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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Assessment of model parameters in MFiX particle-in-cell approach

The limitations in numerical treatment of solids-phase in conventional methods like Discrete Element Model and Two-Fluid Model have facilitated the development of alternative techniques such as Particle-In-Cell (PIC). However, a number of parameters are involved in PIC due to its empiricism. In this work, global sensitivity analysis of PIC model parameters is performed under three distinct operating regimes common in chemical engineering applications, viz. settling bed, bubbling fluidized bed and circulating fluidized bed. Simulations were performed using the PIC method in Multiphase Flow with Interphase eXchanges (MFiX) developed by National Energy Technology Laboratory (NETL). A non-intrusive uncertainty quantification (UQ) based approach is applied using Nodeworks to first construct an adequate surrogate model and then identify the most influential parameters in each case. This knowledge will aid in developing an effective design of experiments and determine optimal parameters through techniques such as deterministic or statistical calibration.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2018

Transient Cold Flow Simulation of Fast Fluidized Bed Fuel Reactors for Chemical-Looping Combustion

Circulating fluidized bed in chemical-looping combustion (CLC) is a recent technology that provides great advantage for gas–solid interaction and efficiency. In order to obtain a thorough understanding of this technology and to assess its effectiveness for industrial scale deployment, numerical simulations are conducted. Computational fluid dynamics (CFD) simulations are performed with dense discrete phase model (DDPM) to simulate the gas–solid interactions. CFD commercial software ansysfluent is used for the simulations. Two bed materials of different particle density and diameter, namely the molochite and Fe100, are used in studying the hydrodynamics and particle behavior in a fuel reactor corresponding to the experimental setup of Haider et al. (2016, “A Hydrodynamic Study of a Fast-Bed Dual Circulating Fluidized Bed for Chemical Looping Combustion,” Energy Technol., 4(10), pp. 1254–1262.) at Cranfield University in the UK. Both the simulations show satisfactory agreement with the experimental data for both the static pressure and volume fraction at various heights above the gas inlet in the reactor. It is found that an appropriate drag law should be used in the simulation depending on the particle size and flow conditions in order to obtain accurate results. Furthermore, the simulations demonstrate the ability of CFD/DDPM to accurately capture the physics of circulating fluidized bed-based CLC process at pilot scale which can be extended to industrial scale projects.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Development of Enabling Technologies for Chemical Looping Combustion and Chemical Looping with Oxygen Uncoupling (Final Report)

This report summarizes results from the project, “Development of Enabling Technologies for Chemical Looping Combustion and Chemical Looping with Oxygen Uncoupling,” which evaluated several aspects of dual fluidized bed chemical looping combustion and chemical looping with oxygen uncoupling (CLOU). The objective was to provide tools and enabling technologies to help advance fluidized bed chemical looping technology to pilot, demonstration and commercial scale. One focus area is oxygen carriers, which are key to chemical looping combustion. The copper oxygen carrier-coal ash system was systematically evaluated through a combination of thermodynamic modeling and lab-scale experiments, taking into consideration different oxygen carrier support materials and coal types. A method of mapping “safe” and “risk” zones for different combinations was established, and recommendations for target conditions are provided. In addition, a simple solution for limiting negative influence of some coal ashes, namely adding small amounts of calcium to the system, is proposed. In addition, a novel process for recovering and recycling copper from spent oxygen carriers is proposed. A new approach for design and operation of loop seals in a CLOU system was developed, and involves distinct gas injection points and a short horizontal section to help control the fate of the fluidizing gases. For the air-to-fuel reactor loop seal, the upstream side is fluidized with air, ideally input into the side rather than into the bottom, which prevents uncoupling (reduction) of the oxygen carrier before entering the fuel reactor. Also, alternative for separating oxygen carrier particles and gas in circulating fluidized bed-based chemical looping system is proposed. A new reduced reaction scheme for conversion of coal in copper-based CLOU was developed and implemented into CPFD Software’s Barracuda VR package. The resulting model provides higher fidelity than the baseline, especially when it comes to minor reactions that are part of the overall combustion environment. For in-reactor heat extraction, it was determined in this project that the best way to do that in a dual circulating fluidized-bed system is through heat exchange low in the air reactor. The air reactor is the hotter of the two and for a fast-fluidized circulating bed, the lower, more dense section has a higher heat transfer coefficient and offers more consistent particle-wall contact since it doesn’t have the splashing behavior the top of the bed does. It was determined that just the wall surface area in the lower quarter to third of the air reactor is sufficient to control temperatures in both reactors. Finally, consideration was given to a new concept for CLC, which involves a staged fuel reactor with a different type of oxygen carrier in each stage.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2014

