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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 OSTI2018

Experimental Validation of a New Cost-Effective and Nonintrusive BTU Meter

This report summarizes the research conducted under a Collaborative Research and Development Agreement with FluxTeq LLC for experimental validation of a new inexpensive and nonintrusive thermal energy meter (referred as a BTU meter). BTU meters measure thermal energy flows in energy systems (e.g., chillers or boilers); measurements of these flows are essential for performance monitoring, fault detection and diagnostics, and control of these energy systems. The key component of a BTU meter is the device for measuring flow rate. Most flow rate meters available today are either intrusive and difficult to install, especially on existing energy systems, or built around sophisticated,very expensive ultrasonic sensors.

47 OTHER INSTRUMENTATION↗
NASA NTRS1955

Performance of Four Experimental High-btu-per-gallon Fuels in a Single Turbojet Combustor

Performance characteristics of four hydrocarbon fuels having high Btu per gallon were determined in a single turbojet combustor. At simulated low-altitude operating conditions, the fuels with high Btu per gallon generally produced more carbon than did JP-4 and JP-5 fuels. The deposits were reduced appreciably with a fuel-oil additive. At high-altitude conditions, the high Btu-per-gallon fuels gave lower efficiencies than did JP-4 or JP-5 fuels. No attempts were made to improve performance by combustor design modification.

Jonash, Edmund R↗
NASA NTRS1976

Energy Conversion Alternatives Study (ECAS), Westinghouse phase 1. Volume 3: Combustors, furnaces and low-BTU gasifiers

Information is presented on the design, performance, operating characteristics, cost, and development status of coal preparation equipment, combustion equipment, furnaces, low-Btu gasification processes, low-temperature carbonization processes, desulfurization processes, and pollution particulate removal equipment. The information was compiled for use by the various cycle concept leaders in determining the performance, capital costs, energy costs, and natural resource requirements of each of their system configurations.

Hamm, J. R.↗
NASA NTRS1977

Performance potential of combined cycles integrated with low-Btu gasifiers for future electric utility applications

A comparison and an assessment of 10 advanced utility power systems on a consistent basis and to a common level of detail were analyzed. Substantial emphasis was given to a combined cycle systems integrated with low-Btu gasifiers. Performance and cost results from that study were presented for these combined cycle systems, together with a comparative evaluation. The effect of the gasifier type and performance and the interface between the gasifier and the power system were discussed.

Nainiger, J. J.↗
NASA NTRS1978

The Texaco coal gasification process for manufacture of medium BTU gas

The development of the Texaco coal gasification process is discussed with particular emphasis on its close relationship to the fully commercialized Texaco synthesis gas generation process for residual oil gasification. The end uses of the product gas are covered, with special attention to electric power generation via combined cycle technology. Control of SO2, NOx, and particulate emissions in the power generating mode is also covered. The application of this technology in a proposed Texaco-Southern California Edison demonstration project is mentioned. Investment information released for a 1000-megawatt advanced combined cycle gasification facility, is also reviewed.

Schlinger, W. G.↗
NASA NTRS1982

NOx results from two combustors tested on medium BTU coal gas

The results of tests of two combustor configurations using coal gas from a 25 ton/day fluidized bed coal gasifier are reported. The trials were run with a ceramic-lined, staged rich/lean burner and an integral, all metal multiannular swirl burner (MASB) using a range of temperatures and pressures representative of industrial turbine inlet conditions. A lean mixture was examined at 104, 197, and 254 Btu/Scf, yielding NO(x) emissions of 5, 20, and 70 ppmv, respectively. The MASB was employed only with a gas rated at 220-270 Btu/Scf, producing 80 ppmv NO(x) at rated engine conditions. The results are concluded to be transferrable to current machines. Further tests on the effects of gas composition, the scaling of combustors to utility size, and the development of improved wall cooling techniques and variable geometry are indicated.

