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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

Technologies for Enhanced Condensation in sCO 2 Power Cycles

The direct fired supercritical carbon dioxide power cycle has higher efficiency, compact machinery footprint, and is resilient under transient operation. It has been shown that improving the cycle main cooler significantly improves performance, including increased cycle efficiency, decreased cost of electricity and decreased cooler outlet temperatures. One way to improve this process is through enhanced condensation techniques and management of condensation fluid. This manuscript provides an overview of active and passive enhanced condensation technologies, with a focus on the passive approaches. compared to passive approaches, active approaches can have higher heat transfer enhancement, but the additional power and infrastructure can be problematic. The passive approaches identified include microfins (helical and herringbone), corrugated tubing, dimpled tubing and pin fins. After comparison it is found that the microfin geometry has the best performance characteristics followed by the additively manufactured pin fins. It is noted that current literature around additively manufactured enhancements is lacking, and investigation of conventional as well as novel geometries fabricated in this manner may be worth further investigation. Benchmark correlations for these geometries are identified and their limitations outlined. For further investigation, a matrix of test articles is presented for possible experimentation.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Enhanced condensation heat transfer using porous silica inverse opal coatings on copper tubes

Abstract Phase-change condensation is commonplace in nature and industry. Since the 1930s, it is well understood that vapor condenses in filmwise mode on clean metallic surfaces whereas it condenses by forming discrete droplets on surfaces coated with a promoter material. In both filmwise and dropwise modes, the condensate is removed when gravity overcomes pinning forces. In this work, we show rapid condensate transport through cracks that formed due to material shrinkage when a copper tube is coated with silica inverse opal structures. Importantly, the high hydraulic conductivity of the cracks promote axial condensate transport that is beneficial for condensation heat transfer. In our experiments, the cracks improved the heat transfer coefficient from ≈ 12 kW/m 2 K for laminar filmwise condensation on smooth clean copper tubes to ≈ 80 kW/m 2 K for inverse opal coated copper tubes; nearly a sevenfold increase from filmwise condensation and identical enhancement with state-of-the-art dropwise condensation. Furthermore, our results show that impregnating the porous structure with oil further improves the heat transfer coefficient by an additional 30% to ≈ 103 kW/m 2 K. Importantly, compared to the fast-degrading dropwise condensation, the inverse opal coated copper tubes maintained high heat transfer rates when the experiments were repeated > 20 times; each experiment lasting 3–4 h. In addition to the new coating approach, the insights gained from this work present a strategy to minimize oil depletion during condensation from lubricated surfaces.

Adera, Solomon↗
DOE OSTI2026

Photodynamic melting of phase-reversed charge stripes and enhanced condensation

The interplay between charge stripes and pairing has long been a subject of scrutiny in a broad class of unconventional superconductors, as in some cases it is unclear whether this interplay benefits the ensuing superfluidity. Experiments that explore the out-of-equilibrium dynamics of these systems aim to tip the balance toward one phase or the other by selectively coupling to relevant modes. Leveraging the fact that competition between stripes and pairing is not exclusive to fermionic systems, we explore the photoirradiation dynamics of interacting hardcore bosons in which density-wave phase-reversal melting leads to enhanced phase-coherent transport response, as quantified by the dynamic amplification of both the zero-momentum occupancy and the condensate fraction, as well as finite out-of-equilibrium charge stiffness and superfluid weight, for a given system size. Finally, our results, obtained using unbiased methods for an interacting system on a ladder geometry, demonstrate how one can engineer time-dependent perturbations to release suppressed orders, potentially providing insight into the underlying mechanism in related experiments.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2025

Designing slippery rough surfaces to enhance dropwise condensation of low surface tension fluid

