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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 847 records · Page 47
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

High Power Density Thermal Energy Storage With Phase Change Material in Enhanced Compact Heat Exchangers

Abstract Performance of a novel ultracompact thermal energy storage (TES) heat exchanger, designed as a microchannel finned-tube exchanger is presented. With water as the heating–cooling fluid in the microchannels, a salt hydrate phase change material (PCM), lithium nitrate trihydrate (LiNO3 · 3H2O), was encased on the fin side. To establish the hypothesis that small-length-scale encasement (<3 mm) of PCM substantially enhances heat transfer to yield very high power-density energy storage, heat exchanger designs with 10 and 24 fins/inch were considered. They were subjected to thermal cycling, or repeated heating (melting) and cooling (freezing), with inlet fluid flow mimicking diurnal variation between 42 °C and 25 °C (representing typical arid-region conditions) over an accelerated time period. By employing salt self-seeding to obviate subcooling during cooling or recrystallization, the TES was found to exhibit stable long-term (100 heating–cooling cycles) operation with very high PCM-side heat transfer coefficients (∼100–500 W/m2 K) and storage power density (∼160–175 kW/m3). In fact, with optimization of heating–cooling fluid flowrate for given charging–discharging time period and exchanger size, power density >300 kW/m3 can be achieved. The results clearly establish that highly compact heat exchangers used as TES units can provide very high-performance alternatives to conventional ones.

Engineering↗
DOE OSTI2024

An Experimental Investigation of Sintered Particle Effect on Heat Transfer Performance in an “Annular Flow” Evaporation Tube

Wicking structures have been widely used within passive heat transfer devices with high heat fluxes, such as heat pipes, to enhance their thermal performance. While wicking structures promote capillary pumping of the working fluid and thin film evaporation, they can result in capillary evaporation and further enhance the evaporation heat transfer. In this study, a 0.5 mm thick layer of 105 µm sintered copper particles was added to the inner wall of a copper tube, aiming to form an “annular flow” and enhance the heat transfer characteristics by taking advantage of thin film and capillary evaporation. Acetone was chosen as the working fluid, and the performance of an evaporation tube was tested for power inputs of 10, 30, 50, and 70 W. For each power input, trials were run at inclination angles varying from -90 deg to 90 deg to investigate the capillary effects. The temperature measurements showed that the temperature distribution along the evaporation tube is always downward sloping, meaning the temperature at the fluid inlet is larger than the outlet. In conclusion, results show that an “annular flow” formed by a thin layer of sintered particles can promote thin film and capillary evaporation and, therefore, boost the evaporation heat transfer coefficient.

42 ENGINEERING↗
DOE OSTI2020

System Design of a 2.0 MWth Sodium/Molten Salt Pilot System

Nitrate molten salt concentrating solar power (CSP) systems are currently deployed globally and are considered state-of the art heat transfer fluids (HTFs) for present day high-temperature operation. Although slightly higher limits may be possible with molten salt, to fully realize SunShot efficiency goals of $15/kWhth HTFs and an LCOE of 6¢/kWh, HTF technologies working at higher temperatures (e.g., 650 °C to 750 °C) will require an alternative to molten salts, such as with alkali metal systems. This investigation explores the development of a 2.0 MWth sodium receiver system that employs a sodium receiver as the HTF, as well as with a ternary chloride (20%NaCl/40%MgCl/40%KCl by mol wt.%) salt as a thermal energy storage (TES) medium to facilitate a 6-hr. storage duration. A sodium-to-salt heat exchanger model as well as a salt-to-sCO2 primary heat exchanger model are employed and evaluated in this investigation. A thermodynamic system design model was developed using Engineering Equation Solver (EES) where state properties were calculated at inlets and outlets along both hot and cold legs of the pilot-scale plant. This investigation assesses receiver performance as well as system efficiency studies for the pump and system operational ranges. Results found that high efficiency sodium receivers were found to have higher heat transfer coefficients and required far less spreading of incident flux. The system performance model results suggest that for a pump speed of 2400 RPM, respective hot and cold pump TDH values were determined to be 260.1–307 ft. and 260.1–307 ft for pump flow rates of 90–120 GPM.

