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VCU Engineering researchers are working to make clean energy easier and cheaper

Sep 4, 2020

3 min

Lane Carasik, Ph.D.

Lane Carasik, Ph.D., assistant professor in VCU’s Department of Mechanical and Nuclear Engineering, is developing methods to make clean energy more cost-effective. He’s motivated by a simple principle.


“The cheaper we make renewable and clean energy, the easier it is to implement it,” he said.


With $100,000 in seed funding from the Jeffress Trust Awards Program, Carasik and his Fluids in Advanced Systems and Technology (FAST) research group are designing efficient, low-cost enhancements to equipment used in solar, nuclear and geothermal energy systems. Jeffress Trust awards support high-impact, one-year projects that integrate computational and quantitative scientific methodologies across a broad range of scientific disciplines.


These energy systems use heat exchangers, which take energy from heat generation components and convert it to electricity. Heat exchangers usually comprise two working substances such as water, steam or air separated by tubes or plates.


The FAST research group is optimizing a specialty insert that can be placed inside a heat exchanger’s tubes to improve performance. To visualize the insert’s form, imagine holding a piece of metal tape in both hands and gently twisting it.


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See the FAST Lab and examples of the heat transfer enhancements being designed there.


“A liquid running through a tube is relatively undisrupted by the geometry of the tube or the shape of the fluid,” Carasik said. “But this twisted tape component spins the fluid. This increases turbulence, which increases heat transfer.”


While “twisted tape” inserts are already in use in some advanced energy systems, the process of fabricating them has been limited by mechanical constraints. Typically, the inserts are placed inside a tube and tack welded at either end. But because of the metal’s limited tensile strength, these inserts can only be twisted a little before they break down and cause manufacturing defects.


3D printing, on the other hand, allows for a more complex — and effective — insert that can be used to characterize heat transfer performance.


“With additive manufacturing, you can actually print tighter, ‘twistier’ versions of them,” Carasik said. “You can also add your own intentional defects to find out how to make the heat transfer better and improve the performance of the whole system.”


Each geometric form the research group prints and tests starts with a world of calculations: thermal-hydraulics design calculations, solid geometry, material properties and more. From there, components are computer-designed, then printed in the Mechanical and Nuclear Engineering Innovation Lab. Finally, they are tested in the FAST research group’s Modular Separation Effects Testing Facility (MSEFT), a scaled testing loop that emulates the operating conditions experienced by these components.


Undergraduates — even first-year students — participate in each step of the process, alongside Carasik, postdoctoral research associate Cody Wiggins, Ph.D., and doctoral student Arturo Cabral.


“I really like getting students into research early on, Carasik said. “By the time they’re three years in, they’re working at a level I would expect from bachelor’s level engineers in industry.”


Senior Meryem Murphy was curious about undergraduate research but had never really participated. “One day, I was arguing with Arturo about something and Dr. Carasik said, ‘If you’re like this all the time, you should work for the lab.’” She took him up on it and spent her junior year working on an MSEFT redesign and running an experiment to see if 3D-prototyped concepts can be replicated with test metals.


Over the summer, Murphy interned with Atomic Alchemy, a medical radioisotope startup in Boise, Idaho. She said the position built on the hard, and soft, skills she gained in the lab.


“Sometimes in class, you’re required to collaborate,” she said. “But in research, it’s just ‘what you do’ to get it done.”


Rising sophomore Ryan McGuire is also looking forward to starting his second year in the lab. During his freshman year, McGuire helped develop a 3D printing technology to duplicate sequences of 3D-printed parts for the FAST research group. It’s called Retrospective Additive Manufacturing Sequencing — RAMS for short.


McGuire said the thrill of solving problems in the lab has made him reassess his own goals.


“When I was younger, I wanted to be [famous],” he said. “But now I no longer want to be famous. Research seems like more fun.”


Upon hearing about McGuire’s change in priorities, Carasik said, “Researchers can be famous too, and for good reason.”

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Lane Carasik, Ph.D.

Lane Carasik, Ph.D.

