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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 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Technoeconomic assessment of distillation heat transfer intensification using aeroelastically fluttering reeds

Dry cooling, where forced air is the heat transfer medium, is a preferable cooling method in arid locations lacking readily available process water. However, such locations often experience high ambient temperatures that limit the effectiveness of air cooling. The objective of this study is to quantify the economic and energetic benefits of heat transfer intensification via the implementation of aeroelastically fluttering reeds to the air-cooled condenser of a methanol distillation column. Condenser size and performance, regarding recovered methanol and required fan power, is evaluated across condenser operating temperatures (T cond ) from 60 to 62°C and heat transfer coefficients (U) U base –2U base for a range of inlet air temperatures based on ambient temperature data from Yuma, Arizona. Under typical design sizing, condenser capital cost was reduced by 6%–35% (1.3U base –2U base ) and nominal methanol recovery was increased from 0.26% to 0.38% (T cond = 62–60°C). At optimized condenser size, all enhanced U and T cond pairs increase methanol recovery and reduce fan power costs compared to the optimal Ubase reference. Overall, using enhanced heat transfer to maintain condenser temperature under a wider range of inlet conditions, rather than to reduce operation temperature, produces more favorable performance. Methanol price is not a determining factor in which pairs are profitable. Analysis was repeated for a global warming scenario, revealing more valuable improvements under elevated temperatures. Energy savings from condenser improvement to a methanol production system are not significant with respect to an optimized conventional system. Furthermore, unit economic and energetic incentives suggest implementation of fluttering reeds may be justified in other applications.

42 ENGINEERING↗
DOE OSTI2026

Towards Thermomechanical Processing of Alloy 709: Progress in Defining High-Temperature Deformation-Recrystallization "Space"

The Advanced Reactor Technologies (ART) Program has established a multi-year plan to develop Alloy 709 advanced stainless steel, generate the data package and develop material-specific design parameters in qualifying it as a new structural material for Class A construction in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Division 5, High Temperature Reactors (ASME 2025). In collaboration with material vendors, the Advanced Materials Development activities under ART have successfully scaled the Alloy 709 plate form production from a laboratory heat of 500 pounds to commercial heats totaling 133,000 pounds of Alloy 709 plate fabricated from three heats. The goal of the overall Alloy 709 development program is to establish the necessary microstructural and mechanical properties relationship for Alloy 709 to ultimately develop fabrication parameters for other product forms such as bars, pipes, and forgings using the available ART Alloy 709 materials. This study will enable its deployment in the industry as an advanced construction material for high-temperature components. The objective of this Alloy 709 development work in FY 2025 is to experimentally determine the high-temperature deformation-recrystallization response of the Alloy 709 heats and to experimentally generate true stress-true strain data for Alloy 709 using the available commercial heat plate materials. Integral to this work is the previous characterization of the as-rolled materials and the determination of an effective solution-annealing process, which was reported in Y. Wang et al., 2023, and the evaluation of the effect of controlled cooling on the resultant precipitation in these commercial heats. This report summarizes and builds on the results of the previous reports to assess the high-temperature deformation behavior as a function of deformation temperature, strain and strain rate using commercial Alloy 709 heat 58776-3RB fabricated by G. O. Carlson and heat 529900-02 fabricated by Allegheny Technologies Incorporated (ATI) Specialty Rolled Products.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

SR19007 - Future TCAP Implementation Issues

This project demonstrates the success of the PDRD program in bringing a concept from the R&D phase to direct plant funding. Although Mini-TCAP technology is overall at a TRL of ~6.5, the specific questions addressed in this project were brought from a low (2-3 TRL) to a TRL 5 over the course of the project. This project successfully completed all initial goals ahead of schedule (inventory control, guard bed, ammonia impact, and cycle time) and furthermore addressed additional scope (continued TCAP evaluation, ion chamber) in FY20. First, this project resolved minor inventory control issues by introducing a new parameter tracking and correcting for inventory changes over multiple cycles. This project also involved modification of the previously constructed plant-configured Mini-TCAP in order to allow ammonia impurity studies. TCAP was tested with ammonia in the feed stream both with and without a guard bed present to determine guard bed efficacy and the effect of ammonia if it enters TCAP. The TCAP columns were then replaced with brazed columns, where the LN2 cooling coil is brazed to the column and the column is self-brazed along the coils. This drastically improved heat transfer and consequently reduced cycle time compared to the previous columns, in which the coils were mechanically held in place. Finally, additional scopes were taken on in FY20, including evaluation of TCAP with faster cycle time and procurement of ion chambers for future TCAP integration.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Exploring Micro-Environmental Conditions of Urban Agrivoltaics: Advancing Sustainable Green Spaces and Agriculture in Temperate Cities

