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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 289 records · Page 16

Development of a DC propulsion system for an electric vehicle

The suitability of the Eaton automatically shifted mechanical transaxle concept for use in a near-term dc powered electric vehicle is evaluated. A prototype dc propulsion system for a passenger electric vehicle was designed, fabricated, tested, installed in a modified Mercury Lynx vehicle and track tested at the contractor's site. The system consisted of a two-axis, three-speed, automatically-shifted mechanical transaxle, 15.2 Kw rated, separately excited traction motor, and a transistorized motor controller with a single chopper providing limited armature current below motor base speed and full range field control above base speed at up to twice rated motor current. The controller utilized a microprocessor to perform motor and vehicle speed monitoring and shift sequencing by means of solenoids applying hydraulic pressure to the transaxle clutches. Bench dynamometer and track testing was performed. Track testing showed best system efficiency for steady-state cruising speeds of 65-80 Km/Hz (40-50 mph). Test results include acceleration, steady speed and SAE J227A/D cycle energy consumption, braking tests and coast down to characterize the vehicle road load.

Kelledes, W. L.↗

Geoscience Laser Altimeter System (GLAS) on the ICESat Mission: Initial Science Measurement Performance

The Geoscience Laser Altimeter System is the space lidar on the NASA ICESat mission. Its design combines an altimeter with 5 cm precision with a laser pointing angle determination system and a dual wavelength cloud and aerosol lidar. GLAS measures the range to the Earth s surface with 1064 nm laser pulses. Each laser pulse produces a precision pointing measurement from the stellar reference system (SRS) and an echo pulse waveform, which permits range determination and waveform spreading analysis. The single shot ranging accuracy is < 10 cm for ice surfaces with slopes < 2 degrees. GLAS also measures atmospheric backscatter profiles at both 1064 and 532 nm. The 1064 nm measurements use an analog Si APD detector and measure the height and profile the backscatter signal from thicker clouds. The measurements at 532 nm use photon counting detectors, and will measure the vertical height distributions of optically thin clouds and aerosol layers Before launch, the measurement performance of GLAS was evaluated using a lidar test instrument called the Bench Check Equipment (BCE). The BCE was developed in parallel with GLAS and served as an inverse altimeter, inverse lidar and a stellar source simulator. It was used to simulate the range of expected optical inputs to the GLAS receiver by illuminating its telescope with simulated background light as well as laser echoes with known powers, energy levels, widths and delay times. The BCE also allowed monitoring of the transmitted laser energy, the angle measurements of the SRS, the co-alignment of the transmitted laser beam to the receiver line of sight, and performance of the flight science algorithms. Performance was evaluated during the GLAS development, before and after environmental tests, and after delivery to the spacecraft. The ICESat observatory was launched into a 94 degree inclination, 590 km altitude circular polar orbit on January 12,2003. Beginning in early February, GLAS was powered on tested in stages. Its 1064 nm optical receiver was evaluated in a several tests using both solar background light and an internal test source. Laser 1 was activated on February 20,2003. GLAS operated with Laser 1 for 38 continuous days on orbit using its 1064 nm receiver channel, producing over 130 million individual laser measurements of the Earth s surface and atmosphere. These nadir-pointed measurements fell along the ICESat s ground track, and spanned more than 4 cycles of the initial 8-day ICESat repeat orbit. The initial GLAS measurement set shows strong echo pulses from ranging to the surface topography, oceans, ice sheets and cloud tops, as well as profiles of clouds and aerosols. The GLAS measurements have unprecedented vertical and angular resolution, and show nearly continuous height profiles of ice, land and ocean surfaces or cloud tops, as well profiles of backscatter from thin clouds and aerosol layers. Examples of these GLAS measurements and an initial assessment of its science measurement performance will be presented.

Abshire, James B.↗

Hot section laser anemometry

The objectives and problems faced in the development of a laser anemometry system for hot section applications was discussed. The goal was to map the flow profiles through and between the vanes and between the rotating blades of a turbine. A laser anemometer system was developed which measures the Doppler shift directly along the optical axis. Some testing is being conducted in a small bench top combustor facility. The cost involved in this testing was also discussed.

