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DOE OSTI2019

Investigation on the Surface Vortex Formation During Mechanical Stirring with an Axial-Flow Impeller Used in an Aluminum Process

The present study investigated the mechanism of surface vortex formation in an aluminum melt vessel stirred by an axial-flow impeller mechanically. The oxide film is formed at the aluminum melt/air interface, and the movement of the interface entrains the oxide film and inclusions. Hence, the transient movement of melt–air interface is significant. The present study conducted a water model experiment and numerical simulation focusing on the movement of gas–liquid interface. The present study found that the oxide film can be entrained by two phenomena: (1) local surface vortex and (2) sloshing near the vessel wall. The local surface vortex is formed due to the pressure distribution around the impeller, and the sloshing is caused by macroinstabilities, which is generated by the discharged flow of axial-flow impeller. Besides, the shape of gas–liquid interface is dependent on the impeller shape. The axial-flow impeller gives rise to steeply curved shape of gas–liquid interface near the impeller shaft.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Experimental validation of an organic rankine-vapor compression cooling cycle using low GWP refrigerant R1234ze(E)

There is a significant global opportunity to capture and utilize low grade waste heat to reduce fossil fuel consumption, greenhouse gas emissions, and improve energy efficiency across a wide range of industries. In this work, an advanced type of thermally activated cooling system, an organic Rankine-vapor compression cycle (ORVC) with novel heat integration strategies, was designed and tested at a relevant scale for industrial waste heat recovery (300 kW th cooling capacity). The ORVC linked an organic Rankine power cycle and a vapor compression cooling cycle using a turbine and compressor that shared a single shaft. The ORVC test facility absorbed waste heat from a liquid stream at 91 °C to simulate engine coolant in diesel generator sets, rejected heat to a glycol stream at 30 °C, and generated chilled water at 7 °C. A cooling capacity of 264 kW ± 3.5 kW was experimentally validated with a COP of 0.56 ± 0.01 during steady-state operation at the design temperatures. The thermal efficiency, accounting for pump work, of the Rankine cycle was 7.7% ± 0.22% and the COP of the vapor compression cycle was 5.25 ± 0.09. The centrifugal turbo-compressor operated at 31.5 kRPM ± 0.3 kRPM, with a turbine and compressor isentropic efficiencies of 76.7% ± 0.90% and 84.8% ± 0.54%, respectively, with near-perfect power transmission between these components. The pressure drop in the piping and heat exchangers were significantly larger than expected which had a detrimental impact on the performance of the ORVC. In addition, the condenser on the cooling cycle could not deliver the subcooling as specified from the design point modeling. Furthermore, the results from the sensitivity analysis showed that the higher condenser glycol outlet temperature had the largest impact on performance, which is consistent with other analytical models in the literature. When the ORVC simulations were updated with experimental values for isentropic efficiencies of the turbomachinery, the thermal COP was 0.66 which represents an estimate of the predicted performance if test facility limitations are overcome.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2023

Aerodynamic Rotor Design for a 25 MW Offshore Downwind Turbine

Continuously increasing offshore wind turbine scales require rotor designs that maximize power and performance. Downwind rotors offer advantages in lower mass due to reduced potential for tower strike, and is especially true at large scales, e.g., for a 25 MW turbine. In this study, three 25 MW downwind rotors, each with different prescribed lift coefficient distributions were designed (chord, geometry, and twist) and compared to maximize power production at unprecedented scales and Reynolds numbers, including a new approach to optimize rotor tilt and coning based on aeroelastic effects. To achieve this objective the design process was focused on achieving high power coefficients, while maximizing swept area and minimizing blade mass. Maximizing swept area was achieved by prescribing pre-cone and shaft tilt angles to ensure the aeroelastic orientation when the blades point upwards was nearly vertical at nearly rated conditions. Maximizing the power coefficient was achieved by prescribing axial induction factor and lift coefficient distributions which were then used as inputs for an inverse rotor design tool. The resulting rotors were then simulated to compare performance and subsequently optimized for minimum rotor mass. To achieve these goals, a high Reynolds number design space was developed using computational predictions as well as new empirical correlations for flatback airfoil drag and maximum lift. Within this design space, three rotors of small, medium and large chords were considered for clean airfoil conditions (effects of premature transition were also considered but did not significantly modify the design space). The results indicated that the medium chord design provided the best performance, producing the highest power in Region 2 from simulations while resulting in the lowest rotor mass, both of which support minimum LCOE. The methodology developed herein can be used for the design of other extreme-scale (upwind and downwind) turbines.

