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Cogeneration Technology Alternatives Study (CTAS). Volume 3: Industrial processes

Cogenerating electric power and process heat in single energy conversion systems rather than separately in utility plants and in process boilers is examined in terms of cost savings. The use of various advanced energy conversion systems are examined and compared with each other and with current technology systems for their savings in fuel energy, costs, and emissions in individual plants and on a national level. About fifty industrial processes from the target energy consuming sectors were used as a basis for matching a similar number of energy conversion systems that are considered as candidate which can be made available by the 1985 to 2000 time period. The sectors considered included food, textiles, lumber, paper, chemicals, petroleum, glass, and primary metals. The energy conversion systems included steam and gas turbines, diesels, thermionics, stirling, closed cycle and steam injected gas turbines, and fuel cells. Fuels considered were coal, both coal and petroleum based residual and distillate liquid fuels, and low Btu gas obtained through the on site gasification of coal. An attempt was made to use consistent assumptions and a consistent set of ground rules specified by NASA for determining performance and cost. Data and narrative descriptions of the industrial processes are given.

Palmer, W. B.↗

Cogeneration Technology Alternatives Study (CTAS). Volume 6: Computer data. Part 1: Coal-fired nocogeneration process boiler, section A

Various advanced energy conversion systems (ECS) are compared with each other and with current technology systems for their savings in fuel energy, costs, and emissions in individual plants and on a national level. About fifty industrial processes from the largest energy consuming sectors were used as a basis for matching a similar number of energy conversion systems that are considered as candidates which can be made available by the 1985 to 2000 time period. The sectors considered included food, textiles, lumber, paper, chemicals, petroleum, glass, and primary metals. The energy conversion systems included steam and gas turbines, diesels, thermionics, stirling, closed cycle and steam injected gas turbines, and fuel cells. Fuels considered were coal, both coal and petroleum based residual and distillate liquid fuels, and low Btu gas obtained through the on-site gasification of coal. Computer generated reports of the fuel consumption and savings, capital costs, economics and emissions of the cogeneration energy conversion systems (ECS's) heat and power matched to the individual industrial processes are presented for coal fired process boilers. National fuel and emissions savings are also reported for each ECS assuming it alone is implemented.

Knightly, W. F.↗

Cogeneration Technology Alternatives Study (CTAS). Volume 5: Cogeneration systems results

The use of various advanced energy conversion systems is examined and compared with each other and with current technology systems for savings in fuel energy, costs, and emissions in individual plants and on a national level. About fifty industrial processes from the largest energy consuming sectors were used as a basis for matching a similar number of energy conversion systems that are considered as candidate which can be made available by the 1985 to 2000 time period. The sectors considered included food, textiles, lumber, paper, chemicals, petroleum, glass, and primary metals. The energy conversion systems included steam and gas turbines, diesels, thermionics, stirling, closed cycle and steam injected gas turbines, and fuel cells. Fuels considered were coal, both coal and petroleum based residual and distillate liquid fuels, and low Btu gas obtained through the on site gasification of coal. The methodology and results of matching the cogeneration energy conversion systems to approximately 50 industrial processes are described. Results include fuel energy saved, levelized annual energy cost saved, return on investment, and operational factors relative to the noncogeneration base cases.

Gerlaugh, H. E.↗

Acoustically-induced modulation spectroscopy for ultra-sensitive gas analysis

A new optical technique has been developed for ultra-sensitive attenuation measurements in gaseous media and, in particular, for determination of low levels of smoke emitted from jet engines. It is a variation on direct light transmission where the sample gas density in a cell is modulated acoustically by a speaker. The amplitude variation of the light transmission is proportional to the gas density and is insensitive to window contamination and detector instabilities. Preliminary analysis and experiments indicate that the instrument promises to measure light absorption to less than 1 percent per meter and allow measurment of smoke emissions from 1 to 100 mg/cu m. The technique has been demonstrated through the use of an absorbing gas, viz., 200 ppm of NO2 in N2 which produces 25 percent per meter absorption.

Pitz, R. W.↗

Characterizing Hazardous Gases from NMC811 Materials and Coin Cells with TGA and Tube-Furnace FTIR-MS Evolved-Gas-Analysis

