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All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Initial Performance Evaluation and Ranking of Thermal Energy Storage Options for Light Water Reactor Integration to Support Modeling and Simulation

This report provides an in-depth analysis of current thermal storage technologies in the marketplace as of 2019 and develops a phenomenological identification ranking table (PIRT) and Figure of Merit (FOM) study for near-term thermal energy storage technologies with light water reactor technology. Particular focus was given the NuScale reactor as part of the Joint Use Modular Plant (JUMP) program between INL, NuScale, and the Utah Associated Municipal Project (UAMPs). Ancillary service industries and technologies are explored in detail to ascertain thermodynamic requirements for integration with thermal energy storage technologies. These industries include steel manufacturing, hydrogen production, desalination, pulp and paper manufacturing. It was determined that a large percentage of these industries can make use of existing nuclear output temperatures and pressures. Storage technologies that can maintain these values are advantageous for coupling purposes. The report then analyzes ten thermal energy storage technologies, with thirteen specific systems discussed in detail regarding their potential to integrate with LWR technology. A ranking tool identified important characteristics of thermal storage and ranked each of the technologies. Concrete, molten salt, and thermal oil sensible heat storages, and steam accumulators evaluated highly. After including cost estimations and qualitatively comparing these technologies, it is recommended that either molten salt or thermal oil is used for implementation with the JUMP module. The TES project cost will likely cost between $14,000,000 and $50,000,000. The potential flexibility of a two-tank sensible heat storage system should be able to demonstrate various new uses for nuclear heat. From power peaking via steam or liquid air heat topping to process heat applications, a two-tank system should be able to best provide a constant power transfer capability to the auxiliary energy consumer. Through commencement of this work, a more refined thermal storage selection process for Nuscale and existing nuclear power plants can be conducted. The ranking system developed here can be used to re-evaluate the energy storage options periodically depending on the projected installation dates. Current results suggest two-tank thermal energy storage is the most relevant technology in the near-term.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

