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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Assessing the limitations of commercial sensors and models for supporting marine carbon dioxide removal monitoring: a case study

Several unknowns remain surrounding marine Carbon Dioxide Removal (mCDR) monitoring, reporting, and verification (MRV) practices and capabilities. Current in-situ sensor technology is limited (primarily pH and pCO 2 ), requiring calculations and assumptions to estimate changes in carbonate chemistry parameters, including total alkalinity (TA). Considering that cost, energy consumption, and accuracy of commercial sensors can vary by orders of magnitude, understanding how well existing sensors perform in an mCDR context is important for this emerging community. Likewise, documenting sensor limitations and how relatively simple models can optimize sensor deployments will improve MRV efforts and support protocol development. Here we (1) compare performance a variety of commercially available sensors in a blind mesocosm experiment simulating ocean alkalinity enhancement (OAE), and how sensor performance impacted carbonate chemistry estimates; (2) evaluate if sensors can distinguish the OAE signal from natural variability during a small scale OAE field test in Sequim Bay, WA, USA, and (3) use an idealized ocean biogeochemistry model to explore optimal sensor network design based on (1) and (2). Our mesocosm results indicate that correctly constraining pH uncertainty will be critical for accurate TA estimates with current sensor technology compared to the less impactful variation caused by uncertainty in pCO 2 (pH data that are presented throughout are reported on the total scale (pH T ) unless otherwise noted). Our pilot field test demonstrated that sensors were capable of distinguishing mCDR signatures from natural variability under optimal real-world conditions. Idealized modeling simulations of the field test showed that a range of sparse and dense (3 to 100) sensors sampling areas of detectable increases will underestimate the net change in surface pH by at least 35–55%, at both realistic and highly elevated alkalinity input levels. We also highlight the limitations of current sensing technology for MRV, and the importance of ocean biogeochemistry models as critical tools for predicting when and where mCDR signals will be detectable using available sensors. Overall, our findings suggest that commercially available pCO 2 sensors and some pH sensors will form an important backbone for mCDR MRV tasks, though complete MRV characterization will require these data to be used in combination with other tools.

OAE↗
DOE OSTI2020

Structural Characterization of Potential Carbon Dioxide Reservoirs and Adjacent Strata within the Llandovery Silurian to Middle Devonian Strata of Ohio

The Midwest Regional Carbon Sequestration Partnership (MRCSP) has incorporated the work of geologic research teams (Geoteams) in its regional characterization, project planning and carbon dioxide (CO 2 ) injection implementation work since the partnership was established by the U.S. Department of Energy (DOE) in 2003. Over this 16-year period, the cohort of Geoteams has grown from five to ten states and has contributed to the characterization of geologic sequestration opportunities, refinement of reservoir and seal data, and supported injection efforts through both predictive and post-injection assessments. This report details the work led by the Ohio Department of Natural Resources, Division of Geological Survey to evaluate the structure of nine formations in the Appalachian Basin of Ohio to assess seal integrity and whether carbon dioxide (CO 2 ) migration pathways could pose a potential risk. As part of Phase II MRCSP work, the Pennsylvania Geological Survey led the characterization of the Llandovery Silurian (“middle Silurian”) to Middle Devonian regional geologic characterization CO 2 utilization and storage. This preliminary assessment included generalized, regional-scale mapping, as well as the development of relatively coarse structure and isochore maps of stratigraphic intervals of interest for the Appalachian Basin. Because this stratigraphic interval offers several enhanced oil recovery targets and secondary targets for CO 2 storage, the Ohio Geological Survey undertook efforts in Phase III to characterize the Ohio’s portion of the Appalachian Basin more precisely and to resolve inconsistencies within Ohio’s formation tops. This study refined the subsurface correlations of the Silurian-through-Devonian stratigraphic section in Ohio. Higher-resolution isochore mapping of the CO 2 storage reservoirs and seals provides greater detail of potential high-porosity zones and potential structural influence on the interval.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

The impact of regional resources and technology availability on carbon dioxide removal potential in the United States

