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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 NTRSDate not supplied

Sizing and Performance Analysis of a MW-Class Electrified Aircraft Propulsion (Eap) System for A Parallel Hybrid Turboprop Concept

Aircraft electrification has emerged as a pivotal research and development focus in the 21st century, gaining international momentum as a strategic approach to curtail fuel consumption and emissions in the civil aviation sector. Under the Electrified Powertrain Flight Demonstration (EPFD) project, NASA and industry partners are raising the technical readiness, addressing integration challenges and gathering data for future standards and regulations for demonstrate Megawatt (MW) class Electrified Aircraft Propulsion (EAP) systems which can be utilized on regional turboprop or single aisle transports. With the rapid emergence of novel EAP concepts, risk reduction efforts are focused on developing the capabilities to evaluate the impacts of electrification at the conceptual design level where high variability in the EAP system architecture must be accounted for. This paper details an integrated, approach to parametric sizing of multi-MW EAP systems with the primary goal of assessing vehicle-level performance sensitivities to variations in electrical system component-level performance metrics. The focus of this work is to investigate the degree to which EAP component parameters such as specific power, efficiency, and energy density impact range and overall fuel savings.

EAP↗

NASA NTRSDate not supplied

Sizing and Performance Analysis of a MegaWatt-Class Electrified Aircraft Propulsion (EAP) System for a Parallel Hybrid Turboprop Concept

EAP↗

NASA NTRS2002

Life-Extending Control for Aircraft Engines Studied

Current aircraft engine controllers are designed and operated to provide both performance and stability margins. However, the standard method of operation results in significant wear and tear on the engine and negatively affects the on-wing life--the time between cycles when the engine must be physically removed from the aircraft for maintenance. The NASA Glenn Research Center and its industrial and academic partners have been working together toward a new control concept that will include engine life usage as part of the control function. The resulting controller will be able to significantly extend the engine's on-wing life with little or no impact on engine performance and operability. The new controller design will utilize damage models to estimate and mitigate the rate and overall accumulation of damage to critical engine parts. The control methods will also provide a means to assess tradeoffs between performance and structural durability on the basis of mission requirements and remaining engine life. Two life-extending control methodologies were studied to reduce the overall life-cycle cost of aircraft engines. The first methodology is to modify the baseline control logic to reduce the thermomechanical fatigue (TMF) damage of cooled stators during acceleration. To accomplish this, an innovative algorithm limits the low-speed rotor acceleration command when the engine has reached a threshold close to the requested thrust. This algorithm allows a significant reduction in TMF damage with only a very small increase in the rise time to reach the commanded rotor speed. The second methodology is to reduce stress rupture/creep damage to turbine blades and uncooled stators by incorporating an engine damage model into the flight mission. Overall operation cost is reduced by an optimization among the flight time, fuel consumption, and component damages. Recent efforts have focused on applying life-extending control technology to an existing commercial turbine engine, and doing so without modifying the hardware or adding sensors. This approach makes it possible to retrofit existing engines with life-extending control technology by changing only the control software in the full-authority digital engine controller (FADEC). The significant results include demonstrating a 20- to 30-percent reduction in TMF damage to the hot section by developing and implementing smart acceleration logic during takeoff. The tradeoff is an increase, from 5.0 to 5.2 sec, in the time required to reach maximum power from ground idle. On a typical flight profile of a cruise at Mach 0.8 at an altitude of 41,000 ft, and cruise time of 104 min, the optimized system showed that a reduction in cruise speed from Mach 0.8 to 0.79 can achieve an estimated 25-to 35-percent creep/rupture damage reduction in the engine's hot section and a fuel savings of 2.1 percent. The tradeoff is an increase in flight time of 1.3 percent (1.4 min).

