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DOE OSTI2021

Fabricating structured particles through rapid hardening and tailored collection methods

Fabrication of functional polymer-based particles by crosslinking UV-curable polymer drops in mid-air and collecting crosslinked particles in a solid container, a liquid suspension, or an air flow. The particles can contain different phases in the form or layered structures that contain one to multiple cores, or structures that are blended with dissolved or emulsified smaller domains. A curing system produces ultraviolet rays that are directed onto the particles in the jet stream from one side. A reflector positioned on other side of the jet stream reflects the ultraviolet rays back onto the particles in the jet stream.

Ye, Congwang↗

DOE OSTI2023

Fabricating structured particles through rapid hardening and tailored collection methods

Ye, Congwang↗

DOE OSTI2021

An experimentally validated evaporative phase change heat transfer model for low mass flux applications using R134a in plate heat exchangers

Plate frame heat exchangers are common in liquid-coupled vapor compression systems due to their compactness and ease of maintenance. In some of these systems, the refrigerant within the evaporator can enter the heat exchanger as a subcooled liquid. As a result, the refrigerant passes through three different phases: single-phase liquid, two-phase fluid, and a superheated vapor. Unfortunately, there have been limited prior studies that have identified the best method to predict performance under these circumstances. Furthermore, previous investigations have not evaluated refrigerant evaporation in large industrial sized plate frame heat exchangers under conditions experienced in the present study experimental test facility, especially at mass fluxes below 7 kg m –2 s –1 . In the present investigation, a model was developed to predict the performance of plate and frame heat exchangers when the fluid enters as a subcooled liquid and exits as a superheated vapor. The model used full-sized plate heat exchanger geometry that was discretized into 20 sections to accurately capture local heat transfer and pressure drop effects. The model was validated using an R134a counter flow heat exchanger used in a turbo-compression cooling system test facility that had subcooled liquid entering the evaporator at low mass fluxes. A variety of empirical correlations were evaluated to determine what combination yielded the best predictive capability over the following range of conditions: 5.8 < G < 6.8 kg m –2 s –1 , 2 < q” < 2.8 kW m –2 , and 10 °C < T sat < 15 °C. When the correlations used a fixed control volume length in the heat flux calculation, the most accurate combination resulted in a mean absolute error of 5.5%. Finally, future studies can use the approach described here to optimize heat exchanger size and performance.

42 ENGINEERING↗

DOE OSTI2024

New insights into the mechanism of ultrasonic atomization for the production of metal powders in additive manufacturing

Ultrasonic atomization is one of the promising technologies for producing metal powders for additive manufacturing, where precise control of particle size and morphology is essential. In this study, we coupled an ultrasonic transducer with a carbon fiber plate and atomized liquid droplets and films under different vibration amplitudes. Water, glycerol, and pure aluminum melt were used to study the atomization mechanism and the resulting droplet/powder characteristics, respectively. High-speed optical and ultrafast synchrotron X-ray imaging were used to study in situ the ultrasonic atomization dynamics, including pulsation and clustering of cavities inside the liquid layer/films, development of capillary waves, and formation of liquid droplets. For the first time, we observed and captured the occurrence of cavitation during the atomization of resting drops, films and impact droplets. The inertial cavitation events interfered with the capillary waves across the interphase boundary, puncturing and breaking the boundary to produce atomized mist. The in situ observation revealed the intricate dynamics of ultrasonic atomization and underscored the pivotal role of cavitation events throughout the entire atomization process. We also conducted experiments on ultrasonic atomization of liquid aluminum, producing particles of perfectly spherical shape. The particle size tended to decrease with reduced vibration amplitude Our work has demonstrated the important processing strategies on how to tailor the particle size while ensuring consistent particle shape and morphology, which is the key processing capability for producing high quality powders for additive manufacturing applications.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Zero-point motion of liquid and solid hydrogen

We present an inelastic neutron scattering study of liquid and solid hydrogen carried out using the wide Angular Range Chopper Spectrometer at Oak Ridge National Laboratory. From the observed dynamic structure factor, we obtained empirical estimates of the molecular mean-squared displacement and average translational kinetic energy. Here we find that the former quantity increases with temperature, indicating that a combination of thermal and quantum effects is important near the liquid-solid phase transition, contrary to previous measurements. We also find that the kinetic energy drops dramatically on melting of the crystals, a consequence of the large increase in molar volume together with the Heisenberg indeterminacy principle. Our results are compared with quantum Monte Carlo simulations based on different model potentials. In general, there is good agreement between our findings and theoretical predictions based on the Silvera-Goldman and Buck potentials.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2024

