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At least 325 records · Page 18

Design and Optimization of a Fast-Switching Electromagnetic Valve Actuator for Off-highway Vehicle Hydraulic Systems

Electrification of off-highway vehicles offers improved efficiency and reduction in greenhouse gas emissions. However, the extremely low power densities of electric machines relative to the hydraulics used in conventional off-highway vehicles makes electrification challenging. Although the recently proposed Hybrid Hydraulic Electric Architecture (HHEA) can overcome this limitation, it requires frequent switching between the pressure rails using switching valves resulting in losses. Fast switching minimizes the switching losses in these valves, which otherwise significantly reduce the overall efficiency of the system. The primary contribution of this paper is the design and optimization of a linear electromagnetic actuator for a fast-switching valve. This paper identifies the actuator requirements to enable fast switching and presents a design and optimization technique to realize actuators that meet the design objectives. In addition, a multi-physics approach is proposed to model the performance of the complete switching valve by considering the electromagnetic, fluidic, and mechanical physics. An optimal actuator design is obtained using the developed optimization framework, and the multi-physics model demonstrates that the selected design achieves a 30% reduction in throttling-related switching losses by switching 70 % faster than comparable commercial valve designs.

Linear actuators, off-highway vehicle electrificat↗

Plant-wide modeling and techno-economic analysis of a direct non-oxidative methane dehydroaromatization process via conventional and microwave-assisted catalysis

Direct non-oxidative methane dehydroaromatization (DHA) process via conventional and microwave (MW)-assisted thermo-catalytic catalysis is studied. Rate models for methane DHA reactions, including the effect of catalyst deactivation, are developed by using the in-house experimental data. Model results for gas concentration profile and catalyst deactivation are in good agreement with the experimental data. This rate model is then used for the development of dynamic multi-scale, multi-physics commercial-scale reactor models. Total number of fixed bed reactors desired for a cyclic steady state process is estimated. Plant-wide models are then developed for conventional and MW-assisted processes for producing products of desired specifications. Techno-economic analysis of the methane DHA process is undertaken. Economics of these methane DHA processes are compared with the typical multi-step natural gas to aromatics production process via methanol synthesis. Sensitivity of internal rate of return (IRR) and net present value (NPV) to various economic and process parameters such as plant scale, desired rate of return, reactor cost, feedstock and utility cost, catalyst variable cost, and MW reactor cost is studied. Here, electric equivalent efficiency of the conventional methane DHA process is found to be 69.2 % and 67.3 % at 750 °C and 800 °C, respectively, while the MW-assisted methane DHA process has the electric equivalent efficiency of 48.9 % at 800 °C. IRRs of the conventional methane DHA process at 750 °C and 800 °C, and MW-assisted process are 15.2 %, 17.5 %, and 18.8 %, respectively for a methane feed flowrate of 19,782 kg/h, while the IRR of the multi-step natural gas to aromatics production process is estimated to be 0 % for the same plant scale. Impact of change in the methane price, electricity price, and catalyst cost is found to be considerable on the process economics, while the cost of the MW reactor is found to have negligible impact.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Integrated Water-Gas-Shift Pre-combustion Carbon Capture Process

TDA Research, Inc (TDA) has developed a highly efficient integrated WGS pre-combustion carbon capture technology and demonstrated its techno-economic viability for use in the Integrated Gasification Combined Cycle (IGCC) power plants that process coal. The new system uses a warm gas CO 2 scrubber integrated with a Water-Gas-Shift (WGS) catalyst to capture greater than 90% of the carbon emissions, which does not increase the cost of electricity (COE) as much as conventional carbon capture technologies.

