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TeGrotenhuis, Ward E.

Publications and source records attributed to TeGrotenhuis, Ward E..

14 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Microchannel reactive distillation for the conversion of aqueous ethanol to ethylene

Here we demonstrate the proof-of-concept for microchannel reactive distillation for alcohol-to-jet application: combining ethanol/water separation and ethanol dehydration in one unit operation. Ethanol is first distilled into the vapor phase, converted to ethylene and water, and then the water co-product is condensed to shift the reaction equilibrium. Process intensification is achieved through rapid mass transfer—ethanol stripping from thin wicks using novel microchannel architectures—leading to lower residence time and improved separation efficiency. Energy savings are realized with integration of unit operations. For example, heat of condensing water can offset vaporizing ethanol. Furthermore, the dehydration reaction equilibrium shifts towards completion by immediate removal of the water byproduct upon formation while maintaining aqueous feedstock in the condensed phase. For aqueous ethanol feedstock (40% w ), 71% ethanol conversion with 91% selectivity to ethylene was demonstrated at 220 °C, 600 psig, and 0.28 h -1 wt hour space velocity. 2.7 stages of separation were also demonstrated, under these conditions, using a device length of 8.3 cm. This provides a height equivalent of a theoretical plate (HETP), a measure of separation efficiency, of ~3.3 cm. By comparison, conventional distillation packing provides an HETP of ~30 cm. Thus, 9.1× reduction in HETP was demonstrated over conventional technology, providing a means for significant energy savings and an example of process intensification. Finally, preliminary process economic analysis indicates that by using microchannel reactive distillation technology, the operating and capital costs for the ethanol separation and dehydration portion of an envisioned alcohol-to-jet process could be reduced by at least 35% and 55%, respectively, relative to the incumbent technology, provided future improvements to microchannel reactive distillation design and operability are made.

10 SYNTHETIC FUELS↗
DOE OSTI2024

Manufacturing Supply Chain Development for Modular Solar-Thermochemical Conversion Platform [Abstract]

We will develop a tunable pulsed electron source capable of generating variable intensity highly-focused electron pulses at high repetition rates. Specifically, we need to demonstrate a high-speed variable electron gun capable of generating a variable intensity electron pulse containing between 102 and 105 electrons with an accelerating voltage of 1kV focused into a spot size <100nm in diameter at with a pulse rate >10MHz (with path to 300MHz). This combined performance cannot be achieved by commercially available electron sources. The primary technology path selected for this work will be to use a photocathode approach, where an easily modulated UV laser is used to stimulate electron emission. The approach utilizes the advances made in the development of the Dynamic TEM (DTEM), though this project will be simpler in that the pulse intensity is lower and there is no requirement for coherency. Alternate paths, including using a traditional electron beam modulated using a v-shaped slit and electrostatically deflecting the beam to adjust intensity; will also be considered for future capabilities. The electron source will then be used generate optically stimulated luminescence (OSL) in lithium fluoride (LiF) substrates to demonstrate the potential for OSL to serve as a basis technology for next generation data storage systems.

42 ENGINEERING↗
DOE OSTI2022

Manufacturing Supply Chain Development for Modular Solar-Thermochemical Conversion Platform - CRADA 387 (Final Report)

Modular chemical process intensification (MCPI) is an emerging field where chemical processing is performed using small-scale modular equipment instead of conventional large centralized chemical plants. Conventional chemical plants benefit from economies of scale that encourage scale-up to ever larger plants. A goal of MCPI is to develop technology that intensifies processing so that equipment can be dramatically smaller and integrated into modular systems. Scale-up occurs by adding more modules in parallel rather than making the equipment larger. A key concept is that equipment and modules can ultimately be cheaper by leveraging economies of mass production, analogous to the automotive industry, in manufacturing the equipment. This project made significant progress toward this outcome by meeting the RAPID institute metric to reduce equipment cost by 20% for each doubling in manufacturing volume. The MCPI application was thermochemical technology that is being commercialized by STARS Technology Corporation, one of the CRADA partners. The technology converts solar and renewable power to chemical energy to produce renewable hydrogen, fuels, and chemicals. The benefit to the public is reduction in greenhouse gases that are contributing to climate change. The project transitioned the steam methane reforming (SMR) reactor from conventional fabrication methods to additive manufacturing (AM) direct metal laser sintering (DMLS) process. This is projected to reduce the cost of making a reactor by 58% when producing 100 reactors per year. Innovations in the DMLS process produced a patented design that reduces reactor weight by 60%. Reductions in material costs and processing time extend the DMLS advantage to higher production volumes. The new design promises to be 38% cheaper than the conventional processes at 1000 units per year. The resulting 87% reduction in the steam methane reforming (SMR) module cost in scaling from current costs meets the RAPID metric. The project was successful in producing and testing the first ever additively manufactured SMR reactors. A reactor achieved over 82% efficiency in converting electric power to chemical energy, which is a world record for an inductively heated SMR. The project has contributed to the design and assembly of a first demonstration plant that is headed to a hydrogen bus filling station in Thousand Palms, CA.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Kelp Energy Products and Marine Renewable Energy for Coastal Alaska Communities

