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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
NASA NTRS2018

Rayleigh Scattering Density Measurements from Ultrafast Lasers in High-Pressure, Cryogenic Wind Tunnels

The Rayleigh scattering signal from femtosecond laser pulses is examined for its utility at making instantaneous density measurements in the NASA Langley 0.3-m Transonic Cryogenic Tunnel. An electron-multiplying CCD camera is used to visualize Rayleigh scattering signal taken concurrently with velocity measurements utilizing the femtosecond laser tagging velocimetry technique (FLEET). The results indicate a strong potential for making instantaneous measurements. Viable single-shot images are obtained over the full operational envelope of the facility, and shot-to-shot variations are found to be on average 6 percent (at 95 percent confidence level) and tend to decrease as the facility density is increased. The Rayleigh scattering signals observed before the optical focus exhibit a characteristically linear dependence on the mass-density of the gas, while signals after the focus exhibit a nonlinear (sublinear) density dependence, indicative of stronger absorption at higher densities. The measured Rayleigh scattering signals compare favorably to theoretical assessments made at the tunnel operating conditions.

Burns, Ross A.↗
NASA NTRS2005

Reconfiguration of Analog Electronics for Extreme Environments: Problem or Solution?

This paper argues in favor of adaptive reconfiguration as a technique to expand the operational envelope of analog electronics for extreme environments (EE). In addition to hardening-by-process and hardening-by-design, "hardening-by-reconfiguration", when applicable, could be used to mitigate drifts, degradation, or damage on electronic devices (chips) in EE, by using re-configurable devices and an adaptive self-reconfiguration of their circuit topology. Conventional circuit design exploits device characteristics within a certain temperature/radiation range; when that is exceeded, the circuit function degrades. On a reconfigurable device, although component parameters change in EE, as long as devices still operate, albeit degraded, a new circuit design, suitable for new parameter values, may be mapped into the reconfigurable structure to recover the initial circuit function. Partly degraded resources are still used, while completely damaged resources are bypassed. Designs suitable for various environmental conditions can be determined prior to operation or can be determined in-situ, by adaptive reconfiguration algorithms running on built-in digital controllers. Laboratory demonstrations of this technique were performed by JPL in several independent experiments in which bulk CMOS reconfigurable devices were exposed to, and degraded by, low temperatures (approx. 196 C), high temperatures (approx.300 C) or radiation (300kRad TID), and then recovered by adaptive reconfiguration using evolutionary search algorithms. Taking this technology from Technology Readiness Level (TRL) 3 to TRL 5 is the target of a current NASA project.

Field Programmable Transistor Array (FPTA)↗
NASA NTRS2004

Turbomachinery for Low-to-High Mach Number Flight

The thrust capability of turbojet cycles is reduced at high flight Mach number (3+) by the increase in inlet stagnation temperature. The 'hot section' temperature limit imposed by materials technology sets the maximum heat addition and, hence, sets the maximum flight Mach number of the operating envelope. Compressor pre-cooling, either via a heat exchanger or mass-injection, has been suggested as a means to reduce compressor inlet temperature and increase mass flow capability, thereby increasing thrust. To date, however, no research has looked at compressor cooling (i.e., using a compressor both to perform work on the gas path air and extract heat from it simultaneously). We wish to assess the feasibility of this novel concept for use in low-to-high Mach number flight. The results to-date show that an axial compressor with cooling: (1) relieves choking in rear stages (hence opening up operability), (2) yields higher-pressure ratio and (3) yields higher efficiency for a given corrected speed and mass flow. The performance benefit is driven: (i) at the blade passage level, by a decrease in the total pressure reduction coefficient and an increase in the flow turning; and (ii) by the reduction in temperature that results in less work required for a given pressure ratio. The latter is a thermodynamic effect. As an example, calculations were performed for an eight-stage compressor with an adiabatic design pressure ratio of 5. By defining non-dimensional cooling as the percentage of compressor inlet stagnation enthalpy removed by a heat sink, the model shows that a non-dimensional cooling of percent in each blade row of the first two stages can increase the compressor pressure ratio by as much as 10-20 percent. Maximum corrected mass flow at a given corrected speed may increase by as much as 5 percent. In addition, efficiency may increase by as much as 5 points. A framework for characterizing and generating the performance map for a cooled compressor has been developed. The approach is based upon CFD computations and mean line analysis. Figures of merit that characterize the bulk performance of blade passage flows with and without cooling are extracted from CFD solutions. Such performance characterization is then applied to a preliminary compressor design framework (mean line). The generic nature of this approach makes it suitable for assessing the effect of different types of compressor cooling schemes, such as heat exchange or evaporative cooling (mass injection). Future work will focus on answering system level questions regarding the feasibility of compressor cooling. Specifically, we wish to determine the operational parametric space in which compressor cooling would be advantageous over other high flight Mach number propulsion concepts. In addition, we will explore the design requirements of cooled compressor turbomachinery, as well as the flow phenomena that limit and control its operation, and the technology barriers that must be crossed for its implementation.

