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DOE OSTI2018

ANSYS Fluent CFD Modeling of Solar Air-Heater Thermoaerodynamics

Numerical modeling of thermal and aerodynamic processes taking place in a solar air heater with light-absorbing L-shaped fins is performed. The study is carried out by means of an ANSYS Fluent Solver with an integrated solar calculator for the city of Samara, Russia. The influence of the design (the step between the fins) and technological variables (the Reynolds number) on heat-exchange processes and flow aerodynamics was established during the CFD analysis. Pictorial contours are determined for the velocity distribution, pressure, and other characteristics of the airflow in the solar air-heater box. Thermoaerodynamic characteristics and effective values of technological parameters for the effective use of a solar air heater are studied. The maximum thermoaerodynamic characteristic for the solar air heater with a finned lightabsorbing surface is 1.91 for Re = 1500, and the minimum test fin pitch is 30 mm.

42 ENGINEERING↗

NASA NTRS2011

Teledyne Energy Systems, Inc., Proton Exchange Member (PEM) Fuel Cell Engineering Model Powerplant. Test Report: Initial Benchmark Tests in the Original Orientation

Proton Exchange Membrane (PEM) fuel cell technology is the leading candidate to replace the alkaline fuel cell technology, currently used on the Shuttle, for future space missions. During a 5-yr development program, a PEM fuel cell powerplant was developed. This report details the initial performance evaluation test results of the powerplant.

Loyselle, Patricia↗

DOE OSTI2023

High-performance multimode elastocaloric cooling system

Developing zero–global warming potential refrigerants has emerged as one area that helps address global climate change concerns. Various high-efficiency caloric cooling techniques meet this goal, but scaling them up to technologically meaningful performance remains challenging. We have developed an elastocaloric cooling system with a maximum cooling power of 260 watts and a maximum temperature span of 22.5 kelvin. These values are among the highest reported for any caloric cooling system. Its key feature is the compression of fatigue-resistant elastocaloric nitinol (NiTi) tubes configured in a versatile multimode heat exchange architecture, which allows the harnessing of both high delivered cooling power and large temperature spans. Our system shows that elastocaloric cooling, which only emerged 8 years ago, is a promising direction for commercializing caloric cooling.

Science & Technology - Other Topics↗

DOE OSTI2024

The Maintainable Fusion Pilot Plant

The US fusion community has coalesced around the goal of building an FPP as described by the National Academies of Science, Engineering, and Medicine (NASEM). In addition to demonstrating the viability of the technologies necessary to operate such a plant, including demonstration of net energy and electricity production, NASEM found that a “fusion pilot plant will need to demonstrate the ability to efficiently perform remote maintenance and replacement in support of the design of a power plant, taking into account details of the consequences of the fusion environment, such as material activation and tritium retention in components.” Current designs of fusion demonstration reactors do usually foresee a regular exchange of their first wall modules, including the tritium breeding blankets. In the European Power Plant Conceptual Studies, it is assumed that a fusion reactor will need to change its divertor every 2 years and its first wall blanket module every 5 to 6 years to reach acceptable availability. Underlying this capability are remote-handling technologies to keep the outage for the exchange of these components short. There are many uncertainties in the remote-handling schemes, and most schemes are at a preconceptual level at best. In addition, the exchange of these components would either produce an enormous rad-waste stream or would require an enormous refurbishment activity with huge cost-prohibitive hot-cells. Past Fusion Nuclear Science Facility (FNSF) preconceptual studies have led to hot cell dimensions of an unbelievable size, likely costing tens of billions of dollars. Already at The Way (previously International Thermonuclear Experimental Reactor, ITER), hot-cells have become cost-prohibitive, demanding redesigns of the ITER first wall to reduce the toxic rad-waste/inventory. In this in-situ PFC repair project, a concept for a long-life, maintainable first wall module concept is developed and tested. This first wall concept relies on innovative remote handling to repair the first wall modules in-situ, avoiding costly refurbishments outside of the tokamak vessel. This approach was highlighted in the Fusion Energy Sciences Advisory Committee (FESAC) report on Transformative Enabling Capabilities for Efficient Advance Toward Fusion Energy. In general, the damage of the first wall armor is due to particle and radiation exposures. Load conditions vary from one fusion reactor design to another. In tokamaks, first wall Plasma Facing Components (PFCs) are exposed to far-Scrape-Off-Layer plasma fluxes, electromagnetic radiation, energetic CX neutrals, and potentially runaway electron beams. Protecting the first wall to the worst-case load conditions would require the design of a very thick first wall armor. Transient heat and particle fluxes due to disruptions or edge localized modes can lead to excessive heat loads resulting potentially in melting PFCs down to the cooling channel. Catastrophic events like these need to be avoided by appropriate disruption mitigation systems. However, failure of these systems will still put a first wall at an unacceptable risk. Hence, a first wall design needs to accommodate the occasional transient heat loads by introducing sacrificial limiters, which will absorb these transients.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Multi-physics Topology OPtimization and Additive Manufacturing for High-temperature Heat Exchangers

