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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 1,063 records · Page 59
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

A Generalized Grain-Scale Model for the Non-Plasma and Plasma-Assisted Hydrogen Direct Reduction of Iron Ore

Direct Reduction of Iron ore using hydrogen (H-DRI) is a promising pathway towards efficient steelmaking and accurate predictive models are a necessity for scale-up and optimization of this technology. However, accurate models of this process remain limited because existing models oversimplify grain-scale phenomena, such as nonlinearity inside grain, self-sufficient porosity, surface reactions, and the role of plasma species. These phenomena are important for flash steelmaking and plasma-assisted H-DRI processes. To address this need, we present a phenomenological model for simulating H-DRI at the scale of a single micron-sized grain of the iron ore. We call this the Transient Reactive Grain Model (TRGM). TRGM incorporates key physical process: gas species transport, a chemical kinetics of material conversion, nanopore structural evolution and, adsorption-desorption surface kinetics at the reactive nanopore surface. The important contribution of this work is that the model provides a dependence on different reductant species, specifically hydrogen atoms versus molecules, so that role of hydrogen plasma reduction can be clarified compared to the use of pure hydrogen gas reduction. TRGM predictions agree well with experimental data for both molecular H2 reduction of Fe2O3 and plasma hydrogen reduction of Fe3O4. Results reveal species concentration gradients with a diffuse reaction zone, and enhanced hydrogen diffusion at the grain outer surface due to evolving porosity. These findings challenge common assumptions in existing models, including sharp reaction fronts, quasi-steady diffusion and kinetics, and the neglect of surface chemistry. As a generalized grain-scale model for H-DRI processes, TRGM has practical applications in flash steelmaking and in-flight reduction using both molecular and plasma hydrogen.

08 HYDROGEN↗
DOE OSTI2025

Extending SST vanadis to Add SIMT Functional Units

Sandia National Laboratories is currently investigating scalable architectural simulation capabilities, with a focus on simulating and evaluating highly scalable supercomputers for high-performance computing applications. This exploration is driven by the shift toward more specialized forms of compute and the need for a more diverse set of accurate models. This project will explore the use of General-Purpose Graphical Processing Units (GPGPUs) in high-performance computing using both physical systems and new simulator models – traditional GPUs as well as tightly-coupled SIMT accelerators.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2016

Validation of gamma-ray detection techniques for safeguards monitoring at natural uranium conversion facilities

Recent IAEA circulars and policy papers have sought to implement safeguards when any purified aqueous uranium solution or uranium oxides suitable for isotopic enrichment or fuel fabrication exists. Under the revised policy, IAEA Policy Paper 18, the starting point for nuclear material under safeguards was reinterpreted, suggesting that purified uranium compounds should be subject to safeguards procedures no later than the first point in the conversion process. In response to this technical need, a combination of simulation models and experimental measurements were employed to develop and validate concepts of nondestructive assay monitoring systems in a natural uranium conversion plant (NUCP). In particular, uranyl nitrate (UO 2 (NO 3 ) 2 ) solution exiting solvent extraction was identified as a key measurement point (KMP), where gamma-ray spectroscopy was selected as the process monitoring tool. The Uranyl Nitrate Calibration Loop Equipment (UNCLE) facility at Oak Ridge National Laboratory was employed to simulate the full-scale operating conditions of a purified uranium-bearing aqueous stream exiting the solvent extraction process in an NUCP. Nondestructive assay techniques using gamma-ray spectroscopy were evaluated to determine their viability as a technical means for drawing safeguards conclusions at NUCPs, and if the IAEA detection requirements of 1 significant quantity (SQ) can be met in a timely way. This work investigated gamma-ray signatures of uranyl nitrate circulating in the UNCLE facility and evaluated various gamma-ray detector sensitivities to uranyl nitrate. These detector validation activities include assessing detector responses to the uranyl nitrate gamma-ray signatures for spectrometers based on sodium iodide, lanthanum bromide, and high-purity germanium detectors. The results of measurements under static and dynamic operating conditions at concentrations ranging from 10–90 g U/L of natural uranyl nitrate are presented. A range of gamma-ray lines is examined, including attenuation for transmission measurement of density and concentration. It was determined that transmission-corrected gamma-ray spectra provide a reliable way to monitor the 235 U concentration of uranyl nitrate solution in transfer pipes in NUCPs. Furthermore, existing predictive and analysis methods are adequate to design and realize practical designs. The 137 Cs transmission source employed in this work is viable but not optimal for 235 U densitometry determination. Validated simulations assessed the viability of 133 Ba and 57Co as alternative densitometry sources. All three gamma-ray detectors are viable for monitoring natural uranium feed; although high-purity germanium is easiest to interpret, it is, however, the least attractive as an installation instrument. Overall, for monitoring throughput in a facility such as UNCLE, emulating the uranium concentration and pump speeds of the Springfields conversion facility in the United Kingdom, an uncertainty of less than 0.17% is required in order to detect the diversion of 1 SQ of uranyl nitrate through changes in uranium concentration over an accountancy period of one year with a detection probability of 50%. As a result, calibrated gamma-ray detection systems are capable of determining the concentration of uranium content in NUCPs, it is only in combination with verifiable operator declarations and supporting data, such as flow rate and enrichment, that safeguards conclusions can be drawn.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2019

