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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Development and experimental evaluation of an acoustic flow meter prototype for measuring air flow

Here, this study outlines the development and testing of a flow meter prototype specifically designed for use in nuclear reactor environments. The meter uses flow-induced vibration to measure flow rates and is designed for remote monitoring in harsh environments where radiation can damage electronics. The device generates a vibration signal produced by a feedback system when fluid flows out of an orifice and interacts with a downstream wedge. The frequency of the vibration signal corresponds directly to flow rate and velocity. The study investigates geometric parameters intrinsic to the prototype, such as orifice height, width, edge distance, and chamber length. Different configurations were also tested, including a bypass loop with variable cross-sections around the device. The investigation results reveal the impact of these geometric parameters on the vibration signal output, providing valuable insights for future design improvements and enhancing the effectiveness of flow metering systems used in nuclear reactor applications.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2025

CFD modeling of turbulent air flow in self-heated gyroid TPMS structures: Thermal-hydraulic performance and validation

The application of mathematically derived geometries, such as triply periodic minimal surface (TPMS) lattices, has garnered significant interest across various fields, including the nuclear sector, due to their superior thermal-hydraulic characteristics for heat transfer compared to traditional plain or finned tubes. Here, this study validates a computational fluid dynamics (CFD) model, evaluates different turbulence models and CFD model settings, and performs uncertainty quantification to provide a comprehensive analysis. Despite extensive research on CFD modeling of TPMS lattices, such as gyroid and diamond geometries, there is a notable lack of publicly available literature providing comprehensive details on numerical analysis aspects, including convergence and methodological best practices. This study embarks on a benchmark analysis of a gyroid geometry to evaluate its thermal-hydraulic performance under turbulent flow conditions and scrutinize various CFD model configurations. The main contributions of this work include validating the CFD model, assessing and comparing different turbulence models, and enhancing pressure drop and temperature prediction capabilities. The results aim to support the development of methodologies needed to benchmark and enhance numerical analysis techniques for TPMS lattices. This work seeks to complement the existing body of knowledge, support the development of TPMS reactor concepts, and improve best practices for CFD modeling of TPMS lattices, ultimately advancing methodologies to support future applications in this domain.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Nonlinear manifold reduced order model

Traditional linear subspace reduced order models (LS-ROMs) are able to accelerate physical simulations in which the intrinsic solution space falls into a subspace with a small dimension, i.e., the solution space has a small Kolmogorov n-width. However, for physical phenomena not of this type, e.g., any advection-dominated flow phenomena such as in traffic flow, atmospheric flows, and air flow over vehicles, a lowdimensional linear subspace poorly approximates the solution. To address cases such as these, we have developed a fast and accurate physics-informed neural network ROM, namely nonlinear manifold ROM (NM-ROM), which can better approximate high-fidelity model solutions with a smaller latent space dimension than the LS-ROMs. Our software takes advantage of the existing numerical methods that are used to solve the corresponding full order models. The efficiency is achieved by developing a hyper-reduction technique in the context of the NM-ROM. Numerical results show that neural networks can learn a more efficient latent space representation on advection-dominated data from 1D and 2D Burgers' equations. A speedup of up to 2.6 for 1D Burgers' and a speedup of 11.7 for 2D Burgers' equations are achieved with an appropriate treatment of the nonlinear terms through a hyper-reduction technique.

Choi, Youngsoo↗
DOE OSTI2024

Cyber-Physical Simulation of an Innovative Solid Oxide Electrolysis Cell - Gas Turbine (SOEC-GT) Hybrid Energy System

To produce green hydrogen at scale and at low cost, the solid oxide electrolysis cell (SOEC) systems would be tied to renewable power sources (mainly solar and wind), leveraging zero-carbon electricity at low prices and even nearly free during overgeneration scenarios. However, due to the intermittency of renewable power generation, the SOEC system is subjected to rapid load transitions that occur not only in diurnal cycles but also in short timeframes (e.g., sub-minute). This can result in fast degradation and thus greatly reduce the SOEC’s lifetime. Our team at the National Energy Technology Laboratory has demonstrated that the anode air flow can have a crucial role in SOEC thermal management. Typically, a higher air flow rate can help to mitigate the local temperature gradient distortion during rapid load transitions. To move a large amount of air, the gas turbine (GT; i.e., compressor-turbine-generator set) has been regarded as the most mature and efficient technology. In this presentation, we show the configuration and preliminary results of an innovative SOEC-GT hybrid energy system in a cyber-physical simulation (CPS) approach.

