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DOE OSTI2017

Fluidized-Bed Heat Transfer Modeling for the Development of Particle/Supercritical-CO2 Heat Exchanger

Concentrating solar power (CSP) technology is moving toward high-temperature and high-performance design. One technology approach is to explore high-temperature heat-transfer fluids and storage, integrated with a high-efficiency power cycle such as the supercritical carbon dioxide (s-CO2) Brayton power cycle. The s-CO2 Brayton power system has great potential to enable the future CSP system to achieve high solar-to-electricity conversion efficiency and to reduce the cost of power generation. Solid particles have been proposed as a possible high-temperature heat-transfer medium that is inexpensive and stable at high temperatures above 1,000 degrees C. The particle/heat exchanger provides a connection between the particles and s-CO2 fluid in the emerging s-CO2 power cycles in order to meet CSP power-cycle performance targets of 50% thermal-to-electric efficiency, and dry cooling at an ambient temperature of 40 degrees C. The development goals for a particle/s-CO2 heat exchanger are to heat s-CO2 to =720 degrees C and to use direct thermal storage with low-cost, stable solid particles. This paper presents heat-transfer modeling to inform the particle/s-CO2 heat-exchanger design and assess design tradeoffs. The heat-transfer process was modeled based on a particle/s-CO2 counterflow configuration. Empirical heat-transfer correlations for the fluidized bed and s-CO2 were used in calculating the heat-transfer area and optimizing the tube layout. A 2-D computational fluid-dynamics simulation was applied for particle distribution and fluidization characterization. The operating conditions were studied from the heat-transfer analysis, and cost was estimated from the sizing of the heat exchanger. The paper shows the path in achieving the cost and performance objectives for a heat-exchanger design.

14 SOLAR ENERGY↗

DOE OSTI2023

Grid Resilient, Self-Powered, Fuel Flexible, High Efficiency Heating System (Final Report)

The Grid Independent High Efficiency System (GIHES) delivers a heating system that operates free from the power grid and provides ultra-low emissions and high efficiency heating for residential and commercial buildings. The project demonstrated two weeks of continuous grid independent operation of a storage water heater equipped with a powered damper. The Thermoelectric Generator (TEG) integrated GIHES technology revolutionizes heating systems to provide grid resilient hot water production, while delivering significant value to the end user by eliminating impacts of power interruption and enhancing comfort, convenience and productivity. The system maximizes the thermal-to-electric conversion efficiency by optimizing location and orientation of the TEGs and durability while lowering system costs. The TEGs generate enough power to charge a battery and run the storage water heater unit with a powered damper uninterrupted by providing the required parasitic electrical power for start-up, shutdown and during idling. Several TEGs were analytically and experimentally evaluated based on the size, surface area and the power being generated before designing and fabricating a complete multi-TEG assembly for integration with the water heater. The GIHES technology can be extended to boilers, furnaces and tankless water heaters and integrated with heat pump to further increase the overall equipment efficiency. The technology has the potential to reduce the amount of dispatch power and peak power plant operation. An advanced burner was designed, developed and 3D printed for fuel flexible operation. The burner was designed to enable tighter integration with TEGs for potentially higher TEG output, should this be necessary. A bench-scale test rig to perform testing of a 200,000 Btu/h burner and capable of handling up to 10% H2 (by volume) was setup at GTI’s laboratory with appropriate safety and controls to ensure smooth and safe operation. Testing of the 3D burner showed < 5 ppm NOx emissions can be achieved for the entire firing range and with different levels of hydrogen blends with natural gas. The burner will enable a more integrated TEG-burner module design for improved system performance, should this be required in the future. Techno-economic analysis (TEA) of the TEG integrated with the water heaters was performed. The testing data and the power output were used to develop the TEA. The analysis for the storage unit with damper showed that the TEG integrated system costs $95. This is much lower than a one-time charge needed to wire and install dedicated power. Discussions with TEG manufacturers and OEM’s will provide more detailed information and methods to further lower these costs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS1989

