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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 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Performance Evaluation of a Single-Phase Grid-Forming Inverter Through Hardware Experiments

This study conducts hardware experiments to assess the performance of a commercial single-phase grid-forming (GFM) inverter using a purely hardware-based approach. We adhere to a testing protocol for the GFM inverter and enhance it by exploring the transient performance of GFM inverters across various grid dynamic events. Quantifiable performance metrics are established for each testing scenario to gain insights into the performance of the single-phase GFM inverters. Based on the comprehensive tests, the following observations are summarized: 1) The performance of the single-phase GFM inverter is satisfactory, and it is capable of being the islanding master for residence homes when the main grid is gone. 2) For frequency response, the inverter is able to stay connected but cannot inject the needed active power to support the grid. This may be improved by the manufacturer by using droop control. 3) The GFM inverter exhibits harmful transients in voltage and frequency during islanding operation, which can be enhanced by maintaining the same operating points before and after the breaker is open.

black start↗
NASA NTRS1989

Psychology of computer use: IX. A menu of self-administered microcomputer-based neurotoxicology tests

This study examined the feasibility of repeated self-administration of a newly developed battery of mental acuity tests which may have application in screening for fitness-for-duty or for persons who may be exposed to environmental stress, toxic agents, or disease. 16 subjects self-administered 18 microcomputer-based tests (13 new, 5 "core"), without proctors, over 10 sessions. The hardware performed well throughout the study and the tests appeared to be easily self-administered. Stabilities and reliabilities of the tests from the "core" battery were comparable to those obtained previously under more controlled experimental conditions. Eight of the new tests exceeded minimum criteria for metric and practical requirements and can be recommended as additions to the menu. Although the average retest reliability was high, cross-correlations between tests were low, implying factorial diversity. The menu can be used to form batteries with flexible total testing time which are likely to tap different mental processes and functions.

NASA Discipline Neuroscience↗
DOE OSTI2024

Performance Evaluation of a Single-Phase Grid-Forming Inverter Through Hardware Experiments

This study conducts hardware experiments to assess the performance of a commercial single-phase grid-forming (GFM) inverter using a purely hardware-based approach. We adhere to a testing protocol for the GFM inverter and enhance it by exploring the transient performance of GFM inverters across various grid dynamic events. Quantifiable performance metrics are established for each testing scenario to gain insights into the performance of the single-phase GFM inverters. Based on the comprehensive tests, the following observations are summarized: 1) The performance of the single-phase GFM inverter is satisfactory, and it is capable of being the islanding master for residence homes when the main grid is gone. 2) For frequency response, the inverter is able to stay connected but cannot inject the needed active power to support the grid. This may be improved by the manufacturer by using droop control. 3) The GFM inverter exhibits harmful transients in voltage and frequency during islanding operation, which can be enhanced by maintaining the same operating points before and after the breaker is open.

dynamic performance↗
NASA NTRS2011

NASA Occupant Protection Standards Development

Current National Aeronautics and Space Administration (NASA) occupant protection standards and requirements are based on extrapolations of biodynamic models, which were based on human tests performed under pre-Space Shuttle human flight programs where the occupants were in different suit and seat configurations than is expected for the Multi Purpose Crew Vehicle (MPCV) and Commercial Crew programs. As a result, there is limited statistical validity to the occupant protection standards. Furthermore, the current standards and requirements have not been validated in relevant spaceflight suit, seat configurations or loading conditions. The objectives of this study were to develop new standards and requirements for occupant protection and rigorously validate these new standards with sub-injurious human testing. To accomplish these objectives we began by determining which critical injuries NASA would like to protect for. We then defined the anthropomorphic test device (ATD) and the associated injury metrics of interest. Finally, we conducted a literature review of available data for the Test Device for Human Occupant Restraint New Technology (THOR-NT) ATD to determine injury assessment reference values (IARV) to serve as a baseline for further development. To better understand NASA s environment, we propose conducting sub-injurious human testing in spaceflight seat and suit configurations with spaceflight dynamic loads, with a sufficiently high number of subjects to validate no injury during nominal landing loads. In addition to validate nominal loads, the THOR-NT ATD will be tested in the same conditions as the human volunteers, allowing correlation between human and ATD responses covering the Orion nominal landing environment and commercial vehicle expected nominal environments. All testing will be conducted without the suit and with the suit to ascertain the contribution of the suit to human and ATD responses. In addition to the testing campaign proposed, additional data analysis is proposed to mine existing human injury and response data from other sources, including military volunteer testing, automotive Crash Injury Research Engineering Network (CIREN), and IndyCar impact and injury data. These data sources can allow a better extrapolation of the ATD responses to off-nominal conditions above the nominal range that can safely be tested. These elements will be used to develop injury risk functions for each of the injury metrics measured from the ATD. These risk functions would serve as the basis for the NASA standards. Finally, we propose defining standard test methodology for evaluating future spacecraft designs against the IARVs, including developing a star-rating system to allow crew safety comparisons between vehicles.

