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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 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

AEOLIAN INTERDUNE FACIES OF THE NAVAJO SANDSTONE, UTAH

During the Early Jurassic an extensive desert environment covered a large area of the Western Interior of the USA. The Navajo Sandstone erg is thought to be one of the largest dunefields preserved in the rock record, estimated to have covered well over 500,000 km2, though the preserved extent is less due to erosion. The Navajo Sandstone outcrops extensively in eastern and southern Utah, forming spectacular domes and arches, including those in Arches National Park. Navajo Sandstone aeolian dunes consist of stacked, tabular sandstone bodies, displaying steeply dipping crossbedding, and are on average 15 m thick, with high porosity and permeability. In addition to these extensive paleodunes, interdune deposits are also documented, consisting of lensoid sandstone or pale grey limestone, of approximately 1-7 m thick. This research forms part of a broader investigation into the Navajo Sandstone in Utah, focusing on its potential as a CO2 reservoir. The internal stratigraphy of the Navajo Sandstone can be complex, with multiple types of aeolian surfaces present including discontinuous inter-dune contacts, and inclined bedding planes associated with large climbing dunes. Interdune deposits may be associated with more laterally extensive stratigraphic surfaces, highlighting their importance in the internal stratigraphic framework of the Navajo Sandstone erg. Here we interpret facies and depositional processes of aeolian interdune deposits of the Navajo Sandstone throughout Utah, using well log, outcrop, and thin sections. Interdune deposits range in type from short lived, small ponds of predominantly reworked aeolian sediment, to comparatively long-lived oases consisting of lakes with extensive ecosystems. This project aims to increase our understanding of an important potential CO2 reservoir, and enhance understanding of stratigraphic complexity within one of the world's most significant aeolian systems.

Mahon, Elizabeth (ORCID:0000000252692454)↗
DOE OSTI2025

Evaluating Microchannel Heat Exchanger Lifetime for Concentrating Solar Power Applications Research Performance Progress Report (RPPR-1)

Microchannel heat exchanger technology is being pursued for next generation CSP concepts for primary power cycle heat addition and power cycle heat recuperation due to the high heat transfer coefficients and pressure containment advantages of small sCO 2 channels. The economics of future CSP plants as dictated by the SETO 2020 or 2030 targets depend on a heat exchanger with a 30-year lifetime (resisting creep, fatigue, corrosion, erosion) and operational characteristics such as fast ramping and the ability to withstand thermal shock. However, the lifetime and operational limits of microchannel heat exchangers operating at high temperatures, particularly those constructed from high-nickel alloys, are not well known. This uncertainty has resulted in heat exchanger vendors not being able to accurately forecast heat exchanger lifetime as required by customers, specify operational limits as required by process engineers to prevent premature heat exchanger failure, or overdesign heat exchanger which leads to higher cost than necessary.

14 SOLAR ENERGY↗
DOE OSTI2025

Capability in Theory, Modeling, and Validation for a Range of Innovative Fusion Concepts using High-Fidelity Moment-Kinetic Models

