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DOE OSTI2022

Performance Testing of a Moving-Bed Gasifier Using Coal, Biomass, and Waste Plastic Blends to Generate White Hydrogen

The objective of this DOE-funded project by the Electric Power Research Institute, Inc. (EPRI), Hamilton Maurer International (HMI) and Sotacarbo S.p.A. (Sotacarbo), is to qualify coal, biomass, and plastic waste blends based on performance testing of selected pellet recipes in a pilot-scale updraft moving-bed gasifier. The testing will provide relevant data to advance the commercial-scale design of the moving-bed gasifier to be able to successfully use these feedstocks to produce hydrogen. In particular, the effects of the waste plastics on feedstock development (i.e., blending and pelletizing) and the resulting products (i.e., syngas compositions, organic condensate production, and ash characteristics) are a focus. The gasifier is Hamilton Mauer International, Inc. (HMI)’s moving-bed gasifier, which has been proven capable of gasifying nearly all coal ranks. It has also shown the ability in prior testing work to gasify wood chips. However, mixtures of these fuels with plastic wastes have not been prepared and gasified together. The feedstocks will be prepared by California Pellet Mill (CPM) under contract to HMI. The technical tasks and current status for this two-year research project are: Feed Procurement and Preparation: Nine different feedstocks were prepared from varying compositions of PRB coal, corn stover biomass, and car fluff waste plastics. Fuel pellets were produced by California Pellet Mill and shipped to Sotacarbo’s test facility in Italy. Test Plan Development: A test plan was created to define the test runs to be performed. The test plan detailed the different tests that were run, instrumentation used, extractive samples taken, and relevant figures of merit. Gasifier Testing: Tests are currently being performed in the pilot-scale gasifier at Sotacarbo using nine different fuel feedstocks generated from varying mixtures of coal, biomass, and plastic wastes. The testing will provide information on gasification reaction efficiency/performance, yielding relevant data for models used to scale up the gasifier design. This task will also include work to reassemble the gasifier at Sotacarbo and perform a baseline 100% coal run. Data Analysis and Reporting: Review of the data, determination of figures of merit, and interpretation of the results to be reported. The results will be used to specify the range of feedstock blends that can be successfully gasified as well as quantify gasifier outputs based on specific blends. This paper will be summarize the pelletizing procedure that insures the viability of the tri-fuel pellets for the gasification runs that are being performed at Sotacarbo’s 30mm up draft moving bed gasifier. Initial gasification tests have been conducted, and all the lab scale tri-fuel pellet gasification runs will be completed by the fall of 2022. Performance data will enable modeling of a full-scale HMI industrial scale gasifier supporting both CHP and Hydrogen production.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2022

Performance Testing of a Moving Bed Gasifier Using Coal, Biomass, and Waste Plastic Blends to Generate White Hydrogen

The objective of this DOE-funded project by the Electric Power Research Institute, Inc. (EPRI), Hamilton Maurer International (HMI) and Sotacarbo S.p.A. (Sotacarbo), is to qualify coal, biomass, and plastic waste blends based on performance testing of selected pellet recipes in a pilot-scale updraft moving-bed gasifier. The testing provides relevant data to advance the commercial-scale design of the moving-bed gasifier to be able to successfully use these feedstocks to produce hydrogen. In particular, the effects of the waste plastics on feedstock development (i.e., blending and pelletizing) and the resulting products (i.e., syngas compositions, organic condensate production, and ash characteristics) are a focus. The gasifier is Hamilton Mauer International, Inc. (HMI)’s moving-bed gasifier, which has been proven capable of gasifying nearly all coal ranks. It has also shown the ability in prior testing work to gasify wood chips. However, mixtures of these fuels with plastic wastes had not yet been prepared and gasified together. The feedstocks were prepared by California Pellet Mill (CPM) under contract to HMI. The technical tasks for this research project included: • Feed Procurement and Preparation: Nine different feedstocks were prepared from varying compositions of PRB coal, corn stover biomass, and car fluff waste plastics. Fuel pellets were produced by California Pellet Mill (CPM) and shipped to Sotacarbo’s test facility in Italy. • Test Plan Development: A test plan was created to define the test runs to be performed. The test plan detailed the different tests that were run, instrumentation used, extractive samples taken, and relevant figures of merit. • Gasifier Testing: Tests were performed in the pilot-scale gasifier at Sotacarbo using nine different fuel feedstocks generated from varying mixtures of coal, biomass, and plastic wastes. The testing provides information on gasification reaction efficiency/performance, yielding relevant data for models used to scale up the gasifier design. This task will also included work to reassemble the gasifier at Sotacarbo and perform a baseline 100% coal run. • Data Analysis and Reporting: Review of the data, determination of figures of merit, and interpretation of the results was reported. The results can be used to specify the range of feedstock blends that can be successfully gasified as well as quantify gasifier outputs based on specific blends. The tri-fuel pelletizing conducted at CPM and gasification testing results from Sotacarbo’s 30mm up draft moving bed gasifier are significant. Providing data for an established gasifier to help accelerate its updated design to be able to accommodate feedstocks composed of coal, biomass, and plastic waste. This should ultimately lead to development and commercialization of a lower cost, white hydrogen generation system.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2023