Somers, Jeffrey T.↗
DOE OSTI2014

SECA Coal-Based Systems - FuelCell Energy, Inc.

The overall goal of this U.S. Department of Energy (DOE) sponsored project is the development of solid oxide fuel cell (SOFC) cell and stack technology suitable for use in highly-efficient, economically-competitive central generation power plant facilities fueled by coal synthesis gas (syngas). This program incorporates the following supporting objectives: • Reduce SOFC-based electrical power generation system cost to $700 or less (2007 dollars) for a greater than 100 MW Integrated Gasification Fuel Cell (IGFC) power plant, exclusive of coal gasification and CO 2 separation subsystem costs. • Achieve an overall IGFC power plant efficiency of at least 50%, from coal (higher heating value or HHV) to AC power (exclusive of CO 2 compression power requirement). • Reduce the release of CO2 to the environment in an IGFC power plant to no more than 10% of the carbon in the syngas. • Increase SOFC stack reliability to achieve a design life of greater than 40,000 hours. At the inception of the project, the efforts were focused on research, design and testing of prototype planar SOFC power generators for stationary applications. FuelCell Energy, Inc. successfully completed the initial stage of the project by meeting the program metrics, culminating in delivery and testing of a 3 kW system at National Energy Technology Laboratory (NETL). Subsequently, the project was re-aligned into a three phase effort with the main goal to develop SOFC technology for application in coal-fueled power plants with >90% carbon capture. Phase I of the Coal-based efforts focused on cell and stack size scale-up with concurrent enhancement of performance, life, cost, and manufacturing characteristics. Also in Phase I, design and analysis of the baseline (greater than 100 MW) power plant system—including concept identification, system definition, and cost analysis—was conducted. Phase II efforts focused on development of a ≥25 kW SOFC stack tower incorporating multiple stack building blocks of scaled-up cells, suitable for integration into a large-scale fuel cell power module. Activities in Phase II also included the development of the baseline system, factory cost estimate for the baseline plant’s power block, and conceptual design of a natural gas fueled sub-MW system to be used for testing and verification of the fuel cell stacks in a system environment. The specific objective for Phase III was the validation of the performance and robustness of stacks and scaled stack arrays suitable for use in large-scale power generation systems such as an IGFC with reliable, fail-safe operation being of paramount importance. The work culminated in the verification tests of a 60 kW SOFC stack module in a power plant facility. This final technical report summarizes the progress made during the project period. Significant progress was made in the areas of cell and stack technology development, stack module design, sub-scale module tests, Baseline Power Plant system development and Proof-of- Concept Module unit design. The development of this technology will significantly advance the nation’s energy security and independence interests while simultaneously addressing environmental concerns, including greenhouse gas emissions and water usage.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2013