Enhancing low surface tension liquid condensation is critical for achieving high energy efficiency and reducing the size of thermal energy systems. Extensive research has focused on promoting dropwise condensation of these liquids using state-of-the-art coatings on plain surfaces. However, maintaining dropwise condensation with low surface tension fluids is challenging due to rivulet formation, resulting in wetted tails that transition to filmwise condensation at elevated heat fluxes. Here, to address this issue, we uncover the role of surface structures and surface chemistry in the dropwise condensation of low surface tension ethanol on slippery rough surfaces (SRS). High-performance dropwise condensation has been achieved on slippery microchannels grafted with perfluoropolyether. The SRS uniquely facilitates rapid lateral droplet removal, enabling faster directional droplet shedding without rivulet formation. The resulting higher droplet removal frequency on SRS leads to heat transfer coefficients 100 % and 500 % higher than conventional dropwise and filmwise condensation on plain surfaces, respectively. Our findings uncover the pivotal role of rapid droplet removal through slippery microchannels in sustaining dropwise condensation of low surface tension liquids. This study introduces a new paradigm for promoting dropwise condensation using engineered SRS that incorporates surface structure and surface chemistry. The work will provide fundamental design guidelines to design efficient and compact condensers that use costly or flammable low global warming potential refrigerants in future refrigeration systems.

Dropwise condensation↗
DOE OSTI2021

Numerical Investigation of Enhanced Dehumidification Processes By Using Dielectrophoresis Principles in Moist Airflows

Dispersed particle-laden flows are encountered in many building and industrial applications, such as flow in a fluidized bed, hydrocarbon transportation in pipelines, and the fouling of air-cooled heat exchangers (Kuruneru et al., 2016; Ray et al., 2019; Wang et al., 2019). Computational fluid dynamic (CFD) models have been developed in recent years to depict particle-fluid and particle-particle interactions in laminar or turbulent flows with increasing accuracy and stability. One particular particle-laden system of interest for moisture control is electrically-enhanced condensation in air and water droplet flows. Electrically-enhanced condensation consists of the use of highly charged water droplets injected in the moist air. The droplets become electric seeds that attract polar water vapor molecules to their surfaces and promote condensation. The nucleation and growth of the charged droplets deplete the vapor phase near a droplet, which is compensated for by the dielectrophoresis flow and diffusion. Dielectrophoresis flow involves surrounding vapor at a distance of about 10 to 100 nm for droplets charged by an electrospray compared to ~2 nm for a single electron charge in a droplet. As the vapor molecules collapse on the surface of the droplets, their initial electrical charge decreases with time due to the neutralization of the ions. While the physics of this phenomena is well known, engineering models for predicting the condensation rates are not available. This work computationally investigates dehumidification of moist airflow in a converging rectangular duct. The objective is to develop an engineering model that predicts water vapor condensation by employing dielectrophoresis principles. We construct a Computational Fluid Dynamics (CFD) model of the duct with electrically-enhanced condensation. The model is implemented in the open-source software OpenFOAM. We utilize the Multi-Phase Particle-In-Cell (MP-PIC) method coupled with a Population Balance Equation (PBE) approach to simulate the particle-laden system. This methodology is an Eulerian-Lagrangian approach used to simulate the droplets' behavior in the humid air. The MP-PIC approach (Andrews and O'Rourke, 1996) mitigates the computational cost by parceling several fundamental particles with similar properties (such as types, sizes, and temperature) into one computational particle. Thus, the billions of particles can be substituted by millions of computational particles without significant loss of information. The PBE was considered with the Lagrangian frame to combine the particle distribution function used in MP-PIC (Kim et al., 2020). This approach preserves mass and energy conservation between the phases in the Eulerian and Lagrangian structures. The PBE in this procedure was directly linked to the discrete parcels, making the simulation of the particle distribution computationally efficient and robust. The MP-PIC-PBE approach used in the present work was applied to the dehumidification of air. Water droplets were injected in the air stream and forced to grow according to experimentally derived correlation. The experiments were conducted on a converging duct with the same geometry and boundary conditions used to build the CFD model. This approach enabled us to approximate the effect of dielectrophoresis phenomena on the droplet and air interface. This presentation will discuss the details of the new CFD model built for the duct, the implementation of the model in OpenFOAM CFD programming language, and the experimental validation of the newly developed model. The results revealed a moderate yet measurable increase in droplet diameter due to water vapor condensation at the vapor-liquid interface of the electrically charged droplets' surface. The seed water droplet particles grew in size by capturing the water vapor in the surrounding air. The OpenFOAM model predicted reductions of humidity in the air from 5 to 10 percent.

