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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
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Novel Membrane-Based Corrosion Sensors For Operating In Natural Gas Pipelines

Membrane-based electrochemical sensors (MBES) provide an attractive option for real-time continuous humidity and corrosion rate measurements inside of natural gas pipelines. The MBES, can use electrochemical techniques such as linear polarization resistance and electrochemical impedance spectroscopy even when a conductive aqueous phase is intermittent or unavailable. We now present field-test performance data of our MBES operated inside a multiphase water and natural gas flow facility. The MBES measured internal corrosion and conductivity at the top, bottom, and side of the pipe spool. Tests were carried out with flow rates of 4.6, 9.1, and 18.3 m/s, temperatures of 21, 29, and 35 °C, and a pressure of 1000 psia. All sensors followed similar trends in open circuit potential, corrosion rate, and conductivity over time. Neither flow rate, temperature, nor build-up of metal-based solids on the sensor surfaces impacted the quality of the electrochemical measurements. The field-test results confirm that the membrane-based electrochemical sensors are suitable for monitoring internal corrosion of operational natural-gas pipelines.

Duffy, Timothy↗
DOE OSTI2023

Electrochemical Characterization of Molten Salt Chemistry During Atmospheric Ingressions

This report describes the salt chemistry and sedimentation studies that were completed in FY23 as part of the Pyrochemical Fuel Cycles – ANL project. The primary objective of these activities was to employ electrochemical methods in order to quantify and gain insights into the reaction mechanisms associated with the interaction of O2 and moisture impurities with the molten chloride salts used for the pyrochemical processing of nuclear materials. If not monitored and controlled, the ingression of these atmospheric impurities can lead to changes in the salt redox conditions and initiate the formation of oxide particles, potentially resulting in operational and safeguards challenges. By elucidating the mechanisms underlying the formation of oxide particles, we can effectively monitor the conditions of the salt and design systems to mitigate the influence of atmospheric O2 and H2O. To achieve these goals, we designed a test system that allowed for precisely controlled gas ingressions into the molten salt vessel. This system included on-line monitoring provided by electrochemical probes that enable near real-time measurements of the salt conditions throughout the course of the experiment. Using this system, we systematically varied experimental conditions, including O2/Ar flow rates and O2 concentrations, to comprehensively understand their impact on solid particle formation. We also used a particle size and shape analyzer to characterize the particles that were generated. Tests in FY23 concentrated on the formation of CeO2 particles, but we also prepared a separate apparatus targeting UO2 particles for use in FY24. We additionally conducted extensive modeling activities in support of this work. This included multiphysics simulations of the gas ingressions along with the development of a machine learning workflow to enable accelerated molecular dynamics modeling of the molten salt chemistry of LiCl-KCl-UCl3. The combination of experimental and modeling tools has allowed us to begin to get a more complete understanding of the reactions that occur when atmospheric ingressions occur in pyroprocessing systems.

Guo, Jicheng↗
DOE OSTI2025

A real-time distributed solid oxide electrolysis cell (SOEC) model for cyber-physical simulation

System integration and dynamic operability between SOEC and balance-of-plant (BoP) components are major technical challenges before realizing rapid load following of SOEC systems. Cyber-physical simulation (CPS) is a leading-edge digital engineering approach and is regarded as the next step beyond Digital Twins. CPS approach can be used to research SOEC system integration and develop dynamic controls prior to actual pilot testing without using a real SOEC. To seamlessly couple with BoP hardware and access non-observable operational parameters (e.g., local temperature gradient) during transients, a distributed one-dimensional (1D) real-time SOEC model was developed. Its real-time execution was demonstrated for 20 to 640 nodes at the fixed time step of 5 ms. A higher excess air ratio enabled smaller local temperature gradients on SOEC solid materials and faster transients upon current density step change from 0.15 to 0.55 A cm -2 . During the transients, the magnitude of the peak temperature gradient nearly doubled in 10 s from -3.5 to -5.9 °C cm -1 . This represents a significant operating risk that can impact the dynamic operability of SOEC systems. In addition, the local temperature gradient was found to change directions on all nodes in SOEC solid materials, with the greatest impact on the upstream nodes. The SOEC model was also tested at the thermal neutral voltage using actual process air flow parameters as variable model inputs. Variable process air temperatures were found to induce alternating local temperature gradients on SOEC solid materials. These are new operational mechanisms for SOEC degradation relevant for load following operational modes yet distinct from previous reports. To mitigate these unfavorable features, the SOEC can be operated at voltages that are slightly (±20 mV) deviated from the thermal neutral voltage. Here, the corresponding net thermal energy change was less than 1.6% of the electric power consumption. This 1D real-time SOEC model established the basis of cyber-physical simulation of SOEC hybrid systems.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