A computational modeling capability is created and available to the fusion community to understand and design lower-cost and innovative fusion concepts. The approach uses high- fidelity kinetic, moment-kinetic, and moment models and includes sophisticated plasma- boundary interactions. A majority of fusion-relevant simulations are performed with magnetohydrodynamic models and hybrid particle-in-cell codes, with limited-fidelity electron and kinetic physics. However, in fusion configurations like Z-pinches, field-reversed- configurations, plasma jet magneto-inertial fusion, spinning mirrors, and others, kinetic effects (both electron and ions) are critical to understand the physics and design scaling into the highly kinetic regime of a burning fusion plasma. Furthermore, as present fusion machines move towards a burning plasma regime, liquid-metal blankets are needed to handle first-wall heat- flux, reduce erosion, and eventually for energy conversion and fuel breeding. The work performed under this ARPA-E BETHE Capability Team advances the state-of-the-art in modeling and understanding plasma dynamics in fusion devices and its coupling with liquid-metal dynamics. These are critical areas of research for fusion energy to become realizable. To address these complex problems, we have leveraged and extended computational capabilities through the code, Gkeyll (developed jointly with Princeton Plasma Physics Laboratory and academic partners), for kinetic and moment modeling of fusion plasmas. The Concept Teams supported by this Capability Team include the Wisconsin High-field Axisymmetric Mirror (WHAM), Centrifugal Mirror Experiment (CFME), Plasma-Jet Magneto- Inertial Fusion (PJMIF), and solid and liquid wall plasma-material interaction studies relevant to a number of fusion concepts including Zap Energy’s Z-pinch. This software is open-source and available to the fusion community as a high-fidelity tool for the design of lower-cost fusion experiments. 3D gyrokinetic simulations of WHAM are now possible for long enough time scales to understand the evolution of interchange instabilities. 3D multi-fluid simulations of CMFE at higher Mach numbers are now possible for detailed design iterations with the goal of stability. The state-of-the-art in understanding shock formation and shock mitigation regimes in merging liners for PJMIF have been furthered by our kinetic simulations. Our novel models and frameworks studying plasma-material interaction by incorporating wall emission for various solid wall materials of relevance to pulsed and steady fusion concepts have advanced the state-of-the-art in our understanding of particle fluxes, heat fluxes, and other quantities at cathodes and anodes. The results from this work may explain discrepancies between experimental and theoretical predictions of achieved current densities in pulsed concepts such as Z-pinches. Another significant contribution of this Capability Team is the development and deployment of a novel experimental platform, LEX (Liquid Electrode eXperiment), at Virginia Tech to understand liquid metal free-surface response to electromagnetic pulses. The novel experiments along with model validation quantified the effect of different materials and sizes of liquid metal droplets on the radiative power balance of fusion plasmas for pulsed concepts. Furthermore, these experiments provided mitigation strategies for violent liquid metal response for high current pulses as would be expected in fusion regimes.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Enabling Low-Temperature (LTP) Ignition Technologies for Multi-Mode Engines through the Development of a Validated High-Fidelity LTP Model for Predicative Simulations Tools

The goal of multi-mode engine architectures is to extend current lean-burn dilution limits with renewable fuels, which requires spark plugs to deposit high energies (hundreds of mJ) in order to initiate ignition and complete combustion. At elevated energy deposition rates, spark plugs experience increased electrode erosion and thermal losses, which ultimately shortens the spark-plug lifetime and lowers ignition efficiency. As such, in order to safeguard the efficiency gains of multi-mode concepts, new and improved ignition technologies are required. Recently, non-equilibrium low-temperature plasmas (LTP) have been shown to promote energy-efficient ignition via quenching and transport of electronically excited atoms and molecules, selective radical production and fast heating of hydrocarbon/air mixtures [1-2]. Thus, LTP is seen as a technology that can potentially improve the energy extraction efficiency of fuels, while enabling kinetically controlled combustion modes towards fuel leaner conditions to realize current DOE VTO goals of improving the sustainability of future mobility [3]. Although many previous studies have demonstrated the efficacy of plasma-assisted ignition to enhance combustion, the detailed enhancement mechanisms remain largely unknown, especially for oxygenated fuels and at elevated pressures that are most relevant to practical engine conditions. These barriers hinder the development of accurate and comprehensive numerical models that seek to describe LTP-based ignition in existing engine design software tools and methods. Current state-of-the-art simulation capabilities for LTP ignition systems are in need of improvements since they deliver qualitative results only due to important limitations of existing approaches. Firstly, validated kinetic models with elementary steps for plasma discharges in oxygenated fuel/air mixtures of relevance to the transportation sector are required. Such kinetic models do not exist at present and will be developed and validated within this project. Secondly, plasma discharges and reactive mixture ignition are multi-scale, unsteady processes requiring high-performance numerical methods and software that execute efficiently on DOE supercomputers. Such software does not exist at present and will be developed and applied to practical LTP ignition scenarios as part of this project. Thirdly, experimental databases that are tailored to serve as benchmark in support of the development of predictive computational models of LTP ignition do not exist and will be part of this project.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Multi-physics Topology OPtimization and Additive Manufacturing for High-temperature Heat Exchangers

