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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 OSTI2022

Real-Time Highly Resolved Spatial-Temporal Vehicle Energy Consumption Estimation Using Machine Learning and Probe Data

Real-time highly resolved spatial-temporal vehicle energy consumption is a key missing dimension in transportation data. Most roadway link-level vehicle energy consumption data are estimated using average annual daily traffic measures derived from the Highway Performance Monitoring System; however, this method does not reflect day-to-day energy consumption fluctuations. As transportation planners and operators are becoming more environmentally attentive, they need accurate real-time link-level vehicle energy consumption data to assess energy and emissions; to incentivize energy-efficient routing; and to estimate energy impact caused by congestion, major events, and severe weather. This paper presents a computational workflow to automate the estimation of time-resolved vehicle energy consumption for each link in a road network of interest using vehicle probe speed and count data in conjunction with machine learning methods in real time. The real-time pipeline can deliver energy estimates within a couple seconds on query to its interface. The proposed method was evaluated on the transportation network of the metropolitan area of Chattanooga, Tennessee. The volume estimation results were validated with ground truth traffic volume data collected in the field. To demonstrate the effectiveness of the proposed method, the energy consumption pipeline was applied to real-world data to quantify road transportation-related energy reduction because of mitigation policies to slow the spread of COVID-19 and to measure energy loss resulting from congestion.

Severino, Joseph↗
DOE OSTI2020

RouteE: A Vehicle Energy Consumption Prediction Engine

The emergence of connected and automated vehicles and smart cities technologies create the opportunity for new mobility modes and routing decision tools, among many others. To achieve maximum mobility and minimum energy consumption, it is critical to understand the energy cost of decisions and optimize accordingly. The Route Energy prediction model (RouteE) enables accurate estimation of energy consumption for a variety of vehicle types over trips or sub-trips where detailed drive cycle data are unavailable. Applications include vehicle route selection, energy accounting and optimization in transportation simulation, and corridor energy analyses, among others. The software is a Python package that includes a variety of pre-trained models from the National Renewable Energy Laboratory (NREL). However, RouteE also enables users to train custom models using their own data sets, making it a robust and valuable tool for both fast calculations and rigorous, data-rich research efforts. The pre-trained RouteE models are established using NREL’s Future Automotive Systems Technology Simulator paired with approximately 1 million miles of drive cycle data from the Transportation Secure Data Center, resulting in energy consumption behavior estimates over a representative sample of driving conditions for the United States. Validations have been performed using on-road fuel consumption data for conventional and electrified vehicle powertrains. Transferring the results of the on-road validation to a larger set of real-world origin-destination pairs, it is estimated that implementing the present methodology in a green-routing application would accurately select the route that consumes the least fuel 90% of the time. The novel machine learning techniques used in RouteE make it a flexible and robust tool for a variety of transportation applications.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Data-Driven Modeling and Optimization of Building Energy Consumption: a Case Study

Installing sensors and Building Automation Systems (BAS) allows controlling the facility operations while generating data that can be analyzed for model development. This work focuses on data-driven modeling of the building to optimize energy consumption. The City of Orlando aims to reduce its energy consumption so, they provided us access to their BAS for data and studying the operation of its facilities. We selected a mid-size pilot building to conduct data analysis and modeling. We develop an Application Programming Interface (API) to login to the servers and scrape data. The scraped data contains features ranging from environmental conditions to equipment activity. This dataset is a time series so, it's handled in accordance and analyzed to investigate patterns and relations between data points that help choose parameters for predictive models for building and equipment. Finally, the models are optimized to reduce the energy consumption of the facility.