Tan, Choon S.↗
NASA NTRS2015

Exercise Equipment Usability Assessment for a Deep Space Concept Vehicle

With international aspirations to send astronauts to deep space, the world is now faced with the complex problem of keeping astronauts healthy in unexplored hostile environments for durations of time never before attempted by humans. The great physical demands imparted by space exploration compound the problem of astronaut health, as the astronauts must not only be healthy, but physically fit upon destination arrival in order to perform the scientific tasks required of them. Additionally, future deep space exploration necessitates the development of environments conducive to long-duration habitation that would supplement propulsive vehicles. Space Launch System (SLS) core stage barrel sections present large volumes of robust structure that can be recycled and used for long duration habitation. This assessment will focus on one such conceptual craft, referred to as the SLS Derived Habitat (SLS-DH). Marshall Space Flight Center's (MSFC) Advanced Concepts Office (ACO) has formulated a high-level layout of this SLS-DH with parameters such as floor number and orientation, floor designations, grid dimensions, wall placement, etc. Yet to be determined, however, is the layout of the exercise area. Currently the SLS-DH features three floors laid out longitudinally, leaving 2m of height between the floor and ceilings. This short distance between levels introduces challenges for proper placement of exercise equipment such as treadmills and stationary bicycles, as the dynamic envelope for the 95th percentile male astronauts is greater than 2m. This study aims to assess the optimal equipment layout and sizing for the exercise area of this habitat. Figure 1 illustrates the layout of the DSH concept demonstrator located at MSFC. The exercise area is located on the lower level, seen here as the front half of the level occupied by a crew member. This small volume does not allow for numerous or bulky exercise machines, so the conceptual equipment has been limited to a treadmill and stationary bicycle. With the most current treadmill aboard the International Space Station (ISS), the Combined Operational Load-Bearing External Resistance Treadmill (COLBERT), being located in an International Standard Payload Rack (ISPR), the bottom of the conceptual treadmill features a height of 38in. Making the treadmill flush with the floor would be impossible in this rack configuration, as the distance from the outer wall of the spacecraft to the bottom floor would be too shallow. From preliminary sizing, the 38in required for the bottom of the treadmill combined with a 78in operational envelope for a 95th percentile may not be accommodated in the exercise area in a vertical orientation. Figure 2 demonstrates the volume required (in maroon) for an ISPR-bound treadmill in the concept demonstrator. Early indications as seen in this figure indicate that the crew members would contact the ceiling in such an arrangement. An assessment will be conducted to evaluate various orientations of exercise equipment in the concept demonstrator. Orientations to be tested include putting the bottom of the treadmill on the wall, having the treadmill at an angle in the floor both horizontally and vertically, and having a shorter (non-rack bound) treadmill in a vertical orientation on the floor. This assessment will yield findings regarding sizing of the area and how well participants feel they could exercise in such an environment. Due to the restrictions of assessing a microgravity vehicle in a normal-gravity environment, simulations in MSFC's Virtual Environments Lab (VEL) may be necessary. Final deliverables will include recommendations regarding the location and size of possible exercise equipment aboard the SLS-Derived DSH.