Zhang, Biao↗
DOE OSTI2025

THERMS Technology Commercialization Fund Final Report

The technology commercialization fund assisted with the design and development of an intermediate scale packed be thermal energy storage system. Presented in this final report is the design, testing, and modeling of a 100 kWh th radial packed-bed. Air is used as a heat transfer fluid and 3/8” pea gravel is used as the storage medium. Testing has demonstrated the formation of a thermocline within the packed-bed. An air charging temperature of 450 °C was achieved resulting in a charging power of 26.5 kWh th . The radial packed-bed was charged for 5 hours and discharged for 5 hours. Minimal temperature variation was observed at the bottom, middle, and top axial locations of the radial packed-bed which suggests that buoyancy and hydrodynamics in the injection well had a minimal effect on the uniformity of air flow through the bed during charging and discharging. This indicates that the forced convection in a radial direction is dominating the flow regime compared to the buoyancy. The findings of this study suggest an increased air duct diameter through the air heater will increase the charging temperature and increase air mass flow through the system. Increased mass flow through the packed-bed is hypothesized to shorten the thermocline length. Modeled and measured results are compared, and it is here determined that a more comprehensive CFD model will aid in the understanding of air flow and thermocline evolution within the packed-bed.

25 ENERGY STORAGE↗
DOE OSTI2025

Measuring the Aerosol Collection Efficiency and Detector Face Deposition of the Bladewerx KatanaGBM™ (Glove Box Monitor) Continuous Air Monitor

To assist Bladewerx LLC (the Requestor) in testing their new CAM (continuous air monitor) sampler model Bladewerx™ KatanaGBM™ (Glove Box Monitor), the Laboratory (LANL, i.e. Los Alamos National Laboratory) measured the aerosol particle collection efficiency and detector face deposition for several experimental test conditions. Bladewerx LLC provided a prototype KatanaGBM with a set of requested tests. According to these parameters, LANL designed and performed a series of experiments to (A.) Measure the aerosol particle collection efficiency and detector face deposition of the KatanaGBM at three air flow rates of 5, 42, and 70 ALPM (ambient liters per minute), (B.) Measure the collection efficiency and detector face deposition using two sizes of oil droplet particles: 3±1 and 10±1 µm (micron) AED (aerodynamic equivalent diameter), and (C.) Test the KatanaGBM for aerosol collection efficiency and detector face deposition with the wind tunnel’s air flow at three different angles 0°, 45° and 90° (compared to the KatanaGBM’s filter face).

61 RADIATION PROTECTION AND DOSIMETRY↗
DOE OSTI2025

Process intensification approach to enhancing heat and mass transfer: Radio frequency (RF) assisted drying of paper and board

Conventional multi-cylinder drying of paper and board typically relies on both conductive drying from steam-heated cylinders and convective drying, where heated air flows over the paper web surface. Conduction primarily contributes to heat transfer, while convection is the main driver of mass transfer. However, conventional drying systems are heavily dependent on steam, usually powered by fossil fuels, and are often energy-inefficient with high levels of waste. Additionally, these surface-driven processes result in a lower percentage of energy absorption compared to the energy supplied, leading to significant energy losses. To improve this long-standing process, an experimental system was developed to investigate a process intensification approach involving the integration of Radio Frequency (RF) heating, a volumetric electromagnetic technology, alongside traditional conduction and convection drying methods. This study also emphasizes the use of sensors to continuously monitor key parameters such as moisture content, supply system temperatures, sample temperatures, air flows, and drying rates in real-time. The effect of RF as an auxiliary energy source in localized environments at varying moisture levels was explored to optimize industrial drying systems, quantify potential improvements, and provide insights for future studies. Experimental results from trials combining RF with convection and with the base case alternating conduction-convection drying processes are presented. It is shown that RF is a viable process intensification approach for paper drying improving the drying rate and energy intensity at higher moisture contents. These findings offer valuable insights for process intensification and contribute to the process development, modeling, and simulation of advanced paper drying techniques.

