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Implementation of the Glued Sphere Discrete Element Model for Non-Spherical Particles in MFiX Software
To enhance solver capabilities, simulation flexibility and model validation within the MFiX software, the U.S. Department of Energy (DOE) is funding efforts to develop and integrate the glued-sphere discrete element method into the latest version of MFiX as a dedicated computational module. The glued-sphere discrete element method is a numerical technique to depict the behavior of non-spherical particles in granular flows or particulate systems by representing them as a collection of component spheres. These spheres are bonded together to approximate the shape and mechanical/chemical properties of a more complex particle. The method effectively reuses the existing sphere-sphere collision algorithm, interphase momentum and heat transfer calculations utilized in the traditional discrete element method, extending these capabilities to non-spherical particles. Additionally, this method explicitly resolves intra-particle temperature and species distributions. The MFiX glued-sphere computational module includes tools for generating glued sphere configurations, a dedicated solver, and visualization capabilities in post-processing. More specifically within the computational module, collision detection and calculations were first performed on component spheres and then mapped onto non-spherical particles. The linear spring-dashpot model was utilized to simulate the sphere-sphere interactions.
Developing Drag Models for Non-Spherical Particles through Machine Learning
The overarching goal of this project is to produce comprehensive experimental and numerical datasets for gas-solid flows in well-controlled settings to understand the aerodynamic drag of non-spherical particles in the dense regime. The datasets and the gained knowledge will be utilized to train deep neural networks in TensorFlow to formulate a general drag model for use directly in NETL MFiX-DEM module in order to help to advance the accuracy and prediction fidelity of the computational tools that will be used in designing and optimizing fluidized beds and chemical looping reactors.
MFiX Development Updates
This presentation discusses recent developments of the Multiphase Flow with Interphase eXchanges (MFiX) software. A brief review of all modeling approaches along with their cost versus accuracy is provided to guide users when selecting a model for a given application. The main new features of the past five official releases of MFiX are described. Improvement in chemistry management allow for easier simulation setup, and faster simulation speed. Progress in the implementation of a thin-wall boundary condition is presented. The major new model development over the past year is the release of the Glued Sphere Particle model (GSP), where component spheres are combined together to represent non-spherical particles. The integration of Machine Learning (ML) workflow in the CFD process is discussed with two applications: a surrogate model for stiff chemistry and the development of a PIC stress model using ML.
Discrete-Element and Material-Point Method (DEM and MPM) Based Solvers for Sustainable Technologies
We present the use of discrete element method (DEM) and material point method (MPM) in three relevant green technology applications that include biomass feedstock handling, lithium-ion battery manufacturing, and high-pressure reverse osmosis. Our open-source DEM and MPM solvers are developed using performance portable grid and particle management library, AMReX, thus enabling superior performance on NVIDIA and AMD GPUs with > 100 million particles. Our DEM solver resolves the motion of individual particles in a granular system and includes a bonded sphere method for modeling non-spherical particles along with Hertzian and liquid bridge-based contact models. We simulate highly variable biomass feedstock flows in large-scale hoppers for biofuel production and electrode calendering in battery manufacturing using DEM. Our simulations predict flow blockage in large scale biomass hoppers and electrode microstructure variations, thus providing valuable information for biofuel and battery manufacturers, respectively. The second half of the talk will be on MPM and its application towards pore resolved simulations of reverse osmosis membranes under compressive loads. We present a validation study of our MPM simulations with membrane microscopy imaging thus providing useful insights on membrane stability under high pressure conditions. We also present a spectral stability analysis of using linear hat, quadratic and cubic spline basis in MPM indicating regions of numerical stability.