downwind rotors↗

DOE OSTI2026

Statorless mixed flow turbine for transonic pulsating inflow

Effective harvesting of power from high speed highly transient inflows such as the outflow of rotating detonation combustors (RDCs) is key to achieving their promised cycle efficiency step jump. To increase power density and efficiency simultaneously, a concept that can directly ingest transonic outflow, addressing the choking is needed, i.e. without additional transition elements. A new statorless design was assessed using a comprehensive approach to quantify all contributions to loss generation in transient flows, locally and globally. The turbine rotor was designed under steady flow conditions with a genetic algorithm. The comparison of power and loss generation between steady and unsteady flow results shows that a design methodology under steady-state conditions is suitable to characterize the performance of different designs. Three design families were further assessed under highly transient transonic conditions including traveling shock waves with a relative total pressure amplitude of 149.6% around the mean value and inflow angle variations from -26.5 deg to +51.8 deg. The oblique shock impinging on the pressure side (PS) of the turbine augments the shaft power extraction. When the oblique shock reflects between the pressure side and suction side (SS), its strength diminishes. This paper provides design guidelines on efficient turbine work extraction from the shocks emanating from detonation combustors.

rotating detonation engines↗

DOE OSTI2025

Dynamic response of a freely rotating butterfly valve in the advanced test reactor – dynamic fluid-body interaction modeling

To regulate primary coolant flow in the Advanced Test Reactor (ATR), a butterfly valve was installed between the primary coolant pumps and the reactor core. If the mechanical connection between the valve's disk and its shaft ever fails, the disk will rotate freely. Rapid disk rotation may induce pressure surges that could damage upstream pipes. In the present work, the rotational trajectory and pressure evolution during a disk free-rotation scenario were analyzed via the dynamic fluid-body interaction (DFBI) approach in STAR-CCM+, with the movement of a solid being driven by the forces and moment/torque imposed by its surrounding fluid. Assuming a large initial opening angle, the disk accelerates slowly, but swiftly passes the closed position. As a result of the sudden valve closure, a pressure surge occurs in the upstream pipes, exceeding their maximum allowable pressure. Furthermore, the disk does not stabilize at the closed position but continually oscillates due to the unsteady nature of the coolant flow. Because of the significant and continuous water hammer effect, a fix to the butterfly valve is being implemented to prevent rapid valve closure due to failure at the valve's disk/shaft mechanical connection.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2021

Rotor blade imbalance fault detection for variable-speed marine current turbines via generator power signal analysis

Marine hydrokinetic (MHK) turbines extract renewable energy from oceanic environments. However, due to the harsh conditions that these turbines operate in, system performance naturally degrades over time. Thus, ensuring efficient condition-based maintenance is imperative towards guaranteeing reliable operation and reduced costs for marine hydrokinetic power. This work proposes a novel framework aimed at identifying and classifying the severity of rotor blade pitch imbalance faults experienced by marine current turbines (MCTs). In the framework, a Continuous Morlet Wavelet Transform (CMWT) is first utilized to acquire the wavelet coefficients encompassed within the 1P frequency range of the turbine's rotor shaft. From these coefficients, several statistical indices are tabulated into a six-dimensional feature space. Next, Principle Component Analysis (PCA) is employed on the resulting feature space for dimensionality reduction, and then the application of a K-Nearest Neighbor (KNN) machine learning algorithm is utilized for fault detection and severity classification. The effectiveness of the proposed framework is validated using a high-fidelity MCT numerical simulation platform, where results demonstrate that the presence of a pitch imbalance fault can be accurately detected 100% of the time and correctly classified based upon severity more than 97% of the time.