42 ENGINEERING↗
DOE OSTI2025

Dual-Fuel Ammonia Equivalence Ratio Sweep Data

Ammonia (NH3) has garnered significant interest as an alternative fuel for meeting international emissions reduction mandates in sectors with high weight and distance requirements, such as shipping. Technical barriers and unanswered questions remain on the combustion strategies that can maximize ammonia utilization and minimize emissions. Prior research studies at the US Department of Energy’s Oak Ridge National Laboratory have shown strong performance with NH3 under dual-fuel mode using conventional diesel combustion (CDC) manifold air pressure settings. Diesel airflow was initially used to simplify retrofitting (no turbocharger modification), which resulted in air-fuel equivalence ratios (λ) greater than 1.5. To characterize potential improvements in dual-fuel NH3 combustion performance at richer in-cylinder conditions, a global λ sweep compared the use of early (E-pilot) and late (L-pilot) single diesel injections. The experiments were conducted at 1200 RPM and 12.8 ± 0.2 bar (75 % load), and λ was varied by decreasing the commanded air flow to the engine at greater than 90 % ammonia energy substitution level. A diesel injection timing sweep was conducted for both the injection strategies at fixed λ, and the timing with the lowest engine-out N2O emissions was identified. The results indicated an optimal balance between CO2,eq and thermal efficiency benefits both E-pilot and L-pilot injection strategy cases compared with CDC at a λ of 1.4. The indicated nitrogen-based emissions exhibited a strong correlation to the ratio of CA5–50 and ignition delay for L-pilot, but no apparent trend emerged for the E-pilot injection strategy at the tested boundary conditions. This dataset includes the raw experimental data and documentation of the experiment conditions and methods.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2025

A real-time distributed solid oxide electrolysis cell (SOEC) model for cyber-physical simulation

System integration and dynamic operability between SOEC and balance-of-plant (BoP) components are major technical challenges before realizing rapid load following of SOEC systems. Cyber-physical simulation (CPS) is a leading-edge digital engineering approach and is regarded as the next step beyond Digital Twins. CPS approach can be used to research SOEC system integration and develop dynamic controls prior to actual pilot testing without using a real SOEC. To seamlessly couple with BoP hardware and access non-observable operational parameters (e.g., local temperature gradient) during transients, a distributed one-dimensional (1D) real-time SOEC model was developed. Its real-time execution was demonstrated for 20 to 640 nodes at the fixed time step of 5 ms. A higher excess air ratio enabled smaller local temperature gradients on SOEC solid materials and faster transients upon current density step change from 0.15 to 0.55 A cm -2 . During the transients, the magnitude of the peak temperature gradient nearly doubled in 10 s from -3.5 to -5.9 °C cm -1 . This represents a significant operating risk that can impact the dynamic operability of SOEC systems. In addition, the local temperature gradient was found to change directions on all nodes in SOEC solid materials, with the greatest impact on the upstream nodes. The SOEC model was also tested at the thermal neutral voltage using actual process air flow parameters as variable model inputs. Variable process air temperatures were found to induce alternating local temperature gradients on SOEC solid materials. These are new operational mechanisms for SOEC degradation relevant for load following operational modes yet distinct from previous reports. To mitigate these unfavorable features, the SOEC can be operated at voltages that are slightly (±20 mV) deviated from the thermal neutral voltage. Here, the corresponding net thermal energy change was less than 1.6% of the electric power consumption. This 1D real-time SOEC model established the basis of cyber-physical simulation of SOEC hybrid systems.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

The impact of simplified window and exhaust fan assumptions on indoor air quality in multifamily buildings

