RCCS. By focusing on validating this multi-physics approach, the study involves designing test cases that simulate various conditions to verify the numerical models employed. The outcomes of this research will provide critical insights for accurately modeling and optimizing complex nuclear systems like the RCCS.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Coexistence Praxis: The Role of Resource Managers in Wolf-Livestock Interactions on Federal Lands

In resource management, new terms are frequently introduced, reflecting ongoing evolution in the theory and practice of ecology and governance. Yet understandings of what new concepts mean, for whom, and what they imply for management on the ground can vary widely. Coexistence—a prominent concept within the literature and practices around human-wildlife conflict and predator management—is one such term: widely invoked and yet poorly defined. While for some coexistence is the latest paradigm in improving human-wildlife relations, the concept remains debated and indeed even hotly contested by others—particularly on the multiple-use public lands of the American West, where gray wolf conservation, livestock production, and the claims of diverse stakeholders share space. The multiple meanings of coexistence present serious challenges for conservation practice, as what the concept implies or requires can be contested by those most central to its implementation. In this study we examine wolf-livestock management—a classic case of human-wildlife conflict—by focusing on the experiences and perspectives of U.S. Forest Service (USFS) managers. We reviewed coexistence's multivalence in the literature, complementing semi-structured interviews conducted with USFS employees on case study forests from across the western states. Through this, we highlight the complexity and multi-dimensionality of the concept, and the unique yet under-explored perspective that resource managers bring to these debates. This work draws on insights from political ecology to emphasize the situatedness of manager practice—taking place within a broader set of relations and contextual pressures—while extending political ecologists' traditional focus on the resource user to a concern with the resource manager as a key actor in environmental conflicts. Through our engagement with the experiences and perceptions of USFS managers, who must balance conservation aims with long-established land uses like livestock grazing, we hope to clarify the various dimensions of coexistence. Our hope is that this work thus increases the possibility for empathy and collaboration among managers and stakeholders engaged in this complex socio-ecological challenge.

Martin, Jeff Vance↗
DOE OSTI2025

CO2 hydrate crystal thickening, morphology, and Raman spectroscopy in a microfluidic device

Gas hydrates are a solid, crystalline form of water that often form at low temperatures and high pressures. Carbon dioxide (CO2) hydrates may form during carbon dioxide capture and storage (CCS) processes. These solid compounds may form in CO2 pipelines, potentially leading to a full blockage and process shutdown for plug removal. On the other hand, formation of CO2 hydrates may be desired for CO2 capture and separation. In either case, understanding the growth behavior and nature of the hydrates is vital to managing these CCS processes. Using a high-pressure, transparent microfluidic reactor, the crystalline film thickening of CO2 hydrates was observed and measured through visual microscopy and Raman spectroscopy. The impact of subcooling, pressure, and CO2 flow rate was investigated, and only CO2 flow rate was found to have a significant impact on the overall thickness of the film. Visual observations and Raman spectroscopy measurements confirmed that two distinct hydrate layers formed during thickening, one which was more porous than the other. The capillary-like channels in the porous layer indicated a mechanism for mass transfer of water through the hydrate layer. A model was developed based on this observation, and it was fit to the thickening data in order to obtain mass transfer coefficients. Results of this study can be applied to CO2 hydrate formation in pipelines and near porous media used for CO2 capture.

Wadsworth, Lindsey [Colorado School of Mines, Gold↗
DOE OSTI2020

Quarterly Management Document – FY20, 1st Quarter, Physics-based Creep Simulations of Thick Section Welds in High Temperature and Pressure Applications

During the first quarter of FY20, efforts focused on calibrating a computational model using experimental data. The experimental creep data obtain from specimens containing weld metal exhibit considerable inherent variability making calibration of the computational difficult and may not result in an accurate model.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Quarterly Management Document – FY20, 2nd Quarter, Physics-based Creep Simulations of Thick Section Welds in High Temperature and Pressure Applications

During the 2nd quarter of FY20, calibration of the creep model was made using experimental creep data on base metal at temperatures between 700-800 C. The model simulated primary and secondary creep behavior at these temperatures but tended to over estimate creep strain in the tertiary regime at 700 C while underestimating it at higher temperatures. Additional issues were also discovered and will be looked at in greater detail in the 3rd quarter of FY20.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Background-Oriented Schlieren Velocimetry of Helium Coolant Flow in Additively Manufactured Channels