41 EE - Solar Energy Technologies Office (EE-4S)↗
DOE OSTI2022

Accumulator Sizing for the Hybrid Hydraulic Electric Architecture (HHEA) Using Dynamic Programming

Abstract The Hybrid Hydraulic Electric Architecture (HHEA) is an approach to electrifying and improving that does not require very large electric machines. The majority power is provided hydraulically via a set of common pressure rails while small electric machines are used to modulate that power to meet exact demand. Each common pressure rail has an accumulator, which keeps the pressure of each rail near constant as long as the volume in the accumulator does not change much. A main pump adds or removes fluid from each accumulator as needed to reduce volume changes in the accumulators. It is the operation of this main pump which is investigated here. In previous analysis it was assumed that the size of the accumulators was large enough to account for any difference in fluid volume without significantly changing the pressure. In this paper, the required accumulator sizes are studied using a dynamic programming approach. At each time step the inlet and outlet of the main pump could be connected to any of the common pressure rails. These decisions for the main pump were optimized to minimize the required accumulator size. Case studies are conducted using drive cycles from a 22-ton excavator, a 20-ton wheel loader and a 5-ton excavator. The machines could be operated with total accumulator sizes of less than 20, 10, and 5 liters respectively. Required accumulator size was found to vary with pump flow rate, the frequency at which the pump/motor was able to change operating conditions, the tolerance level of pressure deviation and the accumulator’s polytropic index.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Predicting EBC Temperature Limits for Industrial Gas Turbines

Higher turbine inlet temperatures may require the use of ceramic matrix composites (CMC) such as SiC/SIC, which require environmental barrier coatings (EBCs) to protect them against the detrimental effect of water vapor. Here, the goal of this project is to determine the maximum bond coating temperature for EBCs for land-based turbines, where the minimum coating lifetime is 25,000 h. If the temperature exceeds the 1414°C melting point of the Si bond coating, then coatings without a bond coating also need to be evaluated. Thus, current Yb 2 Si 2 O 7 EBCs with a Si bond coating and next-generation EBCs without a Si bond coating are being evaluated in laboratory testing using 1-h cycles in air+90%H 2 O. For this initial work, coatings were deposited on CVD SiC coupons. Reaction kinetics at 1250°, 1300° and 1350°C have been evaluated by measuring the thickness of the thermally grown silica scale after 100–500 h exposures. For comparison, scale growth rates for uncoated SiC and Si specimens in dry and wet environments were included as minimum and maximum values, respectively. Based on a critical scale thickness failure criteria, estimated maximum temperatures were calculated for both EBC systems using this initial data.

42 ENGINEERING↗
DOE OSTI2023

Development of a 300 MWe Utility Scale Oxy-Fuel sCO2 Turbine

A 300 MWe direct-fired supercritical carbon dioxide (sCO2) oxy-fuel turbine is being developed that will burn natural gas-fired, coal syngas and even hydrogen mixtures capable of 1,150ºC turbine inlet temperature at 300 bar. This design will significantly improve the state-of-the-art for thermal efficiency and results in a high-pressure stream of CO2 with 98%+ carbon capture, making the power plant near emission-free and more efficient than Natural Gas Combined Cycle (NGCC) plants with carbon capture. This power plant will be capable of burning coal through gasification and cleanup of the synthesis gas (syngas). sCO2 power cycles are a transformational technology for the energy industry, providing higher efficiency heat source energy conversion for conventional and alternative energy sources. This novel cycle significantly reduces capital costs because of smaller equipment footprints, design modularity, and allows for rapid cyclic load and source following to balance solar and wind energy power swings. Oxy-fuel sCO2 cycles take these advantages even further, utilizing higher firing temperatures, improved efficiency, and simpler carbon capture strategies. This turbine will require cooled turbine nozzles and blades as well as advanced thermal management systems to accommodate these high temperatures. The cooled blade heat transfer correlations required new test programs at higher Reynolds number than air-breathing gas turbines for impingement, serpentine, and pin-fin regions. Novel blade optimization was performed to maximize aerodynamic efficiency, while minimizing cooling flows. A turbine layout was generated utilizing individual combustor cans with cooled liners feeding into a 6-stage axial flow turbine with cooled stator nozzles and turbine blades. The case design and thermal management preliminary design will be described.

