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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 271 records · Page 15

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NASA NTRS1979

Some flow characteristics of conventional and tapered high pressure drop simulated seals

The leak rates through shaft seals with large pressure drops were simulated using gaseous hydrogen, or nitrogen flowing through an annulus with a nonrotating centerbody. The flows were choked. For concentric or eccentric position of the rotor and parallel or convergent tapered flow passages, data and analysis revealed that mass flux or leak rate can be determined from a relation whose normalizing parameters depend on the thermodynamic critical constants of the working fluid and an average flow area expressed in terms of the inlet and exit cross-sectional areas. Using these normalized relations, the flow data for parallel and three convergent tapered shaft seal configurations are in good agreement. Generalization to any simple gas or gas mixture is implied and demonstrated.

Hendricks, R. C.↗

NASA NTRS1987

Design of an ammonia two-phase Prototype Thermal Bus for Space Station

The feasibility of two-phase heat transport systems for use on Space Station was demonstrated by testing the Thermal Bus Technology Demonstrator (TBTD) as part of the Integrated Two-Phase System Test in NASA-JSC's Thermal Test Bed. Under contract to NASA-JSC, Grumman is currently developing the successor to the TBTD, the Prototype Thermal Bus System (TBS). The TBS design, which uses ammonia as the working fluid, is intended to achieve a higher fidelity level than the TBTD by incorporating both improvements based on TBTD testing and realistic design margins, and by addressing Space Station issues such as redundancy and maintenance. The TBS is currently being fabricated, with testing scheduled for late 1987/early 1988. This paper describes the TBS design which features fully redundant plumbing loops, five evaporators designed to represent different heat acquisition interfaces, 14 condensers which mate with either space radiators or facility heat exchangers, and several modular components.

Brown, Richard F.↗

DOE OSTI2022

Preliminary Primary System Thermal Fluids Analysis of a Horizontal Compact HTGR

The Horizontal Compact High Temperature Gas Reactor (HC-HTGR) is being designed by a multi-disciplinary team of nuclear, mechanical, and structural engineers, under the support of a DOE-NE Advanced Reactor Demonstration Program’s Advanced Reactor Concepts-20 (ARC-20) award. The objective of this ARC-20 project is to deliver a conceptual design for the proposed HC-HTGR in 3 years and support its commercialization as a safe, low-cost HTGR. Argonne National Laboratory (Argonne) is collaborating on the thermal hydraulic design and analysis of the HC-HTGR reactor pressure vessel internals. The scope of this work includes ensuring the reactor is able to maintain maximum core temperatures below designated safety thresholds during normal operation, shutdown, and accident conditions. This report documents the preliminary thermal hydraulic analysis of the HC-HTGR core design performed with a 1D fluid-3D solid coupled model built using the System Analysis Module (SAM). This assembly level model was utilized to inform the core assembly design, predict the temperature distribution in the peak power assembly including the peak fuel temperature, coolant channel outlet temperatures, and graphite temperature gradients. A key result of this analysis was the determination that the peak fuel temperature remains below the safety threshold of 1250°C. Additionally, this model was used to assess the assembly coolant channel and bypass flow mass flow rate distribution. Following the assembly level analysis, attention turned to the development of a full core reduced order model to be used to predict the core wide coolant flow distribution and to model certain operational and accidental transients.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

NASA NTRS1979

Some flow characteristics of conventional and tapered high-pressure-drop simulated seals

The leak rates through shaft seals with large pressure drops were simulated using gaseous hydrogen, or nitrogen flowing through an annulus with a nonrotating centerbody. The flows were choked. For concentric or eccentric position of the rotor and parallel or convergent tapered flow passages, data and analysis revealed that mass flux or leak rate can be determined from a relation whose normalizing parameters depend on the thermodynamic critical constants of the working fluid and an average flow area expressed in terms of the inlet and exit cross-sectional areas. Using these normalized relations, the flow data for parallel and three convergent, tapered, shaft-seal configurations are in good agreement. Generalization to any simple gas or gas mixtures is implied and demonstrated in part.

