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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Factors that Impact the Redox Kinetics Associated with Sr1-xAxFeO3 (A = Ca, Ba) in Air Separations Technologies

Perovskite oxides, including SrFeO3-δ, have garnered significant interest for their impressive oxygen storage thermodynamics and kinetics. While traditional oxygen production is performed through cryogenic separation methods at the industrial scale, oxygen carrier-based separations have offered an attractive alternative at the modular scale. Perovskites are considered ideal oxygen carriers, with their structural flexibility minimizing both the thermodynamic barrier and the structural strain related to the oxygen uptake/release cycle. Our latest work has identified a few major factors that directly impact the oxygen release thermodynamics and kinetics for Sr1-xAxFeO3-δ (A = Ca, Ba) materials including elemental composition, crystallographic symmetry, surface area, and pretreatment conditions. This presentation will discuss these factors using Sr1¬-xCaxFeO3 and Ba1-xSrxFeO3 to illustrate their individual and collective impacts on the design of high-performance oxygen carriers when operating at 300-700 °C. Additionally, we will discuss how each of these factors can be leveraged for the numerous catalytic applications also dependent on the redox properties of mixed metal oxides.

Popczun, Eric↗
DOE OSTI2020

Hybrid Fuel Cell—Supercritical CO2 Brayton Cycle for CO2 Sequestration-Ready Combined Heat and Power

The low prices and its relatively low carbon intensity of natural gas have encouraged the coal replacement with natural gas power generation. Such a replacement reduces greenhouse gases and other emissions. To address the significant energy penalty of carbon dioxide (CO2) sequestration in gas turbine systems, a novel high efficiency concept is proposed and analyzed, which integrates a flame-assisted fuel cell (FFC) with a supercritical CO2 (sCO2) Brayton cycle air separation. The air separation enables the exhaust from the system to be CO2 sequestration-ready. The FFC provides the heat required for the sCO2 cycle. Heat rejected from the sCO2 cycle provides the heat required for adsorption-desorption pumping to isolate oxygen via air separation. The maximum electrical efficiency of the FFC sCO2 turbine hybrid (FFCTH) without being CO2 sequestration-ready is 60%, with the maximum penalty being 0.68% at a fuel-rich equivalence ratio (Φ) of 2.8, where Φ is proportional to fuel-air ratio. This electrical efficiency is higher than the standard sCO2 cycle by 6.85%. The maximum power-to-heat ratio of the sequestration-ready FFCTH is 233 at a Φ = 2.8. Even after including the air separation penalty, the electrical efficiency is higher than in previous studies.

10 SYNTHETIC FUELS↗
DOE OSTI2022

Experimental Investigation of the Effect of Atomizing Electrospray Nozzles on the Cooling and Reduced Humidification of Air

Separating sensible and latent cooling have shown the potential to reduce energy consumption in A/C systems for building HVAC applications. Several technologies exist based on vapor-compression refrigeration, enthalpy wheels, chemical adsorption and absorption materials, and mechanical cooling. However, their thermodynamics limits and high energy consumption hinder their deployment in hot and humid climatic regions. This paper focuses on separating sensible and latent cooling by using a new thermodynamics process and in-kind (i.e., non-vapor compression-based) technology. Highly electrically charged water droplets were sprayed in the airflow. These droplets attracted water vapor molecules to their surfaces and promoted condensation. The phenomenon was the result of simultaneous dielectrophoresis and electro-diffusion interactions. Studies in the literature have shown that using multiple capillary electrodes reduced air moisture by up to 5% when using nanometer-size droplets in the spray. Unfortunately, these studies were limited to low airflow rates, and the objective of this paper was to investigate how to scale up this in-kind approach to airflows typical of buildings. In the present paper, droplets of micrometer size were utilized to control the humidity for a 5-cfm flow rate. While this airflow was still low for building applications, it was 100 times fold the airflows in the literature studies. The air was tested at 20°C and at 50 and 80% relative humidity. A two-fluid atomizing nozzle produced the droplets in the spray, and high DC electric potential, up to 25 kV, was used to charge the fine droplets electrically. The air atomizing nozzle with high voltage potential resembled an evaporative cooler process. However, a measurable reduction of the absolute humidity of up to 2% was observed compared to the case of the nozzle with no high voltage potential. The entire device had one small nozzle selected from off-the-shelf components and had less than a 9 cm2 footprint area.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Performance and flexibility improvements of Staged Pressurized Oxy-Combustion