Guo, Te-Huei↗

DOE OSTI2022

Sustainable Biofuels for Low-Carbon Maritime Transportation

The marine shipping sector heavily depends on fossil fuels and is one of the largest petroleum fuel consumers [1,2]. The annual global marine fuel consumption was estimated to be around 400 million metric tons in 2019 (2.5 billion barrels). Moreover, ocean shipping is one of the most significant contributors to sulfur oxides, nitrogen oxides, and particulate matter emissions. Global shipping contributes 13% of human-caused sulfur emissions and 2.6% of anthropogenic carbon dioxide emissions. As a major source of pollutant emissions, the marine industry faces several challenges related to emission regulations. The International Maritime Organization (IMO) has established a framework for reducing the carbon intensity of shipping: 40% reduction relative to 2008 levels by 2030 and 70% reduction by 2050. As the aviation sector, the maritime shipping sector is difficult to decarbonize through electrification. Biofuels offer the best opportunities for decarbonizing marine shipping in the near and medium-term. Advanced biofuels such as pyrolysis bio-oil offer the low-cost potential for meeting carbon reduction goals. For instance, the pyrolysis bio-oil exhibited promising marginal CO2 abatement costs at less than $100/tonne CO2-equivalent at a heavy fuel oil price greater than $1.10/gal [1]. As a potential biofuel option for low-carbon maritime shipping, this presentation focuses on a comparative techno-economic analysis (TEA) of bio-oils produced via a fast pyrolysis-based conversion pathway. The pathway converts a 50/50 blend of forest residues and clean pine to bio-oil via three process options: fast pyrolysis without vapor upgrading, and fast pyrolysis with vapor phase upgrading over ZSM-5 zeolite catalyst and Pt/TiO2 catalyst. The process configuration and operation variation led to different capital and operating costs, as well as the resulting raw bio-oil’s yield and quality, e.g., the water content, total acid number, and carboxylic acid number. The study also determined the minimum upgrading of bio-oils required to enable blending with very low sulfur fuel oil (VLSFO), with the associated costs reflected in TEA. This study shows that bio-oil could be a cost-effective fuel option for decarbonizing maritime shipping. Further research is required with respect to biofuel blending properties, such as compatibility with existing fuel system infrastructure and suitable engine performance.

BIOMASS FUELS↗

NASA NTRS2021

Center for High-Efficiency Electrical Technologies for Aircraft (CHEETA)

The aeronautics industry has been challenged on many fronts to increase efficiency, reduce emissions, and decrease dependency on carbon-based fuels. With subsonic transports serving as the dominant contributor to the fuel consumption and carbon footprint of global aviation, the need for environmentally-responsible transportation has been met with a boom of research in the field of aircraft propulsion electrification across industry, government, and academic organizations. However, adoption of electrified propulsion systems for large commercial aircraft today is unattainable, due to the lack of motors and power electronics appropriately sized for these vehicles, high weight requirements of conventional electrical energy storage systems, and new principles required to design these classes of aircraft. The mission of the Center for High-Efficiency Electrical Technologies for Aircraft (CHEETA) program is to develop, mature, and design disruptive technologies for electric commercial aviation. The associated technologies being researched include distributed aero-propulsion system integration, high-efficiency electrochemical power conversion, flight-weight electric machines and power electronics, materials and systems for superconducting high-efficiency power transmission, and methods for complex system integration and optimization. Additionally, the current program is investigating the use of unconventional energy storage and power generation architectures, such as liquid hydrogen fuel and high-efficiency fuel cell systems. The research program provides a direct line-of-sight to not only achieving, but potentially even exceeding the aviation community goals for transition to alternative propulsion and energy through convergence of various novel technologies. The end result of maturation and integration of these technologies is an aircraft system with a quiet, efficient propulsion system that produces zero carbon dioxide, nitrogen oxides, and particulate matter emissions at the vehicle level.

