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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

ANALYSIS OF SUITABLE METHODOLOGIES FOR COMPRESSOR MASS FLOW RATE CORRECTION TO OTHER SUPERHEAT LEVELS AND REFRIGERANTS

This paper investigates the impact of suction conditions and refrigerant on scroll compressor mass flow rate by using calorimeter tests from AHRI-11 and AHRI-21 reports, published by AHRI's Low-GWP Alternative Refrigerants Evaluation program. Two Copeland scroll compressors (20 and 51 cm3) have been analyzed including different suction conditions (SH = 11K, SH = 22K, Ti = 18ºC) and several refrigerants (R134a, R32, R410A, R404A, etc.). Previous studies have explored response surfaces for energy consumption and mass flow rate variables. This study aims to expand the analysis by identifying the optimal approach to extrapolate mass flow rate from specific suction conditions to others SH or suction temperature levels and refrigerants. The current compressor characterization standard relies on the 1981 Dabiri correlation to correct compressor mass flow rate with suction conditions. Thus, this study aims to assess the adequacy of this correction and explore alternative correction methods for improved results.

Marchante Avellaneda, Javier↗
DOE OSTI2023

Large Eddy Simulation of Rotationally Induced Ingress and Egress around an Axial Seal between Rotor and Stator Disks

In gas turbines, the hot gas exiting the combustor can have temperatures as high as 2000 °C, and some of this hot gas enter into the space between the stator and rotor disks (wheelspace). Since the entering hot gas could damage the disks, its ingestion must be minimized. This is carried out by rim seals and by introducing a cooler flow from the compressor (sealing flow) into the wheelspace. Ingress and egress into rim seals are driven by the stator vanes, the rotor and its rotation, and the rotor blades. This study focuses on the ingress and egress driven by the rotor and its rotation. This is carried out by performing wall-resolved large eddy simulation (LES) around an axial seal in a rotor–stator configuration without vanes and blades. Results obtained show the mechanisms by which the rotor and its rotation induce ingress, egress, and flow trajectories. Kelvin–Helmholtz instability was found to create a wavy shear layer and displacement thickness that produces alternating regions of high and low pressures around the rotor side of the seal. Vortex shedding on the backward-facing side of the seal and its impingement on the rotor side of the seal also produces alternating regions of high and low pressures. The locations of the alternating regions of high and low pressures were found to be statistically stationary and to cause ingress to start on the rotor side of the seal. Vortex shedding and recirculating flow in the seal clearance also cause ingress by entrainment. With the effects of the rotor and its rotation on ingress and egress isolated, this study enables the effects of stator vanes and rotor blades to be assessed.

42 ENGINEERING↗
DOE OSTI2022

Commissioning of a replacement subatmospheric cold box for Jefferson Lab’s Central Helium Liquefier

Jefferson Lab’s Cryogenics Department has designed, fabricated, installed, and commissioned a new subatmospheric cold box to replace one of the two existing units within our Central Helium Liquefier (CHL). The replacement cold box, dubbed SC1R, pumps saturated helium vapor at 0.0385 atm from Jefferson Lab’s continuous electron beam accelerator facility (CEBAF) cryomodules to maintain an operating temperature of nominally 2.1 K. This is accomplished using a five-stage cryogenic centrifugal compressor (cold compressor) system and a brazed aluminum plate-fin heat exchanger operating between 2.1 K and 4.5 K. In this paper we will describe our experience commissioning the SC1R cold box. We will discuss pump-down of the system to 2.1 K and steady-state operation at the cold compressor design flow rates of 170, 200, and 250 g/s. Performance of the heat exchanger and cold compressors has been mapped across a range of flow rates and optimized for CEBAF operations. This commissioning data will be used to monitor future performance and adapt to changing load requirements.