Assistant Professor, Department of Mechanical and Nuclear Engineering

Dr. Carasik researches computational and experimental thermal hydraulics for fusion & nuclear energy and medical isotope production.

Nuclear EngineeringExperimental Thermal-FluidsThermal-Fluids DesignVerification and ValidationComputational Fluid Dynamics
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Nuclear subject matter is complex, so higher education is very important for workforce development. We want to build partnerships, like the one we have with Dominion Energy, that support this goal. A priority for me is continuing to establish relationships with Commonwealth Fusion Systems, which seeks to build and operate the first commercial grid-scale fusion plant in Chesterfield County, Virginia. Our workforce partners will benefit from VCU’s well-trained nuclear engineering graduates joining the workforce. So, aligning our strategy with national energy needs, hiring the right faculty to support our programs and building industry partnerships that benefit our student’s education and career opportunities are important things for VCU Engineering’s nuclear program. Where would you like to see the College of Engineering’s nuclear program 10 years from now? I would like to see growth in the nuclear program. For example, some new graduate courses on topics like nuclear materials or fusion energy. In 2024, I developed a general course for fusion energy, so building out a curriculum that goes more in-depth would be good. When you look at small modular reactors and micro reactors, current energy policy does not allow private companies to build their own. However, as energy demands increase, policy could change to where you see these compact devices installed in places like data centers, for example. A more in-depth curriculum allows VCU Engineering students to step into industry roles that lead growth of the energy industry while also ensuring students are capable of adapting to the changing field and taking advantage of new developments. What sort of cross-disciplinary opportunities are there for the College of Engineering’s nuclear program? Nuclear engineering and nuclear science are very interdisciplinary fields. You have physics that covers the nuclear reaction and the radiation it generates, for example, then chemistry is needed when talking about nuclear fuel cycles and nuclear waste. You also need materials science because good materials capable of withstanding radiation and high temperatures are needed in nuclear fission and fusion energy systems. This science then connects to engineering, building the reactors, the energy distribution systems like a power grid. It is a small sample of the overall work, but you see how mechanical and electrical engineering are key to this part. All these disciplines come together to solve the same problem. One researcher might be figuring out how to confine plasma and make it stable, then another researcher is looking at how plasma can disrupt the containment wall and how to make materials to protect the wall. Within our department, we are making connections between mechanical-focused faculty working on high-temperature ceramics or additive manufacturing techniques and those of us researching nuclear energy systems in order to make joint proposals. We are also collaborating outside VCU. As an example, I am involved with an alliance founded by the Defense Threat Reduction Agency (DTRA) comprised of 17 universities, research labs and military centers. Coordinated through DTRA, we work together on many of the same problems.Through this partnership, my Ph.D. students do summer research rotations with national labs like Lawrence Livermore National Laboratory in California and The Pacific Northwest National Laboratory. We also bring cadets and midshipman into VCU from other institutions, like the DTRA Nuclear Science and Engineering Research Center, United States Military Academy West Point and the Virginia Military Institute, whose students have been part of research experience for undergraduates programs in the summer. How is artificial intelligence impacting the field of nuclear engineering? So, the United States is sponsoring the Genesis Mission, which seeks to transform science innovation through the power of AI. One area of the Genesis Mission is nuclear fission and fusion energy. I see this playing out with the Department of Energy encouraging national labs, universities and industry to work together on applying these AI advancements to solve the research problems of nuclear energy. It is a great opportunity for students, who we can involve in this work to give them real-world experience with topics they will see after graduation. Last semester I taught a course at VCU on the practical applications of AI on nuclear engineering problems. It is not something like ChatGPT or anything like that. What we did is take Google’s TensorFlow platform that is a library of AI models and machine neural networks. Using Python scripting students learn how to apply these AI resources to about 30 problems in mechanical and nuclear engineering. They create scripts, use data sets and run analytics. We have a nuclear reactor simulator and I have some ideas to create AI-based software we can pair with the simulator, then give the software a data set and let it control the operation of the simulator in a safe way. Tell us about your background. What brought you VCU and the Department of Mechanical and Nuclear Engineering? Actually, I am not a mechanical or a nuclear engineer. My background is in physics. 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