Performance Testing of a Moving-Bed Gasifier Using Coal, Biomass, and Waste Plastic Blends to Generate White Hydrogen

The objective of this DOE-funded project by the Electric Power Research Institute, Inc. (EPRI), Hamilton Maurer International (HMI) and Sotacarbo S.p.A. (Sotacarbo), is to qualify coal, biomass, and plastic waste blends based on performance testing of selected pellet recipes in a pilot-scale updraft moving-bed gasifier. The testing provides relevant data to advance the commercial-scale design of the moving-bed gasifier to be able to successfully use these feedstocks to produce hydrogen. In particular, the effects of the waste plastics on feedstock development (i.e., blending and pelletizing) and the resulting products (i.e., syngas compositions, organic condensate production, and ash characteristics) are a focus. The gasifier is Hamilton Mauer International, Inc. (HMI)’s moving-bed gasifier, which has been proven capable of gasifying nearly all coal ranks. It has also shown the ability in prior testing work to gasify wood chips. However, mixtures of these fuels with plastic wastes had not yet been prepared and gasified together. The feedstocks were prepared by California Pellet Mill (CPM) under contract to HMI. The technical tasks for this research project included: • Feed Procurement and Preparation: Nine different feedstocks were prepared from varying compositions of PRB coal, corn stover biomass, and car fluff waste plastics. Fuel pellets were produced by California Pellet Mill (CPM) and shipped to Sotacarbo’s test facility in Italy. • Test Plan Development: A test plan was created to define the test runs to be performed. The test plan detailed the different tests that were run, instrumentation used, extractive samples taken, and relevant figures of merit. • Gasifier Testing: Tests were performed in the pilot-scale gasifier at Sotacarbo using nine different fuel feedstocks generated from varying mixtures of coal, biomass, and plastic wastes. The testing provides information on gasification reaction efficiency/performance, yielding relevant data for models used to scale up the gasifier design. This task will also included work to reassemble the gasifier at Sotacarbo and perform a baseline 100% coal run. • Data Analysis and Reporting: Review of the data, determination of figures of merit, and interpretation of the results was reported. The results can be used to specify the range of feedstock blends that can be successfully gasified as well as quantify gasifier outputs based on specific blends. The tri-fuel pelletizing conducted at CPM and gasification testing results from Sotacarbo’s 30mm up draft moving bed gasifier are significant. Providing data for an established gasifier to help accelerate its updated design to be able to accommodate feedstocks composed of coal, biomass, and plastic waste. This should ultimately lead to development and commercialization of a lower cost, white hydrogen generation system.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2021

