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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 OSTI2020

Inversion of downhole electrical measurements for proppant mapping using very fast simulated annealing

Proppant mapping is critical for optimizing fracture treatment design and improving wells’ productivity. An electrode-based resistivity tool concept was developed earlier for proppant mapping in cased-hole wells. An array of insulating gaps is installed and cemented in place as a permanent part of the casing string. The electrical measurements are performed by imposing a voltage across each insulating gap, one at a time, before and after hydraulic fracture operations. The voltages across other insulating gaps near the transmitter gap are recorded. The method relies on direct excitation of the casing, which is expected to overcome the severe limitations of induction tools in cased-hole wells. A forward model based on a finite volume method has been developed to simulate the tool’s response to one or multiple fractures. To enable the implementation of such a practical system in multistage fractured horizontal wells, a fast and robust inversion approach is required. To that end, we have developed a divide-and-conquer approach based on a global optimization algorithm very fast simulated annealing (VFSA). Specifically, the original inverse problem is divided into subproblems and each subproblem can be solved separately using VFSA. The results indicate that our approach can invert the data and output widths and radii of multiple fractures without requiring a large number of forward simulations. The robustness of the inverse solver is also tested by adding Gaussian noise to the synthetic data. We tested example cases that demonstrate that when up to 5% noise is introduced, VFSA still provides very accurate inversion results with moderate uncertainties. Inversion results with some more realistic conditions, e.g., tilted fractures, complex fractures, and so on, are also presented.

Geochemistry & Geophysics↗
DOE OSTI2024

An Innovative Design of High-Temperature, Sensible Molten Salt Thermal Energy Storage Systems With Geopolymer Insulation

This project aims to mitigate the risks of the current molten salt TES tank designs. The goal is to create a more reliable and cost-effective TES by (1) developing a new material solution for internal thermal insulation and (2) by designing a concrete-based tank structure to eliminate metal-related issues (e.g., corrosion, thermomechanical failure, etc.). Firstly, the project aims to engineer a composite refractory insulation material that possesses sufficient thermal insulation properties without significantly sacrificing the resistance to salt permeation and mechanical strength, which is the major trade-off in traditional refractory insulation design. The primary objective is to perform materials design and optimization of the composite refractory to achieve the required thermal and mechanical properties as suitable internal insulation for molten salt TES. Secondly, the project aims to design a concrete-based TES system with conventional low- cost Portland cement serving as the primary tank structure and the aforementioned composite refractory as the internal thermal insulation and salt containment. The objective is to investigate the technical and economical feasibilities of concrete tanks for high- temperature molten salt storage applications.

14 SOLAR ENERGY↗
DOE OSTI2024

Modeling the impact of high thermal conductivity paper on the performance and life of power transformers

Degradation of insulation paper is a key contributor to the failure of power transformers. Insulation degradation accelerates at elevated temperatures, which highlights the potential for better thermal management to prolong life. While several studies have analyzed the benefits of high thermal conductivity oil for reducing temperatures inside a transformer, this study is an initial assessment of the benefits of high thermal conductivity paper on transformer life. Blending particulates with cellulosic fibers offers a pathway for high thermal conductivity paper (with good dielectric properties), which can reduce internal temperatures. Presently, life extensions that can be achieved by the use of such thermally conducting papers were estimated, with the thermal conductivity of the paper being the key parameter under study. The analytical-numerical thermal model used in this study was validated against experimental measurements in a distribution transformer, adding confidence to the utility of the model. This model was then used to provide estimates of hot-spot temperature reduction resulting from the use of papers with higher thermal conductivity than baseline. Transformer life was predicted conventionally by tracking the degree of polymerization of paper over time, based on an Arrhenius model. Results indicate that increasing the thermal conductivity of paper from 0.2 W/mK (baseline) to 1W/mK reduces the hot spot temperature by 10°C. While degradation significantly depends on the moisture and oxygen content, the model shows that such a temperature reduction can increase life for all conditions, by as much as a factor of three.