TESTING THE NO-HAIR THEOREM WITH OBSERVATIONS IN THE ELECTROMAGNETIC SPECTRUM. IV. RELATIVISTICALLY BROADENED IRON LINES

According to the no-hair theorem, astrophysical black holes are fully characterized by their masses and spins and are described by the Kerr metric. This theorem can be tested observationally by measuring (at least) three different multipole moments of the spacetimes of black holes. In this paper, we calculate the profiles of fluorescent iron lines emitted from the accretion flows around black hole candidates within a framework that allows us to perform the calculation as a function of its mass and spin as well as of a free parameter that measures potential deviations from the Kerr metric. We show that such deviations lead to line profiles that are significantly altered and may exhibit a modified flux ratio of the two peaks in their characteristic double-peaked shape. We also show that the disk inclination can be measured independently of the spin and the deviation parameter at low to intermediate inclination angles, as in the case of Kerr black holes. We estimate the precision that near-future X-ray missions such as Astro-H and ATHENA+ are required to achieve in order to resolve deviations from the Kerr metric in iron line profiles and show that constraints on such deviations will be strongest for rapidly spinning black holes. More generally, we show that measuring the line profile with a precision of {approx}5% at disk inclinations of 30 Degree-Sign or 60 Degree-Sign constrains the deviation parameter to order unity for values of the spin a {approx}> 0.5M.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2018

Groundwater flow and heat transport for systems undergoing freeze-thaw: Intercomparison of numerical simulators for 2D test cases

In high-elevation, boreal and arctic regions, hydrological processes and associated water bodies can be strongly influenced by the distribution of permafrost. Recent field and modeling studies indicate that a fully-coupled multidimensional thermo-hydraulic approach is required to accurately model the evolution of these permafrost-impacted landscapes and groundwater systems. However, the relatively new and complex numerical codes being developed for coupled non-linear freeze-thaw systems require verification. Here in this paper, this issue is addressed by means of an intercomparison of thirteen numerical codes for two-dimensional test cases with several performance metrics (PMs). These codes comprise a wide range of numerical approaches, spatial and temporal discretization strategies, and computational efficiencies. Results suggest that the codes provide robust results for the test cases considered and that minor discrepancies are explained by computational precision. However, larger discrepancies are observed for some PMs resulting from differences in the governing equations, discretization issues, or in the freezing curve used by some codes.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS2003

Effects on Diagnostic Parameters After Removing Additional Synchronous Gear Meshes

Gear cracks are typically difficult to diagnose with sufficient time before catastrophic damage occurs. Significant damage must be present before algorithms appear to be able to detect the damage. Frequently there are multiple gear meshes on a single shaft. Since they are all synchronous with the shaft frequency, the commonly used synchronous averaging technique is ineffective in removing other gear mesh effects. Carefully applying a filter to these extraneous gear mesh frequencies can reduce the overall vibration signal and increase the accuracy of commonly used vibration metrics. The vibration signals from three seeded fault tests were analyzed using this filtering procedure. Both the filtered and unfiltered vibration signals were then analyzed using commonly used fault detection metrics and compared. The tests were conducted on aerospace quality spur gears in a test rig. The tests were conducted at speeds ranging from 2500 to 5000 revolutions per minute and torques from 184 to 228 percent of design load. The inability to detect these cracks with high confidence results from the high loading which is causing fast fracture as opposed to stable crack growth. The results indicate that these techniques do not currently produce an indication of damage that significantly exceeds experimental scatter.

Decker, Harry J.↗
DOE OSTI2020

Comprehensive Approach to Measure the Mobility Energy Productivity of Freight Transport

Freight travel accounts for a major share of the energy consumed in the transportation sector in any country, and the United States is no exception. Understanding and modeling freight movement are critical, particularly in the context of capturing the impact of emerging technologies on freight travel and its externalities. The domain of freight modeling and forecasting has been gaining pace in recent years, but advancement in comprehensive freight performance metrics is still lagging. Conventional freight performance metrics such as truck-miles, ton-miles, or value-miles are unidimensional and aggregate in nature, making them unsuitable to accurately capture the impact of emerging transportation trends on the performance or productivity of freight systems. Addressing the research need, this paper presents the “Freight Mobility Energy Productivity” metric to quantify freight productivity of current as well as future freight systems, accounting for various costs associated with freight transport. The proposed metric was implemented using data from the Freight Analysis Framework along with other published sources, and shows intuitive results in quantifying freight productivity. Further, a scenario analysis exercise was conducted to test the capability of the metric in tracking improvements in system-level freight productivity as a result of vehicle electrification. The relative differences in Freight Mobility Energy Productivity scores help identify which zones benefit from the vehicle powertrain technology improvement. The results of the scenario analysis reinforce confidence that the proposed metric can be used as a decision support tool in assessing the productivity of existing as well as future freight trends and technologies.

