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At least 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Characterizing the negative triangularity reactor core operating space with integrated modeling

Negative triangularity (NT) has received renewed interest as a fusion reactor regime due to its beneficial power-handling properties, including low scrape-off layer power and a larger divertor wetted area that facilitates simple divertor integration. NT experiments have also demonstrated core performance on par with positive triangularity (PT) high confinement mode (H-mode) without edge-localized modes (ELMs), encouraging further study of an NT reactor core. In this work, we use integrated modeling to scope the operating space around two NT reactor strategies. The first is the high-field, compact fusion pilot plant concept Modular, Adjustable, NT ARC (MANTA) and the second is a low field, high aspect ratio concept based on work by Medvedev et al. By integrating equilibrium, core transport, and edge ballooning instability models, we establish a range of operating points with less than 50 MW scrape-off layer power and fusion power comparable to PT H-mode reactor concepts. Heating and seeded impurities are leveraged to accomplish the same fusion performance and scrape-off layer exhaust power for various pressure edge boundary conditions. Scans over these pressure edge conditions accommodate any current uncertainty of the properties of the NT edge and show that the performance of an NT reactor will be extremely dependent on the edge pressure. The high-field case is found to enable lower scrape-off layer power because it is capable of reaching high fusion powers at a relatively compact size, which allows increased separatrix density without exceeding the Greenwald density limit. Adjustments in NT shaping exhibit small changes in fusion power, with an increase in fusion power density seen at weaker NT. Infinite-n ballooning instability models indicate that an NT reactor core can reach fusion powers comparable to leading PT H-mode reactor concepts while remaining ballooning-stable. Seeded krypton is leveraged to further lower scrape-off layer power since NT does not have a requirement to remain in H-mode while still maintaining high confinement. We contextualize the NT reactor operating space by comparing to popular PT H-mode reactor concepts, and find that NT exhibits competitive ELM-free performance with these concepts for a variety of edge conditions while maintaining relatively low scrape-off layer power.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

In-Situ Bioleaching of Manganese by Dissimilatory Reduction

This report describes the development of a biological leaching process for recovery of manganese from low-grade ores, with a high degree of selectivity against contaminants such as iron. This results in the production of manganese that is suitable for battery manufacture and other electrical applications. The leaching process makes use of a community of metal reducing organisms that solubilize manganese at a pH of approximately 4.5. These organisms are nourished by simple organic molecules such as acetate that are generated by decomposition of biomass. A series of long-term laboratory experiments were carried out to determine the necessary operating parameters, followed by construction of a small pilot plant processing approximately 100 kg of ore. This pilot unit was operated for two years, demonstrating the ability to consistently produce high-grade manganese at a commercially viable rate.

25 ENERGY STORAGE↗
DOE OSTI2024

Heliostat Observation System Commercialization Qualification HOS-C-Q (Final Technical Report)

Heliostat fields are one of the main components of a concentrated solar thermal plant. As GEN3 technology has been developed at pilot plant level targeting higher temperatures >700C, having a precise Heliostat field control system will enable the success of the GEN3 technology. Heliogen Inc. has developed the next generation of control systems for heliostat fields. Their early development was on single facet heliostats at their R&D facility in Lancaster, California. This new system allows for a closed loop integration to a current open loop setup of a regular Heliostat control system. Sandia National Laboratories and Heliogen Inc. have partnered together to test Heliogen’ s innovative new SOHOT system at the National Solar Thermal Test Facility.

14 SOLAR ENERGY↗
DOE OSTI2023

Modeling Advanced Strippers for CO2 Capture from Gas-Fired Power Plants using Aqueous Piperazine