Hendricks, R. C.↗

NASA NTRS2010

Air Data Boom System Development for the Max Launch Abort System (MLAS) Flight Experiment

In 2007, the NASA Exploration Systems Mission Directorate (ESMD) chartered the NASA Engineering Safety Center (NESC) to demonstrate an alternate launch abort concept as risk mitigation for the Orion project's baseline "tower" design. On July 8, 2009, a full scale and passively, aerodynamically stabilized MLAS launch abort demonstrator was successfully launched from Wallops Flight Facility following nearly two years of development work on the launch abort concept: from a napkin sketch to a flight demonstration of the full-scale flight test vehicle. The MLAS flight test vehicle was instrumented with a suite of aerodynamic sensors. The purpose was to obtain sufficient data to demonstrate that the vehicle demonstrated the behavior predicted by Computational Fluid Dynamics (CFD) analysis and wind tunnel testing. This paper describes development of the Air Data Boom (ADB) component of the aerodynamic sensor suite.

Woods-Vedeler, Jessica A.↗

DOE OSTI2024

Thermodynamic Analysis of Nano-Electrospray Induced Gas Jets

Nano-electrospray (nES) produces a plume of charged liquid droplets which have drag interactions with the surrounding gas after they are emitted from a source capillary. The resulting induced gas flow has often been considered unimportant, but we have demonstrated that a gas microjet of significant velocity up to 10s of m/s can be produced. In this work we present a thermodynamic framework that enables analysis of gas jet generation from electrosprays and introduce the important metrics for such analysis, effectiveness (a measure of momentum transfer from the electrosprayed aerosol to gas) and efficiency (a measure of energy conversion from electrical energy generating the electrospray to gas kinetic energy). This analytical framework is applicable to any two-phase flows consisting of discrete conservative-force-driven particles which exchange momentum with an inert, otherwise quiescent fluid medium to yield a co-flowing two-phase jet. Here, we apply this framework to sprays of water from nano-electrospray emitters to demonstrate that increasing the applied electrical potential difference, increasing liquid mass flowrate, and decreasing droplet size all can increase electrospray induced gas jet strength, but only the latter two do so while also increasing the momentum transfer effectiveness and energy conversion efficiency.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

NASA NTRSDate not supplied

Autonomous Measurement of Electrochemical Redox Couples for In-Situ Characterization of Enceladus Plume Samples

A 3D-printed microfluidic electrochemical cell with integrated electrodes was developed to demonstrate autonomous in-situ electrochemical characterization of terrestrial seawater samples. The system is designed to extend the capabilities of the 2008 Phoenix Lander’s Wet Chemistry Laboratory (WCL) that analyzed the soluble chemistry of the Martian soil, by miniaturizing its fluidic architecture for analysis of µL-volume samples as expected from an Enceladus fly-by mission. The microfluidic device has a total fluid volume of 48 µL and includes dual channels each populated with 7 electrodes. Measurement of pH was measured using an iridium oxide electrode. Cyclic voltammetry with Au, Pt, and glassy carbon working electrodes was used to measure redox couples in synthetic seawater that contained inorganic and bio-organic molecules. Glassy carbon was found to have minimal risk of interference from constituents of synthetic seawater when measuring molecular organic redox species; however, care must be used to prevent interference due to potential oxidation or dissolution in the case of Au working electrodes. A completely autonomous end-to-end run including sample delivery was performed, to demonstrate the feasibility of microfluidic-based cyclic voltammetry measurements for in-situ characterization of redox couples in Ocean World samples.