Yel Mahi, Maliha↗
DOE OSTI2023

Enhanced internal condensation of R1233zd(E) on micro- and nanostructured copper and aluminum surfaces

In-tube condensation of refrigerants is an important process which affects thermal efficiency in many applications, ranging from refrigeration and air conditioning to electronics thermal management. In-tube heat transfer and pressure drop are important to heat exchanger sizing and design. Here, in this work, micro- and nanostructured surfaces are applied to the internal wetted areas of copper and aluminum mini-channels to enhance the condensation heat transfer coefficient of hydrofluorocarbon R1233zd(E) refrigerant. To achieve scalable nanomanufacturing, surfaces were uniformly structured by relying on hydrochloric acid etching of aluminum and chemical oxidation of copper. The etched aluminum surfaces exhibited a 150% increase in heat transfer coefficient compared to smooth aluminum channels at specific qualities, with a 66% heat transfer coefficient improvement for complete phase change from saturated vapor to saturated liquid. Copper oxide structures showed no discernable difference in thermal-hydraulic performance when compared to smooth copper channels. Critical dimensionless parameters governing the heat transfer enhancement were identified by varying the tube internal diameter (2.3 mm to 4.7 mm), refrigerant mass flux (50 to 300 kg/(m 2 ·s)), and refrigerant quality (0 to 1). The dimensionless parameters include the Bond number normalized to the condensate film thickness, and the Weber number modified by the vapor friction factor. The relatively small increase in pressure drop (< 10%) associated with these surface enhancements further supports the promise of this method. The scalable and cost-effective techniques used to create these aluminum microstructures may reduce manufacturing cost when compared with current enhancement approaches such as extrusion, drawing, and welding.

42 ENGINEERING↗
DOE OSTI2020

Aerosol Impacts on Mesoscale Convective Systems Forming Under Different Vertical Wind Shear Conditions

Following our previous study of wind shear effect on mesoscale convective system (MCS) organization under a clean atmospheric condition using the Weather Research and Forecasting model coupled with Spectral-Bin Microphysics, we conduct sensitivity simulations by increasing cloud condensation nuclei (CCN) concentration and investigate aerosol impacts on MCSs forming under different wind shear conditions. We find that, aerosols induce stronger updrafts and downdrafts in all MCSs. The stronger updrafts and enlarged convective core area contribute to larger vertical mass fluxes and enhance precipitation, indicating convective invigoration. Increased updraft speed below 8-km altitude mainly results from enhanced condensational heating, and increased water loading effect is not large enough to overcome the increase in thermal buoyancy. Interestingly, above 8-km altitude we see reduced updraft speed by the increased aerosols due to reduced vertical pressure perturbation gradient force, and weakened depositional growth due to competition of water vapor by enhanced condensation. The accumulated rainfall and mean rain rate are increased, with an increased occurrence frequency of heavy rain. The increase of rain rate is seen in both convective and stratiform regions, with a more significant increase in convective rain rate. In general, we see a higher frequency of deep convective cloud in the polluted condition because of invigorated convection, and more stratiform/anvil clouds, but a lower frequency of shallow warm clouds. The unanimously invigorated MCSs by aerosols under various wind shear conditions revealed by this study has an important implication in weather and climate at warm and humid regions that are influenced by pollution.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Enhancing Synchronous Condenser Operation of Hydrogenerators

Hydropower plants are sometimes dispatched below capacity or even shut down to meet water regulations. These can temporarily be repurposed to operate as synchronous condensers. To enable this capability, this paper proposes a design that allows hydrogenerators to safely operate as synchronous condensers, providing fast voltage and reactive power support under both normal and boost conditions. The proposed design integrates capability curves with hydrogenerators’ excitation systems through modifications using proposed MVA-field current curve, current controller, and limiter. The design is implemented locally at the machine for rapid response. Simulation results demonstrate the effectiveness of the proposed design and using hydrogenerators as synchronous condensers in power grids.