Staged Pressurized Oxy-Combustion (SPOC) is a low-carbon coal combustion power technology being developed by Washington University in St. Louis (WUSTL). Oxy-combustion plants enable straightforward capture of carbon dioxide (CO 2 ) by removing most of the nitrogen in the combustion air prior to use, thereby burning fuel in near-pure oxygen instead of air, producing a flue gas containing primarily CO 2 and water. CO 2 capture at amounts > 90% is possible, often using cryogenic air separation. Oxy-combustion typically relies on flue gas recycle (FGR) to reduce the peak temperature and radiation that would otherwise occur in a fuel/oxygen only flame. SPOC reduces the peak temperatures of combustion by utilizing two or more pressurized boiler modules connected in series to produce fuel staging; hence, only a portion of the fuel is combusted in any given furnace module. This means that the thermal energy released at each stage can be captured and removed from the gases prior to subsequent stages, when more fuel is introduced. This allows the SPOC process to operate with minimal FGR, avoiding the associated efficiency losses and additional costs. Also, the process operates at an elevated gas-side pressure, reducing boiler size, enhancing heat transfer to achieve a compact boiler configuration as compared to an atmospheric-pressure boiler design, and allowing for recovery of the latent heat of the water from the flue gas at a temperature useful to the steam cycle. The resultant net efficiency of the system is over 3 percentage points greater than traditional atmospheric-pressure oxy-combustion, and 7 percentage points greater than the post combustion variant, representing a step-change improvement over first-generation capture technologies. To further develop the concept, WUSTL and the Electric Power Research Institute, Inc., organized a project with American Air Liquide, Inc., Doosan Babcock Limited, and the U.S. Department of Energy to investigate a practicable and workable boiler design. The team has identified the potential for enhanced process flexibility for controlling power generation over a wider load range than is normally available to conventional coal-fired power plants due to the staged nature of the heat release. With increasing intermittent renewable generator contribution, on-demand generators need to be highly flexible to participate in the future energy market, requiring extensive operation at reduced load. Conventional coal-fired steam generators typically face challenges in maintaining temperature control of the reheat steam and main steam at reduced loads. This results in inefficient operation, both in terms of the boiler efficiency and steam turbine heat rate. The results of this project show the SPOC process is capable of exceptional turndown, both on a stage basis and with the ability to bypass entire stages. Oxygen-supply flexibility was also investigated, as this is also a key consideration for the overall flexibility of the SPOC process given the operating constraints of conventional air separation units. A boiler design concept assessment was conducted and was focused on delivering compact and constructible design. The assessment checked appropriate tube operating metal temperatures at full load and at lower operating loads, balanced against the needs of efficient coal combustion, and the resultant slagging and ash environments. Combustion testing in the 100-kWth pressurized combustion test rig at WUSTL was carried out to validate the combustion, heat flux profiles and burnout at multiple loads. Combustion parameters investigated were flame stability, fuel burnout, ash composition, radiative heat flux, and temperature profiles. The results of these tests formed the basis of a full-scale boiler design that will encompass improvements in both efficiency and flexibility over conventional oxy-combustion processes. The air separation unit flexibility was investigated, and associated cost implications were addressed. Detailed economic assessment results for a 550 MWe net power block are also provided, allowing for a comparison against the baseline NETL oxy-combustion and post combustion capture cases.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2025

A Data-Driven Framework for Predicting the Sorting and Screening Performance of an Integrated Biomass Feedstock Preprocessing System

