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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Technology Maturation of Wireless Harsh Environment Sensors For Improved Condition Based Monitoring Of Coal Fired Power Generation

The overall goal of this project was to demonstrate and develop the usage of high-temperature (HT) harsh-environment (HE) wireless surface acoustic wave resonator (SAWR) sensor technology to promote reliable maintenance through condition-based maintenance (CBM) for field applications in harsh service conditions associated with power plant environments. The project aimed to advance the HT HE wireless SAWR sensor technology from TRL 5 to TRL 7. In addition to HT HE wireless temperature sensing, efforts were dedicated during this project to investigate, develop and increase the TRL from 3 to 5 for the following technologies: (a) HT HE strain sensors to address additional CBM monitoring needs, such as boiler tube mechanical / thermal stresses, which can provide early indications for boiler tube cracking and failure; and (b) HT aluminum nitride (AlN) and scandium aluminum nitride (ScAlN) based piezoelectric thin film fabrication and implementation of SAW sensors, with the goal of releasing the need to use single crystal piezoelectric materials for SAWRs and thus broaden possible technology applications to non-planar and harder to modify surfaces. To achieve the goals mentioned above, UMaine and its partner, Environetix Technologies Corporation, established partnerships with the following power plants: Longview Power (Maidsville, WV), a coal-fired power plant; Penobscot Energy Recovery Corp (PERC, Orrington, ME), a waste-to-energy power plant; and the UMaine Steam Plant (Orono, ME), an oil / natural gas power plant. To realize wireless HT HE SAWR sensor systems in these harsh service conditions, the University of Maine research team worked with Environetix and these power plants to define, design, fabricate, test and validate a mature prototype wireless temperature SAWR sensor system for boiler tube applications within the HT HE of the reheater pass damper chamber to directly and wirelessly monitor the temperature at eighteen independent boiler tube locations. The system included three levels, or “tiers”, of wireless communication to enable remote monitoring: Tier 1, the wireless link in the reheater pass damper chamber directly accessing the sensors on the boilers; Tier 2, the wireless local area network link, transmitting processed sensor information within the power plant to the Tier 3, a commercial wireless signal carrier company for secure remote data monitoring outside of the power plant. Regarding the wireless sensor system installed at Longview Power, temperature information from the boilers was continuously transmitted from the Longview boilers at Maidsville, WV, to Environetix headquarters, Orono, ME, over a 34 month period, when the system was finally decommissioned. Strain sensors and piezoelectric ScAlN thin film sensors were successfully installed on the exhaust duct at the UMaine Steam Power plant. The advances in wireless strain sensors and thin film piezoelectric film fabrication and testing were performed mostly in UMaine laboratories and field tested at the UMaine Steam Plant, due to its close proximity to UMaine/Environetix, access to the plant facility, and due to difficulties in accessing the other power plants during the COVID shut-down period. The project accomplished the TRL level increase of the targeted CBM technologies through the successful fabrication, installation, test, and validation of dedicated and commercial wireless sensor systems, utilizing the three different power plants. The outcomes of this project, including the wireless sensor data capability, are expected to yield an advance for CBM in harsh power plant environments. The reduction of maintenance costs, improved safety during plant operation, and increased power plant efficiency will lead to increased revenues (i.e., fewer forced outages) due to better process monitoring enabled by the wireless HT HE SAWR temperature sensor technology.

20 FOSSIL-FUELED POWER PLANTS↗
NASA NTRS1978

Direct firing of coal for power production

The use of new technology and advanced emission control hardware to reduce emissions from the direct combustion of coal to produce electricity in California is considered. The technical feasibilty of a demonstration project on an existing 81-MW boiler is demonstrated.

