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Insights into the rapid two-phase transport dynamics in different structured porous transport layers of water electrolyzers through high-speed visualization
In proton exchange membrane electrolyzer cells (PEMECs), maintaining efficient two-phase transport is one of the most important functions of porous transport layers (PTLs). To enhance the two-phase transport in PTLs, thin/titanium liquid/gas diffusion layers (TT-LGDLs) are introduced in PEMECs, and their difference from the conventional Ti felt PTLs are analyzed in-situ through high-speed and microscale visualization and electrochemical characterizations. The visualization results show that unfavorable large slugs can be greatly reduced in the PEMEC with a TT-LGDL compared to the PEMEC with a Ti felt PTL. More importantly, the recovery capability of water starvation with different PTLs is studied. After water starvation, the PEMEC with the TT-LGDL can recover the water starvation much more rapidly than the Ti felt cell, benefiting from its short and straight-through flow paths. Furthermore, the TT-LGDL tends to generate oxygen bubbles that are almost six times smaller and 236 times more frequently than the Ti felt PTL, indicating significantly boosted removal efficiency of produced oxygen and PEMEC performance. Finally, this study offers new insights into the dynamic processes of two-phase transport and the recovery capability of water starvation for different PTLs, which will provide valuable guidance for further optimization of PTLs and performance enhancement of PEMECs.
Modeling Single and Two-Phase Transport in Thin Porous Layers Using a Composite Continuum-Pore Network Formulation
In this work, a composite continuum-pore network formulation is presented to model single and two-phase transport thin porous layers, such as gas diffusion layers in polymer electrolyte fuel cells (PEFCs) and active electrodes in redox flow batteries (RFBs). The formulation can be integrated into CFD codes, thus combining the ease of implementation of continuum-based modeling and the computational power of pore-network modeling. The composite model includes a control volume (CV) mesh at the layer scale, which embeds a cubic pore network [1,2]. The pore-network model is used to determine analytically local anisotropic effective transport properties (local effective diffusivity and permeability), which are mapped onto the CV mesh to simulate transport in the porous transport layer [3,4]. Good agreement is found between the predicted global effective transport properties (global effective diffusivity and permeability) under dry and wet conditions and previous experimental data reported in the literature for Toray TGP-H series carbon paper. Water saturation distributions are also compared with results obtained using X-ray computed tomography [4]. [1] P.A. García-Salaberri, I.V. Zenyuk, J.T. Gostick, A.Z. Weber, Modeling Gas Diffusion Layer in Polymer Electrolyte Fuel Cells Using a Continuum-Based Pore-Network Formulation, ECS Trans. 97 (2020) 615. [2] P.A. García-Salaberri, Modeling diffusion and convection in thin porous transport layers using a composite continuum-network model: Application to gas diffusion layers in polymer electrolyte fuel cells, Int J. Heat Mass Transf. (2020), submitted. [3] P.A. García-Salaberri, J.T. Gostick, G. Hwang, A.Z. Weber, M. Vera, Effective diffusivity in partially-saturated carbon-fiber gas diffusion layers: Effect of local saturation and application to macroscopic continuum models, J. Power Sources 296 (2015) 440–453. [4] P.A. García-Salaberri, G. Hwang, M. Vera, A.Z. Weber, J.T. Gostick, Effective diffusivity in partially-saturated carbon-fiber gas diffusion layers: Effect of through-plane saturation distribution, Int. J. Heat Mass Transf. 86 (2015) 319–333.
Thermal management of instruments on space platforms using a high capacity two-phase heat transport system
A system utilizing a pumped, two-phase single component working fluid for heat exchange and transport services necessary to meet the temperature control requirements of typical orbiting instrument payloads on space platforms is described. The design characteristics of the system is presented, together with a presentation of a laboratory apparatus for demonstration of proof of concept. Results indicate that the pumped two-phase design concept can meet a wide range of thermal performance requirements with the only penalty being the requirement for a small liquid pump.
Working fluid selection for space-based two-phase heat transport systems
The working fluid for externally-mounted, space-based two-phase heat transport systems is considered. A sequence of screening criteria involving freezing and critical point temperatures and latent heat of vaporization and vapor density are applied to a data base of 860 fluids. The thermal performance of the 52 fluids which pass this preliminary screening are then ranked according to their impact on the weight of a reference system. Upon considering other nonthermal criteria (flammability, toxicity, and chemical stability) a final set of 10 preferred fluids is obtained. The effects of variations in system parameters is investigated for these 10 fluids by means of a factorial design.