Nieberding, W. C.↗

DeSelenator: A Se-Removal Process for Environmental Decontamination of Wastewaters from Coal-Burning Power Plants

Selenium may become a toxic contaminant of freshwater systems when released into the environment through industrial wastewaters from mining, coal-burning power plants, or oil refining. Efficient and cost-effective Se-removal technologies are therefore necessary to reduce Se concentrations in these wastewaters to below the regulatory discharge limits. In this study, we have demonstrated an effective process that removes Se, mostly as selenate anions, from wastewaters generated by coal-burning power plants. This process, dubbed DeSelenator, leverages the high concentration of sulfate relative to selenate in the wastewater and the propensity of these oxyanions to cocrystallize with benzene-bis-iminoguanidinium (BBIG) cations into extremely insoluble salts (on par with BaSO 4 ). The SO 4 2− /SeO 4 2− cocrystallization with BBIG removes over 90% of S and Se from the wastewater. Following removal of the precipitate by filtration, the filtrate is passed over an anion-exchange resin that further reduces selenium concentration to 5 ppb, the EPA’s regulatory limit for freshwater systems. Finally, the effluent is passed over an activated carbon column, which removes 99.8% of the residual BBIG ligand remaining after crystallization, allowing for the safe discharge of the treated water into the environment. The Se-removal process was first optimized in the lab at the bench scale and then tested in the field at the Tennessee Valley Authority’s Bull Run coal-burning power plant. A technoeconomic assessment found the cost of water treatment with DeSelenator is on par with that of the active biological method, which is currently considered a state-of-the-art Se-removal technology.

anions↗

Critical Component/Technology Gap in 21 st Century Power Plant Gasification Based Polygeneration: Advanced Ceramic Membranes/Modules for Ultra Efficient Hydrogen (H 2 ) Production/Carbon Dioxide (CO 2 ) Capture for Coal-Based Polygeneration

The 21 st Century Power Plant Gasification Based Polygeneration power plant layout is a relatively straightforward retrofit of well-established ammonia synthesis technology to the baseline IGCC process and envisions co-production of power and chemicals from coal in the context of carbon capture. A Dual Stage Membrane Process (DSMP) for pre-combustion CO 2 capture in a coal fired IGCC power plant has been demonstrated by Media and Process Technology Inc (MPT) (DE-FE0013064) in bench-scale live gas testing at the NCCC. This work, however, highlighted the importance of permeate purge capability to deliver deep H 2 recovery at moderate pressures and high carbon capture performance. Further, in the area of warm gas processing, a permeate purgeable membrane support for a wide range of inorganic high-performance membrane materials (CMS, Pd-alloy, zeolite, ZIF, graphene, etc.) was not available and hence had been a common and significant barrier to their commercialization. Hence, the Critical Technology Gap to implementing the DSMP in the Polygeneration power plant and more broadly in advanced warm gas separation applications was the inability to permeate purge the membranes coupled with the lack of the availability of a high packing density scalable package design. To overcome this Critical Technology Gap, in this project, the primary objective was the development of a permeate purgeable full ceramic support for these high-performance inorganic membranes and the complementary high packing density housing. Our goal and approach were to extend our “candle filter” design to a “dual end open” package to enable permeate purge and scalability. Microporous ceramic membranes have been proven to be a low cost, stable material for high temperature applications under harsh environment. They are the leading support choice of researchers in advanced inorganic membrane development in applications such as pre-combustion CO 2 capture. The new 2nd Generation “dual end open” bundle developed in this project is a universal support for these existing and emerging inorganic membrane technologies that up to now have lacked a pathway out of the laboratory. The full ceramic permeate purgeable support represents a transformational technology and opens the door to commercialization of these advanced membrane materials in a wide array of mega scale commercial applications in gas (and liquid) processing under aggressive conditions not suited to conventional polymeric membranes.

