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DOE OSTI2022

Advanced Stirling Power Generation System for Combined Heat and Power

The goal of this project was the development of an advanced Free-Piston Stirling Engine (FPSE) power generation for combined heat and power application. The innovative approach used in this project was the use of Additively Manufactured (AM) for critical components of an FPSE. A Stirling convertor consists of three major components/subassemblies, 1) Stirling engine, 2) linear alternator, and 3) gas fuel burner. The primary focus of this project was the design of the FPSE. This engine was integrated with an ITC/Qnergy 1 kW linear alternator. The integrated convertor was then coupled to a gas burner.

09 BIOMASS FUELS↗

NASA NTRS2011

All-Solid-State 2.45-to-2.78-THz Source

Sources in the THz range are required in order for NASA to implement heterodyne instruments in this frequency range. The source that has been demonstrated here will be used for an instrument on the SOFIA platform as well as for upcoming astrophysics missions. There are currently no electronic sources in the 2 3- THz frequency range. An electronically tunable compact source in this frequency range is needed for lab spectroscopy as well as for compact space-deployable heterodyne receivers. This solution for obtaining useful power levels in the 2 3- THz range is based on utilizing power-combined multiplier stages. Utilizing power combining, the input power can be distributed between different multiplier chips and then recombined after the frequency multiplication. A continuous wave (CW) coherent source covering 2.48 2.75 THz, with greater than 10 percent instantaneous and tuning bandwidth, and having l 14 W of output power at room temperature, has been demonstrated. This source is based on a 91.8 101.8-GHz synthesizer followed by a power amplifier and three cascaded frequency triplers. It demonstrates that purely electronic solid-state sources can generate a useful amount of power in a region of the electromagnetic spectrum where lasers (solid-state or gas) were previously the only available coherent sources. The bandwidth, agility, and operability of this THz source has enabled wideband, high-resolution spectroscopic measurements of water, methanol, and carbon monoxide with a resolution and signal-to-noise ratio unmatched by other existing systems, providing new insight in the physics of these molecules. Further - more, the power and optical beam quality are high enough to observe the Lamb-dip effect in water. The source frequency has an absolute accuracy better than 1 part in 1012, and the spectrometer achieves sub-Doppler frequency resolution better than 1 part in 108. The harmonic purity is better than 25 dB. This source can serve as a local oscillator for a variety of heterodyne systems, and can be used as a method for precision control of more powerful but much less frequency-agile quantum mechanical terahertz sources.

Mehdi, Imran↗

NASA NTRS2005

A Ka-Band Wide-Bandgap Solid-State Power Amplifier: Architecture Performance Estimates

Motivated by recent advances in wide-bandgap (WBG) gallium nitride (GaN) semiconductor technology, there is considerable interest in developing efficient solidstate power amplifiers (SSPAs) as an alternative to the traveling-wave tube amplifier (TWTA) for space applications. This article documents the results of a study to investigate power-combining technology and SSPA architectures that can enable a 120-W, 40 percent power-added efficiency (PAE) SSPA. Results of the study indicate that architectures based on at least three power combiner designs are likely to enable the target SSPA. The proposed architectures can power combine 16 to 32 individual monolithic microwave integrated circuits (MMICs) with >80 percent combining efficiency. This corresponds to MMIC requirements of 5- to 10-W output power and >48 percent PAE. For the three proposed architectures [1], detailed analysis and design of the power combiner are presented. The first architecture studied is based on a 16-way septum combiner that offers low loss and high isolation over the design band of 31 to 36 GHz. Analysis of a 2-way prototype septum combiner had an input match >25 dB, output match >30 dB, insertion loss <0.02 dB, and isolation >30 dB over the design band. A 16-way design, based on cascading this combiner in a binary fashion, is documented. The second architecture is based on a 24-way waveguide radial combiner. A prototype 24-way radial base was analyzed to have an input match >30 dB (under equal excitation of all input ports). The match of the mode transducer that forms the output of a radial combiner was found to be >27 dB. The functional bandwidth of the radial base and mode transducer, which together will form a radial combiner/divider, exceeded the design band. The third architecture employs a 32-way, parallel-plate radial combiner. Simulation results indicated an input match >24 dB, output match >22 dB, insertion loss <0.23 dB, and adjacent port isolation >20 dB over the design band. All three architectures utilize a low-loss MMIC amplifier module based on commercial MMIC packaging and a custom microstrip-to-rectangular-waveguide transition. The insertion loss of the module is expected to be 0.45 dB over the design band.