Importance of helium-3 for the future

Relevant plasma physics principles of thermonuclear research; the state of plasma physics as it pertains to the D-He(3) cycle; the technological benefits of the D-He(3) fuel cycle; the availability of He(3); and its location, methods of extraction and cost are discussed. A perspective on the rate of progress toward the goal of heating the confined plasma fuel to sufficiently high temperatures at high enough densities and for long enough times to cause substantial fusion of the atoms to take place is given in graphical form. The main technological advantages resulting from the D-He(3) fuel cycle, when compared with the DT cycle, are as follows: (1) increased electrical conversion efficiency; (2) reduced radiation damage to reactors; (3) reduced radioactive waste; (4) an increased level of safety in case of an accident; (5) the lower cost of electricity; and (6) the shorter time to commercialization. An account is given of mining He(3) on the Moon.

Kulcinski, Gerald L.↗

NASA NTRS2014

High Efficiency Quantum Well Waveguide Solar Cells and Methods for Constructing the Same

Photon absorption, and thus current generation, is hindered in conventional thin-film solar cell designs, including quantum well structures, by the limited path length of incident light passing vertically through the device. Optical scattering into lateral waveguide structures provides a physical mechanism to increase photocurrent generation through in-plane light trapping. However, the insertion of wells of high refractive index material with lower energy gap into the device structure often results in lower voltage operation, and hence lower photovoltaic power conversion efficiency. The voltage output of an InGaAs quantum well waveguide photovoltaic device can be increased by employing a III-V material structure with an extended wide band gap emitter heterojunction. Analysis of the light IV characteristics reveals that non-radiative recombination components of the underlying dark diode current have been reduced, exposing the limiting radiative recombination component and providing a pathway for realizing solar-electric conversion efficiency of 30% or more in single junction cells.

Welser, Roger E.↗

NASA NTRS2018

High Efficiency Quantum Well Waveguide Solar Cells and Methods for Constructing the Same

Welser, Roger E.↗

DOE OSTI2016

Improved thermoelectric performance of (Fe,Co)Sb{sub 3}-type skutterudites from first-principles

Skutterudite materials have been considered as promising thermoelectric candidates due to intrinsically good electrical conductivity and tailorable thermal conductivity. Options for improving thermal-to-electrical conversion efficiency include identifying novel materials, adding filler atoms, and substitutional dopants. Incorporating filler or substitutional dopant atoms in the skutterudite compounds can enhance phonon scattering, resulting in reduction of thermal conductivity, as well as improving electrical conductivity. The structures, electronic properties, and thermal properties of double-filled Ca{sub 0.5}Ce{sub 0.5}Fe{sub 4}Sb{sub 12} and Co{sub 4}Sb{sub 12−2x}Te{sub x}Ge{sub x} compounds (x = 0, 0.5, 1, 2, 3, and 6) have been studied using density functional theory-based calculations. Both Ca/Ce filler atoms in FeSb{sub 3} and Te/Ge substitution in CoSb{sub 3} cause a decrease in lattice constant for the compounds. As Te/Ge substitution concentration increases, lattice constant decreases and structural distortion of pnictogen rings in the compounds occurs. This indicates a break in cubic symmetry of the structure. The presence of fillers and substitutions cause an increase in electrical conductivity and a gradual decrease in electronic band gap. A transition from direct to indirect band-gap semiconducting behavior is found at x = 3. Phonon density of states for both compounds indicate phonon band broadening by the incorporation of fillers and substitutional atoms. Both systems are also assumed to have acoustic-mode-dominated lattice thermal conductivity. For the Co{sub 4}Sb{sub 12−2x}Te{sub x}Ge{sub x} compounds, x = 3 has the lowest phonon dispersion gradient and lattice thermal conductivity, agreeing well with experimental measurements. Our results exhibit the improvement of thermoelectric properties of skutterudite compounds through fillers and substitutional doping.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2023

AN OVERVIEW OF THE DESIGN AND PERFORMANCE TESTING OF A 275 BAR INTEGRALLY GEARED SUPERCRITICAL CO2 COMPRESSOR FOR POWER GENERATION