Agrivoltaics, the integrated land use combining renewable energy production and agriculture, can potentially address key challenges faced by urban communities, including limited access to vacant land, fresh produce, and electricity. However, urban agrivoltaics has rarely been considered a viable solution, primarily due to a lack of experimental systems demonstrating the functionality of urban food production or green spaces alongside solar energy production. To evaluate the potential of solar photovoltaics to help mitigate heat stress on urban agriculture and green spaces in a temperate climate, we examined the microclimatic changes introduced by an urban agrivoltaics system (UrAV) when combined with vegetable crops and turfgrass, respectively. Accordingly, we installed an experimental setup instrumented with environmental sensors to compare full-sun conditions with those of an agrivoltaics system designed for urban environments. We found minimal differences for both land cover types between the control and agrivoltaics sites in air and soil temperature. However, during periods of intensified summer heat, temperatures beneath the panels cooled due to reductions in wind speed and relative humidity, which impeded the movement of hot, moist air and reduced reference evapotranspiration. Further, soil moisture in UrAV was highly spatially heterogeneous, influenced by the layout of the photovoltaic panels and their support structure, which redistributed rainfall and controlled where solar radiation could penetrate and drive evapotranspiration. Overall, our results suggest that PV-induced environmental changes in temperate climates are compatible with cultivating turfgrass or appropriate crops. These findings can help planners and designers integrate agrivoltaics into community gardens, farms, and green spaces in temperate cities.

14 SOLAR ENERGY↗
DOE OSTI2023

Evaluation of Corrosion Behavior of Various Fe- and Ni-Based Alloys in Molten Li 2 BeF 4 (FLiBe)

Reliable performance of structural alloys is essential for the successful implementation of Generation-IV fluoride salt–cooled high-temperature reactors (FHRs). Most FHR designs are considering molten salt (2LiF-BeF 2 ), or FLiBe, as a primary coolant or fuel carrier. The main corrosion mechanism for alloys exposed to molten fluoride salts is the selective dealloying of active alloying elements. Alloy composition has a significant effect on their high-temperature mechanical properties, but also affects their corrosion behavior. Although Hastelloy-N and its variants show good corrosion resistance compared to higher Cr-containing Ni- or Fe-based alloys, the mechanical properties of these alloys degrade quickly at temperatures above ~600°C. Twelve Ni-based or Fe-based alloys were selected due to their high temperature stability or their low Cr alloy composition and tested for their corrosion behavior in FLiBe. The results show that the mode and the extent of alloy degradation by selective dissolution mechanism corelates well with the overall alloy composition, and not just the concentration of active elements. It was found that there was good correlation between weight loss of the tested alloys and the ratio of major active elements (Cr, Mn) to that of the more noble alloying elements (Ni, Mo).

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

SAS4A/SASSYS-1 Validation with EBR-II Tests Performed During the SHRT Testing Program