This document summarizes the results of a U.S. Department of Energy (DOE)-sponsored project conducted to understand, evaluate, and address the challenges related to kelp processing and alternative off-season use of the seafood industry capacity in Alaska, and address the potential use of marine renewable energy (MRE) systems to provide the necessary power for potential unit operations associated with kelp processing.

09 BIOMASS FUELS↗
DOE OSTI2018

Isotope Enrichment Using Microchannel Distillation Technology (Final Report)

The Pacific Northwest National Laboratory has successfully demonstrated isotopic enrichment with microchannel distillation (MCD) technology, a capability for process intensification of chemical boiling point separations (CBPS). Sixty separation stages were achieved in a single device, a new record for process intensification technologies. The minimum length of a separation stage was 0.41 cm, a factor of 5 smaller than the best commercial advanced structured packing. The reduced separation stage length dramatically shortens the column length, which is particularly important for isotopic enrichment that typically requires thousands of stages. A key advantage of MCD technology is scalability, which was demonstrated by increasing the length of the test device by a factor of 2.5 and doubling the number of channels while improving performance. Results were obtained for two separations, propane from propylene and isotopic enrichment of methane, which along with previous results with other separations, demonstrates the versatility and utility of MCD for difficult separations. By employing capillary forces, MCD devices can operated in a horizontal configuration that facilitates a lower equipment profile and compact systems. Compact systems are easier and cheaper to insulate and operate at cryogenic temperatures that are typical for isotopic enrichment. MCD devices have been operated as low as the normal boiling point of methane, -162°C, and as high as the boiling point of diesel fuel, ~300°C.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

Process Intensification of Distillation using a Microwick Technology to Demonstrate Separation of Propane and Propylene

Process intensification (PI) of distillation using a microchannel distillation (MCD) device successfully reduced the height of a theoretical plate (HETP) in separating propane and propylene to 1 cm, representing 10 theoretical stages. Mass transfer is enhanced by using thin wicking structures that are 0.17 mm thick in counter-flow with vapor. Liquid is segregated in the wicks by applying a siphon, which also enables the device to operate horizontally. A scalable device containing 11 wicks was operated cryogenically in total reflux. The HETP varied between 1.0 and 3.7 cm, representing a dramatic reduction over commercial structured packings and comparable to other PI approaches. Significant improvements are expected with further development. Potential application for intensified distillation processes include distributed manufacturing and difficult separations involving close boiling compounds and meeting high purity specifications. The ultimate application is isotopic enrichment, where the number of stages required is typically multiple thousands.

Distillation, Process Intensification, Microchanne↗
DOE OSTI2016

Affordable Hybrid Heat Pump Clothes Dryer

This project was successful in demonstrating the feasibility of a step change in residential clothes dryer energy efficiency by demonstrating heat pump technology capable of 50% energy savings over conventional standard-size electric dryers with comparable drying times. A prototype system was designed from off-the-shelf components that can meet the project’s efficiency goals and are affordable. An experimental prototype system was built based on the design that reached 50% energy savings. Improvements have been identified that will reduce drying times of over 60 minutes to reach the goal of 40 minutes. Nevertheless, the prototype represents a step change in efficiency over heat pump dryers recently introduced to the U.S. market, with 30% improvement in energy efficiency at comparable drying times.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2015