Papay, L. T.↗
DOE OSTI2022

Mitigation of Aerosol Impacts of Ash Deposition and Emissions from Coal Combustion (Final Technical Report)

This project was selected under FOA-0001989 Area of Interest (AOI) 2 – Power Plant Component Improvement. The objective of this AOI was to test and validate technologies and methodologies that can improve the efficiency, reliability, and/or flexibility of individual power plant components in existing plants. The aerosol mitigation technology comprises injection of sorbent into the boiler through injection lances using a positive-pressure blower. The injected sorbent interacts with flame-vaporized aerosolforming components produced during combustion reducing the abundance of sub-micrometer (< 1 micron) particles and fireside ash deposits in the boiler. The primary objective of this project was to validate a sorbent-based technology for mitigating fireside heat transfer surface fouling-related challenges in a full-scale coal-fired power generation facility, thereby, improving plant performance and reliability.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

Wireless Patch Antenna Characterization for Live Health Monitoring Using Machine Learning

Temperature monitoring in extreme environments, such as coal-fired power plants, was addressed by designing and testing wireless patch antennas for use in machine learning-aided temperature estimation. The sensors were designed to monitor the temperature and health of boiler systems. Wireless interrogation of the sensor was performed using a Vector Network Analyzer (VNA) and a pair of interrogation antennas to capture resonance behavior under varying thermal and spatial conditions with sensitivities ranging from 0.052 to 0.20 $\frac{𝑀𝐻𝑧}{°C}$. Sensor calibration was conducted using a Long Short-Term Memory (LSTM) model, which leveraged temporal patterns to account for hysteresis effects. The calibration method demonstrated improved performance when combined with an LSTM model, achieving up to a 76% improvement in temperature estimation error when compared with Linear Regression (LR). The experiments highlighted an innovative solution for patch antenna-based non-contact temperature measurement, which addresses limitations with conventional methods such as RFID-based systems, infrared, and thermocouples.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2023

Process Design and Techno-Economic Analysis of the Modular Staged Pressurized Oxy-Combustion (SPOC) Power Plant for Biomass

This work describes the process design and techno-economic analysis (TEA) of the modular stage pressurized oxy-combustion (SPOC) power plant for biomass firing and coal-biomass co-firing. The SPOC process was modelled using Aspen Plus®, and largely based on a previous model designed by this group for SPOC coal firing. To enable comparison with current National Energy Technology Laboratory (NETL) Bio-Energy Carbon Capture and Storage (BECCS) studies, a 550 MWe SPOC power plant with a supercritical Rankine cycle (241 bar, 593°C, and 593°C), and 90% carbon capture was modeled, and hybrid poplar biomass was chosen. Two cases were evaluated, namely 100% biomass (carbon negative) and 25% biomass co-firing (carbon neutral), and the 100% Powder River Basin coal firing case was chosen for comparison purposes. In the SPOC process, oxygen is produced via a cryogenic air separation unit (ASU) and the heat generated from the compression of air is integrated into the steam cycle and utilized for boiler feed water regeneration. Unique to the SPOC process, the boilers are arranged in a series-parallel configuration, with minimized flue gas recirculation. The flue gas is cooled and scrubbed in the direct-contact cooler (DCC) column, and the water leaving the bottom of the DCC is at a sufficiently high temperature that it can be used for boiler feed water heating, improving plant thermal efficiency. The SPOC efficiencies were above the BECCS cases with capture, and no efficiency penalty on the SPOC plant was observed with an increase of biomass in the mix mostly due to the higher oxygen content in biomass that resulted in lower oxygen requirement from the ASU, and the higher moisture in biomass that due to the key benefit of the SPOC process can be partially recovered as latent heat.