A New Plasma Radar Concept for Simultaneous Magnetic and Density Measurements

An innovative, compact 288GHz interferometer has been fabricated, tested, installed and successfully demonstrated on the LAPD-U magnetized plasma at UCLA. The system takes advantage of frequency modulated (FM) radar techniques to deliver a compact heterodyne system. In addition, the reflected power from the source is taken advantage of to eliminate the need for additional quasi-optical components. Electron density in LAPD-U plasma has recently been increased substantially thereby requiring a higher frequency/shorter wavelength interferometer to avoid deleterious refractive effects. This system satisfies those needs. The system uses a 96GHz varactor tuned Gunn oscillator which passes to a passive tripler. This tripler has ~3% conversion efficiency. The 288GHz radiation is then coupled to free space using a so-called dual-mode or Pickett horn. The output 288GHz beam is then coupled to an aspheric lens manufactured from low-loss, high-density polyethylene. This lens is employed to collimate the emerging beam. Small axial adjustment of the lens position can also be used to create a slowly focusing beam so as to optimize the measured signal. In addition, up-down or side-to-side adjustment of the lens can be utilized to steer the beam vertically or horizontally – again to optimize alignment. The propagating beam passes through a beam splitter and then through a water-free, bubble-free fused quartz window into the LAPD-U vacuum vessel. The beam-splitter is a thin sheet of G10 which reflects a small fraction of the incident power (~5 %) towards a zero-bias detector optimized for the frequency range from 220 to 300GHz. Note that waveguides at this frequency have dimensions of ~0.9mm x 0.45mm and so have very large conductive losses. This drives the use of quasi-optical propagation. The detector requires no DC bias and is very responsive (> 1V/mW into 1MΩ). Radiation is coupled to the detector via a similar lens-horn arrangement used for the launch. This reflected beam acts as the local oscillator or reference millimeter-wave beam for the detector. The remainder of the launched source beam then enters the LAPD-U vacuum vessel and passes through the plasma at the mid-plane until reaching the opposing port which is closed off with an aluminum flange. This flange is used as a mirror to retroreflect the incident 288GHz beam back along its path. The retroreflected beam exits the input port but does NOT couple directly into the zero-bias detector. Instead, the majority of the return power continues towards the 288GHz source. As mentioned above the transmitted beam enters the source a second time. This would appear undesirable. However, at these frequencies multipliers are highly non-linear elements which results in a significant portion of the return beam (~20%) re-emerging from the multiplier and horn and then coupling via the G10 beam-splitter to the zero-bias detector. This approach eliminated the need for a second quasi-optical beam-splitter. The system is extremely compact measuring approximately 28 inches x 20 inches. The above did not explain how heterodyne operation was achieved. As mentioned above the Gunn oscillator is able to be varactor tuned. This allows a low voltage to be applied to control the operating frequency of the Gunn oscillator. During heterodyne operation a sawtooth shaped voltage is applied to the varactor at 750kHz using an 80MHz Arbitrary Waveform Generator (AWG). This voltage changes the Gunn frequency linearly during the up-sweep which is then reset abruptly at the sawtooth crash to be immediately followed by another linear sweep. Passage through the 288GHz multiplier triples the frequency change experienced by the electromagnetic wave. These frequency changes are small – tens of megahertz. This FM radar approach results in the launched electromagnetic wave frequencies at the detector for the reference and plasma wave to be different. The approximately 10 ns delay propagation delay for the plasma beam results in the local oscillator and plasma beams NOT having an identical frequency – there is in fact a fixed difference frequency. The frequency tuning level of the Gunn oscillator is then adjusted so that there is ONE cycle of this difference frequency during each linear ramp. During the sawtooth crash or downward re-sweep this one cycle replays in reverse but on a very fast timescale. The process then repeats. Low-pass filtering eliminates the fast re-sweep to leave a pure sine wave heterodyne signal. When the plasma is present it introduces a phase delay in the sine wave (caused by the extremely small Doppler shift resulting from the optical path length change). Of course, to measure this phase change we need a reference. This is simply obtained from an arbitrary waveform generator which provides a synchronized output pulse train which again is low pass filtered to obtain a 750kHz sinusoidal voltage reference for the interferometer. The interferometer was installed on LAPD-U where it has worked reliably and has established that electron densities exceeding 1x10 13 cm -3 are routinely achieved. In addition, the system sensitivity was able to easily observe density fluctuation at frequencies up to 50kHz. FM Radar techniques have enabled a full demonstration of a compact, sensitive, high frequency (288GHz/1mm) heterodyne interferometer.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2015

Power module packaging with double sided planar interconnection and heat exchangers

A double sided cooled power module package having a single phase leg topology includes two IGBT and two diode semiconductor dies. Each IGBT die is spaced apart from a diode semiconductor die, forming a switch unit. Two switch units are placed in a planar face-up and face-down configuration. A pair of DBC or other insulated metallic substrates is affixed to each side of the planar phase leg semiconductor dies to form a sandwich structure. Attachment layers are disposed on outer surfaces of the substrates and two heat exchangers are affixed to the substrates by rigid bond layers. The heat exchangers, made of copper or aluminum, have passages for carrying coolant. The power package is manufactured in a two-step assembly and heating process where direct bonds are formed for all bond layers by soldering, sintering, solid diffusion bonding or transient liquid diffusion bonding, with a specially designed jig and fixture.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2016

TH-AB-BRA-01: A Novel Doubly-Focused Multileaf Collimator Design for MR-Guided Radiation Therapy