The EBR-II sodium-cooled fast reactor supported a wide range of fast reactor research activities. The final fifteen years of operations at EBR-II were used for experiments and tests to demonstrate the importance of passive safety in liquid metal reactors and the capability of such systems to provide strong passive responses during off-normal conditions. The Shutdown Heat Removal Test program at EBR-II provided test data supporting the validation of computer codes for design, licensing, and operation of LMRs, among other objectives. The program included nearly sixty tests, most of which were protected and unprotected loss of flow and loss of heat sink tests run at various initial powers and flow rates. This report documents the results of modeling and simulation of tests from the Shutdown Heat Removal Test program to support validation of Argonne’s SAS4A/SASSYS-1 fast reactor safety analysis code. SHRT-17 was a protected loss of flow test where a loss of electrical power to all sodium coolant pumps was simulated to demonstrate the effectiveness of natural circulation cooling characteristics. SHRT-45R was an unprotected loss of flow test where the control rod scram function of the plant protection system was disabled to demonstrate the effectiveness of EBR-II’s passive reactivity feedbacks. BOP-301 and BOP-302R were unprotected loss of heat sink tests that demonstrated how reactivity feedback effects driven by changes to the core inlet temperature can shut down the fission process. This validation activity leverages modeling and simulation efforts that originated under an International Atomic Energy Agency Coordinated Research Project for benchmark analysis of the EBR-II Shutdown Heat Removal Tests. The SAS4A/SASSYS-1 models originally developed for the CRP have been modernized to utilize new code features and modeling practices. Differences between the predicted and measured test data were explored and the causes of these differences were identified as being due to modeling approximations, uncertainty in transient component behavior, and instrumentation uncertainties. Overall, it was concluded that for SHRT-17, SHRT-45R, BOP-301, and BOP-302R there was good agreement between the flow, power, and temperature predictions and the measured data.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

How transient effects can change the inferred plasma temperatures when using K-shell sulfur line ratios in a time dependent iron sulfide plasma

This paper describes how the steady state atomic kinetics approximation can underestimate the electron temperature determined from K-shell lines in ps-time-scale transient plasmas. In particular, we model the temperature determination of solid FeS targets used in opacity experiments at the Orion laser facility from the ratio of sulfur He-α to Ly-α lines. Such experiments use short-pulse lasers to heat a thin microdot of FeS buried in a plastic target to temperatures of more than 1 keV and densities of approximately 1–2 g/cm 3 . Using atomic kinetics calculations based on a temperature history from a radiation hydrodynamic simulation of the target evolution, the peak temperature inferred from the sulfur line ratios is 1.29 keV at 3.1 ps as compared with the input peak temperature of 1.41 keV at 2.0 ps. There is a time lag of 1.2 ps at the peak, and an overall 0.5 ps time lag in the temporal history of the temperature as the plasma cools over the next 10 ps.

Rilloraza, Francisco↗
DOE OSTI2024

Interpretative 3D MHD modelling of deuterium SPI into a JET H-mode plasma

Abstract The pre-thermal quench (pre-TQ) dynamics of a pure deuterium ( D 2 ) shattered pellet injection (SPI) into a 3 MA / 7 MJ JET H-mode plasma is studied via 3D non-linear MHD modelling with the JOREK code. The interpretative modelling captures the overall evolution of the measured density and radiated power. The simulations also identify the importance of the drifts of ablation plasmoids towards the tokamak low field side (LFS) and the impurities in the background plasma in fragment penetration, assimilation, radiative cooling and MHD activity in D 2 SPI experiments. It is found that plasmoid drifts lead to an about 70% reduction of the central line-integrated density (compared to a simulation without drifts) in the JET D 2 SPI discharge considered. Impurities that pre-exist before the SPI as well as those from possible impurity influxes related to the SPI are shown to dominate the radiation in the considered discharge. With inputs from JOREK simulations, modelling with the Lagrangian particle-based pellet code PELOTON reproduces the deviation of the SPI fragments in the direction of the major radius as observed by the fast camera. This confirms the role of rocket effects and plasmoid drifts in the considered discharge and reinforces the validity of the JOREK modelling. The limited core density rise due to plasmoid drifts and the strong radiative cooling and MHD activity with impurities (depending on their species and concentration) could limit the effectiveness of LFS D 2 SPI in runaway electron avoidance and are worth considering in the design of the ITER disruption mitigation system.