Energy performance of 5 m piperazine was evaluated with an advanced stripper at the pilot scale, accounting for heat loss. Modeling studies indicated that heat loss at locations other than the heat source impacted the heat duty. For strippers with excess packing, the column was the most important source of heat loss, and values as low as 0.03 GJ/hr can cause pinch and reabsorption of CO2. Solvents like 5 m PZ are more affected by heat loss in the column due to a top-side temperature pinch at high lean loading. Heat loss impacts NGCC CO2 capture more than coal-based CO2 capture. Surface temperature measurements pilot plants showed that heat loss was 50-75% controlled by natural convection. Measured heat loss was correlated with steam flowrate and wind speed and ranged from 8126 to 219668 Btu/hr, representing 35% of the measured heat rate on average. Net heat duty linearly varied with CO2 removal at low lean loading and was similar for coal and NGCC conditions at fixed removal. At 90% removal, net heat duty was about 2.5 GJ/t with 4 and 12% CO2 in the flue gas. 7 At NGCC conditions, strippers with finite packing can benefit from a flashing feed to the top of the column by using a hot bypass. A flashing feed was linked to a reduction in irreversibility of the stripper from temperature driving forces. It also reduces heat duty by up to 6% at fixed packing height and reduces packing requirement for a fixed steam heater size compared to a warm bypass. Lean loading and lean solvent rate were effective handles to maximize profitability of a fixed stripper design at low gas price. High ambient temperature operation can benefit from low pressure stripping to about 0.18 lean loading at 150 ℃ to maintain the cyclic capacity at reduced rich loading. At low gas price, the capture plant was able to maximize profitability even with a high heat duty of 2.7-3.1 GJ/t at a lean loading of 0.2-0.22 mol/mol. Heat recovery by partial water vapor condensation in a gas-liquid exchanger can be replaced by a direct contact condenser (DCC). The DCC improved gas cooling and reduced heat duty compared to the CO2 exchanger at 0.2 lean loading. The DCC when used with a 150 ℃/5.5 bar stripper can reduce the cost of capture compared to the base case by $3- 4/tonne at 15 ft of packing (optimum) but increases cost of capture by $6/tonne with a 120 ℃/2 bar stripper and 10 ft of packing (optimum). The DCC can work effectively with a solvent with a high heat of absorption and thermal stability.

Suresh Babu, Athreya↗
DOE OSTI2023

Diagnosing an IFE Power Plant

This white paper for the Basic Research Needs for Plasma Diagnostics workshop lists a selected set of measurements required for normal and off-normal operation of an Inertial Fusion Energy power plant. An Inertial Fusion Energy (IFE) power plant will require instruments that record how well it is performing and, more importantly, sufficient instruments to diagnose failures during routine operation. It is assumed in this white paper that operating specifications and tolerances have been established before the plant begins operation so that only a minimal set of instruments is required. A pilot plant (a DEMO) would require more instrumentation in order to set those requirements and tolerances. This white paper assumes a laser-based IFE plant that operates at up to 20 Hz. Two scenarios are considered below. One is for routine, nominal operation and the other is when an implosion fails to produce energy.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1972

Estimation of nonlinear pilot model parameters including time delay.

Investigation of the feasibility of using a Kalman filter estimator for the identification of unknown parameters in nonlinear dynamic systems with a time delay. The problem considered is the application of estimation theory to determine the parameters of a family of pilot models containing delayed states. In particular, the pilot-plant dynamics are described by differential-difference equations of the retarded type. The pilot delay, included as one of the unknown parameters to be determined, is kept in pure form as opposed to the Pade approximations generally used for these systems. Problem areas associated with processing real pilot response data are included in the discussion.

