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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 OSTI2026

CO2 Handling & Electrolyzer Efficiency Scaling Evaluator

CHEESE is an interactive dashboard tool for estimating the performance and material requirements of carbon dioxide electrolysis systems. It helps users evaluate how electrode area, current density, product selectivity, gas flow, cell voltage, and the number of cells in a stack affect system operation. The dashboard provides simple and advanced modes so it can be used for both quick estimates and more detailed engineering analysis. Users can estimate product output, carbon dioxide use, electrical power, electrode area, gas and liquid flow rates, energy efficiency, material cost per test, and the effect of scaling from a single cell to a multi cell stack. It also includes tools for examining carbon balance, equipment durability, component replacement, and changes in performance over time. This is intended to help both academia and industry researchers who are either getting into CO2 electrolysis on lab-scale or are trying to establish a larger footprint. CHEESE presents results through tables, charts, and simplified cell and stack diagrams. It is intended to support research planning, experimental design, comparison of operating conditions, and early stage scale up studies.

Prajapati, Aditya [Lawrence Livermore National Lab↗
DOE OSTI2021

Diesel-like Fuels, Combustion, and Emissions

The need to reduce the carbon footprint from medium- and heavy-duty diesel engines is clear; low-carbon biofuels are a powerful means to achieve this. Liquid fuels are rapidly deployed because existing infrastructure can be utilized for their production, transport, and distribution. Their impact is unique as they can decrease the greenhouse gas (GHG) emissions of existing vehicles and in applications resistant to electrification. However, introducing new diesel-like bio-blends into the market is very challenging. At a minimum, it requires a comprehensive understanding of the life-cycle GHG emissions of the fuels, the implications for refinery optimization and economics, the fuel’s impact on the infrastructure, the effect on the combustion performance of current and future vehicle fleets, and finally the implications for exhaust aftertreatment systems and compliance with emissions regulations. Such understanding is sought within the Co-Optima project.

02 PETROLEUM↗
DOE OSTI2024

Pilot-Scale Algal Oil Production

The main objective of the project is complete: development of a preliminary planning and design for a pilot-scale algal oil cultivation and processing facility, FEL-3 design with -5% / +15% cost estimate accuracy, and conversion of the algal oil to biofuel in an off-site existing bio-oil refinery. The design basis includes 10 tons per day of dried algae cultivated with CO 2 supplied by direct air capture, electricity supplied solar power, well water supply, zero liquid discharge, off-site extraction, and off-site conversion of oil to biofuel. The design and permitting package is an important milestone in the path to commercialization of algal biofuels and bioproducts as it provides the preliminary design, permitting path, long-term land lease, planning documents, and team needed for success in future engineering, construction, start-up and operations of a pilot-scale farm at a site in Paso Robles, CA. Outcomes of the business assessment include (i) identification of a product spectrum for economical algal biofuels using co-products with markets that are commensurate with production of 6-7 billion gallons per year of sustainable aviation fuel (SAF), renewable diesel, and renewable gasoline, (ii) a path toward near-term contribution of algae oil to SAF, and (iii) an approach for long-term operation of a pilot-scale farm.

09 BIOMASS FUELS↗
DOE OSTI2023

High Temperature Ternary Chloride Molten Salt Pump

This work investigates the design criteria considering thermal, structural, and material selection of a ternary chloride (MgCl2-NaCl-KCl) molten salt pump that is capable of running at temperatures above 720 °C. In this work, preliminary testing of salt-wetted hydrodynamic bearings was done to investigate different material pairings including Colmonoy grades, Stellite grades, and a novel Nickel Tungsten Carbide alloy (HybrimetTM NiWC3b) used as a High Velocity Oxygen Fuel (HVOF) coating. The coating has shown to withstand the corrosive nature of the molten salt. The pump wetted components are made of Inconel 625 and features a carbon ring seal (CIRPAC Seal) flooded with a N2 gas flow on the overhead to keep salt vapors from interacting with the external ambient air. A comprehensive pump test program has been completed. Over 90 hours run time pumping hot chloride salts at temperatures up to 720 °C in which enough data was captured to produce performance curves at 3 different operating speeds. This research showcases a promising design for use in the Concentrated Solar Power (CSP) Gen 3 liquid-pathway and sets the ground for further development and use of the HybrimetTM NiWC3b as a competitive alternative to available superalloys.