24 - POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Impacts of cloud microphysics parameterizations on simulated aerosol–cloud interactions for deep convective clouds over Houston

Aerosol–cloud interactions remain largely uncertain with respect to predicting their impacts on weather and climate. Cloud microphysics parameterization is one of the factors leading to large uncertainty. Here, we investigate the impacts of anthropogenic aerosols on the convective intensity and precipitation of a thunderstorm occurring on 19 June 2013 over Houston with the Chemistry version of Weather Research and Forecast model (WRF-Chem) using the Morrison two-moment bulk scheme and spectral bin microphysics (SBM) scheme. We find that the SBM predicts a deep convective cloud that shows better agreement with observations in terms of reflectivity and precipitation compared with the Morrison bulk scheme that has been used in many weather and climate models. With the SBM scheme, we see a significant invigoration effect on convective intensity and precipitation by anthropogenic aerosols, mainly through enhanced condensation latent heating. Such an effect is absent with the Morrison two-moment bulk microphysics, mainly because the saturation adjustment approach for droplet condensation and evaporation calculation limits the enhancement by aerosols in (1) condensation latent heat by removing the dependence of condensation on droplets and aerosols and (2) ice-related processes because the approach leads to stronger warm rain and weaker ice processes than the explicit supersaturation approach.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Impacts of long-range-transported mineral dust on summertime convective cloud and precipitation: a case study over the Taiwan region

As one of the most abundant atmospheric aerosols and effective ice nuclei, mineral dust affects clouds and precipitation in the Earth system. Here numerical experiments are carried out to investigate the impacts of dust aerosols on summertime convective clouds and precipitation over the mountainous region of Taiwan by acting as ice-nucleating particles. We run the Weather Research and Forecasting model (WRF) with the Morrison two-moment and spectral-bin microphysics (SBM) schemes at 3 km resolution, using dust number concentrations from a global chemical transport model (GEOS-Chem-APM). The case study indicates that the long-range-transported mineral dust, with relatively low number concentrations, can notably affect the properties of convective clouds (ice and liquid water contents, cloud top height, and cloud coverage) and precipitation (spatial pattern and intensity). The effects of dust are evident during strong convective periods, with significantly increased ice water contents in the mixed-phase regime via the enhanced heterogeneous freezing. With both the Morrison and SBM schemes, we see the invigoration effects of dust aerosols on the convective intensity through enhanced condensation and deposition latent heating. The low-altitude dust particles are uplifted to the freezing level by updrafts, which, in turn, enhance the convective cloud development through immersion freezing and convective invigoration. Compared to the Morrison scheme, the SBM scheme predicts more realistic precipitation and different invigoration effects of dust. The differences are partially attributed to the saturation adjustment approach utilized in the bulk scheme, which leads to a stronger enhancement of condensation at midlatitudes to low altitudes and a weaker deposition increase at the upper level.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Robust silane self-assembled monolayer coatings on plasma-engineered copper surfaces promoting dropwise condensation

Dropwise condensation is well known to result in better heat transfer performance owing to efficient condensate/droplet removal, which can be harnessed in various industrial heat/mass transfer applications such as power generation and conversion, water harvesting/desalination, and electronics thermal management. The key to enhancing condensation via the dropwise mode is thin low surface energy coatings (<100 nm) with low contact angle hysteresis. Ultrathin (<5 nm) silane self-assembled monolayers (or SAMs) have been widely studied to promote dropwise condensation due to their minimal thermal resistance and scalable integration processes. Such thin coatings typically degrade within an hour during condensation of water vapor. After coating failure, water vapor condensation transitions to the inefficient filmwise mode with poor heat transfer performance. We enhance silane SAM quality and durability during water vapor condensation on copper compared to state-of-the-art silane coatings on metal surfaces. We achieve this via (i) surface polishing to sub-10 nm levels, (ii) pure oxygen plasma surface treatment, and (iii) silane coating integration with the copper substrate in an anhydrous/moisture-free environment. The resulting silane SAM has low contact angle hysteresis (≈20°) and promotes efficient dropwise condensation of water for >360 hours without any visible sign of coating failure/degradation in the absence of non-condensable gases. We further demonstrate enhanced heat transfer performance (≈5-7× increase over filmwise condensation) over an extended period of time. Surface characterization data post-condensation leads us to propose that in the absence of non-condensable gases in the vapor environment, the silane SAM degrades due to reduction and subsequent dissolution of copper oxide at the oligomer-substrate interface. The experiments also indicate that the magnitude of surface subcooling (or condensation rate) affects the rate of coating degradation. Finally, this work identifies a pathway to durable dropwise promoter coatings that will enable efficient heat transfer in industrial applications.