The characteristics of mechanically sorted and screened lignocellulosic biomass, such as the mass contents of corn stover anatomical fractions (leaves, husks, stalks, cobs, etc.), can be used to calculate the intermediate feedstock quality attributes “yield” and “purity” that indicate the conversion efficiency of biocrude. No prior study has investigated the correlations from the characteristics of raw biomass and preprocessing unit operation parameters to those intermediate feedstock quality attributes. This work presents a data-driven framework for assessing and predicting the intermediate feedstock quality attributes in an integrated biomass feedstock preprocessing system. Our study used corn stover as a typical type of herbaceous biomass because of its abundance in the U.S. It began with data acquisition of moisture content, particle size distribution, and anatomical fractions of the materials after each unit operation in the system. The objective of this preprocessing system is to minimize husks and leaves and maximizing cobs and stalks by mechanically separating the materials into three streams via disc screen and air separator. Prototype neural network models were then developed to evaluate the feasibility of predicting process outcomes based on measurable parameters. It is found that incorporating physical constraints into these prediction models significantly enhances the accuracy of the predicted yield and purity against the ground truth data. The experimental data and model predictions indicate that decreasing throughput increases purity, while higher throughput results in lower purity. Finally, an optimization problem was introduced to search optimal combinations of feed material properties and preprocessing unit operation parameters, as the intermediate feedstock quality attributes – yield and purity, appeared to be competing factors. The study also suggests the continual need to improve the data-driven framework’s predictability by incorporating more accurate physical models to describe the dynamics in the preprocessing units such as the air separator.

09 - BIOMASS FUELS↗
DOE OSTI2023

Upscaling of asymmetric hollow fiber‐supported thin film membranes for oxygen separation from air: Proof of concept

Abstract Hollow fiber membranes demonstrate various advantages for high performance oxygen separation. However, the small diameters of hollow fibers and the brittleness of ceramics limit their mechanical strength, imposing great difficulties on stack and module development. Gas‐tight sealing is another challenge for upscaling of hollow fiber membrane technology. Low temperature sealant materials of epoxy resin or silicon are typically used for hollow fiber stacks, requiring that the sealing portions be located out of hot zone. Consequently, only partial length of hollow fibers participates in oxygen permeation. In this study, upscaling of our recently developed asymmetric hollow fiber‐supported thin film membranes is conducted, where individual hollow fibers are assembled in parallel to form a stack. A reliable gas‐tight sealing is obtained by combining ceramic paste with conductive adhesive ink cohesively. Comprehensive oxygen permeation test is conducted with the sealing portions being in hot zone and compared with a single hollow fiber membrane. Fundamental mechanism is discussed to understand the performances and their differences. An accelerated long‐term test (∼320 h, 16 thermal cycles) demonstrates excellent stability and robustness of the stack and sealing. The characterization of post‐test samples further confirms excellent stability and robustness of the phases and microstructures of the stack.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Performance of a Natural Gas Solid Oxide Fuel Cell System With and Without Carbon Capture

The fuel cell program at the United States Department of Energy (DOE) National Energy Technology Laboratory (NETL) is focused on the development of low-cost, highly efficient, and reliable fossil-fuel-based solid oxide fuel cell (SOFC) power systems that can generate environmentally-friendly electric power with at least 90 percent carbon capture. NETL’s SOFC technology development roadmap is aligned with near-term market opportunities in the distributed generation sector to validate and advance the technology while paving the way for utility-scale natural gas (NG)- and coal-derived synthesis gas-fueled applications via progressively larger system demonstrations. The present study represents a part of a series of system evaluations being carried out at NETL to aid in prioritizing technological advances along research pathways to the realization of utility-scale SOFC systems, a transformational goal of the fuel cell program. In particular, the system performance of utility-scale NG fuel cell (NGFC) systems with and without carbon dioxide (CO2) capture is presented. The NGFC system analyzed features an external auto-thermal reformer (ATR) feeding the fuel to the SOFC system consisting of planar anode-supported SOFC with separated anode and cathode off-gas streams. In systems with CO2 capture, an air separation unit (ASU) is used to provide the oxygen for the ATR and for the combustion of unutilized fuel in the SOFC anode exhaust along with a CO2 purification unit to provide a nearly pure CO2 stream suitable for transport for usage in enhanced oil recovery operations or for storage in underground saline formations. Remaining thermal energy in the exhaust gases is recovered in a bottoming steam Rankine cycle while supplying any process heat requirements. A reduced order model (ROM) developed at the Pacific Northwest National Laboratory (PNNL) is used to predict the SOFC performance. The ROM, while being computationally effective for system studies, provides other detailed information about the state of the stack, such as the internal temperature gradient, generally not available from simple performance models often used to represent the SOFC. Such additional information can be important in system optimization studies to preclude operation under off-design conditions that can adversely impact overall system reliability. The NGFC system performance was analyzed by varying salient system parameters, including the percent of internal (to the SOFC module) NG reformation—ranging from 0 to 100 percent—fuel utilization, and current density. The impact of advances in underlying SOFC technology on electrical performance was also explored.