Sherlock, T. P.↗
DOE OSTI2013

Estimation of the Optimal Brachytherapy Utilization Rate in the Treatment of Gynecological Cancers and Comparison With Patterns of Care

Purpose: We aimed to estimate the optimal proportion of all gynecological cancers that should be treated with brachytherapy (BT)-the optimal brachytherapy utilization rate (BTU)-to compare this with actual gynecological BTU and to assess the effects of nonmedical factors on access to BT. Methods and Materials: The previously constructed inter/multinational guideline-based peer-reviewed models of optimal BTU for cancers of the uterine cervix, uterine corpus, and vagina were combined to estimate optimal BTU for all gynecological cancers. The robustness of the model was tested by univariate and multivariate sensitivity analyses. The resulting model was applied to New South Wales (NSW), the United States, and Western Europe. Actual BTU was determined for NSW by a retrospective patterns-of-care study of BT; for Western Europe from published reports; and for the United States from Surveillance, Epidemiology, and End Results data. Differences between optimal and actual BTU were assessed. The effect of nonmedical factors on access to BT in NSW were analyzed. Results: Gynecological BTU was as follows: NSW 28% optimal (95% confidence interval [CI] 26%-33%) compared with 14% actual; United States 30% optimal (95% CI 26%-34%) and 10% actual; and Western Europe 27% optimal (95% CI 25%-32%) and 16% actual. On multivariate analysis, NSW patients were more likely to undergo gynecological BT if residing in Area Health Service equipped with BT (odds ratio 1.76, P=.008) and if residing in socioeconomically disadvantaged postcodes (odds ratio 1.12, P=.05), but remoteness of residence was not significant. Conclusions: Gynecological BT is underutilized in NSW, Western Europe, and the United States given evidence-based guidelines. Access to BT equipment in NSW was significantly associated with higher utilization rates. Causes of underutilization elsewhere were undetermined. Our model of optimal BTU can be used as a quality assurance tool, providing an evidence-based benchmark against which actual patterns of practice can be measured. It can also be used to assist in determining the adequacy of BT resource allocation.

62 RADIOLOGY AND NUCLEAR MEDICINE↗
NASA NTRSDate not supplied

EVA Planning: Using Neutral Buoyancy Laboratory (NBL) Training to Predict in-Flight Energy Expenditure

Metabolic rate (“met rate”) is the amount of energy expended over a period of time and is influenced by many factors including body composition, level of physical activity, resting metabolic rate, sex, age, and food intake. Met rate is measured during Extravehicular Activity (EVA) training at the Neutral Buoyancy Laboratory (NBL) and during in-flight EVAs through indirect calorimetry, calculating energy expenditure from respiratory measurements of O 2 consumption and/or CO 2 production. During Extravehicular Activity (EVA) planning, metabolic cost is important to consider and is used to inform EVA duration based on spacesuit consumables associated with life support systems. Currently, NBL and previous ISS EVA met rate data for specified crewmembers are utilized to predict in-flight EVA metabolic costs based on a proposed EVA timeline. Timeline data collected during training is used to relate met rates to specific EVA activities, which are in turn assigned to more generalized EVA task categories, categorizing by both task type and restraint type. EVA task categories include EVA Setup/Cleanup, Worksite Setup/Cleanup, Cable Routing, Bolts, Fluid Connectors, Electrical Connectors, R&R Work, Miscellaneous Work, Incapacitated Crew Rescue (being rescued or performing), Assisted Crew Rescue (being assisted or performing), and Translation. Restraint types consist of Free-Float, Body Restraint Tether (BRT), Articulating Portable Foot Restraint (APFR), and Space Station Remote Manipulator System (SSRMS). From a crewmember’s historical data, individualized 10th, 50th and 90th percentile met rate estimates are generated for each task category and used to estimate the proposed EVA timeline metabolic cost. In-flight metabolic data (“As-Executed”) from recent ISS US EVAs 85-88 (totaling eight EVA crewmember met rates) was compared with their predicted metabolic cost (“As-Planned”) to evaluate the accuracy of the current met rate estimation method. Across the four EVAs, As-Executed Cumulative EVA Total Metabolic Cost (M = 5893.78 BTU, SD = 816.60) was not significantly different compared to As-Planned Cumulative EVA Total Metabolic Cost (M = 6106.60 BTU, SD = 826.62; t(7) = 0.751 , p = .477). Though not a significant difference, generally, As-Planned total estimates were slightly higher than As-Executed total metabolic cost. Relative Error for Cumulative EVA Total Metabolic Cost ranged from -33% to 14.7%, depending on the crewmember and EVA. When comparing As-Planned to A-Executed EVA task categories for Bolts, Electrical Connectors, EVA Cleanup, EVA Setup, Miscellaneous Work, Translation, Worksite Cleanup, and Worksite Setup during these EVAs, no significant differences were observed, however, there was a significant difference in As-Planned (M = 783.71 BTU, SD = 408.88) compared to As-Executed (M = 608.87 BTU, SD = 425.29) metabolic cost for the task category of Repair-and-Replace (R&R) Work (t(17) = 3.21 , p = .005). Looking closer within the R&R Work task category, As-Executed R&R Work with Free-Float restraint type (M = 706.17 BTU, SD = 352.18) was significantly less than As-Planned R&R Work with Free-Float restraint type (M= 887.96 BTU, SD = 381.42; t(12) = 2.59, p < .024). As-Executed R&R Work with SSRMS Restraint type (M = 355.89 BTU, SD = 534.65) was not significantly different from As-Planned values (M = 512.69 BTU, SD = 383.34; t(4) = 1.88, p = 0.132). These findings suggest that the energy expended performing R&R Work (Free-Float) is lower in flight than predicted. Accurate predictions of the metabolic cost of EVA are essential for planning and executing successful ISS EVAs. Overall, the current met rate prediction method is similar to actual in-flight values, slightly erring on the side of overestimation. Future work includes analysis of more historical in-flight EVA data to increase the power of the analysis, evaluating the NBL-ISS met rate conversion factor between NBL and ISS tasks, as well as exploring methods of substitution when crewmembers are missing prior task category data.