47 OTHER INSTRUMENTATION↗
DOE OSTI2020

A Comprehensive Approach to Measure the Efficiency of Freight Transport: Freight Mobility Energy Productivity (F-MEP) Metric

Freight travel accounts for a major share of the energy consumed in the transportation sector in any country, and the United States is no exception. Understanding and modeling freight movement is critical, particularly in the context of capturing the impact of emerging technologies on freight travel and its externalities. The domain of freight modeling and forecasting is gaining pace in the recent years, but advancement in comprehensive freight performance metrics is still lagging. Conventional freight performance metrics such as truck-miles, ton-miles, or value-miles are unidimensional and aggregated in nature, making them unsuitable to accurately capture the impact of emerging transportation trends on the performance of freight systems. Addressing this research need, this paper presents the 'Freight Mobility Energy Productivity' metric to quantify freight performance of current as well as future freight systems, accounting for various costs associated with freight transport. The proposed metric was implemented using data from the Freight Analysis Framework along with other published sources, which shows intuitive results in quantifying freight performance. Further, a scenario analysis exercise was conducted to test the capability of the metric in tracking improvements in system-level freight efficiency as a result of vehicle powertrain technology improvement. Results of the scenario analysis reinforce confidence that the proposed metric can be used as a decision support tool in assessing the efficiency of existing as well as future freight trends and technologies.

25 ENERGY STORAGE↗
DOE OSTI2020

A Comprehensive Approach to Measure the Mobility Energy Productivity of Freight Transport: Preprint

Freight travel accounts for a major share of the energy consumed in the transportation sector in any country, and the United States is no exception. Understanding and modeling freight movement are critical, particularly in the context of capturing the impact of emerging technologies on freight travel and its externalities. The domain of freight modeling and forecasting is gaining pace in the recent years, but advancement in comprehensive freight performance metrics is still lagging. Conventional freight performance metrics such as truck-miles, ton-miles, or value-miles are unidimensional and aggregate in nature, making them unsuitable to accurately capture the impact of emerging transportation trends on the performance or productivity of freight systems. Addressing the research need, this paper presents the “Freight Mobility Energy Productivity” metric to quantify freight productivity of current as well as future freight systems, accounting for various costs associated with freight transport. The proposed metric was implemented using data from the Freight Analysis Framework along with other published sources, which shows intuitive results in quantifying freight productivity. Further, a scenario analysis exercise was conducted to test the capability of the metric in tracking improvements in system-level freight productivity as a result of vehicle electrification. The relative differences in Freight Mobility Energy Productivity scores help identify which zones benefit from the vehicle powertrain technology improvement. The results of the scenario analysis reinforce confidence that the proposed metric can be used as a decision support tool in assessing the productivity of existing as well as future freight trends and technologies.

47 OTHER INSTRUMENTATION↗
DOE OSTI2012

Taming Wild Horses: The Need for Virtual Time-based Scheduling of VMs in Network Simulations

The next generation of scalable network simulators employ virtual machines (VMs) to act as high-fidelity models of traffic producer/consumer nodes in simulated networks. However, network simulations could be inaccurate if VMs are not scheduled according to virtual time, especially when many VMs are hosted per simulator core in a multi-core simulator environment. Since VMs are by default free-running, on the outset, it is not clear if, and to what extent, their untamed execution affects the results in simulated scenarios. Here, we provide the first quantitative basis for establishing the need for generalized virtual time scheduling of VMs in network simulators, based on an actual prototyped implementations. To exercise breadth, our system is tested with multiple disparate applications: (a) a set of message passing parallel programs, (b) a computer worm propagation phenomenon, and (c) a mobile ad-hoc wireless network simulation. We define and use error metrics and benchmarks in scaled tests to empirically report the poor match of traditional, fairness-based VM scheduling to VM-based network simulation, and also clearly show the better performance of our simulation-specific scheduler, with up to 64 VMs hosted on a 12-core simulator node.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2016