A High-Performance Discrete-Element Framework for Simulating Flow and Jamming of Moisture Bearing Biomass Feedstocks
We developed and verified a high-performance open-source discrete element method (DEM) solver with simultaneously-supported feedstock-specific interaction models, including bonded-sphere, liquid bridge, cohesion, and non-linear contact models. Our solver uses parallel data structures on hybrid central and graphics processing unit (CPU/GPU) architectures, with favorable strong scaling performance observed for large problem sizes comprised of (100 M particles), and 4X single-node GPU speedup. The particles for corn stover feedstock were conceptualized and calibrated based on experimental measurements and results. Sensitivity analyses demonstrate that the mass flow rate from a wedge hopper is governed primarily by moisture content, friction coefficient, and cohesion energy density. The model is used to reproduce experimentally observed hopper jamming results, highlighting that the experimental no-flow trends can only be achieved by using non-spherical particles, liquid bridge and cohesion models, highlighting the importance of using concurrent feedstock specialized models for the effective representation of biomass material handling problems.
Ultraviolet digital holographic microscopy (DHM) of micron-scale particles from shocked Sn ejecta
A cloud of very fast, O (km/s), and very fine, O (µm), particles may be ejected when a strong shock impacts and possibly melts the free surface of a solid metal. To quantify these dynamics, this work develops an ultraviolet, long-working distance, two-pulse Digital Holographic Microscopy (DHM) configuration and is the first to replace film recording with digital sensors for this challenging application. A proposed multi-iteration DHM processing algorithm is demonstrated for automated measures of the sizes, velocities, and three-dimensional positions of non-spherical particles. Ejecta as small as 2 µm diameter are successfully tracked, while uncertainty simulations indicate that particle size distributions are accurately quantified for diameters ≥4 µm. These techniques are demonstrated on three explosively driven experiments. Measured ejecta size and velocity statistics are shown to be consistent with prior film-based recording, while also revealing spatial variations in velocities and 3D positions that have yet to be widely investigated. Having eliminated time-consuming analog film processing, the methodologies proposed here are expected to significantly accelerate future experimental investigation of ejecta physics.
CROCUS Dual Polarization Ceilometer Data at Northeastern Illinois University Rooftop
This dataset is from the Department of Energy Office of Science funded project, CROCUS Urban Integrated Field Laboratory (https://crocus-urban.org/). The dual-polarization ceilometer (Vaisala CL61) is an autonomous lidar system operating at 910 nm wavelength, providing valuable measurements for understanding atmospheric boundary layer evolution, air quality, and cloud-aerosol interactions. The CL61 measures the backscattered signal intensity alternating between parallel- and cross-polarization signals. The unique depolarization measurement capability improves discrimination between different particle types, such as liquid droplets, ice crystals, and aerosols. The depolarization is highly dependent on the scatterer shape and orientation (spherical vs non-spherical particles), with the linear depolarization ratio providing a measure of dominant backscatter signal component from atmospheric particles at various heights, essentially allowing discrimination between liquid and solid particles. With its efficient optical system, CL61’s improved signal-to-noise ratio compared to traditional ceilometers allows studying detailed vertical profiles of aerosols and clouds up to 15 km height.Datasets are stored in a netCDF data format, and we we encourage users to make use of the associated toolkits available from Unidata (https://www.unidata.ucar.edu/software/netcdf/), Project Pythia (https://foundations.projectpythia.org/core/data-formats/netcdf-cf.html), and our “Instrument Cookbooks” (https://crocus-urban.github.io/instrument-cookbooks) for more information on how to process the metadata-rich datasets.