Physics↗
DOE OSTI2024

Numerical Simulation and Experimental Comparison of System Analysis Module 1D Mixing Model for Cold Shock Transients in the Gallium Thermal-Hydraulic Mixing Facility

Abstract Liquid metals are being investigated as coolants in many advanced reactor designs because of their high thermal conductivity and effectiveness at high temperatures. However, they often pose challenges to reactor operation and safety because of the complex thermal mixing and stratification in the plenum of pool-type reactor designs. The advanced system analysis code System Analysis Module (SAM) currently under development at Argonne National Laboratory aims to develop and implement thermal mixing models to accurately capture these complex thermal fluid behaviors. In this study, the SAM thermal mixing model was compared against experimental data from the Gallium Thermal-Hydraulic Experiment facility, a scaled liquid metal test facility that uses gallium as a surrogate fluid to investigate the stratification and thermal mixing of low-Prandtl-number fluids in the upper plenum of a liquid metal-cooled reactor. Two cold shock transient cases were used: one with stable stratified flow (Ri = 32) and one with stronger thermal mixing (Ri = 0.5). The resultant temperatures were then compared with the experimental temperatures over the entire plenum to assess the ability of the mixing models to capture the thermal behavior and to better correspond mixing parameters to various flow scenarios. Generally, the zero-dimensional mixing model was more capable of capturing the bulk temperature of the component modeled assuming that an accurate mass flow rate was provided, but it was inherently unable to capture thermal gradients in space. The one-dimensional mixing model was capable of capturing that the thermal gradients provided accurate selection of the mixing coefficients. Further, the temperature at the outlet junction was compared over time for each of the mixing models with the recorded experimental temperature. The implemented mixing models demonstrated the ability to effectively capture the overall thermal behavior for stronger mixing scenarios but struggled with more stably stratified flows. It was found that a system analysis code's covering of the entire range of different operating conditions still remains a challenging task, and it is suggested that further model and closure improvements are necessary to accurately capture complex thermal mixing and stratification phenomena.

stratification↗
DOE OSTI2022

Albedo susceptibility of northeastern Pacific stratocumulus: the role of covarying meteorological conditions

Abstract. Quantification of the radiative adjustment of marine low clouds to aerosol perturbations, regionally and globally, remains the largest source of uncertainty in assessing current and future climate. One of the important steps towards quantifying the role of aerosol in modifying cloud radiative properties is to quantify the susceptibility of cloud albedo and liquid water path (LWP) to perturbations in cloud droplet number concentration (Nd). We use 10 years of spaceborne observations from the polar-orbiting Aqua satellite to quantify the albedo susceptibility of marine low clouds to Nd perturbations over the northeast (NE) Pacific stratocumulus (Sc) region. Mutual information analysis reveals a dominating control of cloud state (e.g., LWP and Nd) on low-cloud albedo susceptibility, relative to the meteorological states that drive these cloud states. Through a LWP–Nd space decomposition of albedo susceptibilities, we show clear separation among susceptibility regimes (brightening or darkening), consistent with previously established mechanisms through which aerosol modulates cloud properties. These regimes include (i) thin non-precipitating clouds (LWP < 55 g m−2) that exhibit brightening (occurring 37 % of the time), corresponding to the Twomey effect; (ii) thicker non-precipitating clouds, corresponding to entrainment-driven negative LWP adjustments that manifest as a darkening regime (36 % of the time); and (iii) another brightening regime (22 % of the time) consisting of mostly precipitating clouds, corresponding to precipitation-suppression LWP positive adjustments. Overall, we find an annual-mean regional low-cloud brightening potential of 20.8±2.68 W m−2 ln(Nd)−1, despite an overall negative LWP adjustment for non-precipitating marine stratocumulus, owing to the high occurrence of the Twomey–brightening regime. Over the NE Pacific, clear seasonal covariabilities among meteorological factors related to the large-scale circulation are found to play an important role in grouping conditions favorable for each susceptibility regime. When considering the covarying meteorological conditions, our results indicate that for the northeastern Pacific stratocumulus, clouds that exhibit the strongest brightening potential occur most frequently within shallow marine boundary layers over a cool ocean surface with a stable atmosphere and a dry free troposphere above. Clouds that exhibit a darkening potential associated with negative LWP adjustments occur most frequently within deep marine boundary layers in which the atmospheric instability and the ocean surface are not strong and warm enough to produce frequent precipitation. Cloud brightening associated with warm-rain suppression is found to preferably occur either under unstable atmospheric conditions or humid free-tropospheric conditions that co-occur with a warm ocean surface.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2019