To achieve net zero carbon emissions by mid-century, the United States may need to rely on carbon dioxide removal (CDR) to offset emissions from difficult-to-decarbonize sectors and/or shortfalls in near-term mitigation efforts. CDR can be delivered using many approaches with different requirements for land, water, geologic carbon storage capacity, energy, and other resources. The availability of these resources varies by region in the U.S. suggesting that CDR deployment will be uneven across the country. Using the global change analysis model for the United States (GCAM-USA), we modeled six classes of CDR and explored their potential using four scenarios: a scenario where all the CDR pathways are available (Full Portfolio), a scenario with restricted carbon capture and storage (Low CCS), a scenario where the availability of bio-based CDR options is limited (Low Bio), and a scenario with constraints on enhanced rock weathering (ERW) capabilities (Low ERW). We find that by employing a diverse set of CDR approaches, the U.S. could remove between 1 and 1.9 GtCO 2 /yr by midcentury. In the Full Portfolio scenario, direct air carbon capture and storage (DACCS) predominates, delivering approximately 50% of CO 2 removal, with bioenergy with carbon capture and storage contributing 25%, and ERW delivering 11.5%. Texas and the agricultural Midwest lead in CDR deployment due to their abundant agricultural land and geological storage availability. In the Low CCS scenario, reliance on DACCS decreases, easing pressure on energy systems but increasing pressure on the land. In all cases CDR deployment was found to drive important impacts on energy, land, or materials supply chains (to supply ERW, for example) and these effects were generally more pronounced when fewer CDR technologies were available.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Strong Correspondence in Evapotranspiration and Carbon Dioxide Fluxes Between Different Eddy Covariance Systems Enables Quantification of Landscape Heterogeneity in Dryland Fluxes

Abstract The eddy covariance method is widely used to investigate fluxes of energy, water, and carbon dioxide at landscape scales, providing important information on how ecological systems function. Flux measurements quantify ecosystem responses to environmental perturbations and management strategies, including nature‐based climate‐change mitigation measures. However, due to the high cost of conventional instrumentation, most eddy covariance studies employ a single system, limiting spatial representation to the flux footprint. Insufficient replication may be limiting our understanding of ecosystem behavior. To address this limitation, we deployed eight lower‐cost eddy covariance systems in two clusters around two conventional eddy covariance systems in the Chihuahuan Desert of North America for a period of 2 years. These dryland settings characterized by large temperature variations and relatively low carbon dioxide fluxes represented a challenging setting for eddy covariance. We found very good closure of energy and water balance across all systems (within ±9% of unity). We found very good correspondence between the lower‐cost and conventional systems' fluxes of sensible heat (with concordance correlation coefficient (CCC) of ≥0.87), latent energy (evapotranspiration; CCC ≥ 0.89), and useful correspondence in the net ecosystem exchange ((NEE); with CCC ≥ 0.4) at the daily temporal resolution. Relative to the conventional systems, the low‐frequency systems were characterized by a higher level of random error, particularly in the NEE fluxes. Lower‐cost systems can enable wider deployment affording better replication and sampling of spatiotemporal variability at the expense of greater measurement noise that might be limiting for certain applications. Replicated eddy covariance observations may be useful when addressing gaps in the existing monitoring of critical and underrepresented ecosystems and for measuring areas larger than a single flux footprint.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Copper nanoparticle structures for reduction of carbon dioxide to multicarbon products

This disclosure provides systems, methods, and apparatus related to copper nanoparticle structures for reduction of carbon dioxide to multicarbon products. In one aspect, a method includes providing a plurality of copper nanoparticles. The plurality of copper nanoparticles are deposited on a support. The plurality of copper nanoparticles are transformed to a plurality of copper structures during an operation in which carbon dioxide is reduced. The plurality of copper nanoparticles on the support are used as a working electrode in an electrochemical cell during the operation.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Gas Hydrate Film Growth in Microfluidic Channels for Carbon Dioxide Capture and Sequestration Applications

Gas or clathrate hydrates are a solid, crystalline compound composed of water and guest molecules that typically form at high pressure and low temperature conditions. Carbon dioxide (CO2) hydrates may be involved in several carbon dioxide capture and sequestration (CCS) applications, including CO2 pipeline transportation and CO2 offshore sequestration. Within these applications, the formation mechanism and kinetics must be well understood to manage the CCS processes, either by preventing or promoting hydrate formation. In this work, a high-pressure glass microfluidic reactor is used in tandem with visual microscopy and in-situ Raman spectroscopy to study both the morphological and kinetic behavior of gas hydrate crystals. Subcooling, pressure, and CO2 flow rate are investigated for their impact on the thickening behavior of pure CO2 hydrates, with flow rate being the only parameter to have a significant effect. Visual and Raman spectroscopy evidence show that both a dense hydrate layer and a porous hydrate layer form, and the latter may provide a path for mass transfer to continue hydrate crystallization. A first principles mass transfer model is developed to describe CO2 hydrate crystal thickening at the interface between gas and water. The impacts of gas impurities and channel wettability are also studied. This method is further applied to investigate the conversion of methane hydrate to CO2 hydrate for combined energy recovery and methane hydrate formation. The authors acknowledge the US Department of Energy Basic Energy Science award # DE-SC0022162.

