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NASA NTRSDate not supplied

Model Predictive Control Strategies for Turbine Electrified Energy Management

The increasing electrification of aircraft propulsion systems is leading to new control architectures being developed to address integration between electric machines and gas-based turbine engines. For hybrid-electric propulsion systems, current conceptual architectures often couple electric machines with the shafts of gas turbine engines and introduce energy storage. Leveraging the electrical power system of hybridized engines, Turbine Electrified Energy Management (TEEM) is a recent control approach that improves transient operability in an effort to enable more efficient and lighter weight turbomachinery. This study seeks to expand TEEM’s application beyond traditional proportional integral (PI) control by presenting linear model predictive control (MPC) schemes to execute the TEEM concept. Through constraint selection and cost function design, transient operability goals for TEEM are considered with no external logic or saturation. Unique to the designs are the use of a washout filter, which simplifies transient detection and motor activation logic. The proposed architectures are implemented with both centralized MPC and distributed MPC approaches, and comparisons are drawn to a benchmark PI controller simulated on a nonlinear turbofan engine model at one ground condition and one cruise condition. Performance is evaluated using compressor maps, stall margin performance, and two novel metrics: transient stack usage and transient excursion integral. Results reveal the linear MPC scheme performs comparably to the baseline controller and can be implemented in at least two distinct configurations with potential for further modifications, thus establishing the groundwork for future investigations.

Model Predictive Control↗
NASA NTRSDate not supplied

Model Predictive Control Strategies for Turbine Electrified Energy Management

The increasing electrification of aircraft propulsion systems is leading to new control architectures being developed to address integration between electric machines and gas-based turbine engines. For hybrid-electric propulsion systems, current conceptual architectures often couple electric machines with the shafts of gas turbine engines and introduce energy storage. Leveraging the electrical power system of hybridized engines, Turbine Electrified Energy Management (TEEM) is a recent control approach that improves transient operability in an effort to enable more efficient and lighter weight turbomachinery. This study seeks to expand TEEM’s application beyond traditional proportional-integral (PI) control by presenting linear model predictive control (MPC) schemes to execute the TEEM concept. Through constraint selection and cost function design, transient operability goals for TEEM are considered with no external logic or saturation. Unique to the designs are the use of a washout filter, which simplifies transient detection and motor activation logic. The proposed architectures are implemented with both centralized MPC and distributed MPC approaches, and comparisons are drawn to a benchmark PI controller simulated on a nonlinear turbofan engine model at one ground condition and one cruise condition. Performance is evaluated using compressor maps, stall margin performance, and two novel metrics: transient stack usage and transient excursion integral. Results reveal the linear MPC scheme performs comparably to the baseline controller and can be implemented in at least two distinct configurations with potential for further modifications, thus establishing the groundwork for future investigations.

Model Predictive Control↗
NASA NTRS2023

Model Predictive Control Strategies for Turbine Electrified Energy Management

The increasing electrification of aircraft propulsion systems is leading to new control architectures being developed to address integration between electric machines and gas-based turbine engines. For hybrid-electric propulsion systems, current conceptual architectures often couple electric machines with the shafts of gas turbine engines and introduce energy storage. Leveraging the electrical power system of hybridized engines, Turbine Electrified Energy Management (TEEM) is a recent control approach that improves transient operability in an effort to enable more efficient and lighter weight turbomachinery. This study seeks to expand TEEM’s application beyond traditional proportional-integral (PI) control by presenting linear model predictive control (MPC) schemes to execute the TEEM concept. Through constraint selection and cost function design, transient operability goals for TEEM are considered with no external logic or saturation. Unique to the designs are the use of a washout filter, which simplifies transient detection and motor activation logic. The proposed architectures are implemented with both centralized MPC and distributed MPC approaches, and comparisons are drawn to a benchmark PI controller simulated on a nonlinear turbofan engine model at one ground condition and one cruise condition. Performance is evaluated using compressor maps, stall margin performance, and two novel metrics: transient stack usage and transient excursion integral. Results reveal the linear MPC scheme performs comparably to the baseline controller and can be implemented in at least two distinct configurations with potential for further modifications, thus establishing the groundwork for future investigations.

