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All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Data-Driven Probabilistic Anomaly Detection for Electricity Market under Cyber Attacks

Information and communication technologies have been widely used in smart grid for efficient operation. However, these technologies are vulnerable to malicious cyber attacks, which may lead to severe reliability and economic issues. Recently, a variety of data-driven anomaly detection approaches have been explored to detect potential cyber attacks in smart grids. In this paper, we researched on the electricity market data aiming to identify anomalies from the locational marginal prices (LMPs) and provide a new indicator for potential cyber attacks in power grids. Specifically, a novel data-driven probabilistic anomaly detection framework is proposed for electricity market, which consists of three major components: long short-term memory (LSTM) based deterministic electricity price forecasting, probabilistic electricity price forecasting and anomaly detection. This framework is tested on a model-based electricity market simulator under two types of cyber attacks, i.e., load redistribution attack (LRA) and price responsive attack (PRA). Numerical results on the simulated LMPs show that the proposed framework is capable of detecting data anomalies over these attacks.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

Challenges and opportunities in verification and validation of low temperature plasma simulations and experiments

This paper describes the verification and validation (V&V) framework developed for the stochastic Particle-in-Cell, Direct Simulation Monte Carlo code Aleph. An ideal framework for V&V from the viewpoint of the authors is described where a physics problem is defined, and relevant physics models and parameters to the defined problem are assessed and captured in a Phenomena Identification and Ranking Table (PIRT). Furthermore, numerous V&V examples guided by the PIRT for a simple gas discharge are shown to demonstrate the V&V process applied to a real-world simulation tool with the overall goal to demonstrably increase the confidence in the results for the simulation tool and its predictive capability. Although many examples are provided here to demonstrate elements of the framework, the primary goal of this work is to introduce this framework and not to provide a fully complete implementation, which would be a much longer document. Comparisons and contrasts are made to more usual approaches to V&V, and techniques new to the low-temperature plasma community are introduced. Specific challenges relating to the sufficiency of available data (e.g., cross sections), the limits of ad hoc validation approaches, the additional difficulty of utilizing a stochastic simulation tool, and the extreme cost of formal validation are discussed.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2016

Multiscale Investigation of Thermal Transport in UO{sub 2} Fuel using Modeling and Simulation

The thermal conductivity of the UO{sub 2} fuel in light water reactors (LWRs) defines how efficiently heat is transported from the fuel to the coolant, and thus directly influences the reactor efficiency. Unfortunately, the same fission events that generate heat also cause radiation damage and fission product formation that decreases the thermal conductivity. This reduction in thermal conductivity reduces the safety of the reactor in addition to its efficiency, because excess heat generated during an accident cannot be transported from the fuel, resulting in high temperatures that can result in melting. Because thermal conductivity plays such an important role in reactor efficiency and safety, many experiments have been conducted to measure the thermal conductivity of UO{sub 2} and how it changes during reactor operation. Experiments on unirradiated fuel have resulted in a large set of data indicating how the bulk thermal conductivity changes as a function of temperature, which was used to develop a semiempirical model. Additional experiments have been conducted to determine how the thermal conductivity of UO{sub 2} changes as a function of burnup, leading to burnup dependent models fitted to the data. While these empirical models perform well within the conditions at which the data was collected, they cannot be extrapolated outside of those conditions. In addition, while burnup is a measure of the amount of fissioning that has occurred, it cannot account for the impact of the operating conditions on the thermal conductivity. While experimental data provides an empirical view on the value of the thermal conductivity in the fuel during reactor operation, a more mechanistic understanding of how temperature and burnup impact the transport of heat through the fuel would be extremely valuable. Such an understanding would allow for a more accurate prediction of fuel performance, but it could also be used to direct modifications to the fuel that would raise the thermal conductivity or reduce the impact of burnup. In this work we summarize recent efforts to use modeling and simulation at the atomistic and mesoscales to obtain a mechanistic understanding of thermal transport in UO{sub 2}. The thermal conductivity of LWR fuel is one of the most critical material parameters impacting the efficiency and safety of the reactor. Thus, a significant effort is being made to develop a mechanistic understanding of the impact of temperature and burnup on it. In this work, we have provided a short summary of modeling and simulation efforts being carried out at the atomistic and mesoscale to understand this critical property. These research efforts are providing a fundamental understanding of the thermal transport in unirradiated UO{sub 2}, as well as the impact of radiation damage and fission products on thermal transport. These efforts have been focused on UO{sub 2}, but they also are laying the framework for conducted similar simulations to investigate new accident tolerant fuel concepts. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