Rhodes, Brooke M.↗
DOE OSTI2026

Optimization of the FRIB beam dump: a hybrid genetic algorithm and reinforcement learning approach

The operational envelope of high-power-density systems, such as particle accelerators and advanced nuclear energy systems, is critically constrained by the need to manage extreme thermal loads. To address this, we present a novel hybrid optimization framework combining a genetic algorithm (GA) with a soft actor-critic (SAC) deep reinforcement learning agent. This framework was applied to a practical high-heat-flux problem: redesigning the beam dump at the Facility for Rare Isotope Beams (FRIB) for a power upgrade from 20 kW to 50 kW. The resulting design, validated by three-dimensional conjugate heat transfer simulations, suppresses hazardous hot spots and yields a markedly more uniform temperature distribution. This provides a robust operating margin, increasing the average power-handling capability by 72% relative to the current design, demonstrating the framework’s potential to solve complex thermal management challenges in both accelerator technology and advanced nuclear systems.

Accelerator↗
NASA NTRS2013

High-Efficiency Nested Hall Thrusters for Robotic Solar System Exploration

This work describes the scaling and design attributes of Nested Hall Thrusters (NHT) with extremely large operational envelopes, including a wide range of throttleability in power and specific impulse at high efficiency (>50%). NHTs have the potential to provide the game changing performance, powerprocessing capabilities, and cost effectiveness required to enable missions that cannot otherwise be accomplished. NHTs were first identified in the electric propulsion community as a path to 100- kW class thrusters for human missions. This study aimed to identify the performance capabilities NHTs can provide for NASA robotic and human missions, with an emphasis on 10-kW class thrusters well-suited for robotic exploration. A key outcome of this work has been the identification of NHTs as nearly constant-efficiency devices over large power throttling ratios, especially in direct-drive power systems. NHT systems sized for robotic solar system exploration are predicted to be capable of high-efficiency operation over nearly their entire power throttling range. A traditional Annular Hall Thruster (AHT) consists of a single annular discharge chamber where the propellant is ionized and accelerated. In an NHT, multiple annular channels are concentrically stacked. The channels can be operated in unison or individually depending on the available power or required performance. When throttling an AHT, performance must be sacrificed since a single channel cannot satisfy the diverse design attributes needed to maintain high thrust efficiency. NHTs can satisfy these requirements by varying which channels are operated and thereby offer significant benefits in terms of thruster performance, especially under deep power throttling conditions where the efficiency of an AHT suffers since a single channel can only operate efficiently (>50%) over a narrow power throttling ratio (3:1). Designs for 10-kW class NHTs were developed and compared with AHT systems. Power processing systems were considered using either traditional Power Processing Units (PPU) or Direct Drive Units (DDU). In a PPU-based system, power from the solar arrays is transformed from the low voltage of the arrays to the high voltage needed by the thruster. In a DDU-based system, power from the solar arrays is fed to the thruster without conversion. DDU-based systems are attractive for their simplicity since they eliminate the most complex and expensive part of the propulsion system. The results point to the strong potential of NHTs operating with either PPUs or DDUs to benefit robotic and human missions through their unprecedented power and specific impulse throttling capabilities. NHTs coupled to traditional PPUs are predicted to offer high-efficiency (>50%) power throttling ratios 320% greater than present capabilities, while NHTs with direct-drive power systems (DDU) could exceed existing capabilities by 340%. Because the NHT-DDU approach is implicitly low-cost, NHT-DDU technology has the potential to radically reduce the cost of SEP-enabled NASA missions while simultaneously enabling unprecedented performance capability.

Hofer, Richard R.↗
NASA NTRS1991

ARCFLO analysis for high-enthalpy arc heaters

Feasibility, physical constraints, and preliminary design and operating envelope are calculated for a next-generation segmented arc heater with enthalpies of 70-90 MJ/kg, for simulation of fast lunar or Martian return trajectories. The ARCFLO computer program is modified for improved accuracy in high-enthalpy radiation-dominated flows. The ARCFLO band-radiation model is compared with the state-of-the-art spectral-radiation code NEQAIR. The band-radiation model is corrected, and band-absorption coefficients are reduced by up to 40 percent at high temperatures. Parametric studies show that, with conventional wall-heating limitations, high mass flow and high enthalpy are contradictory design goals owing to the increase of radiation losses with pressure, current density, and constrictor diameter. With existing hardware limitations, an enthalpy of 70 MJ/kg with a flow rate of 0.1 kg/s can be achieved in a constrictor with 5-6 cm diameter operating near 3-atm stagnation pressure. The total power is under 100 MW, but the current is very high: 14,000-18,000 amperes.

