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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 OSTI2024

Numerical Investigation of High Delta T Sensible Storage Integrated CO2 Heat Pump: Preprint

To assist building heating electrification, this paper numerically investigates a load flexible heat pump system for commercial buildings. The system consists of a CO2 vapor compression cycle, a sensible thermal storage tank, and an air handling unit. The thermal storage medium is inexpensive, non-toxic and stable anti-freeze solution (30% potassium acetate). The air handing unit has an indoor coil and a ventilation coil. The system can be used to manage building electric load. During peak hours, the heat pump is off and the hot solution water is discharged from the tank to heat up the indoor air and ventilation air. During the hour of charge, the heat pump delivers hot solution water to the tank and to the air. The tank can also stand by while the heat pump provides space heating directly. We selected a medium sized office building located in Minnesota as the representative building and used EnergyPlus to obtain its 24 hour load data. We designed three storage tank volumes assuming 50 degrees C, 65 degrees C and 80 degrees C tank temperatures to independently provide the building load for 4 hours in the morning. The higher the tank temperature, the smaller the required volume, and thus higher energy density. The effective energy density is 78 with an 80 degrees C tank, and 40 kWhth/m3 with 50 degrees C. We simulated the tank integrated heat pump performance subjected to the 24-hour building load profile and ambient data. The baseline is the same system without storage tank. There was a trade-off between the storage energy density and the charging COP. The charge hour COP was 2.77 to charge the tank to 80 degrees C, and 3.01 to 50 degrees C. The proposed system could shift building load from the peak hours (8:00 - 12:00) to off-business hour (23:00 - 7:00+1). It eliminated 100% compressor electricity use during the peak hours, and avoided a peak electric power of 34 kW. The 65 degrees C tank saved 9.5 kWhe (4%) considering all day operation, which was the best balance between energy density and the system operation efficiency among the three options.

CO2 heat pump↗
DOE OSTI2023

Compatibility of Wrought Superalloys with Supercritical CO2

Supercritical CO2 (sCO2) power cycles, particularly direct-fired cycles, have the possibility of revolutionizing clean fossil energy with peak temperatures above 700 °C and wrought precipitation strengthened alloys like Haynes 282™ for structural components. At temperatures <650 °C, it would be desirable to use less expensive alloys, however, steels are known to be susceptible to carburization. Laboratory 300 bar sCO2 autoclave results were collected on a range of alloys including less expensive Ni-based alloys like 825 compared to advanced austenitic steels like alloy 709 at 600 °C. Both alloys 825 and 709 formed thin, protective Cr-rich oxides after 1,000 h. Alloy 825 also was exposed for 1,000 h in sCO2 at 800 °C and compared to a range of Ni-based alloys. Comparing alloys 625, 825, and 282, the mass gain increased with increasing alloy Ti content under these conditions. High Al superalloys did not perform significantly better under these conditions at 800 °C.

Pint, Bruce↗
DOE OSTI2023

Manufacturing and Hydro Testing of a 10 MWe sCO2 Axial Turbine

Abstract Supercritical CO2 (sCO2) power cycles designed for thermodynamic efficiencies above 50% push component designs into pressure and temperature combinations that approach the limits of American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code and ASME Piping Design Codes with Turbine inlet conditions near 250 bar and 715 °C. These design conditions which limit available materials to high nickel alloys are compounded by the high fluid densities of sCO2 at these conditions which result in very compact machinery at the 10 MWe class which are currently being developed for the DOE supercritical transformational electric power (STEP) program. Design of the STEP Turbine is complete with integrated lessons learned from a previous 1 MWth subscale demonstration of a high temperature 10 MWe Turbine designed under the DOE SunShot Program. Fabrication of the STEP Turbine is nearing completion with all housings and pressure containing components in hand. This paper provides a detailed look at design intentions and limitations for the pressurized sections of the main pressure casing and the fabrication of key turbine components. Additional discussion is provided regarding postfabrication inspection and acceptance of the casing for use after issues with casing welds were identified late in the fabrication process.

