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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Benefits of Dual Fuel Heat Pump Grid-responsive Control: A Model-based Control Optimization Approach Using Building and Equipment Co-simulation

Conventional dual fuel heat pumps lack the intelligent control mechanisms to efficiently manage the switch between heat pump and furnace, leading to sub-optimal energy usage and, in some cases, increased operating costs. To resolve this gap, this study applies optimized control on hybrid heat pumps. With a focus on equipment control strategies, we compare the performances of five spacing heating equipment, including a conventional heat pump (HP), a conventional furnace, a dual fuel heat pump (DFHP) with conventional control, a dual fuel heat pump with smart control, and a novel seamlessly fuel flexible heat pump (SFFHP). While DFHP runs on either gas or electricity at any given moment, SFFHP concurrently consumes gas and electricity by continuously optimizing the proportion of each. In this research, a co-simulation framework is developed by integrating a building envelope model with a physics-based heat pump simulation model to analyze the benefits of grid-responsive controls of DFHP and SFFHP. The model-based optimal controls adjust the operation of the heat pump and gas furnace based on utility price signals and marginal grid emission to minimize utility cost and CO 2 emissions for multiple climate zones, different utility tariffs, and marginal grid emission scenarios. Case studies in Chicago and Los Angeles demonstrate that SFFHP and DFHP, with model-based optimal control, can deliver significant reductions in peak demand, utility cost, and CO 2 emission. In Chicago, SFFHP and smart controlled DFHP yield up to 64.7% and 61.7% utility cost reduction and up to 15.7% and 8.5% CO 2 emission reduction compared to the gas furnace. In Los Angeles, SFFHP and smart controlled DFHP achieve up to 43.6% and 40.1% utility cost reduction and up to 13.8% and 14.1% CO2 emission reduction compared to conventional heat pumps. In conclusion, by leveraging the fuel flexibility nature of dual fuel heat pumps, the model-based control optimization approach makes dual fuel heat pump an attractive option for demand response programs.

Control↗
DOE OSTI2023

Co-design optimization of combined heat and power-based microgrids

With the emergent need for clean and reliable energy resources, hybrid energy systems, such as the microgrid, are widely adopted in the United States. A microgrid can consist of various distributed energy resources, for instance, combined heat and power (CHP) systems. Here, the CHP module is a distributed cogeneration technology that produces electricity and recaptures heat generated as a by-product. It is an energy-efficient technology converting heat that would otherwise be wasted to valuable thermal energy. For an optimal system configuration, this study develops a novel co-design optimization framework for CHP-based cogeneration microgrids. The framework provides the stakeholder with a method to optimize investments and attain resilient operations. The proposed co-design framework has a mixed integer programming (MIP) model that outputs decisions for both plant designs and operating controls. The microgrid considered in this study contains six components: the CHP, boiler, heat recovery unit, thermal storage system, power storage system, and photovoltaic plant. After solving the MIP model, the optimal design parameters of each component can be found to minimize the total installation cost of all components in the microgrid. Furthermore, the online costs from energy production, operation, maintenance, machine startup, and disruption-induced unsatisfied loads are minimized by solving the optimal control decisions for operations. Case studies based on designing a CHP-based microgrid with empirical data are conducted. Moreover, we consider both nominal and disruptive operational scenarios to validate the performance of the proposed co-design framework in terms of a cost-effective, resilient system.

42 ENGINEERING↗
DOE OSTI2025

Real time heat load calculation software based on EPICS for Fermilab PIP-II CM tests

Fermilab has a project to improve the proton beam energy which is called PIP-II (the 2nd Proton Improvement Plan). There is a superconducting linear accelerator, LINAC, to improve the proton beam power and the LINAC consists of 5 types of cryomodules (CM), 1 HWR CM, 2 SSR1 CM, 4 SSR2 CM, LB650 CM, and HB650 CM. The prototypes of these cryomodules are being tested at Fermilab’s CryoModule Test Facility (CMTF). Heat load measurements are an important part of the prototype CM testing. The CMTF cryogenic control system was developed based on the ACNET (Accelerator Control NETwork) for CM testing for other projects, but the PIP-II cryogenic control system will be implemented using the Experimental Physics and Industrial Control System (EPICS). As part of the prototype CM testing campaign an EPICS based control system has been implemented at CMTF. This EPICS cryogenic control system includes real time heat load calculation software utilizing the Fortran implementation of Hepak. This paper details the real time heat load calculation software developed for the prototype CM testing including the first results from the HB 650 CM.