Model Predictive Control↗
NASA NTRS2005

Numerical Study of High-Temperature Jet Flow Using RANS/LES and PANS Formulations

Two multi-scale-type turbulence models are implemented in the PAB3D solver. The models are based on modifying the Reynolds Averaged Navier-Stokes (RANS) equations. The first scheme is a hybrid RANS/LES model utilizing the two-equation (k(epsilon)) model with a RANS/LES transition function dependent on grid spacing and the computed turbulence length scale. The second scheme is a modified version of the Partially Averaged Navier-Stokes (PANS) model, where the unresolved kinetic energy parameter (f(sub k)) is allowed to vary as a function of grid spacing and the turbulence length scale. This parameter is estimated based on a novel two-stage procedure to efficiently estimate the level of scale resolution possible for a given flow on a given grid for Partial Averaged Navier-Stokes (PANS). It has been found that the prescribed scale resolution can play a major role in obtaining accurate flow solutions. The parameter f(sub k) varies between zero and one and equal to one in the viscous sub layer, and when the RANS turbulent viscosity becomes smaller than the LES viscosity. The formulation, usage methodology, and validation examples are presented to demonstrate the enhancement of PAB3D's time-accurate and turbulence modeling capabilities. The accurate simulations of flow and turbulent quantities will provide valuable tool for accurate jet noise predictions. Solutions from these models are compared to RANS results and experimental data for high-temperature jet flows. The current results show promise for the capability of hybrid RANS/LES and PANS in simulating such flow phenomena.

Abdol-Hamid, Khaled S.↗
NASA NTRS2004

Numerical Study of Flow Past a Circular Cylinder Using RANS, Hybrid RANS/LES and PANS Formulations

Two multiscale type turbulence models are implemented in the PAB3D solver. The models are based on modifying the Reynolds Averaged Navier-Stokes (RANS) equations. The first scheme is a hybrid RANS/LES model utilizing the two-equation (k(sub epsilon)) model with a RANS/LES transition function dependent on grid spacing and the computed turbulence length scale. The second scheme is a modified version of the partially averaged Navier-Stokes (PANS) model, where the unresolved kinetic energy parameter (f(sub k)) is allowed to vary as a function of grid spacing and the turbulence length scale. Solutions from these models are compared to RANS results and experimental data for a stationary and rotating cylinder. The parameter f(sub k) varies between zero and one and has the characteristic to be equal to one in the viscous sub layer, and when the RANS turbulent viscosity becomes smaller than the LES viscosity. The formulation, usage methodology, and validation example are presented to demonstrate the enhancement of PAB3D's time-accurate and turbulence modeling capabilities. The models are compared to RANS results and experimental data for turbulent separated flows (TS) and laminar separated flows (LS) around stationary and rotating cylinders. For a stationary cylinder, the TS case is accurately simulated using the general two-equation k(sub epsilon) turbulence model (eddy-viscosity model). PAB3D accurately predicts the drag coefficient (CD), lift coefficient (CL) and the Strouhal number (St). The LS case was a challenge for the RANS computation with an eddy-viscosity turbulence model. The RANS/LES and PANS performed well and showed marked improvements over the RANS solution. The modified PANS model was the most accurate. For the rotating cylinder, the spin ratio varied from zero to one, and the PANS results were in good agreement with published experimental data. RANS/LES and PANS capture both temporal and spatial fluctuations and produce large-scale structures that do not occur in the RANS simulation. The current results show promise for the capability of PANS in simulating unsteady and complex flow phenomena.

Elmiligui, Alaa A.↗
NASA NTRS2008

Calculations of High-Temperature Jet Flow Using Hybrid Reynolds-Average Navier-Stokes Formulations