Langevin Dynamics modeling of gas-phase ion-ion recombination (Final Technical Report)
A self-consistent trajectory simulation approach to model MN reactions (Fig. 1) which incorporates the probability of electron transfer as a Monte Carlo operator (Fig. 2) was developed and published as Liu et al. J. Chem. Phys. 159, 114111 (2023). The electron transfer probability p ET estimated using the two-state Landau-Zener (LZ) theory was incorporated into classical trajectory simulations to elicit predictions of MN reaction cross-section σ (vacuum) or rate constant β (finite pressure). Electronic structure calculations with multireference configuration interaction (MRCI) and large correlation consistent basis sets were used to derive inputs to the LZ theory. The key advance of our trajectory simulation approach is the incorporation of electron transfer probability and the inclusion of the effect of ion-neutral interactions on MN using a Langevin representation of the effect of neutral gas on ions. For H + – H - and Li + – H(D) - pairs, our approach quantitatively agrees with measured speed-dependent cross-sections for up to ~10 5 m/s. For the ion pair Ne + – Cl - , our predictions of the MN rate constant at ~1 torr are a factor of ~2 – 3 higher than the experimentally measured value. Similarly, for Xe + – F - in the pressure range of ~20000 – 80000 Pa, our predictions of the MN rate constant are ~20% lower but are in excellent qualitative agreement with experimental data. The paradigm of using trajectory simulations to self-consistently model MN reactions is the basis for inclusion of additional non-classical, and static magnetic and electric field effects. Subsequent work, published as Roy et al. focused on modeling recombination rate constant for three ion pairs (rare gas Ar + cation and halide anions): Ar + – Cl - , Ar + – Br - , Ar + – I - , 2) considering spin-orbit couplings in the electronic structure calculations to obtain high-fidelity estimates of the electron transfer probability and incorporated within the classical trajectory simulations to elicit predictions. In addition to calculations of ion-ion recombination rate constants, a classical trajectory simulation technique (published as Roy et al. J. Chem. Phys. 162(9), 094104 (2023)) that uses quaternions to represent orientation of non-spherical particles (ions or aerosol particles) was developed to simulate the recombination of diatomic or more generally, polyatomic molecules. Finally, several other ion pairs such as Ne + – Cl - , Kr + – Cl - , were explored using the developed semi-classical trajectory simulations to understand various challenges in tackling electronic structure calculations. Using empirical approaches to parameterize the electron transfer radius, trajectory simulations were also used to probe the effect of ion number density on MN rate constant.
Sizing ice hydrometeor populations using the dual-wavelength radar ratio
Dual-wavelength (3.2 and 0.32 cm, i.e., X- and W-radar bands) radar ratio (DWR) measurements in ice clouds and precipitation using Canada's National Research Council Institute for Aerospace Research airborne radar are compared to closely collocated particle microphysical in situ sampling data in order to develop relations between DWR and characteristic hydrometeor size. This study uses the radar and in situ data sets collected during the In-Cloud ICing and Large-drop Experiment (ICICLE) campaign in midlatitude frontal clouds. Since atmospheric particle scattering at X band is predominantly in the Rayleigh regime and the W-band frequency is the highest frequency usually used for hydrometeor remote sensing, the X–W-band combination provides a relatively strong dual-wavelength reflectivity difference. This study considers radar and in situ measurements conducted in relatively homogeneous cloud and precipitation conditions. Measurements show that under these conditions, the difference between the X-band radar reflectivities observed with vertical and horizontal pointing of the radar beam are generally small and often negligible. However, W-band reflectivities at vertical beam pointing are, on average, larger than those for horizontal beam pointing by about 4 dB, which is a non-Rayleigh scattering effect from preferentially oriented non-spherical particles. A horizontal radar beam DWR–mean volume particle size relation, D v , provides robust estimates of this characteristic size for populations of particles with different habits. Uncertainties of D v retrievals using DWR are around 0.6 mm when D v is greater than approximately 1 mm. Size estimates using vertical radar beam DWRs have larger uncertainties due to smaller dual-wavelength signals and stronger influences of hydrometeor habits and orientations at this geometry of beam pointing. Mean relations among different characteristic sizes, which describe the entire particle size distribution (PSD), such as D v , and other sizes used in various applications (e.g., the mean, effective, and median sizes) are derived, so the results of this study can be used for estimating different PSD characteristic sizes.