Implementation of the LAX-Wendroff Method in Cobra-TF for Solving Two-Phase Flow Transport Equations
COBRA-TF (Coolant Boiling in Rod Arrays Two Fluid), or CTF, is a subchannel code used to conduct the reactor core thermal hydraulic (T/H) solution in both standalone and coupled multi-physics applications. CTF applies the first-order upwind spatial discretization scheme for solving two-phase flow conservation equations. In this work, the second-order Lax-Wendroff (L-W) scheme has been implemented in CTF to solve the two-phase flow transport equations to improve numerical accuracy in both temporal and spatial discretization. To avoid the oscillation issue, a non-linear flux limiter VA (Van Albada) is employed for the convective terms in the transport equations. Assessments have been carried out to evaluate the performance and stability of the implemented second-order L-W scheme. It has been found that the L-W scheme performs better than the upwind scheme for the single-phase and two-phase flow problems in terms of numerical accuracy and computational efficiency.
Electric Aircraft Thermal Management Using a Two-Phase Heat Transport System with Solid-State Thermal Switching Capability
Advanced Cooling Technologies, Inc. (ACT) is collaborating with NASA Glenn Research Center (GRC) to develop a heat pipe-based thermal delivery system to efficiently manage the waste heat generated onboard an electric aircraft. The heat pipe system will interface with NASA GRC’s thermoacoustic heat pump in order to recycle waste heat by transporting thermal energy to various end users onboard the aircraft. This paper discusses the layout of theoretical heat pipe networks for a MW-class commercial electric aircraft. This is followed by a discussion of progress made on the development of a novel two-phase heat transport system with solid-state thermal switching and control capabilities.
Implementation of two-phase gas transport into VERA for molten salt reactor analysis
Molten salt reactors (MSRs) are a class of next-generation nuclear reactors that have received recent industrial and research interest. A generalized species transport solver was implemented in the Virtual Environment for Reactor Applications (VERA) computing suite to extend this tool to analyze liquid-fueled MSRs. This core simulator has been extended to model the transport of fission product gases into a collection of circulating gas bubbles with the purpose of removing the gases. This paper presents the governing species transport equation, along with various nuclear source terms. Development of the source term for phase migration is discussed, along with a simplified interfacial area tracking method. Finally, a case study on a simplified MSR loop is presented in which modeling parameters were varied to assess their impact on gas removal. The steady state results show that parameters such as bubble diameter, gas injection rate and mass transfer coefficient have a low to moderate effect on the fraction of xenon in the core region. Removal efficiency has the greatest effect on the fraction in the core region. After the pump bowl, bubble diameter has a minor effect on the fraction of xenon in the gas void. Finally, these results point out that increasing parameters such as mass transfer coefficient, gas injection rate, and removal efficiency drives the xenon into the circulating gas void, while decreasing bubble diameter also drives xenon into the gas void by increasing interfacial area.
An aggregation-based nonlinear multigrid solver for two-phase flow and transport in porous media
A nonlinear multigrid solver for two-phase flow and transport in a mixed fractional-flow velocity-pressure-saturation formulation is proposed. The solver, which is under the framework of the full approximation scheme (FAS), extends our previous work on nonlinear multigrid for heterogeneous diffusion problems. The coarse spaces in the multigrid hierarchy are constructed by first aggregating degrees of freedom, and then solving some local flow problems. The mixed formulation and the choice of coarse spaces allow us to assemble the coarse problems without visiting finer levels during the solving phase, which is crucial for the scalability of multigrid methods. Specifically, a natural generalization of the upwind flux can be evaluated directly on coarse levels using the precomputed coarse flux basis vectors. We find that the resulting solver is applicable to problems discretized on general unstructured grids. The performance of the proposed nonlinear multigrid solver in comparison with the standard single level Newton's method is demonstrated through challenging numerical examples. It is observed that the proposed solver is robust for highly nonlinear problems and clearly outperforms Newton's method in the case of high Courant-Friedrichs-Lewy (CFL) numbers.
Thermal management system options for high power space platforms
Thermal Management System (TMS) design options for a high power (75kWe), low earth orbit, multimodule space platform were investigated. The approach taken was to establish a baseline TMS representative of current technology, and to make incremental improvements through successive subsystem trades that lead to a candidate TMS. The TMS trades included centralized and decentralized transport, single-phase and two-phase transport, alternate working fluids, liquid loop and heat pipe radiators, deployed fixed, body mounted and steerable radiators, and thermal storage. The subsystem options were evaluated against criteria such as weight, TMS power requirement, reliability, system isothermality penalty, and growth potential.