Wadsworth, Lindsey [Colorado School of Mines, Gold↗
DOE OSTI2023

Solvent Dynamics Are Critical to Understanding Carbon Dioxide Dissolution and Hydration in Water

Simulations of carbon dioxide (CO 2 ) in water may aid in understanding the impact of its accumulation in aquatic environments and help advance technologies for carbon capture and utilization (via, e.g., mineralization). Quantum mechanical (QM) simulations based on static molecular models with polarizable continuum solvation poorly reproduce the energetics of CO 2 hydration to form carbonic acid in water, independent of the level of QM theory employed. Only with density-functional-theory-based molecular dynamics and rare-event sampling, followed by energy corrections based on embedded correlated wavefunction theory (in conjunction with density functional embedding theory), can a close agreement between theory and experiment be achieved. Such multilevel simulations can serve as benchmarks for simpler, less costly models, giving insight into potential errors of the latter. The strong influence of sampling/averaging over dynamical solvent configurations on the energetics stems from the difference in polarity of both the transition state and product (both polar) versus the reactant (nonpolar). When a solute undergoes a change in polarity during reaction, affecting its interaction with the solvent, careful assessment of the energetic contribution of the solvent response to this change is critical. Here, we show that static models (without structural sampling) that incorporate three explicit water molecules can yield far superior results than models with more explicit water molecules because fewer water molecules yield less configurational artifacts. Static models intelligently incorporating both explicit (molecules directly participating in the reaction) and implicit solvation, along with a proper QM theory, e.g., CCSD(T) for closed-shell systems, can close the accuracy gap between static and dynamic models.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Carbon Dioxide Flux Measurement System (CO2FLX) Instrument Handbook

The Southern Great Plains (SGP) carbon dioxide flux (CO2 flux) measurement systems provide half-hour average fluxes of CO2, H2O (latent heat), and sensible heat. The fluxes are obtained by the eddy covariance technique, which computes the flux as the mean product of the vertical wind component with CO2 and H2O densities, or estimated virtual temperature. A three-dimensional sonic anemometer is used to obtain the orthogonal wind components and the virtual (sonic) temperature. An infrared gas analyzer is used to obtain the CO2 and H2O densities. A separate sub-system also collects half-hour average measures of meteorological and soil variables from separate 4-m towers.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

A New Coupled Biogeochemical Modeling Approach Provides Accurate Predictions of Methane and Carbon Dioxide Fluxes Across Diverse Tidal Wetlands

Abstract Tidal wetlands provide valuable ecosystem services, including storing large amounts of carbon. However, the net exchanges of carbon dioxide (CO 2 ) and methane (CH 4 ) in tidal wetlands are highly uncertain. While several biogeochemical models can operate in tidal wetlands, they have yet to be parameterized and validated against high‐frequency, ecosystem‐scale CO 2 and CH 4 flux measurements across diverse sites. We paired the Cohort Marsh Equilibrium Model (CMEM) with a version of the PEPRMT model called PEPRMT‐Tidal, which considers the effects of water table height, sulfate, and nitrate availability on CO 2 and CH 4 emissions. Using a model‐data fusion approach, we parameterized the model with three sites and validated it with two independent sites, with representation from the three marine coasts of North America. Gross primary productivity (GPP) and ecosystem respiration (R eco ) modules explained, on average, 73% of the variation in CO 2 exchange with low model error (normalized root mean square error (nRMSE) <1). The CH 4 module also explained the majority of variance in CH 4 emissions in validation sites ( R 2 = 0.54; nRMSE = 1.15). The PEPRMT‐Tidal‐CMEM model coupling is a key advance toward constraining estimates of greenhouse gas emissions across diverse North American tidal wetlands. Further analyses of model error and case studies during changing salinity conditions guide future modeling efforts regarding four main processes: (a) the influence of salinity and nitrate on GPP, (b) the influence of laterally transported dissolved inorganic C on R eco , (c) heterogeneous sulfate availability and methylotrophic methanogenesis impacts on surface CH 4 emissions, and (d) CH 4 responses to non‐periodic changes in salinity.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Leaf Trait Plasticity Alters Competitive Ability and Functioning of Simulated Tropical Trees in Response to Elevated Carbon Dioxide