Two multiscale-type turbulence models are implemented in the PAB3D solver. The models are based on modifying the Reynolds-averaged Navier Stokes equations. The first scheme is a hybrid Reynolds-averaged- Navier Stokes/large-eddy-simulation model using the two-equation k(epsilon) model with a Reynolds-averaged-Navier Stokes/large-eddy-simulation transition function dependent on grid spacing and the computed turbulence length scale. The second scheme is a modified version of the partially averaged Navier Stokes model in which the unresolved kinetic energy parameter f(sub k) is allowed to vary as a function of grid spacing and the turbulence length scale. This parameter is estimated based on a novel two-stage procedure to efficiently estimate the level of scale resolution possible for a given flow on a given grid for partially averaged Navier Stokes. It has been found that the prescribed scale resolution can play a major role in obtaining accurate flow solutions. The parameter f(sub k) varies between zero and one and is equal to one in the viscous sublayer and when the Reynolds-averaged Navier Stokes turbulent viscosity becomes smaller than the large-eddy-simulation viscosity. The formulation, usage methodology, and validation examples are presented to demonstrate the enhancement of PAB3D's time-accurate turbulence modeling capabilities. The accurate simulations of flow and turbulent quantities will provide a valuable tool for accurate jet noise predictions. Solutions from these models are compared with Reynolds-averaged Navier Stokes results and experimental data for high-temperature jet flows. The current results show promise for the capability of hybrid Reynolds-averaged Navier Stokes and large eddy simulation and partially averaged Navier Stokes in simulating such flow phenomena.

Abdol-Hamid, Khaled S.↗
NASA NTRS2013

Assessments of a Turbulence Model Based on Menter's Modification to Rotta's Two-Equation Model

The main objective of this paper is to construct a turbulence model with a more reliable second equation simulating length scale. In the present paper, we assess the length scale equation based on Menter s modification to Rotta s two-equation model. Rotta shows that a reliable second equation can be formed in an exact transport equation from the turbulent length scale L and kinetic energy. Rotta s equation is well suited for a term-by-term modeling and shows some interesting features compared to other approaches. The most important difference is that the formulation leads to a natural inclusion of higher order velocity derivatives into the source terms of the scale equation, which has the potential to enhance the capability of Reynolds-averaged Navier-Stokes (RANS) to simulate unsteady flows. The model is implemented in the PAB3D solver with complete formulation, usage methodology, and validation examples to demonstrate its capabilities. The detailed studies include grid convergence. Near-wall and shear flows cases are documented and compared with experimental and Large Eddy Simulation (LES) data. The results from this formulation are as good or better than the well-known SST turbulence model and much better than k-epsilon results. Overall, the study provides useful insights into the model capability in predicting attached and separated flows.

Abdol-Hamid, Khaled S.↗
NASA NTRS2005

Tectonic-Climate Interactions in Action Orogenic Belts: Quantification of Dynamic Topography with SRTM data

This project was undertaken to examine the approach to steady state in collisional mountain belts. Although the primary thrust of this grant was to look at larger collisional mountain belts, such as the Himalaya, the Tien Shan, and Southern Alps, we began by looking at smaller structures represented by growing and propagating folds. Like ranges that are evolving toward a topographic steady state, these folds undergo a series of morphologic changes as they are progressively uplifted and eroded. We wanted to document the nature of these changes and to try to discern some of the underlying controls on them. We initially focused on the Wheeler Ridge anticline in southern California. Subsequently, we progressed to looking at the topographic development and the effects of differential uplift and glaciation on the Kyrgyz Range in the northern Tien Shan. This range is unusual inasmuch as it is transformed along its length from a simple uplift with a largely preserved Mesozoic erosion surface arching across it to a highly dissected and heavily glaciated uplift in the region where uplift has been sustained at higher rates over longer intervals. In efforts to understand the distribution of erosion rates at 10(exp 3) - 10(exp 5) year time scales, cosmogenic radionuclide (CRN) concentrations have been gaining increasingly widespread usage (Brown et al., 1995; Riebe et al., 2004; Riebe et al., 2001; Vance et al., 2003). Most studies to date, however, have been conducted in slowly eroding ranges. In rapidly eroding mountains where landslides deliver most of the sediments to the rivers, we hypothesized that CRN concentrations could be highly perturbed by the stochastic processes of landsliding. Therefore, we undertook the development of a numerical model that simulated the effects of both landsliding and grain-by-grain attrition within fluvial catchments. This modeling effort has shown the effects of catchment size and erosion rate on CRN concentrations and allows a prediction of where to sample to obtain the optimal erosion rate estimates using CRN techniques. Finally, we developed computational techniques to operate on DEMs to extract useful information that would enable quantification of climate-erosion interactions. In particular, we worked on rapid techniques to define catchments of any given range of sizes, to extract channel gradients, to combine precipitation information to calculate discharge, and to utilize various stream-power models to determine the erosional energy within any given catchment within a transect. We briefly describe results from Wheeler Ridge, the Kyrgyz Range, the Nepal Himalaya, and our numerical modeling.