Schiess, J. R.↗
DOE OSTI2021

MODELING AND TESTING OF A NOVEL ULTRA-LOW TEMPERATURE SCO2 OPPOSING PISTON EXPANDER

The Flameless Pressurized Oxy-Combustion (FPO) cycle, a novel flexible fuel technology, is being developed into a large pilot. This effort seeks to complete the preliminary engineering and planning of a 25 MWth Pilot Plant that will demonstrate the technology for scale-up to a commercial unit. The technology, pioneered by ITEA at the 5 MWth scale, must be brought to a higher technology readiness level (TRL) to be viable at the commercial scale. The 25 MWth pilot cycle was optimized for cost and technology development and demonstration. Preliminary drawings, layouts, and plans were defined. Process flow diagrams were used to describe the pilot configuration in greater detail. A heat and mass balance with stream data was created. A master equipment list specified the operating conditions for major pieces of equipment within the pilot using this heat and mass balance. The 25 MWth FPO pilot is assessed for environmental performance. A test campaign is developed to assess the type of test and number of hours required for pilot demonstration. The environmental performance is compared against projected performance at the commercial scale. This project builds upon extensive evaluation of the techno-economic performance of the FPO technology already performed by ITEA. This includes system improvements, such as the addition of a turbo-expander to the flue gas stream. Some of the performance-enhancing components are not as well defined as others. The primary goal of this effort was to bring all of the core cycle components to the same level of design maturity. A techno-economic assessment (TEA) evaluated the FPO technology at the commercial scale in comparison to the NETL baseline cases. The reference plants were used in combination with proprietary equipment estimates to build a plant capital cost and cost of electricity evaluation. FPO performed better than the sub-bituminous post-combustion capture cases. Further preliminary estimates of improvements to the FPO cycle show even further gains when compared to conventional carbon capture methods.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

DEVELOPMENT OF A 25 MWTH FLAMELESS PRESSURIZED OXY-COMBUSTION PILOT

The Flameless Pressurized Oxy-Combustion (FPO) cycle, a novel flexible fuel technology, is being developed into a large pilot. This effort seeks to complete the preliminary engineering and planning of a 25 MWth Pilot Plant that will demonstrate the technology for scale-up to a commercial unit. The technology, pioneered by ITEA at the 5 MWth scale, must be brought to a higher technology readiness level (TRL) to be viable at the commercial scale. The 25 MWth pilot cycle was optimized for cost and technology development and demonstration. Preliminary drawings, layouts, and plans were defined. Process flow diagrams were used to describe the pilot configuration in greater detail. A heat and mass balance with stream data was created. A master equipment list specified the operating conditions for major pieces of equipment within the pilot using this heat and mass balance. The 25 MWth FPO pilot is assessed for environmental performance. A test campaign is developed to assess the type of test and number of hours required for pilot demonstration. The environmental performance is compared against projected performance at the commercial scale. This project builds upon extensive evaluation of the techno-economic performance of the FPO technology already performed by ITEA. This includes system improvements, such as the addition of a turbo-expander to the flue gas stream. Some of the performance-enhancing components are not as well defined as others. The primary goal of this effort was to bring all of the core cycle components to the same level of design maturity. A techno-economic assessment (TEA) evaluated the FPO technology at the commercial scale in comparison to the NETL baseline cases. The reference plants were used in combination with proprietary equipment estimates to build a plant capital cost and cost of electricity evaluation. FPO performed better than the sub-bituminous post-combustion capture cases. Further preliminary estimates of improvements to the FPO cycle show even further gains when compared to conventional carbon capture methods.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2020

Scale-up of Next Generation Nano-Enhanced Composite Materials for Longer Lasting Consumer Goods

The objective for this project was to create an industrial-scale manufacturing operation for Vertically Aligned Carbon Nanotube Forests (VACNTs), which make up N12 Technologies’ (N12) NanoStitch® product, a prepreg additive that makes advanced composites tougher, lighter, and more durable. This was achieved using University of Dayton Research Institute’s (UDRI) 60-inch Nano Adaptive Hybrid Fabric (NAHF-X) reactor system. N12 had a unique and effective nanomaterial-based product that they were manufacturing on small-scale 1-inch wide substrate machines in Boston, MA. UDRI had a large-scale 60-inch wide nanomaterial growth reactor available for scaling up 2nd party products in Dayton, OH. Thanks to the successful cooperation between both parties, this project resulted in the world’s first industrial-scale continuous VACNT film pilot plant in Dayton, OH with an increase in VACNT supply production rate of >10X. This scale up enabled market validation via testing programs and pilot manufacturing operations with a number of customers.

