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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Process and control variables from the mercury loop at the SNS's mercury target

Set of process and control variables corresponding to the mercury process loop at the Spallation Neutron Source's (SNS) mercury target. The data corresponds to 36 measurement signals (pressure, temperature, flows, valve position, etc.) spanning from 2017/01/01 to 2023/12/31. Each signal is broken intro three-month intervals, resulting in a total of 28 files per signal during the aforementioned period of time.

mercury loop↗
DOE OSTI2023

A review on the sizing and selection of control valves for thermal hydraulics for reactor system applications

This study presents an overview regarding how to model/size, choose, and maintain control valves (CVs) for a reactor system thermal hydraulics experimentation—specifically simulating pipe break(s) and a loss of coolant accident (LOCA) analysis. In a thermal hydraulics test loop, CVs modulate fluid flow according to the control signal generated by the controller to control the process parameter. The selection of a CV in industrial applications involves many factors, including process diversity, safety, and reliability. Further, the key issues and challenges for performing proper mathematical modeling, installation, servicing, and calibration are also discussed for the benefit of operators and end-users. Additionally, this research includes case studies illustrating major plant-level accidents associated with the malfunctioning of valves. Therefore, the study will serve as a knowledge base or reference guide for young professionals and operators who wish to better understand process control applications.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2014

Potential for reactive pulsed-dc magnetron sputtering of nanocomposite VO{sub x} microbolometer thin films

Vanadium oxide (VO{sub x}) thin films were deposited by reactive pulsed-dc sputtering a metallic vanadium target in argon/oxygen mixtures with substrate bias. Hysteretic oxidation of the vanadium target surface was assessed by measuring the average cathode current during deposition. Nonuniform oxidization of the target surface was analyzed by Raman spectroscopy. The VO{sub x} film deposition rate, resistivity, and temperature coefficient of resistance were correlated to oxygen to argon ratio, processing pressure, target-to-substrate distance, and oxygen inlet positions. To deposit VO{sub x} in the resistivity range of 0.1–10 Ω-cm with good uniformity and process control, lower processing pressure, larger target-to-substrate distance, and oxygen inlet near the substrate are useful.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Computational Flame Diagnostics for Direct Numerical Simulations with Detailed Chemistry of Transportation Fuels

The goal of the proposed research is to create computational flame diagnostics (CFLD) that are rigorous numerical algorithms for systematic detection of critical flame features, such as ignition, extinction, and premixed and non-premixed flamelets, and to understand the underlying physicochemical processes controlling limit flame phenomena, flame stabilization, turbulence-chemistry interactions and pollutant emissions etc. The goal has been accomplished through an integrated effort on mechanism reduction, direct numerical simulations (DNS) of flames at engine conditions and a variety of turbulent flames with transport fuels, computational diagnostics, turbulence modeling, and DNS data mining and data reduction. The computational diagnostics are primarily based on the chemical explosive mode analysis (CEMA) and a recently developed bifurcation analysis using datasets from first-principle simulations of 0-D reactors, 1-D laminar flames, and 2-D and 3-D DNS (collaboration with J.H. Chen and S. Som at Argonne, and C.S. Yoo at UNIST). Non-stiff reduced mechanisms for transportation fuels amenable for 3-D DNS are developed through graph-based methods and timescale analysis. The flame structures, stabilization mechanisms, local ignition and extinction etc., and the rate controlling chemical processes are unambiguously identified through CFLD. CEMA is further employed to segment complex turbulent flames based on the critical flame features, such as premixed reaction fronts, and to enable zone-adaptive turbulent combustion modeling.

42 ENGINEERING↗
DOE OSTI2019

Report on plasma jet printer for sensor fabrication with process parameters optimized by simulation input

The In-Pile Instrumentation program conducts research to develop instrumentation that provides information regarding test conditions, as well as fuel and materials properties during irradiation. Such instruments must be miniaturized, robust to the nuclear reactor environment, and provide real-time data aligned with user needs. Towards this end, additive manufacturing techniques such as aerosol jet printing and Plasma Jet Printing, have demonstrated significant potential for the development of advanced in-pile instrumentation. Process control during the manufacturing process is critical in order to consistently create reliable sensors. This report details experimental and computational work aimed towards improved process control for robust sensor production using printing techniques.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Automated Growth of Photocathodes [Slides]