This research significantly advances the understanding of high-temperature heat exchanger design through an integrated approach that combines topology optimization (TO), triply periodic minimal surface (TPMS) structures, additive manufacturing (AM) and thermohydraulic testing. Each of these components contributes uniquely to a unified, high-performance design, fabrication and testing workflow. Topology optimization serves as the foundation of the design methodology by providing a systematic way to determine the most effective material layout for separating hot and cold fluids while maximizing thermal performance. The researchers introduced a novel three-material optimization framework using two density fields to represent hot fluid, cold fluid, and solid domains. This approach enables automated discovery of optimal shapes and flow paths that cannot be intuitively designed, especially under constraints imposed by manufacturing technologies. Furthermore, constraints such as minimal wall thickness and overhang angles were embedded into the optimization process, ensuring that resulting designs are not only thermally efficient but also manufacturable using modern additive techniques. In parallel, the study delves into the use of Gyroid-based TPMS geometries for constructing the core of the heat exchanger. TPMS structures are known for their high surface area, excellent fluid mixing capabilities, and minimal pressure drop characteristics. The researchers applied a data-driven modeling framework using Heteroscedastic Sparse Gaussian Process Regression (HSGPR) combined with genetic algorithms. This allowed for the rapid evaluation and optimization of key geometric parameters such as frequency, iso-value, and phase shift. The result was a set of Gyroid structures tailored for high heat transfer and low flow resistance, demonstrating clear improvements over conventional straight-channel designs. After the designing process, additive manufacturing played a critical role by turning these highly complex, optimized geometries into physical components. Utilizing Laser Powder Bed Fusion (LPBF) with Haynes 282, the study demonstrated the feasibility of fabricating these heat exchangers at high precision. Post-processing methods, including dilation-erosion operations, were applied to ensure local features adhered to self-supporting constraints. The fabricated structures were then subjected to thermohydraulic testing under conditions representative of supercritical CO 2 Brayton cycles, validating the predicted performance and confirming the viability of the full design-to-fabrication pipeline. Finally, thermohydraulic testing across the above studies served as a crucial experimental validation of advanced heat exchanger. Under consistent high-temperature and high-pressure conditions using supercritical CO 2 , the testing demonstrated that both TO and Gyroid-based TPMS designs significantly outperformed conventional straight-channel HXs. The TO design achieved a 115% increase in UA and NTU and a 27.6% boost in gravimetric power density, while the data-driven optimized Gyroid design delivered a 166% increase in UA and NTU and improved effectiveness from 68.7% to 86.1%. These results validate the simulation models, confirm the manufacturability of complex geometries under AM constraints, and provide key insights into design-performance trade-offs, thereby advancing the development of high-efficiency, compact heat exchangers for extreme environments.

36 MATERIALS SCIENCE↗
DOE OSTI2025

From Stewardship to Transformation: Toward a Nuclear Enterprise for the 21st Century