Planetary Instruments↗

DOE OSTI2022

Mechanically-, Thermally, and Chemically-Robust High-Temperature Ceramic Composites

In an effort to lower the levelized cost of electricity generated by Concentrated Solar Power (CSP) plants, the heat-to-electricity conversion efficiency may be increased by operating such plants with higher turbine inlet temperatures using closed Brayton cycles with high-pressure, supercritical carbon dioxide (sCO 2 ) as the working fluid. For example, if the turbine inlet temperature is raised to ≥750°C, in combination with sCO2 closed Brayton cycles, the relative heat-to-electricity efficiency may be raised by more than 20% (compared to subcritical steam Rankine cycles operating with turbine inlet temperatures ≤550°C). The associated reduction in the cost of dispatchable electricity from such CSP plants (utilizing high-temperature thermal energy storage) would be an important breakthrough on the path towards direct competition with fossil-fuel-based plants. A key barrier to achieve such high-temperature efficient operation has been the limited thermomechanical performance of metal alloys used in compact, primary printed circuit- type heat exchangers (PCHEXs) for heat transfer to high-pressure sCO 2 . The maximum allowed stresses for the use of conventional stainless steels and nickel-based superalloys at high sCO 2 pressures (≥20 MPa) decline rapidly at temperatures ≥550°C. This project has been focused on demonstrating the desired high-temperature properties and attractive manufacturing characteristics of mechanically-, thermally-, and chemically-robust ceramic/metal composites (cermets), in order to allow for the use of such composites in primary PCHEXs for heat transfer to sCO 2 at ≥750°C and ≥20 MPa in CSP plants. Prior work with high-temperature, co-continuous carbide/refractory metal cermets, such as ZrC/W composites, has already demonstrated: i) the attractive combination of high-temperature properties exhibited by such materials (e.g., high values of stiffness, failure strength, and thermal conductivity at 800°C), and ii) cost-effective processes for manufacturing PCHEX plates comprised of such cermets with tailorable channel patterns. However, ZrC/W cermets were not found to be inherently corrosion resistant in sCO 2 at 750°C and 20 MPa. While the application of a Cu coating to ZrC/W surfaces, along with a modest addition (50 ppm) of CO to CO 2 , rendered such composites resistant to corrosion for 1000 h in such sCO 2 -based fluids at 750°C, such additional steps would increase the design complexity of such cermet-based components. An alternative approach (the focus of this project) is to develop mechanically-robust, cost- effective cermets that are inherently resistant to high-temperature oxidation in air and CO 2 . The overall goals of this project have been to demonstrate: i) the oxidation resistance of at least one cermet at 750°C in air and in CO 2 (i.e., with a projected annual corrosion ≤30 μm), ii) the mechanically robust nature of at least one cermet at 750°C (i.e., with an average failure strength ≥200 MPa), and iii) that the selected cermet can be manufactured via low-cost forming techniques.

14 SOLAR ENERGY↗

NASA NTRS1993

Flow and Heat Transfer in 180-Degree Turn Square Ducts: Effects of Turning Configuration and System Rotation

Forced flow through channels connected by sharp bends is frequently encountered in various rocket and gas turbine engines. For example, the transfer ducts, the coolant channels surround the combustion chamber, the internal cooling passage in a blade or vane, the flow path in the fuel element of a nuclear rocket engine, the flow around a pressure relieve valve piston, and the recirculated base flow of multiple engine clustered nozzles. Transport phenomena involved in such a flow passage are complex and considered to be very different from those of conventional turning flow with relatively mild radii of curvature. While previous research pertaining to this subject has been focused primarily on the experimental heat transfer, very little analytical work is directed to understanding the flowfield and energy transport in the passage. Therefore, the primary goal of this paper is to benchmark the predicted wall heat fluxes using a state-of-the-art computational fluid dynamics (CFD) formulation against those of measurement for a rectangular turn duct. Other secondary goals include studying the effects of turning configurations, e.g., the semi-circular turn, and the rounded-corner turn, and the effect of system rotation. The computed heat fluxes for the rectangular turn duct compared favorably with those of the experimental data. The results show that the flow pattern, pressure drop, and heat transfer characteristics are different among the three turning configurations, and are substantially different with system rotation. Also demonstrated in this work is that the present computational approach is quite effective and efficient and will be suitable for flow and thermal modeling in rocket and turbine engine applications.

