Load sharing energy savings methodology for systems with multiple centrifugal compressors
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32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
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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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Identifying Energy Inefficiencies in Compressed Air Systems: A Systematic Approach with the Compressed Air Scoping Tool
This paper highlights the importance of improving compressed air systems, outlines the tool’s development and features, and underscores its value as a nonbiased resource for system evaluation and optimization. Additionally, the paper presents a case study based on a food manufacturing facility to demonstrate the practical application of the tool. Furthermore, the paper discusses potential future opportunities for enhancing the CA Scoping Tool.
compressed air benchmarking↗
Tool permits damage-free removal of solar cell
Modified soldering iron extracts a wrap-around solar cell that is attached with solder or adhesive to a substrate without destroying the cell removed or damaging adjacent cells. Heat, vacuum, and compressed air, operated from a special head attached to the soldering iron, loosen, extract, and protect the cell.
Beckley, J. E., Jr.↗
A cryocooler for applications requiring low magnetic and mechanical interference
A very low-power, low-interference Stirling cryocooler is being developed based on principles and techniques described in several previous publications over the last four years. It differs in several important details from those built previously. It uses a tapered displacer based upon an analytical optimization procedure. The displacer is driven by an auxiliary piston and cylinder (rather than by mechanical linkage) using some of the working fluid itself to provide the driving force. This provides smooth, vibration-free motion, and, more importantly, allows complete mechanical and spatial separation of the cryostat from the pressure-wave generator. Either of two different pressure-wave generators can be used. One is a non-contaminating, unlubricated ceramic piston and cylinder. The other is a compressed-air-operated rubber diaphragm with motor-driven valves to cycle the pressure between appropriate limits.
Zimmerman, J. E.↗
Chapter 22: Compressed Air Evaluation Protocol. The Uniform Methods Project: Methods for Determining Energy Efficiency Savings for Specific Measures (September 2011 - August 2020)
Compressed-air systems are used widely throughout industry for many operations, including pneumatic tools, packaging and automation equipment, conveyors, and other industrial process operations. Compressed-air systems are defined as a group of subsystems composed of air compressors, air treatment equipment, controls, piping, pneumatic tools, pneumatically powered machinery, and process applications using compressed air. A compressed-air system has three primary functional subsystems: supply, distribution, and demand. Air compressors are the primary energy consumers in a compressed-air system and are the primary focus of this protocol. The two compressed-air energy efficiency measures specifically addressed in this protocol are: high-efficiency/variable speed drive (VSD) compressor replacing modulating, load/unload, or constant-speed compressor; compressed-air leak survey and repairs. This protocol provides direction on how to reliably verify savings from these two measures using a consistent approach for each.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Gasoline fuels properties for multi-mode operation – Observations in a GDI and the CFR engine
The combustion behavior of five full boiling range RON98 gasoline blends was evaluated for multi-mode operation in a GDI and the CFR octane rating engine. The GDI engine tests were conducted with stoichiometric air-fuel ratio in spark-ignition (SI), and with air-diluted homogeneous charge compression ignition (HCCI) mode. In the CFR engine, the knocking combustion was analyzed under standard RON testing conditions at both peak knocking lambda and stoichiometric air-fuel ratios, whereas compression ignited operation was characterized by utilizing the HCCI number test protocol. Disparate knock limited SI and HCCI combustion behavior was observed for the test fuels, despite four of the fuels having the same RON and octane sensitivity. It was found that knock-limited combustion phasing in the GDI engine did not align well with the RON. However, a detailed comparison of knock-limited SI operation in the GDI and CFR engine revealed that a more appropriate effective RON based on a common knock intensity metric (MAPO) and stoichiometric air-fuel ratio resulted in comparable knock characterization between the two engine platforms. Furthermore, the critical intake air temperature and the critical compression ratio were proposed to characterize knock-limited SI operation, while the minimum intake air heating and compression ratio were used to define a fuel's autoignition propensity for compression ignition operation in the GDI and CFR engine, respectively. Finally, each fuel's characteristic compression ratio needed to obtain knock-limited SI (KLSI) and HCCI operation was used to calculate an effective multi-mode octane number (MM-ON) based on the primary reference fuel blends.
33 ADVANCED PROPULSION SYSTEMS↗
Cryomodule Compressed Air Panels
RF couplers require compressed air to maintain operational temperature and performance. Each type of cryomodule has a different configuration dependent on the number of RF cavities and their specifications. Compressed air panels will be mounted on the lifting brackets of the cryomodules to provide support for the hardware.
