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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

Comparative experimental study of heat transfer processes in accumulation energy recovery exchangers

In this study, an experimental comparison between three different energy accumulating ceramic heat exchangers for energy recovery in ventilation systems was presented. The units were selected to represent three different approaches on the energy recovery process: honeycomb structure with more accumulation mass (more energy can be stored in one unit)- Unit 1.1, honeycomb structure with lower accumulation mass- Unit 1.2, and a rectangular structure with expanded heat transfer surface- Unit 1.3. The achieved results are useful for the future application of such units in ventilation systems. It was established that all evaluated units demonstrated an acceptable effectiveness of thermal energy recovery from the exhaust air. Their average energy recovery efficiency ranged between 70 % and 80 %, aligning with expected performance benchmarks for regenerative heat exchangers employed in contemporary mechanical ventilation systems. It was also established that the factor which has the highest impact on thermal effectiveness is the heat transfer surface available in the tested heat exchangers. Units with the highest number of channels (i.e., with the highest amount of single channel walls, which can be used for heat transfer) achieve the highest thermal effectiveness. However, higher thermal effectiveness can negatively affect the ventilation potential of the units. Unit 1.3, which was characterized by the highest thermal efficiency, was also characterized by the lowest achievable flow rate. It was also found that the important technical aspect that should be taken into account when analyzing accumulation energy recovery units is also the fluctuation of the supply air temperature. The ability to ensure minimal temperature fluctuations is a significant operational advantage, as it ensures a higher level of safety at lower outside temperatures.

Energy recovery↗

Effects of multiple simultaneous faults on characteristic fault detection features of a heat pump in cooling mode

Faults in air-cooled vapor compression air-conditioning systems are known to reduce performance, including efficiency, capacity, and lifespan. Their effects have been studied, and fault detection and diagnostic (FDD) methods have been developed as tools for field technicians to install or repair systems, or for monitoring to alert operators to the fault’s presence. Most of this work has focused on faults that occur singly. It is likely that in some systems, multiple faults occur simultaneously, but it is uncertain what effects this may have on diagnostics. Here, this paper describes a laboratory study of a split system air source heat pump in which combinations of two, three, and four simultaneous faults occur. The study includes all combinations of: improper evaporator airflow; overcharge or undercharge of refrigerant; liquid line restrictions; and non-condensable gas in the refrigerant, each at multiple fault intensities. Fault features – those characteristics that can be determined from measurements, for use in diagnostics – are analyzed, and the key fault features are presented. A robust existing method for determining refrigerant charge, the virtual refrigerant charge sensor (VRC) is tested using the multiple fault data, in order to understand how its performance is impacted by the combined faults. The VRC performs well, typically able to correctly determine whether a system is undercharged or overcharged, but the magnitude estimates are impacted. The results suggest that simple subcooling-based methods of charging a system are likely to provide unsatisfactory results when other faults are present.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Robust and Spectrally Selective Aerogels for Solar Receivers

The development of next generation concentrated solar thermal (CST) plants requires solar receivers to reach high temperatures (> 600°C) while minimizing costs. Efficiently generating such high temperatures using a line-focusing collector and an air-stable receiver has the potential to change the current CSP paradigm because it would: (1) result in large improvements in system-level efficiency of line-focusing systems by enabling the use of high-efficiency supercritical CO 2 power cycles; (2) decrease the LCOE of line-focusing systems to meet SETO 2030 goals; (3) maintain performance over the lifetime of the CSP plant by avoiding issues related to breakdown of vacuum. The use of aerogels as transparent insulating materials (TIMs) in solar thermal receivers has the potential to enable such improvements. Specifically, aerogels can be placed in front of a black (or partially selective) high-temperature absorber to allow sunlight to transmit to the absorber but block heat from escaping. These materials can improve the efficiency and simplify the complexity of thermal transport systems by enabling operation at moderate or no vacuum levels. These potential benefits have been explicitly identified by SETO as ‘high impact’. The use of mesoporous silica as a TIM has already led to large improvements in solar collection efficiency. Nevertheless, these materials inherently lose structural integrity and the ability to suppress radiation losses at high temperatures. Here, we address these challenges by leveraging 1-cycle atomic layer deposition of aluminum oxide onto a silica aerogel to form a thermally stable interfacial layer that is transparent to sunlight but broadly absorbs in the mid-infrared. This interfacial absorption results in a two-fold reduction in measured heat losses from an absorber at 700°C and solar thermal efficiency of 81% at 700°C under 60 Suns, based on measurements of heat loss and solar transmittance. Extended-duration heat treatment reveals that the multicomponent aerogel is stable at high temperatures relative to a silica aerogel. Furthermore, we experimentally demonstrate the concept of using infrared plasmon resonances to selectively enhance the thermal absorption coefficient of TIMs in order to strongly suppress thermal radiative losses at high temperatures. We term this mechanism plasmon-enhanced greenhouse selectivity (PEGS). Unlike silica aerogels, where much of the IR absorption is lost at high temperatures, local surface plasmon resonances (LSPRs) in doped oxide nanoparticles overlap a significant portion of the blackbody spectrum and are maintained at high temperatures. Overall, this work paves the way for next-generation solar thermal energy using thermally robust transparent insulating materials.

