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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

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↗
DOE OSTI2021

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↗
DOE OSTI2025

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Standards and practices around compressed air systems are evolving as previous golden rules become outdated and unhelpful.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↗
DOE OSTI2020

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↗
DOE OSTI2020

Increasing Compressed Gas Energy Storage Density Using CO2–N2 Gas Mixture

This paper demonstrates a new method by which the energy storage density of compressed air systems is increased by 56.8% by changing the composition of the compressed gas to include a condensable component. A higher storage density of 7.33 MJ/m3 is possible using a mixture of 88% CO2 and 12% N2 compared to 4.67 MJ/m3 using pure N2. This ratio of gases representing an optimum mixture was determined through computer simulations that considered a variety of different proportions from pure CO2 to pure N2. The computer simulations are based on a thermodynamic equilibrium model that predicts the mixture composition as a function of volume and pressure under progressive compression to ultimately identify the optimal mixture composition (88% CO2 + 12% N2). The model and simulations predict that the optimal gas mixture attains a higher energy storage density than using either of the pure gases.

25 ENERGY STORAGE↗
DOE OSTI2020

Feasibility of using thermal response methods for nonintrusive compressed air flow measurement

Robust, low-cost nonintrusive flow meters are of interest in many industries. Particularly, a reliable nonintrusive flow measurement for the diagnosis of air leaks in compressed air systems is desirable. Measurement of the air flow due to leaks in the system ensures an accurate estimation of potential cost and energy savings. This study evaluates a novel method of using thermal responses to nonintrusively measure leakage rates in compressed air lines. The method uses heat and the resulting thermal response to calculate the flow rate inside the compressed air line. Compared to the current methods for flow measurement, this method can simplify flow measurement while decreasing the sensitivity to errors when measuring flow rates. In this study, the methodology of the proposed method is explained along with the potential advantages to the design. Two approaches are evaluated: a dynamic step response and sinusoidal frequency response. Simulated tests evaluate the feasibility of the proposed methods, followed by experiments that validate the simulation results. A clear correlation between the thermal step response and the flow rate indicate viability of the proposed method in simulation. Experimental results yielded similar results, confirming the validity of the proposed method. The results of a field test in an industrial environment demonstrate the capability of the approach to other flow rate measurement techniques.

42 ENGINEERING↗
DOE OSTI2022

Near isothermal compressed air energy storage system in residential and commercial buildings: Techno-economic analysis

Electrical energy storage systems offer a wide range of options to efficiently manage our power supply infrastructure. Energy and environmental security via renewable resources and energy storage devices will also play a critical role in addressing the supply-demand challenges. A novel energy efficient storage system based on near isothermal compressed air energy storage concept, named as Ground-Level Integrated Diverse Energy Storage (GLIDES) is analyzed for integration with residential and commercial buildings. Additionally, the influence of different configurational aspects on key performance and cost attributes is presented in this study. GLIDES modules in the range of 0.5 kWh–15 kWh configurations were considered for residential buildings whereas 25 kW h–500 kW h modules were considered for commercial buildings. Detailed cost and performance analysis of the GLIDES module proved them to be an effective resource in lowering the peak energy demand and corresponding utility bills.

25 ENERGY STORAGE↗
DOE OSTI2023

Techno-Economic Analysis and Optimization of a Compressed-Air Energy Storage System Integrated with a Natural Gas Combined-Cycle Plant

