Engineering the Size of Bicontinuous Nanospheres via Multi-Inlet Vortex Mixing
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Almunif, Sultan [Department of Biomedical Engineer↗
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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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Design of an Additively Manufactured Recuperator With 800 °C Inlet Temperature for sCO2 Power Cycle Application
Abstract Recuperators with design temperatures at and above 800 °C can further increase the thermal efficiency of supercritical CO2 power cycles by enabling higher turbine exhaust temperatures. Mar-M247 is a well-suited nickel-based superalloy for high temperature service due to its high creep strength that prevents excessive material thickness being required for pressure containment. Additive manufacturing using a high-speed laser-directed energy deposition (L-DED) process presents a promising solution, with build trials demonstrating the ability to produce nonconventional flow channels for enhanced heat transfer. A design process is presented that includes aerothermal and mechanical evaluation to maximize performance within the constraints of the manufacturing process. A 2-D heat transfer network and pressure drop code allows prediction of flow distribution and its effect on overall thermal performance. Established literature correlations, along with CFD simulation, inform the prediction of heat transfer coefficients and friction factors for the flowpaths and enhancement features in the heat exchanger core. Mechanical evaluation using finite element analysis (FEA) modeling with the intent of the ASME Boiler & Pressure Vessel Code (BPVC) Section VIII, Div. 2 assesses the operational safety of the design. The detailed design features annular finned passages that take advantage of helical flow paths to distribute the flow from separated headers to shared heat transfer surfaces. Performance predictions for the recuperator at a 50 kW scale provide insights into the feasibility of the additively manufactured (AM) process to produce recuperators on a commercial scale that extend existing operating envelopes.
Engineering↗
Bubble Transport through a Porous Lattice with an Applied Inlet Flow
Within gas-evolving electrochemical systems, bubbles negatively impact performance by covering electrode active sites for reactions, blocking electric field lines, and obstructing liquid electrolyte flow causing pressure buildup. Recent additive manufacturing advances have enabled tuned porous electrode microstructures to be created, but producing systems that maximize electrochemical throughput and minimize bubble impact remains challenging. Thus, improved physical understanding of and modeling capabilities for bubble behavior are critical to improve electrolyzer design. To address this need, this study examines rising stage bubbles within a lattice with an applied liquid flow—an underexplored regime that strongly influences an electrochemical bubble’s fate. Notably, theoretical predictions and resolved bubble simulations are complemented by experiments from a 3D-printed visualization cell that matches the simulation geometry. The minimum threshold flow rate to achieve bubble breakthrough is found to be larger for higher porosities and for smaller bubbles. Different-sized bubbles decrease expected electrochemical performance in different ways; smaller bubbles tend to stay stuck but cover less solid surface, while larger bubbles more readily break through but cover more surface while in the lattice. The bubble trajectory, deformation, and contact area provide insight into these different behaviors. These findings provide design guidelines toward creating more effective electrolyzers.
Guo, Jack [Lawrence Livermore National Laboratory ↗
Tidal Resource Data from Sequim Bay Inlet, WA, August 2020
Data from a Nortek Signature1000 deployed on a lander for 14 days in Aug 2020 in the entrance to Sequim Bay, WA. Raw data were processed using the DOLfYN python package and standardized using the ME Data Pipeline python package, tsdat version 0.2.12. Processed data were partitioned into 24 hour increments and saved in the NETCDF file format.
16 TIDAL AND WAVE POWER↗
Demonstrated Low Pressure Loss Inlet and Low Equivalence Ratio Operation of a Rotating Detonation Engine (RDE) for Power Generation
Presentation. An Aerojet Rocketdyne (AR) program was funded by the National Energy Technology Laboratory (NETL), part of the U.S. Department of Energy, to evaluate the benefits of an RDE in a turbine power plant system. Aerojet Rocketdyne subcontracted a variety of support for the program with efforts in modeling, diagnostic techniques, and test campaigns. Over the span of the program more than 700 hot fire tests were conducted at 4 facilities with 7 RDE assemblies. This presentation will cover results from the final test campaign conducted by Aerojet Rocketdyne.
