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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 OSTI2021

Sensitivity Analysis of Particle-In-Cell Modeling Parameters in Settling Bed, Bubbling Fluidized Bed and Circulating Fluidized Bed

The objective of the work presented is to perform a preliminary sensitivity analysis of particle-in-cell (PIC) model parameters when applied to settling bed, bubbling fluidized bed, and circulating fluidized bed simulations. These examples correspond to widely different flow conditions commonly seen in chemical engineering applications. Simulations were performed using the PIC method in the open-source software Multiphase Flow with Interphase eXchanges (MFiX) developed by the National Energy Technology Laboratory (NETL). As part of the non-intrusive uncertainty quantification (UQ) analysis, simulation campaigns were generated using Nodeworks. Sampling locations or settings for PIC model parameters were determined using the Latin Hypercube method. Response surfaces were created using radial basis functions (RBF), and Sobol’ indices were estimated to quantify the influence of model parameters on the quantities of interest (QoI). This study marks a first step towards systematically determining optimal ranges for model parameters used in MFiX-PIC. Based on limited experience, it is expected that these values would depend strongly on flow conditions. Given the complexity of the multiphase flow systems under analysis, a non-intrusive UQ based approach is used to identify the most influential parameters in each case. This prior knowledge will help in proposing an effective design of experiments (DoE) and determine optimal parameters through techniques such as deterministic or Bayesian calibration, which will be pursued in the future.

42 ENGINEERING↗
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 OSTI2024

Probing Thermal Transport in Fluidized Bed Using Modulated Photothermal Radiometry

Abstract In concentrated solar power (CSP) applications, fluidized bed is a promising approach for high heat transfer coefficient (HTC) solar receivers and heat exchangers. However, the complexity of multiphase mixing has made it difficult to characterize and analyze the heat transfer mechanism. This paper presents an experimental study on simultaneously characterizing heat transfer in both the near-wall and the bulk regions of a fluidized bed using modulated photothermal radiometry (MPR). The MPR is a non-contact frequency-domain technique using an intensity-modulated laser as the heat source and surface infrared emission as thermometry. The thermal penetration depth of the laser heating is varied by controlling its modulation frequency, and thus the measurement can resolve the near-wall and the bulk thermal resistances. With the MPR technique, we measured fluidized silica sands with a mean size of 164 μm in a vertical channel of 6 mm depth. Our results show that the near-wall thermal resistance is substantially increased with increasing gas velocity, which partially offsets the benefit of higher HTC brought by stronger particle mixing during the fluidization. We also used the MPR to quantify the improvement in particle-wall heat transfer in an inclined channel. We found that an 8° inclination towards the heat exchanging side led to a lower near-wall thermal resistance and a higher HTC at high gas velocities. This work demonstrates that the MPR technique is a useful tool to quantify the important near-wall thermal resistance from a bulk particle bed, which not only advances our understanding of heat transfer in fluidized beds, but may also contribute to the design of fluidized bed heat exchangers with higher HTC.

14 SOLAR ENERGY↗
DOE OSTI2025

Quantifying particle movement in a spout-fluidized bed with irregular feedstock morphology

Here, the spout-bed fluidization behavior of nonspherical, 140 μm SiC feedstock was quantified via particle image velocimetry for varying gas distributor geometries. A bench-scale, room-temperature fluidization setup was assembled to model a 50 mm fluidized bed chemical vapor deposition (FB-CVD) system, and fluidized bed motion was captured using a high-speed camera. Modular tips with varying inlet geometries were 3D printed and tested on the bench-scale rig using identical feedstock and gas flow rates in the range of 3.0–9.0 L/min. Fluidization behavior was quantified by extracting parameters of the bed velocity, frequency, dead time, and other measurements, which were ranked for each inlet geometry configuration tested. The results from this work demonstrate that changing the path of inlet gas flow can significantly change the hydrodynamics within a spout-fluidized bed under identical feedstock, loading, and flow rate conditions, potentially enabling experimental control of particle fluidization behavior for a given condition. Moreover, composite rankings of fluidization behavior for unique distributor geometries hold potential to guide the design of FB-CVD experiments for various engineering and scientific applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Enriched hydrogen production over air and air-steam fluidized bed gasification in a bubbling fluidized bed reactor with CaO: Effects of biomass and bed material catalyst

