Search NASA⌕ Search

Engineering topics

Bayham, Samuel

Publications and source records attributed to Bayham, Samuel.

At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Cyber-Physical Simulation of an Innovative Solid Oxide Electrolysis Cell - Gas Turbine (SOEC-GT) Hybrid Energy System

To produce green hydrogen at scale and at low cost, the solid oxide electrolysis cell (SOEC) systems would be tied to renewable power sources (mainly solar and wind), leveraging zero-carbon electricity at low prices and even nearly free during overgeneration scenarios. However, due to the intermittency of renewable power generation, the SOEC system is subjected to rapid load transitions that occur not only in diurnal cycles but also in short timeframes (e.g., sub-minute). This can result in fast degradation and thus greatly reduce the SOEC’s lifetime. Our team at the National Energy Technology Laboratory has demonstrated that the anode air flow can have a crucial role in SOEC thermal management. Typically, a higher air flow rate can help to mitigate the local temperature gradient distortion during rapid load transitions. To move a large amount of air, the gas turbine (GT; i.e., compressor-turbine-generator set) has been regarded as the most mature and efficient technology. In this presentation, we show the configuration and preliminary results of an innovative SOEC-GT hybrid energy system in a cyber-physical simulation (CPS) approach.

Zhang, Biao↗
DOE OSTI2024

Advanced Reaction Systems

An overview of NETL's Gasification Systems R&D was provided at DOE's Hydrogen and Fuel Cells Technology Office (HFTO) Annual Merit Review (AMR) on May 7, 2024, in Arlington, VA. The objective of the Advanced Reaction Systems Portfolio is to design, develop, and analyze technologies to support the mission of the Gasification Program to enable the use of diverse feedstocks to produce hydrogen and other value-added products with net-zero greenhouse gas emissions.

Lewis, Eric↗
DOE OSTI2024

Advanced Reaction Systems

An overview of NETL's Gasification Systems R&D was provided at the 2024 FECM/NETL Spring R&D Project Review Meeting on April 24, 2024, in Pittsburgh, PA. The objective of the Advanced Reaction Systems Portfolio is to design, develop, and analyze technologies to support the mission of the Gasification Program to enable the use of diverse feedstocks to produce hydrogen and other value-added products with net-zero greenhouse gas emissions.

Lewis, Eric↗
DOE OSTI2024

A machine learning approach for determining temperature-dependent bandgap of metal oxides utilizing Allen–Heine–Cardona theory and O’Donnell model parameterization

To evaluate the high temperature sensing properties of metal oxide and perovskite materials suitable for use in combustion environments, it is necessary to understand the temperature dependence of their bandgaps. Although such temperature-driven changes can be calculated via the Allen–Heine–Cardona (AHC) theory, which assesses electron–phonon coupling for the bandgap correction at given temperatures, this approach is computationally demanding. Another approach to predict bandgap temperature-dependence is the O’Donnell model, which uses analytical expressions with multiple fitting parameters that require bandgap information at 0 K. This work employs data-driven Gaussian process regression (GPR) to predict the parameters employed in the O’Donnell model from a set of physical features. We use a sample of 54 metal oxides for which density functional theory has been performed to calculate the bandgap at 0 K, and the AHC calculations have been carried out to determine the shift in the bandgap at non-zero temperatures. As the AHC calculations are impractical for high-throughput screening of materials, the developed GPR model attempts to alleviate this issue by predicting the O'Donnell parameters purely from physical features. To mitigate the reliability issues arising from the very small size of the dataset, we apply a Bayesian technique to improve the generalizability of the data-driven models as well as quantify the uncertainty associated with the predictions. The method captures well the overall trend of the O’Donnell parameters with respect to a reduced feature set obtained by transforming the available physical features. Quantifying the associated uncertainty helps us understand the reliability of the predictions of the O’Donnell parameters and, therefore, the bandgap as a function of temperature for any novel material.

36 MATERIALS SCIENCE↗
DOE OSTI2023

A real-time multiphysics model of a pressurized solid oxide electrolysis cell (SOEC) for cyber-physical simulation

Solid oxide electrolysis cells (SOEC) can play important roles in integrated energy systems (IES) as the hydrogen production hub and the resilience energy hub. When tied to a microgrid with high renewable penetration, the SOEC is subjected to rapid load transitions in response to the intermittent renewable generations that occur not only in diurnal cycles but also in short timeframes (e.g., sub-minute). The cyber-physical simulation approach can derisk operability research but requires a real-time dynamic SOEC model. In the present work, a real-time multiphysics model for pressurized SOEC is developed and validated in the pressure range from 1.4 to 8bar. Further, the accuracy of the single repeating unit (SRU) assumption in SOEC stack simulation is quantified. A guidance of more than 45 cells in one SOEC stack is recommended to safely apply the SRU assumption. Modeling results suggest that at a given current density, more power is consumed by SOEC at elevated operating pressures. The anode air and cathode stream have major impacts on thermal management, highlighting the potential benefit of integrating SOEC with other thermal processes in IES. To achieve high hydrogen production efficiency, the SOEC could operate at the maximum endothermic point to maximize the use of thermal energy. The real-time execution of the developed SOEC model is also demonstrated, which only takes 0.1% of the fixed time step of 5ms. The developed model establishes the basis for cyber-physical simulation of SOEC hybrid systems.