42 ENGINEERING↗
DOE OSTI2025

Dependence of Convective Cloud Microphysical Properties on Environmental Conditions during the TRACER and ESCAPE Field Campaigns: A Synergistic Approach of Observations, Machine Learning and Parcel Models

The sensitivity of convective clouds to aerosols and their interactions with environment, combined with limited observational constraints in parameterizations, introduces significant uncertainties in atmospheric models. Here, this study investigates the dependence of convective cloud microphysical properties on environmental conditions using a synergistic approach that combines unique observations from the TRACER and ESCAPE field campaigns, machine learning techniques, and parcel model simulations with a super-droplet microphysics scheme. A random forest algorithm identifies in-situ vertical velocity (w), temperature (T), and surface fine-mode aerosol mass concentration as the three most important environmental conditions influencing cloud properties including liquid water content (LWC), number concentration for particles with D max < 50 μm (N c ,<50), 50 μm ≤ D max ≤ 3000 μm (N c,50–3000 ), and droplet effective diameter (D e ). Results show that LWC, N c,<50 , and N c,50–3000 significantly increase with w in updrafts. Across w bins, as T decreases, LWC, D e , and N c,50–3000 increase, while N c,<50 decreases, which are closely linked to the distance above cloud bases. Warmer cloud bases yield higher LWC, greater N c,50–3000 , and smaller N c,<50 , while polluted environments produce greater N c,<50 . Parcel model simulations successfully replicate these observed dependencies. The simulation results indicate that warmer cloud bases enhance condensation generating larger droplets, and differences in droplet sizes are then amplified through collision-coalescence, resulting in a greater N c,50–3000 . Polluted conditions result in a greater N c,<50 primarily due to enhanced cloud condensation nuclei activation despite increased collision-coalescence rates compared to pristine conditions. This study provides observed quantitative patterns characterizing cloud microphysical properties as a function of key environmental parameters, offering valuable constraints for improving physics parameterizations and numerical models.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Sensitivity Analysis of an Electrospray Dehumidification System

Electrically enhanced condensation achieved by an electrospray system can enhance dehumidification in HVAC applications if successfully scaled up. The first step towards scale-up is identifying critical design and operating parameters that significantly impact dehumidification for the electrospray system. Sensitivity analysis is one approach for identifying critical parameters. This paper presents a methodology that can efficiently perform quantitative sensitivity analysis on a computationally expensive high fidelity simulation model, which is a computational fluid dynamics (CFD) model of the electrospray system. The methodology employs surrogate modeling and Sobol sensitivity analysis. We estimate the main and total effect Sobol sensitivity indices of four operating parameters of the electrospray system. The results reveal that the most important parameter is the size of the sprayed droplets, followed by the volumetric flow rate of the bulk air and injected water in the system. The water injection velocity of the spray was found to have little to no impact on dehumidification.