An integrally geared compressor-expander (compander) for supercritical CO2 (sCO2) was developed to convert thermal energy to electricity. With operating pressures of 275 bar, this turbomachine represents the state of the art in integrally geared machine architecture, hitting compressor inlet densities of 600 kg/m3 and discharge pressures of 275 bar. The product development was funded by the Department of Energy’s Energy Efficiency and Renewable Energy Office under EE0007114 to advance the state of the art in concentrated solar power applications; however, the technology itself is agnostic to heat source, and is predicted to achieve a thermal-to-electric conversion efficiency of 50% for any indirect heat source capable of providing turbine inlet temperatures of 700°C or greater. While the program encompassed the design and testing for the compressor and turbine elements, this paper will focus on the compressor design and operation. The paper will begin with an introduction to the cycle design and analysis of an indirectly heated integrally geared sCO2 compander, a discussion of the mechanical and aerodynamic design of the compressor that is a two stage radial compressor operating subcritically at 27,512 rpm, and will then proceed to describe the test facility and measured data to characterize the performance and robustness of the machine. The paper will conclude with a discussion on lessons learned throughout the course of commissioning and testing. Practical aspects of testing a compressor operating near the dome including complications relating to obtaining an accurate compressor flow map, efficiency calculations, flow unsteadiness, and associated measurement uncertainties will be discussed.

wilkes, jason↗

DOE OSTI2025

High Power Density, Carbon Neutral Electrical Power Generation for Air Vehicles

The synergistic integration of a Solid Oxide Fuel Cell-Combustor (SOFC-C) with a turbogenerator (TG) will provide a very high fuel-to-electricity conversion efficiency while maintaining high power-to-weight ratio during high-altitude flight. The proposed SOFC-C-TG power generation technology exceeds the REEACH technical performance targets (TPT). This unique concept addresses many of the challenges faced in all electric propulsion-based aviation. The system has high part-load efficiency (more than 65% lower heating value (LHV)) during long cruise times, load following capability, high-power capacity at high altitudes adapting to low temperatures and pressures, rapid startup time of less than 30 minutes (proven with current SOFC technology), high power density (more than 3.2 kW/kg), efficient thermal management, and a foundation for a compact, efficient electrical storage and power generation system (ESPG). The SOFC-C concept achieves the technology targets by reducing the complexity of traditional fuel cell-gas turbine hybrid systems (FC-GT). The SOFC-C does not require heat exchangers and dramatically reduces the balance of plant increasing power density and performance in efficiency. The reduction in mass through elimination of heat exchangers, external reformer, and other components dramatically decreases the overall thermal dampening of the system which enables rapid startup and load following capability. Direct control of the cathode inlet temperature of the SOFC-C enables rapid warm-up of the SOFC tubes with the ability to reach operating temperature and full power in less than 30 minutes.

03 NATURAL GAS↗

DOE OSTI2021

Revisiting Theoretical Limits for One Degree-of-Freedom Wave Energy Converters

This work revisits the theoretical limits of one degree-of-freedom wave energy converters (WECs). This work considers the floating sphere used in the OES Task 10 WEC modeling and verification effort for analysis. Analytical equations are derived to determine bounds on displacement amplitude, time-averaged power (TAP), and power-take-off (PTO) force. A unique result found shows that the TAP absorbed by a WEC can be defined solely by the inertial properties and radiation hydrodynamic coefficients. In addition, a unique expression for the PTO force was derived that provides lower and upper bounds when resistive control is used to maximize power generation. For complex conjugate control, this same expression only provides a lower bound, as there is theoretically no upper bound. These bounds assist in comparing the performance of the floating sphere if it were to extract energy using surge or heave motion. The analysis shows because of differences in hydrodynamic coefficients for each oscillating mode, there are different frequency ranges that provide better power capture efficiency. The influence of a motion constraint on TAP while utilizing a nonideal power take-off is examined and found to reduce the losses associated with bidirectional energy flow. The expression to calculate TAP with a nonideal PTO is modified by the electrical conversion efficiency and the ratio of the PTO spring and damping coefficients. Furthermore, the PTO spring and damping coefficients were separated in the expression, allowing for limits to be set on the PTO coefficients to ensure net power generation.