Sensitivity of Arctic Clouds to Ice Microphysical Processes in the NorESM2 Climate Model

Abstract Ice formation remains one of the most poorly represented microphysical processes in climate models. While primary ice production (PIP) parameterizations are known to have a large influence on the modeled cloud properties, the representation of secondary ice production (SIP) is incomplete and its corresponding impact is therefore largely unquantified. Furthermore, ice aggregation is another important process for the total cloud ice budget, which also remains largely unconstrained. In this study, we examine the impact of PIP, SIP, and ice aggregation on Arctic clouds, using the Norwegian Earth System Model, version 2 (NorESM2). Simulations with both prognostic and diagnostic PIP show that heterogeneous freezing alone cannot reproduce the observed cloud ice content. The implementation of missing SIP mechanisms (collisional breakup, drop shattering, and sublimation breakup) in NorESM2 improves the modeled ice properties, while improvements in liquid content occur only in simulations with prognostic PIP. However, results are sensitive to the description of collisional breakup. This mechanism, which dominates SIP in the examined conditions, is very sensitive to the treatment of the sublimation correction factor, a poorly constrained parameter that is included in the utilized parameterization. Finally, variations in ice aggregation treatment can also significantly impact cloud properties, mainly through their impact on collisional breakup efficiency. Overall, enhancement in ice production through the addition of SIP mechanisms and the reduction in ice aggregation (in line with radar observations of shallow Arctic clouds) result in enhanced cloud cover and decreased TOA radiation biases, compared to satellite measurements, especially during the cold months. Significance Statement Arctic clouds remain a large source of uncertainty in projections of the future climate due to the poor representation of the microphysical processes that govern their life cycle. Ice formation is among the least understood processes. While it is widely recognized that better constraints on primary ice production (PIP) are needed to improve existing parameterizations, we show that secondary ice production (SIP) and ice aggregation can have also a significant impact on ice number concentrations. Constraining ice formation through the addition of missing SIP mechanisms and reducing ice aggregation can improve the representation of the cloud macrophysical properties and enhance total cloud cover in the Arctic region, which in turn contributes to decreased TOA radiation biases in the cold months.

Meteorology & Atmospheric Sciences↗

DOE OSTI2022

ORGANIC RANKINE CYCLE TURBINE AND HEAT EXCHANGER SIZING FOR LIQUID AIR COMBINED CYCLE

Cryogenic energy storage offers several opportunities to design turbomachinery and other equipment for novel cycles. This paper presents the design and analysis of turbomachinery and heat exchangers for an Organic Rankine Cycle (ORC) subsystem for a hybrid energy storage concept. The Liquid Air Combined Cycle is an energy storage system that stores air at cryogenic conditions at times with high variable renewable energy to be dispatched along with a gas turbine to recover the exhaust heat. In order to re-vaporize the air, the liquid air is coupled with an ORC as an additional bottoming cycle. The ORC turbine is expected to expand the fluid with a pressure ratio of nearly 30 and a flow rate of approximately 45 kg/s. Sizing calculations for both a radial and axial turbine solution were performed over a range of speeds and stages to determine the optimal design point. The results show that either an axial (8- or 9-stage) or radial (four stages at two shaft speeds) turbine are capable of handling the pressure ratios. Further trades of the two configurations would be required to determine the best option. The ORC system also incorporates five heat exchangers to distribute heat, vaporize the liquid air, or recover exhaust heat from the gas turbine. Three heat exchangers were analyzed to understand the size of heat exchangers and pressure drop for the overall system. Different types of heat exchangers were explored for the different purposes, including plate-fin heat exchangers, gasketed plate heat exchangers and shell-in-tube heat exchangers. It was determined that the ORC recuperator, liquid-air vaporizer, and vaporized air pre-heater would be counter-flow heat exchangers using a gasketed plate design. Keywords: Energy Storage, Liquid Air Energy Storage, Organic Rankine Cycle

Pryor, Owen↗

DOE OSTI2020

Direct observation of the momentum distribution and renormalization factor in lithium

