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DOE OSTI2025

Development of a Digital Twin for Hydrogen Dispersion and Safety Assessment in an Electrolyzer Based Hydrogen Production Facility

Digital twin models are virtual representations of physical systems that use real-time data to simulate and optimize performance. This study presents the development and initial implementation of a digital twin (DT) for the electrolyzer-based hydrogen production facility at NREL's Advanced Research on Integrated Energy Systems (ARIES), focused on enhancing safety and optimizing sensor placement through physics-based simulations and metadata integration. The DT incorporates detailed facility-specific information, including component layout, leak locations, and controlled release parameters, to model hydrogen dispersion under varying environmental conditions. Using steady-state computational fluid dynamics (CFD) simulations informed by real meteorological data, such as wind speed, direction, and vertical wind profiles, the DT enables visualization of hydrogen plume behavior and spatial concentration distributions. Comparative analysis between high and low wind speed scenarios illustrates the significant influence of wind dynamics on plume shape and extent, with horizontal momentum dominating dispersion at higher speeds, while buoyancy effects become more prominent under low wind conditions. These simulations generate a rich dataset embedded within the DT, allowing users to assess potential leak outcomes and identify optimal sensor locations based on concentration thresholds. The model supports scenario-based analysis to guide safety strategies and equipment deployment for open-area hydrogen infrastructure. The digital twin thus serves as a dynamic platform for virtual prototyping, providing predictive insight into hydrogen behavior and enhancing risk-informed decision-making. This initial phase establishes a validated foundation for future integration of transient, uncontrolled leak scenarios and real-time sensor feedback, positioning the DT as a critical tool for safety design, operational planning, and adaptive monitoring in hydrogen systems. Overall, the approach demonstrates the value of combining environmental data with digital simulations to inform safer and more efficient deployment of hydrogen technologies.

08 HYDROGEN↗

DOE OSTI2026

Development of a Digital Twin for Hydrogen Dispersion and Safety Assessment in an Electrolyzer-Based Hydrogen Production Facility: Preprint

Digital twin models are virtual representations of physical systems that use real-time data to simulate and optimize performance. This study presents the development and initial implementation of a digital twin (DT) for the electrolyzer-based hydrogen production facility at the National Renewable Energy Laboratory (NREL)'s Advanced Research on Integrated Energy Systems (ARIES), focused on enhancing safety and optimizing sensor placement through physics-based simulations and metadata integration. The DT incorporates detailed facility-specific information, including component layout, leak locations, and controlled release parameters, to model hydrogen dispersion under varying environmental conditions. Using steady-state computational fluid dynamics (CFD) simulations informed by real meteorological data, such as wind speed, direction, and vertical wind profiles, the DT enables visualization of hydrogen plume behavior and spatial concentration distributions. Comparative analysis between high and low wind speed scenarios illustrates the significant influence of wind dynamics on plume shape and extent, with horizontal momentum dominating dispersion at higher speeds, while buoyancy effects become more prominent under low wind conditions. These simulations generate a rich dataset embedded within the DT, allowing users to assess potential leak outcomes and identify optimal sensor locations based on concentration thresholds. The model supports scenario-based analysis to guide safety strategies and equipment deployment for open-area hydrogen infrastructure. The digital twin thus serves as a dynamic platform for virtual prototyping, providing predictive insight into hydrogen behavior and enhancing risk-informed decision-making. This initial phase establishes a validated foundation for future integration of transient, uncontrolled leak scenarios and real-time sensor feedback, positioning the DT as a critical tool for safety design, operational planning, and adaptive monitoring in hydrogen systems. Overall, the approach demonstrates the value of combining environmental data with digital simulations to inform safer and more efficient deployment of hydrogen technologies.

08 HYDROGEN↗

DOE OSTI2013

FlexIO: I/O Middleware for Location-Flexible Scientific Data Analytics

Increasingly severe I/O bottlenecks on High-End Computing machines are prompting scientists to process simulation output data online while simulations are running and before storing data on disk. There are several options to place data analytics along the I/O path: on compute nodes, on separate nodes dedicated to analytics, or after data is stored on persistent storage. Since different placements have different impact on performance and cost, there is a consequent need for flexibility in the location of data analytics. The FlexIO middleware described in this paper makes it easy for scientists to obtain such flexibility, by offering simple abstractions and diverse data movement methods to couple simulation with analytics. Various placement policies can be built on top of FlexIO to exploit the trade-offs in performing analytics at different levels of the I/O hierarchy. Experimental results demonstrate that FlexIO can support a variety of simulation and analytics workloads at large scale through flexible placement options, efficient data movement, and dynamic deployment of data manipulation functionalities.