Gasification of Mixed Blends of Coal, Biomass, and Plastic Waste

The objective of this DOE-funded project by the Electric Power Research Institute, Inc. (EPRI), Hamilton Maurer International (HMI) and Sotacarbo S.p.A. (Sotacarbo), is to qualify coal, biomass, and plastic waste blends based on performance testing of selected pellet recipes in a pilot-scale updraft moving-bed gasifier. The testing provides relevant data to advance the commercial-scale design of the moving-bed gasifier to be able to successfully use these feedstocks to produce hydrogen. In particular, the effects of the waste plastics on feedstock development (i.e., blending and pelletizing) and the resulting products (i.e., syngas compositions, organic condensate production, and ash characteristics) are a focus. The gasifier is Hamilton Mauer International, Inc. (HMI)’s moving-bed gasifier, which has been proven capable of gasifying nearly all coal ranks. It has also shown the ability in prior testing work to gasify wood chips. However, mixtures of these fuels with plastic wastes had not yet been prepared and gasified together. The feedstocks were prepared by California Pellet Mill (CPM) under contract to HMI. The technical tasks for this research project included: • Feed Procurement and Preparation: Nine different feedstocks were prepared from varying compositions of PRB coal, corn stover biomass, and car fluff waste plastics. Fuel pellets were produced by California Pellet Mill (CPM) and shipped to Sotacarbo’s test facility in Italy. • Test Plan Development: A test plan was created to define the test runs to be performed. The test plan detailed the different tests that were run, instrumentation used, extractive samples taken, and relevant figures of merit. • Gasifier Testing: Tests were performed in the pilot-scale gasifier at Sotacarbo using nine different fuel feedstocks generated from varying mixtures of coal, biomass, and plastic wastes. The testing provides information on gasification reaction efficiency/performance, yielding relevant data for models used to scale up the gasifier design. This task will also included work to reassemble the gasifier at Sotacarbo and perform a baseline 100% coal run. • Data Analysis and Reporting: Review of the data, determination of figures of merit, and interpretation of the results was reported. The results can be used to specify the range of feedstock blends that can be successfully gasified as well as quantify gasifier outputs based on specific blends. The tri-fuel pelletizing conducted at CPM and gasification testing results from Sotacarbo’s 30mm up draft moving bed gasifier are significant. Providing data for an established gasifier to help accelerate its updated design to be able to accommodate feedstocks composed of coal, biomass, and plastic waste. This should ultimately lead to development and commercialization of a lower cost, white hydrogen generation system.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2025

Advancements in NEAMS Tool Capabilities for Multiphysics Simulation of Fast Reactor Core Bowing and Identification of Validation Test Data

Under the U.S. Department of Energy Office of Nuclear Energy Advanced Modeling and Simulation (NEAMS) Program, an integrated multiphysics approach is being developed to model the core bowing phenomena important to liquid metal-cooled fast reactors. Core bowing is an important passive safety mechanism in liquid metal-cooled fast reactors and involves Multiphysics effects including radiation transport, fluid flow, heat transfer, and mechanical response to temperature and flux gradients. This report summarizes recent progress on developing a multiphysics, MOOSE-based workflow to predict core bowing and associated reactivity feedback. Last year, thermal fluids and mechanics were coupled on a multi-assembly benchmark problem based on ABR-1000 design. This year, the reactor physics code Griffin was assessed for readiness of core bowing calculations. Preliminary integration of Griffin’s ring-heterogeneous model with thermal fluids and thermal mechanics solvers was performed. Specifically, thermal-mechanics and reactor physics were coupled for single- and multi-assembly problems, and reactor physics and subchannel methods were coupled for a single assembly model. Finally, the workflow of all three physics was preliminarily demonstrated on a single assembly model. Caveats and future development needed have been identified. To supplement the multiphysics demonstration, verification and assessment efforts of thermos-mechanical capabilities for modeling thermo-mechanical core bowing behavior were continued by analyzing IAEA Verification Problem 5 which includes radiation swelling and creep. Additionally, a small core reactor physics benchmark defined by Japan Atomic Energy Agency (JAEA) was performed to assess neutronics models for estimating reactivity feedback. Finally, Fast Flux Test Facility (FFTF) validation test data for core bowing phenomena has been identified and summarized, with a recommended path forward for validation once this capability is mature.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1976

Fluid dynamic research at NASA-Ames Research Center related to transonic wind tunnel design and testing techniques