Photocathode (alkali antimonides & tellurides) thin film growth state of the art remains largely an art of “cooking” instead of a controlled technological process. Our technology is a method of growing thin films by molecular beam deposition, that applies specifically to photoemissive films. We discovered that some of the photoemissive properties of Cs3Sb (easily measurable) strongly depend on the film’s stoichiometry (very difficult to measure, especially in real time). Such correlation allows to implement a feedback loop that adjusts the ratio of Cs and Sb fluxes in real time and thus maintains the same stoichiometric composition of the film during the whole growth cycle that may last for hours/days. Proposed scheme constitutes true, robust and versatile process control for the growth of alkali antimonide thin films.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Computerized Operator Support System – Phase II Development

A computerized operator support system (COSS) prototype for nuclear control room process control is proposed and discussed. The COSS aids operators in addressing rapid plant upsets that would otherwise result in the shutdown of the power plant and interrupt electrical power generation, representing significant costs to the owning utility. In its current stage of development the prototype demonstrates four advanced functions operators can use to more efficiently monitor and control the plant. These advanced functions consist of: (1) a synthesized and intuitive high level overview display of system components and interrelations, (2) an enthalpy-based mathematical chemical and volume control system (CVCS) model to detect and diagnose component failures, (3) recommended strategies to mitigate component failure effects and return the plant back to pre-fault status, and (4) computer-based procedures to walk the operator through the recommended mitigation actions. The COSS was demonstrated to a group of operators and their feedback was collected. The operators responded positively to the COSS capabilities and features and indicated the system would be an effective operator aid. The operators also suggested several additional features and capabilities for the next iteration of development. Future versions of the COSS prototype will include additional plant systems, flexible computer-based procedure presentation formats, and support for simultaneous component fault diagnosis and dual fault synergistic mitigation action strategies to more efficiently arrest any plant upsets.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Development and Test of High Temperature Surface Acoustic Wave Gas Sensors

The demand for sensors in hostile environments, such as power plant environments, aerospace environments, oil and gas extraction, and high-temperature metallurgy environments, has risen over the past decades in a continuous attempt to increase process control, improve energy and process efficiency in production, reduce operational and maintenance costs, increase safety, and perform condition-based maintenance in equipment and structures operating in high-temperature harsh-environment conditions. The increased reliability, improved performance, and development of new sensors and networks with a multitude of components, especially wireless networks, are the target for operation in harsh environments. Gas sensors, in particular H2 sensors, operating above 200 C are required in the instrumentation, process control and general safety of a number of industries including coal, natural gas, and nuclear power generation facilities, the aerospace and automotive industries, metallurgical production and defense-related applications. The surface acoustic wave (SAW) platform is a particularly promising option for high-temperature, harsh-environment gas sensing applications since the platform exhibits advantages, such as battery-free and wireless operation, small size, possibility for scale production using well-developed technologies from the semiconductor industry, and low cost of installation and operation. In this work, one-port SAW resonators (SAWRs) operating along five different orientations on a commercially available langasite (LGS) wafer employing Pt-Al2O3 electrodes and reflectors were designed, fabricated, and used as high-temperature H2 sensors. Two of the selected orientations were predicted and confirmed to have temperature-compensated operation above 150 C. A gas sensor test setup was developed, capable of gas cycling between N2, O2 and N2/H2 mixtures under extended high-temperature periods (up to 650 C for over 20 hours). Thin film Pt-Al2O3 was used as the electrode material for the transducers and reflectors capable of high-temperature operation, and also as H2 sensing film. In addition, yttria-stabilized zirconia (YSZ) thin films with Pt decoration were tested as sensing films aimed to enhance the SAWR sensor response to H2. The SAW devices were monitored in excess of 1700 hours in real-time during gas cycling sequences up to 600 C, leading to the following findings: i) the Pt-Al2O3 electrodes performed better for H2 sensing than the Pt-decorated YSZ sensing film, showing as much as 50% higher frequency variation response in the 200 C to 400 C range; ii) different crystallographic orientations operating on the same LGS wafer experienced different responses to H2 exposures up to 500 C; iii) the surface oxidation state of the SAWR sensors was shown to have an important impact on subsequent H2 exposure responses. In addition, a sensor system employing two LGS SAWRs, aligned along two different orientations, has been developed to simultaneously determine H2 presence and temperature. Finally, wireless interrogation of a SAWR sensor was successful within the gas cycling test fixture, and successful wireless H2 detection was achieved above 400 C.