Purpose: To describe the physical and dosimetric properties of a novel double-stack multileaf collimator (MLC). Methods: One of the compromises made in the MLC design has been to employ linear-motion singly-divergent shapes. Because the MLC leading edge moves linearly, it is rounded to provide a consistent, albeit compromised penumbra. The MLC employed in the new linac-based MR-IGRT unit is designed to be doubly focused in that each leaf moves in an arc centered at the source, and the sides of the leaves are machined such that they lie parallel to a line between the leaf edge and the source. The curvature of the MLC keeps motors and encoders in lower magnetic field. However, high spatial-resolution leaves are difficult to manufacture to sufficiently tight tolerances and difficult to move due to restricted space on the gantry. Wider leaves alleviate this problem with less moving parts but the coarse resolution disallows treating very small lesions. This compromise has been overcome by splitting the MLC leaf bank into two sets, stacked one upon the other and offset half of a leaf width. The dosimetry has been simulated using Monte-Carlo and a 6 MV linac in a 0.35 T magnetic field. Results: The combined MLC leaf set has a spatial resolution of effectively half of the leaf width, 4mm here. The dosimetry resolution and conformality are consistent with 4mm wide MLC assisted by inverse fluence modulation. Also, because each leaf junction is backed up by the stacked leaf that lies over the junction, the problem of tongue-and-groove dosimetry has been greatly reduced. The novel MLC design allows the use of more powerful leaf motors than would be otherwise possible if a single MLC bank is employed. Conclusions: The stacked MLC will provide highly conformal dose distributions suitable for stereotactic radiation therapy of small lesions. The research was funded by ViewRay, Inc.

60 APPLIED LIFE SCIENCES↗
NASA NTRS2007

Advancement of the Wide-angle JEM-EUSO Optical System with Holographic and Fresnel Lenses

JEM-EUSO is a space mission to observe extremely high-energy cosmic rays, evolved from the previous design studies of EUSO. It is adjusted for the Japan Experiment Module (JEM) of the International Space Station (ISS). JEM-EUSO uses a wide-angle refractive telescope in near-ultraviolet wavelength region to observe from ISS the time-and-space-resolved atmospheric fluorescence images of the extensive air showers. The JEM-EUSO optics is re-designed after the ESA-Phase A studies to upgrade the light-collecting-power by using a new material CYTOP, and its overall light-collecting power is about 1.5 times higher than the ESA-Phase A baseline optics. We describe in this paper an optimized optics design that maximizes the sensitivity of JEM-EUSO, and the results of the optics manufacturing tests.

Takizawa, Y.↗
NASA NTRS2014

Combinatorial Multidomain Mesoporous Chips and a Method for Fractionation, Stabilization, and Storage of Biomolecules

A new fractionation device shows desirable features for exploratory screening and biomarker discovery. The constituent MSCs may be tailored for desired pore sizes and surface properties and for the sequestration and enrichment of extremely low abundant protein and peptides in desired ranges of the mass/charge spectrum. The MSCs are effective in yielding reproducible extracts from complex biological samples as small as 10 microliter in a time as short as 30 minutes. They are inexpensive to manufacture, and allow for scaled up production to attain the simultaneous processing of a large number of samples. The MSCs are multiplexed, label-free diagnostic tools with the potential of biological recognition moiety modification for enhanced specificity. The MSCs may store, protect and stabilize biological fluids, enabling the simplified and cost-effective collection and transportation of clinical samples. The MSC-based device may serve as a diagnostic tool to complement histopathology, imaging, and other conventional clinical techniques. The MSCs mediated identification of disease-specific protein signatures may help in the selection of personalized therapeutic combinations, in the real-time assessment of therapeutic efficacy and toxicity, and in the rational modulation of therapy based on the changes in the protein networks associated with the prognosis and the drug resistance of the disease.