Neutron Star Mergers Might Not Be the Only Source of r -process Elements in the Milky Way

Probing the origin of r -process elements in the universe represents a multidisciplinary challenge. We review the observational evidence that probes the properties of r -process sites, and address them using galactic chemical evolution simulations, binary population synthesis models, and nucleosynthesis calculations. Our motivation is to define which astrophysical sites have significantly contributed to the total mass of r -process elements present in our Galaxy. We found discrepancies with the neutron star (NS–NS) merger scenario. When we assume that they are the only site, the decreasing trend of [Eu/Fe] at [Fe/H] > -1 in the disk of the Milky Way cannot be reproduced while accounting for the delay-time distribution (DTD) of coalescence times ( ∝t -1 ) derived from short gamma-ray bursts (GRBs) and population synthesis models. Steeper DTD functions ( ∝t -1.5 ) or power laws combined with a strong burst of mergers before the onset of supernovae (SNe) Ia can reproduce the [Eu/Fe] trend, but this scenario is inconsistent with the similar fraction of short GRBs and SNe Ia occurring in early-type galaxies, and it reduces the probability of detecting GW170817 in an early-type galaxy. One solution is to assume an additional production site of Eu that would be active in the early universe, but would fade away with increasing metallicity. If this is correct, this additional site could be responsible for roughly 50% of the Eu production in the early universe before the onset of SNe Ia. Rare classes of supernovae could be this additional r -process source, but hydrodynamic simulations still need to ensure the conditions for a robust r -process pattern.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2016

Collaborative Project: Building improved optimized parameter estimation algorithms to improve methane and nitrogen fluxes in a climate model