Computer Science↗

DOE OSTI2025

High fidelity blade-resolved and actuator line data from a 16 turbine wind farm simulation using ExaWind

This data was generated with the ExaWind code suite (https://github.com/Exawind) as a demonstration of a large, 16 turbine wind farm simulation, calculated using two different levels of fidelity. The lower level of fidelity approach uses an actuator line approach to represent the turbines, and was simulated with AMR-Wind (https://github.com/Exawind/amr-wind/) as the background flow solver, coupled to OpenFAST (https://github.com/OpenFAST/openfast). The higher level of fidelity simulation uses a blade-resolved approach, and is done using AMR-Wind, Nalu-Wind (https://github.com/Exawind/nalu-wind), OpenFAST, and TIOGA (https://github.com/Exawind/tioga). In the blade-resolved simulation, ExaWind couples together a background flow solver, AMR-Wind, and a near-body solver, Nalu-Wind, through an overset technique from the TIOGA application. OpenFAST handles the structural dynamics of the turbine blades and towers, which informs the fluid-structure interaction of the wind turbines with the flow solvers. In the actuator line simulation, a mesh of 295M elements was used for a 5km x 5km domain, and it was simulated using 256 nodes (2048 GPU's) on the Oak Ridge Leadership Computing Facility Frontier supercomputer. For the blade-resolved simulation, 1.5B element mesh was used in the AMR-Wind background 5km x 5km domain, and 16M elements were used for each turbine in the Nalu-Wind domains, for a total of 1.7B elements. This was simulated using 384 nodes on Frontier, with each node using 56 cores for Nalu-Wind and 8 GPU cores. The data in this archive includes the turbine outputs from OpenFAST, 2D sampling planes from AMR-Wind, and full-field solution files from AMR-Wind and Nalu-Wind.

17 WIND ENERGY↗

DOE OSTI2014

Integrating advanced materials simulation techniques into an automated data analysis workflow at the Spallation Neutron Source

This presentation will review developments on the integration of advanced modeling and simulation techniques into the analysis step of experimental data obtained at the Spallation Neutron Source. A workflow framework for the purpose of refining molecular mechanics force-fields against quasi-elastic neutron scattering data is presented. The workflow combines software components to submit model simulations to remote high performance computers, a message broker interface for communications between the optimizer engine and the simulation production step, and tools to convolve the simulated data with the experimental resolution. A test application shows the correction to a popular fixed-charge water model in order to account polarization effects due to the presence of solvated ions. Future enhancements to the refinement workflow are discussed. This work is funded through the DOE Center for Accelerating Materials Modeling.

Borreguero Calvo, Jose M↗

DOE OSTI2025

Data from "Deep Potential Molecular Dynamics Simulations of Low-Temperature Plasma-Surface Interactions"

Data and input files related to the paper "Deep Potential Molecular Dynamics Simulations of Low-Temperature Plasma-Surface Interactions" (https://doi.org/10.1116/6.0004027). This includes the final DP model used in all simulations, training data set, example input files to run DeepMD (with LAMMPS), and data tables summarizing the results obtained from the simulations.

machine learning models↗

DOE OSTI2025

Digital Filter Design for Point-on-Wave Sensors: Highlighting Frequency Response Limitations and Enhancing Grid Simulation Accuracy

Data is proving to be the backbone of today's and, more importantly, tomorrow's grid. As the system changes and introduces fast-acting devices like power electronics, overall observability tends to decrease from the utility point-of-view. This can be mitigated by adding more high-fidelity sensors onto the grid, although this incurs a cost. These sensors are never ideal, and each have unique frequency responses that may influence the data produced. This may, in turn, impact the protection and control of the power grid. This paper presents a methodology of representing these point-on-wave sensors digitally by estimating digital-filter representations of them, thereby introducing means of improving the sensor models used in electromagnetic-transient (EMT) simulations. This may help with identifying potential high-frequency, sensor-induced distortions, and system resonance compensation. Three commercial-grade medium-voltage point-on-wave sensors are utilized in a lab environment to obtain experimental frequency responses with a frequency sweep, and it is shown that both Infinite Impulse Response (IIR) and Finite Impulse Response (FIR) filter representations may approximate these responses with varying degrees of accuracy, though each has their own strengths and weaknesses. It is found that, in general, FIR estimation better approximates these sensors than IIR estimation does.