Mastracci, B.↗
DOE OSTI2025

Experimental study of a tri-functional propane hydronic heat pump

This study investigates the performance of a propane hydronic heat pump system for space cooling, heating, and water heating applications, focusing on various operational conditions, with a total refrigerant charge below 1200 g. Cooling performance was evaluated at different outdoor temperatures, compressor stages (capacity levels), and water flow rates. The results showed that the coefficient of performance (COP) for cooling was higher at lower outdoor temperatures, with peak values exceeding 5.0 under low-stage operation and lower water flow rate. The cooling capacity increased with higher flow rates and compressor stages, reaching 12 kW. Space heating performance, evaluated at ambient temperatures ranging from −8.3 °C to 16.7 °C, revealed a decrease in COP with lower temperatures. However, high-stage operation maintained higher heating capacities even at low temperatures. The system demonstrated high Heating Seasonal Performance Factors (HSPF), exceeding 10.0. For water heating, the COP decreased with lower ambient temperatures and higher supply water temperatures. The system efficiently heated an 189-L water tank, outperforming conventional water heaters, with process COPs exceeding 4.0 under cooling-season conditions. Despite some efficiency loss due to defrosting at low temperatures, the propane heat pump consistently delivered strong performance. Seasonal energy efficiency ratios (SEER) and seasonal heating COP values indicated significant overall efficiency. The study concludes that propane is a promising refrigerant for heat pump systems, with future research needed to future reduce total system charge and optimize system performance through advanced controls and heat exchanger designs.

Hu, Yifeng [ORNL] (ORCID:0000000242875185)↗
DOE OSTI2026

Conceptual design of a replacement 2.1 K cold box for the Spallation Neutron Source Central Helium Liquefier

Abstract After more than 20 years of operation, the cold compressor technology in use at the Spallation Neutron Source (SNS) is obsolete, and replacement parts and service are no longer available. SNS has partnered with Jefferson Lab to design and construct a replacement sub-atmospheric cold box outfitted with modern cold compressor technology. The general design follows from Jefferson Lab’s experience on other recent sub-atmospheric cold box projects. Design decisions are backed by thorough engineering analysis to ensure technical requirements are met in a cost-effective manner. Conceptual design of the replacement cold box has been completed, and will be summarized in this paper. It features five cold compressors with an operating flow range of 80-140 g/s, and includes piping and valving to support cold compressor maintenance without interrupting flow circulation to the load. The approach to thermal shielding, insulation, and integration of the upgraded cold compressor hardware into the existing SNS control system will also be addressed.

Mastracci, B [Thomas Jefferson National Accelerato↗
DOE OSTI2023

Switchable system for high-salinity brine desalination and fractional precipitation

A saline feed stream flows into a liquid-liquid extraction system; and a volatile organic solvent flows through a main compressor. The compressed volatile organic solvent then flows through a solvent regenerator, which can be a heat exchanger or a combination of a vaporization device and a condenser, to cool the volatile organic solvent. The cooled volatile organic solvent in liquid phase then flows into the liquid-liquid extraction system, where the saline feed stream contacts the volatile organic solvent to selectively extract water from the saline feed stream into the volatile organic solvent, producing a concentrated brine and an organic-rich mixture of water and the volatile organic solvent. The organic-rich mixture flows from the liquid-liquid extraction system into the solvent regenerator, where the organic-rich mixture is heated to produce an organic-rich vapor and desalinated water; and the organic-rich vapor is recycled as volatile organic solvent back into the liquid-liquid extraction system.

Wilson, Aaron D.↗
DOE OSTI2021

Operation of Natural Gas Pipeline Networks With Storage Under Transient Flow Conditions

Here, we formulate a nonlinear optimal control problem for intraday operation of a natural gas pipeline network that includes storage reservoirs. The dynamics of compressible gas flow through pipes, compressors, reservoirs, and wells are considered. In particular, a reservoir is modeled as a rigid, hollow container that stores gas under isothermal conditions and uniform density, and a well is modeled as a vertical pipe. For each pipe, flow dynamics are described by a coupled partial differential equation (PDE) system in density and mass flux variables, with momentum dissipation modeled using the Darcy–Wiesbach friction approximation. Compressors are modeled as scaling up the pressure of gas between the inlet and outlet. The governing equations for all network components are spatially discretized and assembled into a nonlinear differential-algebraic equation (DAE) system, which synthesizes above-ground pipeline and subsurface reservoir dynamics into a single reduced-order model. We seek to maximize an objective function that quantifies economic profit and network efficiency subject to the flow equations and inequalities that represent operating limitations. The problem is solved using a primal–dual interior point solver, and the solutions are validated in computational experiments and simulations on several pipeline test networks to demonstrate the effectiveness of the proposed methodology.