Wang, Ten-See↗

DOE OSTI2023

Investigation of methane and ethane pyrolysis with highly active and durable iron-alumina catalyst to produce hydrogen and valuable nano carbons: Continuous fluidized bed tests and reaction rate analysis

The goal of this research work was to evaluate a novel iron-alumina catalyst for methane and ethane pyrolysis with high conversion rates to H 2 with a long life time to address two major issues reported with previous catalysts. Fluidized bed tests demonstrated continuous hydrogen production while collecting carbon containing fines. During the 230 h fluid bed test the methane conversion rate to hydrogen at 700 °C remained above 80% for 160 h while creating valuable nano carbons. Similarly high catalyst lifetimes with high methane conversions have not been reported before. Ethane was more active than methane for pyrolysis with 100% conversion to H 2 . Transmission electron microscopy and Raman analysis of the carbon showed single and multiwall nanotubes and conglomerate nano-fibers. Ethane did not impact the allotrope of carbon formed. TGA was used to create a data array that was used for kinetic analysis and reaction model parametric regressions. Ethane had a higher rate of pyrolysis that was 2.3–2.8 times that of methane. Ethane pyrolysis was found to be more sensitive to temperature with a higher activation energy of 62 kJ/mol as compared to methane at 43 kJ/mol. The frequency factor, A i , was significantly higher for ethane at 0.73 [[kmol/m 3 -sec]/[N/m2] n ] compared to 0.03 for methane on the same basis. Both gases had a functional partial pressure order dependence of ~0.6 based on the regression analysis.

08 HYDROGEN↗

NASA NTRS1991

Results from the cascaded variable conductance heatpipe experiment on LDEF

A Variable Conductance Heat Pipe Experiment (CVCHPE) was successfully flown onboard the LDEF and demonstrated temperature control better than +/- 0.3 C during 50 days of on-orbit data collection in a widely varying external environment. The experiment used two series connected, dry reservoir variable conductance heat pipes which require no electrical power for operation. The heat pipes used a central artery design with ammonia working fluid and nitrogen control gas.

Grote, Michael G.↗

NASA NTRS1992

Results from the LDEF/A0076 cascaded variable conductance heatpipe experiment

The A0076 Variable Conductance Heat Pipe Experiment (CVCHPE) on the Long Duration Exposure Facility (LDEF) demonstrated temperature control better than +/- 0.3 C during fifty days on on-orbit data collection in a widely varying external environment. The experiment used two series connected, dry reservoir variable conductance heat pipes which require no electrical power for operation. The heat pipes used a central artery design with ammonia working fluid and nitrogen control gas. The LDEF was in orbit for almost six years rather than the planned one year mission. Although no additional data were taken during this extended period, post-test data indicated that the set point drifted upward less than 1 C per year. There were significant changes to the appearance of all external thermal control surfaces primarily due to atomic oxygen degradation, and one small anomaly in the electronics. These changes, though, had little effect on the CVCHPE performance.

Grote, Michael G.↗

NASA NTRS1993

Foil bearing performance in liquid nitrogen and liquid oxygen

Space transfer vehicles and other power and propulsion systems require long-life turbopumps. Rolling-element bearings used in current turbopumps do not have sufficient life for these applications. Process fluid foil bearings have established long life, with exceptional reliability, over a wide range of temperatures and fluids in many high-speed turbomachinery applications. However, actual data on bearing performance in cryogenic fluids has been minimal. The National Aeronautics and Space Administration (NASA) and AlliedSignal Aerospace Systems and Equipment (ASE) have attempted to characterize the leaf-type compliant foil bearing in oxygen and nitrogen. The work performed under a joint internal research and development program between Marshall Space Flight Center (MSFC) and ASE demonstrated that the foil bearing has load capacities of at least 266 psi in liquid oxygen and 352 psi in liquid nitrogen. In addition, the bearing demonstrated a direct damping coefficient of 40 to 50 lb-sec/in. with a damping ratio of .7 to 1.4 in. liquid nitrogen using a bearing sized for upper-stage turbopumps. With the results from this testing and the years of successful use in air cycle machines and other applications, leaf-type compliant foil bearings are ready for testing in liquid oxygen turbopumps.