36 MATERIALS SCIENCE↗
NASA NTRS1979

Survey of MHD plant applications

Open-cycle MHD is one of the major R&D efforts in the Department of Energy's program to meet the national goal of reducing U.S. dependence on oil through increased utilization of coal. MHD offers an effective way to use coal to produce electric power at low cost in a highly efficient and environmentally acceptable manner. Open-cycle MHD plants are categorized by the MHD combustor oxidizer, its temperature and the method of preheat. The paper discusses MHD baseline plant design, open-cycle MHD plant in the Energy Conversion Alternatives Study (ECAS), early commercial MHD plants, conceptual studies of the engineering test facility, retrofit (addition of an MHD topping cycle to an existing steam plant), and other potential applications and concepts. Emphasis is placed on a survey of both completed and ongoing studies to define both commercial and pilot plant design, cost, and performance.

Lynch, J. J.↗
DOE OSTI2026

Tokamak Energy’s pre-concept design for a fusion power plant: an overview of ST-E1

Climate change and rapidly rising energy demand, driven in part by artificial intelligence and data-centre growth, create an urgent need for stable, low-carbon, and abundant power. Fusion is a promising long-term solution, yet its commercialisation faces a fundamental paradox in today’s investment environment: pilot plants are essential to de-risk physics, engineering, and operations, but their limited lifetime energy output and high upfront costs make them difficult to finance. This paper presents Tokamak Energy’s response: ST-E1, a pre-concept design for a low-aspect-ratio tokamak power plant engineered specifically to overcome this challenge. ST-E1 is designed from the outset for phased operation—pilot and commercial phases, with an upgrade phase in between—with emphasis on commercial viability, maintainability, nuclear engineering, modularity, and upgradability. A key design principle is the deliberate separation of long-lived assets, such as the magnet cage and vacuum vessel, from replaceable in-vessel systems. This provides an attractive and credible investment approach to generate operational data and de-risk key technologies while preserving most capital-intensive assets for later commercial phases. The architecture supports continuous optimisation toward high net electric power (targeting 800–1000 MW net electric), a normalised capital expenditure of $\$$ 12–14k/kW of net electric power, and high availability (targeting > 80%). A tokamak core with a 5 m major radius, aspect ratio of 2.3, and on-plasma axis toroidal field of 5.25 T was selected to meet these objectives. This paper summarises the ST-E1 design philosophy, principal features, and development methodology. It introduces a Focus Collection of 11 papers detailing the pre-concept design of the entire tokamak and corresponding plant.

ST-E1↗
DOE OSTI2024

Electrochemical Control for Corrosion in Molten Chlorides During CSP Plant Operation

The Liquid Pathway of the Concentrating Solar Power Generation 3 (CSP Gen3) program proposed low-cost molten chloride salt for energy storage. However, online corrosion control was identified as a remining major risk of the Liquid Pathway approach. This project addressed that risk. Electrochemical solutions for corrosion mitigation during CSP plant operation were investigated and their feasibility and scalability were evaluated. The leading cause of corrosion in molten chloride salt systems was identified as corrosive impurities that form within the salt upon exposure to trace amounts of air and moisture. Leveraging electrochemistry, reduction/oxidation reactions can be employed to remove these corrosive impurities. In Phase 1 of this project, a bench-scale batch electrochemical reactor was designed, fabricated, and used to assess the kinetics and thermodynamics of electrochemical salt purification. In Phase 2, a laboratory-scale flow reactor was designed, fabricated, and used to assess the efficacy of the electrochemical method under flowing conditions. Results show that under proposed operating conditions for the Liquid Pathway Gen3 Pilot Plant, the electrochemical method is significantly more effective at removing impurities than alternative chemical and thermal methods, and that the electrochemical method produces less harmful byproducts. A key advance made in the course of this project was the development of a 2-electrode method for electrochemical purification that is more scalable than previously developed 3 electrode methods. This novel method is based on Magnesium (Mg) electrowinning. A provisional patent based on this invention has been submitted (USPTO Application No. 63/480,355). Additional key advances made during this project include assessment of the effect of dissimilar alloys on corrosion, kinetic and thermodynamic evaluation of thermolysis reactions of impurities within the molten salt, characterization of byproducts of purification reactions, and generation of IP focused on isolating value-added products using molten salt-based electrochemistry that could be deployed to valorize the process (USPTO Application No. 63/478,806). Ultimately, this project represented a step toward feasibility of Liquid Pathway Gen3 CSP. The method developed under this project could significantly reduce capital expenses and operating costs and increase plant profitability by enabling use of less expensive alloys, decreasing maintenance, and increasing plant longevity. Key focus areas for follow-on work have been identified as 1) evaluation of the efficacy of the electrochemical method under turbulent conditions in a larger flow system, such as the FASTR loop, 2) development of methods for removal of purification byproducts, 3) modeling pilot and industrial scale performance of electrochemical salt purification during plant operation and 4) further assessment of the effect of impurities on salt vapor phase.

