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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Technology Development and Integration for Volume Production of High Purity Rare Earth Metals from Phosphate Processing

Under this project and in collaboration with Pacific Northwest National Laboratory (PNNL), Oak Ridge National Laboratory (ORNL), Florida International University (FIU), and Mosaic, the FIPR Institute successfully developed and demonstrated on laboratory batch scale a complete processing technology for production of high-purity rare earth elements (REE) in the form of mixed rare earth oxides (MREO) and rare earth metals (REM) using phosphoric acid sludge (a byproduct from phosphate mining) as the REE feedstock. Based on the research results, a technical research plan has been developed with expanded team members to elevate the technology readiness level (TRL) of the subject technology from 4 to 6 by conducting continuous testing of the processing flowsheet with the ultimate goal of producing about 900 tons per year of REM using the phosphate mining byproduct. Those 900 tons of REM would contain approximately 180 tons of Y, 120 tons of Nd, 50 tons of Gd, 37 tons of Dy, 33 tons of Sm, and 31 tons of Pr, meeting the US demand of roughly 39%, 6%, 42%, 48%, 101% and 7% for these elements, respectively. The advanced technologies for REE separation and purification involves three technology companies: K-Technologies, Inc. would test their continuous-ion-exchange/continuous-ion chromatography technologies on both the REE leachate and solvent extraction concentrate for 4 production of high-purity individual or binary REM. Rare Earth Salts would test their innovative electrochemical technology on the REE leachate or re-dissolved MREO in dilute acid for production of high-purity individual or binary REM. Rare Earth Technologies, Inc. would evaluate their advanced chromatographic separation technology on the dissolved MREO product for production of high-purity individual or binary REM.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Regulatory Technology Development Plan Sodium Fast Reactor. Mechanistic Source Term Development

Construction and operation of a nuclear power installation in the U.S. requires licensing by the U.S. Nuclear Regulatory Commission (NRC). A vital part of this licensing process and integrated safety assessment entails the analysis of a source term (or source terms) that represents the release of radionuclides during normal operation and accident sequences. Historically, nuclear plant source term analyses have utilized deterministic, bounding assessments of the radionuclides released to the environment. Significant advancements in technical capabilities and the knowledge state have enabled the development of more realistic analyses such that a mechanistic source term (MST) assessment is now expected to be a requirement of advanced reactor licensing. This report focuses on the state of development of an MST for a sodium fast reactor (SFR), with the intent of aiding in the process of MST definition by qualitatively identifying and characterizing the major sources and transport processes of radionuclides. Due to common design characteristics among current U.S. SFR vendor designs, a metal-fuel, pool-type SFR has been selected as the reference design for this work, with all phenomenological discussions geared toward this specific reactor configuration. This works also aims to identify the key gaps and uncertainties in the current knowledge state that must be addressed for SFR MST development. It is anticipated that this knowledge state assessment can enable the coordination of technology and analysis tool development discussions such that any knowledge gaps may be addressed. Sources of radionuclides considered in this report include releases originating both in-vessel and ex-vessel, including in-core fuel, primary sodium and cover gas cleanup systems, and spent fuel movement and handling. Transport phenomena affecting various release groups are identified and qualitatively discussed, including fuel pin and primary coolant retention, and behavior in the cover gas and containment. Radionuclides released from a primary sodium fire are also considered as potential sources. Any available experimental data and pertinent results relevant to the aforementioned phenomena are discussed, and operating incidents at domestically operated facilities are also examined. Considering the extensive range of phenomena affecting the release of radionuclides, the existing state of knowledge generally appears to be substantial, and may be sufficient in most areas. For core damage accidents, high retention rates should be expected within the fuel matrix and primary sodium coolant for all radionuclides other than the noble gases. These factors greatly reduce the magnitude of possible radionuclide release to the environment. Several possible gaps within the knowledgebase were identified during this effort. First, there are uncertainties with regard to radionuclide release from metal fuel in the molten state. Another knowledge gap appears in the available thermodynamic data regarding the behavior of lanthanides and actinides in liquid sodium. While not necessarily a phenomenological knowledge gap, a determination of the data requirements for MST development should be formally made prior to the expenditure of significant future research efforts. That is, if additional experimentation is performed in support of MST development, it is important to identify the proper quality assurance requirements for licensing