Two Polymorphs of BaZn 2 P 2 : Crystal Structures, Phase Transition, and Transport Properties
Here, the novel α-BaZn 2 P 2 structural polymorph has been synthesized and structurally characterized for the first time. Its structure, elu-cidated from single crystal X-ray diffraction, indicates that the compound crystallizes in the orthorhombic α-BaCu 2 S 2 structure type, with unit cell parameters a = 9.7567(14) Å, b = 4.1266(6) Å, and c = 10.6000(15) Å. With β-BaZn 2 P 2 being previously iden-tified as belonging to the ThCr 2 Si 2 family, and with the precedent of structural phase transitions between the α-BaCu 2 S 2 type and the ThCr 2 Si 2 type, the potential for the pattern to be extended to the two different structural forms of BaZn 2 P 2 was explored. Thermal analysis suggest that a first order phase transition occurs at ~1123 K, whereby the low-temperature orthorhombic α-phase transforms to a high-temperature tetragonal β-BaZn 2 P 2 ; the structure of which was also studied and confirmed by single-crystal X-ray diffraction. Preliminary transport properties and band structure calculations indicate that α-BaZn 2 P 2 is a p-type, narrow-gap semiconductor with a direct bandgap (Eg) of 0.5 eV. The Seebeck coefficient, S(T), for the material increases steadily from the room temperature value of 119 µV/K to 184 µV/K at 600 K. The electrical resistivity of α-BaZn 2 P 2 is relatively high, on the order of 40 mΩ·cm, and the ρ(T) dependence shows gradual decrease upon heating. Such behavior is comparable to those of the typical semimetals or degenerate semiconductors. Although the observed values of the as-synthesized samples are not optimal, the carrier concentration can apparently be tuned to fall between the values of metals and semiconductors, thus providing an open window for optimizing this phase towards achieving an enhanced thermoelectric figure of merit zT. The calculated indirect band gap for the β-BaZn 2 P 2 phase is Eg = 0.03 eV which is about an order of magnitude lower than that of α-BaZn 2 P 2 . It is expected that the cage-like structural motif and layered structure possessed by α-BaZn 2 P 2 and β-BaZn 2 P 2 phases, respectively, would promote the realiza-tion of a low thermal conductivity in both compounds.
A pumped, two-phase flow heat transport system for orbiting instrument payloads
A pumped two-phase (heat absorption/heat rejection) thermal transport system for orbiting instrument payloads is investigated. The thermofluid characteristics necessary for the system design are discussed. A preliminary design with a series arrangement of four instrument heat stations and six radiators in a single loop is described in detail, and the total mass is estimated to be 134 kg, with the radiators, instrument heat stations, and fluid reservoir accounting for approximately 86, 24, and 12 kg, respectively. The evaluation of preliminary test results shows that the system has potential advantages; however, further research is necessary in the areas of one-g and zero-g heat transfer coefficients/fluid regimes, fluid by-pass temperature control, and reliability of small pumps.
Thermal management system technology development for space station applications
A short discussion of the history to date of the NASA thermal management system technology development program is presented, and the current status of several ongoing studies and hardware demonstration tasks is reported. One element of technology that is required for long-life, high-power orbital platforms/stations that is being developed is heat rejection and a space-constructable radiator system. Aspects of this project include high-efficiency fin concepts, a heat pipe quick-disconnect device, high-capacity heat pipes, and an alternate interface heat exchanger design. In the area of heat acquisition and transport, developments in a pumped two-phase transport loop, a capillary pumped transport loop using the concept of thermal utility are reported. An example of a thermal management system concept is provided.
Investigating Evaporation in Gas Diffusion Layers for Fuel Cells with X-ray Computed Tomography
Understanding evaporation in porous media and the associated water distribution for a given saturation is critical for optimizing many different technologies including polymer-electrolyte fuel cells. In these devices, heat and mass-transport are coupled due to the two-phase transport of water and operating temperatures from subzero to 80°C. Especially critical is understanding phase change in the mixed wettability, carbon gas-diffusion layers (GDLs). While previous works have measured evaporation rates empirically for a given saturation, there remains a need to explore the mechanisms governing evaporation, which are tied directly to the internal water distribution. Here in this paper, liquid-water evaporation rates in GDLs are measured in situ using synchrotron X-ray computed tomography (CT). X-ray CT allows visualizing the evaporating water-front location and interfacial water/air surface area, thereby enabling true surface-area based evaporation rates. It is found that the overall specific evaporation rate is essentially constant as a function of saturation and that the water/air interfacial area scales almost linearly with saturation. To isolate transport and kinetic contributions to the overall evaporation rate, we systematically varied gas flow rate and composition. A three-dimensional mathematical model with direct meshes of liquid-water evaporation fronts from the X-ray CT studies allowed for the determination that the evaporation is transport limited. The overall results provide insight into evaporation phenomena in porous media.