42 ENGINEERING↗
DOE OSTI2021

Characterization of Highly Thermally Conductive Organic Substrates for a Double-Sided Cooled Power Module

Abstract Silicon-Carbide (SiC) power devices have become a promising option for traditional Silicon (Si) due to the superior material properties. To fully take advantage of the SiC devices, a high-performance power device packaging solution is necessary. This study proposes a cost-effective double-sided cooled (DSC) 1.2 kV SiC half-bridge power module using organic epoxy-resin composite dielectric (ERCD) substrates. The high mechanical and thermal performance of the power module is achieved by the low-modulus, moderate thermal conductivity, and relatively thin (120 μm) layer of ERCD material compared with traditional metal-clad ceramic approaches. This novel organic dielectric can withstand high voltage (5 kV @ 120 μm) and operate up to 250°C continuously, which is indispensable for high power applications. The thermal modeling results show that the equivalent thermal resistance junction-to-case (Rjc_eq) of the DSC power module using dual direct bonded copper (DBC) is 17% higher than the dual ERCD configuration. Furthermore, a non-insulated DSC power module concept is proposed for maximizing thermal performance by considering thermal vias in the ERCD substrate and direct-soldered heat sink. A thought process for optimization of thermal via design is demonstrated and it shows up to 24% of improvement on thermal performance compared with the insulated DSC power module.

Double-sided cooling, epoxy-resin composite dielec↗
DOE OSTI2021

Validation and Verification for INL Modelica-based TEDS models Via Experimental Results

This report provides an overview on the verification and validation (V&V) of the Thermal Energy Distribution System (TEDS) model developed in the Modelica process modeling ecosystem using experimental data. Model development has led to the creation of a dynamic process model of the experimental TEDS facility housed within the Energy Systems Laboratory (ESL) at Idaho National Laboratory (INL). The model was then used during the preconstruction phase of the experimental effort to inform experimental design (e.g., insulation requirements, bypass line placement, expected performance of components) and to test innovative control schemes prior to the initial operation. The TEDS model developed in Modelica includes the primary components of the TEDS experimental unit: a 200kW Chromalox heater; a single-tank packed-bed thermal energy storage system filled with 0.125-inch alumina (Al2O3) beads; an ethylene-glycol-to-Therminol-66 heat exchanger; system piping; five control valves; and all associated temperature, pressure, and volumetric flow sensors. Using the Institute of Electrical and Electronics Engineers (IEEE) V&V methodologies, considered the gold standard in the engineering field, the model was verified using a combination of static analysis, spatial convergence, and regression tests. Then using dynamic time warping (DTW) initial runs to validate and tune the TEDS model versus the experiment were conducted. This tuning method was accomplished using the INL Risk Analysis Virtual ENvironment (RAVEN) software package. Tuning is required to account for physical phenomena that are less understood within the empirical heat transfer correlations. Through the commencement of this work, a systems-level model of TEDS with associated control systems, sensors, piping diameters, and component capabilities has been created. This model was utilized in the pre-experimental phase to inform system design, insulation thicknesses, and potential control schemes to operate the system effectively and safely. Then, initial experimental startup and operational data were used to demonstrate the validation and tuning methodology. This process demonstrates the classical two-step approach of a model informing experimental design followed by the experiment validation and tuning the model.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Technical Performance of Refractory Liners for Molten Chloride Salt Thermal Energy Storage Systems