A COMPUTATIONAL AND EXPERIMENTAL STUDY OF METAL AND COVALENT ORGANIC FRAMEWORKS USED IN ADSORPTION COOLING

Metal-organic frameworks (MOFs) have recently attracted enormous interest over the past few years due to their potential applications in energy storage and gas separation. However, there have been few reports on MOFs for adsorption cooling applications. Adsorption cooling technology is an established alternative to mechanical vapor compression refrigeration systems. Adsorption cooling is an excellent alternative in industrial environments where waste heat is available. Applications also include hybrid systems, refrigeration, power-plant dry cooling, cryogenics, vehicular systems and building HVAC. Adsorption based cooling and refrigeration systems have several advantages including few moving parts and negligible power consumption. Key disadvantages include large thermal mass, bulkiness, complex controls, and low COP (0.2-0.5). We explored the use of metal organic frameworks that have very high mass loading and relatively low heats of adsorption, with certain combinations of refrigerants to demonstrate a new type of highly efficient adsorption chiller. An adsorption chiller based on MOFs suggests that a thermally-driven COP>1 may be possible with these materials, which would represent a fundamental breakthrough in performance of adsorption chiller technology. Computational fluid dynamics combined with a system level lumped-parameter model have been used to project size and performance for chillers with a cooling capacity ranging from a few kW to several thousand kW. In addition, a cost model has been developed to project manufactured cost of entire systems. These systems rely on stacked micro/mini-scale architectures to enhance heat and mass transfer. Presented herein are computational and experimental results for hydrophyilic MOFs, fluorophilic MOFs and also flourophilic Covalent-organic frameworks (COFs).

adsorption↗
DOE OSTI2015

Integrated solar thermochemical reaction system for steam methane reforming

Solar-aided upgrade of the energy content of fossil fuels, such as natural gas, can provide a near-term transition path towards a future solar-fuel economy and reduce carbon dioxide emission from fossil fuel consumption. Both steam and dry reforming a methane-containing fuel stream have been studied with concentrated solar power as the energy input to drive the highly endothermic reactions but the concept has not been demonstrated at a commercial scale. Under a current project with the U.S. Department of Energy, PNNL is developing an integrated solar thermochemical reaction system that combines solar concentrators with micro- and meso-channel reactors and heat exchangers to accomplish more than 20% solar augment of methane higher heating value. The objective of our three-year project is to develop and prepare for commercialization such solar reforming system with a high enough efficiency to serve as the frontend of a conventional natural gas (or biogas) combined cycle power plant, producing power with a levelized cost of electricity less than 6¢/kWh, without subsidies, by the year 2020. In this paper, we present results from the first year of our project that demonstrated a solar-to-chemical energy conversion efficiency as high as 69% with a prototype reaction system.

03 NATURAL GAS↗
DOE OSTI2014

Clothes Dryer Automatic Termination Evaluation

Volume 2: Improved Sensor and Control Designs Many residential clothes dryers on the market today provide automatic cycles that are intended to stop when the clothes are dry, as determined by the final remaining moisture content (RMC). However, testing of automatic termination cycles has shown that many dryers are susceptible to over-drying of loads, leading to excess energy consumption. In particular, tests performed using the DOE Test Procedure in Appendix D2 of 10 CFR 430 subpart B have shown that as much as 62% of the energy used in a cycle may be from over-drying. Volume 1 of this report shows an average of 20% excess energy from over-drying when running automatic cycles with various load compositions and dryer settings. Consequently, improving automatic termination sensors and algorithms has the potential for substantial energy savings in the U.S.

algorithm↗
NASA NTRS2001

Normal Gravity Testing of a Microchannel Phase Separator for In Situ Resource Utilization

A microchannel separator, with 2.7 millimeters as the smallest dimension, was tested, and a pore throat structure captured and removed liquid from a gas-liquid stream. The microchannel device was tested over a of gas and liquid flow rates ranging from 0.0005 up to 0. 14 volume fraction of liquid. Four liquids were tested with air. The biggest factor affecting the throughput is the capacity of liquid flow through the pore throat, which is dictated by permeability, liquid viscosity, flow area, pore throat thickness, and pressure difference across the pore throat. Typically, complete separation of gas and liquid fractions was lost when the liquid flow rate reached about 40 to 60% of the pore throat capacity. However, this could occur over a range of 10 to 90% utilization of pore throat capacity. Breakthrough occurs in the microchannel phase separator at conditions similar to the annular to plug flow transition of two-phase microgravity pipe flow implying that operating in the proper flow regime is crucial. Analysis indicates that the Bond number did not affect performance, supporting the premise that hydrodynamic, interfacial, and capillary forces are more important than gravity. However, the relative importance of gravity is better discerned through testing under reduced gravity conditions.

TeGrotenhuis, Ward E.↗