Milos, Frank S.↗
NASA NTRS1982

Systems evaluation of thermal bus concepts

Thermal bus concepts, to provide a centralized thermal utility for large, multihundred kilowatt space platforms, were studied and the results are summarized. Concepts were generated, defined, and screened for inclusion in system level thermal bus trades. Parametric trade studies were conducted in order to define the operational envelope, performance, and physical characteristics of each. Two concepts were selected as offering the most promise for thermal bus development. All of four concepts involved two phase flow in order to meet the required isothermal nature of the thermal bus. Two of the concepts employ a mechanical means to circulate the working fluid, a liquid pump in one case and a vapor compressor in another. Another concept utilizes direct osmosis as the driving force of the thermal bus. The fourth concept was a high capacity monogroove heat pipe. After preliminary sizing and screening, three of these concepts were selected to carry into the trade studies. The monogroove heat pipe concept was deemed unsuitable for further consideration because of its heat transport limitations. One additional concept utilizing capillary forces to drive the working fluid was added. Parametric system level trade studies were performed. Sizing and weight calculations were performed for thermal bus sizes ranging from 5 to 350 kW and operating temperatures in the range of 4 to 120 C. System level considerations such as heat rejection and electrical power penalties and interface temperature losses were included in the weight calculations.

Stalmach, D. D.↗
NASA NTRS2010

CECE: Expanding the Envelope of Deep Throttling Technology in Liquid Oxygen/Liquid Hydrogen Rocket Engines for NASA Exploration Missions

As one of the first technology development programs awarded by NASA under the Vision for Space Exploration, the Pratt & Whitney Rocketdyne (PWR) Deep Throttling, Common Extensible Cryogenic Engine (CECE) program was selected by NASA in November 2004 to begin technology development and demonstration toward a deep throttling, cryogenic engine supporting ongoing trade studies for NASA s Lunar Lander descent stage. The CECE program leverages the maturity and previous investment of a flight-proven hydrogen/oxygen expander cycle engine, the PWR RL10, to develop and demonstrate an unprecedented combination of reliability, safety, durability, throttlability, and restart capabilities in high-energy, cryogenic, in-space propulsion. The testbed selected for the deep throttling demonstration phases of this program was a minimally modified RL10 engine, allowing for maximum current production engine commonality and extensibility with minimum program cost. Four series of demonstrator engine tests have been successfully completed between April 2006 and April 2010, accumulating 7,436 seconds of hot fire time over 47 separate tests. While the first two test series explored low power combustion (chug) and system instabilities, the third test series investigated and was ultimately successful in demonstrating several mitigating technologies for these instabilities and achieved a stable throttling ratio of 13:1. The fourth test series significantly expanded the engine s operability envelope by successfully demonstrating a closed-loop control system and extensive transient modeling to enable lower power engine starting, faster throttle ramp rates, and mission-specific ignition testing. The final hot fire test demonstrated a chug-free, minimum power level of 5.9%, corresponding to an overall 17.6:1 throttling ratio achieved. In total, these tests have provided an early technology demonstration of an enabling cryogenic propulsion concept with invaluable system-level technology data acquisition toward design and development risk mitigation for future lander descent main engines.

Giuliano, Victor J.↗
DOE OSTI2025

Enhancing EnergyPlus capabilities to model dynamic building envelopes using python plugin

Nearly half of the energy consumption in the United States is related to buildings, resulting in an urgent need to develop innovative technologies to improve building energy efficiency. Dynamic building envelopes, comprising switchable insulation and thermal energy storage materials, have been proposed recently as a promising solution to reduce buildings' heating and cooling loads by thermally coupling the indoor environment with the ambient environment when beneficial while decoupling them when outdoor conditions are not favorable. Although various related technologies are still underway, the whole-building energy modeling tools, like EnergyPlus, do not have the capability to simulate the transient and dynamic nature of dynamic envelope materials and components to accurately predict their impact on building energy use. The objective of this study is to formulate a method in EnergyPlus simulation engine to model multilayer envelopes, comprising dynamic building materials with variable thermophysical properties, and discuss the changes made to the program using a Python plugin. Furthermore, the thermal performance of the dynamic envelopes using the proposed method is compared and verified with the results from a well-established commercial code, COMSOL Multiphysics. A parametric assessment is also conducted to evaluate the energy efficiency benefits of dynamic envelopes in a single-family residential building, demonstrating total annual energy savings up to 11.6 %, when a dynamic envelope operates alone, and up to 18.2 % when it is combined with a thin layer of phase change material as a thermal storage medium. Finally, a United States wide energy efficiency assessment is presented to showcase the geographical spread of the energy savings. The method designed and implemented in this study provides the researchers with the ability to implement their dynamic insulation methods in EnergyPlus and evaluate the whole building energy impact.