Abuse testing is useful for informing the risks of different battery chemistries but has been limited to larger formats. This paper conducted thermal abuse tests at the smaller coin cell level to determine its relevance in specifying vent gas flammability and toxicity. A nitrogen purge carried the evolved gases into a parallel Fourier-transform infrared spectrometer (FTIR) and a mass spectrometer (MS) downstream of the tube furnace. The experimental system was validated by comparing evolved gas data for single components between the tube furnace system and a thermogravimetric analysis (TGA) instrument. Multiple samples were tested during validation, including CaCO3, electrolyte, delithiated NMC 811 cathode, and lithiated graphite anode. Temperature-resolved gas evolution of HF, CO2, CO, H2, and hydrocarbons from isolated components helped to characterize the emission sources. A previously unreported H2 generation mechanism was found. It was shown that the reduced NMC cathode acts as a catalyst to crack polypropylene-decomposed hydrocarbons into H2 at around 450 degrees C. It was also shown, while studying LiPF6 thermal decomposition, that using the tube furnace with a coin cell casing as the sample holder has some advantages for evolved-gas analysis of environmentally sensitive samples relative to testing in TGA instruments. After validation with single components, a fully charged NMC 811 coin cell was failed in the tube furnace. The measured evolved gases were found to be a combination of the species measured from the single component tests. H2 formation related to the reduced cathode was found to have greater abundance than H2 formed from the anode. Hydrogen fluoride emission factors and diethyl carbonate conversion emission factors assist in understanding the gaseous hazards for larger format cells.

25 ENERGY STORAGE↗

Cogeneration Technology Alternatives Study (CTAS). Volume 1: Summary report

Large savings can be made in industry by cogenerating electric power and process heat in single energy conversion systems rather than separately in utility plants and in process boilers. About fifty industrial processes from the largest energy consuming sectors were used as a basis for matching a similar number of energy conversion systems that are considered as candidates which can be made available by the 1985 to 2000 time period. The sectors considered included food, textiles, lumber, paper, chemicals, petroleum, glass, and primary metals. The energy conversion systems included steam and gas turbines, diesels, thermionics, stirling, closed-cycle and steam injected gas turbines, and fuel cells. Fuels considered were coal, both coal and petroleum-based residual and distillate liquid fuels, and low Btu gas obtained through the on-site gasification of coal. An attempt was made to use consistent assumptions and a consistent set of ground rules for determining performance and cost in individual plants and on a national level. It was found that: (1) atmospheric and pressurized fluidized bed steam turbine systems were the most attractive of the direct coal-fired systems; and (2) open-cycle gas turbines with heat recovery steam generators and combined-cycles with NO(x) emission reduction and moderately increased firing temperatures were the most attractive of the coal-derived liquid-fired systems.

Gerlaugh, H. E.↗

Cogeneration Technology Alternatives Study (CTAS). Volume 4: Energy conversion systems

Industrial processes from the largest energy consuming sectors were used as a basis for matching a similar number of energy conversion systems that are considered as candidate which can be made available by the 1985 to 2000 time period. The sectors considered included food, textiles, lumber, paper, chemicals, petroleum, glass, and primary metals. The energy conversion systems included steam and gas turbines, diesels, thermionics, stirling, closed-cycle and steam injected gas turbines, and fuel cells. Fuels considered were coal, both coal and petroleum-based residual and distillate liquid fuels, and low Btu gas obtained through the on-site gasification of coal. An attempt was made to use consistent assumptions and a consistent set of ground rules specified by NASA for determining performance and cost. The advanced and commercially available cogeneration energy conversion systems studied in CTAS are fined together with their performance, capital costs, and the research and developments required to bring them to this level of performance.

Brown, D. H.↗

Physical model and experimental validation of a high temperature proton exchange membrane electrochemical hydrogen pump cell for efficient single-stage extraction of low concentration hydrogen gas

There is interest in valorization of existing natural gas infrastructure to facilitate the co-transportation of hydrogen via blending of hydrogen gas initially at limited concentrations of 1–20 vol% H2 and to subsequently extract hydrogen at fuel cell quality standards (SAE J2719/ISO14687-2). High temperature proton exchange membrane electrochemical hydrogen pump (HT-PEM EHP) based on phosphoric acid doped polybenzimidazole (PA-PBI) exhibits good performance at elevated temperatures (>120 °C), which provides desirable tolerance to non-methane natural gas constituents that are problematic for lower temperature based EHP. To better understand the suitability of the HT-PEM EHP for such gas separation processes, a two-dimensional model of EHP based on PA-PBI was developed. The model is validated for several relevant operating conditions and across cells with differing amounts of phosphoric acid content in the electrodes. Operando micro x-ray computed tomography (CT) imaging of an HT-PEM EHP was used to further validate physical parameters and assumptions of the model. The impacts of pressure, relative humidity of the anode feed, and concentration of feed gases on separation performance are investigated. This study shows that a specific energy of separation of 5.1 kWh/kg H2 at a hydrogen recovery factor (HRF) of 50 vol% can be achieved in a single stage with the EHP, producing fuel cell quality hydrogen purity of 99.99 vol% H2 from a 2 vol% H2/CH4 feed blend, while pressurizing the product H2 at a pressure ratio of 1.3 relative to feed pressure.