The erosion of the global security environment over the last two decades has been rapid and dramatic. It appears also to be accelerating. There are deep and widening concerns in the United States and among its allies and partners that deterrence too has eroded at both the conventional and nuclear levels. The Strategic Posture Commission captured the essence of the problem in its October 2023 report—the United States seeks to meet the challenges of complex multipolar nuclear rivalry in the 21 st century with a slimmed down version of a nuclear deterrent designed in the middle of the 20 th century. With great urgency, the Commission recommended that something more and/or different is needed than simply the replacement of legacy systems with modern variants. But the U.S. nuclear security enterprise was reshaped after the Cold War to support the stockpile stewardship mission—not renewed designed, engineering, and production at scale. It has long fallen short of the agility, flexibility, and adaptiveness periodically asked of it by national leaders. In recent years, however, the message of urgency has been clearly received in the enterprise. Its culture has begun to shift. It has also been received by those in Washington D.C. responsible for funding and guiding the enterprise. The result is an enterprise in transition. Stockpile stewardship has given way to stockpile transformation. Risk aversion is giving way to risk management. Innovation and adaptation have been embraced. Experience to date has yielded some important lessons about what works and what doesn’t in terms of accelerating and delivering the needed innovation and adaptation. It has revealed the enduring character of some challenges. But it has also revealed that a much more agile and effective enterprise is within the national reach—something that will pay important dividends for deterrence, assurance, strategic stability, and peace.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
DOE OSTI2025

MPEX AI Digital Twins

All magnetically confined plasma fusion power plant concepts (Tokamak, Spherical Tokamak, Stellarator, Mirror, ...) must exhaust the heat and plasma from the core confinement region to the material walls. The primary channel for this exhaust is through a plasma divertor which directs plasma along open magnetic field lines to a material target. The Material Plasma Exposure eXperiment (MPEX) illustrated in Figure 1, is a high-power, steady-state linear plasma device designed to produce the plasma material interaction (PMI) conditions of the divertor of future magnetic confinement fusion power plants: energy flux 20MW/m 2 , ion fluence 1031/m 2 , pulse duration 106 sec. These goals of plasma exposure in MPEX are well beyond those achieved in magnetic fusion experimental devices. Successfully achieving these high power steady state conditions for long pulses requires operational control of the heating and particle sources and the plasma flux to the walls and target. The MPEX AI Hot Spot Controller, proposed in this project, will help achieve the operational milestones of MPEX. The MPEX device will begin commissioning at the end of FY26. A smaller proto-MPEX was operated for 14,666 plasma discharges and will resume operation in September of 2025 as proto-MPEX-lite, with reduced capability, to test a new window for the Helicon plasma source. The proto-MPEX data has undergone surrogate modeling with machine learning methods (R. Archibald, 2022 IEEE International Conference on Big Data). This proto-MPEX data will be used to begin development of the AI digital twins described in this white paper. The scientific mission of MPEX is to qualify materials of different composition for use in the high energy and plasma flux conditions of a fusion power plant. The materials exposed in MPEX will in some cases be exposed to high neutron fluxes at other ORNL facilities to measure the changes to their PMI properties. The targets exposed in MPEX will be transported under vacuum to a Surface Analysis Station (SAS). The SAS will be equipped with the following diagnostics: Focused Ion Beam (FIB) for trench milling, 100-400 angstrom resolution scanning electron microscope (SEM), surface mapping x-ray spectrometer, high