14 SOLAR ENERGY↗
DOE OSTI2022

Pumped Thermal Energy Storage With Liquid Storage

Pumped Thermal Energy Storage (PTES) uses electricity to power a heat pump; transferring heat from a cold space to a hot space forms a hot and a cold thermal reservoir, thereby storing energy. To discharge, the temperature difference between the two stores is used to drive a heat engine which generates electricity. In this chapter, PTES systems which store energy in liquids will be described. The chapter will concentrate on Joule-Brayton power cycles with molten salt storage. Part-load operation of Joule-Brayton PTES with liquid storage can be managed with "inventory control," and it is demonstrated that this control method leads to relatively good performance over a range of operating points.

Carnot batteries↗
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

Operational Modes of a 2.0 MWth Chloride Molten-Salt Pilot-Scale System

The limit of traditional solar-salt thermal stability is around 600 °C with ambient air as the cover gas. Nitrate molten salt concentrating solar power (CSP) systems are currently deployed globally and are considered to be state-of the art heat transfer fluids (HTFs) for present day high-temperature operation. However, decomposition challenges occur with these salts for operation beyond 600 C. Although slightly higher limits may be possible with solar salt, to fully realize SunShot efficiency goals of $15/kWhth HTFs and an LCOE of 6¢/kWh, molten-salt technologies working at higher temperatures (e.g., 650 °C to 750 °C) will require an alternative salt chemistry composition, such as chlorides. In this investigation a 2.0MWth Pilot-scale CSP plant design is developed to assess thermodynamic performance potential for operation up to 720 C. Here, an Engineering Equation Solver (EES) model is developed with respect to 14 state-points from the base of a solar tower at the Sandia National Laboratories, National Solar Thermal Test Facility (NSTTF), to solar receiver mounted 120 ft. above the ground. The system design considers a ternary chloride ternary chloride (20%NaCl/40%MgCl/40%KCl by mol%) salt as the HTF, with 6 hrs. of storage and a 1 MWth primary salt to sCO2 heat exchanger. Preliminary system modelling results indicate a minimum non-dimensional Cv of 60 required for both cold and hot-side throttle recirculation valves for the operational pump operating between speeds of 1800 and 2400 RPM. Further receiver comparison study results suggest that the ternary salt requires an average 15.2% higher receiver flux with a slightly lower calculated receiver efficiency when compared to a binary carnelite salt to achieve a 2.0 MWth desired input power design.

associated liquids↗
DOE OSTI2024

Ab-initio molecular dynamics study of eutectic chloride salt: MgCl2–NaCl–KCl

Ionic liquid materials are viable candidates as a heat transfer fluid (HTF) in a wide range of applications, notably within concentrated solar power (CSP) technology and molten salt reactors (MSRs). For next-generation CSP and MSR technologies that strive for higher power generation efficiency, a HTF with wide liquid phase range and energy storage capabilities is crucial. Studies have shown that eutectic chloride salts exhibit thermal stability at high temperatures, high heat storage capacity, and are less expensive than nitrate and carbonate salts. However, the experimental data needed to fully evaluate the potential of eutectic chloride salts as a HTF contender are scarce and entail large uncertainties. Considering the high cost and potential hazards associated with the experimental methods used to determine the properties of ionic liquids, molecular modeling can be used as a viable alternative resource. In this study, the eutectic ternary chloride salt MgCl 2 –NaCl–KCl is modeled using ab-initio molecular dynamics simulations (AIMDs) in the liquid phase. Using the simulated data, the thermophysical and transport properties of eutectic chloride salt can be calculated: density, viscosity, heat capacity, diffusion coefficient, and ionic conductivity. For an initial model validation, experimental pair-distribution function data were obtained from X-ray total scattering techniques and compared to the theoretical pair-distribution function. Additionally, theoretical viscosity values are compared to experimental viscosity values for a similar system. The results provide a starting foundation for a MgCl 2 –NaCl–KCl model that can be extended to predict other fundamental properties.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2023