High-pressure helium gas cooling is an attractive solution for thermal management of the fusion blanket first wall, as this coolant is chemically and neutronically inert and separable from hydrogenic species. However, due to the low thermal mass of helium, geometric optimization of these channels is required to provide sufficient cooling at manageable flow rates and pumping burdens. Increasingly, analysis and optimization of these coolant channels rely on computational fluid dynamics (CFD) simulations, and these require relevant experimental data for turbulence model validation. Toward this end, a high-pressure helium gas flow visualization system has been employed to image the flow of helium in flow channels with one-sided heating, mimicking the blanket first wall environment. Flow of helium at 4 MPa pressure and flow rates up to 68 g/s (Reynolds number 57 000) is supplied to rectangular channel test sections, with uniform heating applied to the bottom wall of the channel at heat fluxes varied between roughly 50 and 130 kW/m2. A high-speed camera is used to image index of refraction (IOR) gradients in the fluid via background-oriented schlieren (BOS), and temperature and pressure instrumentation are used to characterize thermal-hydraulic performance of each channel. Cross correlation of time-resolved BOS images is then used to calculate time-averaged 2-D helium velocity fields. Flow in additively manufactured (AM) channels is examined in this manner, including both featureless channels and those containing baffling as a heat transfer enhancement. The flow distribution seen in the featureless case differs significantly from that seen in prior simulations, whereas the flow in the baffled case shows the predicted behavior of flow forced along the heated wall. This augmented flow distribution is seen to increase the heat transfer coefficient in the baffled test section. Here, strategies are discussed for ongoing and future validation of these simulations, with the aim of model deployment for blanket cooling design and optimization.

Additive manufacturing↗
DOE OSTI2026

Short-term electricity load forecasting: Application-driven evaluation of machine learning models across spatial and temporal scales

As we transition towards a decarbonized economy, the integration of variable renewable energy resources and new demands (e.g., electric vehicles, heat pumps) into the electricity grid places unprecedented pressure on grid operators to effectively anticipate and manage peak load. In this context, machine learning algorithms are proving to be indispensable for accurate short-term load forecasting, a crucial task to address these challenges. This study benchmarks 6 machine learning algorithms, including three neural networks and three tree-based algorithms, across various levels of spatial aggregation and time horizons (1, 4, 8, 24, and 48 h). The central contribution of this work is the comparison and analysis of load forecasting models not only based on statistical metrics, but also based on a novel error metric, which evaluates the cost implications of forecast errors for power system stakeholders. Results show that tree-based models outperform neural networks, based on statistical metrics, and yield less skewed error distributions for most spatial scales. However, through the lens of the novel error metric, neural networks are the more competitive choice, especially for forecast horizons that exceed 8 h. The study concludes with actionable recommendations to grid operators and highlights the need for the development of error metrics that link forecasting accuracy to operational costs. To promote transparency and open science, the datasets and Python code are open-sourced via a supplementary repository.

Houben, Nikolaus↗
DOE OSTI2020

Proposed Analytical Methods for Determining Filter Media Properties

High Efficiency Particulate Air (HEPA) filters, commonly used in nuclear filtration applications, are an integral part of the waste management processes in nuclear plants. HEPA filters are 99.97% efficient filtration devices characterized by their high resistance to air flow, or pressure drop. From theoretical models, the initial pressure drop across a clean filter is proven to be a function of the filter media fiber diameters and porosity of the media. These filter properties are relatively difficult to obtain with traditional manual methods; therefore, there is a need to develop analytical methods to find the fiber diameter and porosity to determine the pressure drop. Typically, these values can be found by substituting a calculated representative value based upon measured values, such as equivalent fiber diameter based upon a clean pressure drop. However, these values may also be directly recorded and measured by incorporating Scanning Electron Microscope (SEM) image analysis and other measurement methods to analyze the filter media and determine its physical properties without the need for media testing. DiameterJ, an open source Java plug-in, used with ImageJ, can process images of filter media taken by an SEM to find statistical data such as mean fiber diameter and porosity. To produce the raw data, SEM images of two filter media type samples are taken and segmented in DiameterJ using the traditional and statistical region merging segmentation algorithms. Manual segmentation is necessary after the initial segmentation by the algorithms as the images tend to be too complex for the algorithms to output with the necessary accuracy. However, complications exist in the manual segmentation process as these methods can be time intensive and prone to the individual bias of the user. This in turn can skew the final mean fiber diameter result, and lead to either an over or under prediction of the pressure drop. It was also discovered that the porosity data produced by DiameterJ is inaccurate, as the SEM analyzes the three-dimensional filter media by projecting its geometry onto a plane and analyzing it as a two-dimensional binary image. Thus, the porosity is artificially inflated through the segmentation process, rendering this result incorrect. Alternatively, density determination, gravimetric analysis, and thickness testing of the filter media is collectively used to determine the filter fiber porosity. Together, the SEM image analysis and analytical lab methods produce results through direct measurements which allow for the prediction of the initial pressure drop from clean filter media without the need for prior media testing to collect pressure data. By improving upon this proposed analytical method in the future, there is potential to streamline the process of finding these filter properties into a more direct methodology for determining the pressure drop across HEPA filters.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