Ayes Moncada, Armando↗
DOE OSTI2018

Producing Desired Properties From a Broader Spectrum of Compositions - 18167

The U.S. Department of Energy, Office of River Protection has an extensive research program to develop low-activity waste and high-level waste glass compositions for the balance of mission of the Waste Treatment and Immobilization Plant (WTP). The fundamental data stemming from this program will support development of advanced glass formulations, key process control models, and processing strategies to ensure safe and successful operations for both the Low-Activity Waste and High-Level Waste facilities with an appreciation toward reducing overall mission life. (author)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Optimal control to handle variations in moisture content and reactor in-feed rate

The variations in feedstock characteristics, such as moisture and particle size distribution, lead to an inconsistent flow of feedstock from the biomass pre-processing system to the reactor in-feed system. These inconsistencies result in low on-stream times at the reactor in-feed equipment. This research develops an optimal process control method for a biomass pre-processing system comprised of milling and densification operations to provide the consistent flow of feedstock to a reactor's throat. This method uses a mixed-integer optimization model to identify optimal bale sequencing, equipment in-feed rate, and buffer location and size in the biomass pre-processing system. This method, referred to as the hybrid process control (HPC), aims to maximize throughput over time. We compare HPC with a baseline feed forward process control. Our case study based on switchgrass finds that HPC reduces the variation of a reactor's feeding rate by up to 100% without increasing the operating cost of the biomass pre-processing system for biomass with moisture ranging from 10 to 25%. Additionally, HPC reduces the cost of processing biomass by 0.36%–2.22%, and reduces processing time by 0.35%-2.24%. Furthermore, a biorefinery can adapt HPC to achieve its design capacity.

09 BIOMASS FUELS↗
DOE OSTI2014

Carbon Capture Simulation Initiative: A Case Study in Multi-Scale Modeling and New Challenges

Abstract: Advanced multi-scale modeling and simulation has the potential to dramatically reduce development time, resulting in considerable cost savings. The Carbon Capture Simulation Initiative is a partnership among national laboratories, industry and universities that is developing and deploying a suite of multi-scale modeling and simulation tools including basic data submodels, steady-state and dynamic process models, process optimization and uncertainty quantification tools, an advanced dynamic process control framework, high-resolution filtered computational-fluid-dynamic (CFD) submodels, validated high-fidelity device-scale CFD models with quantified uncertainty, and a risk analysis framework. These tools and models enable basic data submodels, including thermodynamics and kinetics, to be used within detailed process models to synthesize and optimize a process. The resulting process informs the development of process control systems and more detailed simulations of potential equipment to improve the design and reduce scale-up risk. Quantification and propagation of uncertainty across scales is an essential part of these tools and models.

42 ENGINEERING↗
DOE OSTI2014

Experimental investigation of wood combustion in a fixed bed with hot air

Highlights: • Upward combustion is a new combustion concept with ignition by hot primary air. • Upward combustion has three stages: short drying, rapid devolatilization and char combustion. • Variation of fuel moisture and inert content have little influence on the combustion. • Experimental comparison between conventional and upward combustion is presented. - Abstract: Waste combustion on a grate with energy recovery is an important pillar of municipal solid waste (MSW) management in the Netherlands. In MSW incinerators fresh waste stacked on a grate enters the combustion chamber, heats up by radiation from the flame above the layer and ignition occurs. Typically, the reaction zone starts at the top of the waste layer and propagates downwards, producing heat for drying and devolatilization of the fresh waste below it until the ignition front reaches the grate. The control of this process is mainly based on empiricism. MSW is a highly inhomogeneous fuel with continuous fluctuating moisture content, heating value and chemical composition. The resulting process fluctuations may cause process control difficulties, fouling and corrosion issues, extra maintenance, and unplanned stops. In the new concept the fuel layer is ignited by means of preheated air (T > 220 °C) from below without any external ignition source. As a result a combustion front will be formed close to the grate and will propagate upwards. That is why this approach is denoted by upward combustion. Experimental research has been carried out in a batch reactor with height of 4.55 m, an inner diameter of 200 mm and a fuel layer height up to 1 m. Due to a high quality two-layer insulation adiabatic conditions can be assumed. The primary air can be preheated up to 350 °C, and the secondary air is distributed via nozzles above the waste layer. During the experiments, temperatures along the height of the reactor, gas composition and total weight decrease are continuously monitored. The influence of the primary air speed, fuel moisture and inert content on the combustion characteristics (ignition rate, combustion rate, ignition front speed and temperature of the reaction zone) is evaluated. The upward combustion concept decouples the drying, devolatilization and burnout phase. In this way the moisture and inert content of the waste have almost no influence on the combustion process. In this paper an experimental comparison between conventional and reversed combustion is presented.

