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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Scale tests of the new DUNE data pipeline

In preparation for the second runs of the ProtoDUNE detectors at CERN (NP02 and NP04)[1], DUNE has established a new data pipeline for bringing the data from the EHN-1 experimental hall at CERN to primary tape storage at Fermilab and CERN, and then spreading it out to a distributed disk data store at many locations around the world. This system includes a new Ingest Daemon and a new Declaration Daemon. The Rucio[2] replica catalog, and FTS3 transport are used to transport all files. All file metadata is declared to the new MetaCat[3] metadata service. All of these new components have been successfully tested at a scale equal to the expected output of the detector data acquisition system (~2-4 GB/s), and the expected network bandwidth out of the experimental hall. We present the procedure that was used to test and the results of the test.

Timm, Steven↗
DOE OSTI2016

Monitoring of Wind Turbine Gearbox Condition through Oil and Wear Debris Analysis: A Full-Scale Testing Perspective

Despite the wind industry's dramatic development during the past decade, it is still challenged by premature turbine subsystem/component failures, especially for turbines rated above 1 MW. Because a crane is needed for each replacement, gearboxes have been a focal point for improvement in reliability and availability. Condition monitoring (CM) is a technique that can help improve these factors, leading to reduced turbine operation and maintenance costs and, subsequently, lower cost of energy for wind power. Although technical benefits of CM for the wind industry are normally recognized, there is a lack of published information on the advantages and limitations of each CM technique confirmed by objective data from full-scale tests. This article presents first-hand oil and wear debris analysis results obtained through tests that were based on full-scale wind turbine gearboxes rated at 750 kW. The tests were conducted at the 2.5-MW dynamometer test facility at the National Wind Technology Center at the National Renewable Energy Laboratory. The gearboxes were tested in three conditions: run-in, healthy, and damaged. The investigated CM techniques include real-time oil condition and wear debris monitoring, both inline and online sensors, and offline oil sample and wear debris analysis, both onsite and offsite laboratories. The reported results and observations help increase wind industry awareness of the benefits and limitations of oil and debris analysis technologies and highlight the challenges in these technologies and other tribological fields for the Society of Tribologists and Lubrication Engineers and other organizations to help address, leading to extended gearbox service life.

17 WIND ENERGY↗
DOE OSTI2024

High Temperature Test Facility At Scale Testing, Validation, and Demonstration

Theses slides will be used to brief the Tribal DOE and Council Chairman for the project listed below. The High Temperature Test Facility (HTTF) is a demonstration-scale high temperature electrolysis (HTE) system that provides the ability to produce, process, store, and dispense electrolytically produced hydrogen. The system will be designed to accommodate electrolysis systems from various industry partners. The HTTF will be supplied up to 10 MW of power for electrolysis at 5 separate test article locations, each up to 2MW. The system will include post-processing and compression, storage, and capabilities to provide hydrogen for consumption by future end users. The HTTF will also provide the ability to test and demonstrate an HTE system in a configuration that would simulate the use of a nuclear generated steam supply for the high temperature heat source. The HTTF will be located at the Central Facilities Area (CFA) adjacent to CFA-686 on the INL site, 45 miles west of Idaho Falls.

08 HYDROGEN↗
DOE OSTI2017

1:52 Scale Testing of the First US Commercial Scale Floating Wind Turbine, VolturnUS: Testing Overview and the Evolution of Scale Model Testing Methods