This research significantly advances the understanding of high-temperature heat exchanger design through an integrated approach that combines topology optimization (TO), triply periodic minimal surface (TPMS) structures, additive manufacturing (AM) and thermohydraulic testing. Each of these components contributes uniquely to a unified, high-performance design, fabrication and testing workflow. Topology optimization serves as the foundation of the design methodology by providing a systematic way to determine the most effective material layout for separating hot and cold fluids while maximizing thermal performance. The researchers introduced a novel three-material optimization framework using two density fields to represent hot fluid, cold fluid, and solid domains. This approach enables automated discovery of optimal shapes and flow paths that cannot be intuitively designed, especially under constraints imposed by manufacturing technologies. Furthermore, constraints such as minimal wall thickness and overhang angles were embedded into the optimization process, ensuring that resulting designs are not only thermally efficient but also manufacturable using modern additive techniques. In parallel, the study delves into the use of Gyroid-based TPMS geometries for constructing the core of the heat exchanger. TPMS structures are known for their high surface area, excellent fluid mixing capabilities, and minimal pressure drop characteristics. The researchers applied a data-driven modeling framework using Heteroscedastic Sparse Gaussian Process Regression (HSGPR) combined with genetic algorithms. This allowed for the rapid evaluation and optimization of key geometric parameters such as frequency, iso-value, and phase shift. The result was a set of Gyroid structures tailored for high heat transfer and low flow resistance, demonstrating clear improvements over conventional straight-channel designs. After the designing process, additive manufacturing played a critical role by turning these highly complex, optimized geometries into physical components. Utilizing Laser Powder Bed Fusion (LPBF) with Haynes 282, the study demonstrated the feasibility of fabricating these heat exchangers at high precision. Post-processing methods, including dilation-erosion operations, were applied to ensure local features adhered to self-supporting constraints. The fabricated structures were then subjected to thermohydraulic testing under conditions representative of supercritical CO 2 Brayton cycles, validating the predicted performance and confirming the viability of the full design-to-fabrication pipeline. Finally, thermohydraulic testing across the above studies served as a crucial experimental validation of advanced heat exchanger. Under consistent high-temperature and high-pressure conditions using supercritical CO 2 , the testing demonstrated that both TO and Gyroid-based TPMS designs significantly outperformed conventional straight-channel HXs. The TO design achieved a 115% increase in UA and NTU and a 27.6% boost in gravimetric power density, while the data-driven optimized Gyroid design delivered a 166% increase in UA and NTU and improved effectiveness from 68.7% to 86.1%. These results validate the simulation models, confirm the manufacturability of complex geometries under AM constraints, and provide key insights into design-performance trade-offs, thereby advancing the development of high-efficiency, compact heat exchangers for extreme environments.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Electrostatic Potential of Functional Cations as a Predictor of Hydroxide Diffusion Pathways in Nanoconfined Environments of Anion Exchange Membranes

Nanoconfined anion exchange membranes (AEMs) play a vital role in emerging electrochemical technologies. The ability to control dominant hydroxide diffusion pathways is an important goal in the design of nanoconfined AEMs. Such control can shorten hydroxide transport pathways between electrodes, reduce transport resistance, and enhance device performance. In this work, we propose an electrostatic potential (ESP) approach to explore the effect of the polymer electrolyte cation spacing on hydroxide diffusion pathways from a molecular perspective. By exploring cation ESP energy surfaces and validating outcomes through prior ab initio molecular dynamics simulations of nanoconfined AEMs, we find that we can achieve control over preferred hydroxide diffusion pathways by adjusting the cation spacing. The results presented in this work provide a unique and straightforward approach to predict preferential hydroxide diffusion pathways, enabling efficient design of highly conductive nanoconfined AEM materials for electrochemical technologies.