Engineering↗
DOE OSTI2022

Creep and Fatigue Characterization of High Strength Alloy Thin Sections in Advanced CO2 Heat Exchangers

The objective of this work was to characterize and model elevated temperature creep and fatigue behavior for thin sheet and foil forms of gamma-prime strengthened alloys in wrought form and as-processed folded and brazed constructions. This work was motivated by the demanding temperature and pressure service conditions of the GEN3 Concentrated Solar Power (CSP) and supercritical CO2 (sCO2) power cycle working fluid. More specifically, the possibility of leveraging the superior creep strength of gamma-prime alloys in folded-fin and brazed-plate heat exchanger constructions. Gamma-prime alloys represent a step-change in raw-material strength over solid-solution strengthened alloys. And the folded-fin and brazed-plate heat exchanger architecture is lightweight and leverages cost-effective material stock forms. The investigation contained two parallel paths. (1) The first is referred to as a fundamental investigation where Oak Ridge National Laboratory conducts uniaxial creep testing on thin sheet and foil in wrought form. This effort aimed to serve as a benchmark against a relatively sparse existing database and a baseline comparison for path number 2. (2) The second path is referred to as the practical investigation where Brayton Energy manufactures plate-fin heat exchangers and performs pressurized creep and fatigue testing. This effort aimed to de-risk heat exchanger manufacturing process for service under sCO2 CSP conditions. A total of 14 uniaxial creep tests were completed using Haynes 282 thin sheet and foil. A variety of heat treatments were specified to coincide with path number 2. Baseline metallography of test samples and creep strength performance are contained. Benchmarks relatively to existing thick-form Haynes 282 are made, as well as to other thin-form Nickel-based superalloys. Description of a wrought-form modeling approach for thin gamma-prime alloys is also discussed. A total of 11 pressurized creep and fatigue tests were completed successfully with Haynes 282 heat exchanger prototypes. Manufacturing processing details, testing details, testing results, and failure analysis are discussed. Additionally, creep modeling techniques to predict failure are discussed, and modeling to support technological-to-market. In conclusion, Haynes 282 foils were demonstrated to yield rupture two-to-three orders of magnitude higher than Haynes 230 foils under similar conditions. And the manufactured heat exchanger prototypes demonstrated strength similar to the wrought constituents. Both of which contribute to elevated performance potential or cost savings in practice. Discussion is included.

14 SOLAR ENERGY↗
DOE OSTI2023

Assessing carbon storage capacity and saturation across six central US grasslands using data–model integration

Abstract. Future global changes will impact carbon (C) fluxes and pools in most terrestrial ecosystems and the feedback of terrestrial carbon cycling to atmospheric CO2. Determining the vulnerability of C in ecosystems to future environmental change is thus vital for targeted land management and policy. The C capacity of an ecosystem is a function of its C inputs (e.g., net primary productivity – NPP) and how long C remains in the system before being respired back to the atmosphere. The proportion of C capacity currently stored by an ecosystem (i.e., its C saturation) provides information about the potential for long-term C pools to be altered by environmental and land management regimes. We estimated C capacity, C saturation, NPP, and ecosystem C residence time in six US grasslands spanning temperature and precipitation gradients by integrating high temporal resolution C pool and flux data with a process-based C model. As expected, NPP across grasslands was strongly correlated with mean annual precipitation (MAP), yet C residence time was not related to MAP or mean annual temperature (MAT). We link soil temperature, soil moisture, and inherent C turnover rates (potentially due to microbial function and tissue quality) as determinants of carbon residence time. Overall, we found that intermediates between extremes in moisture and temperature had low C saturation, indicating that C in these grasslands may trend upwards and be buffered against global change impacts. Hot and dry grasslands had greatest C saturation due to both small C inputs through NPP and high C turnover rates during soil moisture conditions favorable for microbial activity. Additionally, leaching of soil C during monsoon events may lead to C loss. C saturation was also high in tallgrass prairie due to frequent fire that reduced inputs of aboveground plant material. Accordingly, we suggest that both hot, dry ecosystems and those frequently disturbed should be subject to careful land management and policy decisions to prevent losses of C stored in these systems.