The response of tropical ecosystems to elevated carbon dioxide (CO 2 ) remains a critical uncertainty in projections of future climate. Here, we investigate how leaf trait plasticity in response to elevated CO 2 alters projections of tropical forest competitive dynamics and functioning. We use vegetation demographic model simulations to quantify how plasticity in leaf mass per area and leaf carbon to nitrogen ratio alter the responses of carbon uptake, evapotranspiration, and competitive ability to a doubling of CO 2 in a tropical forest. Observationally constrained leaf trait plasticity in response to CO 2 fertilization reduces the degree to which tropical tree carbon uptake is affected by a doubling of CO 2 (up to -14.7% as compared to a case with no plasticity; 95% confidence interval [CI95%] -14.4 to -15.0). It also diminishes evapotranspiration (up to -7.0%, CI95% -6.4 to -7.7), and lowers competitive ability in comparison to a tree with no plasticity. Consideration of leaf trait plasticity to elevated CO 2 lowers tropical ecosystem carbon uptake and evapotranspirative cooling in the absence of changes in plant-type abundance. However, “plastic” responses to high CO 2 which maintain higher levels of plant productivity, many of which fall outside of the observed range of response, are potentially more competitively advantageous, thus, including changes in plant type abundance may mitigate these decreases in ecosystem functioning. Models that explicitly represent competition between plants with alternative leaf trait plasticity in response to elevated CO 2 are needed to capture these influences on tropical forest functioning and large-scale climate.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Abrupt permafrost thaw drives spatially heterogeneous soil moisture and carbon dioxide fluxes in upland tundra

Permafrost thaw causes the seasonally thawed active layer to deepen, causing the Arctic to shift toward carbon release as soil organic matter becomes susceptible to decomposition. Ground subsidence initiated by ice loss can cause these soils to collapse abruptly, rapidly shifting soil moisture as microtopography changes and also accelerating carbon and nutrient mobilization. The uncertainty of soil moisture trajectories during thaw makes it difficult to predict the role of abrupt thaw in suppressing or exacerbating carbon losses. Here, in this study, we investigated the role of shifting soil moisture conditions on carbon dioxide fluxes during a 13-year permafrost warming experiment that exhibited abrupt thaw. Warming deepened the active layer differentially across treatments, leading to variable rates of subsidence and formation of thermokarst depressions. In turn, differential subsidence caused a gradient of moisture conditions, with some plots becoming consistently inundated with water within thermokarst depressions and others exhibiting generally dry, but more variable soil moisture conditions outside of thermokarst depressions. Experimentally induced permafrost thaw initially drove increasing rates of growing season gross primary productivity (GPP), ecosystem respiration (R eco ), and net ecosystem exchange (NEE) (higher carbon uptake), but the formation of thermokarst depressions began to reverse this trend with a high level of spatial heterogeneity. Plots that subsided at the slowest rate stayed relatively dry and supported higher CO 2 fluxes throughout the 13-year experiment, while plots that subsided very rapidly into the center of a thermokarst feature became consistently wet and experienced a rapid decline in growing season GPP, R eco , and NEE (lower carbon uptake or carbon release). These findings indicate that Earth system models, which do not simulate subsidence and often predict drier active layer conditions, likely overestimate net growing season carbon uptake in abruptly thawing landscapes.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Numerical Simulations of Carbon Dioxide Storage Efficiency in Heterogeneous Reservoir Models

The U.S. Department of Energy’s National Energy Technology Laboratory (DOE-NETL) has been developing methods and tools (the online Carbon Dioxide Storage prospeCtive Resource Estimation Excel aNalysis (CO2-SCREEN) tool) to estimate carbon dioxide (CO2) storage potential in subsurface reservoirs. The CO2 storage efficiency terms are input in the tool to calculate storage potential in targeted reservoirs. In this effort, two CO2 storage efficiency terms were evaluated: volumetric displacement ( E V ) and microscopic displacement ( E d ). The first term deals with efficiency of CO2 propagation into an accessible reservoir volume, while the second term evaluates effectiveness of native fluid displacement with CO2. The interpreted well logs and core sample measurements were applied to create the heterogeneous reservoir models including geostatistical realizations of porosity and intrinsic permeability fields. Supercritical CO2 was injected over the course of 30 years into brine-saturated reservoir models for clastics, limestone, and dolomite lithologies and deltaic fluvial, aeolian, shallow marine, and reef depositional environments by means of varying reservoir parameters and injection scenarios. The reservoir models providing vertically heterogeneous petrophysical properties and designated as “layered reservoir models” (with homogeneous parameters along each layer of the model) were not determined to be a transition between the homogeneous and heterogeneous models in respect to storage efficiency. Another finding shows that high-efficiency factors do not necessarily mean increased CO2 storage; they rather indicate that the available volume and pore space are more fully utilized. The CO2 storage efficiency factors were evaluated dynamically at the select time points using P 10 ‐ P 50 ‐ P 90 percentiles. The results of this study show that the P 10 ‐ P 90 distribution for volumetric efficiency is wider when compared to the microscopic efficiency. It was found that where dominant buoyancy forces drive the plume to the top of a target formation, the volumetric efficiency is low. Tighter sandstone and carbonate formations show prevalence of capillary forces and better utilization of reservoir volume.