25 ENERGY STORAGE↗

DOE OSTI2026

Public Reference Data for Megawatt-Scale Hydrogen Electrolysis - NLR Historical Solar PV

The U.S. Department of Energy and National Laboratory of the Rockies (NLR) demonstrate hydrogen electrolysis from variable sources, hydrogen compression and storage, and hydrogen fuel cell power production using megawatt-scale equipment at NLR’s Flatirons Campus as part of the Advanced Research on Integrated Energy Systems (ARIES) research platform. This dataset represents part of that effort and is intended for academic, national laboratory, industrial, and other stakeholders to plan, design, and validate models of megawatt-scale hydrogen technologies and diverse energy infrastructure nationwide. These data provide a baseline for how existing hydrogen electrolysis technologies perform when coupled with various energy technologies. Future datasets will demonstrate how existing hydrogen fuel cell technologies can provide controllable, dispatchable, and variable power output for artificial intelligence data centers and other variable loads. This dataset entry describes the behavior of a 1.25-MW proton exchange membrane MC250 electrolyzer system, manufactured by Nel Hydrogen , [1] when fed historical data generated by the 430-kW, fixed-axis solar photovoltaic (PV) array located at NLR’s Flatirons Campus. (While the electrolyzer balance of plant supports up to 2.5 MW of electrolysis, NLR only has a single 1.25-MW electrolysis stack.) Solar PV power output data for the 2020 calendar year were categorized on a daily basis by total energy generation and standard deviation. Each day was then ranked by these metrics, and the 25th, 50th, and 100th percentiles were selected. The 75th percentile day did not exhibit sufficient variability to make for a valuable experiment. A similar process was used for the related historical wind dataset . [2] The historical days in 2020 that represented these percentiles are Dec. 19, March 29, and May 4, respectively. The entire solar day’s power profile was then fed through the MC250 electrolyzer. Due to its length, the 100th percentile day experiment was split into two parts, and the final 3 hours of the solar day were not captured. These final 3 hours contained no spikes or dips of interest and simply represented a slow decay of input solar power. Also, a single timestamp (13:13:47 on Jan. 14, 2026) was lost in the hydrogen system supervisory control and data acquisition. Finally, during the 25th percentile experiment (solar day Dec. 19, 2020) data recording was lost from 11:00:13 to 11:14:45. The roughly 15 minutes of the solar profile were rerun at the end of the experiment and spliced into this time slot during post-processing. The electrolysis system controls hydrogen production by varying direct current applied to the stack, from a maximum of 3,000 A to a minimum safe operation of 300 A, or 10%. Because the current–voltage characteristic changes as the stack ages and efficiency degrades, the actual minimum safe operating power changes over time. The historical solar profiles were translated from power (kilowatts) to current (amperes) using a curve fit with calibration data and sent to the electrolyzer power supply at 1-Hz frequency. For more details on the statistical analysis process, see the slide deck “Public Reference Data for Megawatt-Scale Hydrogen Electrolysis: NLR Historical Solar PV Analysis and Profile Generation” accessible with this data entry. These datasets report relevant hydrogen balance-of-plant and system data, all captured at 1 Hz, including hydrogen mass production measured with an Emerson Coriolis flow meter. Each .zip file represents a single solar PV electrolysis experiment and is formatted as: {technology}_{percentile}_{scaling factor} For instance, “solarPV-430kW_25_2x.zip” reports the experiment using the 25th percentile solar data from the historical 2020 solar PV dataset, scaled to 200%. Scaling factors were applied to the generated solar PV power output files to more closely match the 1.25-MW capacity of the electrolyzer. Each .zip folder contains the following files: A .csv file containing raw data. An .xlsx file explaining all the fields in the raw data. A .png plot showing the time series of hydrogen production, electrolysis power consumption, and solar power input. A PDF file detailing the historical solar data statistical analysis used to generate the solar profile. An experiment labeled “characterization_200.zip” demonstrates the MC250 electrolyzer steady-state response with 30-minute load steps for a total duration of 5 hours. Finally, a .csv file is provided with all experiments combined into one dataset labeled "combined_solarPV_experiments.csv". [1] nelhydrogen.com/product/mc-series-electrolyser . [2] data.nlr.gov/submissions/316 .