14 SOLAR ENERGY↗

Robust and Spectrally Selective Aerogels for Solar Receivers (Final Technical Report)

The development of next generation concentrated solar thermal (CST) plants requires solar receivers to reach high temperatures (> 600°C) while minimizing costs. Efficiently generating such high temperatures using a line-focusing collector and an air-stable receiver has the potential to change the current CSP paradigm because it would: (1) result in large improvements in system-level efficiency of line-focusing systems by enabling the use of high-efficiency supercritical CO2 power cycles; (2) decrease the LCOE of line-focusing systems to meet SETO 2030 goals; (3) maintain performance over the lifetime of the CSP plant by avoiding issues related to breakdown of vacuum. The use of aerogels as transparent insulating materials (TIMs) in solar thermal receivers has the potential to enable such improvements. Specifically, aerogels can be placed in front of a black (or partially selective) high-temperature absorber to allow sunlight to transmit to the absorber but block heat from escaping. These materials can improve the efficiency and simplify the complexity of thermal transport systems by enabling operation at moderate or no vacuum levels. These potential benefits have been explicitly identified by SETO as ‘high impact’. The use of mesoporous silica as a TIM has already led to large improvements in solar collection efficiency. Nevertheless, these materials inherently lose structural integrity and the ability to suppress radiation losses at high temperatures. Here, we address these challenges by leveraging 1-cycle atomic layer deposition of aluminum oxide onto a silica aerogel to form a thermally stable interfacial layer that is transparent to sunlight but broadly absorbs in the mid-infrared. This interfacial absorption results in a two-fold reduction in measured heat losses from an absorber at 700°C and solar thermal efficiency of 81% at 700°C under 60 Suns, based on measurements of heat loss and solar transmittance. Extended-duration heat treatment reveals that the multicomponent aerogel is stable at high temperatures relative to a silica aerogel. Furthermore, we experimentally demonstrate the concept of using infrared plasmon resonances to selectively enhance the thermal absorption coefficient of TIMs in order to strongly suppress thermal radiative losses at high temperatures. We term this mechanism plasmon-enhanced greenhouse selectivity (PEGS). Unlike silica aerogels, where much of the IR absorption is lost at high temperatures, local surface plasmon resonances (LSPRs) in doped oxide nanoparticles overlap a significant portion of the blackbody spectrum and are maintained at high temperatures. Overall, this work paves the way for next-generation solar thermal energy using thermally robust transparent insulating materials.

14 SOLAR ENERGY↗

Different Damp-Heat-Induced Series Resistance Degradation Behaviors in Fielded Crystalline Silicon Photovoltaic Modules Due to Difference in Bill of Materials

This case study investigates mono-crystalline silicon modules from underperforming portions of a utility-scale photovoltaic power plant. Field-collected I-V curves and electroluminescence imaging suggested that increased series resistance was a primary factor driving module degradation. Selected modules were removed from the field for further analysis, including incremental damp heat accelerated testing, which confirmed a progression in series resistance degradation. Two distinct cell degradation behaviors became apparent during the investigation. Cross-sectional scanning electron microscopy (with elemental analysis) and scanning spreading resistance microscopy identified key differences between the two degradation mechanisms, primarily grid finger width and contact resistance. Additionally, the study highlights the reliability implications of retest requirements in International Electrotechnical Commission 61215 for material changes and how they may have mitigated the degradation observed at this site.