01 COAL, LIGNITE, AND PEAT↗

Development of a 300 MWe Utility Scale Oxy-Fuel sCO2 Turbine

A 300 MWe direct-fired supercritical carbon dioxide (sCO2) oxy-fuel turbine is being developed that will burn natural gas-fired, coal syngas and even hydrogen mixtures capable of 1,150ºC turbine inlet temperature at 300 bar. This design will significantly improve the state-of-the-art for thermal efficiency and results in a high-pressure stream of CO2 with 98%+ carbon capture, making the power plant near emission-free and more efficient than Natural Gas Combined Cycle (NGCC) plants with carbon capture. This power plant will be capable of burning coal through gasification and cleanup of the synthesis gas (syngas). sCO2 power cycles are a transformational technology for the energy industry, providing higher efficiency heat source energy conversion for conventional and alternative energy sources. This novel cycle significantly reduces capital costs because of smaller equipment footprints, design modularity, and allows for rapid cyclic load and source following to balance solar and wind energy power swings. Oxy-fuel sCO2 cycles take these advantages even further, utilizing higher firing temperatures, improved efficiency, and simpler carbon capture strategies. This turbine will require cooled turbine nozzles and blades as well as advanced thermal management systems to accommodate these high temperatures. The cooled blade heat transfer correlations required new test programs at higher Reynolds number than air-breathing gas turbines for impingement, serpentine, and pin-fin regions. Novel blade optimization was performed to maximize aerodynamic efficiency, while minimizing cooling flows. A turbine layout was generated utilizing individual combustor cans with cooled liners feeding into a 6-stage axial flow turbine with cooled stator nozzles and turbine blades. The case design and thermal management preliminary design will be described.

Moore, Jeffrey↗

Coupling Waste Feedstocks to Microbial Protein for a Circular Food System

The global food system is responsible for approximately 34% of annual greenhouse gas (GHG) emissions and up to 85% of water consumption. This critical sector suffers from intensive and inefficient land and water use, the generation of multiple (solid, liquid, and gaseous) waste streams, and high fuel, fertilizer, and pesticide consumption. The production of waste-derived microbial protein (MP) represents a promising alternative for reducing the environmental impacts of protein production relative to conventional agriculture. MP can be mass-produced in volumetrically scalable cultivation processes on short timescales, enabling facile up-scaling with lower greenhouse gas emissions, land use, and water impacts than animal and, in some cases, plant protein production. MP can also be produced from waste feedstocks, diverting waste from landfills or the natural environment. Here, we present the availability and suitability of waste feedstocks for MP production, as well as the fermentation and downstream processes required to convert MP into human food products. We discuss the challenges and opportunities facing waste-derived bacterial MP and highlight key areas for innovation in both the microbiology and process design space for a more sustainable and circular food system.

BASIC BIOLOGICAL SCIENCES,ENERGY PLANNING, POLICY,↗

Bituminous Coal and Natural Gas to Electricity: >90% Capture Cases Technical Note

This technical note provides cost and performance estimates for post combustion carbon capture (PCCC) systems designed for greater than 90 percent capture on conventional PC- and NG-fueled power plants. The cost and performance estimates provided here were developed using the National Energy Technology Laboratory’s (NETL’s) well-documented methodology for conducting technoeconomic analysis of fossil energy conversion systems and leveraging published performance and cost projections for higher capture rate systems. Included in this technical note is a brief description of the method used to adjust select 90 percent capture cases from NETL’s Cost and Performance Baselines for Fossil Energy Systems Volume 1: Bituminous Coal and Natural Gas to Electricity, hereafter referred to as the Baseline Study. This technical note is intended to serve as an interim update to NETL’s Baseline Study cases by providing cost and performance estimates for high capture PCCC technology that can be deployed in the near-term at fossil-fueled electricity generating units.