25 ENERGY STORAGE↗
DOE OSTI2023

Hydrogen Safety Review for Gas Turbines, SOFC, and High Temperature Hydrogen Production

This report presents an introduction and summary on hydrogen safety issues, as they relate to hydrogen production, storage, and use in the energy sector, primarily as related to electricity generation by gas turbines, and solid oxide fuel cells (SOFC), and hydrogen production from gasification and steam methane reforming processes. The impetus behind this effort is the U.S. DOE goal for decarbonization of the power generation sector by the year 2035. In many cases, hydrogen is expected to replace natural gas as the primary fuel source (or form of energy storage) to achieve this goal. Advanced technologies for large-scale energy production using hydrogen as a fuel source which can be deployed over the next 5–10 years will be required. However, to develop and mature these hydrogen-based technologies, it will be critical to identify the safety issues related to widespread use of hydrogen as a fuel source, so that they may be addressed prior to widespread deployment.

08 HYDROGEN↗
DOE OSTI2022

Rapid Load Transition for Integrated Solid Oxide Fuel Cell - Gas Turbine (SOFC-GT) Energy Systems: A Demonstration of the Potential for Grid Response

Rapid load transition is an essential requirement for integrated energy systems to maintain grid resilience as more renewable resources are added to the grid. Integrated solid oxide fuel cell - gas turbine (SOFC-GT) systems can provide high efficiency and low carbon emissions over a broad range of turndown. These hybrids also have the potential to enable rapid grid response. The challenge has been to demonstrate effective control strategies to manage load transitions. In the present study, a load transition of ~50% was achieved in 10 s using a novel but simple strategy. Power demand on the SOFC and the GT were ramped down concurrently. During this transition, the SOFC anode fuel was manipulated to maintain SOFC fuel utilization while the cathode inlet air flow and temperature were also manipulated to thermally protect the SOFC. This study was conducted using the Hybrid Performance (Hyper) facility at the National Energy Technology Laboratory (NETL) in a co-simulation environment with the Idaho National Laboratory (INL)'s grid-simulation. The load ramping strategy was tested using a hardware-based cyber-physical simulation methodology. The results demonstrate a high-fidelity representation of SOFC-GT hybrid dynamics and validation of the control strategy. Thermal and electrochemical transients indicated that the SOFC was well protected during rapid load turndown without violating operability constraints. This demonstration revealed the non-linear nature of tightly coupled SOFC-GT system components, especially the non-linear response of SOFC cathode air flow and inlet temperature controls. These results highlight the needs and challenges in developing adaptive automatic controls for autonomous rapid load transitions. This work demonstrates that SOFC-GT hybrids are a viable option to provide the fast-ramping characteristics essential to accommodate high levels of variable renewable power while maintaining grid resilience, reliability, and environmental performance. The results also demonstrate the utility of co-simulation in advancing the tightly-coupled integrated energy systems needed to meet goals for zero-carbon power generation.

DIRECT ENERGY CONVERSION,POWER TRANSMISSION AND DI↗
DOE OSTI2021

Analyzing Gas Turbine-Generator Performance of the Hybrid Power System

We report kinetic energy available from the turbomachinery may boost short-term ramp rates during load shifting between generator and fuel cell that may be exploited to optimize the performance of turbine-fuel cell hybrid systems during load following. The paper starts with modeling a gas turbine, gearbox, and generator sitting on the rigid shafts as a two-mass model primarily for estimating the rotational inertia available from the turbogenerator. The gas turbine and its environment impose constraints of available space allowances, measurements from high-speed rotating parts, lack of accessibility to the shaft of measure, making replacements and/or required installation adjustments of the torque transducer difficult. It is demonstrated that in the absence of torque measurement, the data containing only a slow excursion of the rotor motion in response to a slight load change is sufficient to determine inertia and damping coefficients from the model. Furthermore, the generator’s reactive power capability was investigated because it serves as an asset in integrated hybrid systems to meet dynamic reactive power demands, reducing the burden on the fuel cell’s power electronics control in generating reactive power.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Reduction of Ultrafine Hematite for a Spouting Bed Chemical Looping Process - Presentation