Real-time monitoring of the orthohydrogen fraction in a liquid hydrogen moderator

Here, we present the first direct measurements of the orthohydrogen fraction in an operating liquid hydrogen moderator loop at a high-powered neutron source. We have developed a Raman immersion probe capable of characterizing the orthohydrogen and parahydrogen makeup of a liquid hydrogen loop approximately every ten seconds, which can see orthohydrogen fractions lower than 0.20 without difficulty. At the Spallation Neutron Source, where the time-averaged power deposition in the studied moderator system is around 0.02 W/cm 3 , the orthohydrogen fraction increases with beam power and equilibrates at levels of 0.40 and responds to beam trips in a dynamic fashion. Additionally, we find that without deliberate catalyst systems in place, the relaxation due to the piping in the system has insignificant effect in catalyzing the relaxation of freshly condensed hydrogen toward thermodynamic equilibrium, and that the radiation levels associated with activation in a non-operating spallation neutron source target-moderator-reflector assembly likewise has insignificant effect on the liquid hydrogen kinetics.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

Effects of frequency and pulse width on electron density, hydrogen peroxide generation, and perfluorooctanoic acid mineralization in a nanosecond pulsed discharge gas-liquid plasma reactor

Plasma electron density and temperature were characterized in a continuous flowing gas-liquid film reactor with argon carrier gas by time-resolved optical emission spectroscopy. The plasma parameters were studied as a function of time for varying pulse widths and frequencies. Pulse frequency was varied between 1 and 10 kHz at 16 kV (input voltage) and 40 ns (pulse width) using an Eagle Harbor Technologies, Inc. (EHT) power supply and 5–100 kHz using an Airity Technologies, LLC (AT) power supply. The pulse width was varied between 40 and 200 ns at 16 kV, 2 kHz with the EHT power supply. Optimal frequencies of 5 and 20 kHz were observed for peak electron density with EHT and AT power supplies, respectively. The peak electron density increased with increasing pulse width between 40 and 200 ns using the EHT power supply. Hydrogen peroxide exiting the reactor in the liquid phase increased with discharge power irrespective of the power supply or pulse parameters. Mineralization of 12.5, 50, and 200 ppm perfluorooctanoic acid (PFOA) dissolved in DI water to fluoride (F - ) correlated to the peak electron density. Glycerol, a liquid-phase hydroxyl radical scavenger, depleted hydrogen peroxide but did not affect PFOA mineralization. CO, a gas-phase hydroxyl radical scavenger, led to a reduction in the formation of F - production, suggesting hydroxyl radicals in the gas-liquid film play a necessary, but not singular, role in mineralization of PFOA.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

A high efficiency and low vibration liquid nitrogen cooling system for silicon crystal based x-ray optics

A compact low-cost cryocooling system has been designed, constructed, and tested at SLAC National Accelerator Laboratory. The cooling power is provided by natural convection and phase change of the liquid nitrogen. The initial application was to cool silicon crystal optics to the sub-100 K range. A silicon crystal of dimension (width × depth × height) 50 × 50 × 30 mm3 has been used with an electric heater on the top surface in this prototyping test. This system can effectively provide more than 80 W of cooling power to the optics with a consumption of liquid nitrogen less than 2.1 l/h. The vibration of the silicon crystal was monitored during the tests with added electric heater power on the crystal. We note the vibration of the silicon crystal due to liquid nitrogen boiling is negligible.

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

New High-Strength Ni-based Alloys for High Temperature Service in Liquid Fluoride Salt Environments