08 HYDROGEN↗

NASA NTRS1990

Cryogenic hydrogen-induced air-liquefaction technologies

Extensive use of a special advanced airbreathing propulsion archives data base, as well as direct contacts with individuals who were active in the field in previous years, a technical assessment of cryogenic hydrogen induced air liquefaction, as a prospective onboard aerospace vehicle process, was performed and documented in 1986. The resulting assessment report is summarized. Technical findings relating the status of air liquefaction technology are presented both as a singular technical area, and also as that of a cluster of collateral technical areas including: Compact lightweight cryogenic heat exchangers; Heat exchanger atmospheric constituents fouling alleviation; Para/ortho hydrogen shift conversion catalysts; Hydrogen turbine expanders, cryogenic air compressors and liquid air pumps; Hydrogen recycling using slush hydrogen as heat sinks; Liquid hydrogen/liquid air rocket type combustion devices; Air Collection and Enrichment System (ACES); and Technically related engine concepts.

Escher, William J. D.↗

NASA NTRS1993

Brayton Power Conversion System Parametric Design Modelling for Nuclear Electric Propulsion

The parametrically based closed Brayton cycle (CBC) computer design model was developed for inclusion into the NASA LeRC overall Nuclear Electric Propulsion (NEP) end-to-end systems model. The code is intended to provide greater depth to the NEP system modeling which is required to more accurately predict the impact of specific technology on system performance. The CBC model is parametrically based to allow for conducting detailed optimization studies and to provide for easy integration into an overall optimizer driver routine. The power conversion model includes the modeling of the turbines, alternators, compressors, ducting, and heat exchangers (hot-side heat exchanger and recuperator). The code predicts performance to significant detail. The system characteristics determined include estimates of mass, efficiency, and the characteristic dimensions of the major power conversion system components. These characteristics are parametrically modeled as a function of input parameters such as the aerodynamic configuration (axial or radial), turbine inlet temperature, cycle temperature ratio, power level, lifetime, materials, and redundancy.

Ashe, Thomas L.↗

NASA NTRS1994

Mars power system concept definition study. Volume 1: Study results

A preliminary top level study was completed to define power system concepts applicable to Mars surface applications. This effort included definition of power system requirements and selection of power systems with the potential for high commonality. These power systems included dynamic isotope, Proton Exchange Membrane (PEM) regenerative fuel cell, sodium sulfur battery, photovoltaic, and reactor concepts. Design influencing factors were identified. Characterization studies were then done for each concept to determine system performance, size/volume, and mass. Operations studies were done to determine emplacement/deployment maintenance/servicing, and startup/shutdown requirements. Technology development roadmaps were written for each candidate power system (included in Volume 2). Example power system architectures were defined and compared on a mass basis. The dynamic isotope power system and nuclear reactor power system architectures had significantly lower total masses than the photovoltaic system architectures. Integrated development and deployment time phasing plans were completed for an example DIPS and reactor architecture option to determine the development strategies required to meet the mission scenario requirements.

Littman, Franklin D.↗

DOE OSTI2026

Making Small-Volume Heat Pump Water Heaters Larger: A Design Framework for Integrated Phase Change Material Heat Exchangers