Operando Neutron Imaging of Reaction Extent and Particle Swelling Informs Limiting Factors for Salt Hydrate Thermochemical Energy Storage

Salt hydrates are a promising thermochemical energy storage medium that stores heat through the reversible uptake (hydration) and release (dehydration) of water vapor. Our study deploys operando neutron imaging to investigate salt hydrate performance with high spatial resolution (42 μm pixels). For flow over a packed bed with diffusion-driven transport, measurements reveal the formation of a solid diffusion layer due to particle swelling for the pure SrBr2 salt. In contrast, the SrBr2–vermiculite composite exhibits significantly less swelling and more than a 2-fold increase in the apparent water vapor diffusivity. For axial flow through a packed bed, neutron imaging confirms theoretically predicted transitions from a moving reaction front to a homogeneous profile with an increase in humid air flow rate. Our study establishes neutron imaging as a powerful technique to advance fundamental understanding of thermochemical systems and help guide composite material design.

Kinzer, Bryan [ORNL] (ORCID:0000000337804910)↗
DOE OSTI2022

Hydrogenolysis of n -eicosane over Ru-based catalysts in a continuous flow reactor

The hydrogenolysis of n-eicosane (C 20 H 42 ) was studied under differential conditions over Ru-based catalysts including Ru/SiO 2 , Ru/TiO 2 , and Ru/SBA-15, using a continuous flow reactor that was specially designed for large hydrocarbon reactants that are solids at room temperature. Similar rates and product distributions were obtained for Ru/SiO 2 and Ru/SBA-15 at 433 K, with the most abundant products being C 1 and C 19 hydrocarbons and smaller amounts of C 8 to C 18 also being produced. The higher yield of C 1 and C 19 indicates that cleavage of the terminal C-C bond is somewhat more facile than an internal C-C bond. At 473 K the product distribution shifted to mostly C 1 suggesting that, at this temperature, the adsorbed alkyl fragments undergo complete C-C bond scission prior to desorbing. Here, the conversion was also found to be inversely proportional to the H 2 pressure. Similar results were obtained for Ru/TiO 2 except this catalyst was found to be less active than both Ru/SiO 2 and Ru/SBA-15.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Preconditioners for multiphase poromechanics with strong capillarity

This paper aims to enhance the performance of Newton–Krylov solvers for coupled poromechanical problems with two-phase flow. In particular, we investigate the impact of capillary pressure on preconditioning strategies. Capillarity complicates the coupling between the solid deformation and fluid pressure degrees of freedom, as well as increases the nonlinearity of the system. Depending on the capillary pressure relation used in the constitutive formulation, the flow equations may exhibit a spectrum of advection-dominated to diffusion-dominated behavior. We propose preconditioning approaches that account for this behavior and lead to robust numerical performance within a broad range of regimes.

42 ENGINEERING↗
DOE OSTI2023

Operational and scaling-up barriers of SOEC and mitigation strategies to boost H 2 production- a comprehensive review

Solid oxide electrolysis cells (SOECs) proffer a flexible and environmentally friendly solution to reduce CO 2 emissions and/or produce H 2 fuel for various applications. Here, the integration of this technology with renewable energy systems makes them even more promising in realizing a near-perpetual green energy infrastructure in the near future. SOEC technology has achieved stupendous improvement in recent years, and some of the limiting factors to the commercialization of this technology have been explored. It is, therefore, necessary to have a succinct outlook of the different factors that contribute to the recent developments in SOEC technology. The current work presents a comprehensive review of the state-of-the-art SOEC component materials and their degradation mechanisms, SOEC modeling essentials and efficiencies, and the scalability of SOECs. Although SOEC is considered a highly promising technology and sufficient multifaceted research has been done, yet not been widely commercialized. Despite the improvement to mitigate degradation of the SOEC materials, a large share of the degradation concerns sprang from charge transfer reaction at the triple-phase boundaries of the H 2 -electrode. Part of which can be improved by microkinetic modeling of these materials supported by their characterization to give insight into their development. Some other directions for the future in advancing this technology toward the commercialization stage are thoroughly addressed.

