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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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At least 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

High-temperature high-pressure microfluidic system for rapid screening of supercritical CO 2 foaming agents

CO 2 foam helps to increase the viscosity of CO 2 flood fluid and thus improve the process efficiency of the anthropogenic greenhouse gas’s subsurface utilization and sequestration. Successful CO 2 foam formation mandates the development of high-performance chemicals at close to reservoir conditions, which in turn requires extensive laboratory tests and evaluations. This work demonstrates the utilization of a microfluidic reservoir analogue for rapid evaluation and screening of commercial surfactants (i.e., Cocamidopropyl Hydroxysultaine, Lauramidopropyl Betaine, Tallow Amine Ethoxylate, N,N,N' Trimethyl-N'-Tallow-1,3-diaminopropane, and Sodium Alpha Olefin Sulfonate) based on their performance to produce supercritical CO 2 foam at high salinity, temperature, and pressure conditions. The microfluidic analogue was designed to represent the pore sizes of the geologic reservoir rock and to operate at 100 °C and 13.8 MPa. Values of the pressure drop across the microfluidic analogue during flow of the CO 2 foam through its pore network was used to evaluate the strength of the generated foam and utilized only milliliters of liquid. The transparent microfluidic pore network allows in-situ quantitative visualization of CO 2 foam to calculate its half-life under static conditions while observing if there is any damage to the pore network due to precipitation and blockage. The microfluidic mobility reduction results agree with those of foam loop rheometer measurements, however, the microfluidic approach provided more accurate foam stability data to differentiate the foaming agent as compared with conventional balk testing. The results obtained here supports the utility of microfluidic systems for rapid screening of chemicals for carbon sequestration or enhanced oil recovery operations.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Simulation of the supercritical CO 2 recompression Brayton power cycle with a high-temperature regenerator

The supercritical carbon dioxide (sCO 2 ) recompression Brayton cycle promises higher efficiency and lower capital cost than traditional steam Rankine power cycles. However, achieving high efficiency requires large, highly effective recuperators. Regenerators may be a low-cost alternative to printed circuit and micro-tube heat exchangers for recuperation in sCO 2 power cycles. Regenerators are a periodic heat exchanger in which thermal energy is extracted from the hot stream, stored in solid media, and then released to the cold stream at a later time. Fixed bed regenerators with valves to direct fluid are the preferred method for implementing regenerators in power cycles, but the inherently transient nature of these systems has not been characterized for this application. This study presents the simulation of a high-temperature regenerator within a 10 MWe sCO 2 recompression Brayton cycle. A transient, one-dimensional regenerator model presented in a previous study is used to simulate the regenerator. Dynamic heat exchanger models are also developed for the precooler, low-temperature recuperator, and primary heat exchanger, and the compressors and the turbine are modeled with off-design performance maps. We assess two regenerator-valve design options; one for fast switching, and one for reduced flow rate fluctuations. System simulation finds that both designs see significant fluctuations in turbomachinery flow rate, turbomachinery and system power, and regenerator discharge process outlet temperature. While designing the regenerator-valve subsystem for lower fluctuations is possible, the regenerator cold discharge temperature and net power still fluctuate by ±77.6°C and 6%, respectively. Increasing buffer volume is not effective at sufficiently reducing these fluctuations, but adding a packed bed in between the regenerator and the primary heat exchanger can reduce regenerator discharge process outlet temperature fluctuations to 6.4°C. Further reductions could be possible by increasing the size of this packed bed.

42 ENGINEERING↗
DOE OSTI2021

Permeability Evolution of Fractures in Shale in the Presence of Supercritical CO 2

We experimentally examined the impact of supercritical carbon dioxide (scCO 2 ) on fracture permeability and fracture surface characteristics in shales of various compositions. We measured permeability and fracture normal displacement at different effective stresses using both argon and scCO 2 as pore fluids. Both natural fractures and saw cuts in intact samples were used in our study. The permeability and fracture normal displacement decrease after multiple loading/unloading cycles, apparently as the result of inelastic compaction. In samples with high carbonate content, we observe an increase in permeability and fracture surface degradation after more than 3.5 days of exposure to scCO 2 , apparently due to carbonate dissolution. We demonstrate that the sensitivity of permeability to effective normal stress correlates well with the fracture normal displacement. The dependence of permeability on effective normal stress increases after exposure to scCO 2 as the fracture surface became more compliant.