03 NATURAL GAS↗
Characterization of Transmission Losses of Particles with Dp >1 μm in the Aerosol Observing System Inlet Stack
The U.S. Department of Energy (DOE) Atmospheric Radiation Measurement (ARM) user facility deploys specialized Aerosol Observing Systems (AOSs; Figure 1) for ground-based, in situ measurements of properties of atmospheric aerosols in climatically important regions of the world.
54 ENVIRONMENTAL SCIENCES↗
FY25 Report on Water NSTF Testing: Parametric and Accident Testing with Lower Tank Inlet
The Natural Convection Shutdown Heat Removal Test Facility (NSTF) at Argonne National Laboratory has continued to generate empirical validation data on the performance of water-based reactor cavity cooling system (RCCS) for seven years. This data is actively being used to support the development of passive decay heat removal systems for advanced reactors. Distinguishing this facility are 1) the large, ½ scale of the facility and 2) its governance under an NQA-1 qualified program for producing data of the highest pedigree for advanced reactor designers and regulators. In addition to the experimental activities discussed in this report, a computational modeling program continues to support the experimental program and further accuracy and understanding of the computational models. Together, the experimental and computational work create a mutually beneficial relationship integral to the overall program objective of advancing the understanding of the RCCS technology.
21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
Phase I Final Technical Report: Upper Cook Inlet Electrofuels
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16 TIDAL AND WAVE POWER↗
Selectable inlet for aircraft propulsion system heat exchanger
A propulsion system for an aircraft includes a propulsor rotor, an engine core, a housing, a flowpath and a heat exchange system. The engine core is configured to power rotation of the propulsor rotor. The housing includes an inner structure and an outer structure. The outer structure is radially outboard of and axially overlaps the inner structure. The flowpath is downstream of the propulsor rotor and radially between the inner structure and the outer structure. The heat exchange system includes a duct, an exterior orifice, an interior orifice, a flow regulator and a heat exchanger disposed within the duct. The exterior orifice is formed by the outer structure and disposed along an exterior of the housing. The interior orifice is formed by the outer structure and disposed along the flowpath. The flow regulator is configured to selectively fluidly couple the exterior orifice and the interior orifice to the duct.
Sobanski, Jon E.↗
Incineration system and process
An incineration system includes an inlet channel supplying an inlet stream comprising a waste gas containing at least one volatile organic compound, a waste gas sensor measuring at least one property of the waste gas, an oxidizing gas supply controllably providing oxidizing gas to the inlet channel, an incinerator receiving the inlet stream from the inlet channel, an ignitor initiating combustion of the inlet stream in the reaction zone of the incinerator, and a controller receiving data from the waste gas sensor and controlling flow of oxidizing gas from the oxidizing gas supply into the inlet channel. The spiral heat exchanger defines a reaction zone, an incoming path from the inlet channels to the reaction zone, and an outgoing path from the reaction zone to an exhaust channel. The incoming path and the outgoing path extend in alternating concentric spirals with the incoming path being countercurrent to the outgoing path.
42 ENGINEERING↗
Insert system for an airfoil and method of installing same
An insert system for an airfoil plenum includes a first insert and a second insert that include a plurality of impingement openings defined therein. The first insert includes a forward-facing inlet opening. The second insert includes a neck portion having a radial-facing inlet opening, an aft opening, and a cavity in flow communication between the radial-facing inlet opening and the aft opening. The second insert is sized for insertion into the plenum radially through a plenum inlet such that the neck portion is positioned in the plenum inlet. The first insert is sized for insertion into the second insert radially through the radial-facing inlet opening. When the neck portion is positioned in the plenum inlet, the first insert is moveable aftward through the aft opening into an installed position such that the forward-facing inlet opening opens into the cavity.