A chloride-based molten-salt system that uses a ternary blend of MgCl2/KCl/NaCl is investigated to provide higher temperature thermal energy storage capability. Despite higher thermal stability, molten chlorides present several unique challenges, including the design of internal refractory-ceramic liners to prevent the corrosion and thermal stress of alloy tank shells. This work discusses issues and potential solutions related to containment of molten chloride salt, specifically the optimization of the refractory material at the molten salt interface (hot face). The down-selected hot face candidate limits permeation of salt through the material and forms a highly stable secondary surface phase in equilibrium with the molten salt. A mortar is created using the corrosion resistant hot face brick. Brick and mortar composite are subjected to mechanical stress/strain analysis, in order to calculate composite material properties and better inform thermomechanical models. The U.S. Department of Energy Generation 3 (DOE Gen3) program seeks to develop higher efficiency CSP plants that can provide cost-competitive, flexible power in the U.S. electric grid. The proposed Gen3 Liquid Pathway CSP plant closely resembles the configuration of current nitrate salt power towers with two-tank storage (Gen2). The differences between Gen2 and Gen3 include the types of compatible materials used in salt storage tank construction. Stainless steel loses strength at Gen3 temperatures, and although nickel superalloys would be capable of withstanding sustained high temperatures, these materials are prohibitively expensive at scale. Uninsulated tank shells also pose a significant risk as common steels are highly susceptible to chemical attack from molten chloride salt. To address these concerns, refractory-ceramic based containment materials are proposed to line the inside of the hot and cold storage tanks. In doing so, stainless or carbon steel shells may be used in construction depending on the level of insulation provided. The composition of the internal liner requires careful consideration to maximize the efficacy of multiple parameters including corrosion resistance, strength at operating temperature, durability, and cost. This is particularly true for the material at the interface with the salt, known as the "hot face", which is responsible for protecting the insulating layers between the tank shell and the hot face brick layer. The molten salt in this system is superheated over 300 °C above its freeze temperature. Therefore, unlike other industrial processes which use refractory-lined vessels, it is not expected that a freeze plane will develop in the hot face. Therefore, the hot face must be designed to withstand chemical corrosion and inhibit permeation of molten salt into the insulating layers. A down selection was performed to identify a hot face candidate best equipped to maintain thermal, mechanical, and chemical integrity when exposed to molten salt over extended periods of time. Long-duration chemical capability experiments were conducted with the down selected hot face refractory fully immersed in molten chloride salt for up to 3000 hours. The average salt penetration does not exceed 100 microns. When extrapolated to 20 and 30 years of continuous exposure, the expected salt penetration depth is approximately 2.0 mm and 2.9 mm, respectively. A magnesium-rich secondary phases develops at the salt/refractory interface. X-ray diffraction identifies the material as forsterite (Mg2SiO4), which is reported to form synthetically in molten chloride salt solutions. These results suggest the selected hot face will adequately inhibit salt permeation. While there is optimism that the hot face brick will inhibit salt permeation, mortar joints are typically the weakest point of a refractory brick liner. From a thermochemical perspective, differing thermal expansion coefficients may result in the mortar and brick to grow independent of each other, creating gaps through which molten salt can penetrate. To address this issue, NREL has developed an in-house mortar composed of the down selected hot face brick that has been shown to be compatible with the salt. Compressive stress/strain analyses have been performed on the brick/ mortar composites to generate stress/strain curves. Modulus of elasticity and Poisson's ratio of the composite may be calculated from the stress/strain curves, in order to provide more representative data to finite element mechanical models for accurate approximation of stress on the tank shell and the amount of thermal expansion expected within the tank liner.

41 EE - Solar Energy Technologies Office (EE-4S)↗
DOE OSTI2020

Development of the INL Thermal Energy Distribution System (TEDS) in the Modelica Eco-System for Validation and Verification

This report provides an overview on the development of the Thermal Energy Distribution System (TEDS) in the Modelica process model eco-system at Idaho National Laboratory as part of the integrated energy system initiative. Model development has led to the creation of a dynamic process model of the experimental TEDS facility housed within the Engineering Science Laboratory (ESL) at INL. The model was then used during the pre-construction phase of the experimental effort to inform experimental design (insulation requirements, bypass line placement, expected performance of components) and to test innovative control schemes prior to the initial operation. The TEDS model developed in Modelica includes the primary components of the TEDS experimental unit including: a 200kW Chromalox heater, a single-tank packed bed thermal energy storage system filled with 0.125 inch Alumina (Al 2 O 3 ), an ethylene-glycol to Therminol-66 heat exchanger, system piping, six control valves, and all associated temperature, pressure, and mass flow sensors. The model does not include nitrogen fill gas tanks, or associated overfill tanks, as these are not part of standard system control. Two simulation sets were run. The first is a five-hour test that operates as a shakedown test for the facility. This simulation puts the facility through all five potential operating modes and showcases the ability of valving, control sensors, and component controllers to meet the system demands. The second case imposes a typical summer day demand on the system from a region with mixed commercial and residential electrical needs where the generator alone cannot meet peak demand but instead requires the thermal storage unit to act as a peaking unit. Over the course of the fifteen-hour discharge cycle heat losses account for a heat loss of approximately 15°C in outlet temperature. Such heat losses would lead to a decrease in overall system efficiency and may lead to additional design changes for such designs in the future that may include a topping heater. Through commencement of this work, a systems level model of TEDS with associated control systems, sensors, piping diameters, and component capabilities has been created. This model has been utilized in the pre-experimental phase to inform system design, insulation thicknesses, and potential control schemes to operate the system effectively and safely. Once TEDS begins operation, this model will be refined, tuned, and used for validation and verification purposes.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

