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DOE OSTI2012

Development of a dynamic simulator for a natural gas combined cycle (NGCC) power plant with post-combustion carbon capture

The AVESTAR Center located at the U.S. Department of Energy’s National Energy Technology Laboratory and West Virginia University is a world-class research and training environment dedicated to using dynamic process simulation as a tool for advancing the safe, efficient and reliable operation of clean energy plants with CO{sub 2} capture. The AVESTAR Center was launched with a high-fidelity dynamic simulator for an Integrated Gasification Combined Cycle (IGCC) power plant with pre-combustion carbon capture. The IGCC dynamic simulator offers full-scope Operator Training Simulator (OTS) Human Machine Interface (HMI) graphics for realistic, real-time control room operation and is integrated with a 3D virtual Immersive Training Simulator (ITS), thus allowing joint control room and field operator training. The IGCC OTS/ITS solution combines a “gasification with CO{sub 2} capture” process simulator with a “combined cycle” power simulator into a single high-performance dynamic simulation framework. This presentation will describe progress on the development of a natural gas combined cycle (NGCC) dynamic simulator based on the syngas-fired combined cycle portion of AVESTAR’s IGCC dynamic simulator. The 574 MW gross NGCC power plant design consisting of two advanced F-class gas turbines, two heat recovery steam generators (HRSGs), and a steam turbine in a multi-shaft 2x2x1 configuration will be reviewed. Plans for integrating a post-combustion carbon capture system will also be discussed.

03 NATURAL GAS↗

DOE OSTI2017

Effects of the Planetary Temperature on the Circumplanetary Disk and on the Gap

Circumplanetary disks (CPDs) regulate the late accretion to the giant planet and serve as the birthplace for satellites. Understanding their characteristics via simulations also helps to prepare for their observations. Here we study disks around 1, 3, 5, and 10 M {sub Jup} planets with 3D global radiative hydrodynamic simulations with sub-planet peak resolution and various planetary temperatures. We found that as the 1 M {sub Jup} planet radiates away its formation heat, the circumplanetary envelope transitions to a disk between T{sub p}=6000 and 4000 K. In the case of 3–10 M {sub Jup} planets, a disk always forms. The temperature profile of the CPDs is very steep, the inner 1/6th is higher than the silicate condensation temperature, and the entire disk is higher than the water freezing point, making satellite formation impossible in this early stage (<1 Myr). Satellites might form much later and first in the outer parts of the disk, migrating inwards later on. Our disk masses are 1, 7, and 20 40×10{sup −3} M{sub Jup} for the 1, 3, 5, and 10 M {sub Jup} gas giants, respectively, and we provide an empirical formula to estimate the subdisk masses based on the planet- and circumstellar disk (CSD) mass. Our finding is that the cooler the planet, the lower the temperature of the subdisk, and the higher the vertical influx velocities. The planetary gap is also both deeper and wider. We also show that the gaps in 2D and 3D are different. The subdisk eccentricity increases with M{sub p} and violently interacts with the CSD, making satellite-formation less likely when M{sub p}≳5M{sub Jup}.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2015

A multi-beamlet analysis of the MITICA accelerator

The thermo-mechanical analysis and the mechanical design of the accelerator of MITICA (i.e. the full size prototype of the ITER neutral beam injector under construction at RFX [1]) are based on the calculation of the power deposition induced by particle impacts. This calculation is performed by EAMCC [2], a relativistic particle tracking code based on the Monte-Carlo method for describing collisions inside the accelerator, under prescribed electric and magnetic fields. The magnetic field maps are produced by 3D codes, while the electric field maps come from the 2D axi-symmetric code SLACCAD [3]. In order to perform a multi-beamlet analysis, which allows to take into account the beamlet-beamlet repulsion, and to consider other effects neglected under the hypothesis of axi-symmetric beam, a fully 3D version of the code is required. In this paper, a modified version of EAMCC, fully 3D, capable of modifying the mesh of the 3D maps and of dealing with uneven meshes is presented. A finer mesh is used just in the regions where a more detailed description of the fields is required, for a more realistic simulation. A comparison between the original code and the modified version is presented at first, as a validation of the modifications introduced in the latter. Subsequently, the main results of a single-beamlet analysis performed with the two versions of the code are shown and the differences between the 2D and the 3D simulations discussed. The last part is dedicated to the multi-beamlet simulation of the accelerator.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS2008