16 TIDAL AND WAVE POWER↗

NASA NTRS1972

A dynamic solar-electric power/thermal control system for spacecraft.

This paper describes a solar-electric power and active thermal control system for spacecraft with solar energy to electricity conversion efficiency of more than 20%. Briefly, the solar heat energy is absorbed by flat plate collectors yielding above 70% of the energy incident for conversion by an organic condensing cycle. The cycle operates between 132 and 6.67 deg C. The working fluid is F-114 which flows through a solar collector to absorb heat, then through a regenerator and into the radiator where it is condensed to a liquid. The cold liquid flows through two paths, one providing regenerator cooling, the other providing spacecraft thermal control. The system total weight is about 170kg/kW of electrical energy produced. The dynamic system replaces batteries by a thermal capacitor for eclipse period energy storage, thereby eliminating many battery charging and control problems as well as improving efficiency and weight characteristics of the system.

Davis, B. K.↗

DOE OSTI2016

Facile fabrication of novel silver-polypyrrole-multiwall carbon nanotubes nanocomposite for replacement of platinum in dye-sensitized solar cell

This paper demonstrates the facile synthesis of high performance silver-polypyrrole-multiwall carbon nanotubes (Ag-PPy-FMWCNTS) nanocomposites via electrodeposition method on stainless steel substrate and its application as a low cost counter electrode (CE) for the precious platinum (Pt) free DSSC. The nanocomposites were characterized by variety of techniques such as Fourier transforms infrared (FTIR), X-ray diffraction, Scanning electron microscope (SEM), cyclic voltammetry (CV) and Four probe technique respectively. The cyclic voltammetry and Tafel polymerization measurements of Ag-PPy-FMWCNTS nanocomposites CE reveal the favorable electrocatalytic activity and low charge transfer resistance R{sub ct}(2.50 Ω cm{sup 2}) for I{sub 3}{sup −}/I{sup −} redox solution. The four probe studies showed the large electrical conductivity (226S cm{sup −1}) of Ag-PPy-FMWCNTS nanocomposite. The DSSC assembled with Ag-PPy-FMWCNTS nanocomposites CE display the considerable short circuit current density (13.95 mA cm{sup −2}) and acceptable solar to electrical conversion efficiency of 7.6%, which is higher to the efficiency of DSSC with thermally decomposed Pt reference electrode 7.1%. The excellent conversion efficiency, rapid charge transfer in combination with low cost and simple fabrication method of Ag-PPy-FMWCNTS nanocomposites can be exploited as an efficient and potential candidate to replace the Pt CE for large scale production of DSSC.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

DOE OSTI2022

Mechanically-, Thermally, and Chemically-Robust High-Temperature Ceramic Composites

