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Spiral-wound gasket forms low-temperature seal
Spiral-wound cryogenic gasket with one component requires no encapsulant and is easily produced with self-locking features. Seal either opens and closes or is fixed. It is made by skiving strip from circumference of disk of glass-filled material. Successive turns of strip are spirally wrapped in groove machined into one flange surface. Closing joint compresses gasket.
Impedance measurements on a spiral-wound nickel/metal hydride cell cycled in a simulated Leo orbit
A spiral-wound size C cell was cycled at 25 C in a low earth orbit (LEO) regime at 50 percent depth of discharge (DOD) with approximately five percent over-charge. The nominal capacity was 3.5 AH. The cell was cycled for 2000 cycles. Capacity checks and impedance measurements over the complete range of state of charge were made upon receipt and after 500, 1000, and 2000 cycles. The capacity of the cell was essentially unchanged until after the impedance measurements at 2000 cycles. Only small changes in the impedance parameters were observed, but there was somewhat more scatter in the data after 2000 cycles. When the cell was returned to LEO cycling after 2000 cycles, only 38 percent of the capacity could be obtained. It is believed that the cell failed because of an equipment failure at the end of the final impedance measurements which allowed an over-discharge.
Detonation-flame arrester devices for gasoline cargo vapor recovery systems
Empirical data on the deflagration-to-detonation run-up distance for flowing mixtures of gasoline and air in 15.2-cm- (6.0-in.-) diameter piping simulating a vapor recovery system are presented. The quenching capability of eight selected flame control devices subjected to repeated stable detonations was evaluated. The successful detonation-flame arresters were: (1) spiral-wound, crimped aluminum ribbon, (2) foamed nickel-chrome metal, (3) vertically packed bed of aluminum Ballast rings, and (4) water-trap or hydraulic back-pressure valve. Installation configurations for two of the more applicable arresters, the spiral-wound, crimped stainless-steel ribbon and the vertically packed bed of aluminum Ballast rings, were further optimized by a series of parametric tests. The final configuration of these two arresters was demonstrated with repeated detonation tests at conditions that simulated vapor recovery system operation. On these tests, the combustible mixture of gasoline and air continued to flow through the piping for periods up to 120 seconds after the initial detonation had been arrested. There was no indication of continuous burning or reignition occurring on either side of the test arresters.
Advancements in conventional and 3D printed feed spacers in membrane modules
Plate & frame and spiral-wound modules are used for gas separation, pervaporation, reverse osmosis, nanofiltration, ultrafiltration, microfiltration, electro-dialysis, electro-deionization, membrane distillation and forward osmosis membrane processes. Feed channel spacers are an integral part of both module types – providing mechanical support for a cross-flow channel through the module and, in most cases, promoting mixing to enhance mass transfer to reduce concentration polarization and fouling. However, enhanced mass transfer comes at a cost of increased hydraulic pressure losses and stagnant zones wherever a spacer filament touches a membrane surface. Further, these stagnant zones exacerbate membrane fouling and make cleaning more difficult. Efforts to improve feed spacer performance largely focus on adjusting the chemistry or geometry of the spacer to mitigate these challenges. Additive manufacturing (i.e. 3D printing) offers new degrees of freedom in feed spacer design and production, which opens up a new area of research in membrane technology. This review critically assesses the peer-reviewed literature on conventional net- or mesh-style feed spacers in addition to various novel spacer geometries and chemistries produced via 3D printing. We further review and evaluate conventional spacer manufacturing methods and discuss advantages and disadvantages of 3D printed spacers.
Transformational Membranes for Pre-Combustion Carbon Capture (Final Report)
The objectives of this project are to develop a cost-effective design and fabrication process of a novel transformational membrane and its membrane modules that capture CO 2 from coal derived syngas. We have synthesized transformational membranes, scaled up the membrane to a prototype size of 14 inches wide by 20 feet in continuous roll-to-roll fabrication, fabricated at least 9 prototype membrane modules (each with about 2.5-inch diameter, 14-inch length, and 800 cm 2 membrane area) for testing with simulated syngas at OSU to achieve capture with at least 95% CO 2 purity. The membrane modules are in commercial spiral-wound (SW) configuration with a minimal pressure drop (<0.103 bar/meter (1.5 psi/meter)).
Novel Transformational Membranes and Process for CO 2 Capture from Flue Gas (FE0031731)
The objectives of this project are to develop a cost-effective design and fabrication process for a novel transformational membrane and its membrane modules that capture CO 2 from flue gas. Optimization of the novel transformational membrane, scale-up of the membrane to a prototype size of about 20" wide in continuous roll-to-roll fabrication, and construction and testing of a skid for the integrated membrane process will be performed. For the design of this membrane, we use a cost-effective polymer support and coat a thin top layer of the membrane. The simplicity of this membrane design offers a low cost for the membrane element in commercial spiral-wound (SW) configuration (<$2.00/ft 2 or $21.5/m 2 ). The prototype membrane will be used to fabricate 6 pilot-size membrane modules (each about 20" length, 3 modules each at the commercial-size diameter of 8 inches with 35 m 2 membrane area for Stage 1 and 3 modules each at 5-inch diameter with 12 m 2 membrane area for Stage 2) for testing with simulated flue gas at OSU and with actual flue gas at the National Carbon Capture Center, Wilsonville, AL using the skid to capture the CO 2 (at 60 – 90%) with at least 95% CO 2 purity. The prototype membrane modules will be in commercial SW configuration with a minimal pressure drop (<0.103 bar/meter (1.5 psi/meter)). These objectives have been achieved successfully.
