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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 OSTI2025

In situ studies of a molten metal anode ablation in a nearly atmospheric pressure DC arc

A DC arc with a meltable metal anode in a near-atmospheric pressure hydrocarbon gas is an emerging method for producing single-walled carbon nanotubes (SWCNTs). In these systems, evaporation of the molten metal anode determines the formation of catalyst seed particles needed for SWCNT growth, and therefore, should be monitored, controlled, and optimized. Evaluating the anode ablation rate by weighing the anode before and after a synthesis run is unfeasible due to anode carburization in the hydrocarbon atmosphere. To overcome this, we implemented a high-speed, 2D, 2-color pyrometry for reliable temperature measurements of the molten anode in a DC arc. The obtained temperature fields were used to calculate the anode ablation rates. Results showed the importance of resolving the arc and molten pool dynamics, as well as addressing the issue of reflections. Furthermore, significant changes in ablation rates were revealed upon addition of CH 4 , which must be considered when scaling up the production of SWCNTs.

Marangoni↗
DOE OSTI2021

Methods for Evaluating DC Arc Incident Energy in PV Systems: Preprint

Renewable energy systems continue to be one of the fastest growing segments of the energy industry. This paper focuses on the understanding of how photovoltaic (PV) technology behaves under dc arc conditions. Emphasis is placed on the electrical safety aspect of DC arc flash incident energy evaluation. Because of the fast proliferation of PV systems and the lack of formal equivalent calculation guidelines such as IEEE 1584 for AC systems, it has been necessary to rely on different equations and models presented by various researchers over the last few years. This paper discusses the behavior of PV systems under arc conditions and presents the results of available methods to estimate the dc arc flash incident energy. This paper provides a comparative analysis of a proposed arc-flash incident energy calculation method against different laboratory tests including those performed by NREL. Detailed explanations are provided regarding the effect of PV module I-V and P-V curves under arcing conditions. Examples of the application of the proposed calculation method to the test measurements are included.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

DC Arc Incident Energy in Photovoltaic Systems: Methods for Evaluation

Renewable energy systems continue to be one of the fastest growing segments of the energy industry. This article focuses on the understanding of how photovoltaic (PV) technology behaves under dc arc conditions. Emphasis is placed on the electrical safety aspect of dc arc-flash incident energy (IE) evaluation. Because of the fast proliferation of PV systems and lack of formal equivalent calculation guidelines, such as IEEE 1584 for ac systems, it has been necessary to rely on different equations and models presented by various researchers over the last few years. This article discusses the behavior of PV systems under arc conditions and presents the results of the available methods to estimate the dc arc-flash IE. It provides a comparative analysis of a proposed arc-flash IE calculation method against different laboratory tests, including those performed for this article at the National Renewable Energy Laboratory (NREL). Detailed explanations are provided regarding the effect of the PV module current-voltage (I-V) and power-voltage (P-V) curves under arcing conditions. Examples of the application of the proposed calculation method to the test measurements are included.

arc discharges↗
DOE OSTI2022

DC Arc-Flash Safety for 1,500VDC: Methodology, Verification, and Codifying

This project aimed to address critical gaps in understanding arc flash phenomena in commercially operating photovoltaic (PV) plants. Motivated by the global growth of PV systems and the associated safety risks, the research sought to enhance knowledge, improve incident energy prediction models, and contribute to the overall safety and reliability of PV installations.

14 SOLAR ENERGY↗
DOE OSTI2024

Growth of metal nanoparticles in hydrocarbon atmosphere of arc discharge

A direct current (DC) arc discharge is a widely used method for large-scale production of metal nanoparticles, core–shell particles, and carbon nanotubes. Here, the growth of iron nanoparticles is explored in a modified DC arc discharge. Iron particles are produced by the evaporation of an anode, made from low-carbon steel. Methane admixture into argon gas serves as a carbon source. Electron microscopy and elemental analysis suggest that methane and/or products of its decomposition adhere to iron clusters forming a carbon shell, which inhibits iron particle growth until its full encapsulation, at which point the iron core growth is ceased. Experimental observations are explained using an aerosol growth model. The results demonstrate the path to manipulate metal particle size in a hydrocarbon arc environment.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2024

Enhanced Bottom Anode Monitoring in DC Electric Arc Furnaces Using Fiber-Optic Sensors

A pin style bottom anode employs conductive steel rods that serve as the pathway for the high electrical power through rammed refractory at the bottom of a DC Electric Arc Furnace (EAF). Anode wear during operation is important to monitor, as anode replacement is expensive and impacts EAF productivity. Liquid steel penetration into the un-sintered refractory layer can result from rapid electrical power ramp-up, dips in furnace temperature, or operating the anode for too long between EAF campaigns. In extreme cases, the liquid steel may penetrate the bottom of the furnace when anode wear progresses too close to the bottom shell, which is extremely dangerous and must be avoided. The current state of the art for monitoring bottom anode wear employs thermocouples imbedded in the anode pins at points in the anode. However, this approach is not sensitive enough to detect localized damage to the anode, especially when cracking occurs. Here, the present work utilizes fiber optic sensors to monitor the health of the anode, by creating a real-time spatially distributed temperature map of the anode. Unlike the traditional thermocouples, these sensors can be mounted at significantly greater depths, provide distributed temperature measurements, and can withstand temperatures of up to 900°C. Additionally, they are able to perform temperature measurements with a spatial resolution of 1.3 mm at a 5 Hz acquisition rate, providing unprecedented high-density real time monitoring of anode health and increasing the efficiency, and safety of EAF operation.