Herbst, Lilly↗
Compressed Air Scoping Tool Teaches Energy Efficiency Best Practices
Standards and practices around compressed air systems are evolving as previous golden rules become outdated and unhelpful. One of the most referenced guidelines gives us the perfect example: The previous rule of thumb for compressed air storage – 1-3 gal/cfm1,2 – is now accepted to be 3-5 gal/cfm. This change in recommended storage is only one of many in the industry, resulting in industrial users lost in a sea of contradictory best practices. To help combat confusion and poor information sharing, a collaborative effort between Oak Ridge National Laboratory (ORNL) and the Department of Energy’s (DOE’s) Better Plants program created the Compressed Air (CA) Scoping Tool with the most up-to-date best practices in the industry (as of 2023). It can be used as a nonbiased, one-stop shop for best practice recommendations. The Excelbased tool is designed to be an initial step in understanding the operation of a compressed air system, a baselining tool enabling users to comprehend various aspects of a facility’s system from the production of compressed air to its application by end users.
42 ENGINEERING↗
Mechanical rod peening
Tool is inexpensive and gives repeatable results. It is modified commercially-available rod-type weld slag removal gun and is pneumatically operated by regulated compressed air supply.
Minter, E. J.↗
The Nozzle Acoustic Test Rig: an Acoustic and Aerodynamic Free-jet Facility
The nozzle acoustic test rig (NATR) was built at NASA Lewis Research Center to support the High Speed Research Program. The facility is capable of measuring the acoustic and aerodynamic performance of aircraft engine nozzle concepts. Trade-off studies are conducted to compare performance and noise during simulated low-speed flight and takeoff. Located inside an acoustically treated dome with a 62-ft radius, the NATR is a free-jet that has a 53-in. diameter and is driven by an air ejector. This ejector is operated with 125 lb/s of compressed air, at 125 psig, to achieve 375 lb/s at Mach 0.3. Acoustic and aerodynamic data are collected from test nozzles mounted in the free-jet flow. The dome serves to protect the surrounding community from high noise levels generated by the nozzles, and to provide an anechoic environment for acoustic measurements. Information presented in this report summarizes free-jet performance, fluid support systems, and data acquisition capabilities of the NATR.
Castner, Raymond S.↗
Hydraulic Apparatus for Mechanical Testing of Nuts
The figure depicts an apparatus for mechanical testing of nuts. In the original application for which the apparatus was developed, the nuts are of a frangible type designed for use with pyrotechnic devices in spacecraft applications in which there are requirements for rapid, one-time separations of structures that are bolted together. The apparatus can also be used to test nonfrangible nuts engaged without pyrotechnic devices. This apparatus was developed to replace prior testing systems that were extremely heavy and immobile and characterized by long setup times (of the order of an hour for each nut to be tested). This apparatus is mobile, and the setup for each test can now be completed in about five minutes. The apparatus can load a nut under test with a static axial force of as much as 6.8 x 10(exp 5) lb (3.0 MN) and a static moment of as much as 8.5 x 10(exp 4) lb in. (9.6 x 10(exp 3) N(raised dot)m) for a predetermined amount of time. In the case of a test of a frangible nut, the pyrotechnic devices can be exploded to break the nut while the load is applied, in which case the breakage of the nut relieves the load. The apparatus can be operated remotely for safety during an explosive test. The load-generating portion of the apparatus is driven by low-pressure compressed air; the remainder of the apparatus is driven by 110-Vac electricity. From its source, the compressed air is fed to the apparatus through a regulator and a manually operated valve. The regulated compressed air is fed to a pneumatically driven hydraulic pump, which pressurizes oil in a hydraulic cylinder, thereby causing a load to be applied via a hydraulic nut (not to be confused with the nut under test). During operation, the hydraulic pressure is correlated with the applied axial load, which is verified by use of a load cell. Prior to operation, one end of a test stud (which could be an ordinary threaded rod or bolt) is installed in the hydraulic nut. The other end of the test stud passes through a bearing plate; a load cell is slid onto that end, and then the nut to be tested is threaded onto that end and tightened until the nut and load cell press gently against the bearing plate.
