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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

U Metal Oxidation with Steam (U)

The Savannah Rive National Laboratory 9SRNL) is evaluating a method to produce uranium oxide (UO 2 ) from uranium metal using steam. The typical methods for making UO 2 yield powders with particle-size ranges of 1 to 50 micron. The goal of the steam oxidation is to produce a depleted uranium (DU) product with a larger particle size that can be used as a surrogate for testing physical and mechanical process techniques to refine uranium and/or plutonium bearing residues. Several studies in the literature indicated that reactions between uranium metal and steam will yield UO 2 as fine powders in the 160 to 500 °C range, but granular materials form above 500°C. Above 880 °C, a hard compact scale forms on the U metal. Furthermore, sintering of UO 2 occurs at about 1300 °C, but it has been stated that the presence of steam enhances the sintering characteristics of UO 2 . Initial studies into the oxidation of DU metal in an atmosphere of argon and steam have been completed. Oxidation of depleted uranium metal in Ar/steam at 600, 710, 700, and 830 °C yielded at UO 2 product with little or no impurity at each temperature. Although not enough sample was available to perform sieve analysis for particle size distribution, SEM images reveal that a significant volume fraction of the products at 710, 770, and 830 °C exceeds 100 microns. The material produced at 600 °C was too fine for programmatic needs. Questions associated with the UO 2 include morphology of product, mechanical strength of the particles, and performance in milling operations. The size of the samples produced in these tests did not allow for quantitative assessment of particle size of mechanical strength. A qualitative assessment of the particles formed at 710, 770, and 830 °C was that the samples produced at 710 and 770 °C were friable, and the sample produced 830 °C had more mechanical strength. Sintering of the samples in Ar/steam at 970 °C appeared to increase the strength of the particles without changing their general particle size characteristics. Due to the small sample sizes, the increase in strength could not be quantified. If the sintering at 970 °C is inadequate, higher sintering temperatures in Ar/steam can be evaluated. Future work will increase scale of the steam oxidation conditions which yield the most-favorable particle-size distributions with sufficient mechanical strength for programming usage. Further consideration will be given to oxidation temperature, steam addition to the reaction vessel, U metal pretreatment, and sintering conditions after oxidation. The UO 2 production could involve a two-step process where particles are formed in steam at lower temperatures (700-850 °C) and then sintered in Ar/steam at elevated temperatures (950-1200 °C). Larger samples (50-100 g each) will provide sufficient UO 2 product for sieve analysis and assessment of mechanical strength relatives to subsequent milling operations.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Advanced Steam-Electric Power Cycle for Advanced Reactor Concepts

This report presents improvements made to RELAP-7 for modeling Rankine power cycles, which are used on the secondary side of some advanced reactor concepts. For example, for a High-Temperature gas-cooled Reactor Pebble bed Module (HTR-PM), in the primary loop, helium transfers heat from the fuel to a steam generator, and on the secondary side, dry steam from the steam generator applies work to a turbine, which is converted into electrical power by a generator. After passing through the turbine, the steam passes through a condenser and pumped to the steam generator inlet, completing a Rankine cycle on the secondary side. This HTR-PM concept is used as an example to demonstrate a steam-electric power cycle capability in RELAP-7. This power cycle requires a number of different physical components, including a pump, compressor, turbine, steam generator, and condenser. The steam generator is modeled using a heat exchange between primary and secondary loops, and the condenser is modeled using a cooling source term. Recent efforts demonstrated preliminary models for the turbomachinery components (pump/compressor and turbine), but more physical models were required. Furthermore, several improvements were made for the robustness of mixed single-phase/two-phase flow present in a Rankine cycle.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

An Integrated Energy Systems Prototype Human-System Interface for a Steam Extraction Loop System to Support Joint Electricity-Hydrogen Flexible Operations