58 GEOSCIENCES↗
DOE OSTI2021

Compatibility of Steels in Supercritical CO2 at 450°-650°C

Supercritical CO2 (sCO2) power cycles, particularly direct-fired cycles, have the possibility of revolutionizing clean fossil energy. However, in the lower temperature sections of the cycle, lower cost steels are needed in order to lower the cost of the sCO2 technology. Representative 9 and 12%Cr steels and conventional and advanced austenitic steels are being evaluated at 450-650°C using mass change, bulk carbon (C) content and room temperature tensile properties to determine the maximum use temperatures for both direct- and indirect-fired sCO2 cycles. After 1000 h exposures in research grade (RG) sCO2 at 300 bar and RG sCO2 with 1% O2 and 0.1% H2O additions, the results suggest that increasing the Cr content from 9 to 12% yielded no signficant benefit under these conditions but the higher Cr and Ni contents in S31025 provided better compatibility in RG sCO2 at 650°C but limited benefit at 550°C with impurities. For S31609, the formation of Fe-rich oxide after exposure to RG sCO2 at 650°C resulted in both an increase in the bulk C content and a large drop in room temperature ductility. The evidence suggests thin, protective oxides prevented C ingress in these conditions.

Pint, Bruce↗
DOE OSTI2022

Compatibility Of Steels At 450°-650°C In Supercritical CO2 With O2 And H2O Additions

Direct-fired supercritical CO2 (sCO2) power cycles are being commercialized to revolutionize fossil energy as a low-emission power source. However, the cycle will increase O2 and H2O in the sCO2 and the implications of these additions have not been fully studied, particularly for lower cost steels that are needed in the lower temperature segments of the plant. Representative 9 and 12%Cr ferritic-martensitic (FM) steels and conventional and advanced austenitic steels were evaluated at 450-650°C to determine the maximum use temperatures in sCO2 with 1%O2 and 0.1%H2O at 300 bar. Compared to research grade (low impurity) sCO2 in indirect-fired cycles, the mass gains and scale thickness were not significantly changed for FM steels: both formed thick duplex Fe-rich scales. For stainless steels, higher mass gains were observed in all cases with increased Fe-rich oxide nodule formation. After 1000h at 650°C, the measured bulk C content was high for all of the steels with the addition of impurities suggesting a lower maximum operating temperature for steels. The post-exposure impact of the environment on room temperature tensile properties also will be discussed.

Pint, Bruce↗
DOE OSTI2025

Chemically and Mechanically Recyclable Vitrimers from Carbon Dioxide-Based Polycarbonates

Designing thermoset materials with dynamic crosslinks is an important strategy to mitigate rising global carbon dioxide emission levels. The development of polymers from sustainable feedstocks, with efficient manufacturing methods, for high-value applications, and with circular end-of-use solutions is essential for advancing material technologies. One approach involves exploiting carbon dioxide itself as feedstock to create high performance, sustainable materials, by enchaining 50 mol% CO2 via copolymerization with epoxides to yield polycarbonates. This work describes the synthesis, end-functionalization, and curing of poly(propylene carbonate) (PPC) and poly(cyclohexene carbonate) (PCHC) into beta-hydroxy ester vitrimers. These vitrimers demonstrate the ability to be mechanically reprocessed up to 3 times with retention of the material’s properties through dynamic transesterification exchange reactions. The polycarbonate vitrimers with gel fractions exceeding 90 % exhibit high tensile strength (> 50 MPa) and Young’s modulus (> 2 GPa), achieved by varying repeat unit structure in the polymer backbone from the low Tg PPC to the more rigid high Tg PCHC structures. Owing to an entropically favorable chain back-biting mechanism, the network chains can be cleaved and depolymerized into cyclic small molecules. In the case of PCHC, this process enables repolymerization back to polycarbonates with 69 wt.% CO2 retention through life-cycles. The promising mechanical performance and recyclability of these CO2-based polycarbonate vitrimers indicate their potential for sustainable, high-performance materials, paving the way for future innovations in circular polymer technologies and carbon capture utilization.