Development of Self-Assembly Supports Enabling Transformational Membrane Performance for Cost-Effective Carbon Capture
This final technical report describes work conducted by Membrane Technology and Research, Inc. (MTR) for the U.S. Department of Energy (DOE), National Energy Technology Lab (NETL) on the development of membranes with transformational performance for carbon capture under award number DE-FE0031596. The work was performed from June 1, 2018 through May 31, 2024. For more than a decade, MTR has worked in partnership with DOE to develop an innovative membrane-based CO 2 capture process. This effort has included the first test of membrane modules with coal-fired flue gas at the Arizona Public Services (APS) Cholla plant in 2010; the accumulation of >11,000 hours of flue gas operation for Polaris modules on a bench-scale 1 tonne/day (TPD) system at the National Carbon Capture Center (NCCC); scale-up of first-generation (Gen-1) Polaris to a 20 TPD small pilot system, and successful operation of this system on a flue gas slipstream at NCCC and in integrated boiler testing at Babcock & Wilcox (B&W). Through continued development efforts, a second-generation (Gen-2) version of the Polaris membrane has been scaled-up to pilot production. This membrane offers 70% higher CO 2 permeance with similar selectivity to the base case Polaris. MTR also developed planar modules designed specifically for the low-pressure, high-volumetric flow rate process conditions of flue gas operation. These new modules have significantly lower pressure-drop values compared to the type originally used (spiral-wound modules), which results in significant energy savings. The goal of the work described in this report was to improve on the Polaris Gen-2 membrane with the ultimate aim to reduce the cost of carbon capture. The majority of the effort was to develop improved support membranes for the multi-layer composite structure of MTR’s Polaris membrane. Earlier work at MTR had identified the support structure as limiting membrane permeances, not because the support itself represents a permeation resistance, but because the distribution of pores at the surface of the support imposes a geometric restriction to diffusion in the layers above it. Support membranes were prepared from a range of polymers, including commercially available block copolymers and a custom synthesized block copolymer alternative. The best support membranes developed in this project reduced the geometric restriction by a factor of two to three. These supports then were used to produce Polaris composite membranes with improved permeances. The second topic was to create a high-selectivity version of the Polaris membrane. The high-selectivity version uses a novel selective polymeric material and high selectivities were confirmed in experiments at MTR. The material is not easily made into very thin films. Consequently, the permeances are significantly lower than the Polaris Gen-2 membrane. The utility of this membrane is therefore limited to the carbon dioxide purification step that produces liquid CO 2 . A Technical and Economic Analysis (TEA) was performed for a carbon capture system that uses both advanced membrane types. The TEA shows the novel advanced membranes reduce the cost of capture by 10%, from $63.32/tonne CO 2 to $56.90/tonne CO 2 (2022 USD). Most of the development work was carried out with laboratory-scale casting and coating equipment. A number, but not all, of the improvements identified have been implemented on commercial-scale manufacturing equipment. The focus of future work at MTR is to incorporate the advancements made into the Polaris membrane manufacturing process.
Balloon batteries, charged and heated by solar energy
Shielded heat-of-fusion material envelope collects and stores solar heat to maintain temperature during the night cycle at 30,000 feet. Spiral-wound fluoroplastic film structure has low density to avoid damage to aircraft in case of impact.
A lightweight bimetallic actuator for spacecraft thermal control
The design, development, and construction of two types of active thermal-control systems are described. These designs are based on the controlled angular deflections of spiral-wound bimetallic actuators. The use of these actuators and lightweight louvers results in a frictionless system that is low in weight yet simple in design and low in cost. Both designs exhibit high reliability, good performance repeatability, and do not require power from the spacecraft. Design philosophy and implementation, design tradeoffs, and materials selection are reviewed. The test program is described, and results are presented.
Retaining-Ring Installation Tool
New tool eliminates damage to ring through improper tool use. Tool installs spiral-wound retaining rings quickly, reliably, and safely. Tool inserts rings in splined or irregularly shaped bores, bores at bottom of deep ring and slides it along bore until it nests in groove. Pistons are moved by variety of linkages.
Development of a two-stage membrane-based wash-water reclamation subsystem
A two-stage membrane-based subsystem was designed and constructed to enable the recycle of wash waters generated in space. The first stage is a fouling-resistant tube-side-feed hollow-fiber ultrafiltration module, and the second stage is a spiral-wound reverse-osmosis module. Throughout long-term tests, the subsystem consistently produced high-quality permeate, processing actual wash water to 95 percent recovery.