Yoon, S. [Fermilab]↗
DOE OSTI2026

Real time heat load calculation software based on EPICS for Fermilab PIP-II CM tests

Fermilab has a project to improve the proton beam energy which is called PIP-II (the 2nd Proton Improvement Plan). There is a superconducting linear accelerator, LINAC, to improve the proton beam power and the LINAC consists of 5 types of cryomodules (CM), 1 HWR CM, 2 SSR1 CM, 4 SSR2 CM, LB650 CM, and HB650 CM. The prototypes of these cryomodules are being tested at Fermilab’s CryoModule Test Facility (CMTF). Heat load measurements are an important part of the prototype CM testing. The CMTF cryogenic control system was developed based on the ACNET (Accelerator Control NETwork) for CM testing for other projects, but the PIP-II cryogenic control system will be implemented using the Experimental Physics and Industrial Control System (EPICS). As part of the prototype CM testing campaign, an EPICS based control system has been implemented at CMTF. This EPICS cryogenic control system includes real-time heat load calculation software utilizing the Fortran implementation of Hepak. This paper details the real time heat load calculation software developed for the prototype CM testing including the first results from the HB650 CM.

Yoon, S. [Fermilab]↗
DOE OSTI2023

Preliminary Development of Heat Transfer Model-Based Control Algorithms of Liquid Sodium Purification System: Advanced Sensors and Instrumentation Advanced Controls

Monitoring the operation of sodium purification system is essential for efficient operation of sodium fast reactors. In this work, a heat transfer model has been developed for monitoring the plugging meter and cold trap systems at the Mechanisms Engineering Test Loop (METL) liquid sodium facility at Argonne National Laboratory. The model of the purification system was developed by treating the respective aspects of the cold trap purification loop and plugging meter diagnostic loop as two separate control volumes using information from the METL piping and instrumentation diagram (P&ID). A model predictive controller was designed using first order differential equations with the specified boundary conditions. The system behavior was studied with a tuned optimized procedure using the internal cold trap temperature and plugging meter outlet temperature as control variables, and the air blower temperature as an independent variable respectively. Results of computer simulations obtained in this study compared favorably with experimental data showing very good reference tracking response with negligible overshoot as both plugging meter and cold trap physical models approach the setpoint.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Enhancement of Nanostructured Ferritic Alloy 14YWT Properties via Heat Treatment for Post-Consolidation Processing

The nanostructured ferritic alloy 14YWT is a promising candidate for in-core use in generation IV nuclear reactors, due to a dense dispersion of insoluble, ultrafine-scale Y-Ti-O nano-oxides, which provide a high degree of irradiation tolerance and thermal stability. This work investigates the effects of heat treatment on the workability of 14YWT, along with the effect of processing history on abnormal grain structures and radial microstructural uniformity. In this study, a 14YWT rod consolidated at 850 °C was heat treated in argon at 1100 °C, 1150 °C, 1200 °C, or 1250 °C for 1 or 8 hours and changes in mechanical properties and microstructure were examined using microhardness and electron backscattered diffraction (EBSD). Two distinct types of large abnormal grains were observed, each with unique processing origins, including one with high and the other with low strain energy. Consolidation via direct extrusion resulted in radial microstructural gradients, where the center of the rod was softer with larger grain sizes and lower strain energies. These gradients persisted and intensified throughout heat treatment. Based upon this work, the recommended heat treatment for increased workability with minimal microstructural change is 1150 °C for 1 hours.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Two-color pyrometry based flame to fuel surface radiative heat flux diagnostic using flamelets