Moore, Jeffrey↗
DOE OSTI2023

Design and Cooling Performance of Additively Manufactured Ceramic Turbine Vanes

Ceramic materials are of significant interest in aviation and power generation gas turbine engines due to their low density and ability to withstand high temperatures. Increased cycle thermal efficiency and higher specific power output is possible by incorporating ceramic components that enable high turbine inlet temperatures and lower required cooling airflow levels. However, ceramics can be difficult and costly to form into the complex shapes used in gas turbine components, often requiring specialized multi-step processes. Furthermore, ceramic components in the hottest areas of a gas turbine, such as vanes or blade shroud seals, will still likely require cooling which is challenging to implement in conventional ceramic manufacturing approaches. Therefore, this study presents a multidisciplinary approach that investigates the design, fabrication and overall cooling effectiveness evaluation of additively manufactured (AM), polymer derived ceramic (PDC) turbine vanes. A thermo-mechanically optimized vane design was generated, ceramic additive manufacturing of the complex cooling configuration was developed, and quantification of the increase in overall cooling effectiveness was performed in a 1X scale, high-speed facility using infrared thermography. This study produced a PDC AM process, capable of printing complex internal cooling schemes in 1X scale turbine vanes. It was found that the optimized vane more than doubled the overall cooling effectiveness observed in the baseline design, which reasonably agreed with thermomechanical optimization model predictions. Additionally, the optimized ceramic vane outperformed an identical metal vane, in terms of area averaged cooling effectiveness, suggesting that the ceramic vane could operate at reduced coolant flow rates to achieve comparable levels of cooling performance.

Fox, Andrew↗
DOE OSTI2024

Partially cracked ammonia mixture combustion in gas turbine combustors

Ammonia is gaining popularity for single fuel use in existing gas turbines, as it is carbonless, has higher hydrogen content per unit volume than liquid hydrogen, and facilitates easy storage and handling. However, the low flame speed of ammonia makes it prone to flame blow off and remains the chief concern for its use in power generation. Following previous studies that have shown improved combustion performance by partially cracking the fuel, in this computational study, efficacy of partially cracked ammonia as a replacement fuel for natural gas is evaluated. A high-pressure optically accessible combustor operated at ~10 bar pressure with non-vitiated heated air was used as the test platform. This combustor was equipped with a novel multifuel multi-tube micromixing injector (M3 injector). High resolution simulations of the flow fields both in the injector as well as the combustor were performed to understand the fuel mixing in the injector and in the inlet region of the combustor. These modeling results showed that the injector was highly effective for achieving mixture homogeneity at the entrance of the combustor for ammonia and natural gas injection, whereas, for hydrogen an earlier injection facilitating longer residence time would be beneficial. Also, these simulations show that while harnessing waste heat the ideal fuel dissociation fraction is between 0.4 and 0.55 for optimal operation.

Ammonia↗
DOE OSTI2023

Numerical Study of Liquid Piston Compression Using Large-Eddy Simulation and Volume-of-Fluid Approach

Efforts to increase the efficiency of residential and commercial air conditioners and heat pumps have demonstrated that the compressor accounts for most of the system’s electrical energy usage. Therefore, the efficiency of this component should be improved to reduce its energy usage. The US Department of Energy’s Oak Ridge National Laboratory developed a near-isothermal liquid piston compressor (LPC) that uses propylene glycol (PG) to compress CO2. This report presents numerical studies of the LPC in which the compression chamber fills with injected PG from the bottom inlet. Numerical simulations were performed using the large-eddy simulation (LES) with the wall-adapting local eddy-viscosity (WALE) subgrid-scale model coupled with the multiphase volume-of-fluid (VOF) model to simulate the transient interface between gas and liquid and to capture the heat and mass transfer within the compression chamber. In this effort, effects of boundary conditions applied to the LES-VOF calculations (e.g., no wall, an adiabatic wall, and a wall with a heat flux subscribed) to the overall pressure and temperature of CO2 gas as well as the transient evolution of flow and heat transfer evolution within the compression chamber are investigated and discussed. It was found that the LES calculation with no wall have shown no dynamical flow patterns and the volume-averaged temperature of CO2 increased from 305 to 392.7 K, while LES calculations with a constant wall temperature or a wall heat flux had similar increases of CO2 temperatures. Results of LES simulation using a wall heat flux showed different stages in the compression process and revealed dynamical formation and interaction of CO2 gas layers and circulation flow patterns within the chamber that contribute to the overall heat transfer between the solid wall, gas, and liquid surface in the compressor.

