Engineering topics
Hendricks, Terry J.
Publications and source records attributed to Hendricks, Terry J..
Temperature-Staged Thermal Energy Storage Enabling Low Thermal Exergy Loss Reflux Boiling in Full Spectrum Solar Systems
Hybrid full spectrum solar systems (FSSS) designed to capture and convert the full solar wavelength spectrum use hybrid solar photovoltaic/thermodynamic cycles that require low thermal exergy loss systems capable of transferring high thermal energy rates and fluxes with very low temperature differentials and losses. One approach to achieving this capability are high-heat-flux reflux boiling systems that take advantage of high heat transfer boiling and condensation mechanisms. Advanced solar systems are also intermittent by their nature and their electrical generation is often out-of-phase with electric utility power demand, and their required power system cycling reduces efficiency, performance (dispatch ability), lifetime, and reliability. High temperature thermal energy storage (TES) at 300-600°C enables these reflux boiling systems to simultaneously store thermal energy internally to increase the energy dispatch ability of the associated solar system, as this can increase the power generation profile by several hours (up to 6-10 hours) per day. Many TES phase change materials (PCM’s) exist including KNO3, NaNO3, LiBr/KBr, MgCl2/NaCl/KCl, Zn/Mg, and CuCl/NaCl, which have various operating melting points and different latent heats of fusion. Common, cost effective TES PCM's are FeCl2/NaCl/KCl mixtures, whose phase change temperature can be varied and controlled by simple composition adjustments. This paper presents and discusses unique "temperature-staged" thermal energy storage configurations using these TES materials and analysis of such systems integrated into high-heat-flux reflux boiling systems. In this specific application, the TES materials are designed to operate at staged temperatures surrounding an operating design point near 350°C, while providing 18 kW of source heat transfer to operate a thermoacoustic power system during off-sun conditions (e.g., temporary cloud conditions, after sun-down). This work discusses relevant configurations, and critical thermal and entropy models of the TES configurations, which show the inherent minimization of thermal exergy during critical heat transfers within the configurations and systems envisioned.
Heat Exchanger Performance Impacts on Optimum Cost Conditions in Thermoelectric Energy Recovery Designs
Cost is just as important as power density or efficiency for the adoption of waste heat recovery thermoelectric generators (TEG). Prior work [1] has shown that the system design that minimizes cost (e.g., the $/W value) can be close to the designs that maximize the system’s efficiency or power density, however, it is important to understand the relationship between those designs to optimize TEG performance-cost compromises. Expanding on recent work [1, 2, 3] the impact of heat exchanger conditions on the optimum TEG fill factors and cost scaling of a waste heat recovery thermoelectric generator with a detailed treatment of the hot side exhaust heat exchanger has been investigated further. The effect of the heat lost to the environment and updated relationships between the hot-side and cold-side conductances [4] that maximize power output are considered. The optimum fill factor to minimize TEG energy recovery system costs is strongly dependent on the heat leakage fraction, σ, the mass flow rate of the exhaust, the hot-side heat exchanger effectiveness, heat exchanger UAh, and heat flux. These relationships are explored and characterized for typical exhaust gas-flow conditions to show the inherent design complexities. The heat exchanger costs often dominate the TEG cost equation and it is critical to fully understand the tradeoff between heat exchanger performance, optimum TEG fill factors, and cost to establish potentially optimum design points within the cost-performance design space. This work will explore the design tradeoffs and relationships within the cost-efficiency-power density design space for a typical thermoelectric energy recovery system application. The interplay between optimum TEG fill factors and heat exchanger design can impact system footprint, volume, and mass in weight-sensitive applications. Less-effective, low-cost heat exchangers may outperform higher cost alternatives from a market adoption perspective. This shift of emphasis acknowledging the interdependence of optimum TEG fill factors and heat exchanger performance has significant implications on thermoelectric waste heat recovery systems designs and their operation. In addition, preferred TEG design regimes exist that accommodate reasonable compromises in TE performance and cost. This effort highlights how the optimum fill factor–heat exchanger performance relations couple to these optimum TEG performance-cost domains based on TEG-system-level analyses and provides a focus for future system research and development efforts.