In an effort to lower the levelized cost of electricity generated by Concentrated Solar Power (CSP) plants, the heat-to-electricity conversion efficiency may be increased by operating such plants with higher turbine inlet temperatures using closed Brayton cycles with high-pressure, supercritical carbon dioxide (sCO 2 ) as the working fluid. For example, if the turbine inlet temperature is raised to ≥750°C, in combination with sCO2 closed Brayton cycles, the relative heat-to-electricity efficiency may be raised by more than 20% (compared to subcritical steam Rankine cycles operating with turbine inlet temperatures ≤550°C). The associated reduction in the cost of dispatchable electricity from such CSP plants (utilizing high-temperature thermal energy storage) would be an important breakthrough on the path towards direct competition with fossil-fuel-based plants. A key barrier to achieve such high-temperature efficient operation has been the limited thermomechanical performance of metal alloys used in compact, primary printed circuit- type heat exchangers (PCHEXs) for heat transfer to high-pressure sCO 2 . The maximum allowed stresses for the use of conventional stainless steels and nickel-based superalloys at high sCO 2 pressures (≥20 MPa) decline rapidly at temperatures ≥550°C. This project has been focused on demonstrating the desired high-temperature properties and attractive manufacturing characteristics of mechanically-, thermally-, and chemically-robust ceramic/metal composites (cermets), in order to allow for the use of such composites in primary PCHEXs for heat transfer to sCO 2 at ≥750°C and ≥20 MPa in CSP plants. Prior work with high-temperature, co-continuous carbide/refractory metal cermets, such as ZrC/W composites, has already demonstrated: i) the attractive combination of high-temperature properties exhibited by such materials (e.g., high values of stiffness, failure strength, and thermal conductivity at 800°C), and ii) cost-effective processes for manufacturing PCHEX plates comprised of such cermets with tailorable channel patterns. However, ZrC/W cermets were not found to be inherently corrosion resistant in sCO 2 at 750°C and 20 MPa. While the application of a Cu coating to ZrC/W surfaces, along with a modest addition (50 ppm) of CO to CO 2 , rendered such composites resistant to corrosion for 1000 h in such sCO 2 -based fluids at 750°C, such additional steps would increase the design complexity of such cermet-based components. An alternative approach (the focus of this project) is to develop mechanically-robust, cost- effective cermets that are inherently resistant to high-temperature oxidation in air and CO 2 . The overall goals of this project have been to demonstrate: i) the oxidation resistance of at least one cermet at 750°C in air and in CO 2 (i.e., with a projected annual corrosion ≤30 μm), ii) the mechanically robust nature of at least one cermet at 750°C (i.e., with an average failure strength ≥200 MPa), and iii) that the selected cermet can be manufactured via low-cost forming techniques.

14 SOLAR ENERGY↗

NASA NTRS1983

Space power system utilizing Fresnel lenses for solar power and also thermal energy storage

A solar power plant suitable for earth orbits passing through Van Allen radiation belts is described. The solar-to-electricity conversion efficiency is estimated to be around 9 percent, and the expected power-to-weight ratio is competitive with photovoltaic arrays. The system is designed to be self-contained, to be indifferent to radiation belt exposures, store energy for periods when the orbiting system is in earth shadow (so that power generation is contant), have no moving parts and no working fluids, and be robust against micrometeorite attack. No electrical batteries are required.

Turner, R. H.↗

DOE OSTI2022

Hybrid Solid Oxide Fuel Cell/Gas Turbine Model Development for Electric Aviation

A thermodynamic model was developed and validated to analyze a high-performance solid oxide fuel cell and gas turbine (SOFC-GT) hybrid power system for electric aviation. This study used a process simulation software package (ProMax) to study the role of SOFC design and operation on the feasibility and performance of the hybrid system. Standard modules, including compressor, turbine, heat exchanger, reforming reactor, and combustor were used from the ProMax tool suite while a custom module was created to simulate the SOFC stack. The model used an SOFC test data set as an input. Additional SOFC stack performance effects, such as pressure, temperature, and utilization of air and fuel, were added from open source data. System performance predictors were SOFC specific power, fuel-to-electricity conversion efficiency, and hybrid system efficiency. Using these input data and predictors, a static thermodynamic performance model was created that can be modified for different system configurations and operating conditions. Prior to creating the final aircraft performance model, initial demonstration models were developed to validate output results. We used the NASA SOFC model as a benchmark, which was created with their Numerical Propulsion System Simulator (NPSS) software framework. Our output results matched within 1% of both the NASA model and open source SOFC performance data. With confidence gained in the accuracy of this model, a 1-MW SOFC-GT hybrid power system was constructed for an aircraft propulsion concept. Overall hybrid system efficiencies of > 75% FTE were observed during standard 36,000 feet cruise flight conditions.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2016

Metamorphic Epitaxy for Multijunction Solar Cells

Multijunction solar cells have proven to be capable of extremely high efficiencies by combining multiple semiconductor materials with bandgaps tuned to the solar spectrum. Reaching the optimum set of semiconductors often requires combining high-quality materials with different lattice constants into a single device, a challenge particularly suited for metamorphic epitaxy. In this article, we describe different approaches to metamorphic multijunction solar cells, including traditional upright metamorphic, state-of-the-art inverted metamorphic, and forward-looking multijunction designs on silicon. We also describe the underlying materials science of graded buffers that enables metamorphic subcells with low dislocation densities. Following nearly two decades of research, recent efforts have demonstrated high-quality lattice-mismatched multijunction solar cells with very little performance loss related to the mismatch, enabling solar-to-electric conversion efficiencies over 45%.