Model-free adaptive control of supercritical circulating fluidized-bed boilers

A novel 3-Input-3-Output (3.times.3) Fuel-Air Ratio Model-Free Adaptive (MFA) controller is introduced, which can effectively control key process variables including Bed Temperature, Excess O2, and Furnace Negative Pressure of combustion processes of advanced boilers. A novel 7-input-7-output (7.times.7) MFA control system is also described for controlling a combined 3-Input-3-Output (3.times.3) process of Boiler-Turbine-Generator (BTG) units and a 5.times.5 CFB combustion process of advanced boilers. Those boilers include Circulating Fluidized-Bed (CFB) Boilers and Once-Through Supercritical Circulating Fluidized-Bed (OTSC CFB) Boilers.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2013

Mass transfer effects in a gasification riser

In the development of multiphase reacting computational fluid dynamics (CFD) codes, a number of simplifications were incorporated into the codes and models. One of these simplifications was the use of a simplistic mass transfer correlation for the faster reactions and omission of mass transfer effects completely on the moderate speed and slow speed reactions such as those in a fluidized bed gasifier. Another problem that has propagated is that the mass transfer correlation used in the codes is not universal and is being used far from its developed bubbling fluidized bed regime when applied to circulating fluidized bed (CFB) riser reactors. These problems are true for the major CFD codes. To alleviate this problem, a mechanistic based mass transfer coefficient algorithm has been developed based upon an earlier work by Breault et al. This fundamental approach uses the local hydrodynamics to predict a local, time varying mass transfer coefficient. The predicted mass transfer coefficients and the corresponding Sherwood numbers agree well with literature data and are typically about an order of magnitude lower than the correlation noted above. The incorporation of the new mass transfer model gives the expected behavior for all the gasification reactions evaluated in the paper. At the expected and typical design values for the solid flow rate in a CFB riser gasifier an ANOVA analysis has shown the predictions from the new code to be significantly different from the original code predictions. The new algorithm should be used such that the conversions are not over predicted. Additionally, its behaviors with changes in solid flow rate are consistent with the changes in the hydrodynamics.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2021

Sensitivity Analysis of MFiX-PIC Parameters Using Nodeworks, PSUADE, and DAKOTA

The study presented in this report was aimed to demonstrate UQ analysis performed not only with Nodeworks, but also two other well-established UQ software tools from the U.S. DOE’s National Laboratories (PSUADE from Lawrence Livermore National Laboratory and DAKOTA from Sandia National Laboratory). It is important to emphasize that the motivation of this study was not to determine the best UQ software, but to verify if the global sensitivity analyses from the end-to-end workflow in Nodeworks are consistent with the results of other two UQ software. The components of Nodeworks from Python’s ecosystem have been tested as standalone libraries. However, an assessment study for the complete workflow targeting a specific UQ analysis has not been performed for Nodeworks. Hence, this study is expected to serve as an equivalent of solution verification for Nodeworks using other established UQ tools as reference solution. For this purpose, three distinct flow configurations (i.e., settling bed, bubbling fluidized, and circulating fluidized bed) have been used as representative multiphase flow problems of interest. The results of the systematic simulation campaigns performed in an earlier study using the particle-in-cell (PIC) approach in the Multiphase Flow with Interphase eXchanges (MFIX) suite of solvers (i.e., MFiX-PIC) was utilized. The same set of tabulated results was provided as input to the different UQ software for global sensitivity analysis. Results for the three cases indicate that based on the Sobol’ Sensitivity Indices method the order of importance ranking determined by Nodeworks for the Sobol’ Total Sensitivity Indices is consistent with PSUADE and DAKOTA in each case for the five model parameters considered. The input files for Nodeworks for the three cases are also shared through NETL’s Gitlab repository for the reader interested in reproducibility and further analysis (See Section 1.2).

