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At least 19 records

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DOE OSTI2025

Elucidating Pore Network Evolution in Laboratory‐ and Shaft‐Furnace Hydrogen‐Reduced Iron Pellets Using Nanotomographic Characterization

Direct reduced iron (DRI) is an increasingly important feedstock for modern steelmaking. Fundamental research into DRI properties is limited by the discrepancy between the behavior of industrially produced pellets and laboratory‐produced pellets, leading to nongeneralizable conclusions from laboratory work. Here, in this study, a detailed nano‐computed tomographic characterization of ore pellets, hydrogen DRI reduced in a pilot‐scale shaft furnace, and laboratory‐reduced DRI is presented to better understand the microstructurally influenced property differences between the two. The shaft‐furnace‐reduced pellets show lower overall porosity but larger average pore volume thickness and solid volume thickness than the laboratory‐reduced pellets. This effect is attributed to increased sintering behavior in the shaft furnace case. All pellet types show almost entirely connected pore volumes. The tortuosity of the pores is shown to increase with a degree of reduction, though the shaft furnace pellets show lower tortuosity than the laboratory‐reduced pellets. Again, this difference is attributed to the larger pore volume thickness for shaft‐furnace‐reduced pellets.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Accelerated Lifetime Testing of Main Shaft Seals for Tidal Turbine Rotors

This document will briefly discuss the observations and results from an NREL conducted accelerated lifetime testing of the main shaft seal for the Verdant Power fifth generation Gen5 underwater Tidal Energy Converter (TEC) turbine, which successfully performed at the RITE project in 2020-2021. In order to evaluate a 5-year Service Interval ( SI) for this component, testing at NREL operated the main shaft seal nearly continuously for over 135 (text says 130 days on page 5 and 125 days on page 7 and 137 days on page 11) days at a rotational velocity of 160 rpm while the test stand recorded water pressure, barrier fluid pressure, temperature, and number of cycles., representing ~ 40% of the SI. An additional separate test was conducted to measure the aging behavior of the rubber drive rings. The water pressure reservoir was held constant as 29 psi. Barrier fluid pressure remained relatively constant throughout the duration of the test but was seen to sink to as low as 10.1 psi. No barrier fluid leakage was observed throughout the test. A sudden failure occurred within the seal after the power to test machine was interrupted for a scheduled building maintenance procedure. Upon restarting, the main shaft seal lost all ability to prevent water ingress. The exact cause is not known but is believed to be either a seal assembly issue or a change in the alignment of the seal components during or following the power outage. Following seal disassembly, significant wear was seen on one of the graphite sealing rings. Based on these results it is recommended that a follow-on TEAMER be conducted to rectify protocol and assembly issues to further evaluate SI of this component. The support and participation of Verdant Power Inc, Dovetail Solutions LLC and Garlock Manufacturing Inc were instrumental in understanding the results. NREL thanks them for their significant effort.

13 HYDRO ENERGY↗

DOE OSTI2025

Main Shaft Bending Moment Analysis for a Gamesa G97 2-MW Wind Turbine

In a collaborative project between Siemens Gamesa Renewable Energy and the National Renewable Energy Laboratory (NREL), a cost-effective method to measure dynamic main shaft torque and the influence of non-torque loads was applied to the gearbox of the Gamesa G97 2-megawatt (MW) wind turbine at the NREL Flatirons Campus and verified through a field test campaign that took place in 2023. The method involved the installation of fiber-optic sensors on the ring gear of the gearbox. Additionally, traditional strain gauges and a rotary encoder were installed on the main shaft to measure mechanical torque and orthogonal bending moments. We compare the measured total main shaft bending moments from the field test campaign to those predicted by an updated OpenFAST model of the G97 wind turbine for similar environmental conditions. We also assessed the sensitivity of the predicted bending moment to varying levels of turbulence intensity, shear exponent, and yaw error.

17 WIND ENERGY↗

DOE OSTI2026

Proposal to search for long-lived neutral particles in CERN service shafts

Long-lived particles are predicted by many extensions of the Standard Model and have been gaining interest in recent years. In this paper the original proposal is presented for AN Underground Belayed In-Shaft (ANUBIS) detector that substantially extends the sensitivity to particle lifetimes by instrumenting the existing service shafts above the ATLAS or CMS experiments with tracking stations. For scenarios with electrically neutral long-lived particles with 𝑚 ≳ 1~GeV produced at the electroweak scale and above, the lifetime reach is increased by 2-3 orders of magnitude compared to currently operating and approved future experiments at the LHC. Here, the original ANUBIS detector design proposal is outlined along with the projected costs.