Grover, Divas↗
DOE OSTI2026

Diesel Fuel Consumption in Prominent U.S. Open-Pit Mines: Site-Level Estimates

This report presents a comprehensive framework for estimating diesel fuel consumption and prices at open-pit mines in the United States. The framework includes transparent methods for calculating site-level diesel energy use when direct reporting is unavailable, and a structured confidence evaluation for each method. The framework is demonstrated to estimate current diesel consumption at 21 open-pit mines in the United States. Initial findings support ongoing efforts to strengthen the competitiveness and security of the U.S. industrial base by supporting data-driven supply chain analysis and decision-making, improved transparency in mining sector energy use, and targeted deployment of energy innovation and cost-reduction strategies. Future updates to the dataset—coupled with expanded data transparency and method validation—will help ensure that the findings remain relevant as the sector continues to evolve.

02 PETROLEUM↗
DOE OSTI2021

Using Demanded Power and RDE Aggressiveness Metrics to Analyze the Impact of CACC Aggressiveness on Heavy Duty Platooning Power Consumption

Presently, a main mobility sector objective is to reduce its impact on the global greenhouse gas emissions. While there are many techniques being explored, a promising approach to improve fuel economy is to reduce the required energy by using slipstream effects. This study analyzes the demanded engine power and mechanical energy used by heavy-duty trucks during platooning and non-platooning operation to determine the aerodynamic benefits of the slipstream. A series of platooning tests utilizing class 8 semi-trucks platooning via Cooperative Adaptive Cruise Control (CACC) are performed. Comparing the demanded engine power and mechanical energy used reveals the benefits of platooning on the aerodynamic drag while disregarding any potential negative side effects on the engine. However, energy savings were lower than expected in some cases. It was hypothesized that the CACC may have amplified transient platooning events relative to the individual truck baseline results, hampering the potential energy savings. Therefore, the impact of the controller on the observed driving style was analyzed in detail. In order to quantify the transient operational characteristics of the experimental trials, metrics from the European Real Driving Emissions (RDE) legislation were modified to serve as metrics of aggressiveness during platooning. The metrics (v · apos)95 and Relative Positive Acceleration (RPA) were calculated for platooning and non-platooning runs. These results indicate that the CACC induces small acceleration events during platooning to retain the commanded longitudinal separation between vehicles. These small acceleration events increase following vehicle aggressiveness during platooning and prevent the following vehicles from obtaining maximum energy savings. Moreover, a correlation between the RDE metric (v · apos)95 and energy savings is developed. Hence, this work establishes the ability of RDE metrics to assess CACC impacts on platoon energy savings.

European Real Driving Emissions, RDE, greenhouse g↗
DOE OSTI2022

Investigation of Remanufacturing Methods Utilizing Mechanically-Generated and Gas-Atomized Feedstock Production for Directed Energy Deposition Processing Through Specific Energy Consumption Modeling

The goal of this work was to assess the energy consumption of a novel remanufacturing method that utilizes mechanically-generated feedstock for directed energy deposition. Gas-atomization is the state-of-the-art production process for directed energy deposition feedstock, and for this work was incorporated into a remanufacturing process path to provide a comparison method. Specific energy consumption models of remanufacturing utilizing both of these proposed process paths were developed and applied to a case study to investigate energy saving opportunities for future manufacturing paradigms. The energy modelling was done in three stages. First, the mechanically-generated feedstock production energy consumption model was generated from experimental observation. Second, the gas-atomized feedstock production energy consumption model was generated from a combination of experimental observation, reported estimates from the manufacturer, and data found in the literature. Lastly, the energy consumption model of directed energy deposition was derived from experimental observation and compares favorably with reported estimates in the literature. With the models, the specific energy consumption in the two process paths were compared and their application was demonstrated by estimating the energy consumption to remanufacture a bracket. The two feedstock production methods had similar specific energy consumptions. The specific energy consumption of the directed energy deposition process was the greatest component in the respective remanufacturing paths by an order of magnitude; increasing deposition rate is the most important factor for lowering the overall specific energy consumption. The analyzed remanufacturing technologies were estimated to consume less energy than replacement when repairing up to approximately 15% of the original part’s mass.