Boundary scattering in topological Kondo insulator SmB 6

We have studied the effects of phonon-boundary scattering on the thermal transport of topological Kondo insulator SmB6. The studies have been performed using the 3ω method across a temperature range 3–300 K. Our results indicate that the thermal conductivity of micro-sized SmB 6 is of an order of magnitude smaller than that of a bulk single crystal. Using the Callaway model, we analyzed the low-temperature lattice thermal conductivity of the microcrystal and demonstrated that phonon scattering at the sample boundaries is a major contributor to the thermal resistance in this topological material. Furthermore, our study reveals that the temperature dependence of the lattice thermal conductivity exhibits a double-peak structure, suggesting strong phonon–phonon or phonon–defect interactions in this material, characteristic of resonant scattering. Furthermore, these findings will help in a better understanding of thermal transport in advanced materials and devices at the micro scale.

Physics - Condensed matter physics↗
DOE OSTI2023

Defect‐Free Sound Insulator Using Single Metal‐Based Friction Stir Process Array

Metals are excellent conductors for phonon transportation such as vibration, sound, and heat. Generally, metal sound insulators require multimaterial structure or defects and unimetal sound insulators are challenging. Therefore, a design of a defect-free sound insulator made by single alloys with multiple friction stir processes (FSPs) is proposed. Periodic friction stir processing can induce superlattice-like local mechanical properties’ modifications. By experimental acoustic characterization, it is observed that FSP can introduce clear acoustic–elastic property contrast on an aluminum plate by the presence of stir zone and heat-affected zones. In numerical simulations, the signature FSP-induced property profile is periodically and parallelly arranged on a long aluminum plate. The transmission gap frequencies are present on the frequency spectrum with the sound propagation direction perpendicular to the FSP paths. Disorder offsets on FSP periodicity are further introduced. Anderson localization is found on a resonance frequency, which provides −11 dB sound reduction by an exponential decay. Due to the finite design length, the slight disorder can also enhance sound insulation in the periodic transmission gap frequency. In conclusion, with analysis and comparison with different configurations, the best performance in the models can achieve −30 dB sound insulation in the 350 mm-long aluminum alloy plate with 14 parallel FSPs.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Hierarchical thermal-conductive polymer nanocomposites for thermal management

Managing heat in electrical conductors is a major challenge to meet the demands for sustainable energy use and electrical reliability, most notably power electronics and energy-critical electrical machines. Achieving such disparate functionalities, such as high temperature thermal and electrical reliability, require rational design and manufacturing of thermal conductor material and its hierarchical structures. Here we present hierarchical thermal-conductive nanocomposites, consisting of nanostructured ceramic conformal coating and aligned ultrahigh molecular weight polyethylene fiber, to tailor heat dissipation in electric conductors. The hybrid aligned thermal interface exhibits a highly desirable temperature dependent anisotropic high thermal conductivity with 0.98W m –1 K –1 and dielectric strength with 3.4. In addition, electrically insulating thermal interfaces demonstrate high-performing and reliable electrical systems under the dynamic load conditions. The surface temperature of heterogeneous ceramic-polymer encapsulated conductor is 17.8 °C lower than that of polymer-encapsulated conductor at the same electrical load. Consequently, the findings shown here hold great promises for directing heat extraction in electrical machine systems, advancing thermal management for emerging electronic applications.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Characterization of the Redesigned Extended MITL for HERMES III