Soils in natural and managed ecosystems and wetlands are well known sources of methane, nitrous oxides, and reactive nitrogen gases, but the magnitudes of gas flux to the atmosphere are still poorly constrained. Thus, the reasons for the large increases in atmospheric concentrations of methane and nitrous oxide since the preindustrial time period are not well understood. The low atmospheric concentrations of methane and nitrous oxide, despite being more potent greenhouse gases than carbon dioxide, complicate empirical studies to provide explanations. In addition to climate concerns, the emissions of reactive nitrogen gases from soils are important to the changing nitrogen balance in the earth system, subject to human management, and may change substantially in the future. Thus improved modeling of the emission fluxes of these species from the land surface is important. Currently, there are emission modules for methane and some nitrogen species in the Community Earth System Model’s Community Land Model (CLM-ME/N); however, there are large uncertainties and problems in the simulations, resulting in coarse estimates. In this proposal, we seek to improve these emission modules by combining state-of-the-art process modules for emissions, available data, and new optimization methods. In earth science problems, we often have substantial data and knowledge of processes in disparate systems, and thus we need to combine data and a general process level understanding into a model for projections of future climate that are as accurate as possible. The best methodologies for optimization of parameters in earth system models are still being developed. In this proposal we will develop and apply surrogate algorithms that a) were especially developed for computationally expensive simulations like CLM-ME/N models; b) were (in the earlier surrogate optimization Stochastic RBF) demonstrated to perform very well on computationally expensive complex partial differential equations in earth science with limited numbers of simulations; and, c) will be (as part of the proposed research) significantly improved both by adding asynchronous parallelism, early truncation of unsuccessful simulations, and the improvement of both serial and parallel performance by the use of derivative and sensitivity information from global and local surrogate approximations S(x) . The algorithm development and testing will be focused on the CLM-ME/N model application, but the methods are general and are expected to also perform well on optimization for parameter estimation of other climate models and other classes of continuous multimodal optimization problems arising from complex simulation models. In addition, this proposal will compile available datasets of emissions of methane, nitrous oxides and reactive nitrogen species and develop protocols for site level comparisons with the CLM-ME/N. Once the model parameters are optimized against site level data, the model will be simulated at the global level and compared to atmospheric concentration measurements for the current climate, and future emissions will be estimated using climate change as simulated by the CESM. This proposal combines experts in earth system modeling, optimization, computer science, and process level understanding of soil gas emissions in an interdisciplinary team in order to improve the modeling of methane and nitrogen gas emissions. This proposal thus meets the requirements of the SciDAC RFP, by integrating state-of-the-art computer science and earth system to build an improved earth system model.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2015

Predicting the mineral composition of dust aerosols – Part 2: Model evaluation and identification of key processes with observations

A global compilation of nearly sixty measurement studies is used to evaluate two methods of simulating the mineral composition of dust aerosols in an Earth system model. Both methods are based upon a Mean Mineralogical Table (MMT) that relates the soil mineral fractions to a global atlas of arid soil type. The Soil Mineral Fraction (SMF) method assumes that the aerosol mineral fractions match the fractions of the soil. The MMT is based upon soil measurements after wet sieving, a process that destroys aggregates of soil particles that would have been emitted from the original, undisturbed soil. The second method approximately reconstructs the emitted aggregates. This model is referred to as the Aerosol Mineral Fraction (AMF) method because the mineral fractions of the aerosols differ from those of the wet-sieved parent soil, partly due to reaggregation. The AMF method remedies some of the deficiencies of the SMF method in comparison to observations. Only the AMF method exhibits phyllosilicate mass at silt sizes, where they are abundant according to observations. In addition, the AMF quartz fraction of silt particles is in better agreement with measured values, in contrast to the overestimated SMF fraction. Measurements at distinct clay and silt particle sizes are shown to be more useful for evaluation of the models, in contrast to the sum over all particles sizes that is susceptible to compensating errors, as illustrated by the SMF experiment. Model errors suggest that allocation of the emitted silt fraction of each mineral into the corresponding transported size categories is an important remaining source of uncertainty. Evaluation of both models and the MMT is hindered by the limited number of size-resolved measurements of mineral content that sparsely sample aerosols from the major dust sources. In conclusion, the importance of climate processes dependent upon aerosol mineral composition shows the need for global and routine mineral measurements.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

Impacts of feedstock properties on the process economics of fast-pyrolysis biorefineries

Feedstock properties are an important factor affecting process yields and economics of fast pyrolysis biorefineries. Here, this study develops a fast pyrolysis process model sensitive to feedstock properties based on the experimental results. 64 simulations are run to evaluate the impacts of carbon, ash and moisture content in biomass feedstocks on process yields and energy consumptions. An economic analysis is conducted for each run to quantify process economics under different feedstock properties. With biomass feedstocks of 48% carbon and 15% moisture, Minimum Fuel Selling Price (MFSP) increases from 0.97/L to 1.06/L when ash content increases from 1% to 7%, due to reduced hydrocarbon yields. With biomass feedstocks of 48% carbon and 3% ash content, MFSP increases from 1.03/L to 1.08/L when feedstock moisture increases from 15% to 45% as a consequence of increased energy demand for feedstock drying. Finally, the impact of feedstock ash content decreases gradually as ash content increases. Feedstock carbon content has less significant impacts on process economics in this study.