36 MATERIALS SCIENCE↗
DOE OSTI2022

sCO2 Primary Power Large-Scale Pilot Plant FEED Summary

Echogen Power Systems and its project partners the Electric Power Research Institute, CDM Smith, Riley Power Inc. (a Babcock Power Inc. company), and the University of Missouri completed the Front-End Engineering Design (FEED) study of a nominal 10 MWe supercritical carbon dioxide (sCO2) large-scale pilot plant based on Recompression Brayton Cycle (RCBC) architecture. The FEED study was completed under Phase II of the U.S. Department of Energy Fossil Fuel Large-Scale Pilots program. The FEED study scope included the preliminary design of the combustion and environmental control systems, the primary heater, the sCO2 power cycle and its associated turbomachinery, and the balance of plant equipment to determine accurate cost and schedule requirements for fabrication and installation of the system at the University of Missouri’s Combined Cooling, Heat, and Power Plant, located in Columbia, Missouri. The RCBC sCO2 cycle presents superior thermodynamic efficiency compared to steam-Rankine cycles and is adaptable to a broad range of heat sources. The risk aversion of the power generation industry requires a successful large-scale pilot plant demonstration to enable financing and deployment of commercial-scale plants. Therefore, successful construction and demonstration of a 10 MWe RCBC sCO2 power plant would empower a transformational step forward for the efficiency of the next generation of utility power plants. This paper provides details on the primary heater, environmental control systems, and sCO2 power cycle design and performance.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Pressure Exchanger for Energy Recovery in a Trans-Critical CO2 Refrigeration System

Trans-critical CO2 vapor compression (VC) refrigeration cycles require a high compression ratio, which is associated with high expansion losses. To recover these expansion losses, a pressure exchange process between the low- and high-pressure sides of the VC cycle is proposed and examined in this study. The proposed pressure exchange system is an open type constant volume process where the high- and low-pressure flows mix inside the system. This prototype is inspired by the pressure exchangers used in reverse-osmosis (RO) desalination systems. In this system, a 2D model was generated and modeled using the computational fluid dynamics (CFD) technique. The numerical model ignored any losses due to leakage or hydraulic friction and the process is considered adiabatic. For the modeling, it was assumed that the inlet conditions for the two pressure exchanger flows are similar to the flow conditions at the evaporator and gas cooler outlets in a VC cycle. Two parameters are examined to test the validity of the system and understand their effect on the performance, including the inlet flow rate represented by the inlet velocity and the process time represented by the speed of rotation. A total of nine cases were simulated and analyzed in this study.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2025

The Design of a Multiphase CO2 Turbine Test Facility

As the energy market continues to evolve with increased renewables, such as solar and wind energy, the need to balance energy demand with its availability has become increasingly more challenging. The country’s aggressive decarbonization goals in the upcoming decades will increase renewable energy market penetration, thus exacerbating the disparity between energy demand and renewable resource availability. Long-duration energy storage technologies, such as pumped thermal energy storage (PTES), are potential solutions to this challenge with high potential round-trip efficiency (RTE), no geological or geographical constraints, and low safety risks. The charge mode of a PTES system operates a heat pump cycle, converting input power to thermal energy in hot and cold reservoirs. Fundamentally, heat pumps are commonly used in daily life, but the operating conditions required by high RTE PTES systems are outside the design experience of these systems. The low-pressure side of the cycle for a supercritical CO2 (sCO2) PTES operates just above the vapor-dome and potentially drives the turbine to expand into the dome, resulting in multiphase operation in the rear stages of the turbine. This paper presents the design of the test facility for an advanced multiphase-tolerant sCO2 turbine for the heat pump of a PTES system. Heat rejection and pressure loss estimations for the multiphase sections of the test loop presented unforeseen challenges.