42 ENGINEERING↗
DOE OSTI2020

Gasoline Engine and Fuels Offering Reduced Fuel Consumption and Emissions: Vehicle Modeling Final Report

The Gasoline Engine and Fuels Offering Reduced Fuel Consumption and Emissions (GEFORCE) project was proposed in response to the U.S. Department of Energy’s Funding Opportunity Announcement 0991 by a team made up of the members of the Coordinating Research Council (CRC) and the research staff at Oak Ridge National Laboratory (ORNL.) The project focused on investigating the potential benefits that might be attained through synergistic use of specific engine technology together with fuels formulated to represent potential directions that high-octane fuels of the future might progress. A stated objective in the DOE FOA was to demonstrate a 25% reduction in petroleum consumption through optimization of the engine technologies together with a suitable fuel. An advanced engine was constructed and used with a matrix of research fuels to investigate potential avenues for efficiency improvement. The engine incorporated technologies expected to become mainstream for boosted engines in the next 10 to 20 years. These included increased compression ratio, a two-stage turbocharger, and cooled external exhaust gas recirculation (EGR). The fuel matrix was designed to investigate impacts from research octane number (RON), volumetric ethanol content, and the final boiling point of the fuel. The engine calibration was optimized for each fuel individually and data collected to enable vehicle system modelling that projected energy consumption, fuel economy, tailpipe CO₂ emissions, and impact on petroleum consumption for an industry-average mid-size sedan. The engine calibration and data collection were carried out at IAV in Michigan and is the subject of a separate report. IAV provided the engine data to Oak Ridge National Laboratory to support the vehicle modelling portion of the project. The vehicle modelling results show the following trends: Ethanol content does have a consistently strong influence on the fuel economy results for all cycles and all fuels. Among the fuels of a nominal RON level, increasing ethanol content consistently lowers fuel economy, with the 30% ethanol fuels always providing the lowest fuel economy for a given RON level. However, in some cases the energy consumption improvement allows the 30% ethanol fuels to match the fuel economy of the ethanol-free fuel P. These observations underscore the importance of both engine efficiency and fuel volumetric energy content on vehicle fuel economy.; There was no consistent trend in the projected energy consumption results for differences in fuel T90 for all fuels and cycles. Fuel economy projections did show a consistent trend, with the higher T90 fuel providing slightly greater fuel economy when compared to the low T90 fuel of the same ethanol content. The observed trends were consistent with differences in the heating value of the fuels.; The 102-RON fuels provided reduced energy consumption and greater fuel economy for the advanced engine on all drive cycles. The engine compression ratio of 11.5 was higher than would typically be used in a turbocharged engine when 92-RON fuel use is expected. Hence, the engine experiences more efficiency degradation from knock avoidance when using the 92-RON fuels. This degradation causes the fuel economy results for the 92-RON fuels to be lower than those for the 102-RON fuels.; Fuels E and F (92-RON, 30% ethanol) are projected to achieve 10% or greater reduction in petroleum consumption, with fuels K (102-RON, 30% ethanol) and O (97 RON, 30% ethanol) achieving greater than a 20% reduction. Fuel L (102-RON, 30% ethanol) achieves greater than 25% reduction, meeting the petroleum reduction target of the project. All of the fuels that achieve 10% or greater reduction in petroleum consumption are 30% ethanol blends.; Increasing final boiling point increased fuel economy at fixed ethanol content when the 102-RON fuels were used. This trend is a result of differences in the volumetric energy content of the fuels and the projected energy consumption values for the fuels. In the case of the 102-RON fuels, increasing final boiling point also resulted in an increase in the energy content of the fuel. There was not a consistent trend between the energy content and final boiling point for the 92-RON fuels at fixed ethanol content.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS2008