Those that use electricity for water heating, the majority use resistive elements rather than heat pump water heaters (HPWHs), the latter of which use 60-70% less energy than the former. One major barrier to wider HPWH adoption is the added equipment required, which prevents current 50-80-gallon tanks on the market from fitting into smaller utility closets sized for 30-40 gallons, such as those found in manufactured housing. Additionally, these smaller HPWHs tend to underperform relative to their larger counterparts. One solution that addresses both space and performance concerns is thermal energy storage, and in particular, phase change materials (PCMs). PCMs have been studied extensively in building envelope and HVAC systems, but remain a nascent technology in residential water heating. While water itself has a uniquely high energy storage capacity, PCMs have an even higher energy storage density, thus providing the potential to elevate the performance of 40-gallon HPWHs to that of 50-gallon or larger tanks. This research is part of a larger project that seeks to utilize thermal energy storage to enable decarbonized water heating in low-income communities. In this study, we outline the design process used to produce novel PCM heat exchangers for use in small-volume HPWH tanks, including the identification of design constraints and performance targets relevant to real-world applications. In order to ensure optimal PCM utilization and tank storage capacity, we focus here on co-maximizing surface area and PCM volume in the heat exchangers; therefore, this research targets triply periodic minimal surface (TPMS) lattices. TPMS lattices boast enhanced heat transfer capabilities compared to traditional heat exchanger geometries and offer highly tailorable designs; thus, they pair well with the growing field of additive manufacturing, or 3D printing. Starting with a suite of TPMS lattices, we demonstrate a systematic approach for narrowing down feasible designs that comply with identified constraints while meeting PCM performance objectives.

25 ENERGY STORAGE↗

DOE OSTI2021

Impacts of common faults on an air conditioner with a microtube condenser and analysis of fault characteristic features

Split system air conditioners are widely used to cool residential buildings, because of their low cost and simplicity. However, their efficiency is impacted by installation faults, which include: improper refrigerant charge (undercharge or overcharge), improper evaporator airflow, liquid line restrictions (LL), and the presence of non-condensable gas (NC) in the refrigerant. No known previously published research has studied the effect of these four faults on a system equipped with a microtube condenser, which has smaller tube size than a traditional condenser and therefore holds less refrigerant charge, but has a different configuration than a microchannel. Furthermore, very few have studied the impacts of LL and NC. Herein this paper describes laboratory fault tests of a microtube-equipped system, compares the fault impacts with those of a traditional system, and considers the characteristic fault features. The tested system uses R-410A refrigerant and has a scroll compressor, a fixed orifice expansion device, and two fin-tube heat exchangers. The tests were carried out under steady operation with a range of fault intensities and operating conditions. The microtube system’s performance degradation from faults is similar to systems with traditional heat exchangers, despite the reduced capacity to hold refrigerant charge.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Community Resilience through Low-Temperature Geothermal Reservoir Thermal Energy Storage

Submitted data include simulations related to underground thermal battery (UTB) simulations described in Modeling and efficiency study of large scale underground thermal battery deployment, presented at GRC, October 2021. The UTB is comprised of a tank of water, a helical heat exchanger in the center of tank and connected to a water source heat pump, and a phase change material (PCM). Compared to a conventional VBGHE, the UTB is designed to be installed at a much shallower depth, therefore, with a cheaper cost. In addition, the GSHP efficiency is improved due to natural convection of water and additional load capacity provided by PCM. The goal of this study is to explore factors that may affect the efficiency of large-scale UTB deployment. The simulations found in this submission relate to the report on UTB deployment.

15 GEOTHERMAL ENERGY↗

DOE OSTI2024

Hydrogen Production Cost with Anion Exchange Membrane Electrolysis

Rigorous stakeholder-vetted techno-economic analysis was performed to assess the cost of hydrogen (H 2 ) produced using state-of-the-art Anion Exchange Membrane (AEM) electrolysis. Projected high-volume, untaxed and unsubsidized levelized cost of hydrogen (LCOH)1 range from 2020 $\$$1.78 to $\$$3.68/kg H 2 depending on technology year, process design, and electrolyzer project scale, assuming an electricity price of $\$$0.03/kWh and a capacity factor of 97%. The total installed capital cost for an AEM electrolysis plant was estimated from bottom-up stack and process plant cost models. The stack cost model accounts for manufacturing equipment, equipment maintenance, material, tooling, cycle time, yield, labor, utilities and general overhead. The process plant cost model accounts for purchased equipment, installation costs, site preparation, and general overhead costs. For this study, the AEM electrolysis plant is assumed to be a stick-built, greenfield project developed by an engineering, procurement, and construction (EPC) firm with electrolysis stacks purchased directly from an electrolysis stack manufacturer. The price of the electrolysis stacks is based on a bottom-up cost assessment with business markup for the electrolysis company fabricator. Methods from the Hydrogen Analysis (H2A) production model, a peer-reviewed national laboratory-developed discounted cash flow (DCF) model, were used to calculate the production LCOH in 2020 $\$$/kg H 2 . The baseline electricity price case ($\$$0.03/kWh) corresponds to average wholesale electricity prices currently possible in U.S. markets with plentiful wind. Similar low-cost electricity pricing is possible from solar Power Purchase Agreements (PPA) although these prices are typically limited by renewable energy capacity factors.