01 COAL, LIGNITE, AND PEAT↗

High Performance Solvent for NGCC Flue Gas CO 2 Capture (Final Technical Report)

Amine-based solvent absorption is the most mature and reliable technology for large scale CO 2 capture, dating back to the 1930s when monoethanolamine (MEA) was used to treat acid gases from oil refineries. However, while strategic advancements have optimized the CO2 capture process, the cost of capture remains high, where current estimates suggest that CO 2 capture costs are around $\$$72/tonne of CO 2 . To address this, solvent development and optimization have become a focus of current research. This project sought to develop a high-performance solvent to reduce the overall cost of CO 2 capture from NGCC flue gas. Here, solvent optimization focused on: (1) reducing the energy required for CO 2 desorption in a reboiler, (2) improving CO 2 absorption and desorption reaction kinetics, (3) improving solvent stability, and (4) reducing environmental impacts. Susteon has developed and evaluated a promoted solvent, Sustenol™, for NGCC flue gas CO 2 capture. The optimized Sustenol™ also shows a higher dynamic CO 2 absorption capacity of ~0.5 mol CO2 /mol amine compared to 0.25 mol CO2 /mol amine for 30 wt% MEA. Additionally, the solvent is oxidatively, thermally and hydrothermally stable, which leads to lower solvent loss and emissions. These advancements have resulted in a solvent regeneration energy of 2.16 GJ/tonne of CO 2 which is >30% lower than current state-of-the-art commercial and emerging solvents. Combined with empirical data from the bench and pilot scale testing, this preliminary TEA study indicated the cost of CO 2 capture by Sustenol™ for 97% CO 2 removal at $\$$54/tonne and for 90% removal at $\$$49/tonne, with a pathway to achieve $\$$45/tonne of CO 2 with continued process and solvent advancements. Susteon has developed a technology roadmap to reduce the cost of CO 2 capture to <$\$$45/tonne for NGCC flue gas. Susteon plans to derisk this technology for commercial deployment through comprehensive solvent degradation testing, long-term testing in a pilot plant at 5 tonne CO2 /day and demonstration scale testing at 100 tonne CO2 /day with NGCC flue gas and engineering design studies to qualify Sustenol™ as a drop-in replacement solvent.

03 NATURAL GAS↗

Pitch Bearing Rating and Service Life Analysis

Pitch bearings are an essential component in wind turbines used to connect the blade root to the hub. They support the resulting simultaneous radial, axial, and overturning moment loads while allowing relative rotation of the blade to the hub. The most recent evidence indicates the replacement rate for pitch bearings on 3+ MW turbines can be several percent per year, reaching 10% by year 5. This is a far higher replacement rate than both older 1.5 to 2 MW turbines and 2 to 3 MW turbines, which only reach a 10% replacement rate by 14 to 24 years compared to the expected design life of at least 20 years. Typical pitch bearing replacements require the use of a large, expensive crane and removal of the blade(s) or rotor, with a significant amount of downtime. Given the most recent developments in pitch bearing reliability and the publication of the updated NREL and Fraunhofer IWES pitch bearing design guide, the purpose of this report is to update the performance and rating analysis of the example 1.9-meter diameter pitch bearing representative of that installed on a 1.5 MW wind turbine, compare the rating life to the observed service life of similar pitch bearings, and validate the service life modification factor with this large population of bearings. The report will also summarize the pitch bearing contact conditions, thereby serving as a guide for planned bench-level fretting wear tests at Argonne National Laboratory.

17 WIND ENERGY↗

Fuel property effects on Navy aircraft fuel systems

Problems of ensuring compatibility of Navy aircraft with fuels that may be different than the fuels for which the equipment was designed and qualified are discussed. To avoid expensive requalification of all the engines and airframe fuel systems, methodologies to qualify future fuels by using bench-scale and component testing are being sought. Fuel blends with increasing JP5-type aromatic concentration were seen to produce less volume swell than an equivalent aromatic concentration in the reference fuel. Futhermore, blends with naphthenes, decalin, tetralin, and naphthalenes do not deviate significantly from the correlation line of aromatic blends, Similar results are found with tensile strenth and elongation. Other elastomers, sealants, and adhesives are also being tested.

Moses, C. A.↗

Transitioning Active Flow Control to Applications

Active Flow Control Programs at NASA, the U.S. Air Force, and DARPA have been initiated with the goals of obtaining revolutionary advances in aerodynamic performance and maneuvering compared to conventional approaches. These programs envision the use of actuators, sensors, and controllers on applications such as aircraft wings/tails, engine nacelles, internal ducts, nozzles, projectiles, weapons bays, and hydrodynamic vehicles. Anticipated benefits of flow control include reduced weight, part count, and operating cost and reduced fuel burn (and emissions), noise and enhanced safety if the sensors serve a dual role of flow control and health monitoring. To get from the bench-top or laboratory test to adaptive distributed control systems on realistic applications, reliable validated design tools are needed in addition to sub- and large-scale wind-tunnel and flight experiments. This paper will focus on the development of tools for active flow control applications.