Magalhaes, Duarte↗
NASA NTRS1976

Energy Conversion Alternatives Study (ECAS), Westinghouse phase 1. Volume 5: Combined gas-steam turbine cycles

The energy conversion efficiency of gas-steam turbine cycles was investigated for selected combined cycle power plants. Results indicate that it is possible for combined cycle gas-steam turbine power plants to have efficiencies several point higher than conventional steam plants. Induction of low pressure steam into the steam turbine is shown to improve the plant efficiency. Post firing of the boiler of a high temperature combined cycle plant is found to increase net power but to worsen efficiency. A gas turbine pressure ratio of 12 to 1 was found to be close to optimum at all gas turbine inlet temperatures that were studied. The coal using combined cycle plant with an integrated low-Btu gasifier was calculated to have a plant efficiency of 43.6%, a capitalization of $497/kW, and a cost of electricity of 6.75 mills/MJ (24.3 mills/kwh). This combined cycle plant should be considered for base load power generation.

Amos, D. J.↗
NASA NTRS1981

Magnetohydrodynamics (MHD) Engineering Test Facility (ETF) 200 MWe power plant. Conceptual Design Engineering Report (CDER). Volume 2: Engineering. Volume 3: Costs and schedules

Engineering design details for the principal systems, system operating modes, site facilities, and structures of an engineering test facility (ETF) of a 200 MWE power plant are presented. The ETF resembles a coal-fired steam power plant in many ways. It is analogous to a conventional plant which has had the coal combustor replaced with the MHD power train. Most of the ETF components are conventional. They can, however, be sized or configured differently or perform additional functions from those in a conventional coal power plant. The boiler not only generates steam, but also performs the functions of heating the MHD oxidant, recovering seed, and controlling emissions.

Source record↗
DOE OSTI2024

Advanced Coating Compositions and Microstructures to Improve Uptime and Operational Flexibility in Cyclic, Low-Load Thermal Utility Plants

GE, the University of Tennessee, and Oak Ridge National Laboratory collaborated from 2020 to 2023 developing two key technologies for improving the viability of fuel switching and load following in thermal utility plants: a) cost-effective weld overlay compositions for boiler tubing b) cathodic arc coatings that deliver improvements in both erosion resistance and oxidation resistance in high temperature steam for HP turbine blades The team worked through a robust, logical project map to de-risk these two technologies and advance them from TRL 3 to TRL 6. For the cost-effective weld overlay, the team developed a ferritic filler material which was fabricated at a vendor for 18% the average market cost of Inconel 625 wire, had a corrosion rate 3x lower in conditions simulating a biomass-fired superheater and 10x lower in conditions simulating a coal-fired superheater, and was fabricated into prototype overlaid tubing that passed ASME requirements including transverse bending, dye penetrant inspection, and ASTM G-76 evaluation. For the cathodic arc coatings applied to steam turbine blades, the team developed a novel composition that was successfully transferred to a qualified vendor. The vendor was able to produce coated prototypes with 4x the as-deposited erosion resistance and 10.4x the post-steam-exposure erosion resistance of the TiN coating the vendor currently applies on GE steam turbine components, without significantly increasing process cost. These coated prototypes also passed a GE inspection and showed favorable performance in high temperature erosion, nanoindentation, sliding wear, scratch adhesion, and high cycle fatigue testing. If successfully deployed by GE, it is anticipated that the technologies will enable the following: • 25%-50% increase in time between outages for both boilers and HP turbines. • 50% decrease in cost for weld overlay on a per foot basis relative to todays NiCr alloys. • Adequate oxidation resistance and erosion for HP turbine inlet steam at >620°C and >220 bar. • No need for changes in component supply chain or any notable Capital Expenditures. 5 Decreasing component cost, increasing performance, and extending time between outages represent direct value propositions to GE and their customers. For the American consumer, these objectives translate into increased grid reliability (fewer unexpected outages), decreased Levelized Cost of Electricity, and improved environmental health (low-loading/load following to accelerate penetration of renewables). The results also have implications for wear resistant tooling, wire arc additive manufacturing, more durable components for syngas cleanup, and deployment of more efficient thermochemical pathways for carbon negative fuel production

09 BIOMASS FUELS↗
NASA NTRS1980

Thermal energy storage and transport

The extraction of thermal energy from large LWR and coal fired plants for long distance transport to industrial and residential/commercial users is analyzed. Transport of thermal energy as high temperature water is shown to be considerably cheaper than transport as steam, hot oil, or molten salt over a wide temperature range. The delivered heat is competitive with user-generated heat from oil, coal, or electrode boilers at distances well over 50 km when the pipeline operates at high capacity factor. Results indicate that thermal energy storage makes meeting of even very low capacity factor heat demands economic and feasible and gives the utility flexibility to meet coincident electricity and heat demands effectively.