resolution camera, and a future upgrade to a laser induced breakdown spectroscopy quadruple mass spectrometer (LIBS-QMS). The MPEX experiments will generate diverse pre- and post-exposure measurement data of detailed material properties down to the crystal grain level in 3D for post-exposure assessment of PMI damage (e.g. cracking, melting, erosion and redeposition of the material). Physics models for the PMI, and how the material composition and manufacturing impact its performance under high energy plasma exposure, need to be validated with MPEX data to guide the selection of new candidate materials. Our vision for the MPEX AI Digital Twins project is to supply experimental and physics model simulation data to train Artificial Intelligence (AI) models for data processing, analysis, operational control, PMI and materials simulation to maximize the scientific output of the MPEX device. Ultimately, an AI digital twin of MPEX material assessment metrics for tested and synthetic material types with simulated PMI will be trained by the AI Modeling Teams on the experimental and physics simulation data submitted to the American Science Cloud by this project. A purely empirical search for the best material is inefficient given the finite number of samples that can be tested on MPEX. In order to expand the material properties database for training the MPEX Material Assessment AI Digital Twin, and to gain physics understanding of the PMI processes, physics models of the material properties and PMI processes are required. The physics simulations provide detailed simulation data, like impact angles for plasma ions, sputtering yields, transport of the ionized sputtered target material in the plasma, and redeposition locations. This simulation data expands the measurement data for deeper physics understanding. The experimental data is essential to validate the PMI and material structure simulation models. The validated models can then be used to generate new simulation data of MPEX material assessments for synthetic material compositions that have not been exposed in MPEX. These predictive simulations, plus the whole experimental dataset, will be used to train the MPEX Material Assessment AI Digital Twin allowing a rapid generative AI search for new materials with reduced PMI damage by interpolating the domain of the training set. These new optimum materials can be simulated with the physics codes and/or tested in MPEX. The ability of AI neural networks to interpolate multi-dimensional parameter spaces and generate virtual data is exploited for a more efficient search for optimum materials. The advent of the Transformational AI Models Consortium (TAIMC) is an opportunity to engage with state of the art private and public AI developers to achieve the goals of the AI digital twins and AI accelerated physics models proposed in this project. Our partners at ORNL from the Advance Scientific Computing Research (ASCR) organization will collaborate in accelerating the integrated plasma material interaction simulation framework. This simulation framework will provide a platform for generating simulation data across a range of physical fidelities, including hybrid methods that produce multi-fidelity results. This data will be leveraged for AI model development, both for generation of surrogates and the automation of simulation campaigns. A part of the research below will include collaborative efforts with the TAIMC to (i) adapt data storage approaches to ensure AI-readiness, (ii) provide a protypical exemplar to inform and exercise constructed workflows, and (iii) generate and share data, using the TAIMC unified AI data standard, for foundational models that will be trained from multiple sources across the DOE complex. We will also collaborate with the TAIMC, as well as the planned AI modeling teams, to develop approaches for reducing the cost of data generation. These include tailored multi-fidelity approaches as well as fine-tuning strategies to augment general, large-scale foundational models.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Evaluating the feasibility of tidal energy extraction at non-operational gas platforms and effects of sedimentation and sea ice in Cook Inlet (Abstract)