Modeling of the Ablation of Fibrous Materials in the Knudsen Regime

During atmospheric entry of planetary probes, the thermal protection system (TPS) of the probe is exposed to high temperatures under low pressures. In these conditions, carbonous TPS materials undergo gasification in the Knudsen regime leading to mass loss and wall recession called ablation. This work aims to improve the understanding of materiaVenvironment interactions through a study of the coupling between carbon dioxide transport in the Knudsen regime, heterogeneous oxidation of carbon, and sutface recession. A 3D Monte-Carlo simulation tool is used for this study. The fibrous architecture of the materiils, consisting of high porosity random array of carbon fibers, is numerically reproduced on a 3D Cartesian grid. Mass transport in the Knudsen regime from the boundary layer to the surface, and inside this porous material is simulated by random walk. A reaction probability is used to simulate the heterogeneous oxidation reaction. The surface recession is followed by front tracking using a simplified marching cube approach. The output data of the simulations are ablation velocity and dynamic evolution of the material porosity. A parametric study is carried out to analyze the material behavior as a function of Knudsen number for the porous media (length of the mean free path compared to the mean pore diameter) and the intrinsic reactivity of the carbon fibers. The results enable extrapolation of laboratory experimental data to actual entry conditions.

Lachaud, J.↗

DOE OSTI2013

On the feasibility of optical-CT imaging in media of different refractive index

Purpose: Achieving accurate optical-CT 3D dosimetry without the use of viscous refractive index (RI) matching fluids would greatly increase convenience. Methods: Software has been developed to simulate optical-CT 3D dosimetry for a range of scanning configurations including parallel-beam, point, and converging light sources. For each configuration the efficacy of three refractive media was investigated: air, water, a fluid closely matched to PRESAGE{sup Registered-Sign }, and perfect matching (RI = 1.00, 1.33, 1.49, and 1.501 respectively). Reconstructions were performed using both filtered backprojection (FBP) and algebraic reconstruction technique (ART). The efficacy of the three configurations and the two algorithms was evaluated by calculating the usable radius (i.e., the outermost radius where data were accurate to within 2%), and gamma ({Gamma}) analysis. This definition recognizes that for optical-CT imaging, errors are greatest near the edge of the dosimeter, where refraction can be most pronounced. Simulations were performed on three types of dose distribution: uniform, volumetric modulated arc therapy (VMAT), and brachytherapy (Cs-137). Results: For a uniformly irradiated dosimeter the usable radius achieved with filtered backprojection was 68% for water-matching and 31% for dry-scanning in air. Algebraic reconstruction gave usable radii of 99% for both water and air (dry-scanning), indicating greater recovery of useful data for the uniform distribution. FBP and ART performed equally well for a VMAT dose distribution where less dose is delivered near the edge of the dosimeter. In this case, the usable radius was 86% and 53% for scanning in water and air, respectively. For brachytherapy, the usable radius was 99% and 98% for scanning in water and air, respectively using FBP, and a major decrease was seen with ART. Point source geometry provided 1%-2% larger usable radii than parallel geometry. Converging geometry recovered less usable dosimetry data (up to 10% reduced usable radii) than point and parallel geometries. A further disadvantage of converging geometry was an increased requirement on detector size by up to 18 Degree-Sign . Conclusions: For applications where dose information is not required in the periphery of the dosimeter, some dry and low-viscous matching configurations may be feasible. For all three dose distributions (uniform, VMAT, brachytherapy) the point source geometry produced slightly more favorable results (an extra 1%-2% usable radii) than parallel and converging. When dosimetry is required on the periphery, best results were obtained using close refractive matching and ART. A concern for water or dry-scanning is the increase in required detector size, introducing potential cost penalties for manufacturing.