To address the rising electricity demand and greenhouse gas concentration in the environment, considerable effort is being carried out across the globe on installing and operating renewable energy sources. However, the renewable energy production is affected by diurnal and seasonal variability. To ensure that the electric grid remains reliable and resilient even for the high penetration of renewables into the grid, various types of energy storage systems are being investigated. In this paper, a compressed-air energy storage (CAES) system integrated with a natural gas combined-cycle (NGCC) power plant is investigated where air is extracted from the gas turbine compressor or injected back into the gas turbine combustor when it is optimal to do so. First-principles dynamic models of the NGCC plant and CAES are developed along with the development of an economic model. The dynamic optimization of the integrated system is undertaken in the Python/Pyomo platform for maximizing the net present value (NPV). NPV optimization is undertaken for 14 regions/cases considering year-long locational marginal price (LMP) data with a 1 h interval. Design variables such as the storage capacity and storage pressure, as well as the operating variables such as the power plant load, air injection rate, and air extraction rate, are optimized. Results show that the integrated CAES system has a higher NPV than the NGCC-only system for all 14 regions, thus indicating the potential deployment of the integrated system under the assumption of the availability of caverns in close proximity to the NGCC plant. The levelized cost of storage is found to be in the range of 136–145 $/MWh. Roundtrip efficiency is found to be between 74.6–82.5%. A sensitivity study with respect to LMP shows that the LMP profile has a significant impact on the extent of air injection/extraction while capital expenditure reduction has a negligible effect.

25 ENERGY STORAGE↗
DOE OSTI2024

Pathway to Decarbonization Through Industrial Energy Efficiency: Micro and Macro Perspectives from Compressed Air Usage

Abstract Energy audits directly provided the industrial sector with reduced energy costs and avoided emissions. Still, they also lead to far-reaching indirect and induced local, regional, and national benefits. This paper aims to present the techno-economic-environmental analysis to achieve decarbonization through implementing industrial energy efficiency at micro and macro levels. An integrated techno-economic-environmental methodology is developed. Case studies of micro-level carbon reduction efforts through industrial energy efficiency technologies are presented. The broader macroeconomic and environmental effects of technology on society are analyzed using data from 206 energy audits of industrial compressed air systems conducted over 13 years. The impacts show that energy-efficient improvements lead to direct cost savings for manufacturers, boost economic activity across sectors, and affect carbon dioxide emissions both short-term and long-term in the region. Given their extensive benefits, energy audits significantly influence policymaking. We devised a methodology to link micro-level energy audit data with macroeconomic and environmental analyses to quantify these cascading benefits. The economic scenario analysis shows that $228 M has been saved from direct industrial energy savings from implementing all compressed air recommendations in the studied periods and the region. In addition, the investment made through manufacturers would create 2,025 jobs and $383 M annually, cascading regional economic impacts. The environmental analysis shows that the regional manufacturers have directly avoided about 2.8 M metric tons of carbon dioxide emissions.

Engineering↗
DOE OSTI2020

Air compressor load forecasting using artificial neural network

Air compressor systems are responsible for approximately 10% of the electricity consumed in United States and European Union industry. As many researches have proven the effectiveness of using Artificial Neural Network inair compressor performance prediction, there is still a need to forecast the air compressor electrical load profile. The objective of this study is to predict compressed air systems’ electrical load profile, which is valuable to industry practitioners as well as software providers in developing better practice and tools for load managementand look-ahead scheduling programs. Two artificial neural networks, Two-Layer Feed-Forward Neural Networkand Long Short-Term Memory were used to predict an air compressors electrical load. Compressors with three different control mechanisms are evaluated with a total number of 11,874 observations. Here, the forecasts were validated using out-of-sample datasets with 5-fold cross-validation. Models produced average coefficient ofdetermination values from 0.24 to 0.94, average root-mean-square errors from 0.05 kW - 5.83 kW, and meanabsolute scaled errors from 0.20 to 1.33. The results indicate that both artificial neural networks yield goodresults for compressors using variable speed drive (average R 2 = 0.8 and no naïve forecasting), only the longshort-term memory model gives acceptable results for compressors using on/off control (average R 2 = 0.82 and no naïve forecasting), and no satisfactory results are obtained for load/unload type air compressors (models constituting active forecasting).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Performance of an Isobaric Hybrid Compressed Air Energy Storage System at Minimum Entropy Generation