Gaps in Thermal Design Guidelines in the Goddard Space Flight Center GOLD Rules
The GSFC (Goddard Space Flight Center) GOLD Rules (Goddard Open Learning Design; GSFC-STD-1000) provide a reasonably comprehensive list of guidelines for the design and testing of spacecraft and instruments based on the long heritage of successful GSFC missions. In general, all GSFC missions are required to comply with the GOLD Rules across a number of subsystems or to seek waivers to particular GOLD rules where compliance is not practical, either due to the risk posture of a mission or the cost and/or schedule associated with compliance. In thermal subsystems, GOLD Rules are applied to design margins throughout the project life cycle and include temperature margins, heater power margins, and two-phase transport margins. However, no explicit guidance is provided for two thermal design aspects: heater control authority (for stability requirements) and cryogenic design margins (which are often not reasonable to express in terms of temperatures). This can lead to ambiguity and inconsistency among projects when demonstrating GOLD Rules compliance. Two current GSFC projects, TIRS-2 (Thermal InfraRed Sensor 2) and WFIRST (Wide Field InfraRed Survey Telescope), are both missions with cryogenic aspects and active thermal control for stability. This paper seeks to outline the characterization of cryogenic margins during the design process for TIRS-2 and WFIRST as well as the project derived guidelines for heater control authority margin. This effort serves as potential first steps for updating the GOLD Rules to address these two areas in guiding thermal designs at GSFC.
Effect of Sn oxides on the thermal conductivity of polycrystalline SnSe
SnSe is a promising thermoelectric material, with intrinsically low lattice thermal conductivity, κL. Surprisingly, in several reports, polycrystalline samples are found to have a higher thermal conductivity than single crystals. This disparity has been attributed to trace amounts of thermally conductive Sn oxides at the grain boundaries of polycrystalline samples. The same culprit was recently proposed to explain the reduction of κL in purified, oxide-free, SnSe polycrystals. Here, we test this hypothesis by: (i) tuning the type of oxide in SnSe by exploiting thermodynamic stability regions, since Sn-rich or Sn-poor compositions favour the formation of SnO or SnO 2 , respectively; and (ii) varying the quantity of SnO 2 by intentionally oxidizing SnSe powder before consolidation, to obtain samples with quantifiable amounts - up to 15% - of SnO 2 . We find that the κL of SnSe is impervious to changes in the type or the amount of Sn oxide present in the samples. Our results show that a simple “rule of mixtures” cannot be used to estimate the effect of grain boundary oxides on the thermal conductivity of SnSe. These results call for an improved understanding of the intriguing thermal transport mechanisms in SnSe and numerous other systems where a two-phase transport is presumed.
Supercritical Water Oxidation: Testing of Ersatz Wastewater
Supercritical Water Oxidation (SCWO) technology is under consideration by NASA for treatment of wastewater and other wet waste streams. The dramatic changes in water's thermophysical properties near its critical point (374◦C and 22 MPa) result in nearly complete solubility of organics and gases. The absence of inter–phase transport processes and phase separation results in dramatically reduced reaction timescales and the elimination of complications of two–phase transport and processing in reduced gravity. Other advantages are that the product streams are microbially inert,benign, amenable to resource recovery and organic waste. This paper first described the design and construction of tubular SCWO reactor built at NASA Glenn. It consists of separate wastewater and oxidizer inlets, which are independently heated and pressurized to conditions approaching the critical point of water. These flows enter a reactor chamber having a volume of 62 ml. The reactor section is heated to the desired temperature in the range of 450 ◦C – 650 ◦C. A pressure regulator maintains the operating pressure nominally between 27.6 MPa and 28.3 MPa. The reacted fluid is captured downstream of the pressure regulator during an experiment run. A separate vent line may also be used for collection of the effluent. Next, the results of SCWO experiments using both a representative organic (ethanol) as well as a wastewater simulant provided by NASA Ames are presented. Raman analysis of the pre–reacted and post–reacted solutions are presented. Finally, initial efforts on supplementary chemical kinetics modeling of ethanol oxidation with and without inclusion of a nitrogenous compounds (ammonia) are presented.