In residential buildings, the indoor air quality can be significantly affected by ventilation measures initiated by occupants, including the operation of windows and in-unit exhaust fans in kitchens and bathrooms. Many simulations simplify these factors by disregarding window opening behaviors and using fixed schedules for exhaust fan operation across all residential units. To estimate the impact of these simplifications in the U.S. context, this study used coupled CONTAM and EnergyPlus models to simulate airflow and contaminant transport in multifamily buildings. The coupled models parametrically varied climate zone, building airtightness, and mechanical ventilation system types. The study conducted a sensitivity analysis on two key occupant behaviors: (1) operating kitchen and bathroom exhausts on different schedules in individual dwelling units, and (2) scheduling open windows on ground and top floors. The simplified assumptions (i.e. uniform in-unit exhaust fan operation and window operation) had a minimal impact on inter-unit air flow and contaminant transport simulations across a broad range of building air leakage and mechanical ventilation system types. These findings suggest that for buildings with tight construction it is reasonable for most modelling and simulation efforts to ignore the effects of non-uniform exhaust fan operation and window opening.

Occupant behavior↗
DOE OSTI2024

Enhancing particle-to-sCO2 heat exchanger effectiveness through novel high-porosity metallic foams

In this project, a novel concept of Octet-shape based lattice frame material was developed for deployment in particle-to-sCO2 heat exchangers for CSP application. A comprehensive experimental and numerical program was performed to investigate and characterize the thermal and flow transport behavior in high porosity lattice frame material. The thermal properties include effective thermal conductivity and interstitial heat transfer coefficient and flow properties including permeability and inertial coefficient. Above quantities were determined for both air flow and heated particle flow through the porous channels which were representative of the hot channel in a typical counter flow heat exchanger. The cold side of the heat exchanger feature minichannels which are known to be very efficient in thermal transport. The goal of this project was to enhance the overall heat transfer coefficient (Up) on the hot side by introducing Octet-shape based lattice frame material through enhancement in effective thermal conductivity of the channel and through enhancement in the interstitial heat transfer coefficient.

14 SOLAR ENERGY↗
DOE OSTI2025

Modular Hydronic Room Conditioning System (CRADA NFE-24-10120 Final Report)

This project presents the development and validation of high-fidelity numerical models for fin-tube heat exchangers to enable accurate performance prediction and informed design optimization. The modeling framework integrates detailed geometric specifications, thermophysical property data, and system-level constraints to simulate the heat exchanger’s behavior under a range of operating conditions. The model is calibrated using real-world product specifications and validated against experimental data collected from controlled cooling and heating tests. In cooling mode, the model captures the overall trends in capacity and outlet air temperature but tends to underpredict latent effects, especially at lower air flow rates. In heating mode, the simulation consistently overestimates both the thermal capacity and outlet air temperature, indicating the need for refinement in air-side heat transfer assumptions. Despite these deviations, the model provides a solid foundation for optimization, allowing key design variables to be tuned within physical and performance-based constraints. This research advances the ability to simulate, validate, and optimize fin-tube heat exchanger designs with greater confidence and efficiency.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Modular Hydronic Room Conditioning System

This project presents the development and validation of high-fidelity numerical models for fin-tube heat exchangers to enable accurate performance prediction and informed design optimization. The modeling framework integrates detailed geometric specifications, thermophysical property data, and system-level constraints to simulate the heat exchanger’s behavior under a range of operating conditions. The model is calibrated using real-world product specifications and validated against experimental data collected from controlled cooling and heating tests. In cooling mode, the model captures the overall trends in capacity and outlet air temperature but tends to underpredict latent effects, especially at lower air flow rates. In heating mode, the simulation consistently overestimates both the thermal capacity and outlet air temperature, indicating the need for refinement in air-side heat transfer assumptions. Despite these deviations, the model provides a solid foundation for optimization, allowing key design variables to be tuned within physical and performance-based constraints. This research advances the ability to simulate, validate, and optimize fin tube heat exchanger designs with greater confidence and efficiency.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Coupled heat and mass transfer in internally cooled silica gel-coated aluminum foam heat exchangers for dehumidification