42 ENGINEERING↗

DOE OSTI2024

Asynchronicity in opposed-piston RCMs: Does it matter?

Rapid Compression Machines (RCMs) are widely utilized to study combustion phenomena at engine-relevant conditions, and significant efforts are typically made to create a quiescent environment, particularly for investigations of autoignition chemistry. Opposed-piston configurations can be advantageous due to shorter compression times and reduced surface area to volume ratios. Each side must be actuated simultaneously, but this can be challenging in practice. These devices, like most RCMs, utilize hydraulics for actuation, speed control and arrestation of the piston at the end of the stroke; there is no mechanical control or linkage of the two piston trajectories. To quantify the magnitudes and effects of piston asynchronous behavior, this work employs both detailed experimental measurements and, for the first time, high-fidelity, Direct Numerical Simulation (DNS). The boundary conditions are carefully considered applying insight from high-resolution linear variable differential transformer (LVDT) measurements of the piston trajectory and a zero-dimensional kinematics model of the piston-shaft assembly. Sufficient resolution in the piston crevice region is used. The complicated fluid dynamical behavior that can evolve during piston compression and the ensuing delay processes due to offset timings from t offset = 0-10 ms is elucidated. It is found that near t offset = 6 ms and beyond, the boundary layer on the face of the first-seating piston can be sufficiently perturbed, due initially to reemergence of gas from the crevice of the firstseating piston, so that the adiabatic core can become degraded at long ignition delay times. Substantial mixing of colder gas into the interior of the reaction chamber can alter the measurements, similar to effects previously observed for improper piston crevice configuration. In conclusion, experimental techniques to mitigate asynchronous behavior are discussed and demonstrated.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2020

Steady-state off-design modeling of the supercritical carbon dioxide recompression cycle for concentrating solar power applications with two-tank sensible-heat storage

Concentrating solar power researchers are evaluating the potential of the supercritical carbon dioxide recompression cycle to improve the thermal efficiency and decrease the capital costs of next-generation systems. This analysis investigates the steady-state off-design performance of a recompression cycle integrated with two-tank sensible-heat thermal energy storage as the ambient temperature and heat-transfer fluid (HTF) inlet conditions to the cycle change. This paper presents off-design component models and then cycle convergence and control models to maximize net cycle power output while constraining the high-side pressure and air-cooler fan power to their respective design values and fixing the cycle HTF outlet temperature to its design value. Results show that inventory control and air-cooler fan power are important control parameters that can be optimized to maximize off-design power output as the ambient temperature and HTF mass flow rate diverge from design. The high-side pressure and fan power constraints cause the cycle net power to degrade when the ambient temperature is warmer than the design value, and this study calculates a maximum mass flow rate for hot days above which the cycle cannot achieve the design HTF outlet temperature. Finally, the analysis shows that optimizing compressor shaft speeds can improve cold-day performance by around 1.5 percentage points and part-load performance by up to 2.5 percentage points versus a baseline case with no active compressor control.

14 SOLAR ENERGY↗

DOE OSTI2023

Influence of the air-cooled supercritical carbon dioxide recompression cycle design-point on molten salt power tower techno-economic performance

Here, this paper investigates the techno-economic performance of a molten salt power tower integrated with an air-cooled supercritical carbon dioxide recompression cycle. Prior research into the cycle design point showed trade-offs between efficiency, cost, and temperature difference across the heat input, resulting in trade-offs between the design-point generation of the molten salt power tower system and the cost of sensible-heat thermal energy storage. Prior research into cycle off-design showed that colder ambient temperature designs have higher efficiencies on cold days but lower efficiency and capacity degradation on hot days. We present a framework to evaluate how cycle design, cost, and corresponding off-design performance affect the techno-economic performance of the molten salt power tower system. We use a steady-state off-design cycle model assuming fixed shaft speeds, inventory control, and air-cooler fan power control and integrate the cycle model with the molten salt power tower model from the National Renewable Energy Laboratory's System Advisor Model. First, we present a surrogate model that uses a heuristic approach to correct the interpolation when the cycle reaches capacity limitations at ambient temperatures hotter than design. Next, we evaluate how the recompression cycle design-point ambient temperature, air-cooler approach temperature, air-cooler fan power, and recuperator conductance influence cycle and system design metrics. Finally, we complete annual simulations using an hourly "duck curve" pricing schedule and present annual performance metrics to evaluate the cumulative effects of the cycle design parameters and corresponding off-design performance on molten salt power tower techno-economics.