Koushik Datta↗

DOE OSTI2022

Liquid Salt Combined-Cycle Pilot Plant Design

The work described in this report is responsive to the Office of Fossil Energy program ‘Energy Storage for Fossil Power Generation.’ This Phase I report has been prepared by Pintail Power LLC, with support from Nexant ECA, Electric Power Research Institute (EPRI) and Southern Company Services as a deliverable for the U.S. Department of Energy for NETL Award DE-FE-00320016. The Liquid Salt Combined Cycle™ (LSCC™) technology provides large-scale energy storage integrated with Fossil Electric Generating Units (FEGUs) to meet critical needs in the energy transition by providing: • the lowest cost large-scale storage for time-shifting of renewable energy, • superior fuel efficiency to reduce GHGs from dispatchable resources, • flexible capacity and ramping to balance variability of wind and solar resources, • essential grid stability services to assure reliability of a low-carbon grid. The LSCC approach: • employs equipment that has already been proven in utility service, • uses safe, non-toxic, non-degrading, perpetual-life storage medium, • leverages and repurposes existing FEGU assets, • expands the value stack of energy storage to reduce market, financing, and commodity risks. Pintail Power has developed the LSCC technology to meet the need for reliable, efficient, and cost-effective integration of Variable Renewable Energy (VRE) into a low-carbon electric grid by coupling proven thermal energy storage with proven gas turbines, steam turbines, and heat transfer equipment. This novel approach is intended to address the key issues facing the grid and operators of renewable and fossil generating units including: • Overgeneration and curtailment of renewables, • Need for fast ramping dispatchable resources, • Improved efficiency and flexibility of fossil units, • Additional peaking capacity to support electrification of transportation and heating, • Provision of reliability services to support high penetration of VRE, especially synchronous inertia and fast frequency response. A Technology Readiness assessment by EPRI confirmed that LSCC technology consists of commercially proven hardware used in industrial and utility applications. Although the novel LSCC approach has not yet been demonstrated as a complete system, interfaces between major components have been conservatively specified. A Phase III pilot is planned to demonstrate equipment integration and operation. The patented innovation is removal of the evaporator section from the exhaust heat recovery system, with the evaporation performed by stored energy in a separate steam generator. This arrangement couples renewable and fossil power generation via long-duration energy storage to deliver cost, performance, and operational synergies, including superior charging and discharging flexibility, reduced fuel consumption and lower CO 2 emissions compared to conventional Combined Cycle Power Plants, and low-cost, large-scale energy storage. The LSCC technology is composed of proven equipment integrated with gas turbine exhaust heat in a novel system. During charging, electric heaters raise the salt temperature as it flows from the Cold Salt Tank to the Hot Salt Tank. During discharging, hot salt produces steam from feedwater that is heated with gas turbine exhaust, which also superheats steam to drive a steam turbine. LSCC technology can be added to any combustion-turbine to integrate renewable energy, provide needed grid services, and increase the value of fossil electric generating units based on the technology’s following attributes: • Long-duration storage enables time-shifting of VRE to avoid curtailment and impairment of renewable assets. • Long storage duration combined with fast-charging capability increases arbitrage opportunities by storing more energy when the price is low and discharging more hours when the price is high. • Long storage duration allows resource adequacy to be supplied across multiple days to increase reliability and reduce risk. • The stored energy reduces fuel heat rate and GHG emissions, and increases merit, so the LSCC dispatches earlier and longer to increase the plant’s capacity factor and asset value. • The stored energy enables pre-heating and startup of the steam cycle, without operating the gas turbine, to enable fast startup and ramping when dispatched for discharge. • The steam turbine can operate without the gas turbine so it can provide valuable synchronous inertia during charging without consuming fuel. • Fast frequency response and regulation services can be provided during charging using solid-state heater and pump controls to vary the charge power input in response to grid signals. • The LSCC system can be configured for resilience including black start, islanded/micro-grid operation, and even self-recharging of storage using either gas turbine power or gas turbine exhaust heat. The commercialization plan is to add LSCC technology to existing simple cycle gas turbine power plants with the 50MW GE LM6000 aero-derivative gas turbine as the reference design basis. A Techno-economic assessment of the reference design evaluated the benefits (Levelized Avoided Cost of Energy) and costs (Levelized Cost of Energy). The plant definition included all major systems and budgetary vendor quotes. Pintail Power and NexantECA developed the overall cost estimate for the LSCC plant up to the total plant cost level, following the DOE-NETL cost estimate guidelines at AACE Class 3 (-20%/+30%). This includes the equipment cost, bulk material, direct and indirect labor costs to arrive at the bare erected cost. Engineering costs are factored from the BEC and added to it to arrive at the EPC cost. Process and project contingencies were then factored from the EPC cost and rolled-up to yield the total plant cost of $\$$184 million for 1746 MWh of discharge electricity. • At $\$$105/kWh, the reference plant costs less than any of the Energy Storage Systems evaluated by PNNL in 2020 for the Energy Storage Grand Challenge. Operations and Maintenance cost estimates were scaled from combined cycle practice, assuming that the LSCC unit was co-located with and sharing some labor expense with other units, to arrive at $\$$2.2 million per year. Plant economics were evaluated using prices from the ERCOT Day-Ahead Market for calendar year 2019 (excluding the market disruptions from the COVID pandemic and the February 2020 deep freeze event). Assuming economic dispatch in the ERCOT Day-Ahead market, the reference plant capacity factor would have discharged for 2777 hours at 91.9 MW, a 31.66% capacity factor, with a marginal cost of $\$$25.59/MWh, and a LACE of $\$$82.41/MWh. Fixed charges were calculated according to EIA guidelines to arrive at an LCOE of $\$$83.48. The benefit-to-cost ratio of 0.99 suggests that the reference plant would have been cost-effective and competitive in the market. EPRI interviewed selected utilities to gauge the need for, applicability of and interest in the LSCC system. Several utilities are currently managing increased load growth along with the inclusion of increasing levels of renewable generation, putting pressure on conventional generation by requiring increased turndown requirements and ultimately lower capacity factors. All of the utilities interviewed have CO 2 reduction targets in the 2030-2050 timeframe that will severely limit the participation of fossil generation and require better utilization of carbon free generation. While there is limited opportunity for storage in the current markets, the utilities interviewed stated that there will be a substantial need for long duration energy storage in the future given the expected trends. Utilizing an energy storage system will generally be preferred over new gas capacity in some cases, with the capabilities of the LSCC system being a potential option for retrofit to existing simple cycle gas turbine units, allowing them to deliver greater participation in the market with lower carbon intensity. A technology gap assessment and technology maturation plan identified a pilot-scale demonstration as the final step before commercialization. Key gaps to be addressed during the Phase II FEED (Front-End Engineering Design) are component selection and design, commissioning procedures, and operational procedures and the control system for LSCC charging and discharging. The project team has been expanded to include Wood Group PLC as EPC. The proposed Phase II work leads to a pilot-scale engineering demonstration (TRL 6) to be conducted at Southern Company’s Plant Rowan, where the prototype system will perform “all the functions that will be required of the operational system.” The proposed pilot will facilitate commercialization (TRL-9) by scale-up to utility-scale systems integrated with peaking GTs or directly to facility scale systems using industrial GTs. The conceptual design for the pilot plant focuses on the novel integration aspects of LSCC technology. A slipstream of gas turbine exhaust will feed a waste heat recovery unit coupled to a molten salt steam generator heated by stored energy. The pilot is intended to demonstrate all key operating modes of the LSCC technology during charging, discharging and standby. The pilot equipment will be approximately one-seventh scale of the LM6000 commercial target and is expected to have commercial off-ramp potential for facility-scale applications.