Littoral Power Systems (LPS) has been granted a FERC preliminary permit for the Upper Cook Inlet Tidal Energy Project in an area that includes existing non-producing natural gas platforms. LPS is working to understand the feasibility of a 2 MW tidal energy project and is considering multiple technologies, the viability of using the platforms to support deployment and operation of the technologies, as well as the environmental conditions that will interact with tidal energy devices. The proposed TEAMER work will conduct a modeling study to understand 1) current velocity and turbulence; 2) the distribution of sea ice trajectories around the platform; and 3) the likelihood of seabed erosion and deposition through an analysis of shear stress in the seabed near the platforms. The results of this work will contribute to determining the feasibility of the site for tidal energy development.

16 TIDAL AND WAVE POWER↗
DOE OSTI2024

Description of FY25 Theory and Simulation Performance Target: Development of an integrated modeling framework for fusion reactor design and assessment

The urgency to deliver fusion power is growing now more than ever, with increasing pressure for both public programs and private companies to meet milestones timelines and overcome significant remaining technical challenges to ensure growth of a nascent fusion industry in time to meet rapidly growing clean energy demands. With incredible advancements in computation and years of investment in fusion model development and validation, integrated modeling is poised to fill a key role in accelerating the timeline to a fusion pilot plant (FPP). Future fusion pilot plants will operate in regimes far beyond current experience, and device design will rely on physics-based prediction and extrapolation. Many concepts will also rely on simulation to assess safety (shielding, tritium management, materials activation and lifetimes), economics and scalability before the decision to build. Importantly, integrated simulation can be used to reveal and solve the complexities of system integration that may otherwise not be apparent in physical components or models developed in isolation. New experimental test facilities that produce relevant conditions to validate and resolve key technical challenges for various subsystems (materials, blankets, fuel cycle, etc.) have been repeatedly called for by the fusion community but are not yet realized. Integrated modeling has an important role in identifying realistic load conditions (thermal, electromagnetic, plasma, neutron and photon loads, etc.) and defining the components and experiments for these test facilities in order to ensure meaningful validation that sufficiently reduces modeling uncertainties and technical risk for the full integrated reactor. The Fusion REactor Design and Assessment (FREDA) SciDAC project is building a component-based integrated modeling framework & data structure to enable self-consistent, multi-fidelity, iterative optimization workflows for the fusion reactor design process. FREDA aims to shorten the time to viable designs by providing a set of flexible workflows to support the various stages of the design process using an integrated model hierarchy, ranging from the simple analytic descriptions to the highest fidelity, theory-based plasma and engineering modeling developed by the fusion and fission communities. These tools are expected to be needed for timely support of FPP design in the milestone program and in the FIRE collaboratives. The plasma simulation backbone of FREDA is IPS-FASTRAN with newly developed coupled Core-Edge Pedestal-SOL (CESOL) workflows, which is being extended to the far-SOL region up to the plasma facing components. FREDA incorporates the FERMI engineering modeling suite and will enable self-consistent evaluation of the thermal shields, limiters, blanket, magnets, and other surrounding structures with predictions of temperatures, erosion, dpa, activation, tritium generation and transport, creep, corrosion, material degradation, etc. Parametric generation of 3D CAD enables rapid iteration of component geometry in response to plasma and loading specifications.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Renewable low-Z wall for fusion reactors with built-in tritium recovery (Final Technical Report)

This project pursued development of a novel renewable plasma-facing wall technology for fusion reactors. The technology is based on a slurry which can be easily delivered by delivery tubes to the reactor wall. The slurry dries at the hot reactor wall into pebble rods which are extruded out into the hot plasma, where the pebbles break off and fall along the reactor wall and can be recovered by gravity and re-used. The falling pebbles carry away heat and tritium and also protect the wall against large scale erosion or redeposition of material. The research focused on carbon-based pebble rods and demonstrated that pebble rods could be produced from slurry with tolerable levels of outgassing on a reactor-relevant timescale (< 5 minutes). Steady-state handling of reactor relevant (up to 50 MW/m 2 ) normal-incidence heat loads was demonstrated. Pebble release velocities were found to be sufficiently small (< 1 m/s) to allow recovery below the vacuum chamber. Tunability of the pebble rod breaking rate was demonstrated by changing the fill fraction of the interpebble matrix which binds the pebbles together. This work could benefit the public by helping move forward the design of commercially viable fusion energy reactors. Designing a first wall for magnetic fusion reactors which can handle the huge heat loads present and also avoid buildup of tritium-containing deposits is extremely challenging and requires novel approaches like the one being investigated here.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Plasma Surface Interactions: Predicting the Performance and Impact of Dynamic PFC Surfaces

This project focused on the development and integration of high-performance simulation tools to predict the operating behavior of Plasma-Facing Components in magnetic confinement fusion systems. A key objective at Illinois was to assess the impact of the dynamic interplay between the evolving material surface and the magnetized plasma sheath, and characterize the impact of tungsten-based PFCs on plasma contamination, including phenomena such as surface erosion, dynamic recycling of fuel species, and tritium retention, which are critical for the success of future magnetic fusion devices.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

Advanced Materials for Plasma-Exposed Robust Electrodes

The AMPERE project developed a new class of electrode materials that dramatically improve fusion device performance and longevity. By using Volumetrically Complex Materials (VCMs)—advanced porous metal foams optimized via plasma-material interaction science—the project achieved up to 85% reduction in sputtering erosion under fusion-relevant plasma conditions, far surpassing the goal of 40% reduction. This means these novel electrodes produce far fewer impurities and debris in the plasma, addressing a key challenge in fusion reactors by allowing greater plasma efficiency and power output due to the reduction of power losses due to unwanted interactions with wall-borne impurities.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