In this study, a non-intrusive two-color pyrometry based radiative heat flux diagnostic is presented that accounts for the self-absorption effects. This diagnostic relies on looking up the flame temperature and soot volume fraction using the ratio of color intensities obtained from digital cameras and numerical solutions of 1D steady-state diffusion flames. Virtual two color pyrometry of computed flame show a unique one-to-one mapping of strained flames with intensity ratio; thereby allowing flames to be indexed and creation of a two-color flamelet manifold (TCFM). The TCFM is a function of two variables; the ratio of red to green intensities (flame index) and physical distance to the stoichiometric surface defined using a level-set function. The developed diagnostic is used in upward flame spread experiments where an approximate flame hull reconstruction method is applied to provide the 3D level-set function and intensity ratio for use of TCFM to provide radiative absorption properties for 3D ray tracing. Accounting for self- absorption effects provide improved soot volume fraction estimates. In conclusion, the radiative heat flux estimates are found to be in very good agreement with literature and improved results are obtained near the flame base.

42 ENGINEERING↗
DOE OSTI2024

Novel PCM-based fin and tube heat exchanger system for building heating and cooling applications

In the United States, the building sector accounts for 40% of all energy use, and buildings are responsible for more than two-thirds of electricity consumption. Buildings remain the major driver of energy-related carbon emissions, and such emissions are projected to increase in the years ahead because of urbanization and population growth. To accomplish the low carbon energy goal in the building sector, phase change material (PCM)–based thermal energy storage (TES) is increasingly being adopted because it offers several advantages, such as reducing building peak load and energy consumption, enabling large scale deployment of renewables, and improving grid stability. The integration of TES with thermally anisotropic building envelopes (TABEs) is a promising solution because, TABE can redirect natural thermal energy from a building using hydronic loops to TES, and the stored energy can be used later for heating and cooling applications. In this study, we experimentally investigate the thermal performance of a novel fin-tube heat exchanger TES system designed for potential integration with a TABE. An experimental rig for a 5-gal PCM fin-tube heat exchanger system with water as the heat transfer medium is described which records temperatures at the heated and cooled boundaries of the system. Experimental observations provide insight into the role a TES system can play in offsetting a building’s heating and cooling demand and also offer a means to characterize the performance of PCMs for building applications. The scale and study presented in this work will help in the design of future thermal storage systems optimized for storage capacity while also accounting for overall system costs for building applications.

Tamraparni, Achutha↗
DOE OSTI2020

A method to generate heating and cooling schedules based on data from connected thermostats

Internet-connected thermostats are a promising new source of temperature and operational data in homes because they record inside temperatures, setpoints, and HVAC runtimes every five minutes. Over 20 million Internet-connected thermostats have already been installed in American homes. Data from about 20,000 connected thermostats were collected and organized by climate zone, number of occupants, floor area, and day type. A method was developed to create up to 40 representative temperature schedules which, together, can more accurately capture the diversity of heating and cooling behaviors. These results are suitable for input into schedules for building energy simulation models. This information enables more realistic simulations of American heating and cooling behavior, leading to more accurate estimates of energy consumption and savings.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Model-based real-time surface heat flux and temperature estimation for the DIII-D tokamak

A control-oriented model for monitoring of wall power flux densities on the DIII-D tokamak has been successfully implemented and validated experimentally. Future reactors will have to withstand severe steady state high heat flux loads on plasma-facing components (PFCs). Due to the difficulty of directly-measuring local heat fluxes on these components, monitoring and protection of PFCs during the plasma discharge can benefit from simplified physics-based real-time (RT) functional models to estimate and guide heat load control. As a first step into the development, a control-oriented model for monitoring of wall power flux densities and temperatures on DIII-D tokamak has been successfully implemented. The paper discusses the experimental demonstration and comparison of the 2-D model-based wall heat flux algorithm on the DIII-Dinner wall limiter (IWL) against infra-red camera heat flux measurements for limited plasma configurations. The paper also reports on the benchmarking of the field line tracing environment, SMITER, developed at ITER organization on DIII-D tokamak against experimental IR diagnostic data and the derivation of the component shaping weighting factors for the 2-D model-based approach. Here, the extension of the model-based approach for surface temperature estimation on the DIII-D IWL is also presented.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Development of a silicon carbide ceramic based counter-flow heat exchanger by binder jetting and liquid silicon infiltration for concentrating solar power