Impact of the strength and spatial distribution of adsorption sites on methane deliverable capacity in nanoporous materials

The methane deliverable capacity of adsorbent materials is a critical performance metric that will determine the viability of using adsorbed natural gas (ANG) technology in vehicular applications. ARPA-E recently set a target deliverable capacity of 315 cc(STP)/cc that a viable adsorbent material should achieve to yield a driving range competitive with incumbent fuels. However, recent computational screening of hundreds of thousands of materials suggests that the target is unattainable. In this work, we aim to determine whether the observed limits in deliverable capacity (similar to 200 cc(STP)/cc) are fundamental limits arising from thermodynamic or material design constraints. Our efforts focus on simulating methane adsorption isotherms in a large number of systems, resulting in a broad exploration of different combinations of spatial distributions and energetics of adsorption sites. All systems were classified into five adsorption scenarios with varying degrees of realism in the manner that adsorption sites are created and endowed with energetics. The scenarios range from methane adsorption on discrete idealized lattice sites to adsorption in metal-organic frameworks with coordinatively unsaturated sites (CUS) provided by metalated catechol groups. Our findings strongly suggest that the ARPA-E target is unattainable, although not due to thermodynamic constraints but due to material design constraints. On the other hand, we also find that the currently observed deliverable capacity limits may be moderately surpassed. For instance, incorporation of CUS in IRMOF-10 is predicted to yield a 217 cc(STP)/cc deliverable capacity. The modified material has a similar to 0.85 void fraction and a heat of adsorption of similar to 15 kJ/mol. This suggests that similar, moderate improvements over existing materials could be achieved as long as CUS incorporation still maintains a relatively large void fraction. Nonetheless, we conclude that more significant improvements in deliverable capacity will require changes in the currently proposed operation conditions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

Adsorbents and adsorption models for capture of Kr and Xe gas mixtures in fixed-bed columns

Off-gases produced during the reprocessing of used nuclear fuel (UNF) include 129-I 2 , 3-HHO, 14-CO 2 , 85-Kr, and 135-Xe, which are volatilized out into the off-gas. In order to meet regulatory requirements for reprocessing plant emissions, these gases must be captured and removed from the o?-gas stream prior to o?-gas emission. Of particular interest are the noble gases, Kr and Xe, which can be fairly difficult to remove from the off-gas due to their low chemical reactivity. Thus, this work is focused on utilizing engineered adsorbents, AgZ-PAN and HZ-PAN, to capture Kr and Xe from a mixed-gas stream at relatively low temperatures (191–295 K) and various flow rates (50–2000 mL/min). Isothermal data for Kr and Xe on each adsorbent are analyzed to produce the Langmuir parameters needed to model the mixture adsorption capacities at relevant temperatures using the Extended Langmuir model. Those parameters are then incorporated into a fixed-bed adsorption model developed in this work using the Mulitphysics Object-Oriented Simulation Environment (MOOSE). That model is used to simulate breakthrough times for Kr and Xe in packed columns of AgZ-PAN and HZ-PAN, ranging in length from 6 to 20 in., at relevant temperatures and flow rates. Breakthrough times varied from nearly instantaneous for Kr in AgZ-PAN to 30 h for Xe in HZ-PAN. After the developed model was validated by comparisons with experimental break-through data, the model framework was used to simulate the performance of multiple fixed-bed columns connected in series.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Applying Particle Swarm Optimization and Extended Kalman Filtering to Model Kaplan Generation Dynamics for Hydropower Systems

Variable renewable generation is increasing the need for hydropower plants to provide fast and flexible grid support, which places new demands on plant-level dynamic models used for monitoring, control, and operational decision-making. This need is especially important for hydroelectric systems, where turbine and generator dynamics are strongly coupled, nonlinear, and time-varying, making accurate real-time representation difficult. To address this problem, this paper develops a digital twin (DT) framework for a synchronous generator–Kaplan turbine system using an explicit separation of slow turbine dynamics and fast generator dynamics. The turbine subsystem is represented by a six-coefficient model, whose parameters are identified offline using particle swarm optimization, while the generator subsystem is updated online through an extended Kalman filter for real-time state and parameter estimation. These models are integrated within a closed-loop simulation that includes a proportional–integral–derivative–double-derivative governor and excitation system, allowing the DT to track plant behavior under realistic operating conditions. Unlike prior studies that treat turbine and generator modeling separately or rely mainly on simulated inputs, the proposed framework is validated using real operational data from a hydropower plant. Results show that the DT reproduces terminal voltage, active power, and reactive power with a normalized root mean square error of approximately 5%. This hybrid offline–online formulation constitutes the main contribution of the work, providing an adaptive and practically deployable DT for hydropower systems with direct relevance to control improvement, performance monitoring, and grid-support applications under high renewable penetration.

