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DOE OSTI2025

Importance of hydrogen oxidation reaction current in quantifying hydrogen crossover in PEM water electrolyzers at high differential pressure

Understanding hydrogen permeation in proton exchange membrane water electrolyzers (PEMWEs) operating at high differential pressures (>25 bar) is critical towards developing effective gas recombination strategies that enable safe operation and high efficiency. Developing this understanding relies on accurate quantification of hydrogen crossover rates in water electrolyzers operating under such conditions. In this work, we show that PEMWEs operating at high differential pressures exhibit noticeable hydrogen oxidation reaction (HOR) currents. As the HOR consumes part of the permeated hydrogen at the anode, neglecting HOR currents leads to severe underestimation of the hydrogen crossover rate. We implemented a new method combining hydrogen oxidation current with online gas chromatography measurements to accurately quantify hydrogen crossover rates as a function of operating current density in PEMWEs operating at high differential pressures (10–30 bar g ).

25 ENERGY STORAGE↗

DOE OSTI2020

Prediction for Pressure Differential Across HEPA Filter Media Based on Media Characteristics and Particle Size Distribution

A new method for predicting the pressure drop across High Efficiency Particulate Air (HEPA) filter media is proposed based upon mass deposited onto the filter and known physical characteristics of the filter media. Detailed are the methods used in conjunction with current filter loading models to predict the pressure drop, as well as tests conducted to validate the methods. The benefit of a prediction model for practical use lies in the manufacturing and service life of nuclear grade HEPA filters. HEPA filters for use in nuclear facilities have a prescribed expiration date and a maximum allowable operating pressure drop. Therefore, the ability to predict the pressure drop across a filter and relate it to an expected length of service time can enable a reduction in wasted filters. This will allow for more informed decisions to be made based upon the dictated life cycle of the filters. Also, understanding and predicting how the pressure drop of HEPA filter media behaves as a function of physical characteristics and loaded mass can assist in future design and manufacturing of filter media. Currently, most existing pressure drop models are either computationally based or analytical methods relying on data gathered during tests. Neither are practical for prediction; the computational methods are difficult to implement, and the current analytical methods are more useful as tools for analysis. The current analytical model developed by Bergman et al. is based upon the pressure drop from each media fiber and modeling the deposited particles as newly formed fibers. Using Bergman's model and the media properties, air properties, and known aerosol particle size distribution, a pressure drop curve as a function of loaded mass can be created. This curve implies initial loading in the depth of the filter media with a transition to pure surface loading on the filter face, and a sensitivity to an evolving particle size distribution as mass continues to load onto the filter. To implement the predictive model, knowledge of the mean filter fiber diameter and porosity of the filter media is required. Traditionally, the mean fiber diameter is calculated as an effective diameter from prior media testing, however, in this study a Scanning Electron Microscope (SEM) technique is used to acquire this variable. Validation of the predictive model is provided by flat sheet media tests under a controlled environment with a measured particle size distribution of the challenge aerosol and shows reasonable preliminary agreement.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

In-Operando Measurement of Hydrogen Crossover in Proton Exchange Membrane Electrolysis Cells at Differential Pressures

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Wrubel, Jacob A↗

DOE OSTI2021

Fiscal Year 2021 Filtration of Hanford Tank 241-AP-107 Supernatant Samples Obtained at Prototypic Tank Level and Filtered at 16 °C

Bench-scale filtration testing of 8.5 liters of supernatant from Hanford waste tank 241-AP-107, chilled to 16 °C, was conducted using a backpulse dead-end filter (BDEF) filtration system equipped with a feed vessel and a Mott inline filter Model 6610 (Media Grade 5) in the hot cells of the Radiochemical Processing Laboratory at Pacific Northwest National Laboratory. This was done to assess the impact of a lower sampling location within the tank as well the lowered filtration temperature on supernatant stability and fouling. The as-received samples were transferred to 1.5-liter poly bottles and held at 16 °C for approximately 1 week prior to filtration. The feed was filtered through the BDEF system at a targeted flux of 0.065 gpm/ft 2 to match the prototypic operation of the TSCR system. During the initial period of filtration, the differential pressure required to effect filtration at 0.065 gpm/ft 2 increased until it reached 2 psid [the Tank Side Cesium Removal (TSCR) action limit] at 26 hours. After this, the filter was backpulsed to dislodge accumulated solids and reduce this pressure differential. An additional eight backpulses were conducted during the initial filtration period; each time, the target pressure was reached sooner than during the previous interval. Volume filtered decreased from 0.9 to 0.03 m 3 /m 2 over the course of 14 processing hours. After the ninth backpulse, the backpulse frequency had become unsustainable, and it was decided to perform an extensive filter cleaning. The filter was cleaned by draining the chilled AP-107 feed into chilled holding containers, introducing 0.1 M NaOH into the feed vessel, and recirculating the NaOH through the system for 20 minutes before allowing the system to soak for 2 hours without temperature control. A measurable decrease in filter resistance during this recirculation indicated that the 0.1 M NaOH was likely dissolving some of the solids that had deposited on the filter. Post cleaning, the filter resistance was effectively restored to initial conditions as the initial transmembrane pressure was restored to original levels. However, resumed processing of the AP-107 feed at 16 °C continued to result in an increased rate of filter resistance. An additional five backpulses were conducted (four during feed processing, one during subsequent cleaning) before the conclusion of the test. Solids concentrated from the backpulse solutions displayed sodium oxalate-type phases, Al-oxides and sodium Al-oxides/carbonates, iron oxides, and Ca-bearing phases (calcite). The scanning electron microscopy analyses also revealed a large distribution of particles, with some particles, notably sodium phosphate dodecahydrate, having diameters close to 0.5 mm.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