Burbank, Douglas W.↗
NASA NTRSDate not supplied

Providing Long-term Solar and Meteorological Resource Information from NASA Research through the GIS-Enabled POWER Web Services Portal

Solar and other renewable energy systems are optimized using geophysical parameters describing information about the solar resource and meteorological environments and how those environments may be changing in time. The Prediction of Worldwide Renewable Energy Resource (POWER) team at the NASA LaRC Research Center deployed its first version of the revitalized POWER geophysical parameter website that employs Esri Geographic Information System (GIS) tools. This web application provides access to both time series and climatological data sets spanning from a few days behind real-time back to the early 1980’s with a spatial resolution of 0.5 x 0.5 degree, thus extending over 30 years. The GIS tools enable, generate and store climatological averages using spatial queries and calculations in a spatial database resulting in greater accessibility to government agencies, industry and individuals. There is an API that provides data through a URL coding and can also invoked inside user software packages. Output data formats now include ASCII, CSV, geoTiff, JSON and .netCDF. Since May 2018, over 10.4 TB of data have been delivered to fulfill over 110 million data requests from 240,000 unique user IPs (https://power.larc.nasa.gov). This presentation provides an overview of this project and the current version of the new POWER web capabilities through to the end usage. Surface solar parameters are adapted from both the NASA/GEWEX (Global and Energy Water Cycle Exchange) SRB (Surface Radiation Budget) project and the CERES (Clouds and Earth’s Radiant Energy System) data products. The meteorological parameters are adapted from NASA’s MERRA-2 (Modern Era Retrospective-analysis for Research and Applications). We review uncertainty of various basic parameters using surface measurements. After the introduction, we specifically discuss various clusters of parameters for equator pointing tilted surfaces that provide for the estimation of optimal tilt angle by month and year. The discussion will emphasize a few examples of how solar and building engineers are using the data products. We will then preview the capabilities of Version 2 featuring examples of hourly solar and meteorological data products, customized user reports and expanded web mapping services from CERES data products. The web services provide a unique, expandable resource for renewable energy systems engineers to design, evaluate and optimize to environments worldwide.

Solar Resource↗
NASA NTRS1971

Application of Monte Carlo techniques to optimization of high-energy beam transport in a stochastic environment

An algorithm employing a modified sequential random perturbation, or creeping random search, was applied to the problem of optimizing the parameters of a high-energy beam transport system. The stochastic solution of the mathematical model for first-order magnetic-field expansion allows the inclusion of state-variable constraints, and the inclusion of parameter constraints allowed by the method of algorithm application eliminates the possibility of infeasible solutions. The mathematical model and the algorithm were programmed for a real-time simulation facility; thus, two important features are provided to the beam designer: (1) a strong degree of man-machine communication (even to the extent of bypassing the algorithm and applying analog-matching techniques), and (2) extensive graphics for displaying information concerning both algorithm operation and transport-system behavior. Chromatic aberration was also included in the mathematical model and in the optimization process. Results presented show this method as yielding better solutions (in terms of resolutions) to the particular problem than those of a standard analog program as well as demonstrating flexibility, in terms of elements, constraints, and chromatic aberration, allowed by user interaction with both the algorithm and the stochastic model. Example of slit usage and a limited comparison of predicted results and actual results obtained with a 600 MeV cyclotron are given.