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Accelerating technology development to monitor and minimize effects from land‐based wind energy on birds and bats

While wind energy is a key sector of domestic energy production for the United States, operation of wind turbines directly and indirectly adversely affects certain species of birds and bats. The cumulative effect of wind turbine strikes can have both biological and regulatory consequences, and, in some cases, delay permitting and construction or affect ongoing operations. Technology can help quantify and minimize these effects, but the pace of development, acceptance, and adoption of technological solutions is slow. Although adopting cost‐effective technologies may reduce negative effects on wildlife and help achieve both energy production and conservation goals, consensus is lacking among developers, regulators, and the conservation community regarding how to define technology effectiveness and acceptance and how to develop a standardized process for doing so. Removing barriers to technology advancement requires deviating from the status quo. Changes include 1) creating incentives to mitigate impacts, 2) establishing options for research as mitigation, 3) rethinking how research is funded, 4) increasing stakeholder coordination, and 5) increasing the efficiency of research and development. We recommend the creation of a national framework to establish clear criteria and protocols for technology evaluation and adoption.

17 WIND ENERGY↗
DOE OSTI2018

Rapid Freeform Sheet Metal Forming: Technology Development and System Verification

The objective of this project is to develop a transformational RApid Freeform sheet metal Forming Technology (RAFFT) in an industrial environment, which has the potential to increase manufacturing energy efficiency up to ten times, at a fraction of the cost of conventional technologies. The RAFFT technology is a flexible and energy-efficient process that eliminates the need for having geometry-specific forming dies. The innovation lies in the idea of using the energy resource at the local deformation area which provides greater formability, process control, and process flexibility relative to traditional methods. Double-Sided Incremental Forming (DSIF), the core technology in RAFFT, is a new concept for sheet metal forming. A blank sheet is clamped around its periphery and gradually deformed into a complex 3D freeform part by two strategically aligned stylus-type tools that follow a pre-described toolpath. The two tools, one on each side of the blank, can form a part with sharp features for both concave and convex shapes. Since deformation happens locally, the forming force at any instant is significantly decreased when compared to traditional methods. The key advantages of DSIF are its high process flexibility, high energy-efficiency, low capital investment, and the elimination of the need for massive amounts of die casting and machining. Additionally, the enhanced formability and process flexibility of DSIF can open up design spaces and result in greater weight savings.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Large Area Projection Sintering Technology Development (CRADA Final Report)

This CRADA was formed through support of the Innovation Crossroads program, which has been an invaluable experience for Ascend Manufacturing and our additive manufacturing technology. Without Innovation Crossroads, the research, capital and operational requirements to develop our company would have been too high and Ascend Manufacturing simply would not exist. Our patented and federally funded technology would have gone to waste. Through this CRADA, Ascend has been able to collaborate with the worlds experts in additive manufacturing to assist in developing our state of the art technology. This project assisted in developing a fully scalable 3D printing process, developed an industrial and pilot system design, assisted in the fabrication of a pilot system, allowing us to print components with materials impossible by any other 3D printing process. This work has allowed us to achieve significant follow-on funding to fully commercialize this highly capable manufacturing technology.