Using non-invasive MEMS pressure sensors for measuring building envelope air leakage

Micro-electromechanical systems (MEMS)-based sensors have seen significant improvements in accuracy and cost over the past several years, and due to the need for altitude sensing in unmanned aerial vehicles and wearable technologies, absolute pressure sensors have shown the most dramatic improvements. This paper investigates applications of MEMS sensors in commercial buildings, including pairing two absolute pressure sensors to determine differential pressures between different locations in and around buildings. Differential pressure measurements are commonly made in commercial buildings for a number of applications, including static pressure measurements for variable-speed supply fan control, air balancing in hospitals, and for envelope and duct air leakage testing. This paper focuses specifically on envelope air-leakage testing applications of these sensors. The use of continuous pressure measurements in addition to one-time non-intrusive outdoor airflow measurements of rooftop packaged units is investigated. A comparison with standardized leakage testing indicated that continuous measurements with MEMS pressure-sensors were able to estimate envelope leakage to within 3–16% of the standardized test result. In addition, the magnitude and stability of differential pressure differences that can be resolved with absolute pressure sensors are also investigated in the laboratory and the field. Results show that the sensors can be effectively used for pressures seen in low rise buildings with rooftop units.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Advancing Li-plating detection: Motivating a multi-signal correlation approach

Facilitating fast charging in lithium-ion batteries (LiBs) is often linked to Li-plating, which harms performance, longevity, and safety. Early detection of Li-plating is essential for rapid technological development and for preventing performance deterioration and ensuring safety during operation. Fast and real-time detection, using commonly collected measurements like voltage (V), current (I), temperature (T), and pressure (P), is highly desirable. Existing standalone methods relying on electrochemical and mechanical signatures, using half, smaller, or specially designed cells often operated at lower temperatures, fail to account for real-world fast-charging conditions. These signatures may also have inherent unreliability in aged LiBs, a phenomenon currently not-well understood. All these uncertainties have complicated practical implementation of a robust Li-plating detection technique. This study, through multiple case studies involving real-world fast-charging conditions using automotive-grade 11.6 Ah LiBs, shows that many single signal-based diagnostic techniques may be inadequate to detect Li-plating. Among various signatures, end-of-charge rest pressure, differential pressure-sensing, and end-of-charge rest voltage were identified as particularly useful in detecting Li-plating. Furthermore, A multi-signal-based detection technique is shown to be more robust in detecting Li-plating. Using both fresh and aged cells, the results and analysis highlight how detection capabilities are influenced by various factors, including battery design, size, charging speed, operating temperature, and degradation level. Adopting such a multi-signal Li-plating detection approach may be instrumental in the rapid development of battery technology in laboratories, as well as ensuring the enhanced safety of next-generation LiBs in real-world fast-charging applications.

25 ENERGY STORAGE↗

DOE OSTI2021

Methods, systems, and devices to optimize a fluid harvester

An apparatus for energy extraction from fluid flow including an assembly including a plenum. The assembly further includes an aperture extending from an exterior surface to the plenum to allow flow therethrough. The apparatus further includes a channel including an inlet and an outlet in fluid communication with the plenum. The apparatus yet further includes an energy extraction device. The assembly is configured to create a pressure differential between the plenum and the inlet of the channel. The pressure differential causes fluid flow from the inlet of the channel to the plenum. The energy extraction device is configured to extract energy from the fluid flow. The apparatus additionally includes a control system configured to modify the pressure differential to control the fluid flow between the inlet of the channel and the plenum based on a characteristic of an exterior environment.