Review—Drag Coefficients of Non-Spherical and Irregularly Shaped Particles
Abstract The knowledge of simple and relatively accurate closure equations for the drag coefficients of nonspherical particles is very important for Eulerian multiphase numerical codes that require such inputs for the solution of the momentum equation. However, the existing correlations for the drag coefficients are laden with high uncertainty, which propagates in the numerical results. This review paper examines critically the state of our knowledge of the drag coefficients of nonspherical particles starting with our understanding of the “size” and “shape” of particles. Lengthscales and other parameters that have been used to characterize sizes of nonspherical particles are presented. Shape factors and shape descriptors that have been used in past correlations are also presented together with an appraisal of their applicability. Several correlations that have been developed for the determination of the drag coefficients of nonspherical particles with regular and irregular shapes are also presented together with available information on their accuracy and applicability. Based on the review of the available correlations general recommendations are offered on the use of the correlations as closure equations and inputs in computatioal fluid dynamics (CFD) codes.
Shape effects on the local dynamics of suspensions of spheroidal particles
The effect of shape on the dynamics of suspensions of non-spherical heavy particles is examined by fully resolved numerical simulations of oblate and prolate spheroids, as well as spheres, for a density ratio of ten, volume fractions ranging from 0.5% to 5%, and Reynolds numbers between 20 and 30. The dynamics is determined both by the interactions of the particles with the fluid as well as by collisions, with the number and importance of collisions increasing with volume fractions. A single isolated oblate or prolate spheroid falling under gravity generally falls broadside on, for the governing parameters examined here, and at low-volume fractions, the majority of particles in a suspension fall that way. At higher-volume fractions, the orientation is more random. The slip velocity decreases as the volume fraction increases for all shapes, as expected, but the effect of the shape is much less than seen for a single particle. Furthermore, this seems to be due to two effects. For all volume fractions, the most deformed particles cluster more than spheres and less deformed particles, which increases their slip velocity. As the concentration increases, the increased particle interactions also causes more particles to fall short side-on, which reduces the frontal area and the resulting drag, increasing the slip velocity. This second effect is, of course, absent for spherical particles.
Variant selection in laser powder bed fusion of non-spherical Ti-6Al-4V powder
The presence of α/α' on prior β/β grain boundaries directly impacts the final mechanical properties of the titanium alloys. The β/β grain boundary variant selection of titanium alloys has been assumed to be unlikely owing to the high cooling rates in laser powder bed fusion (L-PBF). However, we hypothesize that powder characteristics such as morphology (non-spherical) and particle size (50–120 µm) could affect the initial variant selection in L-PBF processed Ti-6Al-4V alloy by locally altering the cooling rates. Despite the high cooling rate found in L-PBF, the results showed the presence of β/β grain boundary α' lath growth inside two adjacent prior β grains. Electron backscatter diffraction micrographs confirmed the presence of β/β grain boundary variant selection, and synchrotron X-ray high-speed imaging observation revealed the role of the “shadowing effect” on the locally decreased cooling rate because of keyhole depth reduction and the consequent β/β grain boundary α' lath growth. The self-accommodation mechanism was the main variant selection driving force, and the most abundant α/α boundary variant was type 4 (63.26°//[ $\bar{10}$ 5 5 $\bar{3}$ ]). The dominance of Category II α lath clusters associated with the type 4 α/α boundary variant was validated using the phenomenological theory of martensite transformations and analytical calculations, from which the stress needed for the β→α' transformation was calculated.
Tailored particles for powder-based additive manufacturing
The present disclosure relates to a plurality of powder particles configured to be joined in an additive manufacturing process to form a part. Each one of the powder particles has a determined three dimensional, non-spherical shape. The plurality of powder particles are further of dimensions enabling fitting individual ones of the powder particles in abutting relationship with one another. At least a subplurality of the powder particles each have a functionalized surface feature to enhance at least one of clustering or separation of the subplurality of powder particles.