36 MATERIALS SCIENCE↗
DOE OSTI2019

High-Brightness Beam Technology Development for a Future Dynamic Mesoscale Materials Science Capability

A future capability in dynamic mesoscale materials science is needed to study the limitations of materials under irreversible and extreme conditions, where these limitations are caused by nonuniformities and defects in the mesoscale. This capability gap could potentially be closed with an X-ray free-electron laser (XFEL), producing 5 × 10 10 photons with an energy of 42 keV, known as the Matter–Radiation Interactions in Extremes (MaRIE) XFEL. Over the last few years, researchers at the Los Alamos National Laboratory have developed a preconceptual design for a MaRIE-class XFEL based on existing high-brightness beam technologies, including superconducting L-band cryomodules. However, the performance of a MaRIE-class XFEL can be improved and the risk of its operation reduced by investing in emerging high-brightness beam technologies, such as the development of high-gradient normal conducting radio frequency (RF) structures. Additionally, an alternative XFEL architecture, which generates a series of high-current microbunches instead of a single bunch with uniformly high current along it, may suppress the most important emittance degradation effects in the accelerator and in the XFEL undulator. In this paper, we describe the needed dynamic mesoscale materials science capability, a MaRIE-class XFEL, and the proposed microbunched XFEL accelerator architecture in detail.

47 OTHER INSTRUMENTATION↗
DOE OSTI2016

Nuclear-Renewable Hybrid Energy Systems: 2016 Technology Development Program Plan

The United States is in the midst of an energy revolution, spurred by advancement of technology to produce unprecedented supplies of oil and natural gas. Simultaneously, there is an increasing concern for climate change attributed to greenhouse gas (GHG) emissions that, in large part, result from burning fossil fuels. An international consensus has concluded that the U.S. and other developed nations have an imperative to reduce GHG emissions to address these climate change concerns. The global desire to reduce GHG emissions has led to the development and deployment of clean energy resources and technologies, particularly renewable energy technologies, at a rapid rate. At the same time, each of the major energy sectors—the electric grid, industrial manufacturing, transportation, and the residential/commercial consumers— is increasingly becoming linked through information and communications technologies, advanced modeling and simulation, and controls. Coordination of clean energy generation technologies through integrated hybrid energy systems, as defined below, has the potential to further revolutionize energy services at the system level by coordinating the exchange of energy currency among the energy sectors in a manner that optimizes financial efficiency (including capital investments), maximizes thermodynamic efficiency (through best use of exergy, which is the potential to use the available energy in producing energy services), reduces environmental impacts when clean energy inputs are maximized, and provides resources for grid management. Rapid buildout of renewable technologies has been largely driven by local, state, and federal policies, such as renewable portfolio standards and production tax credits that incentivize investment in these generation sources. A foundational assumption within this program plan is that renewable technologies will continue to be major contributors to the future U.S. energy infrastructure. While increased use of clean renewable technologies will aid in achieving reduced GHG emissions, it also presents new challenges to grid management that must be addressed. These challenges primarily derive from the fundamental characteristics of variable renewable generators, such as wind and solar: non-dispatchability, variable production, and reduced electromechanical inertia. This document presents a preliminary research and development (R&D) plan for detailed dynamic simulation and analysis of nuclear-renewable hybrid energy systems (N-R HES), coupled with integrated energy system design, component development, and integrated systems testing. N-R HES are cooperatively-controlled systems that dynamically apportion thermal and/or electrical energy to provide responsive generation to the power grid.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2023

Fully depleted charge‐coupled device design and technology development

Abstract We describe the advancement of fully depleted charge‐coupled device (CCD) technology for scientific applications. Recent efforts on 650–725 m‐thick CCDs for direct dark‐matter and radiation detection with single‐electron sensitivity are described, as well as the technology transfer of the fully depleted CCD technology to 200 mm‐wafer fabrication facilities.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2014

Recovery Act: Oxy-Combustion Technology Development for Industrial-Scale Boiler Applications. Task 4 - Testing in Alstom's 15 MW th Boiler Simulation Facility