Solid desiccant dehumidifiers offer significant potential to improve humidity control in buildings due to their ability to independently regulate latent (humidity) and sensible (temperature) loads. However, adsorption of water vapor by desiccants is an exothermic process; the resulting heat of adsorption increases both the desiccant bed temperature and the temperature of the air flowing over the bed, thereby limiting the performance of desiccant dehumidifiers. To address this problem, desiccant-coated heat exchanger prototypes were developed by coating silica gel onto aluminum foam substrates and integrated with chilled water circulation for effective removal of the heat of adsorption. Prototype heat exchangers with two different pore densities (10 and 20 pores per inch (PPI)) and two different desiccant loadings (∼10.36% and ∼17.80%) were fabricated. Experiments were conducted by varying the inlet air face velocity, chilled water inlet temperature, and chilled water flow rate to investigate the coupled heat and mass transfer characteristics of the prototype heat exchangers over a wide range of operating conditions. The underlying transport mechanisms were analyzed using transient desiccant bed temperature, outlet air temperature, and outlet humidity profiles. The results demonstrate that internal cooling significantly enhances dehumidification performance by maintaining more favorable thermodynamic conditions for water vapor adsorption. Under identical operating conditions, a 20 PPI heat exchanger coated with 25.05 g of silica gel achieved 98.98% higher cumulative water uptake and 97.75% higher moisture removal capacity than the corresponding non-cooled case after 5 min of adsorption. This substantial enhancement was further supported by a validated one-dimensional coupled heat and mass transfer model developed in the present study. To date, this is one of the first experimental studies to systematically investigate the combined effects of internal cooling, foam pore density, and desiccant loading on the performance of silica-gel-coated metal foam heat exchangers under HVAC-relevant operating conditions.

42 ENGINEERING↗
DOE OSTI2025

Operando Neutron Imaging of Reaction Extent and Particle Swelling Informs Limiting Factors for Salt Hydrate Thermochemical Energy Storage

Salt hydrates are a promising thermochemical energy storage medium that stores heat through the reversible uptake (hydration) and release (dehydration) of water vapor. Our study deploys operando neutron imaging to investigate salt hydrate performance with high spatial resolution (42 μm pixels). For flow over a packed bed with diffusion-driven transport, measurements reveal the formation of a solid diffusion layer due to particle swelling for the pure SrBr2 salt. In contrast, the SrBr2–vermiculite composite exhibits significantly less swelling and more than a 2-fold increase in the apparent water vapor diffusivity. For axial flow through a packed bed, neutron imaging confirms theoretically predicted transitions from a moving reaction front to a homogeneous profile with an increase in humid air flow rate. Our study establishes neutron imaging as a powerful technique to advance fundamental understanding of thermochemical systems and help guide composite material design.

Kinzer, Bryan [ORNL] (ORCID:0000000337804910)↗
DOE OSTI2024

Bench-Scale Testing of Monolithic PPI Structured Contactors for Direct Air Capture of CO 2

The overall project objective was to develop, optimize and bench-scale test the integrated embodiment of a leading direct air capture (DAC) sorbent composition, linear-poly(propylenimine) (l-PPI), in a structured material system, specifically a monolithic contactor for achieving low pressure drop, to justify its further scale-up in a subsequent program. The project team was led by CORMETECH, a leading monolithic gas/solid contactor manufacturer for environmental applications, and included Global Thermostat, a well-known DAC start-up, and Georgia Tech, a prominent US academic institution in carbon capture and DAC. The monolithic contactor for l-PPI in this project employed an advanced, cost-effective fabrication technique from CORMETECH, namely a porous monolith substrate directly impregnated with the amine, an approach contrasting to the traditional wash-coating methods used for activating monoliths. The l-PPI monolithic contractor is targeted for use in DAC systems such as the Global Thermostat DAC process, which involves the cyclic operation of ambient air flow over a monolithic amine contactor followed by steam-mediated thermal desorption and CO 2 collection, maximizing volumetric productivity while reducing the auxiliary power required to capture CO 2 from air. The Global Thermostat DAC process currently utilizes poly(ethyleneimine) (PEI) materials as baseline sorbents, which are subject to oxidative degradation and slow capacity fade at the elevated temperature required for efficient CO 2 removal. Georgia Tech, with Global Thermostat, had discovered in lab-scale efforts that l-PPI had superior resistance to oxidative degradation compared to PEI, with similar CO 2 adsorption capacity. While the novel l-PPI sorbent offers significant advantages over PEI for DAC, including potential design simplification and increased process efficiency, it is not commercially available, and prior to this project, had not yet been evaluated on the bench-scale in a structured contactor.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Influence of Surface Defects on WO 3 Photoelectrodes for Catalyzing Chloride Oxidation in Water