The ever-increasing demand for higher system thermal efficiency necessitates the operation of power generation cycles and heat conversion systems for chemical processes at progressively higher temperatures. As the system operating temperature increases, fewer and fewer materials are available with the required mechanical properties and environmental compatibility. This dearth of materials is particularly acute in structural applications at temperatures above 700°C in liquid Fluoride Salt Cooled High-Temperature Reactors (FHRs) and Concentrated Solar Power (CSP) systems where liquid fluoride and/or liquid chloride salts are used for their high thermal capacity and low thermal conductivity to store and transport heat. It has been shown that fluorides and chlorides can degrade the properties of the material used for storage and transport due to corrosive effects thus affecting the performance and lifetime characteristics. Thus, materials used for storage and transport for fluoride/chloride-salt must at the minimum have good compatibility with the salt by exhibiting low corrosion rates at the required temperatures. In addition, since many of the components will be subject to stresses in service, they need to have sufficient strength to resist plastic deformation, and the resistance to time dependent creep deformation at these temperatures, and stress levels. Achieving the combination of these properties required for higher temperatures is particularly challenging considering traditionally, the expected lifetime of some of the components used in these systems are from 30 years (CSP) to 80 years (FHRs). Although 316 stainless steel and associated redox corrosion reduction techniques are being considered for use in the first generational systems, use of 316SS is limited to operating temperatures up to ~ 650°C, thereby resulting in lower reactor efficiencies. Hastelloy ® N, developed at ORNL in the 1950s-60s for molten salt service is currently the leading candidate FHR structural alloy but has inadequate creep properties at high temperatures. Using a computationally-guided approach, Oak Ridge National Laboratory had developed new high strength alloys strengthened by γ’ precipitates (about 2X the strength of Hastelloy ® N) in small laboratory-scale heats that show good resistance to corrosion by fluorides and improved creep rupture life at temperatures up to 850°C (U.S. Patent Application No. 13/833,357 entitled “High Strength Alloys for High Temperature Service in Liquid-Salt Cooled Energy Systems”- granted U. S. Patent No. 9,540,714).

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Alternatives to MARVEL Power Conversion – Comparison of Stirling Engine Thermal Efficiency and Design to other Power Conversion Cycles

The Microreactor Applications, Research, Validation, and Evaluation (MARVEL) Reactor is a small liquid-metal thermal reactor that will be built at the Idaho National Laboratory to demonstrate design and operating processes for microreactors, microgrid integration, and process heat applications. Power conversion in the MARVEL design is provided by Stirling engines, which have disadvantages in nuclear environments. Compared to Stirling engine performance, some alternative power cycles can increase power production when coupled to a liquid-metal thermal reactor In this paper, the thermal efficiency of MARVEL’s power production with Stirling engines is compared to the thermal efficiency of power production with MARVEL and alternative power cycles. Those cycles include a superheated Rankine cycle, open and closed Brayton cycles, and a supercritical carbon dioxide cycle. All cycles (except the Stirling engines) were modeled with an intermediate helium loop to meet MARVEL’s principal design criteria. All models are simple designs with conservative assumptions for consistent comparison. Detailed optimization will depend largely on reactor location and application, and the relative merit of each cycle is discussed for different environmental conditions. The study informs significant early decisions on power cycle design and economic

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

Accessibility and Availability of Gas Stations for Liquid Fuel Supply During Severe Weather Events

Energy infrastructure is a pivotal lifeline with wider inter-dependencies. Electric power is essential to the continued functioning of critical assets; liquid fuels and other physical primary energy commodities that are used to supply the local energy needs of these assets during extreme events when electricity infrastructure is compromised. During Superstorm Sandy, the disruption of fuel supplies in the Tri-state area necessitated increasing situational awareness about oil and natural gas (ONG) systems to redirect fuel supplies to first responders and for restoration efforts. During winter storm events over the past several years, the demand for ONG for heating and power generation has skyrocketed in the north-east, which subsequently had caused ONG price to hit their highest level in years. ONG is a major energy source for restoration and recovery activities. However, very little, if any, situational awareness information about ONG supply and demand is available to those coordinating emergency efforts. Often this lack of information is due to the decentralized nature of the ONG supply chain and proprietary data maintained by private entities. To understand the impact of fuel availability on response and recovery efforts, this research focuses on (i) determining the accessibility to gas stations for liquid fuel supply across space and time, and (ii) examining the spatio-temporal variation of fuel availability and demand during extreme weather events. The broader scope of the project focuses on providing spatio-temporal situational awareness information about ONG availability and demand across the fuel supply chain for positioning of resources for response activities.