01 COAL, LIGNITE, AND PEAT↗

NASA NTRS1958

Experimental Behavior of Pentaborane-Air Combustion Products During Expansion in a Convergent Divergent Nozzle

In order to evaluate the post combustion behavior of boric oxide, pentaborane-air mixtures, burned to completion at a combustor pressure of 3 atmospheres, were expanded through a 7.1-inch-long convergent-divergent nozzle having a 4-inch-diameter throat and an exit-to-throat area ratio of 1.68. The experimentally determined thrust performance was in good agreement with the ideal equilibrium performance at stagnation temperatures of 3300 deg R and lower. The boric oxide vapor at the combustor exit required about 400 F deg supercooling before any condensed phase was observed. For a given thrust, fuel consumption was as much as 20 percent greater than predicted from vapor-pressure data for combustor outlet temperatures i n the vicinity of 3600 deg R. A similar result could be expected in full-scale engines, since the test combustor provided an unusually long dwell time and a highly turbulent environment. During the expansion process, the vapor (when present) did not condense to the extent predicted for an equilibrium expansion process. Moreover, condensation was observed only i n the form of small, abrupt phase changes i n the subsonic flow near the throat. Friction, due to liquid boric oxide films on the nozzle surfaces, was negligible when the surface temperature was above 800 F.

PENTABORANE↗

NASA NTRS1994

Advanced diesel engine component development program, tasks 4-14

This report summarizes the Advanced Diesel Engine Component Development (ADECD) Program to develop and demonstrate critical technology needed to advance the heavy-duty low heat rejection engine concept. Major development activities reported are the design, analysis, and fabrication of monolithic ceramic components; vapor phase and solid film lubrication; electrohydraulic valve actuation; and high pressure common rail injection. An advanced single cylinder test bed was fabricated as a laboratory tool in studying these advanced technologies. This test bed simulates the reciprocator for a system having no cooling system, turbo compounding, Rankine bottoming cycle, common rail injection, and variable valve actuation to achieve fuel consumption of 160 g/kW-hr (.26 lb/hp-hr). The advanced concepts were successfully integrated into the test engine. All ceramic components met their functional and reliability requirements. The firedeck, cast-in-place ports, valves, valve guides, piston cap, and piston ring were made from silicon nitride. Breakthroughs required to implement a 'ceramic' engine included the fabrication of air-gap cylinder heads, elimination of compression gaskets, machining of ceramic valve seats within the ceramic firedeck, fabrication of cast-in-place ceramic port liners, implementation of vapor phase lubrication, and elimination of the engine coolant system. Silicon nitride valves were successfully developed to meet several production abuse test requirements and incorporated into the test bed with a ceramic valve guide and solid film lubrication. The ADECD cylinder head features ceramic port shields to increase insulation and exhaust energy recovery. The combustion chamber includes a ceramic firedeck and piston cap. The tribological challenge posed by top ring reversal temperatures of 550 C was met through the development of vapor phase lubrication using tricresyl phosphate at the ring-liner interface. A solenoid-controlled, variable valve actuation system that eliminated the conventional camshaft was demonstrated on the test bed. High pressure fuel injection via a common rail system was also developed to reduce particulate emissions.