Bottom Anode↗
DOE OSTI2025

Dynamic Heat Flow and Current Distribution Analysis in the Bottom Anode of an Electric Arc Furnace Using Fiber-Optic Sensors

A reliable method for monitoring bottom anode wear during DC Electric Arc Furnace (DC-EAF) operation is of critical importance for safe and efficient steel production. Underestimation of bottom wear poses a serious safety risk that must be avoided, while overestimation of bottom wear also poses challenges, as premature anode replacement is expensive and affects EAF productivity. Previously, we demonstrated that fiber-optic sensors can be successfully deployed to create a spatially distributed temperature map to monitor the health of the anode. The present work explores the heat flow and current density distribution in bottom anode pins to predict bottom wear, steel penetration events, and monitor refractory erosion. Small dynamic variations in pin temperature induced by joule heating during arcing also provide a means to observe local current flows in each pin. When mapped, these measurements provide a real-time view of the non-uniform and dynamic current flow in the bottom anode during EAF operation that can affect bottom wear.

Bottom Anode↗
DOE OSTI2025

Advancing Temperature Monitoring of the Bottom Anode in a Direct Current Electric Arc Furnace Operations with Distributed Optical Fiber Sensors.

The bottom anode in the Direct Current Electric Arc Furnace (DC EAF) is critical for completing the electrical circuit necessary for sustaining the arc within the furnace. For pin-type bottom anodes, monitoring of the temperature of select pins instrumented with thermocouples is performed to track bottom wear in the EAF and inform the operator when the furnace should be removed from service. Furthermore, this work presents the results from a plant trial using distributed temperature monitoring of bottom anode pins in a 165-ton DC EAF over a two-month service period utilizing two optical fiber sensing techniques: fiber Bragg grating (FBG) and Rayleigh backscattering (RBS). The early detection of temperature anomalies along the length of the anode pin through distributed sensing enhances operational safety, providing a robust alternative to traditional thermocouples.

42 ENGINEERING↗
DOE OSTI2022

Nanosynthesis by atmospheric arc discharges excited with pulsed-DC power: a review

Plasma technology is actively used for nanoparticle synthesis and modification. All plasma techniques share the ambition of providing high quality, nanostructured materials with full control over their crystalline state and functional properties. Pulsed-DC physical/chemical vapour deposition, high power impulse magnetron sputtering, and pulsed cathodic arc are consolidated low-temperature plasma processes for the synthesis of high-quality nanocomposite films in vacuum environment. However, atmospheric arc discharge stands out thanks to the high throughput, wide variety, and excellent quality of obtained stand-alone nanomaterials, mainly core–shell nanoparticles, transition metal dichalcogenide monolayers, and carbon-based nanostructures, like graphene and carbon nanotubes. Unique capabilities of this arc technique are due to its flexibility and wide range of plasma parameters achievable by modulation of the frequency, duty cycle, and amplitude of pulse waveform. The many possibilities offered by pulsed arc discharges applied on synthesis of low-dimensional materials are reviewed here. Periodical variations in temperature and density of the pulsing arc plasma enable nanosynthesis with a more rational use of the supplied power. Parameters such as plasma composition, consumed power, process stability, material properties, and economical aspects, are discussed. Lastly a brief outlook towards future tendencies of nanomaterial preparation is proposed. Atmospheric pulsed arcs constitute promising, clean processes providing ecological and sustainable development in the production of nanomaterials both in industry and research laboratories.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2025

Improvements to Passive Heat Removal Systems in SAS4A/SASSYS-1

Safe operation of a sodium cooled fast reactor (SFR) can be significantly aided by heat removal systems that do not rely on active power, but function using passive means. Passive heat removal from such reactors can employ systems that extract heat directly from sodium coolant by utilizing heat exchangers submerged in the coolant and natural circulation of a metal fluid sodium (or sodium potassium eutectic) to heat exchangers (generally air cooled) externally located. These types of systems are generally called Direct Reactor Auxiliary Cooling Systems (DRACS). Another type of passive heat removal system particularly suitable for pool-type SFRs relies on indirect extraction of heat by utilizing air flow in an annular region surrounding the reactor guard vessel which discharges the heat via the chimney effects to the atmosphere. These systems are generally called Reactor Vessel Auxiliary Cooling Systems (RVACS).

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

ARC-SAFE: Accelerated Response semiconducting Contactors and Surge Attenuation For DC Electrical systems (Final Scientific/Technical Report)

The landscape of power transmission and distribution is quickly evolving as more power conversion is done through power electronics and transmitted or distributed at medium voltage direct current (MVDC). As power electronics tend to store less energy and be less resilient to faults than conventional power transformers, a reliable and fast protection against faults is critical to protect power electronics (PE) based infrastructure, especially for medium- and high-voltage applications. This motivates the development of PE based protection circuits to replace slower contemporary electromechanical breakers. In this project a novel PE based MVDC circuit breaker is developed; the new design is comprised of 1) a normally-on leg made of commercially-available, cascaded SiC junction field effect transistors (JFETs) with a passive balancing network, and 2) a normally-off leg based on an optically-triggered gallium nitride (GaN) photoconductive semiconductor switch (PCSS). The normally-off leg was designed to be quickly turned on, to divert current to an auxiliary dissipative circuit, as the normally-on leg is turned off. This approach, using solid-state devices, was selected for a high-performance, fast-switching operation for the DC circuit breaker as compared to approaches that use slower mechanical switches. To be practical, the circuit breaker must have low conduction loss (low Ron) in the normally-on leg and fast coordinated triggering of the normally-off leg to avoid damage from inductive flyback, which could be considerable for long lengths of cable.

24 POWER TRANSMISSION AND DISTRIBUTION↗