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2019

Dover Light & Power 10 MWe Coal Direct Chemical Looping Plant: Final Technical Report - Appendix A Environmental Information Volume

A 10 MWe coal direct chemical looping plant was designed for the City of Dover Municipal Power Plant. The system consisted of a moving bed reducer and circulating fluidized bed combustor. An iron-oxide oxygen carrier was used. The steam cycle included in bed surface in the combustor and conventional convection pass surface. A thorough environmental information volume was generated to support the installation of the system at the plant.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2015

Gasification of high ash, high ash fusion temperature bituminous coals

This invention relates to gasification of high ash bituminous coals that have high ash fusion temperatures. The ash content can be in 15 to 45 weight percent range and ash fusion temperatures can be in 1150.degree. C. to 1500.degree. C. range as well as in excess of 1500.degree. C. In a preferred embodiment, such coals are dealt with a two stage gasification process--a relatively low temperature primary gasification step in a circulating fluidized bed transport gasifier followed by a high temperature partial oxidation step of residual char carbon and small quantities of tar. The system to process such coals further includes an internally circulating fluidized bed to effectively cool the high temperature syngas with the aid of an inert media and without the syngas contacting the heat transfer surfaces. A cyclone downstream of the syngas cooler, operating at relatively low temperatures, effectively reduces loading to a dust filtration unit. Nearly dust- and tar-free syngas for chemicals production or power generation and with over 90%, and preferably over about 98%, overall carbon conversion can be achieved with the preferred process, apparatus and methods outlined in this invention.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2016

Lateral particle size segregation in a riser under core annular flow conditions due to the Saffman lift force

It has been observed under certain flow conditions that there is a measured increase in fine particle concentration at the center of the circulating fluidized bed riser just below the exit to the cyclone. It is hypothesized that the Saffman force might be responsible for this phenomena. Furthermore, this research paper discusses the likelihood of the existence of “Saffman” forces, or lift due to viscous shear, in cylindrical, circulating fluidized bed (CFB) risers operating in the core annular regime.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2020

Experimental and Simulation Analysis of Binary Mixtures of Biomass and Inert Material

A literature review was conducted to identify experiments on various scales of biomass combustion specific to circulating fluidized bed (CFB) combustors. Typical feedstock and inert bed material characteristics for biomass combustion in a CFB were gathered. This information was used to design laboratory-scale, non-reacting experiments on biomass-inert bed material mixtures in a 1-in. cylindrical test rig in the Multiphase Flow Analysis Laboratory (MFAL) in Morgantown, WV. The biomass chosen was a hardwood. Pellets from the hardwood were milled and sieved to obtain three size ranges—small, medium, and large. Three mass loadings of each of the biomass samples were fluidized with glass beads as the inert bed material to study the mixing characteristics under varying fluidizing gas velocities. Hydrodynamic data including pressure drop measurements at select vertical locations and video recordings of the mixture behavior were generated in this effort.

09 BIOMASS FUELS↗
DOE OSTI2022

Scaling CFB risers: Maintaining microstructure dynamics

Over the years there have been numerous approaches to develop a scaleup methodology for circulating fluidized beds. Many of these past approaches have relied on macroscopic definitions of similitude to define dimensionless groups such as Reynolds number, Froude number, density ratios, and dimensional ratios involving different length scales. These approaches have demonstrated various levels of success, but often fail when used outside the bounds of experimental datasets. The issue with these methods is that they rely on macroscopic similitude with the hopes that those conditions would provide microscopic similitude as it does in single phase systems where the Buckingham Pi techniques have given reasonable success. Two of the main reasons for failure are 1) changing fluidization regimes and 2) changing material properties that result in the material falling into a different Geldart group. Both are certain to change the microstructure (local instantaneous volume solids fraction) and changes to the microstructure affect the interphase transport properties of the reactor system, namely the mass transfer and heat transfer. Here, this work presents a new approach towards scaling based upon maintaining similitude at the microscale. It reviews a novel dimensionless flow regime map developed from analysis of the deterministic chaos parameters and higher order moments to ensure microstructure similitude. The work then examines four cases from the literature to assess the scaling approach used: (1) same particle-different scale risers for Geldart Group B particles, (2) Glicksman scaling of atmospheric circulating fluidized bed combustor, (3) same particle-different scale risers for Geldart Group A particles and (4) Glicksman scaling for pressurized gasification. General findings are that none of the scaling approaches produced directly applicable microstructure similar behavior based upon the chaotic and higher moment analysis. The positive take away is that the approach can define scale conditions that will provide similar microstructure that can be us to predict transport behavior.