Lauren Cox↗
DOE OSTI2011

Pyramid Resource Center-Green Energy Center

There are currently over 3,500 USA/Canadian landfills listed by the EPA/EC and like numbers in Europe that are producing methane-rich landfill gas (LFG). This gas is typically made up of 50-percent methane (CH4), 35-percent carbon dioxide (CO2), and 2 to 25% nitrogen and oxygen (N2 & O2), plus dozens of dilute contaminants. LFG is classified as a renewable fuel, because it is generated via biological decay of municipal solid waste, a constant byproduct of human activity. To date, most LFG has been allowed to escape into the atmosphere. On account of its high CH4 content, LFG may contribute to climate change, as CH4 is one of the most harmful greenhouse gases with 21 times the global warming potential of CO2. Of the landfills that collect LFG, most simply flare it. In the past decade, some landfills have begun to use LFG for electricity generation or for direct combustion as low Btu gas. Very few landfills upgrade LFG to high Btu gas. A patented CO2 WashTM process developed by Acrion Technologies Inc., and licensed to Firm Green Inc. shows promise as an economically and environmentally sustainable process to recover energy and prevent pollution from landfills. The CO2 WashTM has already been proven at lab-scale. It upgrades LFG, which consists of 50% methane (CH4) + 35% carbon dioxide (CO2) + 2 to 25% nitrogen + oxygen (N2+O2), 1 to 2% water vapor, and dozens of contaminants (which total a few hundred to a few thousand parts per million). CH4, which by itself has an energy content of 1,012 British thermal units (Btu) per standard cubic foot (SCF), is the only component in LFG that contributes to its energy content, which is therefore about 400-550 Btu/SCF. Accordingly, raw LFG is usually referred to as medium-Btu gas. To be salable, it is necessary to remove essentially all the components besides CH4, while keeping the vast majority of the revenue producing CH4. This is high-Btu gas, yielding 850 to 1,000 Btu/SCF. The CO2 WashTM process upgrades LFG to about 930 Btu/SCF, and reduces the contaminants to levels that make it salable as a vehicle fuel in the form of compressed natural gas (CNG).