03 NATURAL GAS↗
DOE OSTI2023

Detailed Simulations of a Three-Stage Supercritical Carbon Dioxide Axial Compressor with a Focus on the Shrouded Stator Cavities Flow

This paper describes the findings of detailed simulations performed to investigate the impact of seal teeth cavity leakage flow on the aerodynamic and thermal performance of a three-stage supercritical CO 2 axial compressor. The study compares a shrouded stator configuration (with cavities) to a cantilevered stator configuration (without cavities) to highlight their differences. High-fidelity computational fluid dynamics simulations were performed using non-linear harmonic (NLH) and mixing plane assumptions, considering various possible rotor/stator interface configurations for mixing plane calculations. The key performance parameters for each case were compared, and the best-performing configuration selected for further analysis. The individual stage performance parameters are also examined and compared between the cantilevered and shrouded configurations. It was observed that in the shrouded case, the leakage flow enters the cavity downstream of the stator trailing edge and gets entrained into the primary flow upstream of the stator, leading to boundary layer changes at the hub and degradation of stator and downstream rotor performance. Vortical flow structures were also observed in the stator wells, which tended to change the flow angles around the region, thereby affecting mixing and velocity distribution, resulting in a slight deterioration of compressor performance. Additionally, the study examines windage heating due to shear work from rotating walls, including the seal teeth surface. The amount of shear work done on the leakage flow and the corresponding rise in fluid temperature were quantified, tabulated, and further compared with a simple analytical model, showing good agreement between them and, hence, validating the numerical approach used.

42 ENGINEERING↗
DOE OSTI2022

Electrochemical Ammonia Compression

An electrochemical (EC) compressor is a solid-state compression device. For decades, researchers have been studying EC compressors for applications for a variety of energy systems. As the world transitions away from fossil fuel energy sources, EC compression emerges as a promising technique for energy storage, specifically energy stored in the form of pressurized ammonia. Ammonia is also a commonly used refrigerant. The present studies examine the viability of EC compression for ammonia storage and refrigeration. EC ammonia compression increases the concentration of an ammonia-hydrogen mixture via the input of electrical energy and a series of chemical reactions. A polymer electrolyte membrane separates the low-concentration side from the high-concentration side of the device. On the low-pressure (anode) side hydrogen atoms oxidize and react with ammonia molecules, forming positively charge ammonium ions. The ions traverse the membrane electrolytically. The ammonium ions are reduced and revert back to hydrogen and ammonia upon reaching the high-pressure (cathode). An external circuit provides the current needed to sustain the reactions. In this project, we studied the performance of the ammonia EC compressor under a variety of different conditions. We replicated preliminary data and using a small cell with 5 cm2 of active area. We demonstrated the operation of larger cells with 100 cm2 of active area. Further, we used a commercially available hydrogen EC compressor stack to analyze the scaled-up compressor performance. While previous experiments examined only the transient EC compressor performance, we developed test facilities that allowed the compressor to reach steady state. We analyzed the effects of pressure and current on the EC compressor performance. We measured the flow rates of gas leaving the compressors and analyzed the composition using gas chromatography. We tested methods of separating ammonia from the effluent vapor, which contained hydrogen and water vapor. We found that back diffusion adversely affected the performance, especially when we maintained high pressure lifts.

25 ENERGY STORAGE↗
DOE OSTI2020

Novel Seal Design for Effective Mitigation of Methane Emissions from Reciprocating Compressors

The objective of this project was to reduce leakage of compressor rod packing because rod packing accounts for a significant portion of leakage of compressors. To meet the objectives, the project team designed, manufactured, and tested a liquid seal in a full-scale setting to demonstrate the operability of the seal, verify the performance of components, and demonstrate the potential for producing a seal that reduces methane emissions by a minimum of 95% of 1% of the total mass flow of the compressor with minimal wear to the seal.