09 BIOMASS FUELS↗
DOE OSTI2015

Phase-field simulations of GaN growth by selective area epitaxy from complex mask geometries

Three-dimensional phase-field simulations of GaN growth by selective area epitaxy were performed. The model includes a crystallographic-orientation-dependent deposition rate and arbitrarily complex mask geometries. The orientation-dependent deposition rate can be determined from experimental measurements of the relative growth rates of low-index crystallographic facets. Growth on various complex mask geometries was simulated on both c-plane and a-plane template layers. Agreement was observed between simulations and experiment, including complex phenomena occurring at the intersections between facets. The sources of the discrepancies between simulated and experimental morphologies were also investigated. The model provides a route to optimize masks and processing conditions during materials synthesis for solar cells, light-emitting diodes, and other electronic and opto-electronic applications.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2016

Laser pulse driven terahertz generation via resonant transition radiation in inhomogeneous plasmas

An intense, short laser pulse propagating across a plasma boundary ponderomotively drives THz radiation. Full format PIC simulations and theoretical analysis are conducted to investigate the properties of this radiation. Simulation results which show the THz emission originates in regions of varying density and covers a broad spectrum with maximum frequency close to the maximum plasma frequency. In the case of a sharp vacuum-plasma boundary, the radiation is generated symmetrically at the plasma entrance and exit, and its properties are independent of plasma density when the density exceeds a characteristic value determined by the product of the plasma frequency and the laser pulse duration. For a diffuse vacuum-plasma boundary, the emission from the plasma entrance and exit is asymmetric: increasing and decreasing density ramps enhance and diminish the radiated energy, respectively. Enhancements by a factor of 50 are found and simulations show that a 1.66 J, 50 fs driver pulse can generate ∼400 μJ of THz radiation in a 1.2 mm increasing density ramp. We present a model that attributes this effect to a plasma resonance process in the density ramp. The results from the model match those of the simulations for ramp lengths less than 600 μm. For longer ramps for which simulations are too time consuming, the model shows that the amount of radiation reaches a maximum at a ramp length determined by collisional absorption.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Advancing the Understanding of Cloud Microphysical Processes and Aerosol Indirect Effects in High-Latitude Mixed-Phase Clouds by Linking ARM Measurements with Climate Model Simulations (Final Report)

The key objectives of this project were to advance our understanding of cloud microphysical characteristics and aerosol indirect effects on mixed-phase clouds in high latitudes. To improve the representation of ice and mixed-phase clouds in Earth System Models (ESMs), we propose an integrated observation and modeling study of cloud macro- and microphysical properties, including spatial heterogeneities, mass partitioning between ice crystals and supercooled liquid water, effects of ice nucleating particles (INPs), and efficiency of secondary ice production (SIP), etc. Specifically, we took four main approaches in this project: (1) examining macro- and microphysical properties of ice and mixed-phase clouds based on in-situ and ground-based observations from multiple field campaigns funded by the U.S. Department of Energy (DOE) Atmospheric Radiation Measurement (ARM) program, including the Mixed-Phase Arctic Cloud Experiment (M-PACE), Indirect and Semi-Direct Aerosol Campaign (ISDAC), Ice Nucleating Particle Sources at Oliktok Point (INPOP), ARM West Antarctic Radiation Experiment (AWARE), Measurements of Aerosols, Radiation, and Clouds over the Southern Ocean (MARCUS), and Macquarie Island Cloud and Radiation Experiment (MICRE); (2) evaluating the DOE Energy Exascale Earth System Model (E3SM) simulations based on observations, particularly for ice and mixed-phase cloud microphysical properties; (3) examining the impacts of INPs on ice and mixed-phase clouds. Specifically, a series of comparisons were conducted using observations over the Arctic, Southern Ocean, and Antarctica, including comparisons between the lower and higher southern latitudes as well as comparisons between the northern and southern hemispheres. In addition, aerosol indirect effects from distinct sources of dust particles were examined; and (4) investigating the impacts of SIP. Ultimately, these results helped to improve cloud microphysics and aerosol-cloud interaction parameterizations in the E3SM model. Overall, the project provided improved understanding regarding various factors, including thermodynamic, dynamic, and aerosol conditions, on the micro- and macrophysical properties of ice and mixed-phase clouds in the high latitudes. Resulting analysis helped to provide an improved physical basis for refining the current cloud microphysics parameterizations related to ice and mixed-phase clouds in E3SM.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2015