13 HYDRO ENERGY↗
DOE OSTI2026

Three-Dimensional Grid Visualization for Planning Activities: A Dubai Case Study

National Laboratory of the Rockies (NLR), in collaboration with the Dubai Electricity and Water Authority (DEWA) and Infra-X, has undertaken the Energy Visualization Analysis Project. The aim of this project is to enhance analytical and 3D visualization capabilities for distribution network planning and renewable energy integration. As modern grid continues to evolve with large-scale solar PV deployment and emerging distributed energy resources (DERs), the ability to effectively analyze, visualize, and communicate complex grid behaviors has become increasingly critical. The project focuses on developing empirical use cases based on real distribution feeder data and engineering workflows, ensuring the outcomes are directly aligned with operational environment. Through time-series power flow simulations and nodal hosting capacity analysis, the study quantifies the impacts of high PV penetration on voltage and thermal limits within representative 11 kV feeders. These analyses identify specific nodes and conditions where DER integration challenges arise. Furthermore, a Battery Energy Storage System (BESS) optimization algorithm was applied to determine the optimal size and placement of storage systems that can mitigate network constraints and enhance hosting capacity. The comparative results between base-case and BESS-augmented scenarios clearly demonstrate improvements in network stability and load management efficiency. In parallel, the NLR team developed an immersive 3D visualization framework, enabling interactive exploration of grid simulations using commodity head-mounted display (HMD) systems. This framework transforms conventional 2D simulation data into spatially intuitive visual environments - allowing engineers to analyze feeder conditions, PV hosting potential, and BESS effects in real time. This report represents the first foundational phase in establishing a visualization-driven analytical ecosystem. It provides a methodological foundation for data integration, visualization architecture, and simulation-based decision support, paving the way for large-scale adoption of immersive visualization across DEWA's Smart Grid Initiative, R&D activities, and future network resilience studies.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2018

Comparing Genome-Wide Association Study Results from Different Measurements of an Underlying Phenotype

Increasing popularity of high-throughput phenotyping technologies, such as image-based phenotyping, offer novel ways for quantifying plant growth and morphology. These new methods can be more or less accurate and precise than traditional, manual measurements. Many large-scale phenotyping efforts are conducted to enable genome-wide association studies (GWAS), but it is unclear exactly how alternative methods of phenotyping will affect GWAS results. In this study we simulate phenotypes that are controlled by the same set of causal loci but have differing heritability, similar to two different measurements of the same morphological character. We then perform GWAS with the simulated traits and create receiver operating characteristic (ROC) curves from the results. The areas under the ROC curves (AUCs) provide a metric that allows direct comparisons of GWAS results from different simulated traits. We use this framework to evaluate the effects of heritability and the number of causative loci on the AUCs of simulated traits; we also test the differences between AUCs of traits with differing heritability. We find that both increasing the number of causative loci and decreasing the heritability reduce a trait's AUC. We also find that when two traits are controlled by a greater number of causative loci, they are more likely to have significantly different AUCs as the difference between their heritabilities increases. When simulation results are applied to measures of tassel morphology, we find no significant difference between AUCs from GWAS using manual and image-based measurements of typical maize tassel characters. This finding indicates that both measurement methods have similar ability to identify genetic associations. These results provide a framework for deciding between competing phenotyping strategies when the ultimate goal is to generate and use phenotype-genotype associations from GWAS.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2018

Effectiveness of Geophysical Monitoring Methods in Detecting Brine and CO 2 Leakage in Underground Sources of Drinking Water