36 MATERIALS SCIENCE↗

NASA NTRSDate not supplied

Simulation-Aided Design and Interpretation of Results of Microgravity-Based Solidification Experiments

The preparation and interpretation of microgravity experiments conducted on the International Space Station (ISS) can be challenging because of the remote location of the equipment. Although a “ground unit” is typically available on Earth, it is not located in the laboratory of the principal investigator. Furthermore, test experiments in the ground unit cannot fully duplicate heat transfer conditions of the weightless environment, and thus be a reliable reference for experiment design. Under such conditions, numerical simulations are a valuable tool both for preparing the experiments and interpreting the results obtained under terrestrial and micro-gravity conditions. In this work, we developed a detailed 3D model of the “SUBSA” furnace located at the ISS, and demonstrate its use in our present investigation which includes melt growth and vapor growth of InI crystals on the ISS. In 2002, the SUBSA furnace was designed and built for the growth of InSb crystals in the Microgravity Science Glovebox (MSG) at the ISS. The SUBSA furnace features a transparent section without heating elements, where the axial temperature gradient is high. In our present investigation, we have used the same furnace to grow four InI crystals from the melt, and two InI crystals from the vapor phase (2018-2021). InI crystals have ~20 times lower thermal conductivity than InSb crystals. As a result, during melt growth, the InI crystals were exposed to extremely high temperature gradients. To reduce the axial temperature gradient, we added external jackets made from high thermal conductivity material to the growth ampoules. The SUBSA furnace could not be modeled as asymmetric because of its rectangular shape and right-angled transparent section, which contains a convoluted geometry. The rectangular shape of the transparent section further complicates modelling of radiative heat transfer, which dominates in the zone. At present, numerical simulations are being conducted to resolve an apparent discrepancy between the readings of the 5 thermocouples located in the SUBSA furnace, and the observed position of the solid and molten material. The 3D simulation will be presented, along with the calibration and growth experiment results conducted in microgravity and in the SUBSA ground unit. The developed model should be useful for upcoming microgravity investigations planned to be conducted in the SUBSA facility.

V Riabov↗

DOE OSTI2021

Data accompanying the publication "Sensitivity of grass fires burning in marginal conditions to atmospheric turbulence" in the Journal of Geophysical Research-Atmospheres

Data accompanying Jonko, Yedinak, Conley, and Linn (2021): "Sensitivity of grass fires burning in marginal conditions to atmospheric turbulence", JGR-Atmospheres. LA-UR-21-24832. The following files were generated from simulations performed with Los Alamos National Laboratory coupled atmosphere-fire behavior model FIRETEC v1.3: -area_burned.csv contains the area burned per second in m^2 for 45 CORE simulations, 20 INIT simulations and 20 BOUND simulations (85 columns), and 600 seconds of simulation (600 rows). -fire_perimeter.csv containing the fire perimeters in m for 45 CORE simulations, 20 INIT simulations and 20 BOUND simulations (85 columns), and 600 seconds of simulation (600 rows). -consumption_per_second.csv containing consumption in kg/s for 45 CORE simulations, 20 INIT simulations and 20 BOUND simulations (85 columns), and 600 seconds of simulation (600 rows). -rate_of_spread.csv containing the distance of the fire front from the ignition line in m for 45 CORE simulations, 20 INIT simulations and 20 BOUND simulations (85 columns), and 600 seconds of simulation (600 rows). -CORE1_u_10m_300_sec.hdf, INIT3_u_10m_300_sec.hdf, and BOUND3_u_10m_300_sec.hdf contain u wind speeds at 10 m height for 300 seconds (3D: time, x, y) of simulation for simulations CORE1, INIT3, and BOUND3, respectively. -CORE.final.fuel.density.hdf contains final fuel densities in the surface layer of the model (3D: ensemble member, x, y) for all 45 CORE simulations. -CORE{1-45}_3D_u_120_sec.hdf: 45 files containing vertically and horizontally resolved u winds for 120 seconds of simulation (4D: time, x, y, z) for the 45 CORE ensemble members. For additional information about this data, please contact the corresponding author at ajonko@lanl.gov.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Large-Eddy Simulation Study of Flow and Combustion Dynamics in a Full-Scale Hydrogen–Air Rotating Detonation Combustor-Stator Integrated System