Testing of Helium Cooled Metal Molybdenum Disk Target System

NorthStar Medical Radioisotopes LLC is planning to produce the important medical radioisotope molybdenum-99 (Mo-99) through a photonuclear reaction on molybdenum-100 (Mo-100). In this approach, multiple thin disks of enriched molybdenum metal will be bombarded with a 40-MeV electron beam. Because enriched Mo-100 is expensive, we intend to use as much beam power as possible to achieve maximum production yield and minimize the size of the target. This requirement leads to very high beam power density (heat deposition in the target), which sets challenging requirements for cooling. Together with scientists at Los Alamos National Laboratory, a team at Argonne National Laboratory has developed and demonstrated a cooling approach using pressurized helium, which allows for efficient heat removal. One of the challenges in this approach is the management of the heat load on the target window. The target window separates the high-pressure helium atmosphere inside the target from the vacuum in the beamline, so it is constantly under stress from differential pressure. Also, the window is cooled only by the helium gas flow from one side, making the window design challenging. High heat deposition in the target disks also imposes a strict requirement on performance of the helium cooling system and thickness of the target disks. The target disks are produced from metal powder via a press-and-sinter process. The resulting disks do not possess as high a tensile strength as solid molybdenum and might not survive the vibration from the high-velocity helium coolant and the high thermal stress from beam heating.

42 ENGINEERING↗
DOE OSTI2024

Testing of Helium-Cooled Metal Molybdenum Disk Target

NorthStar Medical Radioisotopes LLC is planning to produce an important medical radioisotope, molybdenum-99 (Mo-99), through photonuclear reaction on molybdenum-100 (Mo-100). In this approach, molybdenum metal will be bombarded with a 40-MeV electron beam. Because enriched Mo-100 is expensive, it is desired to use as much beam power as possible to achieve maximum production yield and minimize target mass. This objective leads to very high beam power density (heat deposition in the target), which sets challenging requirements for cooling. Together with scientists at Los Alamos National Laboratory, a team at Argonne National Laboratory has developed and demonstrated a cooling approach using pressurized helium, which allows for efficient heat removal. One of the main challenges in this approach is the management of the heat load on the target window. The target window separates the high-pressure helium inside the target from the vacuum in the beamline, so it is constantly under stress from differential pressure. Also, the window is cooled only by the helium gas flowing on one side, making the window cooling even more challenging. High heat deposition in the target disks also imposes a strict requirement on performance of the helium cooling system and thickness of the target disks. The target disks are produced from metal powder via a press-and-sinter process. The resulting disks do not possess tensile strength as high as solid molybdenum and might not survive the vibration from the high-velocity helium coolant and high thermal stress from beam heating. An Argonne team of scientists performed a series of tests at Argonne’s Low Energy Accelerator Facility (LEAF) [3-7]. This report describes two series of tests for scale down production target designs that utilize full-scale 29 millimeters diameter, 0.75 mm thick press-and-sintered disks. We performed two thermal tests with different beam parameters and configurations of the disk laminations. We compared the results of the window temperature measurements and cooling system parameters obtained in the experiments with those predicted by analytical calculations and Computation Flow Dynamic (CFD) simulations. Results of the experiments and calculations are presented below.

36 MATERIALS SCIENCE↗
DOE OSTI2024

The Challenges of Safe Troubleshooting Work

Troubleshooting work presents electrical and other workers with a challenging combination of physical hazards, working conditions, and time pressure, which can lead to unwanted outcomes if not carefully managed. Summaries of several incidents in which workers were injured or at risk of injury while performing troubleshooting work are presented, identifying organizational weaknesses and error precursors that contributed to each incident. The primary challenges include: Deranged equipment. Equipment that needs troubleshooting is not in a normal operating condition. Actions that are safe when the equipment is in a normal state may not be safe in the deranged state. Work planning and control. The steps taken in troubleshooting are most often determined by the results of the immediately previous diagnostic test, making effective work planning challenging. Multiple types of hazards. Most equipment will present a troubleshooting worker with several types of hazards, including hazardous energy as defined in 29 CFR 1910.147. Portions of the troubleshooting activity may be infeasible without these hazards present. Time pressure. Restoring operation of failed equipment often involves an explicit or implicit sense of urgency. There are effective methods for addressing each challenge, most of which require a combination of advance preparation and management commitment.

Mertz, David E.↗
DOE OSTI2023

ISO 50001-Based Energy Management Systems as a Practical Path for Decarbonization: Initial Findings from a Survey of Technical Assistance Cohort Participants

Organizations face rising pressure to take action to reduce their climate-affecting emissions (i.e., decarbonize). While many responses are possible, an essential approach—strategically managing their energy consumption as an essential business practice via an ISO 50001-based energy management system—is not yet widely recognized as a framework for decarbonization. This study analyzes interim survey results from 24 organizations (a 48% response rate) implementing a rigorous energy management system, one deployed by the U.S. Department of Energy as “50001 Ready”, to test whether participating organizations perceive the energy management system under development as an essential aspect of their decarbonization efforts. The results are preliminary in nature, given the ongoing nature of the program and associated data collection; however, they are sufficient to refute our hypothesis that energy management systems are perceived by organizations participating in 50001 Ready cohorts to primarily affect energy performance with little-to-no connection regarding decarbonization efforts. Major findings include that participants’ decarbonization targets and commitments are driven by market imperatives (highlighting the importance of ISO 50001 as a management system tool) and that they see energy efficiency as vital to decarbonizing. We conclude by suggesting future research directions to further establish the premise that energy management systems are an effective, efficient, and long-lasting decarbonization strategy.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