Gasification is one of the methods of generating biopower or biofuels from biomass waste. In this study, a benchscale fluidized bed reactor was used for biomass air and air-steam gasification. Gasification was performed under constant operating conditions (~780 °C, equivalence ratio = ~0.32) to investigate the effect of biomass (switchgrass, pine residues) and bed materials (sand, CaO+ sand, Al 2 O 3 , and CaO + Al 2 O 3 ). All gasification products, such as synthesis gas (syngas), contaminant gases, tar, and biochar (solid) were comprehensively analyzed. The composition of biomass significantly impacted CO and H 2 yield from volatile combustible matter and fixed carbon. Further, the presence of CaO made the condition favorable for the water-gas shift (WGS) reaction combined with the CO 2 carbonation reaction, which increased H 2 concentration. Additional steam with CaO increased H 2 concentration closer to 50% (N 2 free condition) through the combination reactions of steam hydrocarbon reforming and WGS by producing 44 g H 2 /kg dry biomass and 143 g CO /kg dry biomass . The usage of steam reduced the overall yield of contaminant gases, whereas the usage of CaO or Al 2 O 3 decreased the amount of gasification tar by approximately 5.8–6.5 g tar /kg dry biomass . In conclusion, this study can provide valuable experimental data for biomass waste to produce better quality syngas.

08 HYDROGEN↗
DOE OSTI2022

Velocity Profiling of a Gas–Solid Fluidized Bed Using Electrical Capacitance Volume Tomography

In this study, a method of producing velocity profile maps from electrical capacitance volume tomography (ECVT) measurements by reconstructing displacement from measured changes in capacitance is developed and applied to fluidized bed systems. The mapping of the reconstruction leverages the gradient of the sensitivity distribution of the ECVT sensor to circumvent the need for image cross correlation techniques. Experimental data of both bubbling and slugging fluidized beds are collected in a cold flow model. Adaptation of the technique is discussed in detail, and velocity profiles are obtained for a range of gas flow rates. The produced velocity maps are compared against the established methods of cross correlation and against empirical correlations from the literature and are found to agree well in tracking slug and bubble velocity. The exception is when the tracked object is large relative to the ECVT sensor dimensions, a scenario that can be avoided through proper sensor design. The quantities of average velocity, momentum, and solid and gas volume fraction are derived from the image and velocity profiles. The results demonstrate and extend the power of ECVT as a measurement tool for the study and monitoring of gas–solid fluidized beds by providing a computationally cheaper alternative to 3-D cross correlation for deriving velocity profiles.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

Testing of a 40-kWth Counterflow Particle-Supercritical Carbon Dioxide Narrow-Channel, Fluidized Bed Heat Exchanger

Particle-based primary heat exchangers (HXs) must deliver sCO2 fluid temperatures above 700°C to couple particle-based concentrating solar receivers and thermal energy storage (TES) sub-systems with efficient sCO2 power cycles. Particle-sCO2 HX designs have struggled to meet DOE cost targets (≤ $150/kWth) due to the amount of expensive nickel alloys necessary for manufacturing full-scale, particle-sCO2 HXs. Our team has demonstrated that mild bubbling fluidization of falling particles in a counterflow narrow-channel fluidized bed can reduce required HX surface area and thus, costs by increasing particle-wall heat transfer coefficients hT,w > 800 W m-2 K-1. This paper reports on the fabrication and testing of a stainless steel, particle-sCO2 HX with 12 fluidized-bed channels approximately 10.5 mm deep spaced between diffusion-bonded, micro-channel sCO2 plates. The HX with a core length of ≈0.56 m is fed with CARBOBEAD HSP particles through a short, fluidized freeboard zone just above the core. Testing to date in the National Solar Thermal Test Facility (NSTTF) at Sandia National Laboratories has shown that parallel bed fluidization maintains uniform particle inventory across the instrumented channels. Heat transfer thermal duty between the particle and sCO2 flows exceeds 30 kWth with sCO2 inlet temperatures of 200ºC and particle inlet temperatures up to 440ºC and mass flow rates of 0.2 kg s-1 fluidized by counterflowing gas flow rates of 0.005 kg s-1. Tests at higher particle and sCO2 inlet temperatures (600ºC and 400ºC respectively) are targeted to achieve > 40 kWth with model-predicted overall heat transfer coefficients U > 400 W m-2 K-1.