Kaushal, Tony S.↗

DOE OSTI2020

Experimental and theoretical study of the soot-forming tendencies of furans as potential biofuels

Sustainably-produced biofuels, including furans derived from lignocellulosic biomass, are being studied as potential next-generation fuels. Biofuels have unique structures that are absent in conventional fuels and they potentially emit fewer particulates than conventional fuels because of the presence of oxygen atoms. In this work, we focus on quantification and measurement of sooting tendency. A set of furans was selected and their sooting tendencies were characterized by Yield Sooting Index (YSI), which was obtained by measuring the line-of-sight spectral radiance (LSSR) of a coflow laminar diffusion flame doped with 1000 ppm of each test fuel. The measured YSIs are lower than traditional gasoline fuels and benzenoid aromatics (e.g., YSIbenzene = 100). We also performed numerical simulations with a detailed chemical kinetic mechanism to analyze the flame chemistry of 2-methylfuran (2MF). 4→5 H-atom migration in the furan ring causes 31.0% of the total decomposition and is the dominant fuel consumption pathway leading to soot. DFT calculations via the G4 composite method were carried out to obtain activation energies (Ea) and bond dissociation energies (BDE). The results showed that the 4→5 H-atom migration in the furan ring has the second lowest Ea and subsequently forms a 1,2-diene-substituted ketone derivative as a stable species. The ring-opening products of the 4→5 H-atom migration are propyne + a linear ketene for 2-n-alkylfurans, and 1-butyne + a methyl-substituted ketene for 2-t-butylfuran. These results can explain the trends of the measured YSIs of 2-alkylfurans.

09 BIOMASS FUELS↗

DOE OSTI2020

Influence of ozone addition on the low-temperature oxidation of dimethyl ether in a jet-stirred reactor

The influence of ozone addition on the low-temperature oxidation of dimethyl ether (DME) was investigated experimentally in an atmospheric-pressure jet-stirred reactor, over the temperature range of 400–800 K. Detailed speciation information was obtained by employing synchrotron vacuum ultraviolet photoionization mass spectrometry. Experimental results revealed that the ozone addition had a positive influence on the production of the highly reactive intermediates. Moreover, the low-temperature reactivity of DME was significantly enhanced, which resulted in the broadening of the temperature window of fuel consumption and intermediates formation at lower temperatures. Therefore, novel experimental data of the low temperature regime (400–500 K) could be obtained. The data set of this special temperature regime yielded insights into the DME low-temperature kinetics, which were further supported with modeling analysis based on two existing DME models (Metcalfe et al., 2013; Wang et al., 2015) combined with an ozone sub-mechanism (Zhao et al., 2016). The analysis showed that temperature-sensitive reactions such as the second oxygen channel could be nearly “frozen” at this low temperature (T < 440 K). Furthermore, the production of some intermediates was found to be strongly governed by reaction pairs, such as CH 3 OCH 2 + O 2 = CH 3 OCH 2 O 2 and CH 3 OCH 2 + O 2 = 2 CH 2 O + OH for the CH 2 O formation. This finding could be useful for examining branching ratios in both models, and the analysis suggested the further modification of the branching ratios for the oxygen addition to CH 3 OCH 2 O 2 pathways and the CH 3 OCH 2 O 2 self-reactions were required. Finally, the influences of the O 3 addition in the sensitive reactions of the fuel initial low-temperature oxidation were investigated in this work. It was interesting to note that O 3 addition could change the dominating reactions in the initial low-temperature oxidation, by the addition of some O 3 -related pathways with relatively high sensitivity.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2003

Thruster Limitation Consideration for Formation Flight Control

Physical constraints of any real system can have a drastic effect on its performance. Some of the more recognized constraints are actuator and sensor saturation and bandwidth, power consumption, sampling rate (sensor and control-loop) and computation limits. These constraints can degrade system s performance, such as settling time, overshoot, rising time, and stability margins. In order to address these issues, researchers have investigated the use of robust and nonlinear controllers that can incorporate uncertainty and constraints into a controller design. For instance, uncertainties can be addressed in the synthesis model used in such algorithms as H(sub infinity), or mu. There is a significant amount of literature addressing this type of problem. However, there is one constraint that has not often been considered; that is, actuator authority resolution. In this work, thruster resolution and controller schemes to compensate for this effect are investigated for position and attitude control of a Low Earth Orbit formation flight system. In many academic problems, actuators are assumed to have infinite resolution. In real system applications, such as formation flight systems, the system actuators will not have infinite resolution. High-precision formation flying requires the relative position and the relative attitude to be controlled on the order of millimeters and arc-seconds, respectively. Therefore, the minimum force resolution is a significant concern in this application. Without the sufficient actuator resolution, the system may be unable to attain the required pointing and position precision control. Furthermore, fuel may be wasted due to high-frequency chattering phenomena when attempting to provide a fine control with inadequate actuators. To address this issue, a Sliding Mode Controller is developed along with the boundary Layer Control to provide the best control resolution constraints. A Genetic algorithm is used to optimize the controller parameters according to the states error and fuel consumption criterion. The tradeoffs and effects of the minimum force limitation on performance are studied and compared to the case without the limitation. Furthermore, two methods are proposed to reduce chattering and improve precision.