Joslin, Ronald D.↗

EMI / EMC Design for Class D Payloads (Resource Prospector / NIRVSS)

EMI/EMC techniques are applied to a Class D instrument (NIRVSS) to achieve low noise performance and reduce risk of EMI/EMC testing failures and/or issues during system integration and test. Basic techniques are not terribly expensive or complex, but do require close coordination between electrical and mechanical staff early in the design process. Low-cost methods to test subsystems on the bench without renting an EMI chamber are discussed. This method was applied to the NIRVSS instrument and achieved improvements up to 59dB on conducted emissions measurements between hardware revisions.

low noise↗

Design and Development of a 200-kW Turbo-Electric Distributed Propulsion Testbed

There a few NASA funded electric and hybrid electric projects from different NASA Centers, including the NASA Armstrong Flight Research Center (AFRC) (Edwards, California). Each project identifies a specific technology gap that is currently inhibiting the growth and proliferation of relevant technologies in commercial aviation. This paper describes the design and development of a turbo-electric distributed propulsion (TeDP) hardware-in-the-loop (HIL) simulation bench, which is a test bed for discovering turbo-electric control, distributed electric control, power management control, and integration competencies while providing risk mitigation for future turbo-electric flying demonstrators.

propulsion↗

Surface fatigue life of carburized and hardened M50NiL and AISI 9310 spur gears and rolling-contact test bars

Spur gear endurance tests and rolling-element surface tests were conducted to investigate vacuum-induction-melted, vacuum-arc-melted (VIM-VAR) M50NiL steel for use as a gear steel in advanced aircraft applications, to determine its endurance characteristics, and to compare the results with those for standard VAR and VIM-VAR AISI 9310 gear material. Tests were conducted with spur gears and rolling-contact bars manufactured from VIM-VAR M50NiL and VAR and VIM-VAR AISI 9310. The gear pitch diameter was 8.9 cm (3.5 in.). Gear test conditions were an inlet oil temperature of 320 K (116 F), and outlet oil temperature of 350 K (170 F), a maximum Hertz stress of 1.71 GPa (248 ksi), and a speed of 10,000 rpm. Bench rolling-element fatigue tests were conducted at ambient temperatures with a bar speed of 12,500 rpm and a maximum Hertz stress of 4.83 GPA (700 ksi). The VIM-VAR M50NiL gears had a surface fatigue life that was 4.5 and 11.5 times that for VIM-VAR and VAR AISI 9310 gears, respectively. The surface fatigue life of the VIM-VAR M50NiL rolling-contact bars was 13.2 and 21.6 times that for the VIM-VAR and VAR AISI 9310, respectively. The VIM-VAR M50NiL material was shown to have good resistance to fracture through a fatigue spall and to have fatigue life far superior to that of both VIM-VAR and VAR AISI 9310 gears and rolling-contact bars.

Townsend, Dennis P.↗

Surface fatigue life of carburized and hardened M50NiL and AISI 9310 spur gears and rolling-contact test bars

Spur gear endurance tests and rolling-element surface tests were conducted to investigate vacuum-induction-melted, vacuum-arc-melted (VIM-VAR) M50NiL steel for use as a gear steel in advanced aircraft applications, to determine its endurance characteristics, and to compare the results with those for standard VAR and VIM-VAR AISI 9310 gear material. Tests were conducted with spur gears and rolling-contact bars manufactured from VIM-VAR M50NiL and VAR and VIM-VAR AISI 9310. The gear pitch diameter was 8.9 cm (3.5 in.). Gear test conditions were an inlet oil temperature of 320 K (116 F), and outlet oil temperature of 350 K (170 F), a maximum Hertz stress of 1.71 GPa (248 ksi), and a speed of 10,000 rpm. Bench rolling-element fatigue tests were conducted at ambient temperatures with a bar speed of 12,500 rpm and a maximum Hertz stress of 4.83 GPA (700 ksi). The VIM-VAR M50NiL gears had a surface fatigue life that was 4.5 and 11.5 times that for VIM-VAR and VAR AISI 9310 gears, respectively. The surface fatigue life of the VIM-VAR M50NiL rolling-contact bars was 13.2 and 21.6 times that for the VIM-VAR and VAR AISI 9310, respectively. The VIM-VAR M50NiL material was shown to have good resistance to fracture through a fatigue spall and to have fatigue life far superior to that of both VIM-VAR and VAR AISI 9310 gears and rolling-contact bars.