20 FOSSIL-FUELED POWER PLANTS↗

Cradle-to-Grave Lifecycle Analysis of Greenhouse Gas Emissions of Light-Duty Passenger Vehicles in China: Towards a Carbon-Neutral Future

Vehicle electrification is considered a pathway for on-road transportation decarbonization in China. Different from the conventional gasoline vehicles whose emissions are mainly released from vehicle tailpipes, emissions of battery electric vehicles (BEVs) are from the upstream processes of electricity generation and vehicle manufacturing, thus a comprehensive lifecycle analysis and comparison of BEVs with gasoline vehicles is required to quantify the emission mitigation benefit of vehicle electrification and determine the path to a carbon-neutral future. In the study, we compare the cradle-to-grave (C2G) lifecycle greenhouse gas emissions of gasoline and electric vehicles in China and analyze the greenhouse gas emission reduction of vehicle electrification in different provinces. Results show that under the current technologies, the national average C2G GHG emissions for battery electric vehicles (BEVs) of 100 miles (i.e., 160 km) and 300 miles (i.e., 480 km) all-electric range (AER) are 231 and 279 g CO2eq/km, respectively, 22% and 5% lower than those for gasoline internal combustion engine vehicles (ICEVs). Improving vehicle fuel efficiency by hybridizing gasoline ICEVs can effectively reduce C2G emissions to 212 g CO2eq/km. At the provincial level, C2G GHG emissions of BEVs vary according to the provincial electricity mix. In eight provinces, C2G GHG emissions of BEVs with 300 miles AER (BEV300s) are higher than those of gasoline ICEVs due to the GHG-intensive coal-based electricity mix. In the future scenario, with low carbon fuels (such as high-level bioethanol blending gasoline) and electricity decarbonization, the national average C2G emissions of hybrid electric vehicles (HEVs) and BEV300s can be reduced to 55 and 73 g CO2eq/km, respectively. Further decrease of C2G GHG emissions relies on reducing vehicle-cycle emissions from material processing and vehicle component manufacturing.

33 ADVANCED PROPULSION SYSTEMS↗

Synergistic Integration of Chemo-Resistive and SERS Sensing for Label-Free Multiplex Gas Detection

Practical sensing applications such as real-time safety alerts and clinical diagnoses require sensor devices to differentiate between various target molecules with high sensitivity and selectivity, yet conventional devices such as oxide-based chemo-resistive sensors and metal-based surface-enhanced Raman spectroscopy (SERS) sensors usually do not satisfy such requirements. In this report a label-free, chemo-resistive/SERS multimodal sensor based on a systematically assembled 3D cross-point multifunctional nanoarchitecture (3D-CMA), which has unusually strong enhancements in both “chemo-resistive” and “SERS” sensing characteristics is introduced. 3D-CMA combines several sensing mechanisms and sensing elements via 3D integration of semiconducting SnO 2 nanowire frameworks and dual-functioning Au metallic nanoparticles. It is shown that the multimodal sensor can successfully estimate mixed-gas compositions selectively and quantitatively at the sub-100 ppm level, even for mixtures of gaseous aromatic compounds (nitrobenzene and toluene) with very similar molecular structures. This is enabled by combined chemo-resistive and SERS multimodal sensing providing complementary information.

36 MATERIALS SCIENCE↗

Generalized optimization-based synthesis of membrane systems for multicomponent gas mixture separation

Synthesizing a membrane system to separate multicomponent gas mixture is challenging due to the combinatorial number of feasible configurations and the difficulties in describing the multicomponent permeators. Here we present a mixed-integer nonlinear programming (MINLP) model for synthesizing membrane systems for multicomponent gas mixture separation. The approach employs a richly connected superstructure to represent numerous potential system configurations, and different physics-based surrogate permeator models, such as countercurrent flow or crossflow, to be used in each stage. Moreover, to describe realistic systems, pressure drop equations can be included. We also present solution methods to accelerate the solution process. Through a case study of natural gas sweetening, we demonstrate that the proposed approach is able to obtain good solutions using an off-the-shelf global optimization solver. Finally, we expand the conventional membrane system synthesis problem by introducing feed variability in our model through a case study of an integrated reactor-separation system.