14 SOLAR ENERGY↗
DOE OSTI2024

Particle Vertical Mixing and Horizontal Conveyance Within an Ambient Temperature Fluidized Bed

Previous studies have shown the advantages of particle-to-sCO2 fluidized bed (FB) heat exchangers, which include high heat transfer coefficients, low material cost, and the ability to horizontally convey solid particles. This paper outlines the design and testing of a compact cold flow FB test apparatus to characterize horizontal conveyance through convolutions within a 100 kWth FB heat exchanger design. Horizontal conveyance is an advantage in FBs because it enables more compact designs for heat exchangers. Two mass flow rates, 0.5 & 1 kg/s, at the inlet & outlet of the FB. To determine consistency of the flow rates, Student’s t-tests were used to assess whether the inlet & outlet values were statistically similar. The mass flow rate exiting the bed was statistically similar to the flow rate entering the bed for both cases, but each case featured a wider range and standard deviation. The range and standard deviation of the 1 kg/s flow rate was 0.69-1.23 kg/s and 0.12 kg/s respectively, and the 0.5 kg/s test featured a range and standard deviation of 0.37-0.73 kg/s and 0.09 kg/s, respectively. These measurements provide confidence that large-scale designs can successfully horizontally convey particles at ````~1.5x minimum fluidization velocity (U­mf) without significant variation in flow rate. A method to characterize the degree of particle vertical mixing and bubble frequency within the FB is also introduced. By using a high-resolution camera together with particle velocimetry, particle motion in the X and Y directions can be estimated to assess bed mixing and bubble frequency.

Khalaf, Jawad↗
DOE OSTI2021

Experiment and computational fluid dynamics investigation of biochar elutriation in fluidized bed

Here, in fluidized bed biomass fast pyrolysis, the biomass is converted to biochar and elutriated. The elutriation rate is a key parameter in reactor designs and operations. This research presents a video-based continuous measurement of biochar elutriation rate in a fluidized bed with sands and biomass as bed materials. The fluidized bed is simulated with the Computational Fluid Dynamics - Coarse-Grained Discrete Element Method (CFD-CGDEM) in MFiX. The fluidization behavior of non-spherical sands can be more accurately captured when a rolling friction model is used. The predicted elutriation rate is close to the experimental measurement when the particle size distributions are considered and the filtered drag with a shape correction is used. These results validated the accuracy of the MFiX based CFD framework for the prediction of biochar elutriations in the fluidized bed biomass fast pyrolysis reactor.

09 BIOMASS FUELS↗
DOE OSTI2020

Biomass Combustion in a Circulating Fluidized Bed Combustor

Interest in circulating fluidized bed (CFB) boilers as a power generation technology has skyrocketed in recent years because of several advantages this technology offers over conventional boilers, such as increased gas-solid mixing resulting in higher combustion efficiency and the ability to use lower quality fuels. CFB combustors are operated at lower temperatures than conventional thermal power generation combustors, thus reducing NO x emissions. SO 2 emissions are conveniently controlled through the addition of Ca-based sulphur sorbents within the combustor. This report summarizes the current modeling effort on a 50 kW th CFB combustor with a diameter of 10 cm and a height of 5 m; designed, built, and operated at CanmetENERGY in Ottawa, Canada employing the multiphase particle-in-cell (PIC) approach in the open-source Multiphase Flow with Interphase eXchanges (MFiX) Software Suite. The MFiX-PIC model parameters for the simulation are tuned against cold-flow experiments from CanmetENERGY using 9 kg of olivine sand as the inert bed material. It is shown that for the relatively coarse fluid meshes and large parcel sizes necessitated by the scale of the simulation, filter size dependent corrections to the drag law must be incorporated to ensure accuracy of the simulation results. The validated cold flow model is extended to simulate reacting flow with torrefied hardwood as the feedstock and to validate the combustion reaction scheme. The species concentrations at the riser outlet are compared against CanmetENERGY’s experiments and show satisfactory agreement. The simulations demonstrate the ability of MFiX-PIC to accurately capture the physics and chemistry of a circulating fluidized bed combustor at bench scales, which can be further extended to pilot- and industrial-scale systems.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2026

Linking spout fluidization hydrodynamics to pyrolytic carbon deposition characteristics in a fluidized bed chemical vapor deposition reactor