Genge, Gary G.↗

DOE OSTI2026

The future of subsurface monitoring: AEC’s breakthroughs in CCS technology

Carbon capture and storage (CCS) has emerged as a key solution in the fight against climate change. However, for CCS to succeed, it is crucial to ensure that the sequestered CO2 stays safely trapped underground. The U.S. Department of Energy (DOE) has emphasized the need for advancements in subsurface monitoring, measurement, reporting, and verification. Aside from caprock integrity failure, the other primary failure points usually involve defective cement in the casing annulus of wellbores or plugged and abandoned wells. In addition, many energy producers (e.g., oil and gas, geothermal) and storage and disposal operators (e.g., H2 and water) must deal with the same issue. Poorly placed or degraded cement can create pathways for gas or fluid to escape from casing annuli and in plugged and abandoned or orphan wells, posing environmental risks. Yet, a reliable and cost-effective way to monitor cement and well integrity over multiple decades is still unavailable. Traditional geophysical methods like 4D seismic imaging and surface-based electromagnetic monitoring lack the resolution and accuracy for detecting these types of failures (Vasco et al., 2022; Fawad and Mondol, 2021). Wireline logging is expensive to run continuously and is obtrusive to the operation. While fiber optics can potentially be a solution, its bulkiness can significantly compromise the cement's integrity. To address these challenges, the Advanced Energy Consortium (AEC) at The University of Texas at Austin’s Bureau of Economic Geology (the Bureau) has been pioneering research in subsurface monitoring using its portfolio of distributed autonomous microfabricated sensors for harsh subsurface environments since 2008. A class of these microsensors [System on a Chip (SoC)] can be mixed in cement and permanently placed without compromising the cement column; the sensors would then communicate with each other or a data acquisition (DAQ) master node. Another class of the AEC microsensors can be fully autonomous, with rechargeable micro-batteries capable of exceeding 100°C, flash memory, and, currently, a pressure and temperature sensor. They are designed to circulate in mud, geothermal fluids, U-loops, or pipelines. They can log data into memory and are unobtrusive to operations. Our team has been working on a multi-year DOE-funded project (DE-FE0031856)—supported by $2.95M in federal funding and $0.75M in cost-matching from the AEC—to demonstrate SoC sensor utility for CO2 leakage monitoring in CCS applications. This multi-institutional collaboration developed a novel sensing architecture utilizing radiofrequency (RF) microsensors embedded within the cement sheath. These sensors detect CO2 migration and are interrogated via a Smart Casing Collar (SCC).

58 GEOSCIENCES↗

DOE OSTI2023

One System, Many Models: Designing a Surrogate Model for Sulfur Thermal Energy Storage: Preprint

Industrial process heating (IPH) relies primarily on thermal energy generated by fossil fuel combustion to produce, treat, and alter manufactured goods. Thermal energy storage (TES) helps reduce the carbon footprint of IPH systems by facilitating the utilization of renewable and waste heat sources. A promising new TES technology uses elemental sulfur as the heat-storage medium. The design of sulfur TES systems can be evaluated with the aid of computational fluid dynamics (CFD). However, the computational cost of such CFD efforts is prohibitive to comprehensive optimizations over design parameters. To reduce this computational cost, machine learning (ML) models can be developed to act as surrogates for CFD. In this paper, we describe the process of building and evaluating surrogate ML models for facilitating optimization of sulfur TES systems for IPH. To enforce the thermodynamic relationship between the two modeled quantities, we develop a hybrid model for sulfur temperature using both direct predictions of temperature and calculations of temperature from predictions of the heat transfer coefficient. The hybrid model enforces this constraint at the expense of the slightly reduced accuracy compared to two disjoint models. The overall high accuracy observed in our model evaluation demonstrates the usefulness of such surrogate modeling for studying TES systems. This work contributes to the field of TES surrogate modeling by offering a novel accurate hybrid approach to predicting simultaneously the heat transfer coefficient and temperature of the heat storage medium.