Yunjun Xu↗

DOE OSTI2025

Rheology and engine performance of very low sulfur fuel oil blended with 10% fast pyrolysis and hydrothermal liquefaction oils in a 2-stroke crosshead engine

The performance and emissions for a downscaled single-cylinder 2-stroke crosshead engine were determined for a very low sulfur fuel oil (VLSFO) when blended with 10 wt.% fast pyrolysis (FP) or hydrothermal liquefaction (HTL) bio-intermediates. The FP and HTL oils were derived from biomass and were observed to contain lower molecular weight (MW) hydrocarbons than neat VLSFO (which was evaluated as a baseline comparison). The addition of either biofuel reduced the overall viscosity of the VLSFO. Aging tests at 50, 90, and 120°C showed that the dynamic viscosity of VLSFO increased with exposure time up to two weeks. Similar trends were observed for the FP and HTL blends, but a pronounced spike in viscosity occurred for these fuels during the early period of exposure. None of the viscosity increases exceeded the operational limits of fuel system pumps. Engine performance studies were conducted under low, medium and high load operational settings. The relative performance of the test fuels was highly dependent on operating condition. In general, the engine results for the three test fuels were similar, but modest improvements in brake thermal efficiency and brake specific fuel consumption were observed, which may be attributed to the heightened reactivity of low molecular weight fraction of the FP and HTL oils.

09 BIOMASS FUELS↗

NASA NTRS2002

Advanced Engine Cycles Analyzed for Turbofans With Variable-Area Fan Nozzles Actuated by a Shape Memory Alloy

Advanced, large commercial turbofan engines using low-fan-pressure-ratio, very high bypass ratio thermodynamic cycles can offer significant fuel savings over engines currently in operation. Several technological challenges must be addressed, however, before these engines can be designed. To name a few, the high-diameter fans associated with these engines pose a significant packaging and aircraft installation challenge, and a large, heavy gearbox is often necessary to address the differences in ideal operating speeds between the fan and the low-pressure turbine. Also, the large nacelles contribute aerodynamic drag penalties and require long, heavy landing gear when mounted on conventional, low wing aircraft. Nevertheless, the reduced fuel consumption rates of these engines are a compelling economic incentive, and fans designed with low pressure ratios and low tip speeds offer attractive noise-reduction benefits. Another complication associated with low-pressure-ratio fans is their need for variable flow-path geometry. As the design fan pressure ratio is reduced below about 1.4, an operational disparity is set up in the fan between high and low flight speeds. In other words, between takeoff and cruise there is too large a swing in several key fan parameters-- such as speed, flow, and pressure--for a fan to accommodate. One solution to this problem is to make use of a variable-area fan nozzle (VAFN). However, conventional, hydraulically actuated variable nozzles have weight, cost, maintenance, and reliability issues that discourage their use with low-fan-pressure-ratio engine cycles. United Technologies Research, in cooperation with NASA, is developing a revolutionary, lightweight, and reliable shape memory alloy actuator system that can change the on-demand nozzle exit area by up to 20 percent. This "smart material" actuation technology, being studied under NASA's Ultra-Efficient Engine Technology (UEET) Program and Revolutionary Concepts in Aeronautics (RevCon) Program, has the potential to enable the next generation of efficient, quiet, very high bypass ratio turbofans. NASA Glenn Research Center's Propulsion Systems Analysis Office, along with NASA Langley Research Center's Systems Analysis Branch, conducted an independent analytical assessment of this new technology to provide strategic guidance to UEET and RevCon. A 2010-technology-level high-spool engine core was designed for this evaluation. Two families of low-spool components, one with and one without VAFN's, were designed to operate with the core. This "constant core" approach was used to hold most design parameters constant so that any performance differences between the VAFN and fixed nozzle cycles could be attributed to the VAFN technology alone. In this manner, the cycle design regimes that offer a performance payoff when VAFN's are used could be identified. The NASA analytical model of a performance-optimized VAFN turbofan with a fan pressure ratio of 1.28 is shown. Mission analyses of the engines were conducted using the notional, long-haul, advanced commercial twinjet shown. A high wing design was used to accommodate the large high-bypassratio engines. The mission fuel reduction benefit of very high bypass shape-memory-alloy VAFN aircraft was calculated to be 8.3 percent lower than a moderate bypass cycle using a conventional fixed nozzle. Shape-memory-alloy VAFN technology is currently under development in NASA's UEET and RevCon Programs.