Alstom Power Inc. (Alstom), under U.S. DOE/NETL Cooperative Agreement No. DE-NT0005290, is conducting a development program to generate detailed technical information needed for application of oxy-combustion technology. The program is designed to provide the necessary information and understanding for the next step of large-scale commercial demonstration of oxy combustion in tangentially fired boilers and to accelerate the commercialization of this technology. The main project objectives include: Design and develop an innovative oxyfuel system for existing tangentially-fired boiler units that minimizes overall capital investment and operating costs; Evaluate performance of oxyfuel tangentially fired boiler systems in pilot scale tests at Alstom’s 15 MWth tangentially fired Boiler Simulation Facility (BSF); Address technical gaps for the design of oxyfuel commercial utility boilers by focused testing and improvement of engineering and simulation tools; Develop the design, performance and costs for a demonstration scale oxyfuel boiler and auxiliary systems; Develop the design and costs for both industrial and utility commercial scale reference oxyfuel boilers and auxiliary systems that are optimized for overall plant performance and cost; and, Define key design considerations and develop general guidelines for application of results to utility and different industrial applications. The project was initiated in October 2008 and the scope extended in 2010 under an ARRA award. The project is scheduled for completion by April 30, 2014. Central to the project is 15 MWth testing in the BSF, which provided in-depth understanding of oxy-combustion under boiler conditions, detailed data for improvement of design tools, and key information for application to commercial scale oxy-fired boiler design. Eight comprehensive 15 MWth oxy-fired test campaigns were performed with different coals, providing detailed data on combustion, emissions, and thermal behavior over a matrix of fuels, oxy-process variables and boiler design parameters. Significant improvement of CFD modeling tools and validation against 15 MWth experimental data has been completed. Oxy-boiler demonstration and large reference designs have been developed, supported with the information and knowledge gained from the 15 MWth testing. This report addresses the results from the 15 MWth testing in the BSF.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2014

Recovery Act: Oxy-Combustion Technology Development for Industrial-Scale Boiler Applications

Alstom Power Inc. (Alstom), under U.S. DOE/NETL Cooperative Agreement No. DE-NT0005290, is conducting a development program to generate detailed technical information needed for application of oxy-combustion technology. The program is designed to provide the necessary information and understanding for the next step of large-scale commercial demonstration of oxy combustion in tangentially fired boilers and to accelerate the commercialization of this technology. The main project objectives include: • Design and develop an innovative oxyfuel system for existing tangentially-fired boiler units that minimizes overall capital investment and operating costs. • Evaluate performance of oxyfuel tangentially fired boiler systems in pilot scale tests at Alstom’s 15 MWth tangentially fired Boiler Simulation Facility (BSF). • Address technical gaps for the design of oxyfuel commercial utility boilers by focused testing and improvement of engineering and simulation tools. • Develop the design, performance and costs for a demonstration scale oxyfuel boiler and auxiliary systems. • Develop the design and costs for both industrial and utility commercial scale reference oxyfuel boilers and auxiliary systems that are optimized for overall plant performance and cost. • Define key design considerations and develop general guidelines for application of results to utility and different industrial applications. The project was initiated in October 2008 and the scope extended in 2010 under an ARRA award. The project completion date was April 30, 2014. Central to the project is 15 MWth testing in the BSF, which provided in-depth understanding of oxy-combustion under boiler conditions, detailed data for improvement of design tools, and key information for application to commercial scale oxy-fired boiler design. Eight comprehensive 15 MWth oxy-fired test campaigns were performed with different coals, providing detailed data on combustion, emissions, and thermal behavior over a matrix of fuels, oxyprocess variables and boiler design parameters. Significant improvement of CFD modeling tools and validation against 15 MWth experimental data has been completed. Oxy-boiler demonstration and large reference designs have been developed, supported with the information and knowledge gained from the 15 MWth testing. The results from the 15 MWth testing in the BSF and complimentary bench-scale testing are addressed in this volume (Volume II) of the final report. The results of the modeling efforts (Volume III) and the oxy boiler design efforts (Volume IV) are reported in separate volumes.