09 BIOMASS FUELS↗
DOE OSTI2013

New Manufacturing Method for Paper Filler and Fiber Material

The use of fillers in printing and writing papers has become a prerequisite for competing in a global market to reduce the cost of materials. Use of calcium carbonates (ranging from 18% to 30%) as filler is a common practice in the paper industry but the choices of fillers for each type of papers vary widely according to its use. The market for uncoated digital printing paper is one that continues to introduce exciting growth projections. and it is important to understand the effect that new manufacturing methods of calcium carbonates have on the energy efficiency and paper production. Research conducted under this award showed that the new fiber filler composite material has the potential to increase the paper filler content by up to 5% without losing mechanical properties. Benefits of the technology can be summarized as follows for a 1% filler increase per metric ton of paper produced: (i) production cost savings over $12, (ii) Energy savings of 100,900 btu, (iii) CO 2 emission savings of 33 lbs, and additional savings for wood preparation, pulping, recovery of 203593 btu with a 46lbs of CO 2 emission savings per 1% filler increase. In addition the technology has the potential to save: (i) additional $3 per ton of bleached pulp produced, (ii) bleaching energy savings of 170,000 btu, (iii) bleaching CO 2 emission savings of 39 lbs, and (iv) additional savings for replacing conventional bleaching chemicals with a sustainable bleaching chemical is estimated to be 900,000 btu with a 205 lbs of CO 2 emission savings per ton of bleached pulp produced. All the above translates to a estimated annual savings for a 12% filler increase of 296 trillion buts or 51 million barrel of oil equivalent (BOE) or 13.7% of the industries energy demand. This can lead to a increase of renewable energy usage from 56% to close to 70% for the industry sector. CO 2 emission of the industry at a 12% filler increase could be lowered by over 39 million tons annually. If the new technology could be implemented for bleaching process a total annual estimated energy savings potential of 64 trillion buts or 11 million barrel of oil equivalent (BOE) equal to 3% of the paper industries energy demand could be realized. This could lead to a increase of renewable energy usage from 56% to close to 60% for the industry. CO 2 emissions could be lowered by over 7.4 million tons annually. It is estimated that an installed system could also yield a 75 to 100% return of investment (ROI) rate for the capital equipment that need to be installed for the fiber filler composite manufacturing process.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Solar Energy Extension Project

The town of Stratford plans to develop and own a 6 kilowatt (kW) solar array on the roof of a municipal-owned public pavilion on the town green. A SolarEdge level 2 EV charging station will be installed at the pavilion to be used by the public. The charging station will have one charging port. The town will install 3 air source heat pumps in the library located adjacent to the pavilion to reduce the use of propane to heat the library. The town will install 4 air source heat pumps in the Town Hall to reduce the use of #2 heating oil to heat the facility. The 6 kW solar array will provide electricity to the library to offset electricity usage, and when an EV plugs into the charging station the solar will provide electricity to the charging station. There is no ground disturbance or ground trenching associated with this project. The 6 kW solar array on the roof of the pavilion will include 20 (390) watt all black panels. A SolarEdge level 2 EV charger will be installed at the pavilion with the 240 V inverter. The solar array will provide electricity to the library and when a vehicle plugs into the EV charger the solar array will switch to power the charger. Any excess electricity that is generated by the array and not used by the library or the EV charger will be fed onto the grid and the town will receive a net metering credit applied towards future consumption. There is no ground disturbance associated with the EV charger or solar array, and the town will install signage to direct the public to the charger. The library will install 2 (18,000) BTU ductless air source heat pumps and 1 (24,000) BTU unit. This will significantly reduce the amount of propane required to heat the library. The Town Hall will install 2 (36,000) BTU ductless air source heat pumps and 2 (9,000) BTU units to reduce the amount of #2 heating oil required to heat the building.