14 SOLAR ENERGY↗

DOE OSTI2020

Validation of Combined Analytical Methods to Predict Slip in Cylindrical Roller Bearings

This paper presents a combination of models that together calculate the cage and roller speeds of a cylindrical roller bearing. The models consider elastohydrodynamic lubrication and contact elasticity between the roller and raceway, roller centrifugal forces, hydrodynamic lubrication at the cage pocket, and frictional forces. Using these models, the predicted cage and roller speeds and the extent of slip are compared to measurements acquired on cylindrical roller bearings in a commercial gearbox in steady-state and transient operating conditions of a wind turbine. In steady-state conditions at low wind speeds and low lubricant temperatures, cage and roller slip up to 60% occur in the loaded zone of the bearing. In the unloaded zone, up to 80% roller slip occurs. Cage and roller slip then decrease as the lubricant temperature and wind speed increases. In general, the analytical model results match experimental measurements within 10% for lubricant temperatures above 40 degrees C and wind speeds over 10 meters per second. The analytical model is further evaluated during a transient start-up event and highly dynamic emergency stop event and also used to examine changes in the bearing design or lubricant properties. Furthermore, roller and cage slip in cylindrical bearings is a combined effect of the bearing design, applied load, shaft speed, and lubricant properties and temperature, and can be quickly evaluated with the combined analytical models.

17 WIND ENERGY↗

DOE OSTI2021

Engineered extracellular vesicle mimetics from macrophage promotes hair growth in mice and promotes human hair follicle growth

Recent studies clearly show that cell-derived extracellular vesicles (EVs, including exosomes) can promote hair growth. However, large-scale production of EVs remains a big hurdle. Recently, extracellular vesicle mimetics (EMs) engineered by extrusion through various membranes are emerging as a complementary approach for large-scale production. In this study, to investigate their ability to induce hair growth, we generated macrophage-engineered EMs (MAC-EMs) that activated the human dermal papilla (DP) cells in vitro. MAC-EMs intradermally injected into the skin of C57BL/6 mice were retained for up to 72 h. Microscopy imaging revealed that MAC-EMs were predominately internalized into hair follicles. The MAC-EMs treatment induced hair regrowth in mice and hair shaft elongation in a human hair follicle, suggesting the potential of MAC-EMs as an alternative to EVs to overcome clinical limitation.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2020

An in situ shearing x-ray measurement system for exploring structures and dynamics at the solid–liquid interface

Revealing interfacial structure and dynamics has been one of the essential thematic topics in material science and condensed matter physics. Synchrotron-based x-ray scattering techniques can deliver unique and insightful probing of interfacial structures and dynamics, in particular, in reflection geometries with higher surface and interfacial sensitivity than transmission geometries. We demonstrate the design and implementation of an in situ shearing x-ray measurement system, equipped with both inline parallel-plate and cone-and-plate shearing setups and operated at the advanced photon source at Argonne National Laboratory, to investigate the structures and dynamics of end-tethered polymers at the solid-liquid interface. With a precise lifting motor, a micrometer-scale gap can be produced by aligning two surfaces of a rotating upper shaft and a lower sample substrate. A torsional shear flow forms in the gap and applies tangential shear forces on the sample surface. The technical combination with nanoscale rheology and the utilization of in situ x-ray scattering allow us to gain fundamental insights into the complex dynamics in soft interfaces under shearing. In this work, we demonstrate the technical scope and experimental capability of the in situ shearing x-ray system through the measurements of charged polymers at both flat and curved interfaces upon shearing. Furthermore, through the in situ shearing x-ray scattering experiments integrated with theoretical simulations, we aim to develop a detailed understanding of the short-range molecular structure and mesoscale ionic aggregate morphology, as well as ion transport and dynamics in soft interfaces, thereby providing fundamental insight into a long-standing challenge in ionic polymer brushes with a significant technological impact.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Mineralized sclerites in the gorgonian coral Leptogorgia chilensis as a natural jamming system