08 HYDROGEN↗
DOE OSTI2023

Material flow behavior and microstructural refinement of AA6061 alloy during friction extrusion

In this work we used friction extrusion (FE), a solid phase processing technique, to produce dense, fully consolidated 5?mm rods of aluminum alloy 6061 (AA6061). The combination of large shear stresses and high temperatures at the tool-billet interface during extrusion produced equiaxed, dynamically recrystallized grains and finely distributed precipitates. Texture and microstructure evolution during extrusion was investigated in detail using scanning electron microscopy, electron backscatter diffraction, and transmission electron microscopy. Smoothed particle hydrodynamics simulation was performed to study complex material flow during extrusion. Simulation results suggest spiral material flow during extrusion which corroborated experimental results. Advantages of friction extruded microstructure over conventionally extruded counterparts are also explored using flash annealing for solution treatment followed by artificial aging. Mechanical properties of the as-friction extruded, and the artificially aged specimens were evaluated using tensile testing and compared with conventional extruded material properties.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Alkaline cation enrichment and water electrolysis to provide CO 2 mineralization and global-scale carbon management

Provided herein are methods of removing carbon dioxide from an aqueous stream or gaseous stream by: contacting the gaseous stream comprising carbon dioxide, when present, with an aqueous solution comprising ions capable of forming an insoluble carbonate salt; contacting the aqueous solution comprising carbon dioxide with an electroactive mesh that induces its alkalinization thereby forcing the precipitation of a carbonate solid from the solution and thereby the removal of dissolved inorganic carbon by electrolysis; and removing the precipitated carbonate solids from the solution, or the surface of the mesh where they may deposit. Also provided herein are flow-through electrolytic reactors comprising an intake device in fluid connection with a rotating cylinder comprising an electroactive mesh, and a scraping device and/or liquid-spray based device for separating a solid from the mesh surface.

Sant, Gaurav↗
DOE OSTI2021

Effects of detailed geometry and real fluid thermodynamics on Spray G atomization

We present recent results toward the quantification of spray characteristics at engine conditions for an eight-hole counter-bored (stepped) GDI injector-Spray G in the ECN denomination. This computational study is characterized by two novel features: the detailed description of a real injector's internal surfaces via tomographic reconstruction; and a general equation of state that represents the thermodynamic properties of homogeneous liquid-vapor mixtures. The combined level-set moment-of-fluid approach, coupled to an embedded boundary formulation for moving solid walls, makes it possible to seamlessly connect the injector's internal flow to the spray. The Large Eddy Simulation (LES) discussed here presents evidence of partial hydraulic flipping and, during the closing transient, string cavitation. Results are validated by measurements of spray density profiles and droplet size distribution.

42 ENGINEERING↗
DOE OSTI2023

Microextraction–TQ–ICP–MS for the Direct Analysis of U and Pu from Cotton Swipes

Here, the microextraction sampling technique was integrated with triple quadrupole–inductively coupled plasma–mass spectrometry (TQ–ICP–MS) to directly sample and measure the isotopic compositions of uranium (U) and plutonium (Pu) from cotton swipes. Once extracted, the U/Pu were directed into the TQ–ICP–MS instrument for isotopic determination. Carbon dioxide (CO 2 ) and helium (He) gases were delivered to a collision reaction cell within the ICP–MS system for ion separation. The CO 2 reacts with the U + forming UO + which is ultimately separated from the Pu + ions of interest in the third quadrupole. This study demonstrates direct liquid extraction of U/Pu from a solid surface and subsequent measurement by TQ–ICP–MS in <60 s. Flow rates were optimized (0.3 mL min –1 CO 2 and 5 mL min –1 He) in the reaction cell of the ICP–MS system to maximize the Pu signal while minimizing U interferences (i.e., 238 U + tail and 238 UH + ) at m/z 239. Low levels of Pu (~2 pg) were deposited on a cotton swipe along with U at concentrations ranging from 20 to 200 ng. The 240 Pu/ 239 Pu ratio was measured with <7% relative difference from the certified value at all U concentrations. Major and minor U isotope ratios were also measured with <4% relative difference. This highlights that the microextraction–TQ–ICP–MS method can extract a mixed U/Pu sample directly from a cotton swipe and measure both isotopic systems without chemical separation.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Redox-Based Chemical Looping Large-Scale Air Separation Unit Designs Using Perovskite Material