25 ENERGY STORAGE↗
NASA NTRS2017

Structural Design Exploration of an Electric Powered Multi-Propulsor Wing Configuration

Advancements in aircraft electric propulsion may enable an expanded operational envelope for electrically powered vehicles compared to their internal combustion engine counterparts. High aspect ratio wings provide additional lift and drag reduction for a proposed multi-propulsor design, however, the challenge is to reduce the weight of wing structures while maintaining adequate structural and aeroelastic margins. Design exploration using a conventional design-and-build philosophy coupled with a finite element method (FEM)-based design of experiments (DOE) strategy are presented to examine high aspect ratio wing structures that have spanwise distributed electric motors. Multiple leading-edge-mounted engine masses presented a challenge to design a wing within acceptable limits for dynamic and aeroelastic stability. Because the first four primary bending eigenmodes of the proposed wing structure are very sensitive to outboard motor placement, safety-of-flight requirements drove the need for multiple spars, rib attachments, and outboard structural reinforcements in the design. Global aeroelasticity became an increasingly important design constraint during the on-going design process, with outboard motor pod flutter ultimately becoming a primary design constraint. Designers successively generated models to examine stress, dynamics, and aeroelasticity concurrently. This research specifically addressed satisfying multi-disciplinary design criteria to generate fluid-structure interaction solution sets, and produced high aspect ratio primary structure designs for the NASA Scalable Convergent Electric Propulsion Technology and Operations Research (SCEPTOR) project in the Aeronautic Research Mission Directorate at NASA. In this paper, a dynamics-driven, quasi-inverse design methodology is presented to address aerodynamic performance goals and structural challenges encountered for the SCEPTOR demonstrator vehicle. These results are compared with a traditional computer aided design based approach.

Moore, James B.↗
DOE OSTI2024

Design of Mini-Plate-1 Irradiation Test for Qualification of High-Density, Low-Enriched U-10Mo Monolithic Fuel

The United States High Performance Research Reactor project is tasked with fuel development and qualification leading to conversion of higher power research and test reactors in the US from high-enriched uranium (HEU) to low-enriched uranium (LEU) fuels. Here, this manuscript identifies the functional and operational design requirements of the first miniature test plate (mini-plate [MP]) irradiation campaign (MP-1) of commercially fabricated LEU U-10Mo monolithic plate-type fuel and is the precursor to a large parametric mini-plate test (MP-2) aimed at producing the data to support regulatory qualification of the LEU U-10Mo monolithic fuel. The manuscript (1) provides a general description of the selected U-10Mo LEU fuel and (2) defines the overall experiment design and functional requirements to accomplish the specific test objective of MP-1, which is to confirm that the commercially manufactured LEU U-10Mo monolithic fuel meets the established requirements of geometric stability, mechanical integrity and stable and predictable behavior. The fuel testing parameters are established by the need to bound performance behavior within the operational envelope of the reactors being converted.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Reactor and fuel cycle performance of light water reactor fuel with 235 U enrichments above 5%