Efficient, large-scale, and cost-effective energy storage systems provide a means of managing the inherent intermittency of renewable energy sources and drastically increasing their utilization. Compressed air energy storage (CAES) and its derivative architectures have received much attention as a viable solution; however, optimization objectives for these systems have not been thoroughly investigated in the literature. In this work, a hybrid thermal and compressed air energy storage (HT-CAES) system is investigated that mitigates the shortcomings of the otherwise attractive conventional CAES systems and its derivatives—shortcomings such as strict geological locations, low energy densities, and the production of greenhouse gas emissions. The HT-CAES system allows a portion of the available energy to operate a compressor and the remainder to be converted and stored in the form of heat through joule/resistive heating in a high-temperature, sensible, thermal energy storage medium. Internally reversible and irreversible HT-CAES system assumptions were investigated, in addition to regenerative and non-regenerative design configurations. Several system optimization criteria were examined—including maximum energy efficiency, maximum exergy efficiency, maximum work output, and minimum entropy generation—with a focus on whether the latter may lead to conclusive design guidelines in a real system. It is shown that an HT-CAES system designed based on a minimum entropy generation objective may operate at a lower energy and exergy efficiency as well as lower output power than otherwise achievable. Furthermore, optimization objective equivalence is shown to be limited to certain design conditions.

25 ENERGY STORAGE↗
DOE OSTI2022

Predicting industrial building energy consumption with statistical and machine-learning models informed by physical system parameters

The industrial sector consumes about one-third of global energy, making them a frequent target for energy use reduction. Variation in energy usage is observed with weather conditions, as space conditioning needs to change seasonally, and with production, energy-using equipment is directly tied to production rate. Previous models were based on engineering analyses of equipment and relied on site-specific details. Others consisted of single-variable regressors that did not capture all contributions to energy consumption. Further, new modeling techniques could be applied to rectify these weaknesses. Applying data from 45 different manufacturing plants obtained from industrial energy audits, a supervised machine-learning model is developed to create a general predictor for industrial building energy consumption. The model uses features of air enthalpy, solar radiation, and wind speed to predict weather-dependency; motor, steam, and compressed air system parameters to capture support equipment contributions; and operating schedule, production rate, number of employees, and floor area to determine production-dependency. Results showed that a model that used a linear regressor over a transformed feature space could outperform a support vector machine and utilize features more representative of physical systems. Using informed parameters to build a reliable predictor will more accurately characterize a manufacturing facility's energy savings opportunities.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

A Review of Coupled Geochemical–Geomechanical Impacts in Subsurface CO 2 , H 2 , and Air Storage Systems

Increased demand for decarbonization and renewable energy has led to increasing interest in engineered subsurface storage systems for large-scale carbon reduction and energy storage. In these applications, a working fluid (CO 2 , H 2 , air, etc.) is injected into a deep formation for permanent sequestration or seasonal energy storage. The heterogeneous nature of the porous formation and the fluid–rock interactions introduce complexity and uncertainty in the fate of the injected component and host formations in these applications. Interactions between the working gas, native brine, and formation mineralogy must be adequately assessed to evaluate the efficiency, risk, and viability of a particular storage site and operational regime. This study reviews the current state of knowledge about coupled geochemical–geomechanical impacts in geologic carbon sequestration (GCS), underground hydrogen storage (UHS), and compressed air energy storage (CAES) systems involving the injection of CO 2 , H 2 , and air. Specific review topics include (1) existing injection induced geochemical reactions in these systems; (2) the impact of these reactions on the porosity and permeability of host formation; (3) the impact of these reactions on the mechanical properties of host formation; and (4) the investigation of geochemical-geomechanical process in pilot scale GCS. This study helps to facilitate an understanding of the potential geochemical–geomechanical risks involved in different subsurface energy storage systems and highlights future research needs.

08 HYDROGEN↗
DOE OSTI2021

Energy, Exergy, and Emission Analysis on Industrial Air Compressors

Abstract Air compressors, a key fluid power technology, play an essential role in industrial plants and office buildings, hospitals, and other types of facilities. The efficient use of the air compressor is crucial. By controlling unnecessary inefficiencies, high energy consumption can be reduced. This study aims to provide energy and exergy analysis on air compressors for different industries. Detailed case studies were also analyzed. The case study focuses on the energy and exergy analyses of the compressed air system of foundry industries. The results indicate that applying the six improvement recommendations yields significant amounts of energy and cost savings and significant improvements in the system's overall performance. The payback periods for different recommendations are economically feasible and worthwhile to use. The suggested improvement methods can provide cost savings with a low payback period.