computational fluid dynamics↗

NASA NTRS1982

Flows through sequential orifices with heated spacer reservoirs

Flow rates and pressure thermal profiles for two phase choked flows of fluid nitrogen were studied theoretically and experimentally in a four sequential orifice configuration. Both theory and experimental evidence demonstrate that heat addition in the first spacer-reservoir adjacent to the inlet orifice is most effective in reducing the flow rate and that heat addition in the last spacer-reservoir is least effective. The flows are choked at the exit orifice for large spacings and at the inlet orifice for small spacings. The moderate addition of heat available for this experiment did not materially alter this result for large spacings; however, significant heat addition for the small spacings tended to shift the choke point to the exit orifice. Nitrogen is used as the working fluid over a range of states from liquid to gas with a reduced inlet stagnation pressure range to P sub r, o = 2.

Hendricks, R. C.↗

DOE OSTI2023

Density variance dynamics in disparate shock tubes

This report discusses two experiments which investigate thin layer, heavy curtain fragmentation from the perspective of a Reynolds-Averaged mix model, in drastically disparate experimental regimes. The first, the centimeter/millisecond-scale “Horizontal Shock Tube” (HST) is a compressed-gas piston-driven shock tube experiment. The second, the “Multishock thin layer” (Mshock) experiment performed at the National Ignition Facility, is a micrometer/nanosecond-scale laser-driven shock tube experiment. Both are situations in which a heavy plane layer (a ‘curtain’) is initially suspended in a lighter medium. After being shocked from at least one side, the layer translates while its interfaces evolve due to the excitation of the Richtmyer-Meshkov instability at its surfaces. The evolution of density variance, which initially exists only on the surface of the layer, as it comes to encompass the whole layer interior is used as a description of layer fragmentation and dissolution. These experiments have each been simulated in the Los Alamos National Laboratory multi-physics code xRAGE, which includes fundamental hydrodynamics, extended plasma physics and radiation effects which are important to drive the high-energy density experiment, and the Besnard-Harlow-Rauenzahn (BHR) turbulence model. In each, the principal diagnostic for comparison is an experimental metric for the density (co)variance, b, which tracks the moments of the density field at the curtain interfaces and body. Due to experimental constraints in different regimes (i.e. optical diagnostics can be deployed on conventional shock tubes, while the plasma shock tubes must be imaged by x-rays; interfaces can be imposed to specification on laser-driven experiments, which are stored in the solid phase, while conventional experiments have imperfect control of the flow fields which separate the layer, etc.) the experiments are not designed to be perfect scaled cognates of one another. However, despite the separation of six orders of magnitude of scaling in time, and four in space, we are able to demonstrate that the same turbulence model, operating in the same fashion in the same computer code, is able to reproduce results in each experiment, by tracking evolution due to common relevant physics. Additionally, we will present preliminary work toward density variance comparisons in a single-interface Richtmyer-Meshkov configuration, the conventional fluid “Vertical Shock Tube” (VST) experiment, and the Modal Initial Conditions (ModCons) campaign fielded at the OMEGA-EP laser facility.

42 ENGINEERING↗

DOE OSTI2023

Turbulence Modeling with Nek5000/RS, SOD2D and Alya

We present Validation and Verification (V & V) study of two high-order spectral element method (SEM) based Computational Fluid Dyanimcs (CFD) codes that we will utilize for work on turbulence modeling: Nek5000 and SOD2D. While the former solves the incompressible form of Navier-Stokes equation, the latter works with compressible set of equations and uses an entropy-viscosity formulation to account for the discontinuities for high Mach number flows. We demonstrate the accuracy of these codes for two benchmark sub-sonic turbulent flows: periodic channel and pipe flow, by carrying out first and second order statistical analysis, grid convergence and turbulent structure analysis using wall-resolved large eddy simulations (WRLES). Later, we report on the implementation and testing of various wall-modeling strategies for large eddy simulation of turbulent flows in Nek5000. These include both classical log-law based and decision-tree based machine-learning models. Accuracy of these closure strategies are analyzed and necessary future work is outlined.

97 MATHEMATICS AND COMPUTING↗