Kar, Bandana↗
DOE OSTI2022

Pursuing the Ultimate Power of Xenon Dark Matter Detectors (Annual Progress Report)

Liquid xenon-based experiments have been leading direct searches for dark matter – a cornerstone of modern cosmology and particle physics. Despite rapid improvement of experimental sensitivities in the past two decades, no definitive dark matter interactions have been observed. This project aims to expand the physics reach of existing and future xenon dark matter experiments, especially for low-mass dark matter interactions that would fall below the energy thresholds of current detectors. The main approach is to thoroughly characterize and to suppress the low-energy electron background observed in dual-phase xenon Time Projection Chambers (TPCs), which has so far prevented these detectors from achieving lower energy thresholds. Per recent discussion with and approval from the program manager, we have added a new task of experimentally measuring the Migdal effect to this project. The Migdal effect predicts that ultra-low energy dark matter interactions may produce detectable electron recoil signals in liquid xenon at the keV level in addition to much lower energy nuclear recoils. If this effect is experimentally measured, it will drastically improve xenon detectors’ sensitivity to subGeV dark matter interactions. This new task shares strong synergy with the original project goal of pursuing the ultimate power of xenon dark matter experiments.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2025

Fuel cells for single-aisle regional aircraft: System configuration, performance and cost

A hydrogen fuel cell propelled electric aircraft can compete with incumbent turbofan technologies for single-aisle regional aircraft by coupling design of stack, air handling, thermal management, propulsion, and airframe to optimize performance. The stack operates at 95°C to facilitate heat rejection during take-off and below 75°C during cruise to extend lifetime and is oversized to satisfy power requirements at end of life. A multi-stage turbocompressor with a compression ratio >10 is selected to reach high stack power density at 11,300-m cruise altitude. The propulsion system is configured to accommodate air handling within the core duct, an inclined heat exchanger in the outer duct to limit the nacelle size, and variable area nozzles to independently control mass flows through the core and bypass ducts. The airframe is modified for maximum lift coefficient and longer balanced field length for dramatically reduced thrust during take-off, and the fuselage is stretched by 20% to store liquid hydrogen (LH 2 ). Modularization of power systems promotes safety in one engine inoperative scenarios and allows reaching specific power metrics for stack, balance-of-plant and fuel cell system (FCS), necessary for acceptable take-off weight. In conclusion, cost parity requires increase in FCS lifetime, LH 2 cost reduction, and improved FCS specific power.

Catalyst durability↗
DOE OSTI2020

Thermal and magnetic evolution of a crystallizing basal magma ocean in Earth's mantle

We present the thermochemical evolution of a downward crystallizing basal magma ocean (BMO) overlying the liquid outer core and probe its capability to dissipate enough power to generate and sustain an early dynamo. Furthermore, a total of 61 out of 112 scenarios for a BMO with imposed, present-day heat flux, Q BMO , values of 15, 18, and 21 TW and radiogenic heat, Q r , values of 4, 8, and 12 TW fully crystallized during the age of the Earth. Most of these models are energetically capable of inducing magnetic activity for the first 1.5 Gyrs, at least, with durations extending to 2.5 Gyrs; with final core-mantle boundary (CMB) temperatures of 4400 ±500 K-well within current best estimates for inferred temperatures. None of the models with Q BMO = 12 TW achieved a fully crystallized state, which may reflect a lower bound on the present-day heat flux across the CMB. BMO-powered dynamos exhibit strong dependence on the partition coefficient of iron into the liquid layer and its associated melting-point depression for a lower mantle composition at near-CMB conditions-parameters which are poorly constrained to date. Nonetheless, we show that a crystallizing BMO is a plausible mechanism to sustain an early magnetic field.

58 GEOSCIENCES↗
DOE OSTI2020

Internal Insulation and Corrosion Control of Molten Chloride Storage Tanks

The National Renewable Energy Laboratory (NREL) is leading a multi-national team to validate the potential of a chloride-based molten-salt system that uses a ternary blend of MgCl2/KCl/NaCl to provide higher temperature thermal energy storage capability, thereby allowing for higher efficiency in the power block of next-generation concentrating solar power systems. While higher thermal stability, greater operating temperature, and a more efficient power cycle are possible, the molten chlorides present several unique challenges, including the design of internal 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 design of the molten salt storage tanks.

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