Modeling and simulation of the legacy HERMES III Magnetically Insulated Transmission Line (MITL) has been performed using EMPHASIS, an unstructured time-domain electromagnetic (UTDEM) particle-in-cell (PIC) simulation software. This design when used lost roughly half of its current before the pulse reached the load. The cause of the current loss in the MITL was found to be the vacuum impedance changes along the MITL. The MITL was then redesigned to maintain constant impedance and simulated in EMPHASIS once again. Following predicting simulation results, the new MITL was then built, installed, and tested, showing minimal current loss and good agreement with simulation and theoretical results, all of which are reported here. Additionally, an analysis of experimental voltage calculation techniques using cathode and anode currents is performed and compared to simulation results.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

High-performance HZO/InAlN/GaN MISHEMTs for Ka-band application

This paper reports on the demonstration of microwave power performance at 30 GHz on InAlN/GaN metal–insulator–semiconductor high electron mobility transistor (MISHEMT) on silicon substrate by using the Hf 0.5 Zr 0.5 O 2 (HZO) as a gate dielectric. Compared with Schottky gate HEMT, the MISHEMT with a gate length (L G ) of 50 nm presents a significantly enhanced performance with an ON/OFF current ratio (I ON /I OFF ) of 9.3 × 10 7 , a subthreshold swing of 130 mV dec -1 , a low drain-induced barrier lowing of 45 mV V -1 , and a breakdown voltage of 35 V. RF characterizations reveal a current gain cutoff frequency (f T ) of 155 GHz and a maximum oscillation frequency (f max ) of 250 GHz, resulting in high (f T × f max ) 1/2 of 197 GHz and the record high Johnson's figure-of-merit (JFOM = f T × BV) of 5.4 THz V among the reported GaN MISHEMTs on Si. Further, the power performance at 30 GHz exhibits a maximum output power of 1.36 W mm -1 , a maximum power gain of 12.3 dB, and a peak power-added efficiency of 21%, demonstrating the great potential of HZO/InAlN/GaN MISHEMTs for the Ka-band application.

42 ENGINEERING↗
DOE OSTI2022

Characterization of Candidate Insulation Resins for Training Reduction in High Energy Physics Magnets

Superconducting magnets are critical components in particle accelerators and are used to generate and sustain the large magnetic fields needed for High Energy Physics programs. One significant issue with current epoxy insulated Nb$_{3}$Sn magnets is the long training process required before stable magnet performance can be realized. It is believed that training can be significantly reduced by addressing magnet quenching through improvements in the epoxy electrical insulation. In this work, two approaches for insulation modification have been undertaken: (1) addition of thermally conductive fillers to help with quench management and (2) development of insulation resins with high strain capability at cryogenic temperatures. This paper will discuss the characterization of these insulation systems to verify their performance prior to evaluation in subscale Nb$_{3}$Sn canted cosine theta accelerator dipole magnets.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Evaluation of Envelope Energy in a High-Performance Manufactured Home in California

There are important applications for a robust energy model for new construction manufactured homes that can characterize the individual performance of the opaque wall and ceiling components of the building envelope. The efficacy of different insulation materials can be assessed with the confidence that modeled performance will closely predict installed performance. This study uses careful calibration of a standard energy model with a short-term co-heating test in an installed manufactured home to de-aggregate the contributions of planar wall sections from overall building envelope thermal resistance. The methodology takes into account thermal mass effects, solar gains, and physical adjustments to the structure to achieve successful calibration and to inform adjustments to the test procedure for future study.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Analysis of outgassing from natural fibers VIP core to improve their long-term performance

Buildings are the largest consumers of energy accounting for 40% of the total energy use in the US. The use of vacuum insulation panels (VIPs) with large R/in. values offers unique benefits in reducing building energy consumption such as providing excellent thermal insulation with significantly less thickness compared to convention insulation materials. Natural fibers are promising VIP core material because of their low cost and offer good thermal performance. However, the long-term thermal performance of the VIPs with natural fiber core can be compromised because of off-gassing from natural fibers. In this study, we utilize a mass spectrometer based analytical technique to investigate the composition of off-gassing from natural fibers. The result can be used to determine the optimal getters to help maintain the vacuum and improve the long-term thermal performance of the VIP for building insulation.