Recent advances in nuclear fuel materials research, particularly on the topic of accident-tolerant fuels, have brought up potential opportunities for expanding the operating envelope of existing light water reactors. As many of the performance improvements offered by these technologies may be most fully realized by increasing fuel enrichment beyond the standard 5% limit, this paper examines the potential reactor performance and fuel cycle performance of low-enriched uranium oxide fueled light water reactors by generically considering pressurized water reactors with 235 U enrichment from 5 to 7%. Advanced cladding, including accident-tolerant cladding, has the potential to increase fuel burnup limits related to hydrogen in the cladding that coincide with those limits associated with end-of-life reactivity. Therefore, higher enrichment will be necessary in order to realize the higher fuel burnups. This work includes evaluation of the fuel cycle length, discharge burnup, reactivity coefficients, and fuel cycle performance, including radioactive waste and environmental impact metrics per unit energy generated. The analysis was performed using the evaluation metrics from the US Department of Energy Office of Nuclear Energy Fuel Cycle Evaluation and Screening Study. The reactor performance and safety analysis show that enrichments between 5 and 7% would have similar fuel temperature and moderator temperature coefficients. However, the soluble boron coefficient would decrease in magnitude, requiring more corrosive boric acid in the coolant or other methods of reactivity control during the fuel cycle. At these higher enrichments the maximum burnup at the rim of the fuel pellet would increase by almost a factor of two, which is expected to impact the formation of high-burnup structure in the fuel and the corresponding thermo-mechanical fuel properties. The fuel cycle performance assessment shows that increasing enrichment reduces the quantity of high-level waste disposed per unit energy generated, but it increases the natural resource requirements normalized to a gigawatt-electricity-per-year basis. Another impact is the slightly higher discharge burnup, resulting in somewhat different activity levels of the spent nuclear fuel and high-level waste radioactivity at 100 and 100,000 years after fuel discharge. The environmental impacts—including land use, water use, carbon emission, and radiological exposure—are of the same magnitude per unit energy generated. Finally, however, the impacts are distributed differently. Less than 5% enrichment has marginally more impact on the back-end of the fuel cycle, and greater than 5% enrichment has marginally more impact on the front-end of the fuel cycle. Ultimately, no neutronic or reactor safety hindrances to employing light water reactor fuel with enrichments greater than 5% are identified; given the achievable reactor performance benefits with advanced fuels, further practical exploration of increased enrichment fuel is recommended.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Pressure drop and heat transfer characteristics of nitrate salt and supercritical CO 2 in a diffusion-bonded heat exchanger

A lab-scale 316/L stainless steel diffusion-bonded heat exchanger was examined within a coupled high-temperature test facility consisting of an atmospheric-pressure nitrate salt loop and a supercritical carbon dioxide (sCO 2 ) loop operating between 10 and 16 MPa. Pressure loss measurements collected for flow rates up to 0.55 kg/s of Solar Salt and up to 0.6 kg/s of carbon dioxide were used to generate friction factor correlations for the respective circular and semicircular zig-zag flow passages. Heat transfer measurements were also performed over a wide range of conditions to produce Nusselt correlations for the CO 2 and nitrate salt geometries. The Nusselt number is deduced from a heat transfer resistance network and overall conductance measurements collected across the operating envelope of the coupled sCO 2 – nitrate salt test facility. The CO 2 side correlation showed excellent agreement with existing correlations in the literature. Further, the salt side, having nearly circular channels with a different zig-zag angle and hydraulic diameter, yielded a new correlation applicable to the laminar flow regime. To examine the similitude of the friction correlations, pressure drop testing with water was performed on both sides of the component as well. Finally, results from non-destructive examination are discussed to provide insights regarding inspection methods and draining performance of high-temperature liquids in compact heat exchangers.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Integrated system to reduce emissions from natural gas-fired reciprocating engines

Natural gas-fired reciprocating engines (NGFRE), which are naturally aspirated are used in the oil and gas industry for the production, storage, processing, and transmission of natural gas extracted from wells. These stationary, lean-burn engines exhibit increased combustion instability and higher emissions of methane (CH 4 ) and Volatile Organic Compounds (VOCs) at lower loads, resulting in restrictions on the operational envelope of such engines. Here, in this paper, some of the emission reduction technologies for NGFREs are reviewed. Also, an experimental investigation of an integrated system to reduce emissions and improve the combustion performance of an NGFRE is presented. The integrated system consists of an air management package and integrated sensors including an amperometric NOx/O 2 sensor, exhaust temperature thermocouple, pressure transducers and vibration sensors. Experiments were carried out using natural gas and natural gas/propane blends at different load steps, and combustion performance, as well as emissions, were analyzed. For natural gas fuel, the results show that the standard deviation of peak pressure and indicated thermal efficiency (ITE) improved by 67.4 psi and 4.2% respectively, at 40% load. Similarly, CH 4 and Nitrogen Oxides (NOx) emissions reduced considerably by 84% and 63% respectively. However, CO emissions increased from 8 ppm to 152 ppm. At 60% load, the ITE improved by 3.8% and the CH 4 emissions were reduced by 68%. The reduction in VOCs emissions was 63% at 40% load and 69% at 60% load. The findings of this research provide evidence of the effectiveness of the integrated air management system in improving the sustainability of NGFREs. In general, this technology can be implemented on air-assisted combustion applications to improve combustion performance and, consequently, reduce emissions.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Design of a novel carbon/carbon composite microvascular solar receiver