Townsend, Dennis P.↗

Alternative Fuels Research Laboratory

NASA Glenn has invested over $1.5 million in engineering, and infrastructure upgrades to renovate an existing test facility at the NASA Glenn Research Center (GRC), which is now being used as an Alternative Fuels Laboratory. Facility systems have demonstrated reliability and consistency for continuous and safe operations in Fischer-Tropsch (F-T) synthesis and thermal stability testing. This effort is supported by the NASA Fundamental Aeronautics Subsonic Fixed Wing project. The purpose of this test facility is to conduct bench scale F-T catalyst screening experiments. These experiments require the use of a synthesis gas feedstock, which will enable the investigation of F-T reaction kinetics, product yields and hydrocarbon distributions. Currently the facility has the capability of performing three simultaneous reactor screening tests, along with a fourth fixed-bed reactor for catalyst activation studies. Product gas composition and performance data can be continuously obtained with an automated gas sampling system, which directly connects the reactors to a micro-gas chromatograph (micro GC). Liquid and molten product samples are collected intermittently and are analyzed by injecting as a diluted sample into designated gas chromatograph units. The test facility also has the capability of performing thermal stability experiments of alternative aviation fuels with the use of a Hot Liquid Process Simulator (HLPS) (Ref. 1) in accordance to ASTM D 3241 "Thermal Oxidation Stability of Aviation Fuels" (JFTOT method) (Ref. 2). An Ellipsometer will be used to study fuel fouling thicknesses on heated tubes from the HLPS experiments. A detailed overview of the test facility systems and capabilities are described in this paper.

Surgenor, Angela D.↗

Advanced Brine Processing to Enable U.S. Lithium Independence (CRADA Report)

Current production of LiOH, which is needed to make Li-ion battery cathode active materials, utilizes a multistep process including solar evaporation, precipitation with Na 2 CO 3 and then conversion to LiOH using Ca(OH) 2 . This process requires a large amount of land area for solar evaporation, the right weather conditions, and chemicals for the conversion process that result in NaCl and CaCO 3 waste products. The production of Ca(OH) 2 is very energy intensive and evolves significant quantities of CO 2 . An alternative process flow utilizing direct lithium extraction techniques, followed by a chemical free conversion process can have benefits in reducing the needed land requirements and chemicals for traditional brine processing. There are many potential direct lithium extraction technologies that are currently being developed. The direct lithium extraction process from typical brine sources will produce a LiCl solution with some impurities including typically high concentrations of Na. This brine then needs to be converted to LiOH for use in battery cathode production. Ideally this conversion could occur without the use of additional chemicals. Electrochemistry can do this conversion either via electrolysis or bipolar membrane electrodialysis (BPED) to produce LiOH and HCl in solution. BPED utilized bipolar membranes to split water, which has a reduced potential as compared to splitting water at electrodes into hydrogen and oxygen gas. This reduced potential required results in a significant energy savings for BPED over electrolysis methods. This CRADA project aimed to develop such an integrated process using direct lithium extraction followed by BPED to produce a LiOH solution. That solution can then be crystallized into battery grade LiOH. In particular, Albemarle utilized a direct lithium extraction process to produce a concentrated LiCl solution that could be used for the BPED process. The BPED process was first tested using various LiCl solutions with impurity ions added at bench scale to understand the effects of impurities and determine processing parameters. Then testing was performed using the direct lithium extracted brine at the bench scale before scaling the process up. After the process was scaled up a long duration test was carried out to estimate the lifetime of the membranes, which is key to the economics of the BPED process.

25 ENERGY STORAGE↗

Quiet Clean Short-haul Experimental Engine (QCSEE) under-the-wing engine composite fan blade design report

A total of 38 quiet clean short haul experimental engine under the wing composite fan blades were manufactured for various component tests, process and tooling, checkout, and use in the QCSEE UTW engine. The component tests included frequency characterization, strain distribution, bench fatigue, platform static load, whirligig high cycle fatigue, whirligig low cycle fatigue, whirligig strain distribution, and whirligig over-speed. All tests were successfully completed. All blades planned for use in the engine were subjected to and passed a whirligig proof spin test.