solid oxide fuel cell (SOFC), natural gas fuel cel↗
DOE OSTI2020

10 MWE CDCL Large Pilot Plant – pre-FEED Study

Coal Direct Chemical Looping (CDCL) is an advanced oxy-combustion technology that has the potential to substantially reduce the energy penalty and the cost of electricity (COE) for coal-fired power generation with CO₂ capture. The Babcock & Wilcox Company (B&W) and The Ohio State University (OSU) have been collaborating on the development of an iron oxide oxygen-carrier based chemical looping technology for clean power generation with inherent carbon capture. In this process, coal is dried and pulverized prior to being transported into a moving-bed reducer. In the reducer, coal reacts with the oxygen-carrier particles, forming combustion byproducts, predominantly CO₂ and H₂O, while reducing the iron oxide oxidation state from Fe₂O₃ to a mixture of FeO and Fe. The reduced state particles are then transported to a combustor reactor and re-oxidized with air. Following the oxidation, the oxygen-carrier particles are regenerated, and a large amount of heat is released for steam production. The produced steam is sent to a turbine for electricity generation. Meanwhile, the CO₂–rich stream leaving the reducer is cooled, cleaned, and compressed for subsequent pipeline transportation and sequestration. By combining air separation and fuel conversion into a single system, the CDCL technology enables the intensification of oxy-combustion processes by eliminating the energy and cost intensive cryogenic air separation unit and thereby results in higher overall plant efficiencies and lower COE’s. The use of a moving-bed reducer results in high conversions of volatile hydrocarbons and high CO₂ purity, which reduces the cost of downstream CO₂ purification for sequestration or utilization. The Babcock & Wilcox Company in collaboration with The Ohio State University, Johnson & Matthey, The Electric Power Research Institute, and Dover Light & Power completed a Preliminary Front-End Engineering and Design (Pre-FEED) study of a 10 MWe coal-direct chemical looping (CDCL) pilot plant. The planned system is a modular 10 MWe CDCL large pilot facility consisting in 4 modules of 2.5 MWe each, working in parallel and to be hosted within the current structure at the City of Dover’s Municipal Power Plant. The CDCL system can achieve auto-thermal operation and includes a sub-critical steam cycle for power generation. The pilot system was designed to demonstrate full commercial operation at a reduced scale. The coal distribution per plan area is a representative slice of larger commercial arrangements. The system includes a CO₂ recycle system, but it does not include a compression system. The large pilot includes all the environmental control equipment and oxygen carrier and ash handling systems. As part of the project, the Team performed laboratory testing and carried out multiple pilot test campaigns to obtain design and performance information at the 250 kWth CDCL pilot facility at the Babcock & Wilcox Company’s Research Center. The Team demonstrated sustained operations at designed coal inputs, high coal conversion, high CO₂ purity, heat generation on the combustor, low carbon carryover between reactors and low particle attrition. Emissions generated in the reducer reactor were identified as SO₂ and NO x . The commercial manufacturing cost of oxygen carrier particle was evaluated by JM. A particle manufacturing report was generated and submitted to the DOE. Based on the results from the pilot tests and the pre-FEED design efforts, a techno-economic analysis was performed. The study shows that the CDCL process is a promising carbon-friendly technology capable of producing electricity with high efficiency. The estimated COE of the supercritical CDCL plant is $83.3 / MWh, which meets DOE’s target of less than 30% increase in COE when compared to a supercritical PC plant without CO₂ capture. This is the lowest among the existing carbon capture technologies (post-combustion and oxy-combustion) for fossil fuel power plant. CDCL is evaluated to be the most promising technology for carbon capture from the economic aspect.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2020

A modular chemo-selective oxygen production unit to deliver oxygen for advanced combustion systems