Young, David↗
DOE OSTI2024

Patterned Quasi-Liquid Surfaces for Condensation of Low Surface Tension Fluids

Extensive research concerns dropwise condensation of low surface tension fluids to promote energy efficiency and decarbonization in thermal energy systems. However, it is challenging as these fluids typically result in filmwise condensation. Drawing inspiration from the Namib desert beetle that enhances condensation through patterned wettability, conventional beetle-inspired surfaces excel in water condensation but flood when condensing low surface tension fluids. In this work, a patterned quasi-liquid surface is reported that achieves exceptional dropwise condensation of low surface tension fluids. The surface consists of alternating stripes with low surface energy, that is, a perfluoropolyether (PFPE) and fluorinated quasi-liquid surface (FQLS), that shows ultralow contact angle hysteresis for ethanol and hexane. Further, the PFPE stripes are slightly more slippery, acting as slippery bridges that accelerate droplet coalescence and removal. It is experimentally demonstrated that the striped PFPE-FQLS pattern exhibits a heat transfer coefficient 85%, 330%, and 550% higher than that of PFPE, fluorinated silane, and filmwise condensation, respectively. This study reveals that a high contact angle is desired to sustain dropwise condensation, irrespective of contact angle hysteresis. These findings provide a new paradigm for promoting the dropwise condensation of low surface tension fluids and offer valuable insights into surface design for energy sustainability.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Environmental effects on aerosol–cloud interaction in non-precipitating marine boundary layer (MBL) clouds over the eastern North Atlantic

Abstract. Over the eastern North Atlantic (ENA) ocean, a total of 20 non-precipitating single-layer marine boundary layer (MBL) stratus and stratocumulus cloud cases are selected to investigate the impacts of the environmental variables on the aerosol–cloud interaction (ACIr) using the ground-based measurements from the Department of Energy Atmospheric Radiation Measurement (ARM) facility at the ENA site during 2016–2018. The ACIr represents the relative change in cloud droplet effective radius re with respect to the relative change in cloud condensation nuclei (CCN) number concentration at 0.2 % supersaturation (NCCN,0.2 %) in the stratified water vapor environment. The ACIr values vary from −0.01 to 0.22 with increasing sub-cloud boundary layer precipitable water vapor (PWVBL) conditions, indicating that re is more sensitive to the CCN loading under sufficient water vapor supply, owing to the combined effect of enhanced condensational growth and coalescence processes associated with higher Nc and PWVBL. The principal component analysis shows that the most pronounced pattern during the selected cases is the co-variations in the MBL conditions characterized by the vertical component of turbulence kinetic energy (TKEw), the decoupling index (Di), and PWVBL. The environmental effects on ACIr emerge after the data are stratified into different TKEw regimes. The ACIr values, under both lower and higher PWVBL conditions, more than double from the low-TKEw to high-TKEw regime. This can be explained by the fact that stronger boundary layer turbulence maintains a well-mixed MBL, strengthening the connection between cloud microphysical properties and the below-cloud CCN and moisture sources. With sufficient water vapor and low CCN loading, the active coalescence process broadens the cloud droplet size spectra and consequently results in an enlargement of re. The enhanced activation of CCN and the cloud droplet condensational growth induced by the higher below-cloud CCN loading can effectively decrease re, which jointly presents as the increased ACIr. This study examines the importance of environmental effects on the ACIr assessments and provides observational constraints to future model evaluations of aerosol–cloud interactions.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS1991

Hydrogen no-vent fill testing in a 1.2 cubic foot (34 liter) tank

Experimental results of no-vent fill testing with liquid hydrogen in a 1.2 cubic foot (34 liter) stainless steel tank are presented. More than 40 tests were performed with various liquid inlet temperatures, inlet flowrates, initial tank wall temperatures, and liquid injection techniques. Fill levels equal to or exceeding 90 percent by volume were achieved in 40 percent of the tests with the tank pressure limited to a maximum of 30 psia. Three liquid injection techniques were employed; top spray, upward pipe discharge, and bottom diffuser. Effects of each of the varied parameters on the tank pressure history and final fill level are evaluated. The final fill level is found to be indirectly proportional to the initial wall and inlet liquid temperatures and directly proportional to the inlet liquid flowrate. Furthermore, the top spray is the most efficient no-vent fill method of the three configurations examined. The success of this injection method is primarily due to condensation of the ullage vapor onto the incoming liquid droplets. Ullage condensation counteracts the tank pressure rise resulting from energy exchange between the fluid and the warmer tank walls, and ullage compression. Upward pipe discharge from the tank bottom is the next most efficient method. Fluid circulation induced by this fill configuration tends to diminish thermal stratification in the bulk liquid, thus enhancing condensation at the liquid gas interface.

Moran, Matthew E.↗