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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Oxides related to cadmium telluride solar cells

Polycrystalline cadmium telluride (CdTe) is a leading material in photovoltaic technology due to its high absorption coefficient and near-optimum bandgap of 1.44 eV. It is known that CdTe film processing can promote surface oxidation depending on the growth environment and upon exposure to different oxidation conditions. For example, CdTeO3 forms when the CdTe film is treated in heated dry air, while in humid air, CdTe2O5 is detected. These oxides feature tellurium in the oxidation state +4 compared to the +2 state in CdTe. Other possible relevant oxides are CdO, TeO2, and TeO3. Using hybrid density functional calculations, we studied the electronic structure of these oxide materials and their band alignment to CdTe, which are essential parameters in the characterization of the interfaces at grain boundaries. The goal is to understand their stability and possible effects on passivating grain boundaries. The results are compared to the available experimental data.

14 SOLAR ENERGY↗
DOE OSTI2022

Roll-to-Roll Advanced Materials Manufacturing DOE Laboratory Collaboration - Early Stage R&D: Phase 2 and FY21 (Final Report)

R2R processing is used to manufacture a wide range of products for various applications which span many industrial business sectors. The overall R2R methodology has been in use for decades and this continuous technique traditionally involves deposition of material(s) onto substrates or membranes that are on moving webs, carriers or other continuous belt-fed or conveyor-based processes that enable successive steps to build a final product. Established methods that typify R2R processing include tape casting, silk-screen printing, reel-to-reel vacuum deposition/coating, and R2R lithography. Products supported by R2R manufacturing include micro-electronics, electro-chromic window films, PVs, fuel cells for energy conversion, battery electrodes and electrolytes for energy storage, and barrier and membrane materials for decarbonization and air and water filtration. Due to innovation in materials and process equipment, high-quality yet very low-cost multilayer technologies have the potential to be manufactured on a very cost-competitive basis. To move energy-related products from high-cost niche applications to the commercial sector, the means must be available to enable manufacture of these products in a cost-competitive manner. Fortunately, products such as fuel cells, thin- and mid-film PVs, batteries, electrochromic and piezoelectric films, water separation membranes, and other energy saving technologies readily lend themselves to manufacture using R2R approaches. However, more early-stage research is needed to solve the challenge of linking the materials (particles, polymers, solvents, additives) used in ink and slurry formulations and the coating and heated drying processes to the ultimate performance of the final R2R product, especially for a process that uses multiple layers of deposition to achieve the end product.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Life cycle assessment of novel heat exchanger for dry cooling of power plants based on encapsulated phase change materials

Cooling systems in power plants account for approximately 40% of total freshwater withdrawals in the U.S. Due to dwindling access to freshwater resources worldwide, continued operation of wet cooling systems poses a significant engineering challenge. To reduce water consumption, a novel air-cooled heat exchanger has been developed using encapsulated phase change material (EPCM) for dry cooling of power plants. Compared to traditional finned-tube air-cooled condensers, this novel EPCM heat exchanger improves the heat transfer coefficient and power plant efficiency while reducing the pressure drop and cooling system cost. Life cycle assessment (LCA) and techno-economic analysis (TEA) are used to evaluate the environmental and economic performance of EPCM heat exchangers from cradle-to-grave and to compare them to wet cooling and traditional air-cooled condensers. A thermodynamic model is developed to predict the EPCM heat exchanger performance for plant-scale operations. Equipment and construction costs for heat exchangers are estimated based on design parameters obtained from the thermodynamic model. Both process-LCA and economic-input–output LCA are used to simulate and test the sensitivity of EPCM alternatives with commercial wet and dry cooling technologies. We investigate options for EPCM end-of-life management upon retiring the heat exchanger and construct a process-based LCA model to estimate a greenhouse gas (GHG) emissions credit for recycling the EPCM. The life cycle GHG emission of the novel dry cooling technology is 1.16 kg CO 2 eq. /MWh compared with the 1.1–4.3 kg CO 2 eq. /MWh reported for commercial dry cooling technologies and consumes 9.5 L/MWh e of water for cradle-to-gate life cycle, which is significantly lower than that of wet cooling systems. The TEA shows many advantages of EPCM cooling technology over the state-of-art dry cooling solutions. Overall, the EPCM heat exchanger provides a better alternative compared to existing dry cooling and wet cooling technologies.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Technology Feasibility of High-Temperature Heat Pumps for Industrial Drying Process in the US