Due to increasing economic competition from renewables and combined-cycle natural gas plants, nuclear power plants are looking toward flexible operations to enhance their cost competitiveness. The Integrated Energy Systems project under the Light Water Reactor Sustainability program of the U.S. Department of Energy focuses on joint electricity-hydrogen flexible operations. Joint electricity-hydrogen flexible operations entail the nuclear power plant diverting thermal energy via main steam to a hydrogen production plant located nearby. The steam serves to enhance the efficiency of the hydrogen production. Furthermore, high temperature electrolysis requires a large amount of electricity, which the plant can also provide. The plant provides steam and electricity to the hydrogen plant throughout the day, but during peak demand hours the nuclear power plant returns to solely providing electricity to meet the high demand. Through this flexible concept of operations, the plant can optimize the thermal energy it produces without having to maneuver the power of the plant. This report documents the human factors process to design and develop a prototype human-system interface for the steam extraction loop that serves as the conduit between the nuclear power plant and the adjacent hydrogen plant. The design process followed the human factors guidelines set by NUREG-0711, Human Factors Engineering Program Review Model (O’Hara, Higgins, & Fleger, 2012), and expanded upon by the Guideline for Operational Nuclear Usability and Knowledge Elicitation (GONUKE; Boring, Ulrich, Joe, & Lew, 2015; Boring, Lew, & Ulrich, 2016). The design process entailed operator interviews to determine the concept of operations for the steam extraction loop, a review and adaptation of digital interface design concepts developed by the team in prior projects, an iterative design process, and reviews conducted by both operators and human factors experts. Several versions of the prototype human-system interface were developed. Operators were interviewed to determine what design features they found useful and would like to see in the interface. The design underwent a review by human factors experts against NUREG-0700, Human Interface Design Review Guidelines (U.S. Nuclear Regulatory Commission, 2019), to ensure compliance with the latest human factors standards for digital interfaces in nuclear applications. The design was then prototyped as a functional windows-based application integrated with the Generic Pressurized Water Reactor simulator modified to include the steam extraction loop. The simulation is supported by the Human Systems Simulation Laboratory at Idaho National Laboratory, which supports operator-in-the-loop testing. This is an ongoing project and the next phase of the project entails performing an operator-in-the-loop usability study to evaluate the interface and examine the proposed concept of operations to extraction steam from the nuclear power plant for delivery to the coupled hydrogen production plant.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2024

Reactor Containment Passive Safety Analysis: Steam Condensation in Presence of Non-condensable Gas Scaled Experiment and Modeling

This study presents steam condensation scaled experiments and semi-empirical models in presence of nitrogen (N)—a noncondensable gas (NCG), simulating air in the reactor containment—to support water-cooled small modular reactors (SMRs) passive containment cooling system (PCCS) design and analysis. Previous experimental studies on PCCS are focused on fixed and smaller tube (mostly 2-in.) geometries and specific test condition variations, bringing challenges with geometric scaling and mismatching with SMR prototypic design. To address these challenges, this study presents steam condensation test dataset obtained from three scaled test sections of 1-, 2-, and 4-in.-diameter steam condensers with an annular/jacket cooling of 2-, 3-, and 6 in.-diameter tubes, respectively. Test data were collected for steam ranges from 58 to 63 kg/hr., and NCG flow of 4.4 to 13.3 kg/hr. Annular cooling water flow was varied to obtain required testing conditions of saturated steam inlet and fully condensed outlet. Axial temperature test data of bulk cooling water, steam and condensate were collected by thermocouples for three test sections and various steam-NCG mixing/testing conditions. A standard data reduction method was adopted—utilizing iterative and nodalized mass and heat transfer calculation—to estimate axial local heat fluxes, heat transfer coefficients (HTCs), condensation rates, film thickness, and Nusselt number. Based on the obtained dataset semi-empirical model results—a ratio of experimental and Nusselt’s theoretical HTC are presented. Such results and findings are supportive of developing scaled-up testing facility, to enable model validations and accelerate next generation of reactors development and deployment

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2024

Presentation: Reactor Containment Passive Safety Analysis: Steam Condensation in Presence of Non-condensable Gas Scaled Experiment and Modeling