42 ENGINEERING↗

Surface Roughness Effects from Additive Manufacturing in High Efficiency Gas Turbine Combustion Systems

In the past, clean combustion systems were characterized by high system development costs due to growing complexity and escalating manufacturing costs from conventional manufacturing processes. As a result, high efficiency concepts are difficult to design and more difficult to be cost-effectively manufactured. In recent years, with the introduction of additive manufacturing (AM) technologies, the rapid prototyping and mass production processes of clean combustion systems are promising to be significantly simplified with significant reduction in terms of engine manufacturing cost and engine energy cost. Compared with conventional manufacturing built parts, the AM process enabled a simpler design to be adopted for the nozzle, reducing the number of required braze and weld joints from twenty-five to just five. The resulting nozzle was 25% lighter and five times more durable and contributed to a 15% reduction in fuel burn in comparison with the previous model produced. Applying these improvements to a fleet of 5,000 turbofan engines at 150 kN thrust would result in fuel cost savings of $6B annually (at $5/gallon Jet-A fuel price, 700 gallon/hour fuel consumption rate, and 2,300 operational hours per year),and reduce CO2 emissions by more than 25 million tons per year. These advances support core Department of Energy (DOE)missions in energy efficiency, improving productivity, and environmental sustainability. Maximizing the benefit of these new capabilities will require high prediction capability of high speed turbulent flow with wall modeled Large Eddy Simulation (LES). GE Aviation maintains that advanced simulation technology and supercomputing is required in order to provide the appropriate boundary conditions to realize the maximum potential of AM and Ceramic Matrix Composite to reduce cooling flow, a first order penalty on the Brayton cycle. The algorithm developed using the ANSYS/Fluent software would provide the foundation for entirely new avenues of research and development with potential multi-billion dollar impact to the US economy, and significant reduction in carbon based emissions across the aerospace and power generation industries. The formulation of this iWLES (integral wall model for LES) is generic and allows to capture the changes in flow dynamics that have a significant impact on the wall bounded flow characteristics, such as swirler effective area, bulk swirl number, local pressure distribution, exit velocity profile, and turbulence kinetic energy profile. A periodic channel flow with rough flat plate is simulated using LES (Wall-Adapting Local Eddy-viscosity) model to verify the implementation of iWLES in the Fluent User Defined Function (UDF). As the flow fields are highly sensitive due to surface roughness of the wall bounded flows in the combustion systems, there is significant potential to conduct further LES studies focusing on the turbulence boundary layer interaction. Accurately capturing near wall physics will elucidate the impact of rough surfaces on combustor flow and aero-thermal interactions.

99 GENERAL AND MISCELLANEOUS↗

Comparative life-cycle assessments and techno-economic analysis of renewable natural gas production pathways from biogas

Renewable natural gas (RNG) offers a promising pathway for decarbonizing hard-to-abate sectors. This study shows that, relative to conventional upgrading technologies (i.e., membrane separation and pressure swing adsorption), the catalytic methanation reaction (CMR) at water resource recovery facilities doubles RNG output. When consuming lowcarbon hydrogen, the CMR reduces operational energy use and global warming potential. Techno-economic analysis indicates that the CMR is not yet competitive but will become viable if hydrogen reaches $1/kg. Heat integration and hydrogen cost are key drivers of overall performance.

03 NATURAL GAS↗

Economic analysis of precious metal recovery from electronic waste through gas-assisted microflow extraction

The recycling of end-of-life (EoL) electronic products is motivated by the enormous investment of resources in their creation and the environmental concerns associated with electronic waste (e-waste). Hydrometallurgical methods that utilize conventional leaching and solvent extraction are often applied to extract target materials from e-waste; however, these techniques have significant technical and economic limitations when extracting high-value, low concentration metals from complex waste streams. This study proposes and evaluates a novel process based on gas-assisted microflow extraction (GAME) that efficiently recovers precious metals from waste printed circuit boards (WPCBs). Further, an economic analysis is conducted to verify the economic feasibility of the GAME-based process at an industrial scale. The economic outputs are further investigated to identify the most cost-effective production strategies, particularly with respect to the plant feedstock rate. It is envisioned that this study may establish a paradigm for making economically-informed decisions for sustainable technologies.