Myshakin, Evgeniy M.↗
DOE OSTI2022

Plastic Waste Product Captures Carbon Dioxide in Nanometer Pores

We discuss, plastic waste (PW) and increasing atmospheric carbon dioxide (CO 2 ) levels are among the top environmental concerns presently facing humankind. With an ambitious 2050 zero-CO 2 emissions goal, there is a demand for economical CO 2 capture routes. Here we show that the thermal treatment of PW in the presence of potassium acetate yields an effective carbon sorbent with pores width of 0.7–1.4 nm for CO 2 capture. The PW to carbon sorbent process works with single or mixed streams of polyolefin plastics. The CO 2 capacity of the sorbent at 25 °C is 17.0 ± 1.1 wt % (3.80 ± 0.25 mmol g –1 ) at 1 bar and 5.0 ± 0.6 wt % (1.13 ± 0.13 mmol g –1 ) at 0.15 bar, and it regenerates upon reaching 75 ± 5 °C. The CO 2 capture cost from flue gas via this technology is estimated to be <$21 ton –1 CO 2 , much lower than competing CO 2 capture technologies. Hence, this PW-derived carbon material should find utility in the capture of CO 2 from point sources of high CO 2 emissions while providing a use for otherwise deleterious PW.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2020

Aluminum Metal–Organic Framework Triggers Carbon Dioxide Reduction Activity

Confinement of metal centers is a powerful tool to manipulate reactivity and tune selectivity in chemical transformations. While aluminum as a foil is inactive for carbon dioxide reduction and shows high selectivity for the hydrogen evolution reaction, here we show that aluminum confined in a metal-organic framework (MOF), MIL-53(Al), suppresses hydrogen evolution reaction activity and enhances carbon dioxide reduction. This aluminum MOF can produce up to 40% faradaic efficiency for carbon monoxide and formic acid. Here, this study demonstrates that the unique reaction environment created by the MOF enables changes in reaction selectivity and can impart atypical catalytic capabilities to metals.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Experimental Validation of a High-Temperature Test Facility for Future Additive Manufactured Supercritical Carbon Dioxide Turbine Testing

For next-generation power plants to achieve high cycle efficiencies consistent with the Department of Energy's 65% efficiency target, turbomachinery capable of operating within high-temperature power cycles must be demonstrated. Pairing additively manufactured superalloy turbines with the supercritical carbon dioxide (sCO 2 ) power cycle could enable turbine inlet temperatures approaching 1300 °C while providing flexibility in turbine cooling strategies. Development of test facilities to characterize and validate such systems is crucial. In this study, a turbine test facility capable of achieving inlet conditions of 800 °C, 11 MPa, and 0.43 kg/s while accommodating complex auxiliary cooling flow requirements has been designed and constructed to support future testing of a Haynes 282 additively manufactured 30 kW turbine-generator system with advanced cooling channels. This facility enables characterization of aerodynamic performance, leakage, and windage losses. Details of the facility's construction and operation are presented, along with experimental validation tests using an orifice as an expansion device in place of the turbine. These tests confirm that the facility can reach the required conditions, distinguish regions of achievable steady and pseudo-steady conditions, and identify the heater power required for each point in the upcoming turbine campaign. The campaign confirmed that ISO 5167-2 can reliably predict orifice mass flow rates in extreme supercritical carbon dioxide conditions with deviations of 0.5–7.5%.