The US DOE National Risk Assessment Partnership (NRAP), funded through the Office of Fossil Energy and the National Energy Technology Laboratory (NETL), is developing methods to evaluate the effectiveness of monitoring techniques to detect brine and CO 2 leakage from legacy wells into underground sources of drinking water (USDW) overlying a CO 2 storage reservoir. As part of the NRAP Strategic Monitoring task group, we have generated Kimberlina Rev. 1.1 of the simulated aquifer impact data (140 simulations) from a model framework based on a hypothetical, compartmentalized, CO 2 storage reservoir near Kimberlina in the southern San Joaquin Basin, California. Brine and CO 2 leakage along damaged wellbores results in subsurface changes in pressure, CO 2 saturation and total dissolved solids (TDS). CO 2 buoyancy allows a significant fraction of leaked CO 2 to reach shallow permeable zones, which is more detectable by surface geophysical sensors. We generated synthetic geophysical data from the simulated aquifer impact data to assess electrical resistivity tomography (ERT), magnetotellurics (MT), gravity and seismic methods for remote and indirect detection of brine and CO 2 leakage.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Accurate and scalable graph neural network force field and molecular dynamics with direct force architecture

Abstract Recently, machine learning (ML) has been used to address the computational cost that has been limiting ab initio molecular dynamics (AIMD). Here, we present GNNFF, a graph neural network framework to directly predict atomic forces from automatically extracted features of the local atomic environment that are translationally-invariant, but rotationally-covariant to the coordinate of the atoms. We demonstrate that GNNFF not only achieves high performance in terms of force prediction accuracy and computational speed on various materials systems, but also accurately predicts the forces of a large MD system after being trained on forces obtained from a smaller system. Finally, we use our framework to perform an MD simulation of Li 7 P 3 S 11 , a superionic conductor, and show that resulting Li diffusion coefficient is within 14% of that obtained directly from AIMD. The high performance exhibited by GNNFF can be easily generalized to study atomistic level dynamics of other material systems.

Chemistry↗
DOE OSTI2024

Initial energy-momentum to final flow: A general framework for heavy-ion collisions

The evolution of a relativistic heavy-ion collision is typically understood as a process that transmutes the initial geometry of the system into the final momentum distribution of observed hadrons, which can be described via a cumulant expansion of the initial distribution of energy density and is represented at leading order as the well-known eccentricity scaling of anisotropic flow. We extend this framework to include the contribution from initial momentum-space properties, as encoded in other components of the energy-momentum tensor. Furthermore, we confirm the validity of the framework in state-of-the-art hydrodynamic simulations of large and small systems. With this framework, it is possible to separate the effects of early time dynamics from those of final-state evolution, even in the case when the distribution of energy does not fully determine subsequent evolution, as for example, in small systems. Specifically, we answer the question of when and how azimuthal correlations from the initial state survive to the final state. In very small systems such as 𝑝−𝑝, for example, initial momentum degrees of freedom dominate over energy. Thus, even if the system forms a quark-gluon plasma that is well described by hydrodynamics, the usual hydrodynamic picture of the transmutation of initial geometry to final momentum anisotropy is broken. Nevertheless, we show that the hydrodynamic response to the full energy-momentum tensor can be well understood in a similar manner as larger systems. Additionally, this framework elucidates the generic features of the system's evolution that are responsible for the impressive success of hydrodynamic simulations, but which may still hold even in cases where hydrodynamics is not applicable.

Relativistic heavy-ion collisions↗
DOE OSTI2023

Cyber-Physical Reconfiguration for Disaster Resilience of Power Distribution Systems

Cyber-physical distribution systems (CPDS) have emerged from the integration of information technology into distribution systems. While offering substantial benefits, this integration also introduces vulnerabilities. The interaction between cyber networks and distribution systems renders CPDS susceptible to disasters. To ensure critical load supply and system resilience, rapid post-disaster load restoration is required. The paper proposes a critical load restoration (CLR) framework in CPDS using a network reconfiguration approach that exploits the existing post-disaster resources to restore critical loads within the shortest possible time. Using graph theory, the cyber network and distribution system are integrated into a single digraph, minimizing the CLR complexity in CPDS. A cost metric is also defined to satisfy network-specific objectives and constraints. A heuristic is proposed to guide the load restoration process using the cost metric within the integrated digraph. Simulation results confirm the framework's superiority over existing literature, which either overlooks cyber components or prolongs restoration with additional resource deployment.

cyber-physical system↗
DOE OSTI2021

Edge localized mode characteristics and divertor heat flux during stationary and transient phase for CFETR hybrid scenario