Spout fluidized bed chemical vapor deposition (SFB-CVD) is the dominant method for producing pyrolytic carbon (PyC) coatings on tristructural-isotropic (TRISO) fuel particles, yet the relationship between gas injector design, fluidization hydrodynamics, and resulting coating quality remains poorly quantified. Here, in this work, three spout fluidized bed (SFB) nozzle geometries were designed and fabricated to empirically investigate how injector-driven changes in particle circulation influence PyC deposition. The geometries were first evaluated in a room temperature fluidization apparatus using time-resolved particle image velocimetry, which highlighted distinct differences in particle velocity fields, circulation pathways, and overall fluidization quality. Graphite versions of each injector geometry were subsequently implemented in a laboratory-scale SFB-CVD reactor to deposit PyC onto surrogate fuel kernels under similar conditions. Post-deposition characterization included particle morphology, coating thickness, porosity distribution, optical anisotropy, and microindentation mechanical testing. Overall, the results show clear differences in coating microstructure as a function of changing injector geometry, despite mechanical testing indicating comparable elastic modulus values across all coatings. This study provides one of the first fully experimental, quantitative mappings between SFB nozzle geometry, fluidization hydrodynamics, and resulting PyC coating structure. The framework established here supports rational injector design and offers a pathway toward improved coating control in future pilot- and production-scale TRISO fuel fabrication systems.

Coated particle fuel↗
DOE OSTI2022

Experimental Investigation of the Heat Transfer between Finned Tubes and a Bubbling Fluidized Bed with Horizontal Sand Mass Flow

The sandTES technology utilizes a fluidized bed counter current heat exchanger for thermal energy storage applications. Its main feature is an imposed horizontal flow of sand (SiO2) particles fluidized by a vertical air flow across a heat exchanger consisting of several horizontal rows of tubes. Past international research on heat transfer in dense fluidized beds has focused on stationary (stirred tank) systems, and there is little to no information available on the impact of longitudinal or helical fins. Previous pilot plant scale experiments at TU Wien led to the conclusion that the currently available correlations for predicting the heat transfer coefficient between the tube surface and the surrounding fluidized bed are insufficient for the horizontal sand flow imposed by the sandTES technology. Therefore, several smaller test rigs were designed in this study to investigate the influence of different tube arrangements and flow conditions on the external convective heat transfer coefficient and possible improvements by using finned tubes. It could be shown that helically finned tubes in a transversal arrangement, where the horizontal sand flow is perpendicular to the tube axes, allows an increase in the heat transfer coefficient per tube length (i.e., the virtual heat transfer coefficient) by a factor of 3.5 to about 1250 W/m2K at ambient temperature. Based on the literature, this heat transfer coefficient is expected to increase at higher temperatures. The new design criteria allow the design of compact, low-cost heat exchangers for thermal energy storage applications, in particular electro-thermal energy storage.

25 ENERGY STORAGE↗
DOE OSTI2022

Transient simulation of biomass combustion in a circulating fluidized bed riser

Interest in circulating fluidized bed (CFB) boilers as a power generation technology has sky-rocketed in recent years because of several advantages this technology offers over conventional boilers, such as increased gas-solid mixing, which results in higher combustion efficiency and the ability to use lower rank fuels. CFB combustors are operated at lower temperatures than conventional thermal power generation combustors, thus reducing NO x emissions, while SO 2 emissions can be conveniently controlled through the addition of Ca-based sulfur sorbents within the combustor. Herin this paper summarizes the modeling effort on a 50 kW th CFB combustor designed, built, and operated at CanmetENERGY in Ottawa, Canada. The numerical model employs the multiphase particle-in-cell (PIC) approach in the open-source Multiphase Flow with Interphase eXchanges (MFiX) Software Suite. The MFiX-PIC model parameters for the simulation are tuned against cold-flow experiments from CanmetENERGY using olivine sand as the inert bed material. It is shown that for the relatively coarse fluid meshes and large parcel sizes necessitated by the scale of the simulation, filter size dependent corrections to the drag law must be incorporated to ensure accuracy of the simulation results. The validated cold flow model is extended to simulate reacting flow with torrefied hardwood as the feedstock and to validate the combustion reaction scheme. The species concentrations at the riser outlet are compared against CanmetENERGY’s experiments and show satisfactory agreement. The simulations demonstrate the ability of MFiX-PIC to accurately capture both the physics and chemistry of a CFB combustor at bench scales, which can be further extended to pilot- and industrial-scale systems.