Safe Upper-Bounds Inference of Energy Consumption for Java Bytecode Applications

Many space applications such as sensor networks, on-board satellite-based platforms, on-board vehicle monitoring systems, etc. handle large amounts of data and analysis of such data is often critical for the scientific mission. Transmitting such large amounts of data to the remote control station for analysis is usually too expensive for time-critical applications. Instead, modern space applications are increasingly relying on autonomous on-board data analysis. All these applications face many resource constraints. A key requirement is to minimize energy consumption. Several approaches have been developed for estimating the energy consumption of such applications (e.g. [3, 1]) based on measuring actual consumption at run-time for large sets of random inputs. However, this approach has the limitation that it is in general not possible to cover all possible inputs. Using formal techniques offers the potential for inferring safe energy consumption bounds, thus being specially interesting for space exploration and safety-critical systems. We have proposed and implemented a general frame- work for resource usage analysis of Java bytecode [2]. The user defines a set of resource(s) of interest to be tracked and some annotations that describe the cost of some elementary elements of the program for those resources. These values can be constants or, more generally, functions of the input data sizes. The analysis then statically derives an upper bound on the amount of those resources that the program as a whole will consume or provide, also as functions of the input data sizes. This article develops a novel application of the analysis of [2] to inferring safe upper bounds on the energy consumption of Java bytecode applications. We first use a resource model that describes the cost of each bytecode instruction in terms of the joules it consumes. With this resource model, we then generate energy consumption cost relations, which are then used to infer safe upper bounds. How energy consumption for each bytecode instruction is measured is beyond the scope of this paper. Instead, this paper is about how to infer safe energy consumption estimations assuming that those energy consumption costs are provided. For concreteness, we use a simplified version of an existing resource model [1] in which an energy consumption cost for individual Java opcodes is defined.

Navas, Jorge↗
DOE OSTI2024

Physical, socio-psychological, and behavioural determinants of household energy consumption in the UK

Determining which attitudes and behaviours predict household energy consumption can help accelerate the low-carbon energy transition. Conventional approaches in this domain are limited, often relying on survey methods that produce data on individuals’ motivations and self-reported activities without pairing these with actual energy consumption records, which are particularly hard to collect for large, nationally representative samples. This challenge precludes the development of empirical evidence on which attitudes and behaviours influence patterns of energy consumption, thus limiting the extent to which these can inform energy interventions or conservation programs. This study demonstrates a novel methodology for estimating energy consumption in the absence of actual energy records by using a large, publicly available data set of energy consumption in the UK. We develop a predictive model using the Smart Energy Research Laboratory (SERL) data portal (with records from nearly 13,000 UK households) and then use this model to predict energy consumption (both electric and gas) for a sample of 1,000 UK householders for which we separately collect over 200 variables relating to climate change attitudes and practices. Our approach uses a set of over 50 independent variables that are shared between the data sets, allowing us to train a model on the SERL data and use it to analyse the relationship between energy consumption and the opinions, motivations, and daily practices of survey respondents. Results show that electricity consumption is influenced by a broader range of factors compared to gas. Household energy use is best explained by physical dwelling characteristics, socio-demographic variables, and certain behavioural and attitudinal measures. Notably, pro-environmental attitudes, frugality, and conscientiousness correlate with lower energy use, while income and consumerism are linked to higher consumption. We discuss how these findings can inform efforts to decarbonise home energy use in the UK.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Tea consumption and risk of bladder cancer in the Bladder Cancer Epidemiology and Nutritional Determinants (BLEND) Study: Pooled analysis of 12 international cohort studies

Tea has been shown to be associated with reduced risk of several diseases including cardiovascular diseases, stroke, metabolic syndrome, and obesity. However, the results on the relationship between tea consumption and bladder cancer are conflicting. This research aimed to assess the association between tea consumption and risk of bladder cancer using a pooled analysis of prospective cohort data. Individual data from 532,949 participants in 12 cohort studies, were pooled for analyses. Cox regression models stratified by study centre was used to estimate hazard ratios (HR) and corresponding 95% CIs. Fractional polynomial regression models were used to examine the dose–response relationship. A higher level of tea consumption was associated with lower risk of bladder cancer incidence (compared with no tea consumption: HR = 0.87, 95% C.I. = 0.77–0.98 for low consumption; HR = 0.86, 95% C.I. = 0.77–0.96 for moderate consumption; HR = 0.84, 95% C.I. = 0.75–0.95 for high consumption). When stratified by sex and smoking status, this reduced risk was statistically significant among men and current and former smokers. In addition, dose–response analyses showed a lower bladder cancer risk with increment of 100 ml of tea consumption per day (HR-increment = 0.97; 95% CI = 0.96–0.98). A similar inverse association was found among males, current and former smokers while never smokers and females showed non-significant results, suggesting potential sex-dependent effect. Higher consumption of tea is associated with reduced risk of bladder cancer with potential interaction with sex and smoking status. Further studies are needed to clarify the mechanisms for a protective effect of tea (e.g. inhibition of the survival and proliferation of cancer cells and anti-inflammatory mechanisms) and its interaction with smoking and sex.