A silicon carbide ceramic counter-flow heat exchanger with integrated headers was printed by binder jetting additive manufacturing process. Multiple phenolic binder infiltration cycles (3 or 5) followed by pyrolysis were conducted to increase the net carbon content of the printed SiC specimens. Subsequently, to attain full densification, silicon melt infiltration was used. The microstructure and mechanical properties were comprehensively characterized on the densified material. The chemical compositions and visual distribution of the various regions in the specimens were determined via scanning electron microscopy, while X-ray diffraction and synchrotron µ-computed tomography were used to provide a quantitative assessment of the volume fractions of the identified phase regions. Microhardness measurements showed dependence on the local microstructure. The fracture strength of the material was correlated with the specimen density and agreed with the reported values in the literature. High-temperature exposure at 750 °C for up to 200h did not degrade the strength for the specimens with three phenolic-binder infiltrations; however, the strengths degraded for ones with five phenolic-binder infiltrations. The associated fracture toughnesses of the specimens were ~3.4 MPam 1/2 at room temperature and 750°C, and the thermal conductivities varied from >150 W/mK at room temperature to ~45 W/mK at 750°C. Hence, this study validated the use of the binder-jetting printed SiC ceramic materials for high-temperature heat exchanges. Lastly, we also present in this work the first successful fabrication of a binder-jetting printed one-piece dense SiC ceramic heat exchanger body with unblocked channels that can be used for the flow of heat transfer fluids.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Eliminating the Need for Refrigerants Using New Liquid and Salt-Based Cooling and Heat-Pumping Technology (CRADA Final Report)

Calion Technologies, Inc. project team investigated various embodiments of the ionocaloric cycle. Ionocaloric technology provides a new platform for all heating and cooling that is zero-GWP, non-toxic, non-hazardous, and non-flammable. It is well-poised to replace vapor compression technology which uses high-GWP refrigerants which are on track to account for 25% of our global warming budget. Developing the ionocaloric technology as a drop-in replacement for vapor compression was the primary research thrust under this CRADA.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Heating and Cooling Energy Modeling of 3D-Printed Concrete Construction of Residential Buildings [Slides]

3D printed concrete construction (C3DP) is an emerging technology that comes with the associated benefits of high thermal mass walls. We investigated using BEopt software the heating and cooling energy use of a single story C3DP-constructed house. We then compared the heating/cooling energy use of the C3DP house against the corresponding energy use in a traditional timber (wood) frame construction (WFC), as well as a concrete masonry unit (CMU) construction. Both peak energy use for heating and cooling (Btu), as well as base energy use for both heating and cooling (MMBtu/yr) of the C3DP design were compared against the WFC and CMU baseline construction of identical geometries and orientations across all eight climate zones defined in the International Energy Conservation Code (IECC). The BEopt models for all three constructions (C3DP, WFC, and CMU) were built to comply with the 2018 IECC code. Results indicate that C3DP construction has significant heating and cooling energy benefits in certain climate zones, with the highest peak cooling energy savings (9% compared to WFC, and 5% compared to CMU) in the IECC Climate Zone 1 in the month of July. The peak heating and cooling energy demand reduction of C3DP were found to be more significant than the base heating and cooling energy demand in all IECC climate zones. The 2018 IECC compliance-related U-Factor adjustments of all models also resulted in more peak energy savings of the C3DP design in the cooling-dominated climate zones (climate zones 1 and 2), moderate energy savings in moderate climate zones (climate zones 3, 4, and 6), and little to no change in energy savings in very cold climates (climate zones 7 and 8).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Development of a high-temperature Inconel 625 heat exchanger by model design and binder jetting additive manufacturing