Epp, L.↗

NASA NTRS2006

Ka-Band Wide-Bandgap Solid-State Power Amplifier: Prototype Combiner Spurious Mode Suppression and Power Constraints

Results of prototype hardware activities related to a 120-W, 32-GHz (Ka-band) solid-state power amplifier (SSPA) architecture study are presented. Spurious mode suppression and the power-handling capability of a prototype 24-way radial combiner and a prototype 2-way septum binary combiner were investigated. Experimental data indicate that a commercial absorptive filter, designed to pass the circular TE01 mode, effectively suppressed the higher-order modes generated by a narrowband, flower-petal-type mode transducer. However, the same filter was not effective in suppressing higher-order modes generated by the broadband Marie mode transducer that is used in the prototype waveguide radial combiner. Should greater filtering be required by a particular SSPA application, a broadband mode filter that can suppress specifically those higher-order modes that are generated by the Marie transducer will need to be developed. A back-to-back configuration of the prototype radial combiner was tested with drive power up to approximately 50 W. No anomalous behavior was observed. Power measurements of the septum combiner indicate that up to 10-W radio frequency (RF) can be dissipated in the integrated resistive element before a permanent performance shift is observed. Thus, a given adder (a single-stage, 2-way combiner) can safely combine two 20-W sources, and the adder will not be damaged in the event of a source failure. This result is used to calculate the maximum source power that can be safely combined as a function of the number of sources combined and the number of source failures allowed in a multi-stage combiner. The analysis shows that SSPA power >140 W can be generated by power combining 16 sources producing 10 W each. In this configuration, up to three sources could fail with the guarantee that the combiner would not be damaged. Finally, a modified prototype septum combiner design was verified. The improved design reduced the assembly time from over 2 hours to about 15 minutes per adder.

Khan, P.↗

NASA NTRS1983

Semiconductor optoelectronic devices for free-space optical communications

The properties of individual injection lasers are reviewed, and devices of greater complexity are described. These either include or are relevant to monolithic integration configurations of the lasers with their electronic driving circuitry, power combining methods of semiconductor lasers, and electronic methods of steering the radiation patterns of semiconductor lasers and laser arrays. The potential of AlGaAs laser technology for free-space optical communications systems is demonstrated. These solid-state components, which can generate and modulate light, combine the power of a number of sources and perform at least part of the beam pointing functions. Methods are proposed for overcoming the main drawback of semiconductor lasers, that is, their inability to emit the needed amount of optical power in a single-mode operation.

Katz, J.↗

DOE OSTI2020

Combined Heat and Power Deployment Program

Combined heat and power (CHP) is an efficient and clean approach to generating on-site electric power and useful thermal energy from a single fuel source. Instead of purchasing electricity from the distribution grid and burning fuel in an on-site furnace or boiler to produce thermal energy, CHP provides both energy services to a facility in one energy-efficient step.