In the present work, a first-of-its-kind three-dimensional (3D) large-eddy simulation (LES) study is conducted to numerically investigate the combustion dynamics as well as aero-thermal phenomena in a full-scale nonpremixed hydrogen–air rotating detonation engine (RDE) (with a diverging-shaped lower-end wall), when integrated with nozzle guide vanes (NGV) acting as the turbine stator. The wall-modeled LES framework incorporates hydrogen–air detailed chemical kinetics and adaptive mesh refinement (AMR). A comparative analysis is carried out for two operating conditions with different fuel/air mass flow rates but global equivalence ratio of unity, and considering RDE configurations without and with stator. The LES model is validated against available experimental data for the low mass flux condition with respect to detonation wave speed/height, wave dynamics, and axial static pressure distribution. Numerical results indicate significant deflagrative combustion occurring in the fill region near the inner wall due to formation of recirculation zones in the injection near-field driven by the backward facing step. The leading detonation wave is found to be trailed by an azimuthal reflected-shock combustion (ARSC) wave, consistent with experimental observations, which consumes unburned vitiated reactants that leak through the main detonation wave. The main detonation wave characteristics, such as detonation wave speed/height and combustion efficiency, do not change appreciably with the presence of NGV. A novel combustion diagnostic technique based on chemical explosive mode analysis (CEMA) is employed to quantify the fraction of heat release occurring in the detonative mode versus deflagrative mode for the simulated conditions. The exit flow is found to be nearly fully subsonic and supersonic for the low and high mass flux conditions, respectively. Further analysis of the exit flow profiles shows that the presence of NGV renders the flow more axial and significantly impacts the exit Mach number and total pressure, while the total temperature shows negligible change. In addition, the low mass flux operating point, despite exhibiting more deflagrative losses within the combustor, yields overall lower pressure drop from plenum to exhaust, which is mainly attributed to lower pressure drop across the injectors. Lastly, the rotating detonation engine-nozzle guide vanes (RDE-NGV) configuration exhibits higher total pressure loss compared to rotating detonation engine (RDE) without stator across both the mass flux conditions. In conclusion, this study extends the state-of-the-art in numerical modeling of pressure gain combustion (PGC) systems by demonstrating high-fidelity 3D reacting LES of full-scale RDE-NGV systems relevant to RDE-turbine integration for stationary power generation.