14 SOLAR ENERGY↗
DOE OSTI2025

ALICE-USA Barrel Tracking Upgrade (Project Final Report)

The ALICE-USA Barrel Tracking Upgrade (BTU) project began in 2015 to participate in a major upgrade of the Time Projection Chamber (TPC) and the Inner Tracking System (ITS) of the ALICE Experiment at CERN in Geneva, Switzerland. This upgrade increased the maximum readout rate of the ALICE detector to accommodate the increased heavy ion interaction rates following Long Shutdown 2 of the Large Hadron Collider, and greatly improved the vertexing performance of the detector. The original scope was completed and reviewed in November 2019. The BTU project document BTU.19.v1 "ALICE Barrel Tracking Upgrade Project Closeout / Transition to Operations (2019)" from November 2019 describes the status in detail and is attached as Appendix 1 below. At that point, all delivery milestones had been met on time, all Key Performance Parameters (KPPs) of the project had been satisfied, and the project was under budget. Several subsequent No Cost Extensions (NCEs) supported integration and pre-commissioning of the BTU project deliverables at CERN, as well as study and assessment of performance with Pb-Pb collisions at 50 kHz. The BTU project was successfully completed on 30 September 2024.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2012

Selectivity Control in Synergistic Liquid-Liquid Anion Exchange of Univalent Anions via Structure-Specific Cooperativity between Quaternary Ammonium Cations and Anion Receptors

Two anion receptors enhance liquid-liquid anion exchange when added to quaternary alkylammonium chloride anion exchangers, but with a striking dependence upon the structure of the alkylammonium cation. Two anion receptors were investigated, meso-octamethylcalix[4]pyrrole (C4P) and the bisthiourea tweezer 1,1'-(propane-1,3-diyl)bis(3-(4-sec-butylphenyl)thiourea (BTU). C4P has the unique ability in its cone anion-binding conformation to accept an appropriately sized electropositive species in the resulting cup formed by its four electron-rich pyrrole groups, while BTU is not expected to be predisposed for a specific host-guest interaction with the quaternary ammonium cations. It was therefore hypothesized that synergism between C4P and methyltri(C8,10)alkylammonium chloride (Aliquat 336) would be uniquely pronounced owing to insertion of the methyl group of the Aliquat cation into the C4P cup, and we present herein data supporting this expectation. While synergism is comparatively weak for both exchangers with the BTU receptor, synergism between C4P and Aliquat 336 is indeed so strong that anion exchange prefers chloride over more extractable nitrate and trifluoroacetate, effectively overcoming the ubiquitous Hofmeister bias. A thermochemical analysis of synergistic anion exchange has been provided for the first time, unraveling the observed selectivity behavior and resulting in the estimation of binding constants for C4P with the ion pairs of A336+ with Cl , Br , OAcF3 , NO3 , and I . The uniquely strong positive cooperativity between A336 and C4P underscores the advantage of a supramolecular approach in the design of synergistic anion exchange systems.

anion binding↗
DOE OSTI2011

HFC Concrete: A Low-­Energy, Carbon-Dioxide­-Negative Solution for reducing Industrial Greenhouse Gas Emissions (Final Technical Report)

Solidia/CCSM received funding for further research and development of its Low Temperature Solidification Process (LTS), which is used to create hydrate-free concrete (HFC). LTS/HFC is a technology/materials platform that offers wide applicability in the built infrastructure. Most importantly, it provides a means of making concrete without Portland cement. Cement and concrete production is a major consumer of energy and source of industrial greenhouse gas (GHG) emissions. The primary goal of this project was to develop and commercialize a novel material, HFC, which by replacing traditional concrete and cement, reduces both energy use and GHG emissions in the built infrastructure. Traditional concrete uses Portland Cement (PC) as a binder. PC production involves calcination of limestone at ~1450°C, which releases significant amounts of CO 2 gas to the atmosphere and consumes a large amount of energy due to the high temperature required. In contrast, HFC is a carbonate-based hydrate-free concrete (HFC) that consumes CO 2 gas in its production. HFC is made by reaction of silicate minerals with CO 2 at temperatures below 100°C, more than an order-of-magnitude below the temperature required to make PC. Because of this significant difference in temperature, it is estimated that we will be able to reduce energy use in the cement and concrete industry by up to 30 trillion Btu by 2020. Because of the insulating properties of HFC, we believe we will also be able to significantly reduce energy use in the Building sector, though the extent of this saving is not yet quantified. It is estimated that production of a tonne of PC-based concrete requires about 6.2 million Btu of energy and produces over 1 tonne of CO 2 emissions (Choate, 2003). These can be reduced to 1.9 million Btu and 0.025 tonnes of CO 2 emissions per tonne of HFC (with overall CO 2 -negativity possible by increasing carbonation yield). In this way, by replacing PC-based concrete with HFC in infrastructure we can reduce energy use in concrete production by 70%, and reduce CO 2 emissions by 98%; thus the potential to reduce the impact of building materials on global warming and climate change is highly significant. Low Temperature Solidification (LTS) is a breakthrough technology that enables the densification of inorganic materials via a hydrothermal process. The resulting product exhibits excellent control of chemistry and microstructure, to provide durability and mechanical performance that exceeds that of concrete or natural stone. The technology can be used in a wide range of applications including facade panels, interior tiles, roof tiles, countertops, and pre-cast concrete. Replacing traditional building materials and concrete in these applications will result in significant reduction in both energy consumption and CO 2 emissions.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Transportation Energy: A Comparison Including and Excluding Upstream Energy