Theoretical detection threshold of the proton-acoustic range verification technique

Purpose: Range verification in proton therapy using the proton-acoustic signal induced in the Bragg peak was investigated for typical clinical scenarios. The signal generation and detection processes were simulated in order to determine the signal-to-noise limits. Methods: An analytical model was used to calculate the dose distribution and local pressure rise (per proton) for beams of different energy (100 and 160 MeV) and spot widths (1, 5, and 10 mm) in a water phantom. In this method, the acoustic waves propagating from the Bragg peak were generated by the general 3D pressure wave equation implemented using a finite element method. Various beam pulse widths (0.1–10 μs) were simulated by convolving the acoustic waves with Gaussian kernels. A realistic PZT ultrasound transducer (5 cm diameter) was simulated with a Butterworth bandpass filter with consideration of random noise based on a model of thermal noise in the transducer. The signal-to-noise ratio on a per-proton basis was calculated, determining the minimum number of protons required to generate a detectable pulse. The maximum spatial resolution of the proton-acoustic imaging modality was also estimated from the signal spectrum. Results: The calculated noise in the transducer was 12–28 mPa, depending on the transducer central frequency (70–380 kHz). The minimum number of protons detectable by the technique was on the order of 3–30 × 10{sup 6} per pulse, with 30–800 mGy dose per pulse at the Bragg peak. Wider pulses produced signal with lower acoustic frequencies, with 10 μs pulses producing signals with frequency less than 100 kHz. Conclusions: The proton-acoustic process was simulated using a realistic model and the minimal detection limit was established for proton-acoustic range validation. These limits correspond to a best case scenario with a single large detector with no losses and detector thermal noise as the sensitivity limiting factor. Our study indicated practical proton-acoustic range verification may be feasible with approximately 5 × 10{sup 6} protons/pulse and beam current.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2016

Large Scale GPU Accelerated PPMLR-MHD Simulations for Space Weather Forecast

PPMLR-MHD is a new magnetohydrodynamics (MHD) model used to simulate the interactions of the solar wind with the magnetosphere, which has been proved to be the key element of the space weather cause-and-effect chain process from the Sun to Earth. Compared to existing MHD methods, PPMLR-MHD achieves the advantage of high order spatial accuracy and low numerical dissipation. However, the accuracy comes at a cost. On one hand, this method requires more intensive computation. On the other hand, more boundary data is subject to be transferred during the process of simulation. In this work, we present a parallel hybrid solution of the PPMLR-MHD model implemented using the computing capabilities of both CPUs and GPUs. We demonstrate that our optimized implementation alleviates the data transfer overhead by using GPU Direct technology and can scale up to 151 processes and achieve significant performance gains by distributing the workload among the CPUs and GPUs on Titan at Oak Ridge National Laboratory. The performance results show that our implementation is fast enough to carry out highly accurate MHD simulations in real time.