CHP↗

NASA NTRS1997

A Spherical to Plane Wave Transformation Using a Reflectarray

A reflectarray has generally been used as a replacement for a reflector antenna. Using in this capacity, different configurations (prime focus, offset etc.) and various applications (dual frequency, scanning etc.) have been demonstrated with great success. Another potential application that has not been explored previously is the use of reflectarrays to compensate for phase errors in space power combining applications such as space-fed lens and power combining amplifier. In these applications, it is required to convert a spherical wave to a plane wave with proper phase correction added to each element of the reflectarray. This paper reports an experiment to investigate the feasibility of using a reflectarray as an alternative to a lens in space power combining. The experiment involves transforming a spherical wave from a orthomode horn to a plane wave at the horn aperture. The reflcctarray consists of square patches terminated in open stubs to provide necessary phase compensation. In this paper, preliminary results will be presented and the feasibility of such compensation scheme will be discussed.

Zaman, Afroz J.↗

NASA NTRS2005

Ka-Band Wide-Bandgap Solid-State Power Amplifier: Hardware Validation

Motivated by recent advances in wide-bandgap (WBG) gallium nitride (GaN) semiconductor technology, there is considerable interest in developing efficient solid-state power amplifiers (SSPAs) as an alternative to the traveling-wave tube amplifier (TWTA) for space applications. This article documents proof-of-concept hardware used to validate power-combining technologies that may enable a 120-W, 40 percent power-added efficiency (PAE) SSPA. Results in previous articles [1-3] indicate that architectures based on at least three power combiner designs are likely to enable the target SSPA. Previous architecture performance analyses and estimates indicate that the proposed architectures can power combine 16 to 32 individual monolithic microwave integrated circuits (MMICs) with >80 percent combining efficiency. This combining efficiency would correspond to MMIC requirements of 5- to 10-W output power and >48 percent PAE. In order to validate the performance estimates of the three proposed architectures, measurements of proof-of-concept hardware are reported here.

Epp, L.↗

DOE OSTI2020

Feasibility Analysis of Converter-Interfaced Combined Heat and Power System

As a promising new design concept, the converter-interfaced combined heat and power (CHP) system is coupled to the bulk grid through a rectifier and a grid-ready tied inverter. Compared to the traditional directly-coupled CHP system, it removes the requirement for oversizing the CHP generator, limits the short-circuit contribution of the generator and simplifies the grid integration process of CHP system. This paper evaluates the economic benefits of this concept by calculating the annualized Return-on-Investment (ROI) and comparing it to the directly-coupled system. The economic analysis includes timeseries simulations to compute energy transactions with the bulk grid as well as sizing the equipment to calculate the capital and operational costs. Obtained results indicate that in majority of user cases evaluated, the converter-interfaced CHP systems can provide better ROI than directly-coupled systems. Given the additional technical benefits provided by inverter-based distributed energy resources (DERs), the proposed concept is proved to be technically viable and economically feasible.

03 NATURAL GAS↗

NASA NTRS2012

Ka-Band Waveguide Three-Way Serial Combiner for MMIC Amplifiers

In this innovation, the three-way combiner consists internally of two branch-line hybrids that are connected in series by a short length of waveguide. Each branch-line hybrid is designed to combine input signals that are in phase with an amplitude ratio of two. The combiner is constructed in an E-plane split-block arrangement and is precision machined from blocks of aluminum with standard WR-28 waveguide ports. The port impedances of the combiner are matched to that of a standard WR-28 waveguide. The component parts include the power combiner and the MMIC (monolithic microwave integrated circuit) power amplifiers (PAs). The three-way series power combiner is a six-port device. For basic operation, power that enters ports 3, 5, and 6 is combined in phase and appears at port 1. Ports 2 and 4 are isolated ports. The application of the three-way combiner for combining three PAs with unequal output powers was demonstrated. NASA requires narrow-band solid-state power amplifiers (SSPAs) at Ka-band frequencies with output power in the range of 3 to 5 W for radio or gravity science experiments. In addition, NASA also requires wideband, high-efficiency SSPAs at Ka-band frequencies with output power in the range of 5 to 15 W for high-data-rate communications from deep space to Earth. The three-way power combiner is designed to operate over the frequency band of 31.8 to 32.3 GHz, which is NASA s deep-space frequency band.