60 APPLIED LIFE SCIENCES↗
NASA NTRS2012

Optimal Dynamic Sub-Threshold Technique for Extreme Low Power Consumption for VLSI

For miniaturization of electronics systems, power consumption plays a key role in the realm of constraints. Considering the very large scale integration (VLSI) design aspect, as transistor feature size is decreased to 50 nm and below, there is sizable increase in the number of transistors as more functional building blocks are embedded in the same chip. However, the consequent increase in power consumption (dynamic and leakage) will serve as a key constraint to inhibit the advantages of transistor feature size reduction. Power consumption can be reduced by minimizing the voltage supply (for dynamic power consumption) and/or increasing threshold voltage (V(sub th), for reducing leakage power). When the feature size of the transistor is reduced, supply voltage (V(sub dd)) and threshold voltage (V(sub th)) are also reduced accordingly; then, the leakage current becomes a bigger factor of the total power consumption. To maintain low power consumption, operation of electronics at sub-threshold levels can be a potentially strong contender; however, there are two obstacles to be faced: more leakage current per transistor will cause more leakage power consumption, and slow response time when the transistor is operated in weak inversion region. To enable low power consumption and yet obtain high performance, the CMOS (complementary metal oxide semiconductor) transistor as a basic element is viewed and controlled as a four-terminal device: source, drain, gate, and body, as differentiated from the traditional approach with three terminals: i.e., source and body, drain, and gate. This technique features multiple voltage sources to supply the dynamic control, and uses dynamic control to enable low-threshold voltage when the channel (N or P) is active, for speed response enhancement and high threshold voltage, and when the transistor channel (N or P) is inactive, to reduce the leakage current for low-leakage power consumption.

Duong, Tuan A.↗
NASA NTRS2012

Sensitivity of Mission Energy Consumption to Turboelectric Distributed Propulsion Design Assumptions on the N3-X Hybrid Wing Body Aircraft

In a previous study by the authors it was shown that the N3-X, a 300 passenger hybrid wing body (HWB) aircraft with a turboelectric distributed propulsion (TeDP) system, was able to meet the NASA Subsonic Fixed Wing (SFW) project goal for N+3 generation aircraft of at least a 60% reduction in total energy consumption as compared to the best in class current generation aircraft. This previous study combined technology assumptions that represented the highest anticipated values that could be matured to technology readiness level (TRL) 4-6 by 2030. This paper presents the results of a sensitivity analysis of the total mission energy consumption to reductions in each key technology assumption. Of the parameters examined, the mission total energy consumption was most sensitive to changes to total pressure loss in the propulsor inlet. The baseline inlet internal pressure loss is assumed to be an optimistic 0.5%. An inlet pressure loss of 3% increases the total energy consumption 9%. However changes to reduce inlet pressure loss can result in additional distortion to the fan which can reduce fan efficiency or vice versa. It is very important that the inlet and fan be analyzed and optimized as a single unit. The turboshaft hot section is assumed to be made of ceramic matrix composite (CMC) with a 3000 F maximum material temperature. Reducing the maximum material temperature to 2700 F increases the mission energy consumption by only 1.5%. Thus achieving a 3000 F temperature in CMCs is important but not central to achieving the energy consumption objective of the N3-X/TeDP. A key parameter in the efficiency of superconducting motors and generators is the size of the superconducting filaments in the stator. The size of the superconducting filaments in the baseline model is assumed to be 10 microns. A 40 micron filament, which represents current technology, results in a 200% increase in AC losses in the motor and generator stators. This analysis shows that for a system with 40 micron filaments the higher stator losses plus the added weight and power of larger cryocoolers results in a 4% increase in mission energy consumption. If liquid hydrogen is used to cool the superconductors the 40 micron fibers results in a 200% increase in hydrogen required for cooling. Each pound of hydrogen used as fuel displaces 3 pounds of jet fuel. For the N3-X on the reference mission the additional hydrogen due to the increase stator losses reduces the total fuel weight 10%. The lighter fuel load and attendant vehicle resizing reduces the total energy consumption more than the higher stator losses increase it. As a result with hydrogen cooling there is a slight reduction in mission energy consumption with increasing stator losses. This counter intuitive result highlights the need to consider the full system impact of changes rather than just at the component or subsystem level.