We have measured the momentum distribution and renormalization factor $Z_{k_F}$ in liquid and solid lithium by high-resolution Compton scattering. High-resolution data over a wide momentum range exhibit a clear feature of the renormalization and a sharp drop of momentum densities at the Fermi momentum $k_F$. In this work, these results are compared with those computed by quantum Monte Carlo simulation performed both on a disordered crystal and a liquid exhibiting very good agreement. Asymptotic behavior of the experimental and theoretical momentum distributions are examined to estimate $Z_{k_F}$. The experimentally obtained $Z_{k_F} = 0.43^{+0.11}_{–0.01}$ for liquid Li and $0.54^{+0.11}_{–0.02}$ for solid Li are in good agreement with theoretical results of 0.54 ± 0.01 and 0.64 ± 0.01, respectively.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2020

The Role of Ice Splintering on Microphysics of Deep Convective Clouds Forming Under Different Aerosol Conditions: Simulations Using the Model With Spectral Bin Microphysics

Observations during the Ice in Clouds Experiment-Tropical (ICE-T) field experiment show that the ice particles concentration in a developing deep convective clouds at the level of T = -15 °C reached about 500 L -1 , that is, many orders higher than that of ice-nucleating particle. To simulate microphysics of these clouds, the 2-D Hebrew University Cloud model (HUCM) with spectral bin microphysics was used in which two main types of ice multiplication mechanisms were included in addition to the Hallet-Mossop mechanism. In the first ice multiplication mechanism ice splinters form by drop freezing and drop-ice collisions. Ice multiplication of this type dominates during developing stage of cloud evolution, when liquid water content is significant. At later stage when clouds become nearly glaciated, ice crystals are produced largely by ice splintering during ice-ice collisions (the second ice multiplication mechanism). Simulations show that droplet size distributions, as well as size distributions of ice particles, agree well with the measurements during ICE-T. Simulations with different cloud condensation nuclei concentrations show the existence of the “optimum” cloud condensation nuclei concentration (or droplet concentration), at which concentration of ice splinters reaches maximum. In these simulations ice nucleation caused by the direct formation of ice crystals upon ice-nucleating particles, as well as the Hallett-Mossop process, has a negligible contribution to the ice crystal concentration.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

Flow Boiling Pressure Drop Characteristics of Next-generation Refrigerants in a Micro‑fin Copper Tube

This paper presents experimental frictional pressure-drop data for flow boiling of R-410A, R-134a, and next-generation alternatives R-454C, R-455A, R-1234yf, and R-1234ze(E) in a horizontal micro-fin copper tube. Tests were conducted over a range of mass fluxes and evaporation temperatures to characterize refrigerant-dependent two-phase pressure-drop behavior. The results show that frictional pressure gradient increased with mass flux and vapor quality and generally increased as evaporation temperature decreased, with liquid viscosity strongly affecting the observed trends. Among the evaluated correlations, the Goto et al. (2001) model gave the best overall agreement with the measurements before optimization. Further optimization of the Kuo and Wang (1996) and Goto et al. (2001) models reduced the overall mean absolute deviation to below 15%, with the optimized Goto (2001) model providing the most consistent predictions across all six refrigerants. The results support improved pressure-drop prediction and evaporator design for next-generation refrigerants in micro-fin tubes.

Hu, Yifeng [ORNL] (ORCID:0000000242875185)↗

DOE OSTI2022

Screening and evaluation of biomass upgrading strategies for sustainable transportation fuel production with biomass-derived volatile fatty acids

Biomass conversion to fuels and chemicals is crucial to decarbonization, but choosing an advantageous upgrading pathway out of many options is challenging. Rigorously evaluating all candidate pathways (process simulation, product property testing) requires a prohibitive amount of research effort; even simple upgrading schemes have hundreds of possible permutations. We present a method enabling high-throughput screening by approximating upgrading unit operations and drop-in compatibility of products (e.g., fuel properties) and apply it to volatile fatty acid (VFA) conversion to liquid transportation fuels via a MATLAB script, VFA Upgrading to Liquid Transportation fUels Refinery Estimation (VULTURE). VULTURE selects upgrading configurations that maximize fuel blend bio-derived content. We validate VULTURE's approximations through surrogate fuel property testing and process simulation. Techno-economic and life cycle analyses suggest that VFA upgrading processes down-selected by VULTURE are profitable and have low carbon intensities, demonstrating the potential for the strategy to accelerate process development timelines at decreased costs.