Ferrari, Mauro↗
NASA NTRS1974

Lunar module voice recorder

A feasibility unit suitable for use as a voice recorder on the space shuttle was developed. A modification, development, and test program is described. A LM-DSEA recorder was modified to achieve the following goals: (1) redesign case to allow in-flight cartridge change; (2) time code change from LM code to IRIG-B 100 pps code; (3) delete cold plate requirements (also requires deletion of long-term thermal vacuum operation at 0.00001 MMHg); (4) implement track sequence reset during cartridge change; (5) reduce record time per cartridge because of unavailability of LM thin-base tape; and (6) add an internal Vox key circuit to turn on/off transport and electronics with voice data input signal. The recorder was tested at both the LM and shuttle vibration levels. The modified recorder achieved the same level of flutter during vibration as the DSEA recorder prior to modification. Several improvements were made over the specification requirements. The high manufacturing cost is discussed.

Source record↗
DOE OSTI2018

System Advisor Model (SAM) General Description (Version 2017.9.5)

This document describes the capabilities of the System Advisor Model (SAM) developed and distributed by the U.S. Department of Energy's National Renewable Energy Laboratory. The document is for potential users and others wanting to learn about the model's capabilities. SAM is a techno-economic computer model that calculates performance and financial metrics of renewable energy projects. Project developers, policy makers, equipment manufacturers, and researchers use graphs and tables of SAM results in the process of evaluating financial, technology, and incentive options for renewable energy projects. SAM simulates the performance of photovoltaic, concentrating solar power, solar water heating, wind, geothermal, biomass, and conventional power systems. The financial models are for projects that either buy and sell electricity at retail rates (residential and commercial) or sell electricity at a price determined in a power purchase agreement (PPA). SAM's simulation tools facilitate parametric and sensitivity analyses, Monte Carlo simulation and weather variability (P50/P90) studies. SAM can also read input variables from Microsoft Excel worksheets. For software developers, the SAM software development kit (SDK) makes it possible to use SAM simulation modules in their applications written in C/C plus plus, C sharp, Java, Python, MATLAB, and other languages. NREL provides both SAM and the SDK as free downloads at https://sam.nrel.gov. SAM is an open source project, so its source code is available to the public. Researchers can study the code to understand the model algorithms, and software programmers can contribute their own models and enhancements to the project. Technical support and more information about the software are available on the website.

47 OTHER INSTRUMENTATION↗
DOE OSTI2015

SU-E-T-105: An FMEA Survey of Intensity Modulated Radiation Therapy (IMRT) Step and Shoot Dose Delivery Failure Modes

Purpose: To assess the perception of TG-142 tolerance level dose delivery failures in IMRT and the application of FMEA process to this specific aspect of IMRT. Methods: An online survey was distributed to medical physicists worldwide that briefly described 11 different failure modes (FMs) covered by basic quality assurance in step- and-shoot IMRT at or near TG-142 tolerance criteria levels. For each FM, respondents estimated the worst case H&N patient percent dose error and FMEA scores for Occurrence, Detectability, and Severity. Demographic data was also collected. Results: 181 individual and three group responses were submitted. 84% were from North America. Most (76%) individual respondents performed at least 80% clinical work and 92% were nationally certified. Respondent medical physics experience ranged from 2.5–45 years (average 18 years). 52% of individual respondents were at least somewhat familiar with FMEA, while 17% were not familiar. Several IMRT techniques, treatment planning systems and linear accelerator manufacturers were represented. All FMs received widely varying scores ranging from 1–10 for occurrence, at least 1–9 for detectability, and at least 1–7 for severity. Ranking FMs by RPN scores also resulted in large variability, with each FM being ranked both most risky (1st ) and least risky (11th) by different respondents. On average MLC modeling had the highest RPN scores. Individual estimated percent dose errors and severity scores positively correlated (p<0.10) for each FM as expected. No universal correlations were found between the demographic information collected and scoring, percent dose errors, or ranking. Conclusion: FMs investigated overall were evaluated as low to medium risk, with average RPNs less than 110. The ranking of 11 FMs was not agreed upon by the community. Large variability in FMEA scoring may be caused by individual interpretation and/or experience, thus reflecting the subjective nature of the FMEA tool.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2019

Digital Twin for 3D Printing on CNC Machines

A system has been developed for 3D printing by means of arc welding in CNC machines. Modules for high-speed computation and for the training of neural networks (with feedback) may be connected to this 3D printing system so as to optimize the welding process and improve product quality. A digital twin expands the capabilities of CAM systems in preparing control programs and equipment for CNC machines.