The study of edge localized mode (ELM) behavior, stationary heat flux and transient heat flux during the ELM crash phase is performed for a China Fusion Engineering Test Reactor (CFETR) 1 GW hybrid mode operation scenario ($R$ = 7.2 m, ${B_{\text{T}}}$ = 6.5 T, ${I_{\text{p}}}$ = 13.78 MA). Modeling and simulation start with a scenario obtained by multi-code integrated modeling on the one modeling framework for integrated tasks framework. Linear stability and nonlinear simulations of ELM dynamics are carried out using the BOUT++ six-field reduced magnetohydrodynamic module, which show a much smaller ELM energy loss (Δ ELM ~ 0.13%) compared to that of a Type-I ELM. Parametric analysis of the weak linear growth rate and small ELM energy loss characteristics shed light on physics corresponding to a grassy ELM regime for CFETR 1 GW hybrid scenario. The transient heat flux on the divertor target during this small ELM phase is investigated using BOUT++. Here we found that upstream radial transport in the scrape-off-layer (SOL) induced by small ELMs is weak, which keeps it in the drift-dominated region. However, the heat flux width is still broadened to ${\lambda _{\text{q}}}$ = 4.64 mm by the increase of separatrix temperature during ELM nonlinear evolution. The impact of transient peak heat load and ELM energy fluence on tungsten melting and net erosion rate of divertor target is evaluated for the first-time using physics-based transport that connects the pedestal with the SOL. Energy fluence caused by a single ELM pulse is below the tungsten melting limit, while tungsten erosion would exceed the material requirements. We conclude that external mitigation methods, such as divertor detachment and advanced divertor geometry are likely needed for the steady state operation of CFETR.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

RE-INTEGRATE EMT Simulation Tool: Input Data Processing Layer for Bulk Power System

This paper introduces an advanced input data processing layer for EMT simulations of large-scale bulk power systems. The paper proposes two versions of the RE-INTEGRATE EMT simulation tool, RE-INTEGRATE Gen-0 and RE-INTEGRATE Gen-1, which are developed to enhance simulation generalizability, scalability, and accuracy. The framework leverages a generic class design for components to incorporate linear equations, which are generated by discretizing the Differential-Algebraic Equations (DAEs) that represent the dynamics of the components. In addition, the framework employs a parsing algorithm that parses a power system’s raw and dyr files to generate a connectivity graph which is then traversed to form the overall system’s dynamics. The proposed input data processing layer is used to simulate the IEEE 39-bus test system. The obtained results demonstrate the framework’s capability to achieve simulation scalability and accuracy. Further, the results indicate that EMT simulations performed using the proposed automations can effectively handle complex grid configurations.

Mishra, Rahul [ORNL] (ORCID:0000000328205932)↗
DOE OSTI2018

Highly parallelisable simulations of time-dependent viscoplastic fluid flow with structured adaptive mesh refinement

We present the extension of an efficient and highly parallelisable framework for incompressible fluid flow simulations to viscoplastic fluids. The system is governed by incompressible conservation of mass, the Cauchy momentum equation, and a generalised Newtonian constitutive law. In order to simulate a wide range of viscoplastic fluids, we employ the Herschel-Bulkley model for yield-stress fluids with nonlinear stress-strain dependency above the yield limit. We utilise Papanastasiou regularisation in our algorithm to deal with the singularity in apparent viscosity. The resulting system of partial differential equations is solved using the IAMR (Incompressible Adaptive Mesh Refinement) code, which uses second-order Godunov methodology for the advective terms and semi-implicit diffusion in the context of an approximate projection method to solve adaptively refined meshes. By augmenting the IAMR code with the ability to simulate regularised Herschel-Bulkley fluids, we obtain efficient numerical software for time-dependent viscoplastic flow in three dimensions, which can be used to investigate systems not considered previously due to computational expense. We validate results from simulations using this new capability against previously published data for Bingham plastics and power-law fluids in the two-dimensional lid-driven cavity. In doing so, we expand the range of Bingham and Reynolds numbers which have been considered in the benchmark tests. Moreover, extensions to time-dependent flow of Herschel-Bulkley fluids and three spatial dimensions offer new insights into the flow of viscoplastic fluids in this test case, and we provide missing benchmark results for these extensions.