Wilson, Aaron [ORNL] (ORCID:0000000327331697)↗

DOE OSTI2024

Mesoscale modeling and semi-analytical approach for the microstructure-aware effective thermal conductivity of porous polygranular materials

Here we established a comprehensive modeling approach for investigating the microstructure-aware effective thermal conductivity ($κ_{eff}$) for porous microstructures containing solid particles and gaseous pores. Our approach combines the mesoscale computational modeling framework and the semi-analytical method, allowing for efficient prediction of $κ_{eff}$ for realistic porous microstructures, while considering complicated microstructural thermal conduction pathways effectively in the prediction. We used the diffuse-interface mesoscale computational model to generate extensive simulated $κ_{eff}$ data for realistic digital representations of microstructures with wide ranges of porosity ($f_p$), thermal conductivity of the gas phase ($κ_g$), and thermal conductivity of the solid phase ($κ_s$). From the simulated data, we identified two property variation regimes for $κ_{eff}$: (1) a slow $κ_{eff}$ increase for $κ_s ~ κ_g$; and (2) a faster $κ_{eff}$ increase for $κ_s \gg κ_g$. To capture the key features of the relationship between the microstructure and $κ_{eff}$, we derived a semi-analytical model by introducing structure and intensification factors. The two new factors incorporate the calibrated effective contribution of the solid volume with $κ_s$ and additional interfacial effects into the prediction of $κ_{eff}$, respectively, allowing for consideration of parallel, serial, and interfacial conduction mechanisms effectively. Using the selected simulation data, we quantified key model parameters within the semi-analytical model and verified that the parameterized model exhibits excellent agreement with simulated $κ_{eff}$ for the entire range of the parameter space.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Evidence of Completion of Milestone 4: Simulation Testbed Validated with Experimental Data

Milestone 4 is given in the SOPO as being due in quarter 5 (ending 9/11/2020) and is described thus: Milestone 4: Enhanced Simulation Testbed Validated with Experimental Data (UM, Mathieu). Simulation testbed validated with data obtained from experimental testbed, specifically, nonlinear load behaviors and communication network issues observed in the experimental testbed will be modeled in the simulation testbed. The simulation testbed should accurately capture TCL real and reactive power consumption (including during extreme events associated with nonlinear behaviors and communication network failures) to within 5% RMSE error with respect to data obtained from the experimental testbed. The Tasks comprising the work to achieve Milestone 4 are outlined here.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

Evidence of Completion of Milestone 4: Simulation Testbed Validated with Experimental Data

Milestone 4 is given in the SOPO as being due in quarter 5 (ending 9/11/2020) and is described thus: Milestone 4: Enhanced Simulation Testbed Validated with Experimental Data (UM, Mathieu) Simulation testbed validated with data obtained from experimental testbed, specifically, nonlinear load behaviors and communication network issues observed in the experimental testbed will be modeled in the simulation testbed. The simulation testbed should accurately capture TCL real and reactive power consumption (including during extreme events associated with nonlinear behaviors and communication network failures) to within 5% RMSE error with respect to data obtained from the experimental testbed.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2022

Finding Hidden Patterns in High Resolution Wind Flow Model Simulations

Wind flow data is critical in terms of investment decisions and policy making. High resolution data from wind flow model simulations serve as a supplement to the limited resource of original wind flow data collection. Given the large size of data, finding hidden patterns in wind flow model simulations are critical for reducing the dimensionality of the analysis. In this work, we first perform dimension reduction with two autoencoder models: the CNN-based autoencoder (CNN-AE) [1], and hierarchical autoencoder (HIER-AE) [2], and compare their performance with the Principal Component Analysis (PCA). We then investigate the super-resolution of the wind flow data. By training a Generative Adversarial Network (GAN) with 300 epochs, we obtained a trained model with 2× resolution enhancement. We compare the results of GAN with Convolutional Neural Network (CNN), and GAN results show finer structure as expected in the data field images. Also, the kinetic energy spectra comparisons show that GAN outperforms CNN in terms of reproducing the physical properties for high wavenumbers and is critical for analysis where high-wavenumber kinetics play an important role.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2020

Progress on Understanding Rayleigh–Taylor Flow and Mixing Using Synergy Between Simulation, Modeling, and Experiment