Over the past 6 years, the University of Maine (UMaine) has been an active contributor in research and scale-model testing of floating offshore wind turbines (FOWTs). This paper serves to share the evolution of UMaine’s scale-model testing pedigree by exploring the various test campaigns at a high level, culminating with the design validation of the VolturnUS floating platform. These model test campaigns have each provided key insights into the behavior of FOWT platforms as well as improving the ability to perform model tests of FOWTs. In 2011, the UMaine-led DeepCwind Consortium carried out 1/50-scale model tests of a generic tension leg platform (TLP), a semi-submersible (semi), and a spar-buoy (spar) floating platform at the Maritime Research Institute Netherlands (MARIN) test facility. The designs were Froude-scaled and supported a scaled version of the 5-MW National Renewable Energy Laboratory (NREL) offshore research turbine. Data from these tests has been used extensively for numerical simulation validation efforts using NREL’s computer-aided engineering software FAST and laid the foundation for UMaine’s design efforts on VolturnUS. In 2013, UMaine conducted another test campaign at MARIN using the original semi-submersible from 2011 with an improved turbine as well as a 1:50-scale model of the VolturnUS concrete semi-submersible design. The improved DeepCwind semi-submersible data is currently being utilized in the validation of a large number of other analysis codes as part of the International Energy Agency’s OC5 project. In 2015, UMaine opened its own Wind/Wave test facility, the Alfond Wind/Wave Ocean Engineering Laboratory (W2). Utilizing this new facility, UMaine tested the 1:50-scale model DeepCwind semi-submersible, repeating the tests from MARIN, to validate the experimental equipment and procedures as well as demonstrate the capability of the W2. In 2016 UMaine carried out testing of a 1:52-scale model of the 100% design of the VolturnUS with a 6-MW topside as a final design validation to support the US Department of Energy-supported, full-scale Aqua Ventus demonstration project scheduled to be connected to the grid in 2019. A newly designed 6-MW scale model turbine was used in this test and the performance-matched turbine design methodology is described. Selected results from the test campaign and preliminary numerical comparisons are discussed as well as key lessons learned from the model test campaigns are presented.

17 WIND ENERGY↗
DOE OSTI2015

Methods for Quantifying the Uncertainties of LSIT Test Parameters, Test Results, and Full-Scale Mixing Performance Using Models Developed from Scaled Test Data

This report discusses the statistical methods for quantifying uncertainties in 1) test responses and other parameters in the Large Scale Integrated Testing (LSIT), and 2) estimates of coefficients and predictions of mixing performance from models that relate test responses to test parameters. Testing at a larger scale has been committed to by Bechtel National, Inc. and the U.S. Department of Energy (DOE) to “address uncertainties and increase confidence in the projected, full-scale mixing performance and operations” in the Waste Treatment and Immobilization Plant (WTP).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

Pilot Scale Testing of Lignite Adsorption Capability and the Benefits for the Recovery of Rare Earth Elements from Dilute Leach Solutions

Naturally occurring organic materials containing humic acids show a strong affinity towards rare earth elements (REE) and other critical elements. Leaching experiments on lignite coal waste produced from construction sand production revealed that the contained REEs were associated with the organic matter. Furthermore, adsorption studies revealed that the lignite waste was capable of extracting REEs from a model solution and increased the REE content of the lignite waste by more than 100%. As such, this study aimed to utilize the lignite waste to adsorb REEs from pregnant leach solutions and acid mine drainage sources having low REE concentrations and subsequently leach the lignite material to produce pregnant leach solutions containing relatively high amounts of REEs, which benefits the performance and economic viability of downstream separation and purification processes. An integrated flowsheet was developed based on this concept and tested at a pilot scale. The pregnant leachate solution (PLS) was generated from a heap leach pad containing 2000 tons of Baker seam coarse refuse. The pilot scale circuit was comprised of aluminum precipitation, adsorption using the waste lignite, and rare earth-critical metal (RE-CM) precipitation stages in succession. The results indicated that the aluminum precipitation stage removed over 88% and 99% of the Al and Fe, respectively. The adsorption stage increased the REE content associated with the waste lignite from 457 ppm to 1065 ppm on a whole mass basis. Furthermore, the heavy REE (HREE) content in the feedstock increased by approximately 250%, which raised the percentage of HREE in the REE distribution by 19 absolute percentage points. In addition to the REEs, concentrations of other critical elements such as Mn, Ni, and Zn also improved by 75%, 37%, and 250%, respectively. Bench-scale tests revealed that increasing the solids concentration in the waste lignite and PLS mix from 1% to 20% by weight enhanced the adsorption efficiency from 32.0% to 99.5%, respectively. As such, a new flowsheet was proposed which provides significantly higher REE concentrations in the PLS that can be fed directly to solvent extraction and/or oxalic acid precipitation and, thereby, enhancing process efficiency and economics.