Case Study: Integrate Nuclear Water Desalination - Regional Potable Water in Arizona

The present study analyzes the economic viability of an Integrated Energy System (IES) that couples a Reverse Osmosis (RO) water desalination facility with a Nuclear Power Plant (NPP). The case study is conducted in collaboration with Arizona Public Service (APS), the operating owner of the Palo Verde Generating Station (PVGS) NPP. Cooling water for the reactor steam cycle is derived from treated effluent from municipal wastewater treatment plants. APS has established a long-term water resources program to effect a substantial reduction in plant cooling costs through advanced treatment and cooling technologies, and through the use of alternative water sources to replace the increasingly expensive effluent. One possible option is to replace some amount of the annual volume of effluent with brackish groundwater from a local regional aquifer. Although much less expensive than the municipal effluent, the quantity of brackish groundwater that could be used for plant cooling is limited as a result of the salinity and its impact on plant operation. Consequently, supplemental treatment could be required such that a greater amount of brackish groundwater could be used to reduce the demand on effluent. A study was conducted in 2018 by Idaho National Laboratory (INL) to investigate the economics of a PVGS onsite RO desalination plant that would reduce the salinity of a municipal effluent and brackish water blend to an acceptable level. One of the main findings of that study was that the overall economics of water desalination can be greatly improved if, in addition to cooling water for PVGS, potable water could also be produced and sold for profit. In fact, the study concluded that only producing cooling water for PVGS via RO desalination is not economically viable. The present report investigates the economic impact of a large, regional RO desalination plant that could provide potable water for the region, considering the conclusions from the 2018 scoping study. The study looks in particular at the water-market situation for the developing municipalities in the west valley of Phoenix. In addition to providing potable water for the municipalities, the existing infrastructure that conveys effluent to the Palo Verde plant and onsite water treatment facilities could be used to manage the RO concentrate. The processed concentrate could lead to a cost reduction in plant cooling by replacing some amount of effluent. The analysis reported here considers two cases (for various scenarios). First, the Base Case considers that neither the regional nor the onsite RO is built. The 2018 INL study showed that some brackish water can be blended with the municipal effluent water without having to build the onsite RO. That correspond to the maximum economically profitable option. The Base Case is where APS pumps the maximum volume of less-expensive brackish water (limited by water chemistry in the circulating water system), i.e. the case for which cooling water acquisition and treatment cost are lowest (without RO). Second, the proposed RO Case includes two RO plants, one onsite at PVGS and another larger, regional RO plant close to the brackish water wells. The regional RO produces potable water that is sold to the regional municipalities, while the PVGS onsite RO treats (part of) the regional ROs' concentrate and brackish water blend. The desalinated water from the PVGS RO is used in the circulating water system at PVGS. The analysis evaluates the difference in economics, using the Net Present Value (NPV) and Internal Rate of Return (IRR), between the cases. By comparing the two cases, in addition to evaluating the economics of the regional RO, we can also assess the impact of the regional RO on PVGS operational costs and, consequently, APS economics. The study shows that there exist combinations of regional RO and PVGS RO sizes for which the total blowdown and water chemistry limits at PVGS (including regional RO concentrate treatment at PVGS) are satisfied. However, such combinations only exist if no additional brackish water is directly mixed in the tertiary water system at PVGS. This leads to higher Levelized Costs of Potable Water (LCOPW) compared to cases where additional brackish water is injected (but violate the physical constraints). Additional studies are suggested to investigate the benefit of additional brackish water injection (lowers cooling water cost) versus the cost of lifting the physical constraints, e.g. building additional evaporation ponds. Staying in the case of no additional brackish water and satisfying the existing PVGS constraints, the lowest LCOPW (~0.5 $/m 3 ) can be achieved with a size of the regional RO of ~1.4e7 m 3 /yr (11000 AF/yr) capacity, which leads to ~8.63e6 m 3 /yr (7000 AF/yr) of potable water while no onsite RO at PVGS is built. Considering the vii residential water demand model developed for the Phoenix west valley, the NPV for this regional RO would be ~$100 million if all municipalities in the vicinity participate from the beginning of the project.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Removal of impurity Metals as Phosphates from Lithium-ion Battery leachates