Fatigue behavior of low-cost, non-spherical Ti-6Al-4V powder processed via laser powder bed fusion
Hydride-dehydride Ti-6Al-4V powder with particle size distribution of 75–175 μm were used to manufacture fatigue samples. Optimized processing parameters were used to maintain a relative density of >99.5% in the samples. Fatigue tests were carried out in R = σ min /σ max = -1 condition under stresses ranging from 150 to 500 MPa and the results were compared to samples that were additively manufactured using spherical powders. The fatigue lives were similar between the two types of powder; i.e., powder morphology has no effect on fatigue performance. However, the high surface roughness and martensitic microstructure resulting from the laser powder bed fusion process result in poor performance compared to samples machined from conventionally produced materials. In conclusion, crack initiation occurred consistently from surface defects because of high surface roughness of the additively manufactured parts.
On the force exerted on a non-spherical asymmetric dust grain from homogeneous, stationary, isotropic, non-magnetized plasma
Whereas the conventional wisdom suggests that the force between non-magnetized homogeneous, stationary, isotropic plasma, and the dust grain is only possible for the case of relative plasma–grain velocity, it is shown that stationary non-spherical asymmetric dust grain immersed in stationary, non-magnetized, isotropic plasma can experience a force caused by the grain–plasma interactions. The component of the force due to scattering of plasma particles in the limit of infinite Debye length is considered analytically. Both the particle scattering and absorption force components are modeled numerically in the limits of infinite and finite Debye length using a newly developed 2D3V Aspherical Particle-in-Cell code. The code simulates interactions of dust grain of selected non-spherical asymmetric shape with plasmas using dust shape conforming coordinates. Here, the simulations confirm the existence of the force on non-spherical asymmetric grain in stationary non-magnetized plasma and show that the plasma screening effects can lead to reversal of the force direction.
Development and Evaluation of a General Drag Model for Gas-Solid Flows via Deep Learning
This project presents the development and evaluation of a general drag model for gas–solid multiphase flows using deep learning techniques. A comprehensive database of more than 4,000 experimental and numerical data points for spherical and non spherical particles was compiled, incorporating geometric features such as sphericity, aspect ratio, and orientation. Several predictive approaches—including traditional em pirical correlations, machine learning, and deep neural networks—were benchmarked, with the proposed Drag Coefficient Correlation-aided Deep Neural Network (DCC DNN) demonstrating superior accuracy. To account for particle–particle interactions, additional drag data were generated using CFD-based simulations of packed and flu idized beds, leading to the development of a retrained model capable of incorporat ing volume fraction effects. Integration of the trained model with the MFiX CFD solver was achieved using FTorch, enabling drag predictions during discrete element method (DEM) simulations. Validation against experimental data for single particles and fluidized beds confirmed the model’s improved predictive ability, particularly for non-spherical geometries. While the model performed strongly under fluidized con ditions, limitations remained in unfluidized regimes, suggesting a need for expanded datasets. Overall, this study demonstrates the feasibility of combining deep learning with physics-informed CFD to improve drag modeling for gas–solid flows, with promis ing implications for scaling multiphase simulations in industrial applications.
Basic Physical Processes Involving Dust in Fusion Plasmas
This report presents the main outcomes of our research focused on understanding the behavior and effects of dust particles in fusion plasmas, particularly in the edge regions of tokamaks and stellarators. We conducted computer modeling studies of burst injections of carbon and tungsten dust particles in DIII-D like divertor plasmas. The studies investigated effects of transient influx of the low- and high-Z material plasma contaminants in form of dust on the edge plasma dynamics in a modern mid-size tokamak. We also performed theoretical and computational studies of the forces acting on non-spherical dust grains in magnetized and nonmagnetized plasmas. In addition, we cooperated with General Atomics slag management group on development of DIII-D dust injection experiments to measure trajectories of dust grains in the divertor plasma and compare them with DUSTT code predictions for validation of the dust modeling capabilities. We collaborated with JET experimentalists on evaluation of radiative losses induced by injection of mixed neon-deuterium ice pellets for disruption and run-away electron generation mitigation during thermal and current quench phases. We also cooperated with experimentalists at LHD fusion device (Japan) on modeling support of experiments on injection of boron granules in fusion plasma discharges to assess their dynamics and effectiveness for in situ dynamic wall conditioning.