Ravenhall, R.↗

Alternative Fuel Research in Fischer-Tropsch Synthesis

NASA Glenn Research Center has recently constructed an Alternative Fuels Laboratory which is solely being used to perform Fischer-Tropsch (F-T) reactor studies, novel catalyst development and thermal stability experiments. Facility systems have demonstrated reliability and consistency for continuous and safe operations in Fischer-Tropsch synthesis. The purpose of this test facility is to conduct bench scale Fischer-Tropsch (F-T) catalyst screening experiments while focusing on reducing energy inputs, reducing CO2 emissions and increasing product yields within the F-T process. Fischer-Tropsch synthesis is considered a gas to liquid process which reacts syn-gas (a gaseous mixture of hydrogen and carbon monoxide), over the surface of a catalyst material which is then converted into liquids of various hydrocarbon chain length and product distributions1. These hydrocarbons can then be further processed into higher quality liquid fuels such as gasoline and diesel. The experiments performed in this laboratory will enable the investigation of F-T reaction kinetics to focus on newly formulated catalysts, improved process conditions and enhanced catalyst activation methods. Currently the facility has the capability of performing three simultaneous reactor screening tests, along with a fourth fixed-bed reactor used solely for cobalt catalyst activation.

Surgenor, Angela D.↗

Regulatory and Technical Issues Concerning the Detection and Treatment of NDMA-Contaminated Groundwater at NASA WSTF

The National Aeronautics and Space Administration (NASA) White Sands Test Facility (WSTF) was established in 1963 primarily to provide rocket engine testing services for several NASA programs. The groundwater underlying the site has been contaminated as a result of historical operations. Groundwater contaminants include several volatile organic compounds (VOCs) and two semi-volatile compounds: N-nitrosodimethylamine (NDMA) and N-nitrodimethylamine (DMN). This paper discusses some of the technical, analytical, regulatory, and health risk issues associated with the contaminant plume. The plume has moved approximately 2.5 miles downgradient of the facility industrial boundary, with evidence of continued migration. As a result, NASA has proposed a pump and treat system using air strippers and ultraviolet (UV) oxidation to stabilize future movement of the contaminant plume. The system has been designed to treat 1,076 gallons (4,073 liters) per minute, with provisions for future expansion. The UV oxidation process was selected to treat NDMA-contaminated groundwater based on successes at other NDMA-contaminated sites. Bench- and pilot-scale testing of WSTF groundwater confirmed the ability of UV oxidation to destroy NDMA and generated sufficient data to design the proposed full-scale treatment system. NDMA is acutely toxic and is a probable human carcinogen. EPA-recommended health risk criteria for the residential consumption of NDMA/DMN-contaminated groundwater was used to determine that a 1.0 x 10(exp -6) excess cancer risk corresponds to 1.7 parts per trillion (ppt). EPA analytical methods are unable to detect NDMA and DMN in the low ppt range. EPA's current Appendix IX analytical method used to screen for NDMA, Method 8270, can detect NDMA only at levels that are orders of magnitude greater than the recommended health risk level. Additionally, EPA Method 607, the most sensitive EPA approved method, has a detection limit of 150 ppt. This corresponds to an excess cancer risk of 9.0 x 10(exp -5), which exceeds the State of New Mexico's water quality standard of a cancer risk less than 1 x 10(exp -5). The treatment system has been engineered to treat contaminated groundwater to levels significantly below the New Mexico standard. However, the inability of EPA-approved analytical methods to detect NDMA and DMN at low ppt levels, and to provide verification of compliance with the 1 x 10(exp -5) cancer risk, introduces a notable risk to the long-term operation of the system. WSTF has been working with Southwest Research Institute to develop a non-EPA analytical method that can achieve a reporting limit of 1 ppt, which corresponds to an excess cancer risk of 7.6 x 10(exp -7). WSTF is currently developing a proposal to obtain approval from the New Mexico Environment Department (NMED) of this non-EPA method.

Wiebe, D. T.↗