Combustion↗

NASA NTRSDate not supplied

Updates on the Predictive Materials Modeling Software Tools

Updates on NASA‘s efforts to build a Predictive Material Modeling (PMM) framework from the micro-scale to the macro-scale are presented in this abstract. The PMM effort is part of the Entry Systems Modeling (ESM) project under NASA’s Game Changing Development (GCD) program. To reduce the need for extensive testing and accelerate the design cycle process, ESM is developing simulation and modeling tools that enable the characterization of the properties of thermal protection materials and their response to extremely hot plasma. The Porous Microstructure Analysis (PuMA) software has been developed to compute effective material properties and perform material response simulations on digitized microstructures of porous media. PuMA is able to import three-dimensional digital images obtained from X-ray microtomography or to generate artificial microstructures that mimic real materials. PuMA also provides a module for interactive 3D visualizations. Version 3, which was recently released as open-source, includes modules to compute simple morphological properties such as porosity, volume fractions, pore diameter, and specific surface area. Additional capabilities include the determination of effective thermal and electrical conductivity (both radiative and solid conduction - including the ability to simulate local anisotropy for the latter); effective diffusivity and tortuosity from the continuum to the rarefied regime; techniques to determine the local material orientation, as well as mechanical properties (elasticity coefficients), and permeability. Computed properties are then used to inform a macro-scale material response model, such as those implemented in the Porous material Analysis Toolbox based on OpenFOAM (PATO) software developed within ESM. The computational model in PATO is a generic heat and mass transfer model for porous reactive materials containing several solid phases and a single gas phase. The detailed chemical interactions occurring between the solid phases and the gas phase are modeled at the pore scale, assuming Local Thermal Equilibrium. Recent efforts include the development of a mechanical erosion model as well as a unified model allowing an intrinsic coupling between fluid and material. Comparison to flight data (Mars Science Laboratory [MSL] Entry Descent and Landing Instrument [MEDLI] and Mars 2020 MEDLI2) is critical in order to validate these computational tools. Examples of ablative material response using the code will be presented, including 3D simulations of the full-scale heatshield of the MSL capsule. The simulations demonstrated the ability of the modern material response code, PATO, to handle the material response of geometrically complex and large domains through the use of massively parallel computations.

material modeling↗

DOE OSTI2022

r -process nucleosynthesis and kilonovae from hypermassive neutron star post-merger remnants

ABSTRACT We investigate r-process nucleosynthesis and kilonova emission resulting from binary neutron star (BNS) mergers based on a three-dimensional (3D) general-relativistic magnetohydrodynamic (GRMHD) simulation of a hypermassive neutron star (HMNS) remnant. The simulation includes a microphysical finite-temperature equation of state (EOS) and neutrino emission and absorption effects via a leakage scheme. We track the thermodynamic properties of the ejecta using Lagrangian tracer particles and determine its composition using the nuclear reaction network SkyNet. We investigate the impact of neutrinos on the nucleosynthetic yields by varying the neutrino luminosities during post-processing. The ejecta show a broad distribution with respect to their electron fraction Ye, peaking between ∼0.25–0.4 depending on the neutrino luminosity employed. We find that the resulting r-process abundance patterns differ from solar, with no significant production of material beyond the second r-process peak when using luminosities recorded by the tracer particles. We also map the HMNS outflows to the radiation hydrodynamics code SNEC and predict the evolution of the bolometric luminosity as well as broadband light curves of the kilonova. The bolometric light curve peaks on the timescale of a day and the brightest emission is seen in the infrared bands. This is the first direct calculation of the r-process yields and kilonova signal expected from HMNS winds based on 3D GRMHD simulations. For longer-lived remnants, these winds may be the dominant ejecta component producing the kilonova emission.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2015

SU-E-J-45: The Correlation Between CBCT Flat Panel Misalignment and 3D Image Guidance Accuracy

Purpose To simulate the impact of CBCT flat panel misalignment on the image quality, the calculated correction vectors in 3D image guided proton therapy and to determine if these calibration errors can be caught in our QA process. Methods The X-ray source and detector geometrical calibration (flexmap) file of the CBCT system in the AdaPTinsight software (IBA proton therapy) was edited to induce known changes in the rotational and translational calibrations of the imaging panel. Translations of up to ±10 mm in the x, y and z directions (see supplemental) and rotational errors of up to ±3° were induced. The calibration files were then used to reconstruct the CBCT image of a pancreatic patient and CatPhan phantom. Correction vectors were calculated for the patient using the software’s auto match system and compared to baseline values. The CatPhan CBCT images were used for quantitative evaluation of image quality for each type of induced error. Results Translations of 1 to 3 mm in the x and y calibration resulted in corresponding correction vector errors of equal magnitude. Similar 10mm shifts were seen in the y-direction; however, in the x-direction, the image quality was too degraded for a match. These translational errors can be identified through differences in isocenter from orthogonal kV images taken during routine QA. Errors in the z-direction had no effect on the correction vector and image quality.Rotations of the imaging panel calibration resulted in corresponding correction vector rotations of the patient images. These rotations also resulted in degraded image quality which can be identified through quantitative image quality metrics. Conclusion Misalignment of CBCT geometry can lead to incorrect translational and rotational patient correction vectors. These errors can be identified through QA of the imaging isocenter as compared to orthogonal images combined with monitoring of CBCT image quality.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2014