Simultaneous advances in numerical methods and computing, theoretical techniques, and experimental diagnostics have all led independently to better understanding of Rayleigh–Taylor (RT) instability, turbulence, and mixing. In particular, experiments have provided significant motivation for many simulation and modeling studies, as well as validation data. Numerical simulations have also provided data that is not currently measurable or very difficult to measure accurately in RT unstable flows. Thus, simulations have also motivated new measurements in this class of buoyancy-driven flows. This overview discusses simulation and modeling studies synergistic with experiments and examples of how experiments have motivated simulations and models of RT instability, flow, and mixing. First, a brief summary of measured experimental and calculated simulation quantities, of experimental approaches, and of issues and challenges in the simulation and modeling of RT experiments is presented. Implicit large-eddy, direct numerical, and large-eddy simulations validated using RT experimental data are then discussed. This is followed by a discussion of modeling using analytical, modal, buoyancy–drag, and turbulent transport models of RT mixing experiments. The discussion will focus on three-dimensional RT mixing arising from multimode perturbations. Finally, this focused review concludes with a perspective on future simulation, modeling, and experimental directions for further research. Research in simulation and modeling of RT unstable flows, coupled with experiments, has made significant progress over the past several decades. This overview serves as an opportunity to both discuss progress and to stimulate future research on simulation and modeling of this unique class of hydrodynamically unstable turbulent flows.

42 ENGINEERING↗

DOE OSTI2025

Experimental data for damage mechanics simulation challenge

While there are many computational approaches for simulating damage in rock and other materials, few have been ground truth tested with either known experimental data or with blind data sets. Here, in this work, we present a bench-mark laboratory data set for a damage mechanics challenge to compare computational approaches on damage evolution in brittle-ductile materials. The samples were fabricated through additive manufacturing to produce repeatable specimens designed to fail in controlled ways. The failure was induced in the samples using a 3-point bending test to produce different Modes such as Mode I and mixed Modes including I-II, I-III and I-II-III Modes to generate a calibration data set and a blind challenge data set. Data collected included spatial and temporal measurements from traditional digital load–displacement sensors, 2D digital image correlation measurement to map surface deformations, 3D X-ray microscopy to ground-truth the crack-failure geometry, and laser profilometry to capture surface roughness. The data sets are available, on a data repository, to the community to advance computational models to improve our ability to predict damage in brittle-ductile materials.

3-point bending↗

DOE OSTI2014

SU-E-I-45: Reconstruction of CT Images From Sparsely-Sampled Data Using the Logarithmic Barrier Method

Purpose: To develop and investigate whether the logarithmic barrier (LB) method can result in high-quality reconstructed CT images using sparsely-sampled noisy projection data Methods: The objective function is typically formulated as the sum of the total variation (TV) and a data fidelity (DF) term with a parameter λ that governs the relative weight between them. Finding the optimized value of λ is a critical step for this approach to give satisfactory results. The proposed LB method avoid using λ by constructing the objective function as the sum of the TV and a log function whose augment is the DF term. Newton's method was used to solve the optimization problem. The algorithm was coded in MatLab2013b. Both Shepp-Logan phantom and a patient lung CT image were used for demonstration of the algorithm. Measured data were simulated by calculating the projection data using radon transform. A Poisson noise model was used to account for the simulated detector noise. The iteration stopped when the difference of the current TV and the previous one was less than 1%. Results: Shepp-Logan phantom reconstruction study shows that filtered back-projection (FBP) gives high streak artifacts for 30 and 40 projections. Although visually the streak artifacts are less pronounced for 64 and 90 projections in FBP, the 1D pixel profiles indicate that FBP gives noisier reconstructed pixel values than LB does. A lung image reconstruction is presented. It shows that use of 64 projections gives satisfactory reconstructed image quality with regard to noise suppression and sharp edge preservation. Conclusion: This study demonstrates that the logarithmic barrier method can be used to reconstruct CT images from sparsely-amped data. The number of projections around 64 gives a balance between the over-smoothing of the sharp demarcation and noise suppression. Future study may extend to CBCT reconstruction and improvement on computation speed.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2012

Design of Accelerator Online Simulator Server Using Structured Data

Model based control plays an important role for a modern accelerator during beam commissioning, beam study, and even daily operation. With a realistic model, beam behaviour can be predicted and therefore effectively controlled. The approach used by most current high level application environments is to use a built-in simulation engine and feed a realistic model into that simulation engine. Instead of this traditional monolithic structure, a new approach using a client-server architecture is under development. An on-line simulator server is accessed via network accessible structured data. With this approach, a user can easily access multiple simulation codes. This paper describes the design, implementation, and current status of PVData, which defines the structured data, and PVAccess, which provides network access to the structured data.