Commercial oxygen generation technologies deploy either cryogenic air separation or vacuum pressure swing adsorption (VPSA). These technologies can provide nearly pure oxygen but are only economically viable at oxygen production rates of 100-7,000 tonnes/day. The state-of-theart cryogenic air separation plants are impending the theoretical limits of thermodynamic efficiency but cannot be scaled down to cater future needs. Therefore, there is great incentive to develop a new approach for oxygen separation that can accommodate the upcoming demands. Our proposed research approach address to find novel methodologies to provide energy efficient modular O 2 on demand systems for modular gasification and other applications. Small scale modular systems for O 2 production offer certain benefits including enhanced energy efficiency, reduced operating costs and flexibility to tailor location specific needs. Our hypothesis is that a small modular system could be engineered using solvent-based capture and thermal release of oxygen, to enable “oxygen on demand” for any combustion-related technology.

42 ENGINEERING↗
DOE OSTI2025

Carbon‐negative hydrogen from ethanol via catalytic oxidative reforming

Abstract This study evaluated a commercial technology for producing low‐ or negative‐carbon hydrogen through ethanol catalytic oxidative reforming, focusing on the life cycle greenhouse gas emissions, or carbon intensity (CI). Various scenarios were analyzed: (a) comparing corn ethanol (first‐generation or Gen1 ethanol) and cellulosic ethanol (second‐generation or Gen2 ethanol) as feedstocks; (b) assessing carbon capture and sequestration (CCS) for CO 2 from upstream fermentation; and (c) evaluating oxygen sourcing via air separation units vs. on‐site or off‐site water electrolysis using a proton exchange membrane. Findings indicate that the CI for hydrogen production using Gen2 ethanol from corn stover is lower than that of Gen1 corn ethanol. Additionally, using proton exchange membrane‐generated oxygen results in a lower CI than air separation unit‐generated oxygen, regardless of the sourcing method. Implementing CCS for the hydrogen production plant's evolved CO 2 is essential for achieving a net‐negative CI for hydrogen from Gen1 ethanol. All examined scenarios, including both ethanol generations, oxygen sources, and CCS applications, demonstrated a net‐negative carbon intensity, surpassing the life cycle greenhouse gas emissions threshold of 0.45 kg CO 2 e/kg to enable policy credits as outlined in the Inflation Reduction Act §45V. In comparison, the CI for hydrogen from steam methane reforming stands at 3.4 kg CO 2 e/kg with CCS and 9.4 kg CO 2 e/kg without CCS.

08 HYDROGEN↗
DOE OSTI2021

Project Final Report - Advanced Oxygen Separation from Air Using a Novel Mixed Matrix Membrane

This report describes a summary of the findings of the project. The technical work was divided into three activities: 1) technoeconomic analysis; 2) membrane component development (support layer, selective layer development, and gutter layer formulation); and 3) hollow fiber formation. The technoeconomic analysis includes operating, capital, and materials costs of an oxygen enrichment system with 1-3 stages. The analysis concluded that the desired gas quality (90-95% O2) cannot be reached with a single stage. The triple stage system yielded the best overall product quality at lower membrane performance levels but with the highest cost. For the membrane development activities, functionalized nanodiamonds have been shown to slightly improve membrane formation behaviors and gas permeability performance. For example, support layers based on polysulfone-nanodiamond composites have been formed that increase the material’s O2 permeability by over a factor of 150, however, at the cost of selectivity that suggests a change in transport mechanism. Furthermore, nanodiamonds have been found to improve membrane durability. Improvements in selective and gutter layers also have been accomplished. An additional accomplishment is the demonstration of phase inversion of polysulfone-nanodiamond composites that ensures that hollow fiber formation can be performed. Finally, the interfaces between support, gutter, and selective layers were briefly examined and the resulting membrane material consisting of all three layers gave good performance in an O2 separation from N2. The three-layer prototype membrane gave permeability of 29.2-32.2 Barrers, which equates to permeance of approximately 290-320 GPU, which is lower than the TEA informed goal of 500 GPU. O2/N2 selectivity ranged from 5.2-6.2, which is consistent with the less costly two-stage implementation of the technology. In summary, new materials have been developed for O2 concentration from air and are well-suited to a hollow fiber format.

20 FOSSIL-FUELED POWER PLANTS↗