Energy & Fuels↗
DOE OSTI2025

Simple Wins: Driving Effective Implementation of Energy Efficiency Projects

Small- and medium-sized manufacturers (SMMs) in the United States, making up over 98% of manufacturing firms, account for 48.3% of the sector’s energy consumption. Despite access to energy assessments and technical resources, such as those from the US Department of Energy’s Better Plants program and Industrial Training and Assessment Centers, implementation rates for identified energy-saving measures remain lower than expectations, averaging 47%. Some barriers were identified by other researchers as limited workforce capacity, inadequate training, and time constraints hinder progress. This article studied the development of customized checklists together with the energy assessment report as a practical solution to improve implementation rates for energy efficiency projects among SMMs. The framework for the checklists was grounded in five principles: short, precise, actionable, relevant, and codeveloped (SPARC). A case study of a 500,000-squarefoot SMM demonstrates how tailored checklists targeting significant energy users—such as heating, ventilating and air conditioning (HVAC), lighting, and compressed air systems for this facility—can simplify the process for staff to do facility walkthroughs to monitor best practices and track the progress of energy efficiency project implementation.

Guo, Wei [Oak Ridge National Laboratory (ORNL), Oa↗
DOE OSTI2023

Techno-Economic Analysis of a Thermally Integrated Solid Oxide Fuel Cell and Compressed Air Energy Storage Hybrid System

Natural-gas-fueled solid oxide fuel cell (SOFC) systems have the potential for high-efficiency conversion of carbon to power due to the underlying electrochemical conversion process while readily facilitating carbon capture through the separation of the fuel and oxidant sources. Compressed air energy storage (CAES) technology can potentially store significant quantities of energy for later use with a high round-trip efficiency and lower cost when compared with state-of-the-art battery technology. The base load generation capability of SOFC can be coupled with CAES technology to provide a potentially flexible, low-carbon solution to meet the fluctuating electricity demands imposed by the increasing share of intermittent variable renewable energy (VRE) production. SOFC and CAES can be hybridized through thermal integration to maximize power output during periods of high electrical demand and then store power when either demand is low or renewable generation reduces power prices. The techno-economics of a low-carbon hybrid SOFC and CAES system was developed and investigated in the present study. The proposed hybrid system was found to be cost-competitive with other power-generating base-load facilities when power availability was considered. The hybrid system shows increased resilience to changes in a high VRE grid market scenario.

25 ENERGY STORAGE↗
DOE OSTI2022

U.S. Industrial and Commercial Motor System Market Assessment Report. Volume 3: Energy Saving Opportunity

This report seeks to inform the potential for motor systems to support decarbonization by estimating their potential energy, electricity cost, and CO 2 emissions reduction potential from adoption of proven energy efficiency actions and advanced technologies. This is the third and final report in a series of reports disseminating the findings of the U.S. Department of Energy’s (DOE’s) Motor System Market Assessment (MSMA). The MSMA and this report focus on polyphase motor systems greater than or equal to 1 horsepower (hp) in the industrial and commercial sectors. In the U.S. Industrial and Commercial Motor System Market Assessment Report Volume 1: Characteristics of the Installed Base (Volume 1 report), it was determined that these motor systems consume more than 1,000 terawatt-hours (TWh) annually. This equates to 29% of the U.S. electric grid load and results in 765 million metric tons (MMT) of CO 2 emissions and $166 billion in electricity costs. This report finds that substantial reductions to these energy, cost, and emissions impacts are possible, with three areas of significant opportunity being (1) improved load matching, (2) replacing older inefficient motors with more efficient motors, and (3) improving the condition of fluid (e.g., air, water, compressed air) distribution systems. A summary of the savings potential from these three opportunities placed within the context of the overall consumption for motor systems is illustrated in Figure ES 1 (industrial) and Figure ES 2 (commercial).

29 ENERGY PLANNING, POLICY, AND ECONOMY↗