Fluid dynamic research with the objective of developing new and improved technology in both test facility concepts and test techniques is being reported. A summary of efforts and results thus far obtained in four areas is presented. The four area are: (1) the use of heavy gases to obtain high Reynolds numbers at transonic speeds: (2) high Reynolds number tests of the C-141A wing configuration; (3) performance and flow quality of the pilot injector driven wind tunnel; and (4) integration time required to extract accurate static and dynamic data from tests in transonic wind tunnels. Some of the principal conclusions relative to each of the four areas are: (1) Initial attempts to apply analytical corrections to test results using gases with gamma other than 1.4 to simulate conditions in air show promise but need significant improvement; (2) for the C-141A configuration, no Reynolds number less than the full scale flight value provides an accurate simulation of the full scale flow; (3) high ratios of tunnel mass flow rate to injection mass flow rate and high flow quality can be obtained in an injector driven transonic wind tunnel; and (4) integration times of 0.5 to 1.0 sec may be required for static force and pressure tests, respectively, at some transonic test conditions in order to obtain the required data accuracy.

Muhlstein, L., Jr.↗

NASA NTRS1982

Assessment of a 40-kilowatt stirling engine for underground mining applications

An assessment of alternative power souces for underground mining applications was performed. A 40-kW Stirling research engine was tested to evaluate its performance and emission characteristics when operated with helium working gas and diesel fuel. The engine, the test facility, and the test procedures are described. Performance and emission data for the engine operating with helium working gas and diesel fuel are reported and compared with data obtained with hydrogen working gas and unleaded gasoline fuel. Helium diesel test results are compared with the characteristics of current diesel engines and other Stirling engines. External surface temperature data are also presented. Emission and temperature results are compared with the Federal requirements for diesel underground mine engines. The durability potential of Stirling engines is discussed on the basis of the experience gaind during the engine tests.

Cairelli, J. E.↗

NASA NTRS1982

NASA/General Electric broad-specification fuels combustion technology program - Phase I results and status

A program is being conducted to develop the technology required to utilize fuels with broadened properties in aircraft gas turbine engines. The first phase of this program consisted of the experimental evaluation of three different combustor concepts to determine their potential for meeting several specific emissions and performance goals, when operated on broadened property fuels. The three concepts were a single annular combustor; a double annular combustor; and a short single annular combustor with variable geometry. All of these concepts were sized for the General Electric CF6-80 engine. A total of 24 different configurations of these concepts were evaluated in a high pressure test facility, using four test fuels having hydrogen contents between 11.8 and 14%. Fuel effects on combustor performance, durability and emissions, and combustor design features to offset these effects were demonstrated.

Dodds, W. J.↗

NASA NTRS1981

Experimental program for the evaluation of turbofan/turboshaft c conversion technology

A TF34 turbofan engine is being modified to produce shaft power from an output coupling on the fan disk when variable inlet guide vanes are closed to reduce fan airflow. The engine, called a convertible engine, could be used on advanced rotorcraft such as X-wing, ABC (Advanced Blade Concept), and Folding Tilt Rotor, and on V/STOL craft in which two engines are cross-coupled. The engine will be tested on an outdoor static test stand at NASA Lewis Research Center. Steady-state tests will be made to measure performance in turbofan, turboshaft, and combined power output modes. Transient tests will be made to determine the response to the engine and a new digital engine control system for several types of rapid changes in thrust and shaft loads. The paper describes the engine modifications, the test facility equipment, proposed testing techniques for several types of tests, and typical test results predicted from engine performance computer programs.

Mcardle, J. G.↗

NASA NTRS1982

A survey of the three-dimensional high Reynolds number transonic wind tunnel

The facilities for aerodynamic testing of airplane models at transonic speeds and high Reynolds numbers are surveyed. The need for high Reynolds number testing is reviewed, using some experimental results. Some approaches to high Reynolds number testing such as the cryogenic wind tunnel, the induction driven wind tunnel, the Ludwieg tube, the Evans clean tunnel and the hydraulic driven wind tunnel are described. The level of development of high Reynolds number testing facilities in Japan is discussed.