58 GEOSCIENCES↗
DOE OSTI2020

Probing the Effects of NO x and SO x Impurities on Oxy-Fuel Combustion in Supercritical CO 2 : Shock Tube Experiments and Chemical Kinetic Modeling

The direct-fired supercritical carbon dioxide cycles are one of the most promising power generation methods in terms of their efficiency and environmental friendliness. Two important challenges in implementing these cycles are the high pressure (300 bar) and high CO 2 dilution (>80%) in the combustor. The design and development of supercritical oxy-combustors for natural gas require accurate reaction kinetic models to predict the combustion outcomes. The presence of a small amount of impurities in natural gas and other feed streams to oxy-combustors makes these predictions even more complex. During oxy-combustion, trace amounts of nitrogen present in the oxidizer is converted to NO x and gets into the combustion chamber along with the recirculated CO 2 . Similarly, natural gas can contain a trace amount of ammonia and sulfurous impurities that get converted to NO x and SO x and get back into the combustion chamber with recirculated CO 2 . In this work, a reaction model is developed for predicting the effect of impurities such as NO x and SO x on supercritical methane combustion. The base mechanism used in this work is GRI Mech 3.0. H 2 S combustion chemistry is obtained from Bongartz et al. while NOx chemistry is from Konnov. The reaction model is then optimized for a pressure range of 30–300 bar using high-pressure shock tube data from the literature. It is then validated with data obtained from the literature for methane combustion, H 2 S oxidation, and NO x effects on ignition delay. The effect of impurities on CH 4 combustion up to 16 atm is validated using NO x -doped methane studies obtained from the literature. In order to validate the model for high-pressure conditions, experiments are conducted at the UCF shock tube facility using natural gas identical mixtures with N 2 O as an impurity at ~100 bar. Current results show that there is a significant change in ignition delay with the presence of impurities. A comparison is made with experimental data using the developed model and predictions are found to be in good agreement. The model developed was used to study the effect of impurities on CO formation from sCO 2 combustors. It was found that NO x helps in reducing CO formation while the presence of H 2 S results in the formation of more CO. The reaction mechanism developed herein can also be used as a base mechanism to develop reduced mechanisms for use in CFD simulations.

Energy & Fuels↗
DOE OSTI2020

How equation of state selection impacts accuracy near the critical point: Forced convection supercritical CO 2 flow over a cylinder

Increasing application of supercritical fluids leads to increased use of numerical simulations to guide designs. However, the impact of Equations of State (EoS) selection on computational cost and accuracy is not well understood. Laminar flow around a heated cylinder is used as a test case. A robust matrix of 99-simulations is used to analyze the flow of carbon dioxide just above the critical point at the isobaric condition of 8 MPa and temperatures between 305 and 390 K. Four EoS were studied: Ideal Gas Law, cubic EoS’s Peng-Robinson and Soave-Redlich-Kwong, and the Span-Wagner EoS. Results were identical for isothermal cases, but for heated or cooled cases, the high-fidelity Span-Wagner EoS simulations presented drastically different wake structures. Compared to the high-fidelity SW EoS, cEoS’s underestimated Nu values by up to 38% and cEoS’s underestimated CD values by 18–42%. In conclusion, the Span-Wagner EoS required only 17% more computation time then the cubic EoS simulations, making the Span-Wagner EoS recommended for engineering design.

42 ENGINEERING↗
DOE OSTI2020

Geochemical narrowing of cement fracture aperture during multiphase flow of supercritical CO2 and brine

For carbon capture and storage operations, wells are used as a necessary conduit for injecting CO2 at depth, but they can also act as leakage conduits if the cement seals are compromised. The specific objective of this research was to investigate the nature of self-healing of a fracture within cement under multiphase flow of CO2 and brine, and to compare this to a newly developed model. This was accomplished through a laboratory investigation, flowing reacting supercritical CO2 and brine through a cement fracture with multiphase flow. The influent end of the fracture was degraded as evidenced by the formation of cracks across the surface. At the effluent end of the fracture, the initial aperture of 137 µm was reduced to 50 µm. This reduction by 87 µm was similar to results from a recently developed model tested in this study, which predicted an aperture reduction of 80 µm. Our results demonstrated that the model accurately predicted the reactions which occurred in this multiphase flow system.

wellbore, cement, fracture, multiphase-flow, super↗
DOE OSTI2026

Development of a Test-Bed for Testing and Refining EarthEn’s Supercritical CO 2 Based Energy Storage System