09 BIOMASS FUELS↗
DOE OSTI2020

Online Control of Process Variance Using Feedback

For many stochastic control problem formulations, design objectives typically include constraining the covariance of the outputs of the system. Recent engineering challenges have demonstrated an interest in controlling system output covariances to a setpoint. However, open-loop control of system output covariance can be exceptionally challenging when the system has significant plant uncertainties. This paper explores closed-loop control of the system’s output covariance using a windowed variance function. The stochastic nature of the windowed variance feedback means that root locus and other classical control design techniques cannot be immediately used. Expected value analysis is used to generate transfer functions for the average response of such systems, and the results are used to design controllers. Stochastic simulations are presented to verify the analytical results and make other observations concerning closed-loop variance control.

Bieniek, Mitchell↗
DOE OSTI2025

Lightweight Metal Stamping Optimization Enabled by Artificial Intelligence

Successfully manufacturing an automotive body structure made via the sheet metal stamping process depends upon simultaneous consideration of component design, tooling design, stamping process control, and material properties. In many cases, introducing lightweight sheet materials (e.g., aluminum alloys, magnesium alloys, advanced high strength steels) holds the potential to significantly reduce vehicle weight, but challenges the stamping process by introducing materials with inherently less ductility. Successful and repeatable applications require co-developing the stamping process controls with the varying material properties, including formability. During the stamping process, as soon as the forming limit of the sheet is exceeded, the material shows localized necking which quickly leads to splits. Controlling process variability to avoid these material splits will enable deployment of less formable, lighter, and stronger materials for stamped automotive components. A typical optimization procedure for manufacturing requires an iterative process involving parameter setting, execution of computational simulations, and modifying the parameters. The entire process demands substantial computational time, making it impractical for real-time feedback towards rapid corrective actions required for in-line control for running production processes. To overcome this challenge, artificial intelligence (AI) can be leveraged to determine optimal manufacturing parameters within a single manufacturing cycle time. This research proposes an in-line optimization framework incorporating a trained AI model to predict kidney-shaped die forming. Preliminary results indicate that the AI framework can accurately predict draw-in values based on a given parameter set, a process referred to as forward prediction. Furthermore, the AI framework can also predict the optimal parameter set that leads to the desired draw-in values, referred to as inverse optimization (or backward prediction). This research has been performed in collaborations with USCAR (US Council for Automotive Research) and AutoForm. The members of USCAR are Ford, GM, and Stellantis.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Policy-based secure communication with automatic key management for industrial control and automation systems

A method includes generating at least one access vector associated with a specified device in an industrial process control and automation system. The specified device has one of multiple device roles. The at least one access vector is generated based on one or more communication policies defining communications between one or more pairs of devices roles in the industrial process control and automation system, where each pair of device roles includes the device role of the specified device. The method also includes providing the at least one access vector to at least one of the specified device and one or more other devices in the industrial process control and automation system in order to control communications to or from the specified device.

47 OTHER INSTRUMENTATION↗
DOE OSTI2015

Metrology for Fuel Cell Manufacturing

The project was divided into three subprojects. The first subproject is Fuel Cell Manufacturing Variability and Its Impact on Performance. The objective was to determine if flow field channel dimensional variability has an impact on fuel cell performance. The second subproject is Non-contact Sensor Evaluation for Bipolar Plate Manufacturing Process Control and Smart Assembly of Fuel Cell Stacks. The objective was to enable cost reduction in the manufacture of fuel cell plates by providing a rapid non-contact measurement system for in-line process control. The third subproject is Optical Scatterfield Metrology for Online Catalyst Coating Inspection of PEM Soft Goods. The objective was to evaluate the suitability of Optical Scatterfield Microscopy as a viable measurement tool for in situ process control of catalyst coatings.

08 HYDROGEN↗