14 SOLAR ENERGY↗

DOE OSTI2021

Evaluation of external tubular configurations for a high-temperature chloride molten salt solar receiver operating above 700°C

Next-generation concentrating solar power (CSP) tower technologies target operating temperatures exceeding 700°C to increase the thermal-to-electric conversion efficiency. Molten chloride salts are one possible alternative to current commercial molten nitrate salts to enable the higher operating temperature. This paper analyzes the predicted optical, thermal-fluids, and structural performance of traditional external tubular solar receiver configurations applied with a chloride salt heat transfer fluid (HTF) and inlet/outlet temperatures of 500°C/735°C, and considers sensitivity analysis and optimization relative to receiver sizing, tube sizing, number of panels, flow circuit configurations, and solar flux concentration under constraints on internal velocity, pressure drop, wall thickness, and required creep-fatigue lifetime. The high temperature conditions increase the significance of inelastic deformation mechanisms such as creep relative to that expected in commercial 565°C nitrate salt designs. High-temperature creep and creep-fatigue damage in the metal alloy tubes are the key factors that limit allowable solar flux concentration and achievable receiver thermal efficiency at the near-800°C wall temperature conditions. For a traditional external cylindrical receiver configuration, the design parameters and conditions capable of satisfying all constraints produced, at best, a design point receiver efficiency of 78.2%, or 80.5% when excluding receiver intercept efficiency. Variation in the optimal receiver performance relative to uncertainty in the binding maximum velocity, minimum wall thickness, and minimum lifetime constraints is presented.

14 SOLAR ENERGY↗

DOE OSTI2019

Discovery of TaFeSb-based half-Heuslers with high thermoelectric performance

Discovery of thermoelectric materials has long been realized by the Edisonian trial and error approach. However, recent progress in theoretical calculations, including the ability to predict structures of unknown phases along with their thermodynamic stability and functional properties, has enabled the so-called inverse design approach. Compared to the traditional materials discovery, the inverse design approach has the potential to substantially reduce the experimental efforts needed to identify promising compounds with target functionalities. By adopting this approach, here we have discovered several unreported half-Heusler compounds. Among them, the p-type TaFeSb-based half-Heusler demonstrates a record high ZT of ~1.52 at 973 K. Additionally, an ultrahigh average ZT of ~0.93 between 300 and 973 K is achieved. Such an extraordinary thermoelectric performance is further verified by the heat-to-electricity conversion efficiency measurement and a high efficiency of ~11.4% is obtained. Our work demonstrates that the TaFeSb-based half-Heuslers are highly promising for thermoelectric power generation.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Opportunities and challenges for tandem solar cells using metal halide perovskite semiconductors

Metal halide perovskite semiconductors possess excellent optoelectronic properties, allowing them to reach high solar cell performances. They have tunable bandgaps and can be rapidly and cheaply deposited from low-cost precursors, making them ideal candidate materials for tandem solar cells, either by using perovskites as the wide-bandgap top cell paired with low-bandgap silicon or copper indium diselenide bottom cells or by using both wide- and small-bandgap perovskite semiconductors to make all-perovskite tandem solar cells. This Review highlights the unique potential of perovskite tandem solar cells to reach solar-to-electricity conversion efficiencies far above those of single-junction solar cells at low costs. Here, we discuss the recent developments in perovskite-based tandem fabrication, and detail directions for future research to take this technology beyond the proof-of-concept stage.

14 SOLAR ENERGY↗