58 GEOSCIENCES↗
DOE OSTI2016

FutureGen 2.0 Oxy-combustion Large Scale Test – Final Report

The primary objectives of the FutureGen 2.0 CO 2 Oxy-Combustion Large Scale Test Project were to site, permit, design, construct, and commission, an oxy-combustion boiler, gas quality control system, air separation unit, and CO 2 compression and purification unit, together with the necessary supporting and interconnection utilities. The project was to demonstrate at commercial scale (168MWe gross) the capability to cleanly produce electricity through coal combustion at a retrofitted, existing coal-fired power plant; thereby, resulting in near-zeroemissions of all commonly regulated air emissions, as well as 90% CO 2 capture in steady-state operations. The project was to be fully integrated in terms of project management, capacity, capabilities, technical scope, cost, and schedule with the companion FutureGen 2.0 CO 2 Pipeline and Storage Project, a separate but complementary project whose objective was to safely transport, permanently store and monitor the CO 2 captured by the Oxy-combustion Power Plant Project. The FutureGen 2.0 Oxy-Combustion Large Scale Test Project successfully achieved all technical objectives inclusive of front-end-engineering and design, and advanced design required to accurately estimate and contract for the construction, commissioning, and start-up of a commercial-scale "ready to build" power plant using oxy-combustion technology, including full integration with the companion CO 2 Pipeline and Storage project. Ultimately the project did not proceed to construction due to insufficient time to complete necessary EPC contract negotiations and commercial financing prior to expiration of federal co-funding, which triggered a DOE decision to closeout its participation in the project. Through the work that was completed, valuable technical, commercial, and programmatic lessons were learned. This project has significantly advanced the development of near-zero emission technology and will be helpful to plotting the course of, and successfully executing future large demonstration projects. This Final Scientific and Technical Report describes the technology and engineering basis of the project, inclusive of process systems, performance, effluents and emissions, and controls. Further, the project cost estimate, schedule, and permitting requirements are presented, along with a project risk and opportunity assessment. Lessons-learned related to these elements are summarized in this report. Companion reports Oxy-combustion further document the accomplishments and learnings of the project, including: A.01 Project Management Report which describes what was done to coordinate the various participants, and to track their performance with regard to schedule and budget B.02 Lessons Learned - Technology Integration, Value Improvements, and Program Management, which describes the innovations and conclusions that we arrived upon during the development of the project, and makes recommendations for improvement of future projects of a similar nature . B.03 Project Economics, which details the capital and operation costs and their basis, and also illustrates the cost of power produced by the plant with certain sensitivities. B.04 Power Plant, Pipeline, and Injection Site Interfaces, which details the interfaces between the two FutureGen projects B.05 Contractual Mechanisms for Design, Construction, and Operation, which describes the major EPC, and Operations Contracts required to execute the project.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2015

Concepts for Small-Scale Testing of Used Nuclear Fuel

This report documents a concept for a small-scale test involving between one and three Boiling Water Rector (BWR) high burnup (HBU) fuel assemblies. This test would be similar to the DOE funded High Burn-Up (HBU) Confirmatory Data Project to confirm the behavior of used high burn-up fuel under prototypic conditions, only on a smaller scale. The test concept proposed would collect data from fuel stored under prototypic dry storage conditions to mimic, as closely as possible, the conditions HBU UNF experiences during all stages of dry storage: loading, cask drying, inert gas backfilling, and transfer to an Independent Spent Fuel Storage Installation (ISFSI) for multi-year storage.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