Membrane Separation Of Nitrogen Tetroxide
Pilot plant reduces N2O4 content to one-hundredth of inlet value. Permeable-membrane process removes nitrogen tetroxide from stream of nitrogen or helium gas. Operates in conjunction with scrubbing process removing N2O4 from He or N2 after He or N2 used as gas blanket in N2O4-storage tank. First stage of separator divided into two steps for efficiency. Permeate from second step of first stage and residue from second stage returned to inlet of first stage. Each module contains spiral-wound interleaved permeable membranes and spacer sheets.
Advances In Li-TiS2 Cell Techno1ogy
JPL is involved in a NASA sponsored program to develop ambient temperature secondary Lithium - Titanium Disulfide Cells for future space missions. After several years of research on various lithium systems, the Li-TiS2 system was selected for development in view of its practically realizable high specific energy. In the last two years, the efforts were focused on improving the cycle life of the system and optimizing the cell design. A number of approaches, such as the use of mixed solvent electrolytes, the use of alternate anode materials, the operation of cells at low temperature, and the cycling of cells under optimized voltage limits, are examined to improve cycle life performance of this system. Cycling studies in small 150 mAh cell have identified 1.5 M LiAsF6/2-MeTHF, 1.5 M LiAsF6/EC+2-eTHF, and 1.5 M LiAsF6/THF+2-MeTHF+2-MeF as promising electrolytes for Li-TiS2 cells. Li-Al and Li-C were selected for further assessment as candidate anode materials after a detailed theoretical and experimental evaluation. Cycling of the cells at low temperature did not result in improving the cycle life of the cells. Charge and discharge voltage limits were found to have significant influence on the cycle life of the cells activated with 1.5 M LiAsF6/THF+2-MeTHF+2-MeF electrolyte. The influence of design variables, such as ratio of electrode capacity, quantity of electrolyte, pack tightness, cell configuration, etc., on the cycle life performance are being examined as a part of the design optimization study. Spiral-wound 1 Ah cells fabricated for the design studies have completed more than 500 cycles at 50% DOD. This paper summarizes the advances made in the Li-TiS2 technology at JPL since 1989.
Design and Testing of a Small Inductive Pulsed Plasma Thruster
The design and testing of a small inductive pulsed plasma thruster (IPPT), shown in Fig. 1 with all the major subsystems required for a thruster of this kind are described. Thrust measurements and imaging of the device operated in rep-rated mode are presented to quantify the performance envelope of the device. The small IPPT described in this paper was designed to serve as a test-bed for the pulsed gas-valves and solid-state switches required for a IPPTs. A modular design approach was used to permit future modifications and upgrades. The thruster consists of the following sub-systems: a) a multi-turn, spiral-wound acceleration coil (27 cm o.d., 10 cm i.d.) driven by a 10 microFarad capacitor and switched with a high-voltage thyristor, b) a fast pulsed gas-valve, and c.) a glow-discharge pre-ionizer (PI) circuit. The acceleration-coil circuit may be operated at voltages up to 4 kV (the thyristor limit is 4.5 kV). The device may be operated at rep-rates up to 30 Hz with the present gas-valve. Thrust measurements and imaging of the device operated in rep-rated mode will be presented. The pre-ionizer consists of a 0.3 microFarad capacitor charged to 4 kV and connected to two annular stainless-steel electrodes bounding the area of the coil-face. The 4 kV potential is held across them and when the gas is puffed in over the coil, the PI circuit is completed, and a plasma is formed. Even at the less than optimal base-pressure in the chamber (approximately 5 × 10(exp −4) torr), the PI held-off the applied voltage, and only discharged upon command. For a capacitor charge of 2 kV the peak coil current is 4.1 kA, and during this pulse a very bright discharge (much brighter than from the PI alone) was observed (see Fig. 2). Interestingly, for discharges at this charge voltage the PI was not required as the current rise rate, dI/dt, of the coil itself was sufficient to ionize the gas.
Design and Testing of a Small Inductive Pulsed Plasma Thruster
The design and testing of a small inductive pulsed plasma thruster (IPPT) is described. The device was built as a test-bed for the pulsed gas-valves and solid-state switches required for a thruster of this kind, and was designed to be modular to facilitate modification. The thruster in its present configuration consists of a multi-turn, spiral-wound acceleration coil (270 millimeters outer diameter, 100 millimeters inner diameter) driven by a 10 microfarad capacitor and switched with a high-voltage thyristor, a propellant delivery system including a fast pulsed gas-valve, and a glow-discharge pre-ionizer circuit. The acceleration coil circuit may be operated at voltages up to 4 kilovolts (the thyristor limit is 4.5 kilovolts) and the thruster operated at cyclic-rates up to 30 Herz. Initial testing of the thruster, both bench-top and in-vacuum, has been performed. Cyclic operation of the complete device was demonstrated (at 2 Herz), and a number of valuable insights pertaining to the design of these devices have been gained.