Parrish, R. V.↗
NASA NTRSDate not supplied

Runway Configuration Management with Offline Reinforcement Learning

Runway configuration management (RCM) is a challenging task, and it affects the efficiency of the National Airspace System (NAS) and airport surface operations significantly. Each airport, depending on the geometry, capacity, local climate patterns, etc. has multiple configurations for the runway usage for arriving and departing flights. Many factors such as the incoming/outgoing traffic load, wind direction and speed, convective weather, cloud ceiling and other environmental factors might affect the choice of a runway configuration at any point in time. However, other factors such as safety measures and regulations, noise abatement, capacity of each configuration, and preference of the air traffic controllers (ATCs) can also play a significant role in selecting the configuration. A sub-optimal selection of the runway configuration, or delay in making configuration changes might result in significant increase in taxi times for aircraft on the surface of the airport, fuel and energy use of the aircraft, and maintenance costs. It can also lead to safety concerns, such as an aircraft performing one or more go-arounds before being able to land. All these factors make RCM an extremely important and challenging decision-making process for the ATCs. The current state of practice sets the runway configuration by the ATCs based on relevant information available at the time including weather, traffic, noise abatement, safety bounds, etc. This makes the decision-making process subjective based on the accuracy of the available information and the bias in human decision making. Unfortunately, this approach yields poor results (e.g., significant delays) if the predicted outcomes are uncertain and their relative impact is not well understood. This is especially evident when the uncertainty increases the size of possible predicted outcomes (combinatorial explosion in possible scenarios) that cannot be handled by human reasoning. On the other hand, an automated approach based on machine intelligence can make use of historical data and search through all (or significant amount of) possible scenarios under uncertainty and make well-informed decisions.

Milad Memarzadeh↗
NASA NTRS1999

A Study of Direct and Cloud-Mediated Radiative Forcing of Climate Due to Aerosols