Berry, Jonathan Dwight↗
Evaluating Transfer and Pumping of Slurries from Pulsed Jet Mixed Vessels
Due to gravity, solids in slurries will settle if density differences between the solids and liquid are positive (i.e., particle has a negative buoyant force) unless rheological properties and flow conditions are adequate to overcome the gravitational effects. The rate of settling depends on the force balance of the particle, which includes the surface forces associated with fluid rheology. Given the same fluid and solid properties, particles that are larger and denser tend to settle faster. When pumping slurry into a vessel at concentrations precluding hindered settling with insufficient mixing, particle and density distributions can result in preferential settling, creating stratification in the solids concentration within the vessel. For vessels with transfer line inlets located in the lower portion of the tank, the stratified solids concentration may be detrimental to the transfer system performance. Elevated concentrations of solids in the slurry entrained at the inlet to the transfer line can result in the effective viscosity or slurry bulk density exceeding the design limits of the pump. These conditions could result in plugging of the transfer line or onset of cavitation of the pumps because of excessive pressure drop. These conditions can be exacerbated with periodic inlet conditions existing at the transfer line inlet. Periodic conditions can result when vessel mixing is intermittent such as with pulsed jet mixers (PJM). The transfer line inlet conditions are impacted by the periodic nature of the PJM operations with respect to suspension of solids and their transport to the inlet of the transfer line. A scaling approach is presented, and corresponding test requirements are developed for assessing the prevention of plugging the pipeline. Line plugging mechanisms are addressed that do not include plugging due to steady-state high-density slurry entering the transfer line and reducing the net positive suction head available (NPSHA) at the pump inlet to below that required for pump operation. Items considered include the transition to reduced relative flow velocities, such that the critical pipe velocity for solids deposition, Ucd, is not maintained, and segregation of heavy solids during the transport. The recommended requirements to prevent plugging include: • Limits for viscosity and density for entrained slurry to prevent the pressure drop in the pipeline from exceeding pump capacity. • Limits for viscosity and density for entrained slurry to prevent the net positive suction head available (NPSHA) from falling below the net positive suction head required (NPSHR) for operating the pump. • Transfer line velocity and flow rate requirements to maintain solids in suspension, while avoiding line plugging that results from deposition of solids within the transfer line. This paper describes the development of the scaling and testing requirements to verify that proposed approaches for transfer and pump out are appropriately developed
periodic flow, mixing, pipeline plugging, scaling,↗
Positive and Negative Ion CIMS Measurements, SGP, May-June 2024
The negative ion measurements were taken using two LTOF-CIMS with two different nitrate inlets. The data labeled Aerodyne_Inlet used an Aerodyne nitrate inlet. Data labeled PCC used a custom transverse inlet. The positive ion measurements were taken using one LTOF-CIMS with hydronium as an ionization reagent using a custom transverse inlet with an inlet voltage difference of 700 V. See https://doi.org/10.1021/acs.jpca.2c01672 for more information. Peaks were autofit using tofware. Positive ion data is published in the form of peak signal/reagent signal. Data files of peak signal/reagent signal for the two mass spectrometers for the negative ion measurements are separate. Concentrations of H2SO4 are combined into one file. When measurements were overlapping, measurements from the Aerodyne nitrate inlet were used.
54 ENVIRONMENTAL SCIENCES↗
Testing of a 40-kWth Counterflow Particle-Supercritical Carbon Dioxide Narrow-Channel, Fluidized Bed Heat Exchanger
Particle-based primary heat exchangers (HXs) must deliver sCO2 fluid temperatures above 700°C to couple particle-based concentrating solar receivers and thermal energy storage (TES) sub-systems with efficient sCO2 power cycles. Particle-sCO2 HX designs have struggled to meet DOE cost targets (≤ $150/kWth) due to the amount of expensive nickel alloys necessary for manufacturing full-scale, particle-sCO2 HXs. Our team has demonstrated that mild bubbling fluidization of falling particles in a counterflow narrow-channel fluidized bed can reduce required HX surface area and thus, costs by increasing particle-wall heat transfer coefficients hT,w > 800 W m-2 K-1. This paper reports on the fabrication and testing of a stainless steel, particle-sCO2 HX with 12 fluidized-bed channels approximately 10.5 mm deep spaced between diffusion-bonded, micro-channel sCO2 plates. The HX with a core length of ≈0.56 m is fed with CARBOBEAD HSP particles through a short, fluidized freeboard zone just above the core. Testing to date in the National Solar Thermal Test Facility (NSTTF) at Sandia National Laboratories has shown that parallel bed fluidization maintains uniform particle inventory across the instrumented channels. Heat transfer thermal duty between the particle and sCO2 flows exceeds 30 kWth with sCO2 inlet temperatures of 200ºC and particle inlet temperatures up to 440ºC and mass flow rates of 0.2 kg s-1 fluidized by counterflowing gas flow rates of 0.005 kg s-1. Tests at higher particle and sCO2 inlet temperatures (600ºC and 400ºC respectively) are targeted to achieve > 40 kWth with model-predicted overall heat transfer coefficients U > 400 W m-2 K-1.