Oxygen production by means of air separation through redox cycle reactions of Sr 1–x Ca x FeO 3-δ perovskite particles is examined numerically in the context of modular large-scale units. Fixed-bed, multicomponent reactor designs allowing for the recovery of the energy released by the exothermic oxidation (or adsorption) to enhance the endothermic reduction (or desorption) of the perovskite material are considered and compared against a baseline cylindrical packed bed. Numerically, the gas–solid reacting system is approximated as a single-phase reacting gas flow through a porous medium of constant porosity. The redox kinetics account for the oxygen nonstoichiometry of the perovskite, which exhibits a dependence on the temperature and the oxygen partial pressure, in order to describe some mechanisms of the oxygen vacancies. Results show that the spontaneous release of the oxygen from the lattice arrangements, through the thermal management of the heat of the oxidation reaction from the geometrical design of the reactors, can be enhanced up to 4% with respect to the baseline oxygen production of 0.201 g O 2 ·h –1 ·g perovskite –1 with the cylindrical packed bed, in the condition of operations in this work, at 500 °C. Sensitivity to the operation temperature showed that the oxygen production is greatly enhanced by approximately 30% with the increase of the temperature from 500 to 550 °C. We report this result is consistent with experimental observations of faster release of the oxygen from the lattice arrangements of this perovskite at 550 °C.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Less can be more: Insights on the role of electrode microstructure in redox flow batteries from two-dimensional direct numerical simulations

Understanding how to structure a porous electrode to facilitate fluid, mass, and charge transport is key to enhancing the performance of electrochemical devices, such as fuel cells, electrolyzers, and redox flow batteries (RFBs). Here, using a parallel computational framework, direct numerical simulations are carried out on idealized porous electrode microstructures for RFBs. Strategies to improve an electrode design starting from a regular lattice are explored. By introducing vacancies in the ordered arrangement, it is possible to achieve higher voltage efficiency at a given current density, thanks to improved mixing of reactive species, despite reducing the total reactive surface. Careful engineering of the location of vacancies, resulting in a density gradient, outperforms disordered configurations. Our simulation framework is a new tool to explore transport phenomena in RFBs, and our findings suggest new ways to design performant electrodes.

25 ENERGY STORAGE↗
DOE OSTI2025

Incorporating the molecular-scale into a hydrodynamic description of confined aqueous systems

Hydrodynamics provides a continuum-level description of fluid motion, but its applicability at the nanoscale becomes uncertain due to the emerging importance of molecular-level effects such as spatial heterogeneity. Hydrodynamic boundary conditions that incorporate molecular details allow us to partition the system into a near-wall region and a bulk fluid region. We identify a hydrodynamic wall located inside the fluid that determines where slip begins. By extending the hydrodynamic wall with the slip length, the position of the extrapolated wall is established. This offers a unified description of both slip and stagnant flow behaviors, with wall hydrophobicity characterized by the relative location of the extrapolated wall with respect to the physical wall. Employing this concept in analyses of equilibrium molecular dynamics (MD) and non-equilibrium MD simulations of Couette and Poiseuille flows, our results demonstrate consistency between equilibrium and non-equilibrium approaches across different flow types and confinement levels. This demonstrates the robust nature of linear response theory. We then explore the effects of fluid-wall and bulk fluid interactions on the hydrodynamic properties. These findings enhance the effectiveness of molecular-based simulations for investigating complex confined systems in nanofluidics, biology, and colloidal science, offering a complementary molecular-scale perspective to traditional continuum approaches.

flow simulations↗
DOE OSTI2020

Fluid-driven fractures in granular media: Insights from numerical investigations

We investigate the mechanisms of opening-mode fracture initiation in granular media. The study is based on a simulation of grain-scale fluid-grain interactions through a coupled numerical approach in which the discrete element method is used to solve for the mechanics of a solid granular medium, and computational fluid dynamics is used to model fluid flow and drag forces. In this work, we present benchmark problems with analytical solutions and validate this numerical model against experiments on a viscous-drag-driven cavity in the literature. Additional simulation results show fracture initiation mechanisms in a random granular packing subjected to constant boundary stresses and to fluid injection with a localized source. The dimensionless variable $F_s/F_{sk}$ (ratio of seepage force $F_s$ and skeletal force $F_{sk}$) incorporates the impacts of physical properties and injection parameters including fluid viscosity, injection velocity, grain size, and effective stresses, and it has been used as a criterion separating regimes of fluid invasion and drag-driven fracture opening. Our simulation results show that $F_s/F_{sk}$ in combination with $τ_1$ (ratio of diffusion time from hydromechanical coupling and injection time) serves as a prediction of fracture opening within granular packing. We suggest a simple criterion ($F_s/F_{sk}$ > 1 or $τ_1$ > 0.17) that is valid for various types of granular media and injection conditions to determine if fracture opening will occur. Among other applications, this study is useful to predict the initiation and propagation of fractures in natural sediments.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2021