09 BIOMASS FUELS↗
DOE OSTI2024

Modeling hydrodynamic and biomass pyrolysis effects of recycled product gases in a bubbling fluidized bed reactor

Fast pyrolysis of biomass in a fluidized bed reactor is typically conducted in a nitrogen gas environment. Recycling product gas can improve the economics of operating such a system by reducing reliance on pure process streams, but much less is known about how recycling pyrolysis product gas may affect fluidization behavior and pyrolysis kinetics. Therefore, gas effects in a fluidized bed biomass pyrolysis reactor were investigated using engineering correlations, low-order models, and CFD simulations for N 2 , H 2 , CO, CO 2 , and CH 4 carrier gas mixtures. Here, our findings reveal viscosity of a gas mixture can be significantly underestimated depending on the model and correlation. Furthermore, fluidization characteristics such as U mf and gas-solid convective heat transfer can be greatly affected by the gas properties. By utilizing H 2 as the fluidizing gas (instead of N 2 ), while maintaining a constant fluidization ratio (U s /U mf ), the bio-oil yields can be increased ~5%. This is due to the lower density H 2 producing similar hydrodynamics as N 2 at higher gas flow rates. These higher flow rates result in shorter gas residence times, and as a result, less secondary reactions that convert bio-oil to light gases and char. Model results also suggest that bio-oil yield is not significantly affected by the type of carrier gas used, with bio-oil yield varying by ~2% across different gas mixtures while maintaining constant flow rate. In conclusion, this indicates that recycled pyrolytic gas can be used as the carrier gas for biomass pyrolysis.

09 BIOMASS FUELS↗
DOE OSTI2022

Design of a gas-solid-solid separator to remove ash from circulating fluidized bed reactors

Cyclones are one of the most common types of gas-solid separators used in circulating fluidized bed boilers. However, cyclones typically do not allow ash to leave the system through the cyclone exit, causing ash to build up in the fluidized bed and necessitating additional systems to remove ash that builds up in the bed. In this study, an alternative “disengager” gas-solid separator is proposed as a way of inherently separating small and large solids, resulting in a gas-solid-solid separation system where ash is allowed to leave the system along with gas while the desired fluidized bed material is retained. Unlike cyclones, which rely on centrifugal force to separate solids and gas, the disengager separates based on entrainment velocity of the particles. Upwards-flowing gas and particles strike a deflection plate and enter the disengaging chamber where particles with low terminal velocity such as ash fines flow with the gas, while larger particles such as sand fall to the bottom of the separator and are returned to the fluidized bed. In this study, several different proposed disengager configurations are simulated and compared to a typical cyclone using computational fluid dynamic (CFD) simulations. Furthermore, it was found that separation efficiency in the disengager is strongly influenced by the size of the deflection plate, rather than by the size of the unit itself. The predicted separation efficiency showed that compared to a cyclone, the disengager design allows significantly more ash to exit the system but retains a similar amount of desirable material. Additionally, the disengager was predicted to not suffer significantly more erosion that a cyclone.

42 ENGINEERING↗
DOE OSTI2020

A Novel Approach to Modeling Biomass Pyrolysis in a Fluidized Bed Reactor

A novel approach to simulating biomass pyrolysis in a fluidized bed of mostly inert material is presented. The bed is assumed to be externally heated, although simulation of autothermal operation with partial oxidation of the products is a future objective. Combining pyrolysis reaction kinetics developed by the CRECK Modeling Group and a previously published component properties model, material and energy balances are closed by tracking the residence time of biomass particles without regard for their exact spatial distribution. The model is used to simulate a pilot-scale fluidized bed pyrolysis process being developed at Iowa State University, and model predictions are compared with experimental results for red oak and corn stover feedstocks. The results are in general agreement, with the model typically predicting more noncondensable gas and less low-boiling liquid products. The differences are ascribed to the limitations of the kinetics model. This model provides a rigorous energy balance for fluidized bed pyrolysis processes that can be incorporated into commercial flowsheet models with the capacity for future addition of partial oxidation reactions and implementation of improved kinetics models.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