Solar thermal power tower systems are the primary technology being proposed for solar electricity from thermal energy. Operational limits on these towers are often driven by mechanical properties under significant thermal loads, particularly at the receiver where incoming flux is converted to thermal energy. While the solar receiver’s efficiency is largely driven by its optical properties, thermomechanical stresses on the receiver limits the operational envelope. One pathway to higher efficiency is greater allowable solar fluxes on the receiver but novel materials are required. The present study uses computational fluid dynamics to describe a parametric design space for a microvascular carbon/carbon composite solar receiver as a new material option for high flux solar receivers. Simulations are conducted for different microvascular geometries considering the role of material properties and heat transfer fluids, for the impact on thermal efficiency, and allowable strain. Results show that microscale receiver modules made of the proposed carbon/carbon composite could achieve thermal efficiencies over 90% and full-scale receivers can achieve up to 85% thermal efficiency for the design explored considering realistic strain limits, flux levels, and material properties. These values are highly dependent on the heat transfer fluid pairing, the through plane thermal conductivity of the carbon/carbon composite, the path architecture of the microscale receiver, and the incident solar flux profiles.

14 SOLAR ENERGY↗
DOE OSTI2022

Design of an Additively Manufactured Recuperator With 800 °C Inlet Temperature for sCO2 Power Cycle Application

Abstract Recuperators with design temperatures at and above 800 °C can further increase the thermal efficiency of supercritical CO2 power cycles by enabling higher turbine exhaust temperatures. Mar-M247 is a well-suited nickel-based superalloy for high temperature service due to its high creep strength that prevents excessive material thickness being required for pressure containment. Additive manufacturing using a high-speed laser-directed energy deposition (L-DED) process presents a promising solution, with build trials demonstrating the ability to produce nonconventional flow channels for enhanced heat transfer. A design process is presented that includes aerothermal and mechanical evaluation to maximize performance within the constraints of the manufacturing process. A 2-D heat transfer network and pressure drop code allows prediction of flow distribution and its effect on overall thermal performance. Established literature correlations, along with CFD simulation, inform the prediction of heat transfer coefficients and friction factors for the flowpaths and enhancement features in the heat exchanger core. Mechanical evaluation using finite element analysis (FEA) modeling with the intent of the ASME Boiler & Pressure Vessel Code (BPVC) Section VIII, Div. 2 assesses the operational safety of the design. The detailed design features annular finned passages that take advantage of helical flow paths to distribute the flow from separated headers to shared heat transfer surfaces. Performance predictions for the recuperator at a 50 kW scale provide insights into the feasibility of the additively manufactured (AM) process to produce recuperators on a commercial scale that extend existing operating envelopes.

Engineering↗
DOE OSTI2023

Modeling Electrochemical and Rheological Characteristics of Suspension-Based Electrodes for Redox Flow Cells

Flowable suspension-based electrodes (FSEs) have gained attention in recent years, as the integration of solid materials into electrochemical flow cells can offer improved performance and flexible operation. However, under conditions that engender favorable electrochemical properties (e.g., high particle loading, high conductivity, high surface area), FSEs can exhibit non-Newtonian characteristics that impose large pumping losses and flow-dependent transport rates. These multifaceted trade-offs motivate the use of models to broadly explore scaling relationships and better understand design rules for electrochemical devices. To this end, we present a one-dimensional model, integrating porous electrode theory with FSE rheology as well as flow-dependent electron and mass transport under pressure-driven flow. We study FSE behavior as a function of material properties and operating conditions, identifying key dimensionless groups that describe the underlying physical processes. We assess flow cell performance by quantifying electrode polarization and relative pumping losses, establishing generalized property-performance relationships for FSEs. Importantly, we expound relevant operating regimes—based on a subset of dimensionless groups—that inform practical operating envelopes, ultimately helping to guide FSE and cell engineering for electrochemical systems.

25 ENERGY STORAGE↗