Tamraparni, Achutha [ORNL] (ORCID:0000000299658544↗
DOE OSTI2022

Developing a Composite Vacuum Insulated Panel (VIP) Insulation/Vinyl Siding Composite Technology for Retrofitting Residential Walls

This paper reports on a project that has attempted to seize on an opportunity to take a giant leap forward in commercializing a technology that would address a key opportunity to achieve energy savings in the existing residential housing stock. It is typically very difficult to increase the R-value of the walls in existing residential housing as doing so from the inside is disruptive and there have not been good solutions to increase thermal envelope performance from the exterior through adding continuous insulation due to the additional work required to fit existing architectural features to the new wall thickness and to reclad the façade. A high thermal resistivity or R-value per inch product that can be used in these applications offers an excellent solution.This paper summarizes a three-year research project to a produce vacuum insulated panel (VIP)/vinyl siding that would have sufficient R-value to meet the continuous insulation requirements of the 2018 International Energy Conservation Code (IECC, 2018) in all climate zones and has a much thinner profile that will facilitate its application to existing residential homes without the need for expensive retrimming of the architectural details. The paper will supply information on the development of the technology, its thermal modelling, testing, voice of user sessions to solicit input from architects, designers, manufacturers, contractors, and installers, and a techno-economic analysis to gauge its competitiveness with existing product options.

Desjarlais, Andre Omer↗
DOE OSTI2022

Developing a Composite Vacuum Insulated Panel (VIP) Insulation/Vinyl Siding Composite Technology for Retrofitting Residential Walls

This paper reports on a project that has attempted to seize on an opportunity to take a giant leap forward in commercializing a technology that would address a key opportunity to achieve energy savings in the existing residential housing stock. It is typically very difficult to increase the R-value of the walls in existing residential housing as doing so from the inside is disruptive and there have not been good solutions to increase thermal envelope performance from the exterior through adding continuous insulation due to the additional work required to fit existing architectural features to the new wall thickness and to reclad the facade. A high thermal resistivity or R-value per inch product that can be used in these applications offers an excellent solution. This paper summarizes a three-year research project to a produce vacuum insulated panel (VIP)/vinyl siding that would have sufficient R-value to meet the continuous insulation requirements of the 2018 International Energy Conservation Code (IECC, 2018) in all climate zones and has a much thinner profile that will facilitate its application to existing residential homes without the need for expensive retrimming of the architectural details. The paper will supply information on the development of the technology, its thermal modelling, testing, voice of user sessions to solicit input from architects, designers, manufacturers, contractors, and installers, and a techno-economic analysis to gauge its competitiveness with existing product options.

Desjarlais, Andre↗
DOE OSTI2022

Nondestructive Evaluation of Rexolite Insulators for the Purpose of Monitoring the Structural Health of Particle Accelerator

Rexolite is a cross-linked polystyrene plastic with stable electrical properties into the gigahertz frequency range. The ability to withstand high voltage makes Rexolite one of the most used materials as insulators for particle accelerators. Although, Rexolite’s poor outgassing performance relative to traditional vacuum materials such as stainless steel or aluminum deems the necessity to treat Rexolite prior to its use as insulators. Insulators are mandatory for an accelerator system because a uniform electric field is required to ensure the alignment of the accelerated particles. Furthermore, to operate properly, a particle accelerator is required to maintain a high vacuum or even an ultrahigh vacuum. Although, because outgassing is the major contributor to the gas load of a vacuum system, Rexolite insulators with uncontrolled outgassing characteristics can severely damage the particle accelerator. Disassembly and reassembly of a complex system like a particle accelerator is also time consuming.

36 MATERIALS SCIENCE↗