Hinkel, Todd J.↗
A case study of replacing pneumatic tools with battery-powered ones at an automobile assembly plant
Compressed air is ubiquitous in manufacturing facilities and vital for the proper operation of numerous types of manufacturing equipment and processes, but compressed air systems are highly inefficient. One way of reducing compressed air usage and the associated electricity consumption is to replace pneumatic tools with battery-powered ones. This paper studied the energy cost savings and return on investment (ROI) of replacing pneumatic torque wrenches with battery-powered ones at a typical automobile assembly plant. With a total triggered time of 400.6 hours and an assumed electricity rate of $0.10/kWh, the annual energy cost savings was estimated to be $104/year per tool. The simple payback period and ROI were 5.8 years and 17.3%, respectively.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Operational procedure for computer program for design point characteristics of a compressed-air generator with through-flow combustor for V/STOL applications
The computer program described in this report calculates the design-point characteristics of a compressed-air generator for use in V/STOL applications such as systems with a tip-turbine-driven lift fan. The program computes the dimensions and mass, as well as the thermodynamic performance of a model air generator configuration which involves a straight through-flow combustor. Physical and thermodynamic characteristics of the air generator components are also given. The program was written in FORTRAN IV language. Provision has been made so that the program will accept input values in either SI units or U.S. customary units. Each air generator design-point calculation requires about 1.5 seconds of 7094 computer time for execution.
Krebs, R. P.↗
Spectral broadening and compression of picosecond pulses in air using a multi-pass cell
We report the spectral broadening and post-compression of picosecond pulses using a multi-pass cell (MPC) operating in air. A 2 m-long bi-concave cavity with 41 reflections and 96.4% transmission was designed and implemented, optimized for the compression of 5.5 ps, 4.5 mJ pulses from a Yb:YAG laser operating at 1030 nm. A 19.3-fold spectral broadening was obtained, increasing the bandwidth from 0.3 nm to 5.8 nm, which enabled pulse compression down to 547 fs with a symmetric temporal profile close to the transform limit. These results demonstrate the feasibility of using open-air MPCs for high-energy picosecond pulse post-compression, without the need for sealed chambers, while preserving high mode quality and transmission. Scaling to pulse higher energy is discussed.
Zaldivar Escola, F. [Univ. of Buenos Aires (Argent↗
The novel Mechanical Ventilator Milano for the COVID-19 pandemic
This paper presents the Mechanical Ventilator Milano (MVM), a novel intensive therapy mechanical ventilator designed for rapid, large-scale, low-cost production for the COVID-19 pandemic. Free of moving mechanical parts and requiring only a source of compressed oxygen and medical air to operate, the MVM is designed to support the long-term invasive ventilation often required for COVID-19 patients and operates in pressure-regulated ventilation modes, which minimize the risk of furthering lung trauma. The MVM was extensively tested against ISO standards in the laboratory using a breathing simulator, with good agreement between input and measured breathing parameters and performing correctly in response to fault conditions and stability tests. The MVM has obtained Emergency Use Authorization by U.S. Food and Drug Administration (FDA) for use in healthcare settings during the COVID-19 pandemic and Health Canada Medical Device Authorization for Importation or Sale, under Interim Order for Use in Relation to COVID-19. Furthermore, following these certifications, mass production is ongoing and distribution is under way in several countries. The MVM was designed, tested, prepared for certification, and mass produced in the space of a few months by a unique collaboration of respiratory healthcare professionals and experimental physicists, working with industrial partners, and is an excellent ventilator candidate for this pandemic anywhere in the world
60 APPLIED LIFE SCIENCES↗
In Situ Multi-Species (O2, N2, Fuel, Other) Fiber Optic Sensor for Fuel Tank Ullage
A rugged and compact fiber optic sensor system for in situ real-time measurement of nitrogen (N2), oxygen (O2), hydrocarbon (HC) fuel vapors, and other gases has been developed over the past several years at Glenn Research Center. The intrinsically-safe, solid-state fiber optic sensor system provides a 1% precision measurement (by volume) of multiple gases in a 5-sec time window. The sensor has no consumable parts to wear out and requires less than 25 W of electrical power to operate. The sensor head is rugged and compact and is ideal for use in harsh environments such as inside an aircraft fuel tank, or as a feedback sensor in the vent-box of an on-board inert gas generation system (OBIGGS). Multiple sensor heads can be monitored with a single optical detection unit for a cost-effective multi-point sensor system. The present sensor technology is unique in its ability to measure N2 concentration directly, and in its ability to differentiate different types of HC fuels. The present sensor system provides value-added aircraft safety information by simultaneously and directly measuring the nitrogen-oxygen-fuel triplet, which provides the following advantages: (1) information regarding the extent of inerting by N2, (2) information regarding the chemical equivalence ratio, (3) information regarding the composition of the aircraft fuel, and (4) by providing a self-consistent calibration by utilizing a singular sensor for all species. Using the extra information made available by this sensor permits the ignitability of a fuel-oxidizer mixture to be more accurately characterized, which may permit a reduction in the amount of inerting required on a real-time basis, and yet still maintain a fire-safe fuel tank. This translates to an increase in fuel tank fire-safety through a better understanding of the physics of fuel ignition, and at the same time, a reduction in compressed bleed air usage and concomitant aircraft operational costs over the long-run. The present fiber optic sensor can also be used as a false-alarm-free engine/hidden/cargo space fire detector (by measuring increased CO2 and CO, and decreased O2), a multi-point in situ measurement and certification system for halogenated-compound fire protection systems, and for the testing and certification of other aircraft safety sensor systems. The technology (LEW-17826-1) developed in the present sensor system is patent pending.