42 ENGINEERING↗
DOE OSTI2020

The Role of Competitions in Speeding Energy-Efficient Technology Development and Adoption

This conference paper, which will be submitted for publication in the 2020 ACEEE Summer Study on Energy Efficiency in Buildings, describes competition approaches used by the U.S. Department of Energy (DOE) Building Technologies Office (BTO) and other government agencies to encourage the development and adoption of innovative new energy-efficient, high-performing products while spurring external competition to maximize limited resources. The competition model helps to disrupt traditional thinking and introduce, expand, and evolve what’s possible within limited resource conditions. DOE BTO has sponsored technology competitions, including campaigns, challenges, prizes, and technology procurements to speed the uptake of more efficient refrigerators, clothes washers, air conditioners, and many types of highly efficient lighting technologies, including compact fluorescent lamps (CFLs) and light-emitting diode LED-based home and office luminaires, replacement lamps, and street lighting. In this paper, we will draw upon the technology competition frameworks employed by DOE BTO to support ongoing research and development efforts to illustrate the differences between the approaches and to identify which type is likely to be the most effective in a given technology status and market context. We’ll also share examples of the various technology competition types and results. A question-and-answer table helps readers compare and contrast the four competition types. The paper concludes with a summary of lessons learned from past DOE BTO competitions. The paper will be available in the ACEEE 2020 Summer Study proceedings and a related presentation will be given at the conference.

U.S. Department of Energy Building Technologies Of↗
DOE OSTI2020

Millimeter-Wave Imaging Technology Development for Real-Time 2D and 3D Fusion Plasma Diagnostics

Including a one year No-Cost Extension, The University of California, Davis has been funded since 2020 to advance innovative millimeter-wave diagnostics for fusion plasma research. This work includes: (1) Developing and applying cutting-edge System-on-Chip millimeter wave Integrated Circuit (IC) technology for Electron Cyclotron Emission Imaging (ECEI) and Microwave Imaging Reflectometry (MIR) on the DIII-D tokamak and the NSTX-U spherical tokamak. (2) Development of radiation-hardened millimeter-wave chip for diagnostics in harsh environments, utilizing wide bandgap Gallium Nitride (GaN) semiconductors. (3) Integrating forward-modeling synthetic diagnostics to enable advanced, real-time plasma prediction and feedback control. Originally planned as a three-year program (2020–2023), the project was granted a one-year no-cost extension, extending its duration through the end of 2024.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2019

Project: Advanced Oxy-Combustion Technology Development and Scale Up for New and Existing Coal-Fired Power Plants (Phase II) (Final Report)

The objective of this project was to develop an advanced Oxy-Combustion Pressurized Fluidized Bed Combustor (Oxy-PFBC) technology and mature it to TRL 6 through pilot testing. Performance goals included demonstrating capture of 90% or greater of the produced carbon dioxide, with no more than a 35% increase in the cost of electricity. A 1 MWth pilot scale plant was designed, built and operated at CanmetENERGY in Ottawa. Extensive support work was carried out on component testing, analysis and commercial planning. The team members included GTI, Linde, Natural Resources Canada (CanmetENERGY), Pennsylvania State University, Electric Power Research Institute (EPRI), and General Electric. Additional research was provided by the University of Ottawa. Funding was provided by the US Department of Energy, Alberta Innovates and each of the team members. The total funding for Phase II was $\$$18.537M with $\$$12.058M. The period of performance for Phase II was from July 1, 2014 through December 31, 2018. Component testing conducted in preparation for pilot testing included cold flow testing at atmospheric and pressurized conditions, and coal and limestone reactivity tests at elevated temperatures and pressures. These tests validated in-bed heat exchanger heat transfer capability, bed stability, and coal particle residence time predictions. They also quantified coal and limestone reactivity at the expected combustor temperatures and pressures. The 1 MWth pilot testing achieved all performance goals with the exception of carbon conversion. The combustor achieved oxy-combustion at the full target pressure of 8 bar. Two key combustor performance goals that were achieved include exceeding the target sulfur capture in the combustor as well as exceeding the acid dewpoint target at full operating pressure. This validates assumptions about the pressures that can be achieved without acid gas condensation and the associated corrosion risks. The ability to achieve target operating pressures supports combustor cost assumptions. In addition, the CO 2 processing unit (CPU), demonstrated a new technology, the deoxidation (DeOxo) reactor. The CPU achieved all of its performance targets, while the DeOxo reactor demonstrated the ability to achieve 100 ppm or less of oxygen in the flue gas stream to meet CO 2 pipeline specs. The pilot combustor was damaged during testing and an incident investigation was conducted. The primary cause of the hardware damage was due to anomalous temperature readings, caused by sensors buried and insulated in bed particles trapped by heat exchanger tubes near the wall. This led to higher gas velocities than intended, which then caused lower fuel residence time, lower carbon conversion, freeboard burning, and undetected excess temperatures in the combustor. As a result, the TRL 6 goal was not achieved. Updated technoeconomic analysis predicts that the Oxy-PFBC can achieve the goal of <35% increase in COE with 90% CO 2 capture if the carbon conversion performance target can be demonstrated in future testing.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2020