43 PARTICLE ACCELERATORS↗

DOE OSTI2019

Active Subspace Methods for Data-Intensive Inverse Problems

Fostered by advances in computing, simulation and data science have emerged as the third and fourth paradigms enabling scientific discovery. Many mathematical challenges arise when integrating these paradigms to produce new knowledge. One of the most important challenges is the inverse or calibration problem: find the inputs of a simulation such that its outputs agree with a given set of measurements. As both the cost of the complex simulations and the volume of measurement data sets increase, intuition-driven trial-and-error methods for calibration quickly become untenable; modern scientists need more computationally efficient and mathematically rigorous methods. When measurements and simulated predictions contain uncertainty, the Bayesian perspective on statistical inference provides a popular mathematical framework for developing computational methods to solve inverse problems. Markov chain Monte Carlo (MCMC) methods are a mainstay of this framework; they characterize a probability distribution on the space of model inputs that is conditioned on the given measurements. However, despite recent advances, MCMC methods remain impractical for expensive simulations with more than a handful of inputs. At its heart, MCMC searches the space of inputs for corresponding outputs that match measurements, and so it is afflicted with the curse of dimensionality. Additionally, MCMC methods become less efficient as the volume of the measurement data increases, particularly if the measurements are redundant. To make MCMC—and Bayesian methods, in general—amenable to today’s computer models with millions of inputs and terabytes of measurement data, one must devise methods to reduce the dimension of both the simulation inputs and the measurements. For many models used in practice, the outputs vary primarily on a low-dimensional manifold of the nominally high-dimensional input space. Recently developed active subspace methods discover this low-dimensional manifold and exploit it to enable analyses typically suited for low-dimensional settings (e.g., statistical inversion of complex systems). We hypothesize that active subspace methods can provide the necessary dimension reduction, enabling existing Bayesian methods to find solutions for a large class of otherwise intractable statistical inverse problems. We will test the hypothesis with a series of mathematical analyses and computational experiments that will proceed along three research veins: (i) integrating active subspace methods into methods for statistical inversion, (ii) addressing current challenges in active subspace methods, and (iii) incorporating methods for nonlinear dimensionality reduction into active subspace methods. We will apply the methods we develop to real inverse problems in chemical kinetics and turbulent flame modeling. Our team combines expertise in methods for inverse problems, dimension reduction, and reduced order modeling. With a history of active collaboration and thoughtful engagement, we bring enthusiasm and fresh perspectives to a well studied subject. We are excited by the potential opportunity to work together to extend and apply active subspace methods to data-intensive inverse problems.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2020

Future projections and uncertainty assessment of precipitation extremes in the Korean peninsula from the CMIP5 ensemble

Abstract Projections of changes in extreme climate are sometimes predicted by multimodel ensemble methods that combine forecasts from individual simulation models using weighted averaging. One method to assign weight to each model is the Bayesian model averaging (BMA) in which posterior probability is used. For the cases of extreme climate, the generalized extreme value distribution (GEVD) is typically used. We applied the approach of GEV‐embedded BMA to a series of 35 years of the annual maximum daily precipitation data (both historical data and data gathered from simulation experiments for future periods) over the Korean peninsula as simulated by the models in the Coupled Model Intercomparison Project Phase 5 (CMIP5). Simulation data under two Representative Concentration Pathway (RCP) scenarios, namely RCP4.5 and RCP8.5, were used. Observed data and 17 CMIP5 models for 12 gird cells in Korea have been examined to predict future changes in precipitation extremes. A simple regional frequency analysis of pooling observations from three stations in each cell was employed to reduce the estimation variance and local fluctuations. A bias correction technique using the regression‐type transfer function was applied to these simulation data. Return levels spanning over 20 and 50 years, as well as the return periods relative to the reference years (1971–2005), were estimated for two future periods, namely Period 1 (2021–2050) and Period 2 (2066–2095). From these analyses, relative increase observed in the spatially averaged 20‐year (50‐year) return level was approximately 23% (16%) and 45% (36%) in the RCP4.5 and RCP8.5 experiments, respectively, by the end of the 21st century. We concluded that extreme rainfalls will likely occur two times and four times more frequently in the RCP4.5 and RCP8.5 scenarios, respectively, as compared to in the reference years by the end of the 21st century.

Lee, Youngsaeng↗

DOE OSTI2013

Big Data Visual Analytics for Exploratory Earth System Simulation Analysis

Rapid increases in high performance computing are feeding the development of larger and more complex data sets in climate research, which sets the stage for so-called big data analysis challenges. However, conventional climate analysis techniques are inadequate in dealing with the complexities of today s data. In this paper, we describe and demonstrate a visual analytics system, called the Exploratory Data analysis ENvironment (EDEN), with specific application to the analysis of complex earth system simulation data sets. EDEN represents the type of interactive visual analysis tools that are necessary to transform data into insight, thereby improving critical comprehension of earth system processes. In addition to providing an overview of EDEN, we describe real-world studies using both point ensembles and global Community Land Model Version 4 (CLM4) simulations.

big data↗