3D PRINTING↗
DOE OSTI2023

Beyond 15 MW: A cost of energy perspective on the next generation of drivetrain technologies for offshore wind turbines

Leading wind turbine manufacturers are racing to build larger and more powerful offshore machines. Drivetrain configurations often use a permanent-magnet synchronous generator (PMSG), in either a direct-drive configuration or coupled to a gearbox. With increasing demand for critical rare-earth magnets, new generator technologies are emerging to ensure a stable and secure supply chain. We evaluate three different topologies of radial flux synchronous generators employing high field magnets with reduced or no rare-earth content: a direct-drive interior PMSG (DD-IPMSG), a geared drivetrain combining a medium speed gearbox with a PMSG (MS-PMSG), and a direct-drive low-temperature superconducting generator (DD-LTSG). We develop a conceptual design module for each of these technologies within a larger framework for full turbine design. This provides the fairest comparison between technologies at nominal power ratings from 15-25 MW, which represent the next generation of offshore wind turbines. The analyses show that if operational expenditures (OpEx) are constant across the technologies, MS-PMSG results in the lowest LCOE with reductions of up to 7% relative to DD-IPMSG. DD-LTSG also yields lower LCOE values by 2%-3% for fixed-bottom turbines and 3%-5% with a floating platform. However, results are sensitive to OpEx assumptions, with a mere 10% increase causing the conclusions to shift.

17 WIND ENERGY↗
NASA NTRS2005

On Structural Design of a Mobile Lunar Habitat With Multi- Layered Environmental Shielding

This report presents an overview of a Mobile Lunar Habitat (MLH) structural design consisting of advanced composite materials. The habitat design is derived from the cylindrical-shaped U.S. Lab module aboard the International Space Station (ISS) and includes two lateral ports and a hatch at each end that geometrically match those of the ISS Nodes. Thus, several MLH units can be connected together to form a larger lunar outpost of various architectures. For enhanced mobility over the lunar terrain, the MLH uses six articulated insect-like robotic, retractable legs enabling the habitat to .t aboard a launch vehicle. The carbon-composite shell is sandwiched between two layers of hydrogen-rich polyethylene for enhanced radiation shielding. The pressure vessel is covered by modular double-wall panels for meteoroid impact shielding supported by externally mounted stiffeners. The habitat s structure is an assembly of multiple parts manufactured separately and bonded together. Based on the geometric complexity of a part and its material system, an appropriate fabrication process is proposed.

Pruitt, J. R.↗
DOE OSTI2023

A Comparison of Generator Technologies for Offshore Wind Turbines

Leading wind turbine manufacturers are racing to build larger and more powerful offshore machines. Drivetrain configurations often use a permanent-magnet synchronous generator (PMSG), in either a direct-drive configuration or coupled to a gearbox. With increasing demand for critical rare-earth magnets, new generator technologies are emerging to ensure a stable and secure supply chain. We evaluate three different topologies of radial flux synchronous generators employing high field magnets with reduced or no rare-earth content: a direct-drive interior PMSG (DD-IPMSG), a geared drivetrain combining a medium speed gearbox with a PMSG (MS-PMSG), and a direct-drive low-temperature superconducting generator (DD-LTSG). We develop a conceptual design module for each of these technologies within a larger framework for full turbine design. This provides the fairest comparison between technologies at nominal power ratings from 15-25MW, which represent the next generation of offshore wind turbines. The analyses show that if operational expenditures (OpEx) are constant across the technologies, MS-PMSG results in the lowest LCOE with reductions of up to 7% relative to DD-IPMSG. DD-LTSG also yields lower LCOE values by 2-3% for fixed-bottom turbines and 3-5% with a floating platform. However, results are sensitive to OpEx assumptions, with a mere 10% increase causing the conclusions to shift.