Recovery of critical materials from end-of life (EOL) lithium-ion batteries (LIB) is gaining interest as demands for materials grows. Hydrometallurgical processes start with an intermediate product known as black mass which contains critical materials of interest (Co, Ni, Li, and graphite) as well as impurities such as Cu, Al, and Fe. These impurities are deleterious to downstream separation processes, as well as impact functionality of the final products. Here, these impurities effectively compete with most solvent extraction (SX) and metal recovery processes to diminish the overall yields of the desired materials. In this work, a process flowsheet is presented where a previously reported electrochemical leaching (ECL) process is followed by selective precipitation using diammonium hydrogen phosphate (DAP) to remove Cu, Al, and Fe from LIB leachate solutions. The electrochemical leach process removes Cu and produces a pH-adjusted leachate, ca. pH 2, without requiring an extra Cu extraction step. The addition of the precipitant DAP to leachate by slightly adjusting the pH to 3–4 at 45 °C, precipitates 95–99% of Al and Fe as their phosphates and the leachate retains >95% of Co, Ni and Li. After the filtration of phosphate impurities, the solution is ready for further processing, such as SX. As an unexpected result from the leachate processing, 20–30% of the Ni and Co co-crystalize as the double salt after cooling to room temperature, which could provide a shorter route to their recovery.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Turboexpander for Direct Cooling in Hydrogen Vehicle Fueling Infrastructure

Hydrogen fuel cell electric vehicles (FCEVs) have been identified as one of a few options for zero carbon emissions transportation. A major advantage of FCEVs is that they can fuel quickly and follow a familiar fueling behavior to hydrocarbon-fueled vehicles. Whether light duty or heavy duty, the goal for a hydrogen dispenser is to fuel a vehicle in the same amount of time as the fossil fuel equivalent. When hydrogen is dispensed into the vehicle storage system, however, the temperature rises due to the Joule-Thomson effect and the heat of compression. Typically, vehicles store the compressed hydrogen in composite overwrapped pressure vessels that have a polymer liner with an operational temperature limit of 85°C. This temperature limit can be exceeded during fast fueling if hydrogen is not precooled. Precooling allows for a dispenser to fuel a vehicle at a faster flow rate by preventing the storage tank on the vehicle from overheating. Fueling protocols and requirements are presented in SAE J2601 Fueling Protocols for Light Duty Gaseous Hydrogen Surface Vehicles [1]. A heavy-duty equivalent is under development with similar requirements for precooling. Currently, conventional precooling for light-duty vehicle refueling uses a heat exchanger and chiller to cool the hydrogen gas to -40°C before entering the vehicle. The precooling system represents a significant part of the station capital and operating costs, so if the cost of the precooling system can be reduced by improving its efficiency, the overall station capital and operating cost can be reduced. In this project, National Renewable Energy Laboratory (NREL) and Sandia National Laboratories (SNL) researchers teamed up to investigate the turboexpander precooling application. A turboexpander is a device that places a turbine in a flow path where a pressure differential can be attained. This expansion device will extract work and lower the temperature of the fluid as the pressure reduces. While initial calculations based on established principles showed potential for a turboexpander to generate cooled gas, much work needs to be done to prove the concept. Turboexpanders typically work best under steady state conditions, while the dispenser is a very dynamic flow system. Dynamic turboexpander systems have been proven, such as a turbocharger on a gasoline vehicle. The inlet pressure at a dispenser is also much higher than any other known turboexpander system but should behave similarly to higher density fluids at lower pressures. Having both performed initial calculations, NREL and SNL researchers teamed up to investigate the turboexpander precooling application further. A project was soon built around the idea with SNL performing system modeling using previously proven capabilities and NREL performing hardware characterization with established station capabilities. Creare LLC was contracted as the turbomachinery expert to design and build the concept device. Part way through the project, however, contracting issues with the funding partner caused the project to terminate early before building and characterizing the concept device. While the project could not continue, many key findings were already learned. This paper is a summary of those findings.