Felder, James L.↗
DOE OSTI2021

A Review and Outlook on Energy Consumption Estimation Models for Electric Vehicles

Electric vehicles (EVs) are critical to the transition to a low-carbon transportation system. The successful adoption of EVs heavily depends on energy consumption models that can accurately and reliably estimate electricity consumption. This paper reviews the state-of-the-art of EV energy consumption models, aiming to provide guidance for future development of EV applications. Here, we summarize influential variables of EV energy consumption into four categories: vehicle component, vehicle dynamics, traffic and environment related factors. We classify and discuss EV energy consumption models in terms of modeling scale (microscopic vs. macroscopic) and methodology (data-driven vs. rule-based). Our review shows trends of increasing macroscopic models that can be used to estimate trip-level EV energy consumption and increasing data-driven models that utilized machine learning technologies to estimate EV energy consumption based on large volume real-world data. We identify research gaps for EV energy consumption models, including the development of energy estimation models for modes other than personal vehicles (e.g., electric buses, electric trucks, and electric non-road vehicles); the development of energy estimation models that are suitable for applications related to vehicle-to-grid integration; and the development of multi-scale energy estimation models as a holistic modeling approach.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Automated vehicle microscopic energy consumption study (AV-Micro): Data collection and model development

While the Adaptive Cruise Control (ACC) system in automated vehicles (AVs) is expected to impact transportation energy significantly, existing AV energy consumption models only directly adopt those developed with Human-driven Vehicle (HV) data without even slight adaptation or calibration to accommodate unique AV energy consumption features. This study will investigate how accurately HV data-based models can predict the energy consumption of AVs. Empirical trajectory data and corresponding instantaneous energy consumption rates from both AVs and HVs were collected. We adopted two classical HV data-based models to fit these data. The calibration results indicated that these models yield around 20 30% prediction errors for AVs. To further improve the prediction accuracy, this study designed an AV-Micro model by incorporating components of multiple classic energy consumption models that better capture ACC energy consumption features, including piecewise driving behavior. With this, the AV-Micro model achieves lower than 10% prediction errors. The AV-Micro model’s high consistency across different test runs was verified with statistical significance tests, demonstrating its adaptability in different driving profiles. To confirm the discrepancies between the energy consumption features of AVs and HVs, more statistical significance tests were conducted to show that the AV-Micro model cannot be directly applied to HV data. The findings by calibrated AV-Micro models revealed that AVs consume approximately 80.5–146.4 J more energy than HVs for each meter traveled. Furthermore, the frequency analysis of energy consumption indicates that there is still some room for AVs to improve energy efficiency, particularly given their larger amplitude high-frequency fluctuations.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Impact of Non-Steady State Operation on Cooling Water Consumption at Coal- and Natural Gas-Fired Power Plants