Nguyen, Thien D.↗
DOE OSTI2022

Computational Fluid Dynamic Modeling of Dry Cask Simulator with Crosswind

The purpose of this study is to create a STAR-CCM+ model of a Belowground Vertical Dry Cask Simulator (BVDCS) at Sandia National Laboratories (SNL) and validate the model with SNL’s experimental results. The BVDCS consists of a single boiling water reactor assembly fitted with electric heaters encompassed by a containment vessel and shell to represent a belowground spent nuclear fuel (SNF) dry storage system. Blowers are located near the inlet and outlet of the BVDCS to simulate crosswind conditions. In addition to the experimental results, the STAR-CCM+ model developed for this study is compared with a previous computational fluid dynamics (CFD) model in a different software program, which is used as a software-to-software benchmark. The experimental results provide a dataset to compare the STAR-CCM+ model results for a variety of different conditions. The main objective is to validate and improve STAR-CCM+ CFD models for spent nuclear fuel storage systems with explicitly modeled external environments and “wind driven” crossflows. These CFD models aide in the study of external particle deposition in spent nuclear fuel storage systems, which is important to predicting the significance of chloride induced stress corrosion cracking (CISCC). In addition to experimental comparison, a sensitivity analysis study is performed using the STAR-CCM+ model. The sensitivity analysis provides a quantitative assessment of the sensitivity of various parameters. This helps provide information on various parameters that are of particular importance to constructing a model representative of real life systems. The STAR-CCM+ model compared well to the experimental results showing similar responses to changes in cross wind flow, and a number of parameters are identified for model improvement.

Jensen, Ben J.↗
DOE OSTI2015

Growth of SrVO{sub 3} thin films by hybrid molecular beam epitaxy

The authors report the growth of stoichiometric SrVO{sub 3} thin films on (LaAlO{sub 3}){sub 0.3}(Sr{sub 2}AlTaO{sub 6}){sub 0.7} (001) substrates using hybrid molecular beam epitaxy. This growth approach employs a conventional effusion cell to supply elemental A-site Sr and the metalorganic precursor vanadium oxytriisopropoxide (VTIP) to supply vanadium. Oxygen is supplied in its molecular form through a gas inlet. An optimal VTIP:Sr flux ratio has been identified using reflection high-energy electron-diffraction, x-ray diffraction, atomic force microscopy, and scanning transmission electron microscopy, demonstrating stoichiometric SrVO{sub 3} films with atomically flat surface morphology. Away from the optimal VTIP:Sr flux, characteristic changes in the crystalline structure and surface morphology of the films were found, enabling identification of the type of nonstoichiometry. For optimal VTIP:Sr flux ratios, high quality SrVO{sub 3} thin films were obtained with smallest deviation of the lattice parameter from the ideal value and with atomically smooth surfaces, indicative of the good cation stoichiometry achieved by this growth technique.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Characterization of extended channel bioreactors for continuous-flow protein production

In this paper, protein based therapeutics are an important class of drugs, used to treat a variety of medical conditions including cancer and autoimmune diseases. Requiring continuous cold storage, and having a limited shelf life, the ability to produce such therapeutics at the point-of-care would open up new opportunities in distributing medicines and treating patients in more remote locations. Here, the authors describe the first steps in the development of a microfluidic platform that can be used for point-of-care protein synthesis. While biologic medicines, including therapeutic proteins, are commonly produced using recombinant deoxyribonucleic acid (DNA) technology in large batch cell cultures, the system developed here utilizes cell-free protein synthesis (CFPS) technology. CFPS is a scalable technology that uses cell extracts containing the biological machinery required for transcription and translation and combines those extracts with DNA, encoding a specific gene, and the additional metabolites required to produce proteins in vitro. While CFPS reactions are typically performed in batch or fed-batch reactions, a well-engineered reaction scheme may improve both the rate of protein production and the economic efficiency of protein synthesis reactions, as well as enable a more streamlined method for subsequent purification of the protein product—all necessary requirements for point-of-care protein synthesis. In this work, the authors describe a new bioreactor design capable of continuous production of protein using cell-free protein synthesis. The bioreactors were designed with three inlets to separate reactive components prior to on-chip mixing, which lead into a long, narrow, serpentine channel. These multiscale, serpentine channel bioreactors were designed to take advantage of microscale diffusion distances across narrow channels in reactors containing enough volume to produce a therapeutic dose of protein, and open the possibility of performing these reactions continuously and in line with downstream purification modules. Here, the authors demonstrate the capability to produce protein over time with continuous-flow reactions and examine basic design features and operation specifications fundamental to continuous microfluidic protein synthesis.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2016