08 HYDROGEN↗
DOE OSTI2024

“Hybridizing heat-integrated 3D printed modules with mass manufacturable, low pressure drop fiber sorbents” (Final Report)

The overall objective of this proposal was to research, develop, and evaluate a modular direct air capture (DAC) system that is simple and scalable. This system was based on the adsorption of CO 2 into commercial polyamines supported by porous fiber sorbents, which can be produced at kilometer per hour scales using our pre-pilot spinning line. We have housed these fiber materials in novel 3D printed modular housing systems that provide easy-to-manufacture and localized heat integration and flow control. This hybridization of fiber sorbent technology with modular housing provided several advantages that led to lower air pressure drops, higher sorbent productivity, as well as ease of manufacturing and assembly unrivaled by existing and emerging heat integrated contactor designs. The modular housing was fabricated with the following features, at a minimum: (i) a tapered air intake to reduce pressure drop related to entrance effects, (ii) a structured network of heat transfer channels to enable localized cooling and heating during adsorption and desorption, respectively, and (iii) low pressure drop supports for the fiber sorbents. This hybrid manufacturing approach provides a facile method for taking fiber sorbents from lab scale to pilot scale as it dramatically simplifies the fabrication of heat integrated contactor structures.

42 ENGINEERING↗
DOE OSTI2024

Experimental Investigation on Heating Performance of a Cold Climate Thermoelectric-Assisted Heat Pump

To accelerate the electrification of air source heat pumps (ASHPs) in cold climates across the United States, various initiatives have been launched to enhance the effectiveness of ASHPs. One avenue of research involves incorporating thermoelectric (TE) technology into vapor compression refrigeration cycles. This study aims to assess the heating performance of a cold climate ASHP by employing TE modules as a liquid line subcooler. The tested system is a nominal 4.5-ton split heat pump utilizing R410A, equipped with a scroll compressor and an accumulator. An electronic expansion valve was employed for both cooling and heating modes. Two configurations of TE sub-coolers, one utilizing 2 TE bundles and the other 4 TE bundles, were integrated into the liquid line of the tested system. The heating performance of these configurations was evaluated. The results revealed that activating the TE subcooler led to a notable increase in total heat capacity, reaching 1318 W at -15.0 °C and 1164 W at -19.0 °C. The corresponding TE coefficients of performance (COPs) were 1.76 and 1.63, respectively. The activation of the TE sub-cooler resulted in a slight reduction in the overall system COP, with a decrease ranging from -2.6% to -4.2% for these two temperatures. The system COPs were measured at 2.10 and 1.86 for -15.0 °C and -19.0 °C, respectively. This prototype demonstrated a significant augmentation in heating capacity with a minimal sacrifice in COP.

Hu, Yifeng↗
DOE OSTI2020

Advanced Anode for Internal Reforming and Thermal Management in Solid Oxide Fuel Cells

Solid oxide fuel cell (SOFC) is an efficient and clean electrical power generation system compared to conventional combustion based technologies with energy efficiency reaching as high as 85-90% in co-generation mode (electricity and heat). Other advantages of SOFCs are hybridization, modularity of construction, small CO 2 foot print per kWh of generated electricity and fuel flexibility. Hydrocarbons present in the gaseous fuel is utilized in SOFCs by internal or external reforming. There are two different internal reforming concepts: Direct Internal Reforming (DIR) and Indirect Internal Reforming (IIR). For DIR operation, the endothermic reforming reaction and the exothermic reaction from the oxidation reaction are operated together in the single unit eliminating the requirement for a separate fuel reformer. This configuration also simplifies the overall system design, making SOFC more attractive and efficient means of producing electrical power. The main advantage of the DIR type of operation is that the H 2 or CO consumption by the electrochemical reaction could directly promote the conversion of methane at the anode side of the fuel cell resulting in high conversion and high efficiency. The DIR operation, however, requires an anode material that has desired dual catalytic (hetero and electro) properties for reforming reaction and electrochemical reactions. The anode materials also need to remain resistant to carbon formation at the operating temperature and atmosphere with stable cell performance. Another requirement is to match the reforming reactions and electrochemical reactions to avoid local cooling or overheating, which can result in mechanical failure due to thermally induced stresses. Direct internal reforming (DIR) of hydrocarbon fuels simplifies the overall SOFC system design making it more attractive and efficient for producing electrical power. Low cost alloy anodes for distributed internal reforming of methane and other hydrocarbon fuels offer increased fuel-flexibility, reliability, and long term performance stability of solid oxide fuel cells (SOFC). The research program examined modification of the chemical compositions and microstructure of high entropy alloy (HEA) anode materials using thermochemical calculations and process simulation and modeling to achieve distributed reforming over the entire anode to eliminate hot zones. Cell fabrication and testing of the HEA anodes using button cell configuration has been performed to demonstrate the advantages of new anode over traditional Ni-YSZ anodes for distributed reforming and carbon free operation. Technical accomplishments include identification and synthesis of HEA carbon-resistant anode, demonstration of reduction in reforming rate confirmed by GC and modelling data validating effectiveness for thermal management in cell/stacks, electrochemical testing of HEA anode in single cell (HEA-GDC||YSZ||LSM-YSZ) and Characterization of pretest and posttest anode materials by TEM and SEM-EDS confirming carbon-free operation.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2021