Houchens, Brent Charles↗

DOE OSTI2023

Impacts of Different Operation Conditions and Geological Formation Characteristics on CO2 Sequestration in Citronelle Dome, Alabama

Major concerns of carbon dioxide (CO2) sequestration in subsurface formations are knowledge of the well injectivity and gas storage capacity of the formation, the CO2 pressure and saturation plume extensions during and after injection, and the risks associated with CO2 leakage and fault reactivation. Saline reservoirs are considered as one of the target formations for CO2 sequestration through structural, residual, dissolution, and mineral trapping mechanisms. The boundary condition of the saline reservoir dictates the pressure and saturation plume extension of the injected supercritical CO2 that could expand over large distances. This can lead to sources of risk, e.g., leakage and/or fault reactivation due to presence of wells, thief zones, and geological discontinuities. Therefore, there is a critical need to develop a model that describes how risk-related performance metrics (i.e., the CO2 saturation plume size, the pressure differential plume area, and the pressure differential at specific locations) vary as a function of the size of injection, time following injection, injection operations, and geologic environment. In this study, a systematic reservoir modeling studies of anthropogenic CO2 sequestration in Citronelle dome, Alabama, was performed where all relevant scenarios and conditions to address the questions of the saturation and pressure plume size in the area of review (AoR) and post-injection site care (PISC) are considered. The objective for this study was firstly to systematically simulate CO2 sequestration, i.e., saturation dynamics, and pressure behavior over a range of operational and geological conditions and to derive conclusions about the factors influencing saturation and pressure plume size, post-injection behavior, and the risk associated with them, by developing third-generation reduced order models (ROMs) for reservoir behavior. Finally, to assess the uncertainty associated with our studies, Latin Hypercube Sampling (LHS) together with an experimental design technique, i.e., Plackett–Burman design, was used. Application of Pareto charts and respond surfaces enabled us to determine the most important parameters impacting saturation and pressure plume sizes and to quantify the auto- and cross-correlation among different parameters in both history-matched and upscaled models.

58 GEOSCIENCES↗

DOE OSTI2020

Apparatus and method for measuring level

A vessel with a cavity for measuring level is disclosed. The vessel includes a differential pressure sensor having a first port and a second port, a reference tube that connects the first port of the differential pressure sensor to a bottom portion of the cavity, and an impulse tube that connects the second port of the differential pressure sensor to an impulse tube ending. At least a portion of the impulse tube extends through the cavity and ends at a fluid inlet. The fluid inlet is located at a level above the reference tube.

42 ENGINEERING↗

DOE OSTI2022

Onboard early detection and mitigation of lithium plating in fast-charging batteries

Fast-charging is considered as one of the most desired features needed for lithium-ion batteries to accelerate the mainstream adoption of electric vehicles. However, current battery charging protocols mainly consist of conservative rate steps to avoid potential hazardous lithium plating and its associated parasitic reactions. A highly sensitive onboard detection method could enable battery fast-charging without reaching the lithium plating regime. Here, we demonstrate a novel differential pressure sensing method to precisely detect the lithium plating event. By measuring the real-time change of cell pressure per unit of charge (dP/dQ) and comparing it with the threshold defined by the maximum of dP/dQ during lithium-ion intercalation into the negative electrode, the onset of lithium plating before its extensive growth can be detected with high precision. In addition, we show that by integrating this differential pressure sensing into the battery management system (BMS), a dynamic self-regulated charging protocol can be realized to effectively extinguish the lithium plating triggered by low temperature (0 °C) while the conventional static charging protocol leads to catastrophic lithium plating at the same condition. We propose that differential pressure sensing could serve as an early nondestructive diagnosis method to guide the development of fast-charging battery technologies.

25 ENERGY STORAGE↗

DOE OSTI2022

CalWave - Open Water Demonstration - System and Component Overview Content Models and Drawings

Data for the CalWave - Open Water Demonstration, a submerged pressure differential Wave Energy Converter (WEC) Device. Device is moored to the seabed, and the motion of the waves causes the sea level to rise and fall above the device, inducing a pressure differential in the device. The alternating pressure pumps fluid through a system to generate electricity, which is transmitted to shore via bidirectional cables. Documentation and data here includes: System Overview Content Model and Drawings as well as Component Overview Content Model and Drawings.

16 TIDAL AND WAVE POWER↗

DOE OSTI2022

CalWave - Open Water Demonstration - Field Testing Content Models (10/21 - 7/22)

Data for the CalWave - Open Water Demonstration, a submerged pressure differential Wave Energy Converter (WEC) Device. Device is moored to the seabed, and the motion of the waves causes the sea level to rise and fall above the device, inducing a pressure differential in the device. The alternating pressure pumps fluid through a system to generate electricity, which is transmitted to shore via bidirectional cables. Documentation and data here includes: Open Water Demonstration, including field testing content models for nearly 10 months of continuous ocean operation, from October 2021 through July 2022.