Chemical looping combustion research has been a topic of great interest since the mid-1990s, although the concept can be traced much further back. It is a combustion technology for fuel utilization that uses a two-reactor system to produce a carbon free effluent stream from the air reactor and a carbon dioxide rich stream from the fuel reactor with oxygen shuttled between the reactors with an oxygen carrier. Chemical looping combustion has been studied extensively because of this inherent separation of the carbon dioxide combustion product from the atmospheric nitrogen over that past 25 years with hundreds of research papers and tens of books. The oxygen carrier is, in general, a solid such as naturally occurring hematite or an engineered carrier like a copper and iron oxide supported on alumina. System technical and economic research activities conducted at the National Energy Technology Laboratory have shown that the costs associated with the carrier, initial and replacement, are a significant factor in the economic viability of the technology. To overcome this economic challenge, the work reported on in this paper investigates the use of a waste iron oxide as the chemical looping oxygen carrier. This waste material is quite unique as it has a particle size of 0.7 um. Given the particle size, the reactions are quite fast. However, the development of a contactor reactor to mix the fuel with the carrier is a fluidization challenge as the material is a Geldart group C material and highly cohesive. Normally, Geldart group C materials are fluidized with either a vibrating bed. This technique is acceptable for low temperature pharmaceuticals production but does not lend itself to much larger reactors used for power production or operation at temperatures in the order of 1100 to 1200 C. Therefore, a hydrodynamic solution was needed to break up the cohesive structures to replace the vibration. In this instance, it was hypothesized that a spouting bed of large Geldart group B or Geldart group D particles could provide the necessary energy to break up the cohesive structures of the Geldart group C material. This paper presents the reduction performance for this novel carrier material in a laboratory spouting bed reactor.

Breault, Ronald↗
DOE OSTI2021

Development of CuFeMnAlO 4+δ oxygen carrier with high attrition resistance and 50-kWth methane/air chemical looping combustion tests

A Copper-Ferri-Manganese-Aluminate spinel (CuFeMnAlO 4+δ ) oxygen carrier, developed at the US Department of Energy’s (DOE) National Energy Technology Laboratory (NETL), shows promising results for chemical looping combustion with methane. Attrition resistance of the spinel oxygen carrier (160–600 µm) produced by a wet agglomeration method was significantly higher than that observed previously with a Copper-Ferri-Aluminate (CuFeAlO 4 ) oxygen carrier. Improved attrition resistance of the novel carrier can be attributed to minimal alumina phase segregation and minimal carbon formation. Heats of reaction measured by differential scanning calorimetry indicated exothermicity during reduction with methane. The total oxygen transfer capacity of the material was about 10.5 wt% at 850 °C. The attrition resistance and the oxygen transfer capacity of the carrier prepared at a commercial manufacturing facility (180 kg) were very similar to observed values during the development phase with the lab scale preparations. The material displays satisfactory methane conversion and significantly high particle durability during a 54 h test campaign conducted in NETL’s 50-kWth chemical looping dual fluid bed reactor unit at temperatures ranging from 700 to 900 °C. Low oxygen carrier make-up cost, due to the use of natural ore and pigment grade raw materials during synthesis and very low attrition rates, exceeded the performance goals determined by systems studies.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Final Report – Cooperative Research and Development Agreement between National Energy Technology Laboratory and Praxair, Inc.

Praxair and DOE-NETL entered into a collaborative research and development agreement (CRADA) in March 2019 to evaluate economic viability of chemical looping processes for hydrogen, CO, and syngas production in comparison to state-of-the-art conventional processes. Praxair had developed process configurations for producing hydrogen and CO using chemical looping processes. NETL had modeling and system design experience for the chemical looping reactor system. The goal for NETL is to provide performance and design information regarding the chemical looping portion of a potential commercial plant. Praxair’s goal is to evaluate chemical looping processes and try to identify a process that can be commercially relevant within a few years. A key to success for the program will be to develop a chemical looping reactor system that enables significant capital cost reduction and performance improvement for the overall process. This report describes chemical looping-based CO production process, chemical looping reactor system and oxygen carrier material as well as summary of technoeconomic analysis results. Also included in the report are a list of assumptions that were used for designing the chemical looping plant and a list of areas for further study required to validate some of these assumptions in future efforts. The initial goal was to design two chemical looping plants. Case 1 would produce 1 MM scfd Hydrogen from NG, and Case 2 would co-produce hydrogen and 5 MM scfd CO from NG. However, later in the collaboration, it was decided to drop Case 1 as Case 2 process already included hydrogen production.

Bayham, Samuel↗