EarthEn’s energy storage concept leverages supercritical carbon dioxide (sCO 2 ) as a working fluid and relies on compact, high-performance components operating at elevated pressures and temperatures. To accelerate component development and reduce technical risk prior to larger-scale demonstrations, Oak Ridge National Laboratory (ORNL) developed a 100 kW-scale sCO 2 test-bed under a Cooperative Research and Development Agreement with EarthEn (CRADA NO. NFE-24-10050). The objective of the work was to design and construct a flexible experimental facility capable of reproducing key thermodynamic state points and heat-transfer conditions relevant to EarthEn’s thermal energy storage (TES) cycle, with particular emphasis on enabling development and evaluation of next-generation heat exchangers and TES concepts. The test-bed consists of a closed-loop sCO 2 circulation system housed within an open-topped enclosure. In its as-installed configuration, dense-phase sCO 2 is recirculated through a printed circuit recuperator, an electrically heated section, a throttling device used to simulate turbine expansion, and a water-cooled printed circuit heat exchanger that rejects heat to the building chilled-water system before returning to the pump. The pump is driven by a variable frequency drive, enabling controlled adjustment of flow and operating point. A comprehensive instrumentation suite was integrated to support both safe operation and high-quality data collection. Installed sensors include Coriolis flow meters for sCO 2 flow rate and density, resistance temperature detectors and thermocouples distributed throughout the loop (including the heated section and key heat exchanger ports), and pressure transducers for absolute and differential pressure measurements. The facility was designed to support high-pressure (19 MPa nominal) and high-temperature (575°C nominal) operation with credited overpressure protection provided by a rupture disk. Nominal operating conditions were selected to support 100 kW-class testing while maintaining flexibility for non-heated and heated shakedown, control development, and future integration of advanced TES test sections. In parallel with facility development, a system-level thermal-hydraulic model was created using Modelica-based tools to support component sizing, anticipate performance over targeted test conditions, and establish a framework for future model calibration against experimental data. At the conclusion of the project performance period, the facility was in final assembly, and the pressure boundary was nearly completed. However, several practical challenges associated with high-pressure/high-temperature systems and specialized component procurement impacted schedule and prevented initial pump-driven operation and full commissioning within the available resources. This report documents the as-built design, operating capabilities, and instrumentation, and it summarizes key lessons learned related to heater fabrication and testing, first-of-a-kind assembly factors, specialty flange supply constraints, and fill pump corrective actions. Finally, it outlines a phased plan for future commissioning and experimental campaigns, including control and instrumentation shakedown, heater characterization, model calibration, and testing at state points representative of EarthEn’s TES cycle.

25 ENERGY STORAGE↗
DOE OSTI2020

Kinetics and Mechanisms of ZnO to ZIF-8 Transformations in Supercritical CO2 Revealed by in situ X-ray Diffraction

ZIF-8 was synthesized in supercritical carbon dioxide (scCO2). In situ powder X-ray diffraction, ex situ microscopy and simulations, provides a encompassing view of the formation of ZIF-8 and intermediary ZnO@ZIF-8 composites in this nontraditional solvent. Time-resolved imaging exposed divergent physicochemical reaction pathways from previous studies of the growth of anisotropic ZIF-8 core@shell structures in traditional solvents. Synthetically relevant physio-chemical properties of scCO2 were integrated into classical nucleation theory, relating interfacial forces with 3D nu-cleation outcomes. The kinetics of crystallization were examined and displayed a characteristic signature of time- and temperature-dependent mechanisms over the extent of the reaction. Lastly, we show that subtle factors, such as the extent of reaction and the size/shape of sacrificial templates can tailor ZIF-8 composition and size, eliciting control over hierarchical porosity in a nonconventional green solvent.

Sinnwell, Michael A.↗
DOE OSTI2020

Volumetric efficiency and pressure pulsations of a triplex reciprocating supercritical CO 2 pump

A reciprocating triplex pump has been integrated into a closed-loop supercritical carbon dioxide test facility. The pump is designed to compress liquid or supercritical carbon dioxide and has a maximum volumetric flow rate of 51 L/min. A sweep across the pump’s speed range of 100–1000 rev/min was performed with inlet conditions between 60 and 160 bar. The volumetric efficiency was found to increase as pump speed increased from 10 to 40 % before it plateaued at higher pump speeds. The mechanical efficiency increased linearly with pump speed and was not affected by system pressure. Pressure pulsations caused by the plungers and valves were also measured at each speed. Additionally, a 35-liter buffer volume, connected near the pump’s discharge was isolated at each speed to determine its effectiveness as a pulsation dampener. Overall the reciprocating pump was shown to perform exceptionally with liquid or supercritical inlet conditions applicable to many supercritical fluid applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Technoeconomic optimization of superalloy supercritical CO 2 microtube shell-and-tube-heat exchangers

Heat exchangers are critical components of aerospace systems and improve efficiency of operation by providing waste heat recovery. Supercritical CO has emerged as a promising candidate working fluid due to its potential in increasing the power density of heat exchangers. In this paper, a generalized costing model is developed to estimate the capital costs incurred to manufacture microtube shell-and-tube heat exchangers. This model is utilized in conjunction with an accurate and efficient 2D numerical shell-and-tube heat exchanger performance prediction model to conduct optimization studies with two key objectives – minimization of cost and maximization of heat exchanger power density – on supercritical CO microtube heat exchangers utilizing superalloy Haynes 282 as the solid material. A methodology is then demonstrated to optimize these heat exchangers using Particle Swarm Optimization for aerospace applications and highly compact and cost-effective optimal designs with power density around 20 and cost per conductance less than 5 $ ∙ K/W are obtained.