42 ENGINEERING↗

Enabling thermal efficiency improvement and waste heat recovery using liquid air harnessed from offshore renewable energy sources

A novel approach using decoupled processes to harness offshore renewable energy, from marine hydrokinetics, ocean waves, wind, and solar to produce liquid air, is presented here. Offshore renewables interconnection using submarine medium- and high-voltage direct current technologies are used to produce liquid air that can be transported to end-use locations using repurposed liquefied natural gas tankers. Two important possibilities arise from using the proposed technology. The first possibility allows the integration with conventional thermal cycles to improve efficiency. This approach can be used to leverage efficiencies of thermal systems that have already reached a plateau in the maximum achievable efficiency via design and operation optimization. The second possibility is related to the incorporation of low temperature cycles to recover waste heat from other thermal processes. This is important considering that waste heat accounts for more than 60% of the consumed energy in the United States. A detailed technical description of the complete cycle from cryogen generation to end-use of energy is provided. Estimation of efficiency enhancement for thermal plants using liquid air including waste heat recovery is presented.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Controlled dehumidification to extract clean water from a multicomponent gaseous mixture of organic contaminants

Rapid expansion of the unconventional oil and gas extraction has increased American energy independence, but also led to increased production of large amounts of contaminated water. Wastewater from the oil and gas industry contains a wide range of contaminants. Injecting such contaminated water into disposal wells or discharging it to the environment jeopardizes freshwater resources. Conventional and membrane-based wastewater treatment techniques are often not effective choices to treat highly contaminated wastewater; however, a suitable way to remove contaminants from wastewater is to selectively separate water in a process analogous to humidification-dehumidification (HDH). Only a few studies have investigated the use of HDH for wastewater treatment. In this study, a novel HDH system is introduced for treating highly contaminated water, such as oil and gas flowback and produced water. In this HDH process, a non-condensable gas, such as air, mixes with wastewater vapor to facilitate the separation of contaminants. As a result, clean water condenses from the multicomponent gaseous mixture while air carries organic contaminants out of the dehumidification section. A laboratory apparatus was constructed and experiments were performed to investigate the HDH process for wastewater treatment and to study the effects of flow dynamics including air flow rate on the composition of treated water. Different contaminants including benzene, toluene, 2-propanol and 2-butoxyethanol were tested. Experimental results showed that the system can be successfully applied for removing volatile and/or toxic organic contaminants from wastewater. A representative multicomponent mixture of fracking wastewater was successfully treated using the experimental setup and clean water with quality of 98.3% was obtained. It was revealed that increasing the air-to-vapor mass ratio improves purity of treated water. Quantitative analysis showed that by increasing the air-to-vapor mass ratio from 0.6 to 5.9, the fraction of separated 2-propanol through the air was improved from 43% to more than 96% of the initial amount. ASPEN software was employed to simulate equilibrium conditions. Finally, experimental results were observed to have lower mass fraction of residual contaminant in the treated water compared to equilibrium state.