Wintucky, Edwin G.↗

DOE OSTI2021

Front-End Engineering Design (FEED) Study for a Carbon Capture Plant Retrofit to a Natural Gas-Fired Gas Turbine Combined Cycle Power Plant

A comprehensive front-end engineering design (FEED) study has been undertaken for a post-combustion capture (PCC) unit located at Panda’s Sherman natural gas–combined cycle (NGCC) power plant in Sherman, Texas. This is described in a full and unredacted FEED study report with all supporting documents, numbering over 150, also publicly available.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2020

Advanced Gas Turbine and sCO 2 Combined Cycle Power System (Final Report)

The team of Southwest Research Institute (SwRI), Hanwha Power Systems Americas (HPSA), and Solar Turbines Incorporated (Solar) has worked to develop a modular, highly efficient combined-cycle power system consisting of a supercritical carbon dioxide (sCO 2 )-based waste-heat recovery system (WHRS) coupled to a Solar Titan 130 gas turbine (GT). During Phase 1 of the project, the project team used advanced thermodynamic cycle and techno-economic modeling to find an optimal sCO 2 WHRS bottoming cycle and machinery configuration for a Solar Titan 130. In addition to this, a conceptual design of the machinery and overall system layout was created and technology gaps were identified.

30 DIRECT ENERGY CONVERSION↗

NASA NTRS2009

Ka-Band Waveguide Hybrid Combiner for MMIC Amplifiers With Unequal and Arbitrary Power Output Ratio

The design, simulation and characterization of a novel Ka-band (32.05 +/- 0.25 GHz) rectangular waveguide branch-line hybrid unequal power combiner is presented. The manufactured combiner was designed to combine input signals, which are in phase and with an amplitude ratio of two. The measured return loss and isolation of the branch-line hybrid are better than 22 and 27 dB, respectively. The application of the branch-line hybrid for combining two MMIC power amplifiers with output power ratio of two is demonstrated. The measured combining efficiency is approximately 93 percent over the above frequency band.

Simons, Rainee N.↗

DOE OSTI2024

Advanced Airfoils for Efficient Combined Heat Power Systems: Task 4.3 - Gas Turbine Machinery and Systems

Industrial gas turbines are commonly used in steam combined heat and power (CHP) applications. CHP applications have significant environmental and economic benefits that are consistent with the goals of the U.S. Department of Energy. This presentation provides a status update for a DOE effort investigating the impacts of advanced internal cooling technologies for small (5-10 MW) gas turbine CHP applications. The potential efficiency impacts are 2-3 percentage points based on the model and the cooling technologies investigated in this project.

Straub, Douglas↗

DOE OSTI2021

Front-End Engineering Design (FEED) Study for a Carbon Capture Plant Retrofit to a Natural Gas-Fired Gas Turbine Combined Cycle Power Plant (2x2x1 Duct-Fired 758-MWe Facility with F Class Turbines)

A comprehensive front-end engineering design (FEED) study has been undertaken by Bechtel National Inc. (Bechtel) for locating a post-combustion capture and compression (PCC) unit at Panda’s Sherman natural gas–combined cycle (NGCC) power plant in Sherman, Texas. This is described in the unredacted FEED Study report (Attachment 1) with all supporting documents, numbering over 150. The Study Report is publicly available. Sizing of the PCC plant is based on treating an amount of flue gas equivalent to that produced when generating 420 MW, which is approximately 68% of the total flue gas emitted by the NGCC power plant operating at guarantee condition with duct burners off. A reduced power plant capacity factor was used for sizing the PCC plant because the gas turbines at the site often operate at reduced load due to the high penetration of renewable power in the ERCOT region. The cost of carbon capture is primarily driven by capital cost (and therefore is highly sensitive to capacity factor). Sizing the capture unit so that when used it is nearly always operating at full capacity is critical to the economic viability of the proposed investment.