Takashima, K.↗

NASA NTRS1985

Pressure distribution from high Reynolds number tests of a NASA SC(3)-0712(B) airfoil in the Langley 0.3-meter transonic cryogenic tunnel

A wind tunnel investigation of a NASA 12-percent-thick, advanced-technology supercritical airfoil was conducted in the Langley 0.3-Meter Transonic Cryogenic Tunnel (TCT). This investigation represents another in the series of NASA/U.S. industry two-dimensional airfoil studies to be completed in the Advanced Technology Airfoil Tests program. Test temperature was varied from 220 K to 96 K at pressures ranging from 1.2 to 4.3 atm. Mach number was varied from 0.50 to 0.80. This investigation was designed to: (1) test a NASA advanced-technology airfoil from low to flight equivalent Reynolds numbers, (2) provide experience in cryogenic wind-tunnel model design and testing techniques, and (3) demonstrate the suitability of the 0.3-m TCT as an airfoil test facility. All the test objectives were met. The pressure data are presented without analysis in tabulated format and as plots of pressure coefficient versus position on the airfoil. This report was prepared for use in conjunction with the aerodynamic coefficient data published in NASA-TM-86371. Data are included which demonstrate the effects of fixed transition. Also included are remarks on the model design and fabrication.

Johnson, W. G., Jr.↗

NASA NTRS1985

A comparison of experimental and theoretical results for rotordynamic coefficients of four annular gas seals

The test facility and initial test program developed to experimentally measure the fluid forces induced by annular gas seals is described. A comparison of theoretically predicted and experimentally obtained data for smooth and honeycomb seals is provided. And a comparison of experimental data from the tests of three smooth-rotor/smooth-stator seals is provided. The leakage of the working fluid through the seal, the pressure gradient along the seal length, entrance pressure-loss data, and rotordynamic coefficients provide a basis for comparison. A short discussion on seal theory is included, and various rotordynamic coefficient identification schemes are described.

Childs, D. W.↗

NASA NTRS1984

High-temperature gaseous oxygen/hydrogen thrusters for space station

Efforts to determine the critical technologies necessary for the development of a high-temperature GO2/GH2 thruster are reviewed, for space station applications. Two types of thrust chambers are evaluated: one operable at high temperature and the other incorporating regenerative cooling. The high temperature chamber made of rhenium requires minimum cooling of the chamber wall, however, an oxidation barrier should be incorporated to prevent the rhenium thruster from readily oxidizing. The use of rhenium brought about a lower cost, lower weight, and simplicity of fabrication. The igniter-injector, the chamber, the test facility, and the test program are discussed. It is found that an obtained flow split of 58/42 increased the thruster performance from 3893 N-s/Kg to 4030 N-s/Kg for the same chamber pressure and overall mixture ratio. An increase in performance is also observed when the core mixture ratio is lowered. The thruster was tested for 1.9 hrs with no well degradation.

Dowdy, M. W.↗

NASA NTRS1987

Description of an oscillating flow test program

A description of the University of Minnesota Oscillating Flow Test Program is presented. The rationale for isolating the oscillating flow effect for separate study, the objectives of the test program, and the program design criteria are presented along with a description of the test facility and the test plan. The program test domain covers almost the entire operating domain of Stirling engine heat exchangers expressed in terms of the appropriate dimensionless parameters. Phenomena important to Stirling engine performance which are not simulated in the test program are also discussed. Computer analysis results are used to predict apparatus performance.

Seume, J. R.↗

NASA NTRS1986

Debugging tasked Ada programs

The applications for which Ada was developed require distributed implementations of the language and extensive use of tasking facilities. Debugging and testing technology as it applies to parallel features of languages currently falls short of needs. Thus, the development of embedded systems using Ada pose special challenges to the software engineer. Techniques for distributing Ada programs, support for simulating distributed target machines, testing facilities for tasked programs, and debugging support applicable to simulated and to real targets all need to be addressed. A technique is presented for debugging Ada programs that use tasking and it describes a debugger, called AdaTAD, to support the technique. The debugging technique is presented together with the use interface to AdaTAD. The component of AdaTAD that monitors and controls communication among tasks was designed in Ada and is presented through an example with a simple tasked program.