42 ENGINEERING↗
DOE OSTI2022

Toward extreme high-temperature supercritical CO 2 power cycles: Leakage characterization of ceramic 3D-printed heat exchangers

We report future supercritical carbon dioxide (sCO 2 ) Brayton power cycles demand high-performance gas-to-gas heat exchangers (HXs) operating under extreme temperature and pressure conditions at which most existing superalloy materials fail to function safely. Ceramic HXs are deemed excellent candidates for advanced sCO 2 power plants as they can withstand high-temperature working environments. Particularly, ceramic 3D printing enables compact HX topologies employing complex and efficient heat transfer features. However, ceramic 3D-printed walls separating hot and cold flow streams are susceptible to a through-plane leakage inherent to a powder-based manufacturing process, including ceramic 3D printing. A potential leakage through ceramic separating walls poses a significant challenge in developing reliable ceramic 3D-printed HXs and could deteriorate thermal performance. In this study, various parameters, including feedstock slurry, 3D-printing direction, and post-processing conditions, are considered, for the first time, to characterize the argon gas leakage rate associated with alumina 3D-printed parts. Three 3D-printed ceramic structures of flat plates, curved tubes, and small-scale plate-and-frame HXs with various thicknesses are systematically studied to determine powder and ceramic 3D-printing conditions to eliminate the through-plane leakage. The results showed that an alumina 3D-printed plate with a thickness of 0.75 mm demonstrates a permeability of 6 x 10 -4 milli-darcy. An alumina 3D-printed tube with a wall thickness of 0.9 mm revealed a permeability of 9.6 x 10 -7 milli-darcy. Furthermore, leakage test results of functional 3D-printed modules showed a dependency on the 3D-printing direction. Particularly, alumina cell-scale HXs employing 1.5-mm-thick horizontal and vertical 3D-printed separating walls demonstrated impermeability and gas permeability of 7.2 x 10 -5 millidarcy, respectively. Insights gained from the present study facilitate the development of complex ceramic 3D-printed HXs and other balance of plant components for next-generation high-temperature high-pressure sCO 2 power cycles.

36 MATERIALS SCIENCE↗
DOE OSTI2019

The effect of wood composition and supercritical CO 2 extraction on charcoal production in ferroalloy industries

This work demonstrates that the integration of supercritical carbon dioxide extraction with slow pyrolysis is an effective method for the production of value-added chemicals and charcoal that is an attractive alternative to coke for industry. Integration of technologies is key for the development of holistic biorefineries that exploit all parts of the biomass feedstock and generate little or ideally no waste. In fact, the use of waste or low valued wood fractions is attractive due to their plentiful abundance and lack of exploitation. Supercritical carbon dioxide has been demonstrated to be effective at the removal of over half of extractives from low quality wood and forestry wastes, which can account for up to 11 wt %, of the dried biomass in waste needles. High extractive yields by supercritical carbon dioxide extraction illustrates the potential of utilizing low quality wood as an alternative feedstock for the sustainable production of value-added chemicals. We report high yields of steroids and derivatives, terpenes and other plant metabolites were obtained in the extracts of needles, branches and bark. Importantly, supercritical carbon dioxide extraction had little impact neither on the physical properties of original wood nor on the yield of solid charcoal. This indicates that extraction by supercritical carbon dioxide can be used as a method for adding further value to the process by removal of bio-based chemicals, whilst still maintaining the yield of the solid fuel product. Moreover, the heat treatment temperature and supercritical carbon dioxide extraction had a significant impact on the tar yields during pyrolysis, leading to an increase in naphthalene, polycyclic aromatic hydrocarbons, aromatic and phenolic fractions with greater temperature. These results are promising as they show that the charcoal obtained from this renewable feedstock could be used as an alternative to fossil-based coke in applications including ferroalloy industries.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Laser-induced fluorescence thermometry of supercritical CO 2 flows inside a micro-channel

This work demonstrates a thermometric technique using laser-induced fluorescence (LIF) in supercritical carbon dioxide flows in a micro-channel. Rhodamine 6G was used as a temperature-sensitive fluorescent dye. The flow conditions were at a pressure of 7.9 MPa and temperature in the range of 23°–90°C. 2D spatial distributions and time-resolved temperature profiles were obtained at this high pressure. Measured LIF signals showed close relations to the temperatures obtained from resistance temperature detectors.