42 ENGINEERING↗
DOE OSTI2023

Design, scaling and cost evaluations of circulating fluidized-bed systems for biomass pyrolysis

To generate updated and transparent capital cost estimates for biomass fast pyrolysis equipment, refinery fluidized catalytic cracking design and sizing principles are examined and extended to pyrolysis of woody biomass. Capital costs for the sized equipment are estimated with process-industry software. A one-dimensional flow simulation with pyrolysis kinetics is leveraged to validate the fluidization conditions and thermal energy balance. After successful sizing and a system cost estimate of $\$$2.8 M (in 2016 US$\$$) at the biorefinery scale of 1000 metric tons per day (MTD), these methods were exercised for even smaller equipment at the distributed pyrolysis scale with modifications to the process design constraints, and not directly comparable with the 1000 MTD case, arriving at capital cost estimates of $\$$1.2 M for a 500 ton/day system and $\$$0.9 M for a 200 ton/day system. Here in this work, It is noted that this work only estimates purchased equipment costs at the ±50% accuracy level; there are significant other custom factors applicable to each installation based on location, maturity, scale, complexities during installation, engineering and licensing costs, etc. that need to be added on to these estimates to derive investment costs.

09 BIOMASS FUELS↗
DOE OSTI2016

Numerical Simulation Comparison of Two Reactor Configurations for Chemical Looping Combustion and Chemical Looping With Oxygen Uncoupling

Chemical looping with oxygen uncoupling (CLOU) is a carbon capture technology that utilizes a metal oxide as an oxygen carrier to selectively separate oxygen from air and release gaseous O 2 into a reactor where fuel, such as coal, is combusted. Previous research has addressed reactor design for CLOU systems, but little direct comparison between different reactor designs has been performed. This study utilizes Barracuda-VR® for comparison of two system configurations, one uses circulating fluidized beds (CFB) for both the air reactor (AR) and fuel reactor (FR) and another uses bubbling fluidized beds for both reactors. Initial validation of experimental and computational fluid dynamic (CFD) simulations was performed to show that basic trends are captured with the CFD code. The CFD simulations were then used to perform comparison of key performance parameters such as solids circulation rate and reactor residence time, pressure profiles in the reactors and loopseals, and particle velocities in different locations of the reactor as functions of total solids inventory and reactor gas flows. Here, using these simulation results, it was determined that the dual CFB system had larger range for solids circulation rate before choked flow was obtained. Both systems had similar particle velocities for the bottom 80% of particle mass, but the bubbling bed (BB) obtained higher particle velocities as compared to the circulating fluidized-bed FR, due to the transport riser. As a system, the results showed that the dual CFB configuration allowed better control over the range of parameters tested.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2019

Dover Light & Power 10 MWe Coal Direct Chemical Looping Plant - Topical Report - Appendix A Environmental Information Volume

An environmental information volume was generated to support the installation of a 10 MWe coal direct chemical looping power plant at the City of Dover's municipal power plant. The coal direct chemical looping process utilizes Ohio State University's iron oxide based oxygen carrier in a moving bed reducer coupled with a circulating fluidized bed combustor.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2013

Cartesian grid simulations of gas-solids flow systems with complex geometry

Complex geometries encountered in many applications of gas–solids flow need special treatment in most legacy multiphase flow solvers with Cartesian numerical grid. This paper briefly outlines the implementation of a cut cell technique in the open-source multiphase flow solver—MFIX for accurate representation of complex geometries. Specifically, applications of the Cartesian cut cell method to different gas–solids fluidization systems including a small scale bubbling fluidized bed with submerged tube bundle and a complete pilot-scale circulating fluidized bed will be presented. In addition to qualitative predictions on the general flow behaviors inside each system, quantitative comparison with the available experimental data will be presented. Furthermore, some results on extending the current cut-cell technique to Lagrangian–Eulerian simulations will be presented.

42 ENGINEERING↗