Nguyen, Quang-Viet↗
Experimental Demonstration of a Supersonic Spike Ejector
Spike diffusers are presented as a means to improve supersonic ejector efficiency via reduction in shock losses. Design, fabrication, and testing of an articulated prototype is described. Experimental results are compared to empirical performance curves representing the loci of optimal one- and two-stage conventional ejectors driven by dry air and discharging to atmosphere. Operated at a compression ratio of ~10 with all inputs equal, the spike ejector is shown to have achieved up to 2.19X and 1.83X the secondary mass throughput of the one- and two-stage references, respectively. This suggests the potential of spike diffusers to reduce ejector operating costs by ~50%.
wind tunnel↗
Methane Mitigation Thermoelectric Generator (MMTEG) (Final Scientific/ Technical Report)
Gas Technology Institute (GTI) has completed a $1.815M (plus $500K cost share), 54-month Co-operative agreement with the Department of Energy’s National Energy Technology Laboratory to develop a Methane Mitigation Thermoelectric Generator (MMTEG) system for gas field applications. This novel system uses fugitive gas to produce electrical power and consists of Thermoelectric Generators (TEG) driven by a linear burner, an air compressor, an accumulator, valves, batteries, and power electronics. The electrical power generated by the system is used to compress air and, in turn, the air is used to operate the pneumatic valves at the well site instead of using natural gas (NG) which would then be vented. The team completed the project objectives which included (1) Design, fabricate and test an integrated 6We nominal MMTEG prototype system, (2) Design a “retrofit kit” MMTEG system capable of being field tested at a gas well production site, and (3) build and test the field MMTEG system in a laboratory environment. Multiple system options were developed prior to selecting a “Passive” system which meets cost, NG savings, and greenhouse gas (GHG) reduction targets although not as efficient as initially planned. The MMTEG system is built primarily from commercial off-the-shelf parts (in some cases re-purposed) including the heat exchanger, heat rejection, electronic components, and also the TEGs. The team developed and implemented a novel system including the control system developed by Morrison Applied Sciences (MAS). The team completed incremental demonstrations of the hardware prior to the MMTEG system demonstration. A one-year simulation of the air delivery and battery charging subsystems was completed prior to the integration into the MMTEG system. In addition, the team simulated two-years of thermal cycles for integrated Burner/TEG/heat rejection subsystem. Finally, the entire MMTEG system was assembled, and troubleshooting was completed over a two-week period. Next, the MMTEG system was tested to simulate over 15 weeks of entire system operation over approximately four weeks in an accelerated test fashion with minimal intervention (such as changing fuel tanks). The MMTEG system met the key goals of a unit cost of under $1500 while saving 97% of NG expended today (including leakage) on average by pneumatic systems venting to the atmosphere. The MMTEG system reduced GHG emissions by 1000X (using the methane intensification factor of 28 relative to CO2). GTI is currently pursuing a field test of the MMTEG system. Interfacing with producers has provided additional insight into system improvements. Planned improvements include additional weather protection and control system improvements including the implementation of a long- range radio capability to notify operators if there is a fault.
03 NATURAL GAS↗