TU-H-206-02: Novel Linearly-Filled Derenzo PET Phantom Design

Purpose: To design a linearly-filled Derenzo positron emission tomography (PET) phantom, eliminating the extraneous radioisotope volumes in a conventional reservoir-type design. This activity reduction combined with the elimination of bubbles in smaller phantom channels would significantly reduce personnel dose, radioisotope cost, and would improve image quality by reducing out-of-slice activity scatter. Methods: A computer-aided design (CAD) was created of a modular Derenzo phantom consisting of three phantom layers with gaskets between the layers. The central piece contains the active pattern volume and channels connecting adjacent rods in a serpentine pattern. The two end-pieces contained an inlet and an outlet for filling purposes. Phantom prototypes were 3D printed on a Viper Si2 stereolithography machine. The two gaskets were fabricated from silicon sheets using a PLS 6.75 laser cutter. Phantoms were held together by pass-through glass-filled nylon bolts and nuts. Phantoms were filled with {sup 52}Mn, {sup 64}Cu, {sup 74}Br, and {sup 124}I for testing, and were imaged on a Siemens Inveon MicroPET scanner. Results: Four phantom prototypes were constructed using male Leur Lock fittings for inlet/outlet ports. 3D printed layers were sanded to ensure proper coupling to the silicon gaskets. The filling volume for each prototype was approximately 2.4 mL. The filling process was found to be rapid, leak-tight, and with minimal back-pressure. PET images were reconstructed by OSEM3D, and axial slices along the phantom pattern length were averaged to provide final images. Image distortion was isotope dependent with {sup 52}Mn and {sup 64}Cu having the least distortion and {sup 124}I having the most distortion. Conclusion: These results indicate that the linearlyfilled Derenzo design improves on conventional reservoir-type designs by eliminating potential bubbles in small channels and by reducing activity level, radioisotope volume, radioisotope cost, personnel dose, filling time, and out-of-slice activity scatter The method described in this abstract has been filed as a patent application to the US Patent and Trade Office by the Wisconsin Alumni Research Foundation (WARF).

60 APPLIED LIFE SCIENCES↗
DOE OSTI2015

On the possibility of reprocessing spent nuclear fuel and radioactive waste by plasma methods

The concept of plasma separation of spent nuclear fuel and radioactive waste is presented. An approach that is based on using an accelerating potential to overcome the energy and angular spread of plasma ions at the separation region inlet and utilizing a potential well to separate spatially the ions of different masses is proposed. It is demonstrated that such separation may be performed at distances of about 1 m with electrical potentials of about 1 kV and a magnetic field of about 1 kG. The estimates of energy consumption and performance of the plasma separation method are presented. These estimates illustrate its potential for technological application. The results of development and construction of an experimental setup for testing the method of plasma separation are presented.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2016

Analysis of the uncertainties in the physical calculations of water-moderated power reactors of the VVER type by the parameters of models of preparing few-group constants

The article covers the uncertainty analysis of the physical calculations of the VVER reactor core for different meshes of the reference values of the feedback parameters (FBP). Various numbers of nodes of the parametric axes of FBPs and different ranges between them are investigated. The uncertainties of the dynamic calculations are analyzed using RTS RCCA ejection as an example within the framework of the model with the boundary conditions at the core inlet and outlet.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2017

A prototype of an electric-discharge gas flow oxygen−iodine laser: I. Modeling of the processes of singlet oxygen generation in a transverse cryogenic slab RF discharge

The existing kinetic model describing self-sustained and electroionization discharges in mixtures enriched with singlet oxygen has been modified to calculate the characteristics of a flow RF discharge in molecular oxygen and its mixtures with helium. The simulations were performed in the gas plug-flow approximation, i.e., the evolution of the plasma components during their motion along the channel was represented as their evolution in time. The calculations were carried out for the O{sub 2}: He = 1: 0, 1: 1, 1: 2, and 1: 3 mixtures at an oxygen partial pressure of 7.5 Torr. It is shown that, under these conditions, volumetric gas heating in a discharge in pure molecular oxygen prevails over gas cooling via heat conduction even at an electrode temperature as low as ~100 K. When molecular oxygen is diluted with helium, the behavior of the gas temperature changes substantially: heat removal begins to prevail over volumetric gas heating, and the gas temperature at the outlet of the discharge zone drops to ~220–230 K at room gas temperature at the inlet, which is very important in the context of achieving the generation threshold in an electric-discharge oxygen−iodine laser based on a slab cryogenic RF discharge.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