Technology Development and Field Monitoring in nZEB - US Country report IEA HPT Annex 49 Task 3

The International Energy Agency (IEA) Heat Pumping Technologies (HPT) Annex 49, “Design and Integration of Heat Pumps for Nearly Zero Energy Buildings,” deals with the application of heat pumps (HPs) as a core component of the HVAC system for nearly or net-zero energy buildings. This report covers the Task 3 activities of the US team. Three institutions are involved on the US team and have worked on the following projects. 1) Oak Ridge National Laboratory (ORNL) summarized development activities since the conclusion of IEA HPT Annex 40 for several integrated HP (IHP) systems - electric ground-source IHP and air-source IHP versions and engine-driven AS-IHP version. 2) The University of Maryland partnered with ORNL and Blue Bear Management to develop a personal cooling device called RoCo that can provide personalized conditioned air to occupants in inadequately or unconditioned environments. With RoCo, building facility management can elevate the HVAC thermostat settings without compromising occupants’ thermal comfort. Researchers have found that a 4°F increase in thermostat settings can save 12–30% energy savings. Therefore, RoCo is a promising technology that can help reduce building energy consumption and facilitate achievement of net-zero energy building performance. 3) The National Institute of Standards and Technology (NIST) is working on a field study effort on the NIST Net-Zero Energy Residential Test Facility. Two air-source split-system HPs were installed in a residential, net-zero energy home that was constructed as a laboratory on the NIST campus in Gaithersburg, Maryland. The first HP was a two-stage, 7 kW (2 ton), 15.8 seasonal energy efficiency ratio (SEER), 9.05 heating seasonal performance factor (HSPF) conventionally ducted system; the second HP was a variable-speed, 10.6 kW (3 ton), 14 SEER, 8.35 HSPF, high-velocity ducted system. These two systems operated side by side, using separate supply ducts and a common return duct, on a weekly alternating schedule to condition the home that was operated with very consistent simulated thermal loads. The team wanted to determine whether the high-velocity system could provide comparable energy-use efficiency to the conventional system. The results of this study showed that it did meet the required loads and had slightly greater efficiency; the average cooling coefficient of performance (COP) was (0.40 ± 0.11) higher, and the average heating COP was statistically equal. A new firmware was provided at the end of the heating season that greatly improved the performance of the high-velocity system; its average heating COP went from (1.8 ± 0.9) to (2.5 ± 1.1) at a 95% confidence level. The new firmware heating COP averaged (1.05 ± 0.23) higher than the old firmware over the same outdoor temperatures. The defrost performance is very different for these two systems, yet they consumed equivalent energy per HDD. The conventional system uses a timed-initiate, temperature-terminate algorithm with auxiliary electric resistive heating, whereas the high-velocity system uses calculated evaporator parameters with a hot-gas bypass before a full reverse-cycle defrost with no supplementary resistive heat.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Technology development for modern SRF accelerators