SPE5 Sub-Scale Test Series Summary Report

A series of 2 SPE5 sub-scale tests were performed to experimentally confirm that a booster system designed and evaluated in prior tests would properly initiate the PBXN-110 case charge fill. To conduct the experiments, a canister was designed to contain the nominally 50 mm diameter booster tube with an outer fill of approximately 150 mm diameter by 150 mm in length. The canisters were filled with PBXN-110 at NAWS-China Lake and shipped back to LLNL for testing in the High Explosives Applications Facility (HEAF). Piezoelectric crystal pins were placed on the outside of the booster tube before filling, and a series of piezoelectric crystal pins along with Photonic Doppler Velocimetry (PDV) probes were placed on the outer surface of the canister to measure the relative timing and magnitude of the detonation. The 2 piezoelectric crystal pins integral to the booster design were also utilized along with a series of either piezoelectric crystal pins or piezoelectric polymer pads on the top of the canister or outside case that utilized direct contact, gaps, or different thicknesses of RTV cushions to obtain time of arrival data to evaluate the response in preparation for the large-scale SPE5 test. To further quantify the margin of the booster operation, the 1st test (SPE5SS1) was functioned with both detonators and the 2nd test (SPE5SS2) was functioned with only 1 detonator. A full detonation of the material was observed in both experiments as observed by the pin timing and PDV signals. The piezoelectric pads were found to provide a greater measured signal magnitude during the testing with an RTV layer present, and the improved response is due to the larger measurement surface area of the pad. This report will detail the experiment design, canister assembly for filling, final assembly, experiment firing, presentation of the diagnostic results, and a discussion of the results.

36 MATERIALS SCIENCE↗
DOE OSTI2017

LAWPS Technology Maturation Program and Scaled Testing - 17408

The Technology Maturation Program for the Low-Activity Waste Pre-Treatment System (LAWPS) had been developed utilizing the guidance of DOE-Order 413.3B 'Program and Project Management for the Acquisition of Capital Assets' for Technology Readiness and Technology Maturation. The technology maturation plan (TMP) for LAWPS established principal technology elements (TE) for the proposed process, designated critical technology elements (CTE), and identified the necessary activities to mature the technologies for successful deployment of the LAWPS. The testing progress for the integrated engineering scale testing and support activities are presented. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2018

LAWPS Technology Maturation Program and Scaled Testing - 18488

The Technology Maturation Program for the Low-Activity Waste Pre-Treatment System (LAWPS) had been developed utilizing the guidance of DOE-Order 413.3B 'Program and Project Management for the Acquisition of Capital Assets' for Technology Readiness and Technology Maturation. The technology maturation plan (TMP) for LAWPS established principal technology elements (TE) for the proposed process, designated critical technology elements (CTE), and identified the necessary activities to mature the technologies for successful deployment of the LAWPS. The testing progress for the integrated engineering scale testing and support activities are presented. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2016

LAWPS Technology Maturation Program and Scaled Testing - 16589

The Technology Maturation Program for the Low-Activity Waste Pre-Treatment System (LAWPS) had been developed utilizing the guidance of DOE-Order 413.3B for Technology Readiness and Technology Maturation. The technology maturation plan (TMP) for LAWPS established principal technology elements (TEs) for the proposed process, designated critical technology elements (CTEs), and identified the necessary activities to mature the technologies for successful deployment of the LAWPS System. The TMP is being utilized to guide the CTEs advancement to Technical Readiness Level (TRL) 6 for the combined Critical Decision 2 and 3 Milestones (CD-2/3) in the 413.3B process. The development of the TMP, the multi-scale testing program, culminating in the integrated scale testing as a predecessor to achieve TRL 6 are presented. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2016