Burst characteristics of advanced accident-tolerant FeCrAl cladding under temperature transient testing

Here assessment of burst characteristics of accident-tolerant fuel (ATF) claddings is essential to evaluate the safety margins of nuclear reactors, and better understanding can enable accelerated licensing for reactor concepts that include the new materials. Therefore, this study investigated the burst behavior of an ATF candidate of C26M, which is an iron–chromium–aluminum alloy (FeCrAl) under transient testing like the simulated loss-of-coolant accident (LOCA) conditions, except the water-quenching phase, in light-water reactors (LWRs). The effect of LOCA specimen length was assessed in terms of post-burst tube parameters. No critical length effect was determined on the burst pressure, burst location, and burst size measurements. Burst temperature showed larger variation likely due to its measurement approach used in this study. The post-test diametral strain was identified as the critical parameter to reduce the specimen length as compared to tube burst length or width. Postmortem optical metrology and digital image correlation were employed to determine the local strain-state during the simulated LOCA, which showed the loading path was close to equibiaxial conditions in regions away from the burst location, rather than internally pressurized conditions (or “plane-strain” tension). Pst-test microstructural characterizations of the FeCrAl revealed that ductile damage was present at the edge of the outer radial surface while the rest of the material was ruptured via cleavage at LOCA burst temperatures. Furthermore, internal grain boundary cracks were observed at locations away from the tube burst region. This behavior was considered to occur during the cooling down period of the simulated LOCA test. Overall, this study aimed to provide essential data for fuel performance code development by considering micromechanics of the deformation and failure.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Importance of Ambipolar Electric Field in Driving Ion Loss From Mars: Results From a Multifluid MHD Model With the Electron Pressure Equation Included

The multi-fluid (MF) magnetohydrodynamic model of Mars is improved by solving an additional electron pressure equation. Through the electron pressure equation, the electron temperature is calculated based on the effects from various electron-related heating and cooling processes (e.g., photo-electron heating, electron-neutral collision, and electron-ion collision), and thus, the improved model can calculate the electron temperature and the electron pressure force terms self-consistently. Model results of a typical case using the MF with electron pressure equation included model are compared in detail to identical cases using the MF and multi-species models to identify the effect of the improved physics. Here, we find that when the electron pressure equation is included, the general interaction patterns are similar to those with no electron pressure equation. However, the MF with electron pressure equation included model predicts that the electron temperature is much larger than the ion temperature in the ionosphere, consistent with both Viking and Mars Atmosphere and Volatile EvolutioN (MAVEN) observations. Using our numerical model, we also examined in detail the relative importance of different forces in the plasma interaction region. All three models are also applied to a MAVEN event study using identical input conditions; overall, the improved model matches best with MAVEN observations. All of the simulation cases are examined in terms of the total ion loss, and the results show that the inclusion of the electron pressure equation increases the escape rates by 50–110% in total mass, depending on solar condition and strong crustal field orientation, clearly demonstrating the importance of the ambipolar electric field in facilitating ion escape.

79 ASTRONOMY AND ASTROPHYSICS↗