25 ENERGY STORAGE↗
DOE OSTI2020

Analysis of a Fluidized-Bed Particle/Supercritical-CO2 Heat Exchanger in a Concentrating Solar Power System

Concentrating solar power (CSP) development has focused on increasing the energy conversion efficiency and lowering the capital cost. To improve performance, CSP research is moving to high-temperature and high-efficiency designs. One technology approach is to use inexpensive, high-temperature heat transfer fluids and storage, integrated with a high-efficiency power cycle such as the supercritical carbon dioxide (sCO 2 ) Brayton power cycle. The sCO 2 Brayton power cycle has strong potential to achieve performance targets of 50% thermal-to-electric efficiency and dry cooling at an ambient temperature of up to 40 °C and to reduce the cost of power generation. Solid particles have been proposed as a possible high-temperature heat transfer or storage medium that is inexpensive and stable at high temperatures above 1000 °C. The particle/sCO 2 heat exchanger (HX) provides a connection between the particles and sCO 2 fluid in emerging sCO 2 power cycles. This article presents heat transfer modeling to analyze the particle/sCO 2 HX design and assess design tradeoffs including the HX cost. The heat transfer process was modeled based on a particle/sCO 2 counterflow configuration, and empirical heat transfer correlations for the fluidized bed and sCO 2 were used to calculate heat transfer area and estimate the HX cost. A computational fluid dynamics simulation was applied to characterize particle distribution and fluidization. This article shows a path to achieve the cost and performance objectives for a particle/sCO 2 HX design by using fluidized-bed technology.

14 SOLAR ENERGY↗
DOE OSTI2023

Effect of pressure on high-temperature oxidation of Ni alloys in supercritical CO 2 containing impurities

Direct supercritical CO 2 (sCO 2 ) power cycles require structural materials compatible with hot sCO 2 containing high levels of water and oxygen impurities. Chromia-forming Ni-based superalloys, which are leading candidates at temperatures > 600 °C, have shown good compatibility in pure sCO 2 , however potential impurity effects are not well understood. In this report we exposed several commercial Ni-based alloys to 95%CO 2 -4%H 2 O-(1-3)%O 2 at 750 °C and 0.1 or 20 MPa for 2500 h. Protective chromia scales formed in all cases. Nevertheless, water vapor-assisted oxide volatilization clearly occurred at high pressure. The volatilization rates decreased with time, but still represent a potentially serious compatibility issue in real, high-velocity, sCO 2 systems.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Deciphering the altered conformational states of bifunctional thaumarchaeal crotonyl-CoA hydratase and 3-hydroxypropionyl-CoA dehydratase from Nitrosopumilus maritimus

Abstract The thaumarchaeal 3-hydroxypropionate/4-hydroxybutyrate (3HP/4HB) cycle represents one of the most efficient mechanisms for CO2 fixation discovered to date. Within this cycle, the enzyme encoded by Nmar_1308 from Nitrosopumilus maritimus SCM1 plays a crucial role due to its dual functionality as both a crotonyl-CoA hydratase (CCAH) and a 3-hydroxypropionyl-CoA dehydratase (3HPD). Although the importance of a bifunctional enzyme for lowering the cost of biosynthesis, the details of structural dynamics are still missing. Here, in addition to our cryogenic temperature structures, we determined the first ambient temperature structures of the Nmar_1308 protein by Serial Femtosecond X-ray Crystallography (SFX). The determined structures capture previously unobserved conformational dynamics of the Nmar_1308 protein, providing invaluable information for future synthetic biology applications.

Destan, Ebru (ORCID:0000000231290827)↗