14 SOLAR ENERGY↗

Numerical Study of Solar Receiver Tube With Modified Surface Roughness for Enhanced and Selective Absorptivity in Concentrated Solar Power Tower

Abstract Concentrated solar power (CSP) is a reliable renewable energy source that is progressively lowering its cost of energy. However, the heat loss due to reflected and emitted radiation hinders the maximum achievable thermal efficiency for solar receiver tubes on the solar tower. Current solar selective coatings cannot withstand the high temperatures that come with state-of-the-art CSP towers often needing to be recoated soon after initial operation. We intend to use Inconel 718 with different additive manufacturing (AM) practices to construct surfaces that allow for more light-trapping to occur. By adjusting printing parameters, we can tailor a surface to allow for more absorption while diminishing emitted radiation heat loss. By using COMSOL Multiphysics, we can generate these theoretical surfaces to emulate a printed surface, and using the coupled Multiphysics we can simulate how the surface dictates radiation properties. Our results show that by having a rougher surface we can enhance the absorptivity of Inconel 718 (IN718) by 38.8%. We expect this work to transform how solar absorber tubes are manufactured without using selective coatings and supplement the US Department of Energy (DOE) 2030 SunShot Initiative.

14 SOLAR ENERGY↗

Highly Ordered Eutectic Mesostructures via Template‐Directed Solidification within Thermally Engineered Templates

Template-directed self-assembly of solidifying eutectics results in emergence of unique microstructures due to diffusion constraints and thermal gradients imposed by the template. Here, the importance of selecting the template material based on its conductivity to control heat transfer between the template and the solidifying eutectic, and thus the thermal gradients near the solidification front, is demonstrated. Simulations elucidate the relationship between the thermal properties of the eutectic and template and the resultant microstructure. The overarching finding is that templates with low thermal conductivities are generally advantageous for forming highly organized microstructures. When electrochemically porosified silicon pillars (thermal conductivity < 0.3 Wm −1 K −1 ) are used as the template into which an AgCl-KCl eutectic is solidified, 99% of the unit cells in the solidified structure exhibit the same pattern. In contrast, when higher thermal conductivity crystalline silicon pillars (≈100 Wm −1 K −1 ) are utilized, the expected pattern is only present in 50% of the unit cells. The thermally engineered template results in mesostructures with tunable optical properties and reflectances nearly identical to the simulated reflectances of perfect structures, indicating highly ordered patterns are formed over large areas. This work highlights the importance of controlling heat flows in template-directed self-assembly of eutectics.

36 MATERIALS SCIENCE↗

Low-temperature selective laser sintering 3D printing of PEEK-Nylon blends: Impact of thermal post-processing on mechanical properties and thermal stability

Herein, a high-performance polymer (HPP) (polyether ether ketone, PEEK) blended with a commercial low-temperature polymer (polyamide 12, PA-12) was fabricated using a low-temperature selective laser sintering (SLS) 3D printer. Different post-processing heat treatments were implemented after fabrication to tune the thermal and mechanical properties of printed blends. The specific mechanical modulus of the blend was increased up to 79% in comparison to printed PA-12 samples with heat treatment. Additionally, the thermal resistance of the treated blends greatly exceeded the properties observed using PA-12 alone. This research proposes a methodology to fabricate and engineer HPP using desktop SLS printers through a secondary lower melting temperature material and heat treatments.

36 MATERIALS SCIENCE↗

Additively manufactured heat exchangers: a review on opportunities and challenges

Heat Exchangers (HXs) are crucial engineering components for thermal management. The broad range of applications and the current limits of traditional manufacturing techniques has directed designers and researchers to utilize additive manufacturing (AM) technologies to open a new chapter in HXs design and development. AM has created a world of opportunity to redesign HXs in pioneering forms, shapes, and sizes. In other words, AM technologies provides significant opportunities to increase surface area to volume ratio in heat transfer devices. On the other hand, there are certain challenges to overcome in order to fully grasp the benefits of AM technologies. This thorough review study is different from other published review as it intends to highlight the challenges and opportunities in design and manufacturing of HXs. In addition, part of this study is dedicated to investigate the experimental characterization of additively manufactured HXs. Furthermore, the significant details associated with experimental characterization are normally overlooked in review studies.