High-temperature heat pumps are a prospective technology for electrifying and decarbonizing industrial drying processes. This study investigates the technological potential of HTHPs in replacing fossil-fuel burners or steam boilers in industrial spray dryers. The performance of HTHPs with three configurations was investigated, including high high-temperature heat pump boosted with an electric air heater, a steam-generating high-temperature heat pump with multi-stage mechanical vapor compressions, and transcritical high-temperature heat pumps. R1336mzz(Z) is used as the refrigerant in both subcritical and transcritical high-temperature heat pumps, and R717 is used as the working fluid in the mechanical vapor recompression and the heat transfer fluids. Thermodynamic models are built to evaluate the energy efficiency of HTHPs. A case study was carried out on an industrial spray dryer integrated with a waste heat recuperator, where the HTHPs are used to recover precooled air with a dew point of 40℃ and supply heat for drying air at 200℃. For a high-temperature heat pump boosted with an electric air heater, a higher system-level COP is achieved with a high supply temperature from high-temperature heat pump. For a high-temperature heat pump with mechanical vapor recompressions, larger temperature drops in the flashing tank provide higher heat capacities but almost constant values of the coefficient of performance. For a transcritical high-temperature heat pump, an optimum discharge pressure exists for the temperature profiles within the gas cooler and the coefficient of performance. The transcritical high-temperature heat pump provides the best energy efficiency among the three configurations. The theoretical results prove the technical feasibility of high-temperature heat pumps in industrial air-drying applications. .

Wang, Pengtao↗
DOE OSTI2024

Alternating conduction and convection drying of paper – an experimental analysis with a continuous data acquisition approach

In conventional multi-cylinder drying of paper and board, both conductive drying from steam-heated dryer cylinders and convective drying by flowing air over the paper surface in the pockets are used. Conductive drying from steam-heated drying cylinders is a critical component in providing the necessary thermal energy to paper and board as they dry. Steam temperature and internal and external resistances at the contacting surface are critical process parameters influencing the conductive drying process. An experimental setup was developed to study the alternating conductive and convective drying of paper and board. Paper sheet moisture, temperature, and temperature distribution within the heated platen and the instantaneous heat flux as the sheet was being dried were measured. The instantaneous heat flux, contact heat transfer coefficient, and drying rates were determined as drying proceeds. Experimental results, as well as comparisons to literature and commercial data, are presented. The conductive heat transfer coefficients determined were compared to traditional correlations normally used in the modeling of paper drying. Similarly, the convective heat and mass transfer coefficients are also determined and compared to literature data. In addition to the evaluation of alternating conductive and convective drying characteristics of paper and board, the potential inclusion of auxiliary energy components will also be included. Experimental results from the conduction and convection drying system are presented. Furthermore, this data will be useful in process development, intensification of manufacturing processes, and modeling and simulation of paper drying processes.