The soft corals (Cnidaria, Octocorallia), a diverse group of colonial marine invertebrates, can reversibly tune their body stiffness in response to external stimuli. This capability is attributed to their dynamic skeletal systems, which consist of thousands of mineralized skeletal elements, called sclerites, embedded within a gel-like matrix that swells/deswells and unjams/jams the sclerites, thus modulating skeletal stiffness. While sclerite morphology is widely used for species identification, its role in the mechanical performance of a soft coral’s skeletal system is largely unknown. Here, we investigated structure-jamming relationships in sclerite-based skeletal architectures using the red gorgonian octocoral Leptogorgia chilensis as a model system. The sclerites of L. chilensis exhibit a shaft-like geometry with two axial branches and two sets of triradiate side branches, which are aligned with the crystallographic symmetry of the constituent magnesium-containing calcite. By combining multiscale three-dimensional (3D) structural characterization, parametric geometrical modeling, 3D printing, mechanical testing, and discrete element simulations, we demonstrate how sclerite geometry achieves a balanced jamming performance in terms of stiffness, weight, strength, and fracture resistance in comparison to alternative geometries parametrically modified from the native sclerites (e.g., changes in the length and number of side branches). Here, we also found that these performance metrics are achieved through the effective interlocking among side and axial branches, which is further enhanced by the fractal-like microscopic spikes on the branch tips. The findings in this natural jamming system offer insights for designing synthetic mechanotunable material architectures for a wide range of applications, from soft robotics to mechanical dampeners.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Muon flux measurement at China Jinping Underground Laboratory

China Jinping Underground Laboratory (CJPL) is ideal for studying solar, geo-, and supernova neutrinos. A precise measurement of the cosmic-ray background is essential in proceeding with R&D research for these MeV-scale neutrino experiments. Using a 1-ton prototype detector for the Jinping Neutrino Experiment (JNE), we detected 264 high-energy muon events from a 645.2-day dataset from the first phase of CJPL (CJPL-I), reconstructed their directions, and measured the cosmic-ray muon flux to be $(3.53\pm0.22_{\rm{stat.}}\pm0.07_{\rm{sys.}})\times10^{-10}$ cm $^{-2}$s $^{-1}$. The observed angular distributions indicate the leakage of cosmic-ray muon background and agree with simulation data accounting for Jinping mountain's terrain. A survey of muon fluxes at different laboratory locations, considering both those situated under mountains and those down mine shafts, indicates that the flux at the former is generally a factor of $(4\pm2)$ larger than at the latter, with the same vertical overburden. In conclusion, this study provides a convenient back-of-the-envelope estimation for the muon flux of an underground experiment.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2021

A stable corridor for toroidal plasma compression

In this study, a toroidal plasma compressed by a collapsing flux conserver is analyzed to reveal stable scenarios of operation to high compression ratios. The resistive and ideal MHD stability is calculated in full toroidal geometry, using the asymptotic matching method in realistic conditions, and comparing with nonlinear simulations. The near edge current profile, controlled by toroidal field ramping during compression, is shown to be critical to stability due to coupling between poloidal components of the least stable mode. The extension of a length of shaft on axis is also found to be critical at high compression, as the resulting good curvature region in magnetic field stabilizes pressure driven modes that would otherwise be unstable. This work extends from previous studies, which initially showed the existence of a stable scenario, to include findings of more extensive stable zones, detailed effects of geometry, and nonlinear simulations of the instabilities. The nonlinear simulations of the compression are consistent with the linear analyses, confirming both the conservation and stability properties.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2022