Stansberry, John M↗

Investigations of Physical Processes in Microgravity Relevant to Space Electrochemical Power Systems

NASA has performed physical science microgravity flight experiments in the areas of combustion science, fluid physics, material science and fundamental physics research on the International Space Station (ISS) since 2001. The orbital conditions on the ISS provide an environment where gravity driven phenomena, such as buoyant convection, are nearly negligible. Gravity strongly affects fluid behavior by creating forces that drive motion, shape phase boundaries and compress gases. The need for a better understanding of fluid physics has created a vigorous, multidisciplinary research community whose ongoing vitality is marked by the continuous emergence of new fields in both basic and applied science. In particular, the low-gravity environment offers a unique opportunity for the study of fluid physics and transport phenomena that are very relevant to management of fluid - gas separations in fuel cell and electrolysis systems. Experiments conducted in space have yielded rich results. These results provided valuable insights into fundamental fluid and gas phase behavior that apply to space environments and could not be observed in Earth-based labs. As an example, recent capillary flow results have discovered both an unexpected sensitivity to symmetric geometries associated with fluid container shape, and identified key regime maps for design of corner or wedge-shaped passive gas-liquid phase separators. In this presentation we will also briefly review some of physical science related to flight experiments, such as boiling, that have applicability to electrochemical systems, along with ground-based (drop tower, low gravity aircraft) microgravity electrochemical research. These same buoyancy and interfacial phenomena effects will apply to electrochemical power and energy storage systems that perform two-phase separation, such as water-oxygen separation in life support electrolysis, and primary space power generation devices such as passive primary fuel cell.

energy storage↗

Trimethoxymethane: A Fuel For Direct-Oxidation Fuel Cells

Trimethoxymethane (TMM) identified as high-energy fuel for direct-oxidation fuel cells. Synthesized from natural gas (methane) and handled easily because non-toxic, low-vapor-pressure liquid. Data obtained from both half-cell and full-cell tests indicate that TMM oxidized at very high rates. Considered excellent candidate for use in direct-oxidation fuel cells in vehicles and portable power supplies

Olah, George A.↗

Water outlet control mechanism for fuel cell system operation in variable gravity environments

A self-regulated water separator provides centrifugal separation of fuel cell product water from oxidant gas. The system uses the flow energy of the fuel cell's two-phase water and oxidant flow stream and a regulated ejector or other reactant circulation pump providing the two-phase fluid flow. The system further uses a means of controlling the water outlet flow rate away from the water separator that uses both the ejector's or reactant pump's supply pressure and a compressibility sensor to provide overall control of separated water flow either back to the separator or away from the separator.

Vasquez, Arturo↗

High Pressure Vent Line Mishap: Investigation Summary

During testing on the E-1 Test Stand, the High Pressure (HP) Liquid Hydrogen (LH) vent line was displaced off its supports, damaging the expansion joints (EJ), piping, and pipe supports of the line. The damage to the vent line is believed to have occurred during Cell 3 testing on Thursday, September 21, during the first test of the day. The fuel systems being used for Cell 3 testing are connected to the LP and HP LH Vent systems and are being used in Liquid Natural Gas (LNG) service. The Cell 3 interface bleed valve that discharges to the HP LH Vent system was inadvertently left at 100% open during the chill-in process for longer than the typical amount of time. Since this valve is usually at a lower set point or intermittently closed during the chill-in process, more than the typical amount of LNG flowed into the vent line as pre-test procedures continued as normal. The open bleed valve was noticed before test preparations were completed and prior to refilling of the HP LH Tank before test. The test sequence was started, run, and shutdown normally. Video of the flare stack showed an atypical discharge of liquid at the flare stack exit. Pressure downstream of the Cell 3 interface bleed valve (a valve connected to the southernmost part of the vent system) spiked to a higher-than-normal level. No evidence of damage was captured at the time of the event. The system was used in a typical fashion after the event and for 4 subsequent tests on Thursday and Friday, before the damage was observed. A drive-by inspection of the flare stack was performed on Friday (September 22nd) morning before sunrise and before test activities began, but no damage of the vent line was observed at that time. No abnormal system behavior was observed during testing on Friday. The damage was discovered and reported to NASA Test Operations on Monday, initiating the Incident Response Team. The Mishap appointment letter was issued September 27th to formally initiate the Mishap Investigation.

LNG↗

Oil-Free Enabling Technology: Gas Foil Bearings

NASA has developed and commercialized high temperature coatings and bearings for extreme conditions. These technologies are now under consideration by industry for automotive applications such as turbochargers, fuel cell compressors and exhaust gas path mechanism applications. In this presentation, a review of Oil-Free technologies and their current state-of-development is introduced. Key NASA contributions to the field as documented by patents, research papers and technology demonstrations is also presented.

lubrication↗

Stark cell optoacoustic detection of constituent gases in sample

An optoacoustic detector for gas analysis is implemented with Stark effect cell modulation for switching a beam in and out of coincidence with a spectral line of a constituent gas in order to eliminate the heating effect of laser energy in the cell as a source of background noise. By using a multiline laser, and linearly sweeping the DC bias voltage while exciting the cell with a multiline laser, it is possible to obtain a spectrum from which to determine the combinations of excited constituents and determine their concentrations in parts per million.

Margolis, J. S.↗