The Intergovernmental Panel on Climate Change (IPCC) has reported that in the southeastern US and eastern China, the general greenhouse warming due to anthropogenic gaseous emissions is dominated by the cooling effect of anthropogenic aerosols. To verify this model prediction in eastern China and southeastern US, we analyzed regional patterns of climate changes at 72 stations in eastern China during 1951- 94 (44 years), and at 52 stations in the southeastern US during 1949-94 (46 years) to detect the fingerprint of aerosol radiative forcing. It was found that the mean rates of change of annual mean daily, maximum, minimum temperatures and diurnal temperature range (DTR) in eastern China were 0.8, -0.2, 1.8, and -2.0 C/100 years respectively, while the mean rates of change of annual mean daily, maximum, minimum temperatures and DTR in the southeastern US were -0.2, -0.6, 0.2, and -0.8 C/100 years, respectively. This indicates that the high rate of increase in annual mean minimum temperature in eastern China results in a slightly warming trend of daily temperature, while the high rate of decrease in annual mean maximum temperature and low rate of increase in annual mean minimum temperature lead to the cooling trend of daily temperature in the southeastern US. We found that the warming from the longwave forcing due to both greenhouse gases and aerosols was completely counteracted by the shortwave aerosol forcing in the southeastern US in the past 46 years. A slightly overall warming trend in eastern China is evident; winters have become milder. This finding is explained by hypothesizing that increasing energy usage during the past 44 years has resulted in more coal and biomass burning, thus increasing the emission of absorbing soot and organic aerosols in eastern China. Such emissions, in addition to well-known Asia dust and greenhouse gases, may be responsible for the winter warming trend in eastern China that we have reported here. The sensitivity of aerosol radiative properties to aerosol composition, size distribution, relative humidity (RH) is examined for the following aerosol systems: inorganic and organic ions (Cl-, Br-, NO3 -, SO4 2-, Na+, NH4 +, K+, Ca2+, Mg2+, HCOO-, CH3COO-, CH3CH2COO-, CH3COCOO-, OOCCOO2-, MSA-1); water-insoluble inorganic and organic compounds (elemental carbon, n-alkanes, SiO2, Al2O3, Fe2O3 and other organic compounds). The partial molar refraction method was used to calculate the real part of the refractive index. It was found that the asymmetry factor increased by approximately 48% with the real part varying from 1.40 to 1.65, and the single scattering albedo decreased by 24% with the imaginary part varying from -0.005 to -0.1. The asymmetry factor increased by 5.4 times with the geometric standard deviation varying from 1.2 to 3.0. The radiation transmission is very sensitive to the change in size distribution; other factors are not as significant. To determine the aerosol direct radiative forcing (ADRF), the aerosol optical depth (AOD) values at the three operational wavelengths (415, 500 and 673 nm) were determined at a regionally representative site, namely, Mt. Gibbs (35.78 deg N, 82.29 deg W, elevation 2006 m) in Mt. Mitchell State Park, NC, and a site located in an adjacent valley (Black Mountain, 35.66 deg N, 82.38 deg W, elevation 951 m) in the southeastern US. The two sites are separated horizontally by 10 km and vertically by 1 km. It was found that the representative total AOD values at 500 nm at the valley site for highly polluted (HP), marine (M) and continental (C) air masses were 0.68 +/- 0.33, 0.29 +/- 0.19 and 0.10 +/- 0.04, respectively. A search-graph method was used to retrieve the columnar size distribution (number concentration N, effective radius reff and geometric standard deviation=?g) from the optical depth observations at three operational wavelengths. The ground albedo, single scattering albedo and imaginary part of the refractive index were calculated using a mathematically unique procedure involving a Mie code and a radiative transfer code in conjunction with the retrieved aerosol size distribution, AOD, and diffuse-direct irradiance ratio. It was found that N, r(eff) and sigma(g) were in the ranges of 10 to 1.7 x 10(exp 4)/cubic cm, 0.09 to 0.68 micrometers and 1.12 to 2.95, respectively. The asymmetry factor and single scattering albedo were in the ranges of 0.63 to 0.75 and 0.74 to 0.97 respectively. The ground albedo for the forested terrain and imaginary part of refractive index were found to be in the ranges of 0.06 to 0.29 and 0.005 to 0.051 respectively. On the basis of these aerosol radiative properties obtained at the research sites and computations using the Column Radiation Model (CRM) of National Center of Atmospheric Research (NCAR) Community Climate Model (CCM3), it was found that the average cloud-free 24-hour ADRF values were -13 +/- 8, -8 +/- 3, -33 +/- 16 W/square m for marine, continental, and polluted air masses, respectively. On the assumption that the fractional coverage of clouds is 0.61, it was estimated that the annual mean ADRF was 7 +/- 2 W/square m in the southeastern US. The review with respect to the current knowledge of organic acids shows that aerosol formate and acetate concentrations range from 0.02 to 5.3 nmol/cubic m and from 0.03 to 12.4 nmol/cubic m respectively, and that between 34% to 77% of formate and between 21% to 66% of acetate are present in the fine fraction of aerosols. It was found that although most (98-99%) of these volatile organic acids were present in the gas phase, their concentrations in the aerosol particles were sufficient to make them a good candidate for cloud condensation nuclei (CCN). It is hypothesized that organic acids are at least one of the primary sources of CCN in the atmosphere due to their ubiquitous presence in the troposphere, especially over the continental forested areas. The results of our measurements at Palmer Station, Antarctica show that the daily average CCN concentrations at 0.3% and 1% supersaturations ranged from 0.3 to 160/cubic cm and from 4 to 168/cubic cm, respectively, during the period from 17 January to 26 February, 1994. New evidence for substantial and definitive CCN enhancement near and within cloud has been observed at Mt. Mitchell, North Carolina. The results show that the average monthly CCN concentrations were 460 +/- 217, 386 +/- 286, 429 +/- 228 and 238 +/- 134/cubic cm for in-cloud, overcast, clear and rainy conditions, respectively. The typical CCN spectra show that there were a lot of small CCN produced and the ion concentrations (especially H+ and SO4 2-) were very high during the CCN enhancement period. The significantly positive correlation between black carbon (BC) and CCN at 1% supersaturation indicates that a percentage of the BC measured at the site may be in the form of an internal mixture and participated in the formation of CCN.

Yu, Shao-Cai↗
NASA NTRS2021

Hybrid Electric Aircraft Thermal Management: Now, New Visions and Future Concepts and Formulation