42 ENGINEERING↗

Bipolar Membranes for Ion Management in (Photo)Electrochemical Energy Conversion

Conspectus (Photo)electrochemical energy conversion is important in the development of a carbon-neutral energy economy because it can provide a pathway for mitigating the intermittency of renewable energy sources such as wind and solar. In order to operate efficiently, these technologies, which include photoelectrochemical cells, water and CO 2 electrolyzers, fuel cells, and redox flow batteries, require fast charge transfer kinetics at the electrode/electrolyte interface as well as robust ion management in the electrolyte. In conventional electrolyzers and fuel cells, the electrolyte is strongly acidic or basic and ionic current is carried by H + or OH – ions. In contrast, photoelectrodes and electrocatalysts for water splitting are often studied in buffered solutions. The question of ion balance in these systems led us to analyze the polarization losses due to ion concentration gradients in cells that employed various buffer–membrane combinations. Continuously driving the buffer ions across an ionomer membrane not only lowers the buffer capacity of an aqueous electrolyte but also introduces pH gradients that result in significant energy losses. To address the problem, we and other groups have studied the use of reverse-biased bipolar membranes (BPMs) in (photo)electrolytic cells. BPMs consist of an anion exchange layer (AEL) laminated with a cation exchange layer (CEL) and are usually equipped with a catalytic layer in between to accelerate the water dissociation reaction. At the AEL/CEL interface, water dissociates into protons and hydroxide ions, which replenish those consumed at the cathode and anode. Compared to conventional water electrolyzers with proton/anion exchange membranes (PEM/AEM), BPM electrolyzers provide the unique advantage of continuously operating the cathode and anode under different pH conditions, which is desirable when the two electrode reactions have different pH requirements. BPMs also enable the use of buffered electrolytes at pH values that are optimized for electrode stability and product selectivity in applications such as CO 2 electrolysis. Product crossover losses and CO 2 pumping can be dramatically reduced in BPM-based CO 2 electrolyzers, relative to conventional alkaline membranes, by electrostatic repulsion (of anionic products) and electroosmotic drag (for neutral products). BPM-based gas fed CO 2 electrolyzers can achieve high current density, but they suffer from low Faradaic efficiency (FE) due to the acidic local environment of the CEL. This problem can be mitigated by adding an aqueous buffering layer or by creating a weak acid cation exchange film on the CEL face of the membrane. The use of BPMs in fuel cells and redox flow batteries offers some interesting advantages. Configurations with both reverse and forward bias have been studied, but forward bias has been favored due to material compatibility, reaction kinetics, and thermodynamic considerations. The net reaction at the AEL/CEL interface is the acid–base neutralization reaction, which has a high inherent reaction rate constant, but in the BPM is limited to a nanometric space-charge layer and requires efficient catalysis to achieve high current density. Understanding the mechanism of the acid–base neutralization and the opposite process, the water dissociation reaction, will be essential for improving the performance of forward-biased BPMs. In conclusion, this Account reviews our current understanding of the working mechanisms of BPMs and discusses how we can use them to effectively manage ions for various (photo)electrochemical applications.

Yan, Zhifei↗

Evaluation of Torque-Dense Electric Machine Technology for Off-Highway Vehicle Electrification

Electrification of off-highway vehicles offers the benefits of improved energy efficiency, enhanced control, and reduction in greenhouse gas emissions. However, progress towards electrification has been limited by the low torque density (30 kNm/m 3 ) of conventional electric machines compared to mobile hydraulic machines (up to approximately 1000 kNm/m 3 ). This paper reviews emerging variants of electric machines that offer a step improvement in torque density and potential pathway to enable electrified off-highway vehicles. First, sizing approaches for electric and hydraulic machines are developed, and torque-dense electric machines reviewed in literature are compared to commercial hydraulic machines to identify design trends in terms of speed, torque density, and power density. Next, key metrics are identified for the electric machine, based on which the following four emerging electric machine variants that promise to improve torque density are reviewed: i) multi-harmonic machines injection, ii) combined radial-axial flux machines, iii) magnetic gears, and iv) magnetically-geared machines. Here, the findings from this review show that these new electric machines can achieve upwards of 300% improvement in electric machine torque density, with several designs exceeding 100 kNm/m 3 , making them worthy candidates for further research to bridge the torque density gap with hydraulic machines.