Superconducting RF (SRF) linear accelerators are widely used for scientific application. Challenges, status, breakthroughs and progress in SRF technology for accelerator application are discussed.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2015

Combined Heat and Power Systems Technology Development and Demonstration 370 kW High Efficiency Microturbine

The C370 Program was awarded in October 2010 with the ambitious goal of designing and testing the most electrically efficient recuperated microturbine engine at a rated power of less than 500 kW. The aggressive targets for electrical efficiency, emission regulatory compliance, and the estimated price point make the system state-of-the-art for microturbine engine systems. These goals will be met by designing a two stage microturbine engine identified as the low pressure spool and high pressure spool that are based on derivative hardware of Capstone’s current commercially available engines. The development and testing of the engine occurred in two phases. Phase I focused on developing a higher power and more efficient engine, that would become the low pressure spool which is based on Capstone’s C200 (200kW) engine architecture. Phase II integrated the low pressure spool created in Phase I with the high pressure spool, which is based on Capstone’s C65 (65 kW) commercially available engine. Integration of the engines, based on preliminary research, would allow the dual spool engine to provide electrical power in excess of 370 kW, with electrical efficiency approaching 42%. If both of these targets were met coupled with the overall CHP target of 85% total combined heating and electrical efficiency California Air Resources Board (CARB) level emissions, and a price target of $600 per kW, the system would represent a step change in the currently available commercial generation technology. Phase I of the C370 program required the development of the C370 low pressure spool. The goal was to increase the C200 engine power by a minimum of 25% — 250 kW — and efficiency from 32% to 37%. These increases in the C200 engine output were imperative to meet the power requirements of the engine when both spools were integrated. An additional benefit of designing and testing the C370 low pressure spool was the possibility of developing a stand-alone product for possible commercialization. The low pressure spool design activity focused on an aeropath derivative of the current C200 engine. The aeropath derivative included changes to the compressor section —compressor and inducer — and to the turbine nozzle. The increased power also necessitated a larger, more powerful generator and generator controller to support the increased power requirements. These two major design changes were completed by utilizing both advanced 3D modeling and computational fluid dynamics modelling. After design, modeling, and analysis, the decision was made to acquire and integrate the components for testing. The second task of Phase I was to integrate and test the components of the low pressure spool to validate power and efficiency. Acquisition of the components for the low pressure spool was completed utilizing Capstone’s current supplier base. Utilization of Capstone’s supply base for integration of the test article would allow — if the decision was made —expedited commercialization of the product. After integration of the engine components, the engine was tested and evaluated for performance and emissions. Test data analysis confirmed that the engine met all power and efficiency requirements and did so while maintaining CARB level emissions. The emissions were met without the use of any post processing or catalyst. After testing was completed, the DOE authorized — via a milestone review — proceeding to Phase II: the development of the integrated C370 engine. The C370 high pressure spool design activity required significant changes to the C65 engine architecture. The engine required a high power density generator, completely redesigned compressor stage, turbine section, recuperator, controls architecture, and intercooler stage asThe two most critical design challenges were the turbine section (the nozzle and turbine) and the controls architecture. The design and analysis of all of the components was completed and integrated into a system model. The system model — after numerous iterations — indicated that, once integrated, the engine will meet or exceed all system requirements. Unfortunately, the turbine section’s life requirements remain a technical challenge and will require continued refinement of the bi-metallic turbine wheel design and manufacturing approach to meet the life requirement at theses high temperatures. The current controls architecture requires substantial effort to develop a system capable of handling the high-speed, near real-time controls requirement, but it was determined not to be a technical roadblock for the project. The C370 Program has been a significant effort with state-of-the-art technical targets. The targets have pushed Capstone’s designers to the limits of current technology. The program has been fortunate to see many successes: the successful testing of the low pressure spool (C250), the development of new material processes, and the implementation of new design practices. The technology and practices learned during the program will be utilized in Capstone’s current product lines and future products. The C370 Program has been a resounding success on many fronts for the DOE and for Capstone.

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