MO-AB-BRA-05: [18F]NaF PET/CT Imaging Biomarkers in Metastatic Prostate Cancer

Purpose: Clinical use of {sup 18}F-Sodium Fluoride (NaF) PET/CT in metastatic settings often lacks technology to quantitatively measure full disease dynamics due to high tumor burden. This study assesses radiomics-based extraction of NaF PET/CT measures, including global metrics of overall burden and local metrics of disease heterogeneity, in metastatic prostate cancer for correlation to clinical outcomes. Methods: Fifty-six metastatic Castrate-Resistant Prostate Cancer (mCRPC) patients had NaF PET/CT scans performed at baseline and three cycles into chemotherapy (N=16) or androgen-receptor (AR) inhibitors (N=39). A novel technology, Quantitative Total Bone Imaging (QTBI), was used for analysis. Employing hybrid PET/CT segmentation and articulated skeletal-registration, QTBI allows for response assessment of individual lesions. Various SUV metrics were extracted from each lesion (iSUV). Global metrics were extracted from composite lesion-level statistics for each patient (pSUV). Proportion of detected lesions and those with significant response (%-increase or %-decrease) was calculated for each patient based on test-retest limits for iSUV metrics. Cox proportional hazard regression analyses were conducted between imaging metrics and progression-free survival (PFS). Results: Functional burden (pSUV{sub total}) assessed mid-treatment was the strongest univariate predictor of PFS (HR=2.03; p<0.0001). Various global metrics outperformed baseline clinical markers, including fraction of skeletal burden, mean uptake (pSUV{sub mean}), and heterogeneity of average lesion uptake (pSUV{sub hetero}). Of 43 patients with paired baseline/mid-treatment imaging, 40 showed heterogeneity in lesion-level response, containing populations of lesions with both increasing/decreasing metrics. Proportion of lesions with significantly increasing iSUV{sub mean} was highly predictive of clinical PFS (HR=2.0; p=0.0002). Patients exhibiting higher proportion of lesions with decreasing iSUV{sub total} saw prolonged radiographic PFS (HR=0.51; p=0.02). Conclusion: Technology presented here provides comprehensive disease quantification on NaF PET/CT imaging, showing strong correlation to clinical outcomes. Total functional burden as well as proportions of similarly responding lesions was predictive of PFS. This supports ongoing development of NaF PET/CT based imaging biomarkers in mCRPC. Prostate Cancer Foundation.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2019

Avista Turner Energy Storage System: Assessment of Battery Technical Performance

This report investigates the technical performance of the 1 MW, 3.2 MWh advanced vanadium flow battery energy storage system (FBESS), consisting of two 0.5 MW, 1.6 MWh strings, based on a number of reference performance and use case tests. The FBESS is located on the utility 12 kV distribution system, between the Turner Substation and SEL’s manufacturing facility in Pullman, Washington. Reference performance tests (RPTs) were intended to assess the general technical capability of the FBESS (e.g., stored energy capacity, ramp rate performance, ability to track varying charge/discharge commands, direct current (DC) battery internal resistance). Use case tests were used to examine the performance of the FBESS while engaged in specific grid services (e.g., arbitrage, frequency regulation, balancing, volt ampere reactive (var) support, dynamic peak shaving). The project determined performance metrics that are important for understanding FBESS performance when subjected to field operation for achieving economic benefits from measurements and/or calculations. These metrics were: • RTE with and without rest, with and without auxiliary loads • Auxiliary power consumption • Reference signal tracking • Temperature excursions beyond normal operating range • Parasitic power loss unaccounted by auxiliary load during rest, and • State of charge (SOC) excursions beyond normal operating range. These RPT and use case performance metrics were analyzed using recorded test results. In addition, the results and lessons presented are also beneficial for any task or effort that needs technical assessment on similar and different types of FBESS, and BESS in general, based on technical specifications and/or field deployment results, since the assessment methodology remains the same.

25 ENERGY STORAGE↗
DOE OSTI2019

Low-Cost Recuperative Heat Exchanger for Supercritical Carbon Dioxide Power Systems (Final Scientific/Technical Report)