Computer Science↗
DOE OSTI2019

Simulation of Gas Production from Multilayered Hydrate-Bearing Media with Fully Coupled Flow, Thermal, Chemical and Geomechanical Processes Using TOUGH + Millstone. Part 1: Numerical Modeling of Hydrates

TOUGH + Millstone has been developed for the analysis of coupled flow, thermal and geomechanical processes associated with the formation and/or dissociation of CH4-hydrates in geological media. It is composed of two constituent codes: (a) a significantly enhanced version of the TOUGH + HYDRATE simulator, V2.0, that accounts for all known flow, physical, thermodynamic and chemical processes associated with the behavior of hydrate-bearing systems undergoing changes and includes the most recent advances in the description of the system properties, coupled seamlessly with (b) Millstone V1.0, a new code that addresses the conceptual, computational and mathematical shortcomings of earlier codes used to describe the geomechanical response of these systems. The capabilities of TOUGH + Millstone are demonstrated in the simulation and analysis of the system flow, thermal and geomechanical behavior during gas production from a realistic complex offshore hydrate deposit. In the first paper of this series, we discuss the physics underlying the T + H hydrate simulator, the constitutive relationships describing the physical, chemical (equilibrium and kinetic) and thermal processes, the states of the CH 4 + H 2 O system and the sources of critically important data, as well as the mathematical approaches used for the development of the of mass and energy balance equations and their solution. Finally, we provide verification examples of the hydrate code against numerical results from the simulation of laboratory and field experiments.

58 GEOSCIENCES↗
DOE OSTI2026

Watershed response of the Feather River Basin, California, United States of America to future climate changes

Increasing mean annual temperatures under climate change are expected to reduce seasonal snowpack, increase evapotranspiration (ET), and alter summer baseflow in headwater watersheds worldwide. Strong regional variability in hydrologic responses highlights the need for catchment-scale, physically based models to assess future flood risk and water availability. This study examines climate-driven changes in the hydrologic response of the Upper Feather River watershed in the Sierra Nevada Mountains, California. Four priority climate models and two representative concentration pathways (RCP4.5 and RCP8.5) are used to evaluate future hydrologic responses of the watershed. Hydrologic processes are simulated using an objectively calibrated Soil and Water Assessment Tool Plus model for a historical baseline (1986–2005) and a future period 2070–2099), driven by observed and projected precipitation and temperature. Results indicate a declining contribution of snowfall to annual precipitation, with peak snowfall and water yield shifting 1–3 months earlier. Long-term annual maximum flows are projected to increase considerably, whereas low-flow responses are mixed, with both increases and decreases projected by the end of the century. These findings highlight the need for adaptive watershed management to enhance flood protection, water storage, and drought resilience. Future water resource planning should also account for one-to-three-month shifts in peak water yield and surface runoff due to changes in snowmelt timing and a lower snowfall-to-rainfall ratio under climate change. The modeling framework and insights are transferable to other snow-dominated headwater watersheds experiencing climate-driven change.

Tigabu, T [UC Davis]↗
DOE OSTI2017

Investigating added value of regional climate modeling in North American winter storm track simulations