33 ADVANCED PROPULSION SYSTEMS↗

Properties of SiC-Si made via binder jet 3D printing of SiC powder, carbon addition, and silicon melt infiltration

In this work, we report the physical and mechanical properties of ceramic composite materials fabricated by binder jet 3D printing (BJ3DP) with silicon carbide (SiC) powders, followed by phenolic resin infiltration and pyrolysis (IP) to generate carbon, and a final reactive silicon melt infiltration step. After two phenolic resin infiltration and pyrolysis cycles; porosity was less than 2%, Young's modulus was close to 300 GPa, and the flexural strength was 517.6 ± 24.8 MPa. However, diminishing returns were obtained after more than two phenolic resin infiltration and pyrolysis cycles as surface pores in carbon were closed upon the formation of SiC, resulting in reaction choking and residual-free carbon and porosity. The instantaneous coefficient of thermal expansion of the composite was found to be independent of the number of phenolic IP cycles and had values of between 4.2 and 5.0 ppm/°C between 300 and 100°C, whereas the thermal conductivity was found to have a weak dependence on the number of phenolic IP cycles. While the manufacturing procedures described here yielded highly dense, gas impermeable, siliconized SiC composites with properties comparable to those of bulk siliconized silicon carbide processed according to conventional techniques, BJ3DP enables the manufacture of objects with complex shape, unlike conventional techniques.

36 MATERIALS SCIENCE↗

Turboexpander for Direct Cooling in Hydrogen Vehicle Fueling Infrastructure

Hydrogen fuel cell electric vehicles (FCEVs) have been identified as one of a few options for zero carbon emissions transportation. A major advantage of FCEVs is that they can fuel quickly and follow a familiar fueling behavior to hydrocarbon-fueled vehicles. Whether light duty or heavy duty, the goal for a hydrogen dispenser is to fuel a vehicle in the same amount of time as the fossil fuel equivalent. When hydrogen is dispensed into the vehicle storage system, however, the temperature rises due to the Joule-Thomson effect and the heat of compression. Typically, vehicles store the compressed hydrogen in composite overwrapped pressure vessels that have a polymer liner with an operational temperature limit of 85°C. This temperature limit can be exceeded during fast fueling if hydrogen is not precooled. Precooling allows for a dispenser to fuel a vehicle at a faster flow rate by preventing the storage tank on the vehicle from overheating. Fueling protocols and requirements are presented in SAE J2601 Fueling Protocols for Light Duty Gaseous Hydrogen Surface Vehicles [1]. A heavy-duty equivalent is under development with similar requirements for precooling. Currently, conventional precooling for light-duty vehicle refueling uses a heat exchanger and chiller to cool the hydrogen gas to -40°C before entering the vehicle. The precooling system represents a significant part of the station capital and operating costs, so if the cost of the precooling system can be reduced by improving its efficiency, the overall station capital and operating cost can be reduced. In this project, National Renewable Energy Laboratory (NREL) and Sandia National Laboratories (SNL) researchers teamed up to investigate the turboexpander precooling application. A turboexpander is a device that places a turbine in a flow path where a pressure differential can be attained. This expansion device will extract work and lower the temperature of the fluid as the pressure reduces. While initial calculations based on established principles showed potential for a turboexpander to generate cooled gas, much work needs to be done to prove the concept. Turboexpanders typically work best under steady state conditions, while the dispenser is a very dynamic flow system. Dynamic turboexpander systems have been proven, such as a turbocharger on a gasoline vehicle. The inlet pressure at a dispenser is also much higher than any other known turboexpander system but should behave similarly to higher density fluids at lower pressures. Having both performed initial calculations, NREL and SNL researchers teamed up to investigate the turboexpander precooling application further. A project was soon built around the idea with SNL performing system modeling using previously proven capabilities and NREL performing hardware characterization with established station capabilities. Creare LLC was contracted as the turbomachinery expert to design and build the concept device. Part way through the project, however, contracting issues with the funding partner caused the project to terminate early before building and characterizing the concept device. While the project could not continue, many key findings were already learned. This paper is a summary of those findings.

08 HYDROGEN↗