09 BIOMASS FUELS↗

DOE OSTI2020

Durable hybrid electrocatalysts for proton exchange membrane fuel cells

The low durability of carbon-based non-precious metal electrocatalysts hinders their practical applications in proton exchange membrane fuel cells (PEMFCs). In this study, we rationally design a hybrid Pt-Fe-N-C electrocatalyst with unprecedented durability. It consists of abundant Pt and Fe single atoms homogeneously dispersed on the nitrogen-doped carbon support and a small amount of Pt-Fe alloy nanoparticles. A PEMFC with Pt-Fe-N-C as the cathode shows a larger peak power density (0.75 W cm -2 ) than that with Fe-N-C as the cathode (0.50 W cm -2 ). The remarkable durability of Pt-Fe-N-C is reflected from no noticeable drop in the half-wave potential after 70000 potential cycles between 0.6 and 1.0 V in the liquid cell, and 80% current retention after 85 h of potential hold at 0.4 V in the fuel cell. This work demonstrates the feasibility of improving the durability of Fe-N-C material via ultra-low Pt doping and makes non-precious metal electrocatalysts be close to achieving commercial metrics.

25 ENERGY STORAGE↗

DOE OSTI2025

Numerical investigation of two-dimensional buoyancy-driven eddies in liquid metal magnetohydrodynamic flows in breeding blankets *

Abstract Lead–lithium flows are key features in the design of tokamak breeding blanket concepts such as the dual-coolant lead–lithium (DCLL). Since they flow under magnetic fields, they are affected by magnetohydrodynamic (MHD) effects. The neutron flux originating in the tokamak plasma heats the breeding blanket channels in a non-uniform manner, inducing buoyancy forces in the liquid metal. Buoyancy may become a source of quasi-two-dimensional (Q2D) turbulence, and the appearance of eddies may affect the transport of heat and tritium across the blanket. Blankets characterized by high-speed liquid metal flows (such as DCLL) will need ceramic insulating walls to reduce the MHD-related pressure drop in the channels. In our simulations, we have used the Q2D model proposed by Sommeria and Moreau (SM82) which is especially suitable for modeling electrically insulating channel flows. On top of that, we have modelled buoyancy forces in the momentum equation using the Oberbeck–Boussinesq approximation. In this work, we include a validation of the implemented Q2D model in buoyancy-driven cases and identify a thermohydraulic configuration that promotes the generation of eddies and the accumulation of tritium. We also show the results provided by our post-processing tool based on the bi-dimensional fast Fourier transform for eddy detection and characterization. We complete our investigation by performing an initial assessment of how eddies can accumulate tritium in the breeding blanket. We conclude by discussing the relevance of preventing accumulation of tritium within the blanket and suggest a possible solution.

Suarez, Daniel (ORCID:0000000251740100)↗

DOE OSTI2023

Surface Merging Technique to Design GA-Optimized Heat Sinks

High-power density inverters require efficient and small heat dissipation systems. For liquid cooling systems, an effective heat sink design is important to enable higher heat transfer and keep the pressure drop within reasonable limits. A heat sink geometry generated from an extruded, 1D fast Fourier transform can achieve more even temperature distribution and improved heat transfer than a conventional heat sink. Building on this concept, this paper proposes a new heat sink geometry creation algorithm. Instead of one plane profile being extruded, multiple plane profiles, each created from the fast Fourier transform method, are subsequently merged by smooth surfaces along the flow direction of the heat sink. Thus, a 3D heat sink geometry is created that enables 3D coolant flow and efficient heat transfer. The volume of this design was reduced by 50% compared with pin fin heat sinks. Compared with extruded 1D fast Fourier transform heat sinks, the proposed design showed an approximately 5% device temperature reduction and a 20% pressure drop reduction.