Extratropical Cyclone (EC) characteristics depend on a combination of large-scale factors and regional processes. However, the latter are considered to be poorly represented in global climate models (GCMs), partly because their resolution is too coarse. This work describes a framework using possibilities given by regional climate models (RCMs) to gain insight into storm activity during winter over North America (NA). Recent past climate period (1981–2005) is considered to assess EC activity over NA using the NCEP regional reanalysis (NARR) as a reference, along with the European reanalysis ERA-Interim (ERAI) and two CMIP5 GCMs used to drive the Canadian Regional Climate Model—version 5 (CRCM5) and the corresponding regional-scale simulations. While ERAI and GCM simulations show basic agreement with NARR in terms of climatological storm track patterns, detailed bias analyses show that, on the one hand, ERAI presents statistically significant positive biases in terms of EC genesis and therefore occurrence while capturing their intensity fairly well. On the other hand, GCMs present large negative intensity biases in the overall NA domain and particularly over NA eastern coast. In addition, storm occurrence over the northwestern topographic regions is highly overestimated. When the CRCM5 is driven by ERAI, no significant skill deterioration arises and, more importantly, all storm characteristics near areas with marked relief and over regions with large water masses are significantly improved with respect to ERAI. Conversely, in GCMdriven simulations, the added value contributed by CRCM5 is less prominent and systematic, except over western NA areas with high topography and over the Western Atlantic coastlines where the most frequent and intense ECs are located. Despite this significant added-value on seasonalmean characteristics, a caveat is raised on the RCM ability to handle storm temporal ‘seriality’, as a measure of their temporal variability at a given location. In fact, the driving models induce some significant footprints on the RCM skill to reproduce the intra-seasonal pattern of storm activity.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2019

Modeling and Simulation of Porosity in Spray Deposition

Numerical models, consisting of interstitial porosity model and gas porosity model, have been developed to predict the porosity in the spray deposition process. The interstitial porosity model is based on the assumption of liquid feeding in the porous mushy layer of the deposit. The porosity fraction is related to the particle packing density and the amount of the feeding flow during solidification. The gas porosity model is based on the diffusion kinetics of gas pore formation. A numerical simulation of spray deposition for a billet was carried out by coupling the porosity model with the shape and heat-transfer models. The volume fraction and distribution of the porosity were investigated. As a result of the experimental verification, the simulation results showed good agreement with the experimental data. As applications, the models were used to investigate the influence of spray process parameters on porosity formation. The investigation demonstrated that the porosity is substantially influenced by the temperature of the impinging layer and the preheating of the substrate.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Pilot Testing of a Modular Oxygen Production System Using Oxygen Binding Adsorbents (Final Report)

In this project, RTI and Air Liquide have focused on the development of innovative oxygen separation materials and technologies based on reversibly binding of oxygen to enable smaller and cheaper air separations. In alignment with that object the team has had multiple achievements to advance the technology including: Synthesized and characterized novel M-CoSalen (RTIO2Sorb-1) material which showed a dynamic oxygen adsorption capacity in excess of 1wt%. Developed synthesis routes for RTIO2Sorb-1 with commercially relevant techniques and produced batches of 0.25kg and over 4 kg of total synthesis. Synthesized and characterized extrudate forms of the RTIO2Sorb-1 with relevant crush strength and maintained dynamic oxygen adsorption capacity in near 1wt%. Developed techniques for forming structured beds in fiber shapes with conventional materials. Developed a model for O 2 sorption processes to analyze various bed configurations and cycle parameters. Studied classic O 2 solid sorbents reported in the literature to learn oxygen binding mechanisms. Design a 10 kg/day O 2 VPSA pilot system with 2 or 4-bed operation. Completed a techno-economic analysis based on the experimental results and modeling. The overall objective of the project was to design, fabricate, and test a modular O 2 production system and perform a techno-economic analysis (TEA) after testing to determine the cost-benefit of the advanced modular air separation system. The goals of this technology development project were to achieve a bed-size factor (BSF) of less than 600 lb-adsorbent/TPD O 2 (ton/day O 2 ) (as compared with the state-of-the-art BSF of 850), and O 2 -purity greater than 95% at a cost that is projected to be equivalent or lower than the current state of the art (SOTA), commercially available large-scale cryogenic air separation systems. To achieve these goals and objective, the project team executed on (1) oxygen binding adsorbent optimization and scale up, (2) adsorbent material formation process studies to form the adsorbent material into structured beds for rapid pressure swing adsorption (PSA) cycles with low pressure drop, fast mass transfer, and low attrition, (3) cycle development studies to optimize the PSA process, and (4) develop simulation tools for rapid cycle modeling and numerical evaluation/optimization.

20 FOSSIL-FUELED POWER PLANTS↗