High energy gain in three-dimensional simulations of light sail acceleration

The dynamics of radiation pressure acceleration in the relativistic light sail regime are analysed by means of large scale, three-dimensional (3D) particle-in-cell simulations. Differently to other mechanisms, the 3D dynamics leads to faster and higher energy gain than in 1D or 2D geometry. This effect is caused by the local decrease of the target density due to transverse expansion leading to a “lighter sail.” However, the rarefaction of the target leads to an earlier transition to transparency limiting the energy gain. A transverse instability leads to a structured and inhomogeneous ion distribution.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2018

Analysis of Cloud-Resolving Model Simulations for Scale Dependence of Convective Momentum Transport

Abstract We use 3D cloud-resolving model (CRM) simulations of two mesoscale convective systems at midlatitudes and a simple statistical ensemble method to diagnose the scale dependency of convective momentum transport (CMT) and CMT-related properties and evaluate a parameterization scheme for the convection-induced pressure gradient (CIPG) developed by Gregory et al. Gregory et al. relate CIPG to a constant coefficient multiplied by mass flux and vertical mean wind shear. CRM results show that mass fluxes and CMT exhibit strong scale dependency in temporal evolution and vertical structure. The upgradient–downgradient CMT characteristics for updrafts are generally similar between small and large grid spacings, which is consistent with previous understanding, but they can be different for downdrafts across wide-ranging grid spacings. For the small to medium grid spacings (4–64 km), Gregory et al. reproduce some aspects of CIPG scale dependency except for underestimating the variations of CIPG as grid spacing decreases. However, for large grid spacings (128–512 km), Gregory et al. might even less adequately parameterize CIPG because it omits the contribution from either the nonlinear-shear or the buoyancy forcings. Further diagnosis of CRM results suggests that inclusion of nonlinear-shear forcing in Gregory et al. is needed for the large grid spacings. For the small to median grid spacings, a modified Gregory et al. with the three-updraft approach help better capture the variations of CIPG as grid spacing decreases compared to the single updraft approach. Further, the optimal coefficients used in Gregory et al. seem insensitive to grid spacings, but they might be different for updrafts and downdrafts, for different MCS types, and for zonal and meridional components.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2019

EGS Collab Testbed 1: Temperature profile

This submission includes an input file, plot file, Fortran conversion file, and 3D data file from the simulation of the temperature profile within the Test Bed #1 of the EGS Collab project. The simulation was executed with PNNL's STOMP-GT simulator, which reads the input file, and produces the STOMP-GT Simulated 2D Temperature Distribution Data (plot.001302 file). The Fortran conversion file, converts the STOMP-GT Simulated 2D Temperature Distribution Data (plot.001302) 2D results in local coordinates to 3D results in Homestake coordinates.

15 GEOTHERMAL ENERGY↗

NASA NTRSDate not supplied

Fast Assessment of Metal Performance through Dislocation Physics and Machine Learning

The microstructure of metals is key to their mechanical properties. The types, density, composition and morphology of crystal defects all have pronounced impact on the properties. Changes to the microstructure occurring during processing and use can be very striking. The emerging technology additive manufacturing (AM) has the potential to improve performance by allowing optimized designs, but the process and environments can lead to unusual microscale features whose properties must be understood and characterized to enable higher technological readiness levels and application. Experimentally, an extensive evaluation of mechanical properties of 3D printed metals is a challenge, and anomalous effects related to the AM process add complexity. We present a new machine learning (ML) model predicting mechanical response based on dislocation mediated plasticity simulations. A large set of 3D discrete dislocation dynamics simulations with wide ranges of loading conditions is transformed to preprocessed data ready for training with the ML model. The trained model can predict the mechanical response of Mo30W for a given microstructure evolution, providing key information essential for optimization of AM processing.