03 NATURAL GAS↗
DOE OSTI2020

Hybrid Ceramic-CMC Vane with EBC for Future Coal Derived Syngas Fired 65% Efficient Turbine Combined Cycle

The efficiency of both simple cycle and combined cycle power generation systems scale with the peak temperature at which the gas exits the combustor to drive the turbine. In conventional systems, a substantial fraction of the total turbine core flow exiting the compressor is diverted downstream to cool metallic turbine hardware rather than power the turbine, much of which is used to cool the first-stage turbine vane. The use of coal derived syngas fuels provides an additional challenge to the lifetime of materials utilized in the turbine, as particulate byproducts created in the coal gasification process melt in the combustion gas, and can subsequently deposit and interact with the turbine hardware. The development of durable hot-section materials capable of operating at temperature well above that of single crystal superalloy airfoil/zirconia based thermal barrier coatings is critical to realizing 65% efficient coal derived syngas fired gas turbine based power systems. To enable higher turbine inlet temperatures while lowering cooling air requirements, United Technologies Research Center (UTRC), the central R&D laboratory supporting UT Pratt & Whitney, led the conceptual design of a new type of ceramic composite turbine hot section materials system. The design focused on a novel hybrid monolithic ceramic-fiber reinforced ceramic matrix composite (CMC) first stage turbine vane having an environmental barrier coating. By utilizing ceramic construction in the turbine hot-section, the core flow normally used to cool metallic components will be substantially reduced, increasing efficiency and reducing emissions. To provide the framework for future demonstration testing, UTRC partnered with University of North Dakota Energy and Environmental Research Center (UNDEERC) to provide a conceptual design for a gasified coal fed high-pressure turbine combustor system designed to mimic the conditions expected in a future 65% fuel to busbar efficient syngas fueled gas turbine based combined cycle. The UNDEERC and UTRC collaborated on characterizing dusts from coal gasifier filtration systems.

10 SYNTHETIC FUELS↗
DOE OSTI2024

Data From Experiments on Bubbling Fluidization of Zeolite in a Rectangular Bubbling Fluidized Bed

Fluidization experiments were conducted in a lab-scale rectangular bubbling fluidized bed with the objective of generating a high-quality dataset for model validation and artificial intelligence/machine learning (AI/ML) training. Zeolite was chosen as the bed material, and the fluidizing medium was air as supplied by a compressor. Three different flow rates at the inlet were chosen such that the particles were fluidized but not elutriated from the system. The test matrix involved randomization and replicates to provide uncertainty estimates as well as four different batches of zeolite as the bed material. The quantities of interest obtained from this study were statistics of differential pressures, interface heights, and particle velocities. Considering all the components of the elaborate test plan, the results obtained were consistent and reproducible. Characterization tests were performed to estimate particle properties including size, density, coefficient of friction, coefficient of restitution, and minimum fluidization velocity. In addition, the angle of repose from granular discharge experiments has been reported to account for rolling friction, though its effect on the overall process is expected to be negligible.

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

Characterization of Inlet Guide Vane Performance for Discharge Compressor Operation near the Dome of an sCO 2 Pumped Heat Energy Storage

Southwest Research Institute® (SwRI®) developed and tested a Variable Inlet Guide Vane (IGV herein) assembly on an integrally-geared sCO 2 compressor (IGC) to demonstrate compressor operation at both the compressor design point and near the dome and to define the operating limits of the compressor by monitoring for two-phase flow, flow turbulence from the IGVs, and compressor choke and surge as the CO 2 inlet temperature is varied. Performance testing was conducted on an existing integrally-geared, two-stage main compressor designed for near-critical-point operation with CO 2 . This testing campaign validated the IGV design and operation, as well as improved the understanding and confidence in operating compressors and predicting performance characteristics near the critical point where fluid properties change rapidly with temperature. In addition to improving the robust operating limits of an sCO 2 compressor, the development of an IGV for the IGC system improved off-design compressor efficiency by 12%.

25 ENERGY STORAGE↗
DOE OSTI2023

Modeling and optimization of steady flow of natural gas and hydrogen mixtures in pipeline networks

Here, we extend the canonical problems of simulation and optimization of steady-state gas flows in pipeline networks with compressors to the transport of mixtures of highly heterogeneous gases injected throughout a network. Our study is motivated by proposed projects to blend hydrogen generated using clean energy into existing natural gas pipeline systems as part of efforts to reduce the reliance of energy systems on fossil fuels. Flow in a pipe is related to endpoint pressures by a basic Weymouth equation model, with an ideal gas equation of state, where the wave speed depends on the hydrogen concentration. At vertices, in addition to mass balance, we also consider mixing of incoming flows of varying hydrogen concentrations. The problems of interest are the heterogeneous gas flow simulation (HGFS), which determines system pressures and flows given fixed boundary conditions and compressor settings, as well as the heterogeneous gas flow optimization (HGFO), which extremizes an objective by determining optimal boundary conditions and compressor settings. We examine conditions for uniqueness of solutions to the HGFS, as well as compare and contrast mixed-integer and continuous nonlinear programming formulations for the HGFO. We develop computational methods to solve both problems, and examine their performance using four test networks of increasing complexity.