Efficient Loads Surrogates for Waked Turbines in an Array

Accurately and efficiently predicting wind turbine structural loading is a crucial step in wind farm design. Without considering structural loading, wind farm optimization could negatively impact turbine fatigue and ultimate loads, especially for waked and partially waked turbines, which could result in higher maintenance costs and reduced turbine lifetime. However, predicting turbine loads throughout an array is a costly step, as these quantities require time-accurate results across long time histories, which is often intractable for large array optimization. Therefore, surrogate models that link array spacing to load outputs are often used, but the surrogates are then unique to the inflow conditions and array configurations in the training library. This work develops surrogate models for many wind turbine load outputs based solely on rotor plane velocity measurements, with no required input about array configuration or freestream inflow parameters. Surrogate models were constructed for many turbine quantities of interest (QoI), considering mean, standard deviation, ultimate, and fatigue loads. In general, most QoI statistics were accurately captured, as measured by predicted vs. actual correlation coefficient, confirming the suitability of the approach. Temporal mean values of the QoI required only temporal mean measurements of the rotor plane inflow velocity. However, accurate prediction of temporal standard deviation, ultimate, and fatigue values of QoI also required temporal standard deviations of the rotor plane velocity field. Poor surrogate performance was observed when too many correlated inputs were used, such as multiple velocity components. If the fewest inflow parameters are used to construct the surrogates, the average correlation coefficient value for all output QoI statistics is 0.89. Surrogates for standard deviations and damage equivalent loads (DELs) of turbine QoIs generally had lower accuracy and tower-base and shaft load channels posed the most difficult to capture accurately. The results suggest that these surrogates could be easily paired with analytic wake models, which are frequently used for pre-construction wind farm array optimization, to account for turbine loading in addition to power production. By including the optimal inflow conditions, the surrogate accuracy can improve to an average correlation coefficient value for all output QoI statistics of 0.92. This work has established the ability to build accurate surrogates for mean, standard deviation, ultimate load, and DEL turbine QoI values based on the rotor plane inflow velocity, and identified which inflow conditions lead to greater surrogate accuracy.

17 WIND ENERGY↗

DOE OSTI2022

Aeroservoelastic Stability of a Floating Wind Turbine

The problem of negative damping undermines the aeroservoelastic stability of floating offshore wind turbines. The negative damping problem is most prevalent around rated wind speed, where the sensitivity of thrust to wind speed is the largest. This paper investigates the implementation of peak shaving, a controller feature that limits the rated thrust by pitching the blades before rated wind speed is reached. Two controller designs are investigated: a de-tuned controller and a nacelle-feedback controller. A time-domain metric is defined, inspired by Lyapunov theory, in order to compute and assess the stability of floating offshore wind turbines. The model of the International Energy Agency 15-MW reference wind turbine mounted on the University of Maine VolturnUS-S floater is simulated in HAWC2 with the National Renewable Energy Laboratory reference open-source controller. Peak shaving is applied to the two controller designs and stability is assessed. According to the chosen metric, peak shaving does not improve the stability of the system. This is due to the trade-off between loads and error tracking: although the loads and displacements in the fore-aft direction of the turbine are reduced, the rotor-speed tracking is poorer, which increases the shaft torsion fatigue load.

17 WIND ENERGY↗

DOE OSTI2024

Impact of wake steering on loads of downstream wind turbines at an above-rated condition

Wake steering strategies often seek to gain power at the expense of increased fatigue loads. Here, we investigate the feasibility of applying wake steering at an above-rated condition. In such a condition, the farm is operating at rated power, and thus, increased power output is not the goal. Instead, wake steering is considered in the context of load reduction. We perform a sweep of wind directions and yaw misalignment angles, ranging from negative to positive values. This approach allows us to obtain trends and identify asymmetries in turbine response for symmetric scenarios. We use a wind farm consisting of five aligned IEA Wind 15-MW reference wind turbines, and analyze trends related to the blade-root, low-speed shaft, and tower-base moments, both in terms of standard deviation and damage equivalent loads. We show that for any given fixed wind direction, the turbines can be yawed such that the fatigue loads are reduced. Reductions of up to 5% (depending on the component) in terms of standard deviation and damage equivalent loads can be achieved by negatively yawing the turbine. A negative yaw misalignment has shown to be the direction of larger improvements. Such results contrast those found for below-rated conditions, where a positive yaw misalignment is typically preferred. However, since load reduction is not uniform across all component loads, more study and consideration is required before operational recommendations can be made.

17 WIND ENERGY↗