This study presents steam condensation scaled experiments and semi-empirical models in presence of nitrogen--a noncondensable gas (NCG), simulating air in the reactor containment--to support water-cooled small modular reactors (SMRs) passive containment cooling system (PCCS) design and analysis. Previous experimental studies on PCCS are focused on fixed and smaller tube (mostly 2-in.) geometries and specific test condition variations, bringing challenges with geometric scaling and mismatching with SMR prototypic design. To address these challenges, this study presents steam condensation test dataset obtained from three scaled test sections of 1-, 2-, and 4-in.-diameter steam condensers with an annular/jacket cooling of 2-, 3-, and 6 in.-diameter tubes, respectively. Test data were collected for steam ranges from 58 to 63 kg/hr., and NCG flow of 4.4 to 13.3 kg/hr. Annular cooling water flow was varied to obtain required testing conditions of saturated steam inlet and fully condensed outlet. Axial temperature test data of bulk cooling water, steam and condensate were collected by thermocouples for three test sections and various steam-NCG mixing/testing conditions. A standard data reduction method was adopted--utilizing iterative and nodalized mass and heat transfer calculation to estimate axial local heat fluxes, heat transfer coefficients (HTCs), condensation rates, film thickness, and Nusselt number. Based on the obtained dataset semi-empirical model results--a ratio of experimental and Nusselt's theoretical HTC are presented. Such results and findings are supportive of developing scaled-up testing facility, to enable model validations and accelerate next generation of reactors development and deployment.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

Stress rupture of SiC/SiC composite tubes under high-temperature steam

SiC-fiber–reinforced SiC matrix composite cladding for light water reactor fuel elements must withstand high-temperature steam oxidation in a loss-of-coolant accident scenario (LOCA). Current composite designs include an outer monolithic SiC layer, in part, to increase steam oxidation resistance. However, it is not clear how such a structure would behave under high-temperature steam in the case when the monolithic layer cracks and carbon interphases and SiC fibers are exposed to the environment. To fill this knowledge gap, stress-rupture tests of prototypic SiC composite cladding at 1000°C under steam and inert environments were conducted. The applied stress was ~120 MPa, which was beyond the initial cracking stress. The failure lifetime under steam was 400–1300 s, while 75% of the composite specimens did not fail after 3 h of total exposure under inert gases. Microstructural observations suggest that steam oxidation activated slow crack growth in the fibers, which led to failure of the composite. The results from this study suggest that stress rupture in steam environments could be a limiting factor of the cladding under reactor LOCA conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Welding of Haynes 282 to Steels to Enable Modular Rotors for Advanced Ultra Super-Critical Steam Turbines

Steam turbines for an Advanced Ultra Super Critical (AUSC) fossil fired power plant will operate at temperatures well above those of current commercial steam cycles with inlet temperatures more than 760 C , which is beyond the capabilities of alloy steels presently used for steam turbine applications and requires advanced materials. Large components such as steam turbine rotors may be made of nickel based super alloys such as Haynes 282 (H282). However, monolithic forgings of superalloys in the sizes required for large steam turbines rotors can be prohibitively expensive besides many technical challenges. To minimize cost and alleviate the related technical challenges, superalloy use needs to be limited to locations on the steam turbine rotor where strength and temperature requirements cannot be met by conventional steels. This is possible if nickel-based superalloys can be successfully welded to steels and the related technical challenges - machining parts made of dissimilar welded materials, non-destructive examination of such welds for flaw detection; and, material properties of such hybrid components – are sufficiently addressed. In this technology development project, we successfully welded H282 to plates up to ~ 75 mm (~ 3 inches) to a 3.5NiCrMoV steel of similar thickness. Advanced ultrasonic inspection technique called Phased Array Ultrasonic Testing (PAUT) was employed to examine the dissimilar H282-Steel welds, into which flat bottomed side drilled holes (SDH) of various diameters were introduced, to determine the minimum detectable feature sizes; it was shown that with PAUT SDH of dia. down to 0.5 mm could be detected in the base alloys and SDH with dia. down to 2.4 mm could be detected in the weld metal under multiple orientations successfully. An autonomous machining process monitoring system was developed and demonstrated whereby the forces acting on the cutting tool could be actively monitored as the cutting tool transitioned from H282 to Steel across the weld using which the machining parameters can be potentially altered without interruption to extend tool life. This project successfully achieved its objectives of - i. Developing a welding methodology and viable welding geometries, to successfully join H282 to steel 3.5CrMoNiV steel to enable manufacture of modular steam turbine rotors for AUSC applications (conditions of at least 760 °Celsius and 3,100 psia (pounds per square inch absolute pressure) and evaluate the material properties of the welded specimen. ii. Employ the advanced ultrasonic inspection technique to the dissimilar weld metal joint and determine the minimum detectable feature sizes. iii. Develop effective machining techniques to machine such hybrid structures with online tool force monitoring and effect machine state metrics for optimal results.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2025