08 HYDROGEN↗
DOE OSTI2022

Use of Multiple Tracer Gases to Quantify Vane Trailing Edge Flow Into Turbine Rim Seals

Abstract Overlapping features are commonly used as rim seals between stationary and rotating components in a turbine stage. These rim seals are used to prevent main gas path ingestion to the wheelspace cavity, which reduces the lifespan of critical engine components such as the turbine disk. In addition to the overlapping features, purge flow, diverted from the compressor, is injected into the rim cavity to act as an airflow sealing mechanism. Previous research identified that in addition to the purge flow in the rim cavity, cooling flow from the vane trailing edge (VTE) is ingested into the rim seal cavity carrying the potential to cool components in the wheelspace. These previous findings, however, were not able to distinctly separate purge from VTE cooling flows, which is the contribution of this paper based on uniquely using two different tracer gases. A one-stage test turbine operating at engine-relevant conditions and consisting of real engine hardware was used to validate and quantify the ingestion of the VTE flow by independently seeding the purge and VTE flows with two different tracer gases. Experimental results show the presence of VTE flow in the rim seal throughout all purge flowrates evaluated. Circumferential variation of VTE flow was also studied both experimentally and computationally using a computational fluid dynamics model. Results showed that ingested VTE flow can reduce the detrimental effect of hot gas ingestion particularly at higher purge flowrates.

Engineering↗
DOE OSTI2024

Blade Designs For Improved Multi-Phase Performance In sCO 2 Compressors; Part II - Optical Diagnostics In sCO 2 And Experimental Evaluation With Particle Image Velocimetry

This paper presents the second part of a study in which the leading-edge and suction surface of a compressor blade was modified to delay onset of phase change for sCO 2 compressors operating near the critical point. Using a first-of-its-kind apparatus for the measurement of sCO 2 flow fields, Particle Image Velocimetry (PIV) is used for local flow field measurements of two compressor blade geometries: the modified “biased-wedge,” and a conventional constant thickness blade. Utilizing the developed hardware, the feasibility of a simple, laser-based diagnostic for qualitatively measuring liquid phase regions, is also presented. The design of the optical diagnostics rig, a discussion of numerous challenges, and necessary considerations involved in performing optical-based measurements like PIV, in sCO 2 , are discussed. Velocity field measurements for the modified compressor profile show a much lower suction peak compared to a conventional blade. Furthermore, these results validate numerical results at the tested conditions, where the suction side profile of the biased wedge works to minimize the local pressure gradient.

14 SOLAR ENERGY↗
DOE OSTI2023

Development, calibration, and validation of a novel gray-box energy model for residential split air conditioners

Energy models for vapor compression refrigeration in residential air conditioners have been developed through white-box, gray-box, and black-box methods in decades. However, existing white-box and gray-box models require complicated equations with detailed geometries while black-box models require substantial experimental data. Further, this paper aims to develop and validate a simple gray-box steady-state energy model without the need for detailed geometries, which can accurately predict the cooling capacity and electrical power input based on outdoor and indoor air conditions, and supply airflow rates. First three state variables, including the evaporation and condensation temperatures, and refrigerant mass flowrate, are applied to develop the energy model and are solved by three physical equations, including the energy conservations at the evaporator and condenser, and the refrigerant volume-mass flow correlation of the compressor. Secondly, seven performance property functions related to three state variables and three physical equations are identified and calibrated by simple temperature and power measurements. Finally, field experiments are conducted on a residential air conditioner to calibrate these performance property functions and validate the developed model. The validated results reveal the model can accurately predict the cooling capacity and electrical power input, with the normalized root mean square errors of 2.3% and 0.87% respectively.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