Fainter, R. G.↗

NASA NTRS1990

Exhaust Nozzles for Propulsion Systems with Emphasis on Supersonic Cruise Aircraft

This compendium summarizes the contributions of the NASA-Lewis and its contractors to supersonic exhaust nozzle research from 1963 to 1985. Two major research and technology efforts sponsored this nozzle research work; the U.S. Supersonic Transport (SST) Program and the follow-on Supersonic Cruise Research (SCR) Program. They account for two generations of nozzle technology: the first from 1963 to 1971, and the second from 1971 to 1985. First, the equations used to calculate nozzle thrust are introduced. Then the general types of nozzles are presented, followed by a discussion of those types proposed for supersonic aircraft. Next, the first-generation nozzles designed specifically for the Boeing SST and the second-generation nozzles designed under the SCR program are separately reviewed and then compared. A chapter on throttle-dependent afterbody drag is included, since drag has a major effect on the off-design performance of supersonic nozzles. A chapter on the performance of supersonic dash nozzles follows, since these nozzles have similar design problems, Finally, the nozzle test facilities used at NASA-Lewis during this nozzle research effort are identified and discussed. These facilities include static test stands, a transonic wind tunnel, and a flying testbed aircraft. A concluding section points to the future: a third generation of nozzles designed for a new era of high speed civil transports to produce even greater advances in performance, to meet new noise rules, and to ensure the continuity of over two decades of NASA research.

Stitt, Leonard E.↗

NASA NTRS1990

Evaluation of EDR-3 vibration, shock, temperature, and humidity recording unit

The purpose of this evaluation was to determine if the self-contained, off-the-shelf, Environmental Data Recorder 3 (EDR-3) could be qualified to monitor shock, vibration, and temperature during rail transportation of space shuttle solid rocket components. The evaluation testing started in November 1989 and continued until June 1990. Two EDR-3 units were used to monitor both on- and off-plant shipments of shuttle components. In addition, extensive testing was performed at Thiokol's Vibration Test facility, T-53. Testing demonstrated that the EDR-3 is capable of successfully monitoring actual shipments of solid rocket hardware. Thiokol metrology has verified the accuracy of temperature monitoring. In addition, calibrated shock/vibration testing demonstrated that the EDR-3 does accurately record acceleration. It is recommended that the vendor modify the EDR-3 data recovery system to allow remote communication via a 30-foot cable. This would permit communication with the unit mounted on a case segment after a rail car cover is installed. The vendor will make this change and produce a new model, designated EDR-3-10. It is further recommended that Thiokol qualify the EDR-3-10 for transportation monitoring of redesigned solid rocket motor (RSRM) components.

Rees, Kevin G.↗

NASA NTRS1991

Design, building, and testing of the postlanding systems for the assured crew return vehicle

The design, building, and testing of the postlanding support systems for a water-landing Assured Crew Return Vehicle (ACRV) are presented. One ACRV will be permanently docked to Space Station Freedom, fulfilling NASA's commitment to Assured Crew Return Capability in the event of an accident or illness. The configuration of the ACRV is based on an Apollo Command Module (ACM) derivative. The 1990-1991 effort concentrated on the design, building, and testing of a one-fifth scale model of the egress and stabilization systems. The objective was to determine the feasibility of (1) stabilizing the ACM out of the range of motions that cause seasickness and (2) the safe and rapid removal of a sick or injured crew member from the ACRV. The development of the ACRV postlanding systems model was performed at the University of Central Florida with guidance from the Kennedy Space Center ACRV program managers. Emphasis was placed on four major areas. First was design and construction of a one-fifth scale model of the ACM derivative to accommodate the egress and stabilization systems for testing. Second was the identification of a water test facility suitable for testing the model in all possible configurations. Third was the construction of the rapid egress mechanism designed in the previous academic year for incorporation into the ACRV model. The fourth area was construction and motion response testing of the attitude ring and underwater parachute systems.

Hosterman, Kenneth C.↗