08 HYDROGEN↗

NASA NTRS1977

Wash water reclamation technology for advanced manned spacecraft

The results of an analytical study and assessment of state-of-the-art wash water reclamation technology for advanced manned spacecraft is presented. All non-phase-change unit operations, unit processes, and subsystems currently under development by NASA are considered. Included among these are: filtration, ultrafiltration, carbon adsorption, ion exchange, chemical pretreatment, reverse osmosis, hyperfiltration, and certain urea removal techniques. Performance data are given together with the projected weights and sizes of key components and subsystems. In the final assessment, a simple multifiltration approach consisting of surface-type cartridge filters, carbon adsorption and ion exchange resins receives the highest rating for six-man orbital missions of up to 10 years in duration.

Putnam, D. F.↗

DOE OSTI2022

Transformational Solid Oxide Fuel Cell (SOFC) Technology

This project was conducted under the Co-operative Agreement No. DE-FE0027584 with the US Department Energy to developed advanced Solid Oxide Fuel Cell (SOFC) Technologies. The overall objective of this project was to advance SOFC technology at the cell and stack level to enhance cell robustness and durability, increase performance, and reduce balance-of-plant (BOP) requirements. By reducing system complexity combined with the increases in power density and efficiency, the ultimate goal of the project was to increased reliability and to reduce capital and operating costs of installed systems. The project was focused on pathways that will reduce the cost of the SOFC cell and stack, including the following areas: Robust, redox tolerant cell technology Lower cost cell manufacturing through advances in cell design, which will reduce the amount of material, energy and time used in the fabrication of SOFCs High performance, low temperature electrolyte based on improvement of established materials Innovative SOFC stack architecture which truly integrates Balance of Plant functionality into the stack level design Thermal management of the fuel cell stack for increased durability and expanded window of operation Novel stack design amenable for use in sub-MW to multi-MW-scale power plants and having low replacement cost The incorporation of balance-of-plant (BOP) equipment into the stack platform increased the economic viability of smaller scale systems. The project objectives were met by a multi-prong approach, including new cell design complemented with modifications to existing cell technology, as well as a new stack design incorporating components typically included in the BOP, such as heat exchangers, oxidizer, fuel reformers, and recycle systems. The project culminated with demonstration of a stack test validating the viability of the cell and stack improvements. A cost model was also developed to estimate costs for the advanced stack technology at high volume manufacturing levels. The net outcome of the project is SOFC cell and stack technology with costs significantly below current DOE targets without compromising and, in some cases, improving on the performance and degradation rate demonstrated with the current state-of-the-art stack design. The results of this project advanced the reliability, robustness, and endurance of low-cost SOFC technology that ultimately are ready to be deployed in coal power systems with greater than 60 percent efficiency (based on higher heating value of fuel) and the capability for ≥97% CO 2 capture at a cost-of-electricity that is approximately 40 percent below presently available Integrated Gasification Combined Cycle systems.