ANUBIS↗

DOE OSTI2025

SPC-71188 Rev 0 MARVEL Control Drum Rotary Shaft Seal Procurement Specification

Idaho National Laboratory (INL) is developing a microreactor to produce electrical power utilizing a small nuclear core under the Microreactor Application Research Validation and Evaluation (MARVEL) program. This procurement specification defines the requirements for fabrication of the MARVEL Control Drum Rotary Shaft Seal.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗

DOE OSTI2023

Nonlinear analysis and vibro-impact characteristics of a shaft-bearing assembly

Here this study investigates the nonlinear frequency response of a shaft-bearing assembly with vibro-impacts occurring at the bearing clearances. The formation of nonlinear behavior as system parameters change is examined, along with the effects of asymmetries in the nominal, inherently symmetric system. The primary effect of increasing the forcing magnitude or decreasing the contact gap sizes is the formation of grazing-induced chaotic solution branches occurring over a wide frequency range near each system resonance. The system's nominal setup has very hard contact stiffness and shows no evidence of isolas or superharmonic resonances over the frequency ranges of interest. Moderate contact stiffnesses cause symmetry breaking and introduce superharmonic resonance branches of primary resonances. Even if some primary resonances are not present due to the system's inherent symmetry, their superharmonic resonances still manifest. Branches of quasiperiodic isolas (isolated resonance branches) are also discovered, along with a cloud of isolas near a high-frequency resonance. Parameter asymmetries are found to produce a few significant changes in behavior: asymmetric linear stiffness, contact stiffness, and gap size could affect the behavior of primary resonant frequencies and isolas.

42 ENGINEERING↗

DOE OSTI2021

Evaluation of several relevant fractionation processes as possible explanation for radioxenon isotopic activity ratios in samples taken near underground nuclear explosions in shafts and tunnels

Gas samples taken from two historic underground nuclear tests done in 1989 at the Nevada National Security Site (NNSS), formerly the Nevada Test Site (NTS), were examined to determine how xenon isotopes fractionate because of early-time cavity processes, transport through the rock, or dispersal through tunnels. Xenon isotopes are currently being used to distinguish civilian sources of xenon in the atmosphere from sources associated with underground nuclear explosions (UNEs). The two nuclear tests included (1) BARNWELL, a test conducted in a vertical shaft approximately 600 m below ground surface at Pahute Mesa, and (2) DISKO ELM, a horizontal line-of-sight test done in P-tunnel approximately 261 m below the surface of Aqueduct Mesa. Numerical flow and transport models developed for the two sites had mixed success when attempting to match the observed xenon isotope ratios. At the BARNWELL site, the simulated xenon isotope ratios were consistent with measurements from the chimney and ground surface and appeared to have been affected primarily by fractionation during subsurface transport. At the DISKO ELM site, samples taken from two elevations in the chimney failed to show the degree of fractionation predicted by the models during transport and did not show evidence for significant fractionation due to early-time condensation of refractory xenon-precursor radionuclides into the melt glass. Gas samples taken from the adjacent tunnels in the days following the test showed mixed evidence for early-time separation of xenon isotopes from their iodine precursors.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2021

Probe measurements of electric field and electron density fluctuations at megahertz frequencies using in-shaft miniature circuits

In this work, a four-tip electrostatic probe is constructed to measure high-frequency (0.1–10 MHz) fluctuations in both the electric field (one component) and electron density in a laboratory plasma. This probe also provides data for the local electron temperature and density. Circuits for high-frequency measurements are fabricated on two miniature boards, which are embedded in the probe shaft, near the tips to minimize the pickup of common-mode signals. The amplitude and phase response of two circuits to sinusoidal test signals are measured and compared with results from modeling. For both circuits, the phase shift between input and output signals is relatively small (<30°). The performance of the probe is verified in a high-density (~10 13 cm –3 ) and low-temperature (≲10 eV) plasma. The probe successfully measures high-frequency (~2 MHz) fluctuations in the electric field and density, which are associated with lower hybrid drift waves. This probe can provide information on the wave-associated anomalous drag, which can be compared with the classical resistivity.

47 OTHER INSTRUMENTATION↗

DOE OSTI2025

MAGIS-100 Experiment Installation in Shaft

This poster shows the experiment and access system as it will be installed in the MINOS shaft, along with important connecting components such as the atom sources and connection nodes.

Kowalkowski, James B. [Fermilab]↗

DOE OSTI2022

Application of Frequency Division Multiplexing and Neural Networks in the Operation and Diagnosis of the Stator Current and Shaft Position Sensors Used in Electric/Hybrid Vehicles

Fast, precise and robust sensing of currents and motor shaft angle is essential for the excellent performance of electric and hybrid vehicles (EV/HEV). Multiplexing techniques are commonly applied in data acquisition systems (DAQs) to digitize the signals sensed in EV/HEV drives. Frequency-division multiplexing (FDM) applied to get the signals from current sensors and resolver angular position sensor has advantages over conventional multiplexing approaches. However, problems such as aging and mechanical imperfections distort the outputs of those sensors, producing measurement errors of the angular position and currents. Conventional techniques designed to compensate for those errors cannot be applied in signals multiplexed in frequency. This paper proposes online techniques to detect and compensate for the distortions in the resolver sensor and current sensors. The demultiplexing process was adjusted to allow distortion detection and compensation. An auto-associative neural network (ANN) compensates for the current measurement error, while an energy-based technique is applied to compensate for the distortions in the resolver outputs. The obtained results show that the distortions were compensated, allowing a more accurate estimation of stator currents and angular position when FDM is applied in EV/HEV DAQs.

Pereira Pinto, Joao↗

DOE OSTI2022