Increased renewable energy penetration in the electricity grid in coming decades will result in more frequent cycling at thermal power plants. Simultaneously, thermal power plants may face water scarcity with declining availability of cooling water. Therefore, to enhance thermal power plants’ resiliency to water shortages it is important to understand how non-steady conditions due to cycling will impact cooling water consumption and withdrawal intensity. Non-steady operation at power plants has been previously shown to decrease power plant thermal efficiency. Energy balance models have also demonstrated that a decrease in thermal efficiency is expected to increase cooling water consumption intensity. Furthermore, past work has used operating hours data to show idling and cycling gaps where cooling systems operate more than corresponding generators. As a result, an increase in cycling behavior may impact cooling water consumption and withdrawal intensity. This study uses data from the Energy Information Administration (EIA) and Environmental Protection Agency (EPA) to quantify the impact of cycling cooling water consumption intensity for recirculating cooling systems and withdrawal intensity for once-through cooling systems using energy balance and statistical approaches. In a novel application of a fixed effects model to study the effect of temperature on cooling water consumption and withdrawal intensity, this study finds temperature was consistently expected to increase consumption intensity and withdrawal intensity. Non-steady state conditions do not increase cooling water consumption intensity with statistical significance across unit types. However, additional validation of cooling water data is required to confirm these observed trends due to the sensitivity of these findings to model form and concerns with data quality of the dependent variables, cooling water consumption and withdrawal.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2021

Evaluation of Oxygen Consumption as a Sensitive Measure of Electrical Cable Polymer Insulation Degradation

Polymers used as dielectric materials in nuclear grade electrical cables, such as cross-linked polyethylene (XLPE) and ethylene-propylene rubber (EPR), are long-lived and durable. Estimating the decades-long useful service life of polymers experimentally in a feasible timeframe of weeks or months requires greatly accelerated aging in the laboratory at elevated temperatures and/or gamma dose rates. Many limitations of accelerated aging, such as due to artefacts of the process including diffusion limited oxidation and dose rate effects, have been identified that can make accurate lifetime prediction at service conditions challenging. This can be due to differences in degradation mechanisms between rapid and extended aging or to the presence of induction periods during which early aging is undetectable using common metrics of polymer insulation characterization such as tensile elongation at break. Conceptually, an ideal measure of aging would track clearly and predictably with material changes throughout the lifecycle of the evolving material state from early aging through end of useful life. With such a metric accelerated aging could be performed at much milder conditions, conditions closer to those found in long term service, and end of life calculated from the early data. Oxygen consumption has previously been proposed as a sensitive measure of insulation polymer oxidation that might meet such desirable characteristics. In this work, nuclear cable insulation samples of the two most common types, XLPE and EPR, from two of the most sourced manufacturers, RSCC and The Okonite Company, were subjected to gamma irradiation at dose rates of 100, 200, and 300 Gy/hr for up to 42 days at 26°C. The aged samples were used to evaluate oxygen consumption as a sensitive measure of aging for these materials and these conditions. For comparison and validation, the aged samples were also characterized using the more conventional tests of mass change, density, carbonyl index, and yellowness index. For both materials, oxygen consumption during irradiation was found to track consistently with applied dose—oxygen consumption rate was linear with time. Mass change and carbonyl index were also clearly proportional to exposure dose. Yellowness index, a surface sensitive measure, was observed to increase linearly with dose at low exposure levels before plateauing. Sample density was not observed to change under the conditions explored. Oxygen consumption was found to be a particularly sensitive metric to measure the degradation of polymeric cable insulation exposed to radiation. Oxygen consumption was compared to Arrhenius and time-temperature-superposition methods for activation energy calculation using literature date and found to be a useful and viable alternative for lifetime prediction. The techniques developed in this work are anticipated to be valuable in the estimation of insulation aging rates under mild conditions approaching service conditions. Direction comparison of useful life prediction by oxygen consumption with prediction via Arrhenius methodology for thermal aging and existing methods for radiation and combined thermal/radiation aging would serve to further validate this promising approach and refine our understanding of material-specific aging rates.

36 MATERIALS SCIENCE↗