Non-Resource Conservation and Recovery Act Corrective Action Unit (CAU) Post-Closure Inspection Report, Nevada National Security Site, Nevada For Calendar Year 2025

This report includes visual inspection results, descriptions of maintenance and repair activities, and recommendations for CY 2025 for use restrictions (URs) at corrective action sites (CASs) located on the Nevada National Security Site and on the Nevada Test and Training Range (NTTR) that are accessed through the NNSS Main Gate. This document is arranged by project activity (i.e., Industrial Sites, Soils, and Defense Threat Reduction Agency [DTRA]); then by corrective action unit (CAU); and then by CAS. Post-closure UR inspections are performed on an annual basis, unless as noted in text. Post-closure UR inspections verify the condition of physical controls required by each UR, which may include the following activities: • Visual verification of the legibility of signs • Visual inspection of fencing, signs, monuments, and/or markers for indications of wear • Visual inspection of soil covers for indications of subsidence, erosion, or unauthorized use Deficiencies in UR requirements that were identified during CY 2024 inspections and not addressed in the CY 2024 report are addressed in this CY 2025 report.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Dynamic Heat Flow and Current Distribution Analysis in the Bottom Anode of an Electric Arc Furnace Using Fiber-Optic Sensors

A reliable method for monitoring bottom anode wear during DC Electric Arc Furnace (DC-EAF) operation is of critical importance for safe and efficient steel production. Underestimation of bottom wear poses a serious safety risk that must be avoided, while overestimation of bottom wear also poses challenges, as premature anode replacement is expensive and affects EAF productivity. Previously, we demonstrated that fiber-optic sensors can be successfully deployed to create a spatially distributed temperature map to monitor the health of the anode. The present work explores the heat flow and current density distribution in bottom anode pins to predict bottom wear, steel penetration events, and monitor refractory erosion. Small dynamic variations in pin temperature induced by joule heating during arcing also provide a means to observe local current flows in each pin. When mapped, these measurements provide a real-time view of the non-uniform and dynamic current flow in the bottom anode during EAF operation that can affect bottom wear.

Bottom Anode↗
DOE OSTI2024

Global particle buildup simulations with gas puff scan: application to WEST discharge

This paper deals with the distribution of sources, transport, and exhaust of particles in a tokamak. Knowledge and understanding of all the physical phenomena involved in the global particle buildup are necessary to study and predict density regimes and subsequently to develop optimized scenarios for tokamak operation in order to control heat and particle exhaust. Neutral particles and their interactions with plasma are central in this perspective. This paper discusses the impact of varying the intensity of particle fueling in 2D transport simulations of a WEST discharge. Simulations are performed with an updated version of SOLEDGE-HDG that allows a more realistic transport of neutrals using a self-consistent diffusive model based on charge exchange and ionization processes. New code capabilities allow the entire WEST poloidal cross section to be simulated in a realistic configuration for both geometry and the range of control parameters. A gas puff scan illustrates the main features of the sheath-limited, high-recycling, and detached regimes, such as the buildup of the temperature gradient and the pressure drop in the scrape-off layer (SOL), the target temperature falling to 1 eV, and the ionization source moving away from the targets, as well as the particle flux rollover. A crude estimate of wall erosion is also provided, showing the respective role of each plasma wall component in each of these regimes.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Monolithic Polyepoxide Membranes for Nanofiltration Applications and Sustainable Membrane Manufacture