42 ENGINEERING↗

Effect of Pressure and Temperature on Carbon Dioxide Reduction at a Plasmonically Active Silver Cathode

Here, carbon dioxide reduction at a plasmonically active silver cathode was investigated by varying the pressure and temperature at multiple applied potentials under both dark and illuminated conditions to understand the mechanism of selectivity changes driven by plasmon-enhanced electrochemical conversion. Carbon dioxide partial pressures (P Co 2 ) from 0.2 to 1 atm were studied during linear sweep voltammetry and chronoamperometry at -0.7, -0.9, and -1.1 V RHE . At a given applied overpotential the total current density increased with increasing P Co 2 in both the dark and the light, but there were significant differences in the Tafel behavior between dark and illuminated conditions. The reduction of CO 2 to carbon monoxide (CO) was found to have first-order behavior with respect to P Co 2 at all applied potentials in both the dark and the light, likely indicating no change in the rate-determining step upon illumination. Activity for the hydrogen (H 2 ) evolution reaction decreased with increasing P Co 2 at slightly different rates in the dark and the light at each applied potential, making it unclear if light is influencing CO or H 2 intermediate adsorbate coverage. Both formate and methanol production showed no dependence on P Co 2 under any conditions, but the true reaction orders may be masked by the much higher activity for CO and H 2 at the silver cathode. The investigation of product distribution with temperature at 14, 22, and 32°C at -0.7, -0.9, and -1.1 V RHE in both the dark and the light demonstrated that the selectivity changes observed upon illumination are not caused by local heating of the cathode surface.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Microstructural evolution of rapidly solidified hypoeutectic Al 10Cu alloy during non-isothermal annealing transients induced by nano-second laser pulses

The evolution of characteristic nonequilibrium features presenting in morphologically distinct regions of rapid solidification (RS) microstructures in a hypoeutectic Al—10Cu (atomic %) in response to non-isothermal annealing transients has been studied by transmission electron microscopy (TEM). The capabilities of the Movie-Mode Dynamic TEM (MM-DTEM) instrument were used to expose select regions of the RS microstructure to sequences of rapid heating and cooling transients induced by nanosecond laser pulses while permitting in-situ observation. Partial melting, microstructural scale coarsening, morphological changes of the nonequilibrium features in the multi-phase RS microstructure, and solid-state phase transformation were observed. Heterogeneous nucleation of nanoscale θ-Al 2 Cu phase involved metastable supersaturated α-Al and the θ'-Al 2 Cu phases, establishing different sets of orientation relationships for the stable θ-Al 2 Cu and α-Al phases. Replacement of banded morphology grains that formed under conditions driven farthest from equilibrium by an equiaxed nanocrystalline structure comprised of α-Al phase, the primary solidification product, and an intergranular network of Al 2 Cu crystals has been attributed to local remelting. Here the experimental approach explored, permitted discovery of mechanistic details of location-specific transformation pathways activated in the multi-phase RS microstructure of hypoeutectic Al—Cu during subsequent nonisothermal transients.

36 MATERIALS SCIENCE↗

Large area transparent refractory aerogels with high solar thermal performance

Application of transparent silica aerogels in low-temperature solar thermal systems has led to major improvements in performance. In high temperature concentrating solar thermal (CST) systems, aerogels have yet to demonstrate the necessary scalability, durability, and performance to support their widespread deployment. Here, large-area transparent refractory aerogel tiles are synthesized and shown to achieve a record-high receiver figure-of-merit (FOM) at high temperatures. The work leverages a scaled-up process for sol–gel synthesis to control the density of the aerogels for improved solar transmittance and adapts a previous atomic layer deposition (ALD) technique with the aid of predictive reaction-transport modeling. After aging for 10 days at 700 °C, the large-area tiles exhibit a solar-weighted transmittance of 95.6 % and a thermal emittance of 0.31, corresponding to a FOM of 80 % at 100 suns and 700 °C. The observed sintering rates at 700 °C are comparably low to earlier one-inch aerogels, suggesting long-term stability under relevant operating conditions. Furthermore, the study indicates that refractory aerogels are scalable materials for efficient photothermal conversion at high temperatures.