Heat Exchanger Performance Impacts on Optimum Cost Conditions in Thermoelectric Energy Recovery Designs
No abstract available
Energy Harvesting: Unique Systems from Earth to Planets to Deep Space and Beyond - Building and Expanding Our Energy Toolbox
No abstract available
A Universe of Energy – Systems to Capture It All for Planet Earth, Our Solar System, and Beyond – Building & Expanding Our Energy “Toolbox”
No abstract available
Energy Harvesting: Unique Systems from Earth to Planets to Deep Space and Beyond - Building and Expanding Our Energy Toolbox
No abstract available
Temperature-Staged Thermal Energy Storage Enabling Low Thermal Exergy Loss Reflux Boiling in Full Spectrum Solar Systems
No abstract available
Development of Multi-Physics Dynamics Models for High-Frequency Large-Amplitude Structural Response Simulation
An analytic approach is demonstrated to reveal potential pyroshock-driven dynamic effects causing power losses in the Thermo-Electric (TE) module bars of the Mars Science Laboratory (MSL) Multi-Mission Radioisotope Thermoelectric Generator (MMRTG). This study utilizes high-fidelity finite element analysis with SIERRA/PRESTO codes to estimate wave propagation effects due to large-amplitude suddenly-applied pyro shock loads in the MMRTG. A high fidelity model of the TE module bar was created with approximately 30 million degrees-of-freedom (DOF). First, a quasi-static preload was applied on top of the TE module bar, then transient tri-axial acceleration inputs were simultaneously applied on the preloaded module. The applied input acceleration signals were measured during MMRTG shock qualification tests performed at the Jet Propulsion Laboratory. An explicit finite element solver in the SIERRA/PRESTO computational environment, along with a 3000 processor parallel super -computing framework at NASA AMES, was used for the simulation. The simulation results were investigated both qualitatively and quantitatively. The predicted shock wave propagation results provide detailed structural responses throughout the TE module bar, and key insights into the dynamic response (i.e., loads, displacements, accelerations) of critical internal spring/piston compression systems, TE materials, and internal component interfaces in the MMRTG TE module bar. They also provide confidence on the viability of this high-fidelity modeling scheme to accurately predict shock wave propagation patterns within complex structures. This analytic approach is envisioned for modeling shock sensitive hardware susceptible to intense shock environments positioned near shock separation devices in modern space vehicles and systems.
Development of Multi-Physics Dynamics Models for High-Frequency Large-Amplitude Structural Response Simulation
No abstract available
Cost Scaling of a Real-World Exhaust Waste Heat Recovery Thermoelectric Generator: A Deeper Dive
Cost is equally important to power density or efficiency for the adoption of waste heat recovery thermoelectric generators (TEG) in many transportation and industrial energy recovery applications. In many cases the system design that minimizes cost (e.g., the $/W value) can be very different than the design that maximizes the system's efficiency or power density, and it is important to understand the relationship between those designs to optimize TEG performance-cost compromises. Expanding on recent cost analysis work and using more detailed system modeling, an enhanced cost scaling analysis of a waste heat recovery thermoelectric generator with more detailed, coupled treatment of the heat exchangers has been performed. In this analysis, the effect of the heat lost to the environment and updated relationships between the hot-side and cold-side conductances that maximize power output are considered. This coupled thermal and thermoelectric treatment of the exhaust waste heat recovery thermoelectric generator yields modified cost scaling and design optimization equations, which are now strongly dependent on the heat leakage fraction, exhaust mass flow rate, and heat exchanger effectiveness. This work shows that heat exchanger costs most often dominate the overall TE system costs, that it is extremely difficult to escape this regime, and in order to achieve TE system costs of $1/W it is necessary to achieve heat exchanger costs of $1/(W/K). Minimum TE system costs per watt generally coincide with maximum power points, but Preferred TE Design Regimes are identified where there is little cost penalty for moving into regions of higher efficiency and slightly lower power outputs. These regimes are closely tied to previously-identified low cost design regimes. This work shows that the optimum fill factor Fopt minimizing system costs decreases as heat losses increase, and increases as exhaust mass flow rate and heat exchanger effectiveness increase. These findings have profound implications on the design and operation of various thermoelectric (TE) waste heat 3 recovery systems. This work highlights the importance of heat exchanger costs on the overall TEG system costs, quantifies the possible TEG performance-cost domain space based on heat exchanger effects, and provides a focus for future system research and development efforts.