42 ENGINEERING↗
DOE OSTI2026

Dynamic analysis of fully constrained Cable-Driven Parallel Robots for automated prefabricated component installation

This paper presents a dynamic analysis and validation framework to assess a fully constrained six-anchor Cable-Driven Parallel Robot (CDPR) for automated installation of prefabricated facade components. Compared with conventional eight-anchor systems, the six-anchor configuration simplifies setup and reduces cost, but it also reduces control authority, shrinks the wrench-feasible workspace, and tightens orientation limits. Consequently, it is unclear a priori whether dynamically feasible trajectories exist to move the end effector from pickup to the facade. A constrained trajectory optimization is formulated to enforce the system dynamics, cable-tension bounds, and pose/velocity limits, and the framework is evaluated in simulation at three levels: (i) an idealized reference model, (ii) a lab-scale prototype model incorporating measured anchor misalignments and identified damping, and (iii) a full-scale three-story building model with load decomposition for structural feasibility checks. Across these scenarios, the analysis shows that optimal, constraint-satisfying trajectories exist that move the end effector from pickup to installation while maintaining a near-plumb, level orientation at the final pose. Collectively, this multi-scale dynamic analysis and validation framework supports the deployment readiness of the six-anchor CDPR and provides a prototype-based sensitivity case study of how measured anchor placement deviations affect feasibility.

CDPR↗
DOE OSTI2021

Fast and Accurate Machine Learning Strategy for Calculating Partial Atomic Charges in Metal–Organic Frameworks

Computational high-throughput screening using molecular simulations is a powerful tool for identifying top-performing metal–organic frameworks (MOFs) for gas storage and separation applications. Accurate partial atomic charges are often required to model the electrostatic interactions between the MOF and the adsorbate, especially when the adsorption involves molecules with dipole or quadrupole moments such as water and CO 2 . Although ab initio methods can be used to calculate accurate partial atomic charges, these methods are impractical for screening large material databases because of the high computational cost. We developed a random forest machine learning model to predict the partial atomic charges in MOFs using a small yet meaningful set of features that represent both the elemental properties and the local environment of each atom. The model was trained and tested on a collection of about 320 000 density-derived electrostatic and chemical (DDEC) atomic charges calculated on a subset of the Computation-Ready Experimental Metal–Organic Framework (CoRE MOF-2019) database and separately on charge model 5 (CM5) charges. The model predicts accurate atomic charges for MOFs at a fraction of the computational cost of periodic density functional theory (DFT) and is found to be transferable to other porous molecular crystals and zeolites. In conclusion, a strong correlation is observed between the partial atomic charge and the average electronegativity difference between the central atom and its bonded neighbors.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Computational Fluid Dynamics Simulations to Support Efficiency Improvements in Aluminum Smelting Process

Smelting is broadly described as the extraction of a metal from its ore. In the United States, aluminum is commonly produced by smelting alumina in bauxite using the Hall-Héroult process. Optimization of equipment and processes in conventional smelting is crucial to enhancing process efficiency and productivity, is necessary for improving the techno-economic feasibility, which directly manifests as the growth of the American economy. To achieve optima, insightful data on the multiphysics phenomena that are inherent to the process must be obtained through physical investigation or high-fidelity numerical simulations. The resolution of relevant scales in time and space for smelting operations requires intensive, high-performance computing (HPC) simulations. Hostile operating conditions limit physical data acquisition to specific techniques; therefore, these data do not describe the multiscale interaction of simultaneous effects. Fortunately, in recent decades, significant advancements in computing hardware and computational methods have made the numerical resolution of such a complex process possible. In this study, a high-fidelity simulation of aluminum smelting was performed using an open-source tool, OpenFOAM, which analyzed many parameters characteristic to underlying phenomena. A multiphysics model based on the Eulerian-Eulerian multifluid approach was adopted. This model can resolve critical issues in the electrolytic smelting of aluminum, such as bubbling of carbon dioxide from the anode(s), magnetohydrodynamics from electromagnetic effects, ionic dissolution of the alumina in the electrolyte, and the evolution of thermal profiles. This study provides valuable connectivity for characteristic data that can direct the future designs of efficient smelters. A basic framework to model and simulate the smelting process using OpenFOAM is presented for user modification in keeping with process development. Of relevance to the flow field, a detailed investigation of vortices produced by bubble motion and electromagnetics is discussed, along with their impact on the evolution of thermal profiles. The predictions show small-scale vortices in the clearance between the anode and cathode caused by magnetic forces. Predictions also indicate relatively large-scale vortices in the inter-anode space resulting from carbon dioxide rising through the electrolytic flow field. The formation of vortices at the edges of anodes was shown to direct alumina charged by the feeder to the bottom of the anodes, thus preventing the entrapment of gas bubbles in the periphery of the bottom of the anode. Symmetry was observed in the location of cold spots in the electrolytic mixture in the vicinity of the feeder. Cold spots were also observed in the clearance between the anode and cathode due to the flow’s transmission of unconverted alumina to this region.

36 MATERIALS SCIENCE↗