14 SOLAR ENERGY↗
Branching heat exchangers
A heat exchanger includes an external casing and a core. The external casing includes a first inlet, a first outlet, a second inlet, and a second outlet. The core includes an array of branched channels connecting the first inlet and first outlet, an inlet header, and an outlet header. The inlet header is integrally formed with and fluidly connected to the first inlet. The outlet header is integrally formed with and fluidly connected to the first outlet. The branched channels and the external casing define a fluidic passage. The array of branched channels includes a first split, a first juncture, a secondary split, a secondary juncture, and a subset of splits and junctures. The first split and first juncture are common to an entirety of the array of branched channels. The subset of splits and junctures route fluid through interconnections between fluidly parallel branched channels.
Ranjan, Ram↗
Pull Force Evaluation of CCS Insulated End Caps
Insulated end caps installed on DC pins of Combined Charging System (CCS) inlets have been identified as potential debris sources within electric vehicle supply equipment (EVSE) connectors, increasing the risk of electric shock and fire hazards. Although standards such as IEC 62196-1:2022 specify mechanical pull-force requirements for these end caps, it remains unclear whether these requirements provide adequate robustness under real-world conditions. To address this concern, the National Charging Experience (ChargeX) Consortium's Hardware Task Force conducted evaluations of insulated end caps used in OEM CCS inlets. This study assesses the performance of insulated end caps used in OEM CCS inlets, specifically those installed on DC pins, using the procedures defined in IEC 62196-1:2022 (Section Sign) 26.7 and SAE J3400, supplemented by additional experimental conditioning. To ensure relevance to real-world conditions, NLR collaborated with charging network operators (CNOs) to guide the selection of charging inlet samples. Material analyses of the insulated end cap samples were conducted to confirm that the tested materials reflected the types and properties commonly observed in the field. The selected samples underwent temperature and humidity conditioning followed by pull-force testing to evaluate the end-cap integrity. Although SAE J3400 inlets were not directly tested due to limited diversity in available field data, the underlying end-cap principles between CCS and SAE J3400 are comparable, allowing the study's insights to be relevant to both technologies. Overall, this study provides a structured evaluation framework to inform potential refinements to mechanical pull-force requirements in charging standards.
33 ADVANCED PROPULSION SYSTEMS↗
Evaluation of assumptions made by Hygroscopic Tandem Differential Mobility Analyzer inversion routines
The Hygroscopic Tandem Differential Mobility Analyzer (H-TDMA) measures the hygroscopicity of atmospheric particles, and many atmospheric processes that change this hygroscopicity also change the atmospheric size distribution. Two assumptions made during H-TDMA inversion create spurious hygroscopic trends as a function of the changing inlet size distribution. These two assumptions—that the particles exiting the first Differential Mobility Analyzer (DMA1) are singly charged and that the inlet size distribution has a slope of zero (flat)— generate Multi-Charge Dispersion (MCD) bias and Slope bias, respectively. First, we use a model, named TAO, to show that the inlet size distribution could theoretically change the measured ammonium sulfate hygroscopicity by 10%–20% as a function of diameter or experimental time with no change in relative humidity. Secondly, we show experimentally that aerosol emitted from the flaming combustion of grass creates MCD bias. Here, in this experiment, we measure the CPC response of the first three charges and invert these responses using a new routine named Junior. Junior's inversion of each charge shows that one growth factor distribution describes all measured diameters (no growth dependence on diameter). As in the modeling study above, previous publications of this aerosol system, using traditional inversion assumptions, report a decrease in hygroscopicity as DMA1 diameter increases. Unlike traditional inversions, Junior's inversion does not assume the particles are singly charged nor does it make the flat inlet size distribution assumption. Instead, both the inlet size distribution and each charge's CPC response are measured quantities. Thus, the discrepancy between our inversion results and previous publications is likely due to the traditional inversion routine assumptions. This underscores the importance for accounting for Slope and MCD bias during inversions. Experimental results should be carefully analyzed when reporting hygroscopic trends with respect to diameter or experimental time when using the traditional inversion assumptions.
42 ENGINEERING↗