direct drive↗
DOE OSTI2018

Marrying Quality Assurance with Design Engineering - A Winning Partnership! But, a Cultural Divide

Investors would like to be confident that a PV plant will work as promised before investing large sums of money. Data showing that PV modules can withstand thousands of hours of accelerated testing are a comfort, but are not sufficient to characterize the economic useful life (EUL) of the whole PV system. An inability to be confident of every aspect of the system can motivate less favorable contract terms. In the end, a winning partnership is obtained when a carefully engineered, durable design is married with a robust quality management system and the marriage is extended across all parts of the value chain. However, this marriage is challenging because of the conventional cultural divide between design engineers and quality management specialists. International standards are being developed to facilitate this partnership and include technology-specific requirements in the quality management systems used for component manufacture and system design, construction and operation.

14 SOLAR ENERGY↗
DOE OSTI2018

CNC Module for Turning: A New CAM Application

The integrated CAM application for the KOMPAS-3D environment known as CNC Module for Turning is considered. This application permits automated development of control programs for numerically controlled lathes. The user may readily adapt the CAM application for specific production conditions and machine tools, thanks to features such as the following: representation of the cutting tools by means of parametric 3D models, the possibility of including fixed CNC cycles in the control programs, and the use of the Python language for programming of the postprocessors.

42 ENGINEERING↗
DOE OSTI2015

Reversible conversion of dominant polarity in ambipolar polymer/graphene oxide hybrids

The possibility to selectively modulate the charge carrier transport in semiconducting materials is extremely challenging for the development of high performance and low-power consuming logic circuits. Systematical control over the polarity (electrons and holes) in transistor based on solution processed layer by layer polymer/graphene oxide hybrid system has been demonstrated. The conversion degree of the polarity is well controlled and reversible by trapping the opposite carriers. Basically, an electron device is switched to be a hole only device or vice versa. Finally, a hybrid layer ambipolar inverter is demonstrated in which almost no leakage of opposite carrier is found. We conclude that this hybrid material has wide range of applications in planar p-n junctions and logic circuits for high-throughput manufacturing of printed electronic circuits.

36 MATERIALS SCIENCE↗
DOE OSTI2020

A critical literature review of the advances in methane dehydroaromatization over multifunctional metal-promoted zeolite catalysts

We report the drastic rise in shale gas production has encouraged the quest for alternative uses of methane as a chemical feedstock in the manufacturing industry. While two-step syngas routes for methane valorization are deployed commercially, direct one-step routes for methane conversion are attracting much attention. As steam cracking installations have shifted from using oil-based naphtha to shale-based natural gas liquids, production of aromatics has dropped. Methane dehydroaromatization (MDA) is a one-step reaction capable of valorizing methane to hydrogen and benzene. Challenges with the MDA reaction are two-fold: the reaction is thermodynamically limited with low one-pass methane conversion and even the best catalytic systems, Mo/zeolites, suffer rapid deactivation from coking. A catalyst design strategy to improve stability is the use of multifunctional Mo-X/zeolite systems where X is a dopant capable of modulating the stability. In this paper we provide a complete overview of the main Mo-X/zeolite systems used in MDA and critically draw connections among the different types of dopants (X) employed, as a function of the role they play in the reaction/deactivation pathway. We have also dedicated a section to emerging trends with non-Mo based catalysts. The goal of this review article is to establish a basis that will facilitate the identification of useful multifunctional catalytic systems, and recognize gaps in the knowledge of these systems that deserve more attention. Improving MDA systems to the point to which they can be commercially deployed requires a multifaceted approach that combines optimization of the designs of both the catalyst and the reactor configuration. We therefore also provide a brief overview of the most recent advances in process intensification strategies employed with different reactor configurations.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