Berton, Jeffrey J.↗

DOE OSTI2023

Investigation of Technologies to Improve Condenser Heat Transfer and Performance in a Relevant Coal-Fired Power Plant

Improvements in thermal power-generating plant performance is correlated directly to societal benefits including lower cost of reduced fuel consumption, resulting in lower cost of electricity for the consumer and reduced carbon emissions to the atmosphere. Warm steam exhausted from low-pressure steam turbines is condensed to liquid water on the exterior of thin-walled metal condenser tubes with cooling water passing through the tube interior. The condensation of steam creates a vacuum that supports turbine rotation and the concurrent generation of electricity. This vacuum is optimized when heat transfer across the wall of condenser tube is maximized. Common hindrances to heat transfer include foulants in cooling water that may form and adhere to the interior of condenser tubes, including mineral scale, microbiological films, and particulate deposition. Flowing cooling water may also include a laminar layer at the interior metal surfaces that travels more slowly than bulk water flow, serving to impede heat transfer. On the tube exterior, condensing steam forms an insulating layer of water that flows down the tube and reduces the effectiveness of cooling. Both the interior and exterior barriers to optimal heat transfer may be alleviated to some extent by surface treatments. On the tube interior, hydrophobic coatings may be applied that can reduced the adherence of foulants and of the laminar flow layer to the tube surface. On the tube exterior, hydrophobic coatings or mechanical treatments can be applied that may result in the termination of droplet growth and the departure of droplets from the surface rather than coalescence into a continuous layer of flowing water. Fourteen surface treatments were applied to condenser tubes in this study, including eight interior coatings and six exterior treatments, five of which were coatings and one a microstructural texture. Heat transfer measurement equipment simulating conditions in the condenser of an operating power plant was used to determine heat transfer coefficients by measuring sufficient flow, temperature, water chemistry and other data. Several of the tubes with interior surface treatments showed improvement in heat transfer coefficients compared with a plain (uncoated) tube, and several of the tubes with exterior surface treatments also showed enhanced heat transfer coefficients.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2025

Low-Cost Sulfur Thermal Storage for Solar Industrial Process Heat Applications

Industrial process heat (IPH) is one of the largest energy demands in U.S., representing about 10% of all domestic energy consumption. Fuel costs to generate this industrial process heat are generally a top three cost for industry, a major component in American manufacturing competitiveness. Roughly 60% of US IPH demand (about 6,500 TBtu annually) falls in the medium-temperature range of 100–250 °C. While concentrated solar thermal (CST) technologies can provide a cost-effective source of heat in this temperature range, solar intermittency limits their adoption in industries that operate 24/7. Element 16 Technologies, Inc. developed a low-cost sulfur thermal energy storage (TES) technology to bridge this gap by capturing excess solar heat during the day and dispatching it reliably during non-solar hours. The core innovation is the use of sulfur, an abundant, industrial waste byproduct that costs ten times less than molten salt used in commercial TES systems. The overall goal of the project was to advance the design and development of molten sulfur TES to a manufacturing-relevant prototype stage for solar industrial process heat applications, while establishing and validating a realistic pathway to commercial success. Key tasks included corrosion and mechanical durability testing to identify cost-effective materials, design investigations using physics-based simulation tools, techno-economic evaluations of system lifetime costs, and pilot-scale testing for performance verification. Corrosion testing of steel alloys under cyclic molten sulfur conditions showed that austenitic stainless steels in the 300 series performed particularly well, with no structural degradation of welds or joints. Thermal cyclic testing of pilot sulfur TES units up to 1.5 MWh quantified charge/discharge rates, heat losses, round-trip efficiency and validated the system's capability to operate effectively under intermittent charging conditions. A techno-economic model, informed by sulfur TES performance model validated using pilot test data, showed that hybrid solar+sulfur TES+NG boiler systems are economically competitive with incumbent natural gas boilers for multiple locations in the southwest US. In summary, this project established molten sulfur TES as a technically viable pathway to improve economic competitiveness of American manufacturing by lowering the cost of solar industrial process heat.