42 ENGINEERING↗
DOE OSTI2020

Revisiting Recent U.S. Heat Waves in a Warmer and More Humid Climate

The frequency and intensity of heat waves in the United States is projected to increase in the 21st century. We investigate dry and humid heat waves in a pair of high-resolution model simulations that constrain large-scale atmospheric circulation, to isolate the thermodynamic impacts on characteristics of present and future heat waves over the United States. The two kinds of heat waves show differences in mean intensity, amplitude, duration, and frequency over the Southeast, Northeast, and Midwest, while their characteristics are largely similar in the drier central and western United States. In a warmer climate, relative humidity is projected to decrease during dry heat waves, whereas it remains unchanged during humid heat waves. However, the overall increase in daily maximum temperature intensifies the heat stress during future humid and dry heat waves across all regions. With large-scale circulation constrained, these simulations emphasize the importance of thermodynamic drivers in determining future heat wave characteristics.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Comparing Growth Rates of Simulated Moist and Dry Convective Thermals

The spreading rates of convective thermals are linked to their net entrainment, and previous literature has suggested differences in spreading rates between moist and dry thermals. Here, growth rates of idealized numerically simulated axisymmetric dry and moist convective thermals are directly compared. In an environment with dry-neutral stratification, the increase of thermal radius with height dR / dz is a larger by a factor of 1.7 for dry thermals relative to moist thermals. The fractional change in thermal volume ε is also greater for dry thermals within a distance of ~4 radii from the initial thermal height. Values of dR / dz are nearly constant with height for both moist and dry thermals consistent with classical theory based on dimensional analysis. The simulations are also consistent with theory relating impulse, circulation, and spreading rate for dry thermals proposed in previous papers and extended here to moist thermals, predicting they will spread less than dry thermals. Tests adding heating to dry thermals, either spread uniformly across the thermal volume or concentrated in the inner core, indicate that dR / dz and ε are smaller for moist thermals because latent heating is confined mostly to their cores. Additional axisymmetric moist simulations using modified lapse rates and large-eddy simulations support this analysis. Overall, these results indicate that slow spreading rates are a fundamental feature of moist thermals caused by latent heating that alters the spatial distribution of buoyancy within them relative to dry thermals.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Process intensification approach to enhancing heat and mass transfer: Radio frequency (RF) assisted drying of paper and board

Conventional multi-cylinder drying of paper and board typically relies on both conductive drying from steam-heated cylinders and convective drying, where heated air flows over the paper web surface. Conduction primarily contributes to heat transfer, while convection is the main driver of mass transfer. However, conventional drying systems are heavily dependent on steam, usually powered by fossil fuels, and are often energy-inefficient with high levels of waste. Additionally, these surface-driven processes result in a lower percentage of energy absorption compared to the energy supplied, leading to significant energy losses. To improve this long-standing process, an experimental system was developed to investigate a process intensification approach involving the integration of Radio Frequency (RF) heating, a volumetric electromagnetic technology, alongside traditional conduction and convection drying methods. This study also emphasizes the use of sensors to continuously monitor key parameters such as moisture content, supply system temperatures, sample temperatures, air flows, and drying rates in real-time. The effect of RF as an auxiliary energy source in localized environments at varying moisture levels was explored to optimize industrial drying systems, quantify potential improvements, and provide insights for future studies. Experimental results from trials combining RF with convection and with the base case alternating conduction-convection drying processes are presented. It is shown that RF is a viable process intensification approach for paper drying improving the drying rate and energy intensity at higher moisture contents. These findings offer valuable insights for process intensification and contribute to the process development, modeling, and simulation of advanced paper drying techniques.

42 ENGINEERING↗
DOE OSTI2020

Reactions during conversion of simplified low-activity waste glass feeds

The mechanisms that affect the incorporation of 99Tc, a volatile radioactive component of concern, into glass melt during vitrification of low-activity waste (LAW) are being investigated to develop the method to increase the retention of 99Tc in glass waste form. Previous studies with simulated LAW glass feeds (slurry mixture of liquid waste and chemical/mineral additives) demonstrated that the early stage feed-to-glass conversion reactions below 800°C are critical for the Re (used as a nonradioactive surrogate of 99Tc) retention in glass. To examine the effect of feed composition on the feed-to-glass conversion reactions, simplified systems containing major LAW components (NaNO3 and NaOH) and representative additive components (SiO2 and H3BO3) were designed and tested. The ratio of H3BO3 to NaNO3 was varied in three-component system without NaOH and that of NaOH to NaNO3 was varied in the four-component system at a fixed H3BO3 to NaNO3 ratio. As a first step of testing with simplified feeds, this study applied thermal analyses and phase characterization of the reacting feeds, which were performed without the addition of Re, to investigate the evolution of salt phases during slurry drying process and upon heating of dried feeds.