Aerogels↗

Unveiling the Thermal Stability of Sodium Ion Pouch Cells Using Accelerating Rate Calorimetry

The thermal stability of ~420 mAh Na 0.97 Ca 0.03 [Mn 0.39 Fe 0.31 Ni 0.22 Zn 0.08 ]O 2 (NCMFNZO)/hard carbon (HC) pouch cells was investigated using accelerating rate calorimetry (ARC) at elevated temperatures. 1 m NaPF 6 in propylene carbonate (PC):ethyl methyl carbonate (EMC) (1:1 by volume) was used as a control electrolyte. Adding 2 wt% fluoroethylene carbonate to the electrolyte improves the cell's thermal stability by decreasing the self-heating rate (SHR) across the whole testing temperature range. The selected states-of-charge (SoC), including 70%, 84%, and 100%, exhibit minimal impact on the exothermic behavior, except for a slight decrease in SHR after ~275 °C at 70% SoC. When compared to traditional lithium-ion batteries operating at 100% SoC, NCMFNZO/HC pouch cells demonstrate inferior thermal stability compared to LiFePO 4 (LFP)/graphite pouch cells, displaying a higher SHR from 220 to 300 °C. LiNi 0.8 Mn 0.1 Co 0.1 O 2 /graphite + SiO x pouch cells exhibit the worst safety performance, with an early onset temperature of ~100 °C and the highest SHR across the entire temperature range. These results offer a direct comparison of the impact of SoC and electrolyte compositions on the thermal stability of SIBs at elevated temperatures, highlighting that there is still room for improvement in SIBs safety performance compared to LFP/graphite chemistry.

42 ENGINEERING↗

SAM Code Development for Transient Safety Analyses of Fluoride-salt-cooled High-temperature Reactors

The System Analysis Module (SAM) is under development at Argonne National Laboratory as a modern system-level modeling and simulation tool for advanced non-light water reactor safety analyses. It utilizes the object-oriented application framework MOOSE to leverage the modern software environment and advanced numerical methods. The capabilities of SAM are being extended to enable the transient modeling, analysis, and design of various advanced nuclear reactor systems. The molten-salt-cooled pebble-bed reactor, or pebble-bed FHR (PB-FHR) is a promising candidate among advanced nuclear reactor concepts with its improved passive safety characteristics and high thermal efficiency. To support the development and utilization of the SAM code for PB-FHR safety analysis, activities on SAM code enhancements, reference plant model developments, and code validations have been performed in the past a few years to support near-term industry and NRC needs. This report summarizes recent progress under DOE-NE’s Nuclear Energy Advanced Modeling and Simulation program in SAM code development and demonstration for transient safety analysis of Fluoride-salt-cooled High-temperature Reactors. SAM capabilities has been significantly enhanced over the years to add FHR specific modeling features, including salt freezing and thawing, spherical core channel and pebble bed core modeling, solid-fluid thermal radiation, tritium transport and general species transport in fluids and solids, and the general code enhancements on solver schemes of point kinetics module and reactivity feedback models. A reference PB-FHR model is developed, based on publicly available information from Kairos Power’s generic FHR design and the University of California, Berkeley (UCB) Mk1 design. A reference reactor model is foundational to the methodologies employed by NRC to verify the adequacy of computer codes and evaluation models. The reference FHR model was utilized for a number of selected FHR design basis accidents, including station blackout, loss of heat sink, loss of flow, transient overpower, and overcooling events.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

In-situ resource utilization-derived water purification and hydrogen and oxygen production

This disclosure provides an integrated system and method for producing purified water, hydrogen, and oxygen from contaminated water. The contaminated water may be derived from regolith-based resources on the moon, Mars, near-Earth asteroids, or other destination in outer space. The integrated system and method utilize a cold trap to receive the contaminated water in a vapor phase and selectively freeze out water from one or more volatiles. A heat source increases temperature in the cold trap to vaporize the frozen contaminated water to produce a gas stream of water vapor and volatiles. A chemical scrubber may remove one or more volatiles. The integrated system and method utilize ionomer membrane technology to separate the water vapor from remaining volatiles. The water vapor is delivered for crew use or delivered to an electrolyzer to produce hydrogen and oxygen.