14 SOLAR ENERGY↗

DOE OSTI2024

Climate adaptation and sustainability in switchgrass: exploring plant-microbe-soil interactions across continental scale environmental gradients

Less carbon-intensive energy sources are needed to reduce greenhouse gas emissions and their predicted role in climate change. There is growing interest in the potential of biofuels for meeting this need. A critical question is whether large-scale biofuel production can be sustainable over the time scales needed to mitigate our carbon debt from fossil fuel consumption. The carbon balance and ultimately the sustainability of biofuel feedstock production is the result of complex climate-coupled interactions between carbon fixation, sequestration, and release through combustion. Similarly, the long-term productivity of biofuels depends on the environmental factors limiting plant growth. These factors are often related to soil resources which involve complex interactions at the plant-microbe-soil interface impacting their availability and cycling. Our collaborative project addressed sustainable switchgrass (Panicum virgatum) production by exploring Plant Systems, Plant-Microbiome Interactions, and Ecosystem Processes through the integrating lens of Multi-Scale Modeling. Our research was based on detailed characterization of genetically diverse switchgrass genotypes planted in common gardens across a continental latitudinal gradient. The underlying theme of our Plant Systems research was the use of locally adapted plant material to explore plant function, to understand the mechanistic basis of environmental interactions, and to discover the plant genes important for adaptation and sustainability in the face of climate change. Our Plant-Microbiome Interaction project characterized the microbial communities associated with switchgrass using genomic tools. Our Ecosystem Processes research focused on carbon cycle responses at the ecosystem level using stand level plantings. Finally, our Multi-Scale Modeling helped to define conditions of a sustainable biofuel system and identify key tradeoffs between genetic diversity, productivity, and ecosystem services. Genome-wide association analyses were used to identify alleles that contribute to successful establishment and biomass production across North America. Together, our work provided a baseline analyses of the potential of switchgrass as a biofuel feedstock. Our project resulted in a number of successful outcomes. First, we were successful in collecting switchgrass germplasm across the species range, propagating the material, and establishing common garden experiments across the species range. In collaboration with DOE JGI, we successfully assembled the first tetraploid switchgrass genome and published this resource with an analyses of the genetic basis local adaptation from our gardens (Lowry et al. 2019, Lovell et al. 2021). The gardens were used to characterize the genetic architecture for a number of important plant phenotypes. Our project also conducted extensive sampling and sequencing to characterize the bacterial and fungal associates of switchgrass roots and leaves. We showed that host genotype, location, and harvesting practices can play a role in microbiome assembly (Singer et al. 2019 & 2022, Van Wallendael et al. 2020 & 2022, Edwards et al. 2023). Our ecosystem processes work created baseline dataset of carbon and nutrient cycling in realistic stand plantings of switchgrass. Data from this experiment provided new insight into the role of plant traits, phenology, and local environments in ecosystem processes like soil respiration, net-ecosystem exchange, and dynamics of soil and plant nutrients (Ricketts et al. 2023). Finally, our crop modelling experiments help to characterize the sensitivity of common modeling frameworks to parameters, identify key limiters of productivity across large geographic scales, and leverage patterns of local adaptation in prediction. Ultimately, these studies help to identify critical plant-microbe-soil traits that may be manipulated, through breeding or agronomic management, to improve the sustainability of biofuel feedstocks.

09 BIOMASS FUELS↗

DOE OSTI2024

Fuel‐Driven π‐Conjugated Superstructures to Form Transient Conductive Hydrogels

Despite advances in creating dissipative materials with transient properties, such as hydrogels and active droplets, their application remains confined to temporal changes in structural properties. Developing out-of-equilibrium materials whose electronic functions are parameterized by a chemical reaction cycle is challenging. Yet, this class of materials is required to construct biomimetic materials. In contrast to traditional chemical reaction cycles that exploit molecularly dissolved building blocks at thermodynamic equilibrium, we show that fiber structures derived from reactive naphthalene diimide (NDI) building blocks can be used as resting states to form far-from-equilibrium conductive hydrogels after the addition of chemical fuels. Upon fueling the NDI-derived fibers, a dual-component activation and deactivation pathway is deduced by kinetic analysis and is absent when using a molecularly dissolved resting state. Investigating the solid-state morphologies of the structures formed throughout the fuel-driven reaction cycle using cryo-EM reveals that the resting thermodynamic fibers evolve to transient thicker fibrils and layered superstructures. We show that the transient redox-active hydrogels exhibit a nearly threefold increase in electrical conductivity upon fuel consumption before reverting to their original value over hours. In conclusion, these far-from-equilibrium materials are potential candidates in applications such as programmable biorobotics and chemical computing.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