The present work details the development of carbon fiber-reinforced epoxy membranes with excellent rejection of small-molecule dyes. It is a proof-of-concept for a more sustainable membrane design incorporating carbon fibers, and their recycling and reuse. 4,4′-methylenebis(cyclohexylamine) (MBCHA) polymerized with either bisphenol-A-diglycidyl ether (BADGE) or tetraphenolethane tetraglycidylether (EPON Resin 1031) in polyethylene glycol (PEG) were used to make monolithic membranes reinforced by nonwoven carbon fibers. Membrane pore sizes were tuned by adjusting the molecular weight of the PEG used in the initial polymerization. Membranes made of BADGE-MBCHA showed rejection of Rose Bengal approaching 100%, while tuning the pore sizes substantially increased the rejection of Methylene Blue from ~65% to nearly 100%. The membrane with the best permselectivity was made of EPON-MBCHA polymerized in PEG 300. It has an average DI flux of 4.48 LMH/bar and an average rejection of 99.6% and 99.8% for Rose Bengal and Methylene Blue dyes, respectively. Degradation in 1.1 M sodium hypochlorite enabled the retrieval of the carbon fiber from the epoxy matrix, suggesting that the monolithic membranes could be recycled to retrieve high-value products rather than downcycled for incineration or used as a lower selectivity membrane. The mechanism for epoxy degradation is hypothesized to be part chemical and part physical due to intense swelling stress leading to erosion that leaves behind undamaged carbon fibers. The retrieved fibers were successfully used to make another membrane exhibiting similar performance to those made with pristine fibers.

Polymer Science↗
DOE OSTI2025

Anthropogenic Influences on the Chemical and Mineral Composition in Pond Sediment by X-Ray Absorption Spectroscopy and X-Ray Powder Diffraction

Manmade detention ponds have historically been impacted by anthropogenic activities such as rainwater runoff, car emissions, and drainage from infrastructures, which can lead to complications for pond ecosystems. Sediment samples collected from the northern, southern, western, and eastern regions of a small pond on a suburban high school campus on Long Island, NY, were analyzed for potential chemical changes resulting from an inundation of water by a broken water main. Incorporating synchrotron X-ray techniques, sediment was analyzed using Submicron Resolution Spectroscopy, Tender Energy X-ray Spectroscopy, and X-ray Powder Diffraction to examine heavy metals, light elements, and minerals. Results include a Zn:Cu ratio increase from 4:1 to 10:1 in the eastern zone and a higher heavy metal presence in the western zone for all elements examined, with greater distribution throughout the pond post-inundation. Lighter elements appear to remain relatively unchanged. The appearance of diopside in the eastern zone post-inundation samples suggests contamination from the water main break, while the presence of carbonate minerals in the western zone is consistent with erosion of asphalt material from the adjacent parking lot.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Satellite-Based Assessment of Rocket Launch and Coastal Change Impacts on Cape Canaveral Barrier Island, Florida, USA

The Cape Canaveral Barrier Island, home to the National Aeronautics and Space Administration (NASA)’s Kennedy Space Center and the United States (U.S.) Space Force’s Cape Canaveral Space Force Station, is situated in a unique ecological transition zone that supports diverse wildlife. This study evaluates the recent changes in vegetation cover (2016–2023) and dune elevation (2007–2017) within the Cape Canaveral Barrier Island using high-resolution optical satellite and light detection and ranging (LiDAR) data. The study period was chosen to depict the time period of a recent increase in rocket launches. The study objectives include assessing changes in vegetation communities, identifying detectable impacts of liquid propellant launches on nearby vegetation, and evaluating dune elevation and tide level shifts near launchpads. The results indicate vegetation cover changes, including mangrove expansion in wetland areas and the conversion of coastal strands to denser scrubs and hardwood forests, which were likely influenced by mild winters and fire management. While detectable impacts of rocket launches on nearby vegetation were observed, they were less severe than those caused by solid rocket motors. Compounding challenges, such as rising tide levels, beach erosion, and wetland loss, potentially threaten the resilience of launch operations and the surrounding habitats. The volume and scale of launches continue to increase, and a balance between space exploration and ecological conservation is required in this biodiverse region. This study focuses on the assessment of barrier islands’ shorelines.

54 ENVIRONMENTAL SCIENCES↗