03 NATURAL GAS↗

DOE OSTI2017

Energy Efficient Clothes Dryer with IR Heating and Electrostatic Precipitator

The project goal was to develop a revolutionary energy saving technology for residential clothes drying. The team developed an IR (infrared) heating system and NESP (Nebulizer and Electro-Static Precipitator) for integration into a ventless clothes dryer. The proposed technology addresses two of the major inefficiencies in current electric vented dryers by providing effective energy transfer for the removal of the water and recapture of the vapor latent heat. The IR heaters operating in the mid wave (2.5-10um) are very efficient as they target the 3-micron peak absorption of the water molecule. This allows direct energy absorption, unlike conventional element heaters where heat is transferred by convection. The low power NESP removes water vapor from the exhausted stream and recaptures the latent heat in the ESP (Electro-Static Precipitator) exchanger section. This allows the warm dry air to be recirculated back into the drum for additional efficiency savings. The remaining majority of the dryer hardware stays the same. Summing the efficiency gain from the two subcomponents we anticipated the EF (Efficiency Factor) to exceed the goal of 4.04. EF is obtained by dividing the weight (lbs) of water removed by the energy (kWhr) used, where the test load size is 8.45 lbs of bone dry clothing wetted to 57.5% or 4.8lbs of water, and dried to a remaining moisture content of 2.5-5%. Additional benefits include not having to recondition (heat or cool) the large amounts of make-up air to replace the air exhausted by a vented dryer. It was anticipated that the NESP/heat exchanger would be the most challenging and highest risk element in the program. Therefore, the team focused their efforts during Phase 1 of the program on the design, construction, testing, and optimization of the NESP/heat exchanger. At the end Phase 1, the team compared the performance of the NESP/heat exchanger with the system level requirements and made a Go/No-Go decision on proceeding with the second portion of the program. Phase 2 of the program was structured to develop the IR heating system and then integrate it and the NESP/heat exchanger into a residential clothes dryer prototype for final testing. The proposed technology utilizes heat recovery which is known to have the biggest impact on dryer efficiency. The two current mainstream recovery approaches are air to air exchangers and heat pump condenser systems. Air to air exchanges can be very efficient but require large surface areas which are prone to fouling from uncaptured lint. Dryers based on heat pump condenser recovery systems have shown efficiency improvements of 20–60% and are commercially available. The issue with a heat pump condenser approach is the added cost, as typical prices are twice that of standard vented dryers and they are only available in small to medium capacities. The energy factor (EF) for these systems is 5.50 to 6.88 pounds/kWh compared to conventional dryers at 2.75 to 3.67 pounds/kWh. The efficiency improvements for the proposed technology come from the use of IR heating and the NESP. As the concept is in its infancy, and these improvements were difficult to predict without experimental data, assumptions were made based on available literature. IR radiant drying times, when compared to convection, are typically 30% less. This is a result of the fact that radiant energy heats directly and is absorbed at and below the surface, unlike convection heating, that must conduct the heat through the boundary film of air at the clothes surface and rely on wicking of the moisture to the surface. The second area of improvement comes from the NESP. The NESP operation is as follows: 1. Highly charged, micron sized, droplets of water are injected into the dryer exhaust by the Nebulizer. 2. These charged droplets attract water molecules and continue to grow in size, until losing their charge. During this process, latent heat is rejected back into the air stream. 3. The large droplets enter the ESP, where they are recharged and drawn to the ESP wall, to be extracted at the bottom of the ESP. The warm dry air is then recirculated back into the dryer. The proposed technology, at the time of the proposal submission was estimated to have an EF of 4.79. At program completion we have designed, built, tested, integrated and optimized the proposed technologies into a prototype “high efficiency” residential clothes dryer. Testing of the integrated prototype dryer provided insight into the technical effectiveness and economic feasibility of the proposed technologies. The program has the potential of greatly impacting energy savings. The predicted EF of the proposed technology is 4.79, yielding an energy savings of 42% when compared to conventional electric vented dryers. Given there are approximately 84 million dryers in the US consuming ~64 billion kWh per year, a net savings of 27 billion kWh per year or 0.092 quads could be realized. Since the dryer is not vented, make up air from the room is not needed, adding an additional savings of ~1kWh per load, or 23.8 billion kWh per year. In addition, it is envisioned that the proposed ESP, when successful, would potentially find applications in industrial and residential dehumidification.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS2003

Places Only Sails Can Go

Solar sails are a near term, low thrust, propellantless propulsion technology suitable for orbital maneuvering, station keeping, and attitude control applications for small payloads. Furthermore, these functions can be highly integrated, reducing mass, cost and complexity. The solar sail concept is based on momentum exchange with solar flux reflected from a large, deployed thin membrane. Thrust performance increases as the square of the distance to the sun. In comparison to conventional chemical systems, there are missions where solar sails are vastly more and less economical. The less attractive applications involve large payloads, outer solar system transfers, and short trip times. However, for inclination changes and station keeping at locations requiring constant thrust, the solar sail is the only economical option for missions of more than a few weeks duration. We compare the location and energies required for these applications between solar sails, advanced electric propulsion, and conventional rockets. We address the effect on mass fraction to understand solar sail mission cost and capability. Finally, the benefit of potential applications to near term science missions is reported.

Montgomery, Edward E., IV↗