Thirty-eight editions of the Transportation Energy Data Book (Data Book) have been published since the report began in 1976. It was designed as a desk-top reference of statistics and information that characterize transportation activity. The most recent Data Book, edition 38, has 226 tables and 70 figures in the body of the report, with an additional 51 tables in appendices. One of the most-often used tables in the Data Book is referred to by the authors as “the big energy table.” It has transportation energy use in British thermal units (Btu) by mode and fuel type. The data are compiled from about 20 different sources and combined to create a detailed picture of transportation energy use. From the first edition to edition 35 of the Data Book, electricity use in the big energy table was converted from the original kilowatt-hours (kWh) to Btu using the net generation heat rate for fossil fuels. In those days, electricity was used mainly by transit rail. As electricity began to be used in the highway modes with consumer sales of electric vehicles, that process was revisited. Since energy use in the Data Book’s big energy table for all other fuels did not include the upstream energy to create the fuel, it seemed inconsistent to include upstream energy for generation of electricity. Beginning with edition 36, electricity use for the big energy table was converted from kilowatt hours to Btu using the heat content of electricity. Using heat content instead of net generation reduced electricity use data by about two-thirds. Feedback in recent years on the change in process for electricity led to an investigation of the differences in transportation energy use when adding estimates of upstream energy use to all the fuels used in transportation. This report documents the result of that effort.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1947

A Method for Calculating the Heat Required for Windshield Thermal Ice Prevention Based on Extensive Flight Tests in Natural Icing Conditions

An equation is presented for calculating the heat flow required from the surface of an internally heated windshield in order to prevent the formation of ice accretions during flight in specified icing conditions. To ascertain the validity of the equation, comparison is made between calculated values of the heat required and measured values obtained for test windshields in actual flights in icing conditions. The test windshields were internally heated and provided data applicable to two common types of windshield configurations; namely the V-type and the type installed flush with the fuselage contours. These windshields were installed on a twin-engine cargo airplane and the icing flights were conducted over a large area of the United States during the winters of 1945-46 and 1946-47. In addition to the internally heated windshield investigation, some test data were obtained for a windshield ice-prevention system in which heated air was discharged into the windshield boundary layer. The general conclusions resulting from this investigation are as follows: 1) The amount of heat required for the prevention of ice accretions on both flush- and V-type windshields during flight in specified icing conditions can be calculated with a degree of accuracy suitable for design purposes. 2) A heat flow of 2000 to 2500 Btu per hour per square foot is required for complete and continuous protection of a V-type windshield in fight at speeds up to 300 miles per hour in a moderate cumulus icing condition. For the same degree of protection and the same speed range, a value of 1000 Btu per hour per square foot suffices in a moderate stratus icing condition. 3) A heat supply of 1000 Btu per hour per square foot is adequate for a flush windshield located well aft of the fuselage stagnation region, at speeds up to 300 miles per hour, for flight in both stratus and moderate cumulus icing conditions. 4) The external air discharge system of windshield thermal ice prevention is thermally inefficient and requires a heat supply approximately 20 times that required for an internal system having the same performance.