16 TIDAL AND WAVE POWER↗

DOE OSTI2020

VALVE TIMING AND AREA PROFILE SELECTION FOR HYDRAULIC PUMPS AND MOTORS

A significant amount of research has been conducted to select valve timing and area profiles that create efficient and quiet hydraulic pumps and motors. Numerous active valve architectures have been modeled and optimized, but the rationale for the final solution is often unclear. The solution is usually highly dependent on the modeled valve geometry constraints and the duty cycle of the pump or motor for which the valve was optimized. This paper first presents an ideal valve area profile and what compromises are made to design for a working pressure and speed range. The ideal valve area profile is resolved using a piston-cylinder model with a pressure dependent bulk modulus and variable valve openings. The piston-cylinder is first modeled as a pump with passive (check) valves and a specified pressure drop across the valves to determine the ideal area profile. A generalization of the ideal timing is demonstrated for positive pressure differential and positive rotation direction, also known as the first quadrant. The effects on valve timing when varying pressure are shown for the first quadrant, but the trends can be extrapolated for all quadrants of operation. The ideal valve profile is implemented as fixed valve timing, meaning the valve area is only a function of the timing angle, in a pump-motor. The pump-motor is simulated in one rotation direction through a pressure range. Performance is high in pumping operation, but when the pressure differential is reversed, cylinder pressure spikes ensue. Two strategies to modify an ideal valve area profile are presented: timing grooves and a pressure shifted valve timing. Timing grooves reduce pressure spikes and cavitation in the cylinder but generally increase throttling losses. A pressure shifted valve timing has lower throttling energy losses, making it the favored solution.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2020

Aircraft-Integrated Meteorological Measurement System (AIMMS) Instrument Handbook

The AIMMS-20 probe is manufactured by Aventech Research Inc. and measures platform position, velocity, attitude, ambient temperature, static pressure, and the differential pressures from a 5-port hemispheric gust probe, and combines all these measured data into a calculation of the ambient winds. A detailed description of the AIMMS-20 specifications is available here. Note: The Aventech engineers use the aircraft-centric frame of reference common to aeronautical engineering, which defines z as down.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Pressure shifted valve timing

A hydraulic pump-motor includes a cylinder block including a plurality of fluid chambers, a piston in each of the fluid chambers, a cam, a fixed valve area profile, and a timing adjustment actuator. The cam includes a cam surface that engages the pistons and drives movement of the pistons relative to the fluid chambers in response to relative rotation between the cam and the fluid chambers. The fixed valve area profile is configured to control fluid flows between the fluid chambers and first and second ports. The timing adjustment actuator is configured to adjust an angular orientation of the fixed valve area profile relative to an angular orientation of the cam based on a pressure differential between a pressure at the first port and a pressure at the second port.

Boyce-Erickson, Grey C.↗

DOE OSTI2022

CalWave - Open Water Demonstration - LCOE Content Model

16 TIDAL AND WAVE POWER↗

DOE OSTI2022

Niowave: Flow measurement development - FY2022

It is critical to maintain proper flow rate of lead bismuth eutectic (LBE) for the operation of the Niowave converter. The high temperature of the LBE (> 200 °C) makes it difficult to purchase simple off the shelf flow meters. One method that can be used to measure the flow rate indirectly, is to use a venturi, with a known throat diameter and differential pressure measurement across the throat. LANL designed the venturi and after numerous iterations with vendors, narrowed down a differential pressure transducer to use with the venturi.

43 PARTICLE ACCELERATORS↗

DOE OSTI2020

Fluidization of Group A Glass Particles: Experiments and Preliminary Validation

This work is aimed at providing reliable high-quality data from fluidization experiments. Geldart Group A glass beads are used as bed material. The fluidizing medium is air at atmospheric pressure which enters the system at 40% relative humidity. The air inlet velocity is varied over a broad range from 2 U mf to 26 U mf , where the minimum fluidization velocity, U mf , is 0.608 cm/s. There is not a significant change in the mean values of differential pressure; however, there are noticeable trends in their standard deviation values. Preliminary validation studies are performed using the open-source software Multiphase Flow with Interphase eXchanges (MFiX) developed by the National Energy Technology Laboratory (NETL). The results from Eulerian-Eulerian (MFiX-TFM, two-fluid model) and Eulerian-Lagrangian (MFiX-PIC, particle-in-cell) formulations are compared. The work presented in this report highlights the applicability of MFiX-PIC for large-scale applications, and reveals that PIC simulation offers a suitable alternative to TFM simulation when effects due to multiple components or polydispersity are significant. PIC modeling provides a readily extendible framework for such systems. However, PIC models do rely on an empirical closure for inter-particle stress. Some solution discrepancies were evident in MFiX-PIC predictions which require further analysis. As such, the study underlines the need for a systematic approach to quantify the sources of numerical uncertainty within the PIC model. However, even with known empiricism, MFiX-PIC has demonstrated considerable potential in analyzing gas-solid systems. The results obtained are encouraging and warrant further investigation to improve the predictive capability of MFiX-PIC.

36 MATERIALS SCIENCE↗