A nickel-based Inconel 625 superalloy heat exchanger for high-temperature applications was developed via binder jetting additive manufacturing. The material properties were characterized first on printed and sintered parts. Two sintering temperatures were used to investigate the effects of the temperature on densification and microstructure. For channel geometry design, the heat transfer capabilities of the heat exchanger were optimized for the cross-section geometry of fluid flow channels in a counterflow configuration, and a stress analysis was conducted to investigate the effects of channel geometry. After headers were incorporated into the heat exchanger as a one-piece component, a prototype was printed. A complete depowdering was achieved via compressed air blowing, and sintering was performed with the developed profile. Ultimately, a one-piece heat exchanger with a nearly full density was obtained. Heat transfer tests were performed on this unit, and the results were compared with those from the simulations. In this study, systematic processes were developed for an additively manufactured Inconel-based heat exchanger for high-pressure, high-temperature heat transfer applications.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Bio-Based Phase Change Materials (PCMs) for Thermal Energy Storage (Final Scientific/Technical Report)

The goal of this project is to develop a novel bio-based phase change material (PCM) derived from squid ring teeth (SRT) proteins, and design a prototype heat exchanger based on these bio-based PCMs for energy storage and dynamic heat exchange for building thermal energy storage systems. The PCMs, derived from SRT proteins, will demonstrate room temperature energy storage capacities and switchable thermal conductivities that redefine the current state-of-the-art (SOA) for building thermal energy storage. Further, in a single material and with a single manufacturing processes, our proposed thermal battery will be developed with “on demand” thermal conductivity for rapid charging/discharging but superior insulation during energy storage periods. More specifically, our bio-based PCMs have demonstrated: 1) the potential for increased energy storage capacity (i.e., greater than paraffines at room temperature); 2) tunability in thermal conductivity with the largest thermal conductivity switching ratios for an intrinsic material reported to date, and 3) a 100% recyclable and biodegradable PCM with low volatility and toxicity and scalability in its manufacture for both residential and commercial applications. The already established ability for roll-to-roll processing of these non-toxic, non-flammable SRT composites along with their carbon-neutral manufacturing processes that has been pioneered by our team make this solution a disruptive and impactful technology to redefine the current SOA of energy storage technologies. The outcomes of this effort have been: 1) the identification of new bio-based PCM that establishes a new SOA for thermal conductivity and energy storage density at room temperature and 2) the development of a new experimental technique to measure the energy storage density via latent heat measurements during melting of thin films. This new technique can be applied to thin films (as thin as < 1 micrometer), and represents a novel approach for thin film energy storage density measurements. Dynamic thermal energy storage is the missing technology that will enable a grid- interactive efficient building (GEB). For a “smart” building capable of connecting with the power grid, the media must be inexpensive and possess thermal switching capabilities to control the time-dependent heat flow into (and out of) the PCM on demand. Unique to the material system in this program, programmable SRT-based PCM show improvements as compared to traditionally used PCMs, and thus its technical performance will represent a leap forward for the future GEB concept.

25 ENERGY STORAGE↗
DOE OSTI2020

A Nonequilibrium Thermodynamic Approach for Surface Energy Balance Closure

Abstract The surface energy imbalance, viz. that the turbulent dissipation does not fully account for available energy, has for long been an outstanding challenge in geophysical studies. In this study, we developed a novel approach based on nonequilibrium thermodynamics by representing the atmospheric boundary layer as a heat engine. In addition, an analytically tractable approach was used to estimate the ground heat flux based on Green's function approach, which in turn determines the available energy that drives the atmospheric heat engine. The proposed model was evaluated using heat fluxes measured by eight AmeriFlux eddy covariance towers with atmospheric temperature profiles recorded at adjacent radiosonde sites. The surface energy balance closure can be improved by ~11% over various landscapes, by including the estimated power production from the atmospheric heat engine.

Li, Peiyuan↗