Assessment of NuScale SMR Steam Heat Augmentation for Chemical Plant Decarbonization

Nearly 50% of the total energy consumed by the industrial sector in the United States is used to produce process steam with natural gas and coal-fired boilers1 . This project conducts a technoeconomic assessment of a NuScale Small Modular Reactor (SMR) coupled with a chemical plant as an Integrated Energy System (IES) where nuclear produces steam and electric power to meet the requirements of a large chemical plant. In a 2020 study, ORNL evaluated the feasibility of using advanced SMRs, including the NuScale design, to supply energy to the Eastman Chemical Plant. However, since that report was published, NuScale received NRC approval for its uprated 77 MWe design with 56% more power and has also introduced a high-temperature, high pressure, steam heat-augmentation system, a key focus of the new study. The new study also benefits from revised capital costs, a 10-day refueling outage time, reduced plant staffing, higher capacity factors, and a site boundary Emergency Planning Zone methodology. The study consists of a techno-economic assessment of two possible energy sources (nuclear and natural gas) in a number of steam and power generation configurations (NuScale Power Modules (NPMs), boilers and combinations of both) to satisfy the steam and power demand with the most reliable and cost competitive system. A total of 2,947.3 klb/hr of steam and 72.5 MWe of electricity are required for the demonstration case. A range of scenarios and solutions are explored, from a 12-NPM plant (3,000 MWth)—with excess capacity and redundancy, capable of supplying a significant amount of extra power to the grid—to a 4-NPM (1,000 MWth) plant—supplemented with existing boilers or grid power for redundancy. The study uses historical steam and power data from a chemical plant and examines the sensitivity to natural gas and grid power cost variations. Scenarios with up to two times gas and electricity costs were considered. Profitability in a 60-year time horizon was analyzed, consistent with NuScale’s design life specification. A steady-state site integration and reliability analysis was performed, and trade-offs were identified.

20 FOSSIL-FUELED POWER PLANTS↗
NASA NTRS1982

Catalytic combustion with steam injection

The effects of steam injection on (1) catalytic combustion performance, and (2) the tendency of residual fuel to burn in the premixing duct upstream of the catalytic reactor were determined. A petroleum residual, no. 2 diesel, and a blend of middle and heavy distillate coal derived fuels were tested. Fuel and steam were injected together into the preheated airflow entering a 12 cm diameter catalytic combustion test section. The inlet air velocity and pressure were constant at 10 m/s and 600 kPa, respectively. Steam flow rates were varied from 24 percent to 52 percent of the air flow rate. The resulting steam air mixture temperatures varied from 630 to 740 K. Combustion temperatures were in the range of 1200 to 1400 K. The steam had little effect on combustion efficiency or emissions. It was concluded that the steam acts as a diluent which has no adverse effect on catalytic combustion performance for no. 2 diesel and coal derived liquid fuels. Tests with the residual fuel showed that upstream burning could be eliminated with steam injection rates greater than 30 percent of the air flow rate, but inlet mixture temperatures were too low to permit stable catalytic combustion of this fuel.

Anderson, D. N.↗
DOE OSTI2024

Ensemble Manufacturing Techniques for Steam Turbine Components Across Length Scales