Lattice Boltzmann model for conjugate heat transfer across thin walls

A lattice Boltzmann (LB) model with an efficient and accurate interface treatment for conjugate heat transfer across a thin wall between two different media is developed. The proposed interface treatment avoids fine meshing and computation within the thin layer; instead, the energy balance within the thin layer and the conjugate conditions on each interface are utilized to construct explicit updating schemes for the microscopic distribution functions of the LB model at the interior lattice nodes of the two media next to the thin layer. The proposed interface schemes reduce to the standard interface scheme for conjugate conditions in the literature in the limit of zero thickness of the thin layer, and thus it can be considered a more general interface treatment. A simplified version of the interface treatment is also proposed when the heat flux variation along the tangential direction of the thin layer is negligible. Three representative numerical tests are conducted to verify the applicability and accuracy of the proposed interface schemes. The results demonstrate that the intrinsic second-order accuracy of the LB model is preserved with the proposed interface schemes for thin layers with constant tangential fluxes, while for general situations with varying tangential fluxes, first-order accuracy is obtained. Finally, this interface treatment within the LB framework is attractive in conjugate heat transfer modeling involving thin layers for its simplicity, accuracy, and significant reduction in computational resources.

42 ENGINEERING↗
DOE OSTI2020

Non-Destructive Imaging of a Liquid Moving Through Porous Media Using a Computer Tomography Scanner

The most common approach used by modelers to describe movement of liquids through a porous solid, such as cement, sediment, or glass, is to assume a uniform flow rate, such as a Darcy Flux or a diffusion constant. However, this convenient simplification is problematic because in many cases it ignors the presence of fractures and macropores, which commonly dominate water flow and contaminant transport. For this reason, it is common that such modeling results do not reflect the multi-modal flow detected in laboratory and field studies. The objective of this seedling study was to develop a new capability for SRNL to track liquid moving through micro- (matrix-) and macro-flow using an X-ray Computed Topography (CT) Scanner. 4-dimensional anamated renditions were created that permited quantifying traditional matrix flow and macropore flow. These animations were modelled using a public domain software, HYDRUS 1-D, describing one dimension, dual-porosity and dual-permeability processes. This new capability provides a proof of concept for reducing model uncertainty applicable to waste disposal risk calculations, environmental remediation, and waste form development when describing the movement of liquids as they pass through glass, cement, fractured rock, or soil.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

BETO 2021 Peer Review - Continuous Enzymatic Hydrolysis Development (CEHD) WBS 2.4.1.101

The Continuous Enzymatic Hydrolysis Development (CEHD) project aims to reduce the cost and commercialization scale-up risks of biorefinery sugar-lignin production through development of a deployable continuous enzymatic hydrolysis (CEH) process. Through the use of external cross flow membrane filtration loops coupled to enzymatic hydrolysis (EH) reactors, pretreated biomass solids and enzymes are retained for reaction while solubilized product sugars are removed in situ, with high extents of conversion achieved through a series of reactor-membrane unit stages. The CEHD project is focused on advancing CEH as a transformational, process-intensified, lower-cost method for producing soluble clarified biomass sugars and insoluble lignin-rich streams than traditional batch enzymatic hydrolysis (BEH). The project's primary objective is to reduce the cost of CEH to be compellingly lower than conventional BEH, 10% lower in year 1 and 20% lower in year 3 (end of project). A related objective is to expand CEH's operating envelope to increase process efficiency. Through more thorough de-risking and demonstration of CEH, in conjunction with building a suite of modeling and optimization tools that allow for more facile rigorous in silico evaluation of novel CEH designs and modalities, this project intends to elevate industry interest in adopting CEH as an improvement over conventional batch processing. This project was merit reviewed in FY20. It's now in its first year of a new 3-year plan spanning FY21-FY23.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