Closed Brayton super-critical CO 2 power cycles are well suited to waste heat bottoming cycles, due to their increased efficiency and compactness, relative to Rankine steam bottoming cycles. Since waste heat applications would be retrofits, the power system compactness is important. To achieve high efficiency, these power cycles require high pressure recuperative type heat exchangers, of substantial heat duty. Current Printed Circuit Heat Exchangers (PCHE), originally developed for high pressure gas and oil applications, can be used as recuperators, but costs are higher than desired. Altex is developing a purpose-built high pressure and effectiveness recuperator to provide the reliability, compactness, performance and pressure capability of current recuperators, but at a reduced cost. The High Effectiveness Low Cost (HELC) recuperative heat exchanger design yields volume and weight metrics of .0024 m 3 /UA and 10.2 kg/UA, which are 4% and 77.3% below recuperator target metrics, respectively. A 50 kW test article was designed and fabricated. Performance tests on water and oil showed that the HELC design model could predict heat transfer, to within 10% of the measured value. This model was then used to project HELC performance, when operating on supercritical CO 2 . Besides performance tests, the test article was hydrostatically tested, for integrity at up to 4,000 psi pressure. At these conditions, some distortion of channels was encountered. To mitigate distortion, the inserts were redesigned and these results were used to project the cost of 500 kW and 5,083 kW HELC units. The cost metric for the 5,083 kW unit was determined to be $\$ $1,349/UA, which is 10% lower than the recuperator desired cost metric desired target of $\$ $1,500/UA. In addition, the 5,083 kW unit HELC cost of $\$ $61.09/kW is 33.6% lower than the $\$ $92/kW estimated cost for a PCHE. Hydrostatic pressure tests, at up to 4,000psi, showed that the unit did not leak. However, channels were distorted at this pressure differential. Design updates to minimize stress concentrations and distortion were prepared and analyzed, to show that distortion could be controlled, but to date tests have not been run to prove the design. Project results show the potential of the HELC approach, but more work is required to confirm this potential, at the larger scales of interest.

14 SOLAR ENERGY↗
DOE OSTI2020

Supercritical CO2 Recuperators, Presented at The ASME Turbo Expo 2017, June 29, 2017, by Dr. John Kelly, President, Altex Technologies Corporation

Closed Brayton super-critical CO2 power cycles are well suited to waste heat bottoming cycles, due to their increased efficiency and compactness, relative to Rankine steam bottoming cycles. Since waste heat applications would be retrofits, the power system compactness is important. To achieve high efficiency, these power cycles require high pressure recuperative type heat exchangers, of substantial heat duty. Current Printed Circuit Heat Exchangers (PCHE), originally developed for high pressure gas and oil applications, can be used as recuperators, but costs are higher than desired. Altex is developing a purpose-built high pressure and effectiveness recuperator to provide the reliability, compactness, performance and pressure capability of current recuperators, but at a reduced cost. The High Effectiveness Low Cost (HELC) recuperative heat exchanger design yields volume and weight metrics of .0024 m3/UA and 10.2 kg/UA, which are 4% and 77.3% below recuperator target metrics, respectively. A 50 kW test article was designed and fabricated. Performance tests on water and oil showed that the HELC design model could predict heat transfer, to within 10% of the measured value. This model was then used to project HELC performance, when operating on supercritical CO2. Besides performance tests, the test article was hydrostatically tested, for integrity at up to 4,000 psi pressure. At these conditions, some distortion of channels was encountered. To mitigate distortion, the inserts were redesigned and these results were used to project the cost of 500 kW and 5,083 kW HELC units. The cost metric for the 5,083 kW unit was determined to be $1,349/UA, which is 10% lower than the recuperator desired cost metric desired target of $1,500/UA. In addition, the 5,083 kW unit HELC cost of $61.09/kW is 33.6% lower than the $92/kW estimated cost for a PCHE. Hydrostatic pressure tests, at up to 4,000psi, showed that the unit did not leak. However, channels were distorted at this pressure differential. Design updates to minimize stress concentrations and distortion were prepared and analyzed, to show that distortion could be controlled, but to date tests have not been run to prove the design. Project results show the potential of the HELC approach, but more work is required to confirm this potential, at the larger scales of interest.