Faster design to manufacturing requirements were sought for steam turbine components to meet the changing demands of today’s power grid of improved efficiency through operating temperature increases and enhanced operational flexibility from baseload to cyclic operations. Advances in multiple advanced manufacturing (AM) process enabled redesign of turbine components for extreme environments with the potential to reduce cost. AM is of particular interest to improve component functionality, higher temperature capability, and superior durability in large scale steam turbine applications. AM methods have an immense potential to open-up the design space by working directly with the 3D model to produce near-net shapes, enable fast design-manufacturing iterations, thereby significantly reducing product cost and lead-time up to 25 % from current baseline. However, these benefits cannot be fully realized due to the potential for unknown AM processing defects and their resultant effect upon component performance in service. Siemens is partnering with Oak Ridge National Laboratory (ORNL), Electric Power Research Institute (EPRI), and Connecticut Center for Advanced Technology (CCAT) to advance the knowledge of complex process-material interactions for desired microstructures and properties that are closely interlinked to component geometries across different length scales. The proposed program utilized an ensemble of multidisciplinary technologies to accelerate the development of materials, high-throughput experiments for their qualification, and design flexibility/topology optimization for repair/redesign of components to address critical failure mechanisms for improved performance and increased reliability of existing power plant components. The proposed activities, if successfully demonstrated for identified components, will enable paradigm shift in customized manufacturing and accelerated qualification/certification towards increased steam turbine component durability, increased turbine efficiency, and reduced CO 2 emissions in load-following environments compared to today’s technology. Technology maturation is built into the project as successful research will include customized process-component down-selection enabling AM methodologies to be incorporated directly into the existing supply chain. The specific activities of the proposed effort are: 1. Topology optimization of down-selected steam turbine parts that are amenable to additive and hybrid manufacturing for cost/performance improvement. 2. Process-structure-property relationships for five AM processes for steam turbine materials of interest to compare with conventional materials. 3. Perform part/assembly build process using advanced additive/hybrid machine tools followed by quality inspection of the built components for insight into qualification for production scale-up. Steam turbine rig testing of printed components under targeted, well monitored and characterized environmental conditions of for performance comparison of baseline and redesigned components.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Evaluating alternative steam generation pathways in the food industry

Steam generation in the food sector requires substantial energy and cost expenditures, requiring nearly half of its energy intake. Here, we used life cycle assessment and life cycle cost assessment to investigate the cost and energy impacts of steam generating alternatives: NG, biomass and hydrogen boilers and grid-supplied and self-generated electric steam generation systems (electric boilers, renewable thermal energy storage and industrial heat pumps). The analysis starts with a set of average U.S. conditions, where biomass boilers are the most cost-competitive alternative to NG. In a series of scenarios beyond average conditions, the analysis shows energy procurement costs dominate the total life cycle cost for all technologies and, unfortunately, are highly variable geographically and temporally, significantly affecting the viability of the alternatives. Results show that site-energy consumption ranges from 0.3 MMBtu/klb for industrial heat pumps to 1.6 MMBtu/klb for biomass boilers, with heat pumps achieving up to 78% lower energy use compared to natural gas systems. For the steam costs, the results show a range between $\$$8 and $\$$50/klb for NG, with biomass following closely ($\$$11 – $\$$44/klb) and grey hydrogen and IHP next ($\$$13 – $\$$33/klb and $\$$6 - $\$$78/klb), with cost reductions if IHP's cooling is utilized. Factors like operating hours, the need for cooling, and the ability to negotiate utility rates complicate the decision, making site-specific analyses critical. Therefore, we present a decision-making matrix to help manufacturers identify which steam generating technology is the best business decision for their situation. Overall, these results highlight the importance of steam generation for the facility's organizational goals, as well as the criticality of conducting individual site analyses.

Biomass boilers↗
DOE OSTI2024

Enhanced steam oxidation resistance of uranium nitride nuclear fuel pellets

Here, the steam oxidation resistance of UN and UN-(20 vol%)ZrN fuel pellets is evaluated to enhance understanding of steam corrosion mechanisms in advanced nuclear fuel materials. In situ neutron diffraction shows the modified UN fuel pellets form a (U 0.77 ,Zr 0.23 )N solid-solution and the sole crystalline oxidation product detected in bulk is (U 0.77 ,Zr 0.23 )O 2 . U 2 N 3 is not detected in significant quantities during the steam oxidation of UN or (U 0.77 ,Zr 0.23 )N and stable lattice parameters show that hydriding does not take place. Steam oxidation rates, obtained via sequential Rietveld refinement show how (U 0.77 ,Zr 0.23 )N has a higher activation energy (79 ± 1 kJmol -1 vs. 50 ± 5 kJmol -1 ), higher onset temperature (430 °C vs. 400 °C) and slower reaction rates for steam oxidation up to 616 °C, than pure UN. Throughout, both UN and (U 0.77 ,Zr 0.23 )N exhibit linear (non-protective) oxidation kinetics, signifying that degradation of the fuel pellets is caused by the evolution of gaseous products at the interface followed by oxide scale spallation. This quantitative and mechanistic understanding of material degradation enables better defined operating regimes and points towards (U,Zr)N solid solutions as a promising strategy for the design of advanced nuclear fuel materials with enhanced steam corrosion resistance.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Steam caps in geothermal reservoirs can be monitored using seismic noise interferometry