Hausz, W.↗
DOE OSTI2022

Improving Unit Flexibility Utilizing Plasma Ignitors

Coal fired steam generation operators face increasing market challenges, including competition from low cost generation, renewables, and regulatory pressure. These market conditions are forcing utilities to operate their coal assets in a more flexible mode, including more frequent starts and stops, faster ramp rates, frequent cycling, and extended operation at the lowest possible loads. Without upgrades to firing and control systems, pressure parts, and auxiliary systems, CAPEX and OPEX costs will increase significantly. Typically, expensive support fuels (Oil or Gas) are required to maintain safe, stable coal ignition when operating below 25% to 35% MCR (Maximum Continuous Rating). The exact minimum load without support fuel differs depending upon unit design specifications and fuel being burned. Frequent starts also increase the use of support fuels. The firing and burner control systems must be designed to allow for proper operation over the unit’s load range, ensuring that all mechanical components operate properly, and proper control of air and fuel streams can be maintained. To address the need for frequent starts and the need for stable low load operation on coal fired steam generators, this paper discusses options available, including, Firing Systems upgrades, Digital solutions, and pressure part upgrades. Several case studies are included that highlight options available allowing units to stay in operation and reduce CAPEX and OPEX costs.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Report on High-Fidelity Dynamic Modeling of a Coal-Fired Steam Power Plant

As a result of the growth of renewables including solar and wind energy with fluctuating production, fossil fuel power plants are being required to cycle between high and low power production. This cycling is both at a greater frequency and over a wider range than in the past. In many cases, power plants are not designed for this type of cycling operation but can nonetheless endure these challenging operation requirements under the right conditions. In this project, optimal solution for enhanced flexible operations are being investigated using model based estimation and control techniques. To support the development of model-based estimator and model-based controls at GE Global Research, GE Steam Power configured a dynamic model using a reference steam plant design including the boiler, turbine, and water/steam conditioning systems as well as the controls needed for plant cycling with stability and reliability. The dynamic model was built using the APROS® software from VTT, and then calibrated to multiple load conditions from full load (100%TMCR) to partial loads (75%TMCR, 50%TMCR and 25%TMCR) based on internally developed steady state heat balance models at the unit level. These internal heat balance models are based on first principles and extensive engineering experiences from GE Steam Power as an OEM and a services provider. This topical report presents the structure of the unit level dynamic model, the tuning process, and representative simulation results from typical load cycling simulations using the dynamic model.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2020

Optimization of energy requirements for CO 2 post-combustion capture process through advanced thermal integration

The energy optimization modeling work described here was performed to determine efficiency improvements that could be achieved for existing coal-fired power plants to retrofit a partial CO 2 capture from the post-combustion flue gas for carbon sequestration through thermal integration. The work presented includes optimization of the mono-ethanol amine (MEA)-based post-combustion CO 2 capture to reduce energy requirements that could be achieved at existing power plants by thermal integration of the steam turbine cycle, boiler, CO 2 compression train and post-combustion CO 2 capture process to offset efficiency and capacity losses that would be incurred by retrofit or implementation of post-combustion CO 2 capture. Furthermore, partial CO 2 capture, involving treatment of less than 100% of the flue gas leaving the plant and modular design of the CO 2 scrubbing system, was also investigated. Thermal integration of the steam turbine cycle with boiler and CO 2 compression train improved cycle and plant performance and offset, in part, the negative effects of post-combustion CO 2 capture. The best-analyzed integration options improved gross power output by 5% and net unit efficiency by 1.57%, relative to the conventional MEA process. Operating with 40% CO 2 capture increased gross power output by 11.6–14% (depending on the MEA thermal integration option), relative to the conventional MEA integration and 90% CO 2 capture. The improvement in net unit performance is larger compared to the improvement in turbine cycle performance because of the CO 2 compression work, which is also reduced by partial CO 2 capture.