Finger, Barry Wynns↗

X-ray free electron laser heating of water and gold at high static pressure

Probing of reactive materials such as H 2 O ices and fluids at the high pressures and temperatures of planetary interiors is limited by unwanted chemical reactions and confinement failure. Faster experiments can mitigate such issues, but the common approach of adiabatic compression limits the conditions achieved. This study demonstrates a fast experimental strategy for the creation and probing of selected extreme states using static compression coupled with ultrafast X-ray laser heating. Indirect X-ray heating of H 2 O through the use of a gold absorber is evidenced by sample melting inferred from textural changes in the H 2 O diffraction lines and inter-dispersion of gold and H 2 O melts. Coupled with numerical analysis of femtosecond energy absorption, thermal equilibration, and heat transfer, all evidence indicates that temperatures in excess of an electron volt have been reached in the H 2 O at high pressure. Even after repeated heating, samples stayed chemically unchanged from the starting material.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Improving energy efficiency while reducing anthropogenic heat from buildings: how retrofits influence the building stock and urban microclimate in Los Angeles

Anthropogenic heat (AH) from buildings contributes to urban overheating, especially during heat waves, yet building retrofit studies usually evaluate energy savings without assessing impacts on AH. This study quantifies how common building retrofit measures affect both building energy use and AH emissions across the City of Los Angeles. Using a bottom-up urban building energy modeling framework coupled with high-resolution local weather from the Weather Research and Forecasting model with Building Effect Parameterization (WRF-BEP), we evaluate eleven retrofit measures and two multi-measure retrofit packages. HVAC and LED lighting retrofits provide the largest city-wide annual site energy savings, while roof coating is most effective for reducing AH. A package optimized for energy savings reduces summer site energy use by about 32% (2.3 TWh), while a package incorporating AH-focused measures reduces the total AH by over 50% (137 PJ) with minimal difference in energy savings. The AH-aware package produces substantially greater urban cooling, reducing mean near-surface air temperature by up to 0.62 ℃ and peak temperature by up to 3.79 ℃. These results show that retrofit strategies selected only for energy savings may overlook major opportunities for urban heat mitigation. The study provides a framework for integrating AH into building retrofit planning and urban heat resilience policy.

Anthropogenic heat↗

Evaluation of Additively Manufactured Monolithic SiC and SiC-Matrix Ceramic Matrix Composites for Concentrating Solar Receiver Applications - Fabrication and Testing of Receiver Design Feature Specimens in a Simulating Lab Test via Laser Heating

Increasing operating temperatures of solar receivers is paramount to the efficiency of concentrated solar thermal (CST) and solar power (CSP) systems. Owing to its high temperature stability combined with excellent thermal and optical properties, SiC has been the material of choice for application in high-temperature solar receivers. We report the results of our study of the effective heat transfer characteristics of several candidate SiC structure motifs, or feature geometries, which are fabricated via additive manufacturing. The SiC structure motifs studied include different permutations of three-dimensional periodic lattices and defined shapes. A solar-thermal simulating laboratory test setup is constructed using a 4kW CO2 laser system with beam shaping optics to apply concurrent radiative heating power on one face of 2”-diameter cylindrical feature specimens, representing the structure motifs of interest for receiver element design, while flowing through the sample as heat transfer fluid. Using the test setup, simulative test conditions representative of a concentrated solar flux of up to ~2000 suns could be achieved in the lab tests under varying air flow through the test structure. A simple 1D numerical analysis scheme is developed to extract an effective or compound heat transfer coefficient representative of the test structure under steady-state heat flow conditions. The test results and their use to guide the selection and optimization of SiC material and structure motifs for the receiver element design fabrication are discussed.

14 SOLAR ENERGY↗