Jin, Tongan↗
DOE OSTI2021

Methods and systems for 3D printing with powders

A method of printing a three dimensional article (201) can include forming a bottom layer of the three dimensional article (201) by spraying a dry build material powder (210) onto a build platform (230) while heating the dry build material powder (210). The dry build material powder (210) can include metal or ceramic particles mixed with a polymeric binder having a softening point temperature. The dry build material powder (210) can be heated to a temperature above the softening point temperature such that the dry build material powder (210) adheres to the build platform (230). Subsequent layers can be formed by spraying dry build material powder (210) onto a lower layer while heating the dry build material powder (210) such that the dry build material powder (210) adheres to the lower layer.

Fang, Zhigang Zak↗
DOE OSTI2025

Process intensification approach to enhancing heat and mass transfer during drying: Ultrasonic (US) assisted drying of paper and board

Drying of paper and board is conventionally achieved through alternating conduction (steam-heated cylinders) and pocket convection (heated air over the paper web surface). These conventional drying systems rely heavily on steam from fossil fuels, resulting in inefficiencies, high energy usage, and thermal losses due to surface-driven mechanisms. Here, to address these challenges, an experimental system, with in-situ drying characteristics measurements, was developed to investigate process intensification using ultrasonic-based dewatering—a volumetric, pressure-driven acoustic energy system—integrated with conventional drying. The objectives of this study are to assess the impact of ultrasonics (US) on dewatering; compare performances to conventional drying systems; identify improvements in drying rate and energy use as a function of moisture content; and gain potential insights on heat and mass transfer mechanisms during US-assisted drying. US performance was evaluated across frequencies, power levels, pulp types, and basis weights. Results show that improvements to ultrasonic applications in conjunction with convection were 30-43% in drying rate and 20-35% in drying time over continuous and intermittent applications. When combined with conduction and convection, ultrasonics yielded up to 20% improvement in both rate and time and up to 20% reduction in energy consumption. Observations support a hypothesis of extension of the constant rate period due to improved capillary flow at higher moisture content and enhancing vapor diffusion and boundary layer disruption at lower moisture contents during falling rate period. These findings will inform future modeling, simulation, design and optimization of advanced drying systems.

42 ENGINEERING↗
DOE OSTI2024

Experimental analysis of convective drying of paper and board

Conventional multi-cylinder drying of paper and board involves a mixture of conductive drying from steam-heated dryer cylinders and convective drying by the flow of heated air over the surface of the paper web in the pockets. Pocket ventilation is a critical component in assisting heat and mass transfer during the drying process but is the primary contributor towards removing evaporated water from the web. Air temperature, velocity, and humidity are critical parameters involved in the convective drying process. This paper covers an experimental study involving the design and development of a small lab-scale setup for convective drying of various grades of paper and board, monitoring multiple parameters like paper temperature, moisture content, air humidity, temperature, and velocity measured in situ as the drying proceeds with continuous and accurate sampling capabilities for all parameters in the sample and the system. Instantaneous drying rates, heat, and mass transfer coefficients were also deduced for every time step till the paper completely dried. Furthermore, the coefficients obtained were also reported in the form of dimensionless correlations, and the results were compared against traditional correlations used in the modelling of paper drying. Furthermore, this data will be useful in process development, modelling, design, and the paper drying process simulation.