42 ENGINEERING↗
DOE OSTI2022

Solar reduction of carbon dioxide on copper-tin electrocatalysts with energy conversion efficiency near 20%

Abstract Copper catalysts modified with tin have been demonstrated to be selective for the electroreduction of carbon dioxide to carbon monoxide. However, such catalysts require the precise control of tin loading amount. Here, we develop a copper/tin-oxide catalyst with dominant tin oxide surface being formed via a spontaneous exchange reaction between sputtered tin and copper oxide. Even though the surface of this catalyst is tin-rich, it achieves an excellent performance towards carbon monoxide production in a flow cell. This contrasts with copper/tin-oxide prepared via atomic layer deposition since it yields selectivity towards carbon monoxide only on a copper-rich surface. Mechanism studies reveal that the tin sites on the tin-rich copper/tin-oxide surface achieve a suitable binding with adsorbed carbon monoxide under the presence of copper. Powered by a triple-junction solar cell, the copper/tin-oxide based electrolyzer sets a new benchmark solar-to-chemical energy conversion efficiency of 19.9 percent with a Faradaic efficiency of 98.9 percent towards carbon monoxide under simulated standard air mass 1.5 global illumination.

14 SOLAR ENERGY↗
DOE OSTI2026

Scaling considerations for supercritical carbon dioxide cycles including turbomachinery loss models

A modeling framework for the supercritical carbon dioxide recompressed closed Brayton cycle was developed. Unlike typical models, this effort incorporated generalized empirical turbomachinery loss models. Aerodynamic, windage, and leakage losses were considered in order to address the limitations of conventional constant-efficiency turbomachinery assumptions without relying on machine-specific or computationally expensive simulations. The model enables system-level exploration of optimal cycle design across a range of power scales, including smaller scales that are relevant to microreactors and extraterrestrial power applications. Parametric studies and multi-objective optimizations are used to evaluate the trade-offs between thermal efficiency and system compactness based on an analytical heat exchanger scaling model, yielding Pareto-optimal fronts across a range of operating pressures. Results reveal that at small power scales, the Pareto-optimal compressor inlet pressure becomes subcritical due to the increasing influence of density-dependent turbomachinery losses. Here, the relative contributions of each loss mechanism are quantified, and design recommendations are provided for key parameters such as recompression split ratio and generator cavity pressure across varying power scales.

Multi-objective optimization↗
DOE OSTI2025

High-temperature seals for supercritical carbon-dioxide (sCO 2 ) turbines (Final Report)

This is the final report for project DE-FE0031924 titled “High-temperature seals for supercritical carbon-dioxide (sCO 2 ) turbines.” The report provides a summary of the entire project efforts from October 2020 through December 2024 including the high-temperature commercial dry gas seal (DGS) tests and thermal modeling of Task 2, as well as the high-temperature, large-diameter seal design and high-temperature tests of large-diameter seals in Task 3. A key outcome of Task 2 was the testing completion of specially instrumented commercial DGS in the GE-SwRI Apollo sCO 2 compressor (27,000 rpm). Test data from the DGS showed elevated temperatures upwards of 350 o F, which are close to the higher operating temperature limit of the DGS. The temperature measurements provide insight into the expected thermal loads on DGS operating in high-speed sCO 2 compressor and provided test data for validation of an in-house thermal model of the compressor/seal. Under Task 2.0, this report also presents the development of a steady-state conjugate heat-transfer model of the DGS operating in the sCO 2 compressor – a first of its kind model for modeling heat transfer of sCO 2 in an actual operating compressor. The findings of the thermal model show a reasonable match between temperature predictions of the model and the measured temperature data, also pointing out the validity of the approach and assumptions made in modeling the flows, heat transfer coefficients and windage modeling in the rig. Under Task 3.0, this report presents the preliminary design of a large-diameter hybrid face seal (14 inch and 26-inch diameter) for field testing in a land-based GE turbine. The preliminary seal design effort presented in this report under project DE-FE0031924 builds on the development and successful laboratory testing for such large diameter hybrid face seal under the prior DE-FE0024007 project. Key aspects of seal fluid analyses with CFD, mechanical design considerations and assembly considerations in a land-based turbine are presented. Finally, under Task 3.0, this report also presents the continued high-temperature testing of the 14-inch diameter hybrid face seal developed previously under the DE-FE0024007 program. Specifically, test data demonstrating successful non-contact seal operation and seal effective leakage of 0.001-inch with seal inlet temperatures above 700 o F are presented in this report. Successful hybrid seal operation in a laboratory environment for a large diameter (14-inch) seal at temperatures above 700 o F is a major technological milestone for this technology.

01 COAL, LIGNITE, AND PEAT↗