Harvesting geothermal energy often leads to a pressure drop in reservoirs, decreasing their profitability and promoting the formation of steam caps. While steam caps are valuable energy resources, they also alter the reservoir thermodynamics. Accurately measuring the steam fraction in reservoirs is essential for both operational and economic perspectives. However, steam content estimations are very limited both in space and time since current methods rely on direct measurements within production wells. Besides, these estimations normally present large uncertainties. Here, we present a pioneering method for indirectly sampling the steam content in the subsurface using the ever-present seismic background noise. We observe a consistent annual velocity drop in the Hengill geothermal field (Iceland) and establish a correlation between the velocity drop and steam buildup using in-situ borehole data. This application opens new avenues to track the evolution of any gas reservoir in the crust with a surface-based and cost-effective method.

58 GEOSCIENCES↗
DOE OSTI2022

UK-US Collaboration on Fossil Energy R&D: Steam Side Oxidation

In recent years, interest in increasing the efficiency of power plants based on steam generation has led to the need to develop and qualify materials capable of operating at steam temperatures and pressures significantly higher than those employed in current power plants. The overall focus of this international program is on using ferritic-martensitic steels to the maximum possible temperature, before switching to austenitic steels and/or Ni-based alloys. The relatively low Cr content of these alloys raises concerns regarding their resistance to steam oxidation at these higher temperatures. Earlier work in this collaboration addressed the reliability of data from atmospheric pressure, laboratory-based steam oxidation tests. This raised issues regarding how representative the laboratory-grown oxides were compared to those formed on service-exposed material and how the tests could be made more reliable by introducing added complexity. In general laboratory-scale exposures are conducted under isothermal conditions at ambient or slightly elevated pressure, using a relatively low flow rate of steam. The coupons used in these tests are normally flat cuboids which have been ground to homogenise the surface and remove any pre-existing features. However, there is a concern that these samples and exposures are not representative of service conditions, and so it is necessary to quantify the influence of transient conditions, such as heat flux, pressure and sample geometry/surface conditions. To address such concerns a new collaborative program of work was initiated to determine the influence of these added features on oxidation kinetics and oxide scale morphology. The overall aim was to improve the understanding of alloy performance in ultrasupercritical (USC) steam conditions and qualify suitable test procedures.

20 FOSSIL-FUELED POWER PLANTS↗
NASA NTRS1984

Evaluation of dissociated and steam-reformed methanol as automotive engine fuels

Dissociated and steam reformed methanol were evaluated as automotive engine fuels. Advantages and disadvantages in using methanol in the reformed rather than liquid state were discussed. Engine dynamometer tests were conducted with a four cylinder, 2.3 liter, spark ignition automotive engine to determine performance and emission characteristics operating on simulated dissociated and steam reformed methanol (2H2 + CO and 3H2 + CO2 respectively), and liquid methanol. Results are presented for engine performance and emissions as functions of equivalence ratio, at various throttle settings and engine speeds. Operation on dissociated and steam reformed methanol was characterized by flashback (violent propagation of a flame into the intake manifold) which limited operation to lower power output than was obtainable using liquid methanol. It was concluded that: an automobile could not be operated solely on dissociated or steam reformed methanol over the entire required power range - a supplementary fuel system or power source would be necessary to attain higher powers; the use of reformed mechanol, compared to liquid methanol, may result in a small improvement in thermal efficiency in the low power range; dissociated methanol is a better fuel than steam reformed methanol for use in a spark ignition engine; and use of dissociated or steam reformed methanol may result in lower exhaust emissions compared to liquid methanol.