Tungsten oxide (WO 3 ) is an n-type semiconductor due to oxygen vacancies (□ O •• in Kroger-Vink notation) or surface protonation as H x WO 3 . It is one of the few acid-stable oxides under large positive bias, which makes WO 3 ideal for interrogating the mechanism of the chloride oxidation reaction (COR). The large, positive valence band edge of ∼3 eV provides the overpotential necessary to carry out the COR, but the reaction competes with the oxygen-evolution reaction in water. The □ O •• defect density can be controlled by the atmosphere under which the material is annealed, so WO 3 films were prepared by a spin-coating method from an ammonium metatungstate precursor annealed at 500 °C under air, flowing O 2 , and flowing argon. Annealing the films in a flowing O 2 atmosphere hinders the formation of □ O ••, and annealing in Ar leads to greater surface W 6+ , likely due to expelling intercalated H + . The saturated photocurrent density (j ph ) is highest in films with the greatest concentration of W 5+ and greatest concentration of oxide defects: (0.66 mA/cm 2 annealed in air, 0.58 mA/cm 2 annealed in Ar, and 0.49 mA/cm 2 annealed in O 2 , reported at 1.5 V vs Ag/AgCl, pH 3 (before the onset of a dark reaction). The defect concentrations are determined by X-ray photoelectron spectroscopy. In all cases the Faradaic efficiency for the COR is near unity. Finally, we demonstrate that W 5d states can be probed by ligand K-edge X-ray absorption near-edge spectroscopy via pre-edge (Cl 1s → W 5d) transitions, lower in energy than the ligand-centered (Cl 1s → 4p) transition. We use this analysis to show the presence of W─Cl covalent bonds on the WO 3 films post-COR, corroborated by DFT calculations. Furthermore, this result stands in contrast to the commonly assumed mechanistic proposal invoking outer-sphere electron transfer to a physisorbed chloride ion.

Cl K-edge↗
DOE OSTI2026

Alpha-Imaging Detector System Development for Large Area Monitoring

Effective management and disposal of legacy nuclear waste are essential for ensuring safe work environments and minimizing environmental impacts. Monitoring airborne actinide contamination is particularly critical due to the high internal dose potential of alpha-emitting radionuclides. Traditional continuous air monitoring systems (CAMs) used in the industry are limited in the volume of air they can sample, potentially leading to inaccurate radiation detection over large areas. For example, in 2018, elevated levels of airborne Plutonium-239 were detected beyond the controlled areas of the Hanford Plutonium Finishing Plant, highlighting the potential risks to both plant workers and nearby residents. To address these challenges, high-efficiency particulate absorbing (HEPA) air purifiers can enhance air flow by up to 1.5 orders of magnitude, thereby increasing monitoring efficiency and providing a cost-effective solution for large-area surveillance. To quantify the activities of alpha-emitting radionuclides on HEPA filters, the Savannah River National Laboratory is developing an advanced alpha-imaging detection system. This system includes scintillating materials combined with a digital scientific camera. A significant concern in operating such a large-area airborne monitoring system is the handling of HEPA filters, which may be contaminated with radioactive particles. To mitigate these hazards, it is crucial to ensure that any contamination is securely fixed onto the filters. Efforts have been made to optimize the sensitivity of scintillator-epoxy composites and apply them to HEPA filters. These materials were characterized using fluoroscence spectroscopy. These techniques confirmed the purity of the raw materials, the dispersion of scintillators in the epoxy matrix, and the stability of their optical and structural properties post-modification. The optimal scintillator-epoxy composite was selected for use on alpha-spiked HEPA filters to evaluate the efficiency of the sprayer. HEPA filters, embedded with alpha particles collected by an air purifier deployed in an airborne radiation area, have been tested to assess detection efficiency. Future work will focus on employing multiple imaging sensors simultaneously to enhance sensitivity across different regions of the HEPA filter.

Pham, Phuong [Savannah River National Laboratory (↗