42 ENGINEERING↗
DOE OSTI2024

Development of Self-Assembly Supports Enabling Transformational Membrane Performance for Cost-Effective Carbon Capture

This final technical report describes work conducted by Membrane Technology and Research, Inc. (MTR) for the U.S. Department of Energy (DOE), National Energy Technology Lab (NETL) on the development of membranes with transformational performance for carbon capture under award number DE-FE0031596. The work was performed from June 1, 2018 through May 31, 2024. For more than a decade, MTR has worked in partnership with DOE to develop an innovative membrane-based CO 2 capture process. This effort has included the first test of membrane modules with coal-fired flue gas at the Arizona Public Services (APS) Cholla plant in 2010; the accumulation of >11,000 hours of flue gas operation for Polaris modules on a bench-scale 1 tonne/day (TPD) system at the National Carbon Capture Center (NCCC); scale-up of first-generation (Gen-1) Polaris to a 20 TPD small pilot system, and successful operation of this system on a flue gas slipstream at NCCC and in integrated boiler testing at Babcock & Wilcox (B&W). Through continued development efforts, a second-generation (Gen-2) version of the Polaris membrane has been scaled-up to pilot production. This membrane offers 70% higher CO 2 permeance with similar selectivity to the base case Polaris. MTR also developed planar modules designed specifically for the low-pressure, high-volumetric flow rate process conditions of flue gas operation. These new modules have significantly lower pressure-drop values compared to the type originally used (spiral-wound modules), which results in significant energy savings. The goal of the work described in this report was to improve on the Polaris Gen-2 membrane with the ultimate aim to reduce the cost of carbon capture. The majority of the effort was to develop improved support membranes for the multi-layer composite structure of MTR’s Polaris membrane. Earlier work at MTR had identified the support structure as limiting membrane permeances, not because the support itself represents a permeation resistance, but because the distribution of pores at the surface of the support imposes a geometric restriction to diffusion in the layers above it. Support membranes were prepared from a range of polymers, including commercially available block copolymers and a custom synthesized block copolymer alternative. The best support membranes developed in this project reduced the geometric restriction by a factor of two to three. These supports then were used to produce Polaris composite membranes with improved permeances. The second topic was to create a high-selectivity version of the Polaris membrane. The high-selectivity version uses a novel selective polymeric material and high selectivities were confirmed in experiments at MTR. The material is not easily made into very thin films. Consequently, the permeances are significantly lower than the Polaris Gen-2 membrane. The utility of this membrane is therefore limited to the carbon dioxide purification step that produces liquid CO 2 . A Technical and Economic Analysis (TEA) was performed for a carbon capture system that uses both advanced membrane types. The TEA shows the novel advanced membranes reduce the cost of capture by 10%, from $63.32/tonne CO 2 to $56.90/tonne CO 2 (2022 USD). Most of the development work was carried out with laboratory-scale casting and coating equipment. A number, but not all, of the improvements identified have been implemented on commercial-scale manufacturing equipment. The focus of future work at MTR is to incorporate the advancements made into the Polaris membrane manufacturing process.