The global fuel consumption by commercial airlines has increased each year since 2009 and is predicted to reach an all-time high of 97 billion gallons in 2019. There is also an environmental impact from this: CO2 emissions from commercial passenger and freight operations totaled 918 Mt in 2018 (ICCT, 2019), or around 2.5% of global energy-related CO2 emissions. Passenger transport accounted for 81% of the total. Emissions from aviation have grown 32% over the past five years. Coupled with this aspect, there is a continuous and growing need to satisfy ever-growing electrical power needs on commercial and military aircraft. All the armed services (Army, Navy, and Air Force) are continuously trying to enhance UAV (unmanned aerial vehicle) endurance and range across a broad fleet of different aircraft. The commercial Boeing 787 requires about 1.2MWe and that is expected to grow. Current technologies used to supply increased on-board electrical power are generally: 1) “burn more fuel and convert through on-board generators” and 2) use additional heavy (i.e., weight-inefficient) and sometimes unsafe battery systems on-board the aircraft. The aircraft industry is seeking new, innovative ways to satisfy this increasing power demand. One as-yet-untapped power source is the enormous amount of “waste” thermal energy flowing out the jet engine exhaust; some estimates in smaller “by-pass” flow jet engines is several hundreds of kilowatts (e.g., Pratt & Whitney Canada PW545B turbofan). This quantity is much higher in large jet engines associated with commercial aircraft. This large waste thermal energy manifests itself in large temperature differences within the by-pass-flow engine exhaust system relative to outside ambient conditions, because of the actual by-pass engine design configuration. There is strong need to develop thermal technologies and systems that could harness and convert at least a portion of this thermal energy into useful electrical energy to satisfy growing on-board electrical needs. In addition, there is a strong desire within the aircraft and engine manufacturing community to reduce the “carbon footprint” of the industry though reduced fuel usage worldwide. NASA has a robust aircraft electrification program to meet these desires and support industry in its aircraft electrification objectives. This program is integrating thermoacoustic systems, advanced lightweight heat exchanger technology, and advanced heat pipe technology to capture and transport large amounts of engine waste thermal energy for on-board power conversion, advanced heat-pump cooling, and exergy enhancement (i.e., temperature lift). Advanced lightweight heat exchangers are envisioned to capture engine exhaust thermal energy at approximately 673 K and deliver it to efficient thermoacoustic power conversion systems operating at temperature ratios (Thot/Tcold) > 1.6. Advanced heat pipe systems are envisioned to transport thermal energy from low temperature sources, through thermoacoustic heat pumps, to high temperature needs such as wing anti-icing, fuel pre-heating, and combustion air pre-heating. The paper will discuss the current state-of-the-art, objectives, system design architecture, and remaining technical challenges in system formulation within the NASA aircraft electrification program.

Dyson, Rodger↗
NASA NTRS2017

Design and testing of high-performance mini-channel graphite heat exchangers in thermoelectric energy recovery systems

Recent national energy usage studies by Lawrence Livermore National Laboratory in 2015 [1] show that there is approximately 59 Quads (1015 Btu’s) of waste thermal energy throughout various industrial, residential, power generation, and transportation sectors of the U.S. economy. Thermoelectric energy recovery is one important technology for recovering this waste thermal energy in high-temperature industrial, transportation and military energy systems. Thermoelectric generator (TEG) systems in these applications require high performance hot-side and cold-side heat exchangers to provide the critical temperature differential and transfer the required thermal energy. High performance hot-side heat exchangers in these systems are often metal-based due to requirements for high-temperature operation, strength at temperature, corrosion resistance, and chemical stability. However, the generally selected metal-based hot-side heat exchangers (i.e., Inconels, Stainless Steels) suffer from low thermal conductivity, high thermal expansion, and high density, which degrades their thermal performance, leads to high thermal-expansion-driven stresses, and creates relatively high mass/high volume (i.e., low power density) TEG systems that are then difficult to fabricate and integrate into viable energy recovery systems. This paper describes the design and testing of a new, high-temperature minichannel graphite heat exchanger designed for operation up to 500C that is a critical element of a high-power-density TEG power system for aircraft energy recovery. This high-performance graphite heat exchanger represents a new state-of-the-art standard in high-temperature heat exchangers for TEG systems, which provides higher thermal transport, less thermal expansion at operation, lower system level stresses on TE components, and a lighter weight TEG system. This new heat exchanger creates a new design paradigm in TEG system design for terrestrial energy recovery and potential NASA technology infusion into terrestrial energy system applications. This paper will present and discuss the key heat transfer, pressure drop, pumping power analyses and design tradeoffs that created this unique design. Heat transfer and pressure drop modeling was performed with both empirical models based on known heat transfer and friction factor correlations and COMSOL thermal/fluid dynamic modeling of the graphite heat exchanger structure. We will also discuss resulting thermal transport and heat fluxes predicted at the TEG interface level. Heat exchanger performance testing was performed under simulated operating conditions and correlation with test data at the anticipated operating temperature conditions will be presented and discussed.

Shevade, Abhijit↗