Intermediate Scale Testing Recommendation Report

A summary of recommendations for near-term intermediate-scale testing pertaining to a salt repository is provided in this report. Each proposal was asked to implement a phased progression, initiating with test plan production in FY 2017 and early-stage testing, if possible. Beyond 2017, testing is anticipated to progress to an underground setting and involve intermediate-scale field activities. Each test concept was presented at the June 6th 2016 meeting in Las Vegas NV and a team of DOE-NE, DOE-EM, and National Laboratory staff discussed the rnerits of each proposal. Discussions among managers and researchers in the weeks following the meeting led to selection of a path forward for phased testing that includes a series of small diarneter borehole tests designed to illuminate thermomechanical processes and potential vapor and brine transport. These tests are intended to be implemented at the WIPP facility and involve collaboration between SNL, LANL, and LBL. This document summarizes the test concepts generated by the te s of researchers and decisions made subsequent to the June 6th meeting.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2019

Managing Risks via Small/Pilot Scale Testing for INL's Integrated Waste Treatment Unit (IWTU) - 19268

In 2005, the THOR steam reforming fluidized-bed reactor (FBR) technology was selected by the U.S. Department of Energy (DOE) as the technology of choice for treatment of sodium- bearing waste (SBW) at the INL. The basis of the process was to use fluidized bed technology to convert an acidic radioactive nitrate-rich liquid waste into a solid carbonate product suitable for long-term disposal and storage. During initial commissioning, as well as subsequent start-ups, the plant faced many operational challenges, such as stagnant/de-fluidized bed, and wall-scale formation. Such operational issues prompted the original contractor to seek expertise in pilot-scale testing, thereby reaching out to Hazen Research Inc. (HRI, Golden, Co). Several tests were conducted, but the results did not seem to address the underlying issues observed in the full-scale plant, as evidenced by continued operational issues. A systematic approach was then taken by the Fluor-Idaho team (new contractor as of June 2016) with respect to solving these technical issues. First, two different bench-scale, 2-inch fluidized bed reactors (stainless-steal and quartz), were utilized to test several theories to better understand the underlying chemical reactions that may be taking place under expected normal operating conditions. Then, the team designed and built an 18-inch FBR unit, mimicking the full-scale main vessel at IWTU - Denitration Mineralization Reformer (DMR). This was used to test various aspects of operational challenges observed at IWTU, namely particle size control, wall-scale growth-rate control, long-term operational stability, process optimization, and process off- gas filtration challenges. An example of information obtained from bench-scale testing, which was then tested during pilot-scale testing, was the phenomena that an addition of 5 vol % of CO{sub 2} gas into the fluidizing gas system nearly eliminated the formation of agglomerates that had typically led to bed de-fluidization. This change proved to be correct in both the pilot and full-scale testing and will be implemented as part of a long-term operational strategy of IWTU. Several other findings that have provided answers with respect to IWTU operational issues will be discussed in this report. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

Bench-Scale Testing of a High Efficiency, Ultra-Compact Process for Pre-Combustion CO 2 Capture (Final Report)