Lalk, T. R.↗
NASA NTRS2015

In-Space Propulsion, Logistics Reduction, and Evaluation of Steam Reformer Kinetics: Problems and Prospects

Human space missions generate waste materials. A 70-kg crewmember creates a waste stream of 1 kg per day, and a four-person crew on a deep space habitat for a 400+ day mission would create over 1600 kg of waste. Converted into methane, the carbon could be used as a fuel for propulsion or power. The NASA Advanced Exploration Systems (AES) Logistics Reduction and Repurposing (LRR) project is investing in space resource utilization with an emphasis on repurposing logistics materials for useful purposes and has selected steam reforming among many different competitive processes as the preferred method for repurposing organic waste into methane. Already demonstrated at the relevant processing rate of 5.4 kg of waste per day, high temperature oxygenated steam consumes waste and produces carbon dioxide, carbon monoxide, and hydrogen which can then be converted into methane catalytically. However, the steam reforming process has not been studied in microgravity. Data are critically needed to understand the mechanisms that allow use of steam reforming in a reduced gravity environment. This paper reviews the relevant literature, identifies gravity-dependent mechanisms within the steam gasification process, and describes an innovative experiment to acquire the crucial kinetic information in a small-scale reactor specifically designed to operate within the requirements of a reduced gravity aircraft flight. The experiment will determine if the steam reformer process is mass-transport limited, and if so, what level of forced convection will be needed to obtain performance comparable to that in 1-g.

Logistics↗
NASA NTRS2015

Steam Methane Reformation Testing for Air-Independent Solid Oxide Fuel Cell Systems

Recently, NASA has been looking into utilizing landers that can be propelled by LOX-CH (sub 4), to be used for long duration missions. Using landers that utilize such propellants, also provides the opportunity to use solid oxide fuel cells as a power option, especially since they are able to process methane into a reactant through fuel reformation. One type of reformation, called steam methane reformation, is a process to reform methane into a hydrogen-rich product by reacting methane and steam (fuel cell exhaust) over a catalyst. A steam methane reformation system could potentially use the fuel cell's own exhaust to create a reactant stream that is hydrogen-rich, and requires less internal reforming of the incoming methane. Also, steam reformation may hold some advantages over other types of reforming, such as partial oxidation (PROX) reformation. Steam reformation does not require oxygen, while up to 25 percent can be lost in PROX reformation due to unusable CO (sub 2) reformation. NASA's Johnson Space Center has conducted various phases of steam methane reformation testing, as a viable solution for in-space reformation. This has included using two different types of catalysts, developing a custom reformer, and optimizing the test system to find the optimal performance parameters and operating conditions.

Mwara, Kamwana N.↗
DOE OSTI2020

OPTIMAL CONTROL AND ENERGY-SAVING ANALYSIS OF COMMON PRESSURE RAIL ARCHITECTURES: HHEA & STEAM

In recent years several novel hydraulic architectures have been proposed with the intention of significantly increasing system efficiency. Two of these architectures, Steigerung der Energieeffizienz in der Arbeitshydraulik mobiler Arbeitsmaschinen (STEAM), and the Hybrid Hydraulic-Electric Architecture (HHEA), use a system of multiple common pressure rails (CPRs) to serve the multiple degrees-of-freedom of the machine. The key difference is that STEAM throttles hydraulic power from these rails while HHEA combines electric and hydraulic power to meet actuator demands. As a throttle-less architecture, HHEA is expected to save more energy than STEAM at the expense of added complexity. Therefore, it is useful to quantify this additional energy saving. Both systems have discrete operational choices corresponding to how the CPRs are utilized for each actuator. It is necessary to determine optimal operation for each of these architectures for analysis and fair comparison. Techniques for optimal operation of the HHEA have been developed previously from the Langrange multiplier method. Applying the same optimal control method to STEAM encountered some technical challenge leading to the optimal control algorithm not being able to satisfy certain constraints. The issue is analyzed and solved by adding noise to the optimization. Using this proposed algorithm, case studies are performed to compare the energy-saving potentials of STEAM and HHEA for two sizes of excavators and a wheel-loader performing representative duty cycles. The baseline is a standard load-sensing architecture. Results show that STEAM and HHEA can reduce energy consumption between 35-65% and 50-80% respectively

24 POWER TRANSMISSION AND DISTRIBUTION↗