03 NATURAL GAS↗

DOE OSTI2025

CERF Visualization: Projected locations of new natural gas combined cycle power plants (with recirculating cooling) in Wyoming, USA (2020-2050)

Visualization of CERF outputs for years 2030-2050 in 5-year time steps for a region in Wyoming, USA. This visualization was built using a custom CesiumJS application. The region of interest was zoomed into and then the app shows the layered application of natural gas combined cycle power plants (with recirculating cooling) suitability criteria, show the siting for each year in planform, simulates the selection of a site using Net Locational Cost, and then zooms into to show a single functional gas plant and simulates its connection to the grid.

CERF↗

NASA NTRS2008

24-Way Radial Power Combiner/Divider for 31 to 36 GHz

The figure shows a prototype radial power-combining waveguide structure, capable of operation at frequencies from 31 to 36 GHz, that features an unusually large number (N = 24) of combining (input) ports. The combination of wide-band operation and large N is achieved by incorporating several enhancements over a basic radial power-combiner design. In addition, the structure can be operated as a power divider by reversing the roles of the input and output ports. In this structure, full-height waveguides at the combining ports are matched in impedance to reduced-height radial waveguides inside the combiner base. This match is effected by impedance-transforming stepped waveguide sections. This matching scheme is essential to achievement of large N because N is limited by the height of the waveguides in the base. Power is coupled from the 24 reduced- height radial waveguides into the TE01 mode of a circular waveguide in the base with the help of a matching post at the bottom of the base. ( TE signifies transverse electric, the first subscript is the azimuthal mode number, and the second subscript is the radial mode number.) More specifically, the matching post matches the reflections from the walls of the 24 reduced-height waveguides and enables the base design to exceed the bandwidth requirement. After propagating along the circular waveguide, the combined power is coupled, via a mode transducer, to a rectangular waveguide output port. The mode transducer is divided into three sections, each sized and shaped as part of an overall design to satisfy the mode-conversion and output-coupling requirements while enabling the circular waveguide to be wide enough for combining the 24 inputs over the frequency range of 31 to 36 GHz. During the design process, it was found that two different rectangular waveguide outputs could be accommodated through modification of only the first section of the mode converter, thereby enabling operation in multiple frequency ranges.

Epp, Larry↗

DOE OSTI2021

Multiobjective Dynamic Optimization for Optimal Load-Following of Natural Gas Combined Cycle Power Plants under Stress Constraints

With the increasing penetration of intermittent renewable energy sources into the electric grid, there is an associated need for conventional thermal power plants that are designed to operate at base-load conditions to cycle their load rapidly and frequently and operate under low-load conditions. Fast load-following operations lead to plant efficiency loss and the reduction of equipment life. A high-fidelity dynamic model of a natural gas combined cycle power plant, with rigorous equipment level submodels, is developed to capture the plant transient performance and the thermomechanical stress evolution at the high-pressure drum is computed to assess the drum life consumption. Stress evolution is modeled for the location of the edge at the drum/downcomer junction that experiences high circumferential stress amplitude during the fast load-following operation, leading to higher fatigue damage than locations considered under existing design standards. A dynamic optimization problem is solved for optimal load-following operation. Depending on the value of the stress constraint and the desired ramp rate, satisfying the desired stress constraint may be infeasible without relaxing the ramp rate. A multiobjective dynamic optimization problem is solved using a lexicographic approach that minimizes ramp rate relaxation and maximizes efficiency while satisfying stress constraints, avoiding spraying to saturation, and maintaining main steam and reheat steam temperature within bounds. It was observed that the optimal ramp rate can be highly nonlinear as opposed to the industry-standard linear ramp rate. Nonlinear optimal ramp-rate profiles not only help to avoid stress constraints that may be unavoidable by using the linear profile but also result in higher efficiency than the linear profile. Furthermore, the study shows that there is a strong tradeoff between the relaxation in the plant ramp rate and the time-average thermal efficiency.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