Barua, Himel↗

DOE OSTI2025

Compact Absorber Technology Leads to Significant Reduction in the Cost of Point Source CO 2 Capture

The size of columns in traditional absorption-based processes for CO 2 capture contributes significantly to the overall capital cost. A demonstrated method to reduce the cost of point source CO 2 capture, focusing on reducing the absorber height by increasing the liquid-to-gas reaction contact area and decreasing the CO 2 diffusion resistance without increasing gas-side pressure drop is presented along with techno-economic analysis results. Bench-scale tests on the unique Compact Absorber showed overall CO 2 mass transfer enhancement of varying degrees compared to a traditional packed column for similar process conditions, demonstrating that a 60+% reduction in size of a typical post-combustion absorber with a packing height of 70-100 ft and total height of 150-180 ft can be achieved. The techno-economic analysis showed significant cost reductions when the Compact Absorber is combined with other transformative aspects of the University of Kentucky Institute for Decarbonization and Energy Advancement point source CO 2 capture process compared to the U.S. Department of Energy National Energy Technology Laboratory pertinent reference case for pulverized coal plants with CO 2 capture. Here, a levelized cost of electricity excluding CO 2 transportation and storage of $\$95.6$/MWh was estimated, which is a 9% reduction, with a total capital cost contribution of $45/MWh, which is a 12% reduction. Additionally, a breakeven CO 2 sales price also referred to as the cost of CO 2 capture, of $36.70/tonne was estimated when the UK hindered primary amine solvent is used, which is a 20% reduction compared to the reference case.

CO2 capture↗

DOE OSTI2021

MHD flow in liquid metal blankets: Major design issues, MHD guidelines and numerical analysis

The design of breeding blankets represents the major challenge for fusion reactor engineering because of performance requirements and severe operating conditions in terms of heat load and neutron flux. Liquid metal alloys such as lead-lithium, due to their lithium content, can be used to breed tritium, one of the plasma fuel components, and owing to their high thermal conductivity, they may serve as coolants. On the other hand, there are technical issues related to the fact that the liquid metals are electrically conducting and interact with the plasma-confining magnetic field. Induced electric currents and generated electromagnetic forces affect velocity and pressure distribution in the blankets. Magnetohydrodynamic (MHD) flows for fusion applications have been often investigated in simplified geometries, such as pipes, ducts, bends, with focus on their fundamental features. These analyses are essential, since results remain valid as background for the development of blanket designs, even when a concept is dismissed. However, the conceptual study of fusion blankets requires to take into account the global multiple effects, that arise when the full system is considered. Progress made in fusion-related MHD research results from combined numerical and experimental activities. In this paper we review and summarize features of 2D and 3D MHD flows that are typical in liquid metal blankets, together with available correlations for MHD pressure losses. This knowledge can provide simple design MHD guidelines that support a preliminary estimate of MHD effects in a blanket concept, in terms of pressure drop and flow distribution.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Dual-Functional Thermocapacitive Heat Pump with Electrochemical Supercapacitors for Building Thermal Management and Energy Storage

Efficient heating and cooling technologies can help reduce the energy consumption and carbon emissions of buildings. This work explores the use of supercapacitive cells in a multifunctional, liquid-regenerated thermocapacitive heat pump that can provide electrical energy storage in addition to heating and cooling. A proof-of-concept prototype based on eight commercial supercapacitors and using deionized water as a liquid regenerator demonstrated cooling and energy storage capabilities. A peak cooling coefficient of performance (COPc) of 0.27 was achieved at a temperature drop of 0.24 K. The highest measured electrical energy storage density of the cells was 5.93 J cm-3, and the highest cooling power delivered relative to the volume of the cells was 0.58 mW cm-3. This work demonstrates the use of electrochemical energy storage devices in multifunctional equipment for thermal management in buildings.

25 ENERGY STORAGE↗

DOE OSTI2022

Hydrodynamic thermoelectric transport in Corbino geometry

We study hydrodynamic electron transport in Corbino graphene devices. Due to the irrotational character of the flow, the forces exerted on the electron liquid are expelled from the bulk. We show that in the absence of Galilean invariance, force expulsion produces qualitatively new features in thermoelectric transport: (i) it results in drops of both voltage and temperature at the system boundaries and (ii) in conductance measurements in pristine systems, the electric field is not expelled from the bulk. We obtain thermoelectric coefficients of the system in the entire crossover region between charge neutrality and high electron density regime. The thermal conductance exhibits a sensitive Lorentzian dependence on the electron density. The width of the Lorentzian is determined by the fluid viscosity. Furthermore, this enables determination of the viscosity of electron liquid near charge neutrality from purely thermal transport measurements. In general, the thermoelectric response is anomalous: It violates the Matthiessen's rule, the Wiedemann-Franz law, and the Mott relation.

36 MATERIALS SCIENCE↗