The overarching objective of this bench-scale study is to field-validate the technical feasibility of a membrane- and adsorption-enhanced water gas shift (WGS) reaction process that employs a carbon molecular sieve (CMS) membrane reactor (MR) followed by an adsorption reactor (AR) for pre-combustion CO 2 capture while demonstrating progress towards achievement of the overall performance goals of CO 2 capture with 95% CO 2 purity at a cost of electricity (COE) of 30% less than the baseline capture approaches. The main goal of this bench-scale project is to advance the proposed MR-AR transformative CO 2 capture technology to a sufficient maturity level so that our present industrial partners (M&PT and Worley) can potentially adapt the technology for further small pilot-scale testing. The project began at TRL 4, as the system prototype had already been validated in the laboratory on simulated syngas (as part of project DE-FE0026423). The project ended at TRL 5, via scaling-up of the prototype system and testing it on actual syngas at a host site (CAER at the University of Kentucky (UKy)). The project was carried-out in two different phases: In Phase I (during BP1 of the project), the team designed, constructed, and assembled the bench-scale experimental MR-AR system, prepared the membranes, adsorbents, and catalysts, tested the bench-scale unit with simulated syngas to validate functionality, and prepared a preliminary TEA of the technology. In Phase II (during BP2 of the project), the team installed the unit at the test site at the UKy site and completed all utility connections and hookups, field-tested the novel MR-AR process in the bench-scale system using real syngas, collected and analyzed experimental data, and completed a detailed TEA of the technology. A key aim of the project was to identify and address the technical and process risks and to generate information to advance the technology to the next stage of development. All project milestones and success criteria were met. Specifically, the team: (i) designed, constructed and assembled a bench scale system that handled 1 – 5 scfm syngas and tested its functionality with simulated syngas; (ii) prepared high performance CMS membrane tubes (ID: 3.5 mm, OD: 5.7 mm, 30” long) that meet the target H 2 permeance ( > 1 m 3 /(m 2 .hr.bar) or (> 370.3 GPU)) and a target H 2 /CO selectivity >80 at the relevant temperature (up to 300oC) and pressure conditions (up to 25 bar) with a <10% decline in performance over each 250 hr. testing period (iii) procured commercial sour-shift catalyst in sufficient quantity and prepared up to 10 kg of pelletized adsorbent for use at relevant conditions (250oC 2.5wt.% and target sorbent attrition rate < 0.2; (iv) installed the bench-scale unit at the test site (UKy) and tested the MR-AR technology using real syngas for over 250 hr. for both static and flow experiments; (v) updated the TEA analysis based on bench-scale data and met CO 2 capture goals of 95% CO 2 purity at a cost of electricity 30% less than baseline capture approaches. The CMS membranes, HTC adsorbents and catalysts employed all exhibited very robust and stable performance during the long-term run (over a >250 hr live syngas run). Furthermore, the proposed MR-AR IGCC system achieved a LCOE with a N 2 sale price of $\$$ 30/ton, with N 2 compression (no N 2 compression) of 101.2 $\$$/MWh (95.3 $\$$/MWh), which represents a 29.8% (33.9%) LCOE reduction in the baseline IGCC with carbon capture of 144.2 $\$$/MWh. The proposed MR-AR IGCC delivers a CO 2 capture cost of 44.8 $\$$/tonne (39.9 $\$$/tonne) vs 98.1 $\$$/tonne of the baseline capture case and a net power production of 586 MWe (623 MWe) vs 556 MWe of the baseline capture case.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2017

Low Activity Waste Pretreatment System Bench-Scale Testing: Supporting Integrated Testing and Facility Safety Analyses - 17171

The Low Activity Waste Pretreatment System (LAWPS) is being designed to enable the direct feed of waste to the Hanford Tank Waste Treatment and Immobilization Plant (WTP) Low Activity Waste (LAW) facility to be immobilized. Prior to construction of the LAWPS, pilot-scale integrated testing of the key unit operations (crossflow filtration, ion exchange using spherical resorcinol-formaldehyde (sRF) resin) will be conducted by a team led by Washington River Protection Solutions (WRPS) to increase the technology maturation level of the facility’s critical technology elements. As a part of this effort, Pacific Northwest National Laboratory (PNNL) has conducted a series of bench-scale (or engineering-scale) tests to perform two major objectives: (1) support pilot-scale integrated testing of the LAWPS by supplying information or performance data in advance of operating the pilot-scale facility; and (2) collect data needed to establish or confirm assumptions/approaches planned for implementation in the LAWPS safety basis. The first objective was focused in two technical areas: developing simulants that are representative of expected waste feed and can be produced at larger scales, and using these simulants in a bench-scale crossflow filter to establish expected solid-liquid separation performance. The crossflow filter was also used to observe the efficacy (with respect to filter production rate) of selected operational strategies. The second objective also included two technical areas: measuring the effect of sRF resin on hydrogen generation rate under irradiation, and demonstrating that the planned hydrogen management approach is effective and robust. The hydrogen management strategy involves fluidization of the sRF resin bed in the ion exchange columns and recirculating the liquid, a scenario that is planned for testing at full column height. The full height tests at PNNL also supported full-scale IX column testing conducted as part of the technology maturation plan. The experimental approaches used at PNNL in these four technical areas are summarized and selected key preliminary results are provided.

cross flow filtration↗