Jaehyun Cho↗

NASA NTRSDate not supplied

Fast Assessment of Metal Performance through Dislocation Physics and Machine Learning

Jaehyun Cho↗

DOE OSTI2015

3D reconstruction of carbon nanotube networks from neutron scattering experiments

Structure reconstruction from statistical descriptors, such as scattering data obtained using x-rays or neutrons, is essential in understanding various properties of nanocomposites. Scattering based reconstruction can provide a realistic model, over various length scales, that can be used for numerical simulations. In this study, 3D reconstruction of a highly loaded carbon nanotube (CNT)-conducting polymer system based on small and ultra-small angle neutron scattering (SANS and USANS, respectively) data was performed. These light-weight and flexible materials have recently shown great promise for high-performance thermoelectric energy conversion, and their further improvement requires a thorough understanding of their structure-property relationships. The first step in achieving such understanding is to generate models that contain the hierarchy of CNT networks over nano and micron scales. The studied system is a single walled carbon nanotube (SWCNT)/poly (3,4-ethylenedioxythiophene): poly (styrene sulfonate) (PEDOT: PSS). SANS and USANS patterns of the different samples containing 10, 30, and 50 wt% SWCNTs were measured. These curves were then utilized to calculate statistical two-point correlation functions of the nanostructure. These functions along with the geometrical information extracted from SANS data and scanning electron microscopy images were used to reconstruct a representative volume element (RVE) nanostructure. Generated RVEs can be used for simulations of various mechanical and physical properties. This work, therefore, introduces a framework for the reconstruction of 3D RVEs of high volume faction nanocomposites containing high aspect ratio fillers from scattering experiments.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

DOE OSTI2026

Two-phase flow numerical analysis of electrode geometry for alkaline water electrolyzers

Hydrogen is a promising component of a future energy-secure and efficient economy, but its competitiveness depends on reducing production costs. One strategy is to operate alkaline water electrolyzers at higher current densities to increase output. However, this intensifies performance losses due to gas bubble accumulation, which blocks transport pathways and deactivates electrochemically active surfaces. Enhancing bubble evacuation through electrode design is therefore essential. Previous studies have explored various approaches — such as modifying surface morphology, applying sonication or pressure modulation, and introducing surfactants — but these efforts have addressed a limited range of conditions due to the complexity of two-phase flow and electrode geometries. Experiments have also largely been focused on either cell level improvements, which lack the information necessary to isolate each contributing factor, or on modified geometries that are not relevant to practical cell operation. From a modeling perspective, conventional Eulerian multiphase models do not track the complex gas–liquid interfacial dynamics and often neglect surface tension and contact angle effects, reducing their predictive accuracy. To provide insights on the effects of different electrode geometries on the performance of alklaine water electrolyzers this work employs an immersed boundary volume-of-fluid method to simulate bubble behavior in 3D porous electrodes. Multiple base electrode geometries, typically used in practice, with varying porosity are evaluated under a constant surface gas generation rate. Simulation data is analyzed to quantify electrode gas coverage, bubble size dynamics and other relevant metrics. Results show that porosity strongly influences bubble accumulation on electrode surfaces, with higher porosity reducing gas coverage, and its not strictly dependent on the electrode geometry. However, the electrode’s base geometry significantly affects gas accumulation at the separator gap, independent of porosity. A foam electrode geometry resulted in the lowest gas coverage of all electrodes with a median volumetric gas coverage of 11%, but at the cost of a 70% reduction in active area compared with the largest surface area electrode, while gyroid electrodes showed the best trade-off between gas coverage, particularly at the separator surface, and electrochemically active area. In conclusion, the results highlight the need for holistic electrode design strategies.

Alkaline↗