Park, Suhyeon↗
DOE OSTI2024

A One-dimensional Heat Transfer Model for a Cooled Airfoil in a Direct-fired Supercritical CO 2 Turbine

A one-dimensional (1-D) heat transfer model was developed to predict the performance of a cooled airfoil for a supercritical carbon dioxide (sCO 2 ) turbine. The model included the effects of film cooling effectiveness, thermal barrier coating thickness, and internal Nusselt number augmentation. Trends for overall cooling effectiveness versus heat load parameter were obtained for over twelve unique thermal management schemes. The study found that adding a thermal barrier coating was the most effective scheme for increasing the airfoil overall cooling effectiveness. Internal cooling technologies have diminishing returns as the heat transfer coefficient augmentation increases past a factor of five, however the sensitivity of overall cooling effectiveness to heat transfer augmentation scales by a factor of 1.3 when a thermal barrier coating is introduced. Film cooling is seen as a long-term research area which will be inevitably explored as direct sCO 2 systems develop a market presence. However, the model indicates that realizable film cooling effectiveness levels yield a smaller improvement in overall cooling effectiveness than a thermal barrier coating.

42 ENGINEERING↗
DOE OSTI2022

Pressure drop and heat transfer characteristics of nitrate salt and supercritical CO 2 in a diffusion-bonded heat exchanger

A lab-scale 316/L stainless steel diffusion-bonded heat exchanger was examined within a coupled high-temperature test facility consisting of an atmospheric-pressure nitrate salt loop and a supercritical carbon dioxide (sCO 2 ) loop operating between 10 and 16 MPa. Pressure loss measurements collected for flow rates up to 0.55 kg/s of Solar Salt and up to 0.6 kg/s of carbon dioxide were used to generate friction factor correlations for the respective circular and semicircular zig-zag flow passages. Heat transfer measurements were also performed over a wide range of conditions to produce Nusselt correlations for the CO 2 and nitrate salt geometries. The Nusselt number is deduced from a heat transfer resistance network and overall conductance measurements collected across the operating envelope of the coupled sCO 2 – nitrate salt test facility. The CO 2 side correlation showed excellent agreement with existing correlations in the literature. Further, the salt side, having nearly circular channels with a different zig-zag angle and hydraulic diameter, yielded a new correlation applicable to the laminar flow regime. To examine the similitude of the friction correlations, pressure drop testing with water was performed on both sides of the component as well. Finally, results from non-destructive examination are discussed to provide insights regarding inspection methods and draining performance of high-temperature liquids in compact heat exchangers.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Coal to Carbon Fiber – A Novel Supercritical CO 2 Solvated Process

This project aims to demonstrate, independently, the three primary processes necessary to produce carbon fiber from coal feedstock material and assess the potential for those independent processes to integrate into a single, continuous process in order to provide significant cost reductions in the most costly steps of carbon fiber processing. The specific objective of the present research is to assess the technical feasibility for generation of quality carbon fiber pre-cursor materials from coal using a supercritical carbon dioxide (sCO 2 ) solvation process.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Film Cooling Performance Predictions For Air And Supercritical CO 2

The current study explores the possibility of cooling the vanes and blades of a direct-fired sCO 2 turbine using film cooling geometries. The operating conditions of a direct-fired sCO 2 cycle and thermophysical properties of the fluid at those conditions can alter the flow field characteristics of the coolant jet and its mixing with the mainstream. Very little information is present in the literature regarding the performance of film cooling geometries employing a supercritical fluid. The objective of this study is to estimate the resulting film cooling effectiveness while also capturing the effects of the crossflow-to-mainstream velocity ratio on the coolant jet. A computational fluid dynamic model is used to study the coolant jet exiting a cylindrical hole located on a flat plate, with the coolant fed by an internal channel. Steady-state RANS equations were solved along with the SST kω model to provide the turbulence closure. The operating conditions for the direct-fired sCO 2 turbine are obtained using an in-house Cooled Turbine Model. Numerical predictions revealed that the crossflow effects and jet lift-off were more pronounced in the case of sCO 2 when compared to air. Spatial distribution of flow field and cooling effectiveness will be presented at different operating conditions. Recommendations for future studies will be given wherever applicable.

42 ENGINEERING↗