01 COAL, LIGNITE, AND PEAT↗
NASA NTRS1978

Assessment of industrial applications for fuel cell cogeneration systems

The fuel cell energy systems are designed with and without a utility connection for emergency back-up power. Sale of electricity to the utility during periods of low plant demand is not considered. For each of the three industrial applications, conceptual designs were also developed for conventional utility systems relying on purchased electric power and fossil-fired boilers for steam/hot water. The capital investment for each energy system is estimated. Annual operating costs are also determined for each system. These cost estimates are converted to levelized annual costs by applying appropriate economic factors. The breakeven electricity price that would make fuel cell systems competitive with the conventional systems is plotted as a function of naphtha price. The sensitivity of the breakeven point to capital investment and coal price is also evaluated.

Stickles, R. P.↗
NASA NTRS1980

Effect of off-design operation of MHD generators on NO/x/ chemical kinetics

The purpose of this study is to provide a capability for determining the chemical kinetic behavior of one family of pollutants, the nitrogen oxides, in the flow of a coal-fired MHD generator facility. The method used in the study allows the prediction of the nonequilibrium concentration of the minor NO(x) species in a flow otherwise assumed in equilibrium. Consideration is given to the effect of preheat, stoichiometry, and oxygen enrichment of the NO(x) concentration. The effect of preheat and stoichiometry is found to have a significant influence on the NO(x) concentration at the exit of the radiant boiler.

Simmons, G. A.↗
NASA NTRS1978

Economic considerations in coverting from oil/gas firing to coal

Economic considerations involved in fuel conversion such as from oil and/or gas firing to coal are discussed including investments costs for new facilities and equipment (including air pollution control equipment), operation and maintenance costs, and purchased fuel costs. An analytical approach to assessing the cost effectiveness of fuel conversion in terms of the annual net cost of conversion, the equivalent annual number of barrels of oil saved, and the integral rate of return of the conversion investment is presented. Illustrative numerical examples are presented for typical utility boilers and industrial boiler facilities. A further consideration addressed deals with the impacts of these costs on the overall financial structure of the firm and the ability of the firm to raise the necessary investment captial.

Rau, J. G.↗
DOE OSTI2020

Long term predictions of coal fired power plant data using evolved recurrent neural networks

Abstract This work presents an investigation into the ability of recurrent neural networks (RNNs) to provide long term predictions of time series data generated by coal fired power plants. While there are numerous studies which have used artificial neural networks (ANNs) to predict coal plant parameters, to the authors’ knowledge these have almost entirely been restricted to predicting values at the next time step, and not farther into the future. Using a novel neuro-evolution strategy called Evolutionary eXploration of Augmenting Memory Models (EXAMM), we evolved RNNs with advanced memory cells to predict per-minute plant parameters and per-hour boiler parameters up to 8 hours into the future. These data sets were challenging prediction tasks as they involve spiking behavior in the parameters being predicted. While the evolved RNNs were able to successfully predict the spikes in the hourly data they did not perform very well in accurately predicting their severity. The per-minute data proved even more challenging as medium range predictions miscalculated the beginning and ending of spikes, and longer range predictions reverted to long term trends and ignored the spikes entirely. We hope this initial study will motivate further study into this highly challenging prediction problem. The use of fuel properties data generated by a new Coal Tracker Optimization (CTO) program was also investigated and this work shows that their use improved predictive ability of the evolved RNNs.

Automation & Control Systems↗
NASA NTRS1977

Symposium on Combustion /International/, 16th, Massachusetts Institute of Technology, Cambridge, Mass., August 15-20, 1976, Proceedings

Aspects of combustion technology in power systems are considered, taking into account a combustion in large boilers, the control of over-all thermal efficiency of combustion heating systems, a comparison of mathematical models of the radiative behavior of a large-scale experimental furnace, a concentric multiannular swirl burner, and the effects of water introduction on diesel engine combustion and emissions. Attention is also given to combustion and related processes in energy production from coal, spray and droplet combustion, soot formation and growth, the kinetics of elementary reactions, flame structure and chemistry, propellant ignition and combustion, fire and explosion research, mathematical modeling, high output combustion systems, turbulent flames and combustion, and ignition, optical, and electrical properties.

Source record↗