14 SOLAR ENERGY↗
DOE OSTI2020

High Effectiveness, Compact, High Pressure and Low-Cost Recuperator, Presented at The Fifth International Symposium – Super-Critical CO2 Power Cycles, San Antonio, Texas, March 28-31, 2016, by Dr. John Kelly, President, Altex Technologies Corporation

Closed Brayton super-critical CO2 power cycles are well suited to waste heat bottoming cycles, due to their increased efficiency and compactness, relative to Rankine steam bottoming cycles. Since waste heat applications would be retrofits, the power system compactness is important. To achieve high efficiency, these power cycles require high pressure recuperative type heat exchangers, of substantial heat duty. Current Printed Circuit Heat Exchangers (PCHE), originally developed for high pressure gas and oil applications, can be used as recuperators, but costs are higher than desired. Altex is developing a purpose-built high pressure and effectiveness recuperator to provide the reliability, compactness, performance and pressure capability of current recuperators, but at a reduced cost. The High Effectiveness Low Cost (HELC) recuperative heat exchanger design yields volume and weight metrics of .0024 m3/UA and 10.2 kg/UA, which are 4% and 77.3% below recuperator target metrics, respectively. A 50 kW test article was designed and fabricated. Performance tests on water and oil showed that the HELC design model could predict heat transfer, to within 10% of the measured value. This model was then used to project HELC performance, when operating on supercritical CO2. Besides performance tests, the test article was hydrostatically tested, for integrity at up to 4,000 psi pressure. At these conditions, some distortion of channels was encountered. To mitigate distortion, the inserts were redesigned and these results were used to project the cost of 500 kW and 5,083 kW HELC units. The cost metric for the 5,083 kW unit was determined to be $1,349/UA, which is 10% lower than the recuperator desired cost metric desired target of $1,500/UA. In addition, the 5,083 kW unit HELC cost of $61.09/kW is 33.6% lower than the $92/kW estimated cost for a PCHE. Hydrostatic pressure tests, at up to 4,000psi, showed that the unit did not leak. However, channels were distorted at this pressure differential. Design updates to minimize stress concentrations and distortion were prepared and analyzed, to show that distortion could be controlled, but to date tests have not been run to prove the design. Project results show the potential of the HELC approach, but more work is required to confirm this potential, at the larger scales of interest.

14 SOLAR ENERGY↗
DOE OSTI2020

High Effectiveness, Compact, High Pressure and Low Cost Recuperator for Super-Critical CO2 Power Cycles, Paper Presented at The Fifth International Symposium – Super-Critical CO2 Power Cycles, San Antonio, Texas, March 28-31, 2016, by Dr. John Kelly, President, Altex Technologies Corporation

Closed Brayton super-critical CO2 power cycles are well suited to waste heat bottoming cycles, due to their increased efficiency and compactness, relative to Rankine steam bottoming cycles. Since waste heat applications would be retrofits, the power system compactness is important. To achieve high efficiency, these power cycles require high pressure recuperative type heat exchangers, of substantial heat duty. Current Printed Circuit Heat Exchangers (PCHE), originally developed for high pressure gas and oil applications, can be used as recuperators, but costs are higher than desired. Altex is developing a purpose-built high pressure and effectiveness recuperator to provide the reliability, compactness, performance and pressure capability of current recuperators, but at a reduced cost. The High Effectiveness Low Cost (HELC) recuperative heat exchanger design yields volume and weight metrics of .0024 m3/UA and 10.2 kg/UA, which are 4% and 77.3% below recuperator target metrics, respectively. A 50 kW test article was designed and fabricated. Performance tests on water and oil showed that the HELC design model could predict heat transfer, to within 10% of the measured value. This model was then used to project HELC performance, when operating on supercritical CO2. Besides performance tests, the test article was hydrostatically tested, for integrity at up to 4,000 psi pressure. At these conditions, some distortion of channels was encountered. To mitigate distortion, the inserts were redesigned and these results were used to project the cost of 500 kW and 5,083 kW HELC units. The cost metric for the 5,083 kW unit was determined to be $1,349/UA, which is 10% lower than the recuperator desired cost metric desired target of $1,500/UA. In addition, the 5,083 kW unit HELC cost of $61.09/kW is 33.6% lower than the $92/kW estimated cost for a PCHE. Hydrostatic pressure tests, at up to 4,000psi, showed that the unit did not leak. However, channels were distorted at this pressure differential. Design updates to minimize stress concentrations and distortion were prepared and analyzed, to show that distortion could be controlled, but to date tests have not been run to prove the design. Project results show the potential of the HELC approach, but more work is required to confirm this potential, at the larger scales of interest.

14 SOLAR ENERGY↗