42 ENGINEERING↗
DOE OSTI2021

Opposite Responses of the Dry and Moist Eddy Heat Transport Into the Arctic in the PAMIP Experiments

Given uncertainty in the processes involved in polar amplification, elucidating the role of poleward heat and moisture transport is crucial. The Polar Amplification Model Intercomparison Project (PAMIP) permits robust separation of the effects of sea ice loss from sea surface warming under climate change. We utilize a moist isentropic circulation framework that accounts for moisture transport, condensation, and eddy transport, in order to analyze the circulation connecting the mid-latitudes and the Arctic. In PAMIP's atmospheric general circulation model experiments, prescribed sea ice loss reduces poleward heat transport (PHT) by warming the returning moist isentropic circulation at high latitudes, while prescribed warming of the ocean surface increases PHT by strengthening the moist isentropic circulation. Inter-model spread of PHT into the Arctic reflects the tug-of-war between sea-ice and surface-warming effects.

58 GEOSCIENCES↗
DOE OSTI2020

Use of a Pressurized Water Treatment to Prevent Cracking of Internal Gelation Sol-Gel Microspheres

Pressurized water treatments were investigated as a means to prevent cracking of internal gelation sol-gel microspheres upon drying and heating. A batch of gelled cerium oxide microspheres was prepared, split into two samples that were processed with and without a pressurized water treatment, and dried in air at room temperature. Thermal gravimetric analysis was used to compare the mass loss profiles between the two samples and to understand volatile emissions from cerium oxide microspheres during heat treatments up to 600 °C. Microspheres that were processed without a pressurized water treatment lost approximately 4.6 times more mass upon heating than microspheres that were subjected to a pressurized water treatment. Comparison of the cracking behavior of microspheres prepared with and without a pressurized water treatment indicated that microspheres subjected to a pressurized water treatment were virtually crack-free after heat treatments. Conversely, microspheres processed without a pressurized water treatment, which is typical of traditional washing processes, exhibited extensive cracking. Analysis of residues dried from pressurized water treatment effluents indicated that hexamethylenetetramine and urea, which are excess reactants from the internal gelation process, were removed from gelled microspheres during the pressurized water treatment step. Traditional processing methods for preparing internal gelation microspheres use specific feed solution and gelation parameters to reduce subsequent cracking upon drying and heating. Results from this study indicate that more aggressive gel-forming conditions may be used to produce crack-free microspheres, if a pressurized water treatment step is included after washing and before air-drying.

cerium oxide, internal gelation, microsphere, TRIS↗
DOE OSTI2023

Preparation of SiO 2 —TiO 2 composite aerogels and SiO 2 @TiO 2 core-shell aerogels with high thermal stability and enhanced photocatalysis

According to one inventive concept, a method for forming an aerogel includes forming a SiO 2 gel, forming a mixture of the SiO 2 gel and a TiCl 4 -derived precursor sol, wherein the TiCl 4 sol is comprised of TiCl 4 and a solvent, forming a SiO 2 /TiO 2 wet gel, drying the SiO 2 /TiO 2 wet gel, and heating the dried SiO 2 /TiO 2 gel.

Neto, Elias Paiva Ferreira↗
DOE OSTI2021

Mechanism of drying-induced change in the physical properties of concrete: A mesoscale simulation study

Although many studies have found that drying alters the mechanical properties of concrete, the mechanism behind this change remains unclarified. The aim of this study is to elucidate the mechanism of change in properties of concrete after drying through the numerical calculation: a 3D mesoscale rigid-body-spring model (RBSM) with three phases, i.e. mortar, aggregate, and the interfacial transition zone while considering the properties changes of mortar due to drying. Based on the RBSM results, it is concluded that the change in compressive strength due to drying and heating is determined by a balance of the impact of drying-induced microcracking around coarse aggregates and the change in mechanical properties of the mortar due to drying. These mechanisms change the applied load required to reach the critical crack width and distribution, at which rim of the specimen begins to isolate from the core region and the load sustained by the rim decreases.

36 MATERIALS SCIENCE↗