ICE FORMATION↗
NASA NTRS1947

Cooling Characteristics of the V-1650-7 Engine: Coolant-Flow Distribution, Cylinder Temperatures, and Heat Rejections at Typical Operating Conditions - 1

An investigation was conducted to determine the coolant-flow distribu tion, the cylinder temperatures, and the heat rejections of the V-165 0-7 engine . The tests were run a t several power levels varying from minimum fuel consumption to war emergency power and at each power l evel the coolant flows corresponded to the extremes of those likely t o be encountered in typical airplane installations, A mixture of 30-p ercent ethylene glycol and 70-percent water was used as the coolant. The temperature of each cylinder was measured between the exhaust val ves, between the intake valves, in the center of the head, on the exh aust-valve guide, at the top of the barrel on the exhaust side, and o n each exhaust spark-plug gasket. For an increase in engine power fro m 628 to approximately 1700 brake horsepower the average temperature for the cylinder heads between the exhaust valves increased from 437 deg to 517 deg F, the engine coolant heat rejection increased from 12 ,600 to 22,700 Btu. per minute, the oil heat rejection increased from 1030 to 4600 Btu per minute, and the aftercooler-coolant heat reject ion increased from 450 to 3500 Btu -per minute.

Povolny, John H.↗
DOE OSTI2011

Energy Saving Melting and Revert Reduction Technology (Energy SMARRT): Development of CCT Diagrams

One of the most energy intensive industries in the U.S. today is in the melting and casting of steel alloys for use in our advanced technological society. While the majority of steel castings involve low or mild carbon steel for common construction materials, highly-alloyed steels constitute a critical component of many industries due to their excellent properties. However, as the amount of alloying additions increases, the problems associated with casting these materials also increases, resulting in a large waste of energy due to inefficiency and a lack of basic information concerning these often complicated alloy systems. Superaustenitic stainless steels constitute a group of Fe-based alloys that are compositionally balanced to have a purely austenitic matrix and exhibit favorable pitting and crevice corrosion resistant properties and mechanical strength. However, intermetallic precipitates such as sigma (³) and Laves can form during casting or exposure to high-temperature processing, which degrade the corrosion and mechanical properties of the material. Knowledge of the times and temperatures at which these detrimental phases form is imperative if a company is to efficiently produce castings of high quality in the minimum amount of time, using the lowest amount of energy possible, while producing the least amount of material waste. Anecdotal evidence from company representatives revealed that large castings frequently had to be scrapped due to either lower than expected corrosion resistance or extremely low fracture toughness. It was suspected that these poor corrosion and / or mechanical properties were directly related to the type, amount, and location of various intermetallic phases that formed during either the cooling cycle of the castings or subsequent heat treatments. However, no reliable data existed concerning either the time-temperature-transformation (TTT) diagrams or the continuous-cooling-transformation (CCT) diagrams of the super-austenitics. The goal of this study was to accurately characterize the solid-solid phase transformations seen in cast superaustenitic stainless steels. Heat treatments were performed to understand the time and temperature ranges for intermetallic phase formations in alloys CN3MN and CK3McuN. Microstructures were characterized using scanning electron microscopy (SEM), transmission electron microscopy (TEM), and energy and wavelength dispersive spectroscopy (EDS, WDS). In this way TTT and CCT diagrams could be developed for the matrix of samples chosen. As this study consisted of basic research into the development of TTT and CCT diagrams as an aid to the US steel casting industry, there is no formal commercialization plan associated with this task other than presentations and publications via the Steel Founders Society of America to their members. The author is confident that the data contained in this report can be used by steel foundries to refine their casting procedures in such a way as to reduce the amount of waste produced and energy wasted by significantly reducing or eliminating the need for remelting or recasting of material due to unwanted, premature intermetallic formation. This development of high alloy steel CCT diagrams was predicted to result in an average energy savings of 0.05 trillion BTU's/year over a 10 year period (with full funding). With 65% of the proposed funding, current (2011) annual energy saving estimates, based on initial dissemination to the casting industry in 2011and market penetration of 97% by 2020, is 0.14 trillion BTU's/year. The reduction of scrap and improvement in casting yield will also result in a reduction of environmental emissions associated with the melting and pouring of the steel. The average annual estimate of CO2 reduction per year through 2020 is 0.003 Million Metric Tons of Carbon Equivalent (MM TCE)

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