14 SOLAR ENERGY↗
DOE OSTI2022

A Development of Critical Components for the Modular Staged Pressurized Oxy-Combustion Power Plant

DOE's Coal FIRST (Flexible, Innovative, Resilient, Small, Transformative) Initiative was implemented to encourage the development of the coal plant of the future, which will be capable of flexible operation to meet the needs of the grid; using innovative and cutting-edge components that improve efficiency and reduce emissions; providing resilient power to Americans; being small compared to today's conventional utility-scale coal power plants; and transforming how coal power plant technologies are designed and manufactured. The modular Staged, Pressurized Oxy-Combustion (SPOC) process envisioned by and under development at Washington University in St. Louis (WUSTL) has the potential to achieve these goals. The process offers: 1) a modular plant design for improved operational flexibility; 2) fuel-staging combined with pressurized oxy-combustion, which leads to smaller plant size, higher plant efficiency, and lower cost for pollutant and greenhouse gases removal compared with traditional carbon-capture equipped coal power plants; and 3) small modular boilers and pollutant removal units that can be fabricated in shop and assembled on site, further reducing plant capital costs. Under DOE's support (DE-FE0031925), WUSTL is advancing the development of the critical components for the SPOC power plant, including the integrated combustion system and the direct contact cooler (DCC) from TRL 4 to TRL-5, which would allow them to be subsequently incorporated into a pilot plant. These units are the only two components that are not commercially available for a SPOC plant, and hence, their development is a key step toward the commercialization of SPOC. This work presents the objectives, task descriptions, and current progress of the project. So far, the fabrication of a new combustor design and the convective heat transfer boiler has been completed, and the integration of the combustor, boiler, and DCC is underway. Recent results obtained with the newly designed combustor show a stable coal/methane flame while dry-feeding PRB coal under oxy-combustion conditions.

Magalhaes, Duarte↗
DOE OSTI2026

The U.S. Fusion Materials Community Roadmap: Near-term research priorities for the development of plasma-facing and structural materials for fusion power plants

In response to the needs of a rapidly growing private fusion industry, the U.S. Fusion Materials Coordinating Committee (FMCC) and the broader U.S. fusion materials research community undertook an extensive effort to create a comprehensive roadmap for fusion materials development. The result of this effort was the U.S. Fusion Materials Community Roadmap (US-FMCR), which describes the steps needed to advance the technical maturity of leading candidates for plasma-facing materials and structural materials for fusion power plants from laboratory-scale experiments to a point of sufficient technological readiness for industrial adoption and implementation. However, researchers face significant resource constraints as well as very aggressive pilot plant development timelines. Thus, the research strategies detailed in the US-FMCR require further assessment to downselect the specific tasks that must be prioritized within the next two to three years, in order to make the most efficient use of funding, human resources, and experimental facilities. This paper presents an overview of the US-FMCR and its development process. We also present the subset of research objectives that the FMCC identified as the most urgent research priorities for the U.S. fusion materials research community. The state-of-the-art of materials research is also highlighted for each class of materials considered in the US-FMCR. The recommendations presented here integrate an extensive evaluation of the current status of fusion materials research with a broad cross-section of opinion from the wider U.S. fusion community.

Ferry, Sara [Massachusetts Institute of Technology↗
DOE OSTI2020

Pilot testing of CO2 capture from a coal-fired power plant—Part 2: Results from 1-MWe pilot tests

Abstract Using a 1-MWe slipstream pilot plant, solid-sorbent-based post-combustion CO2 capture was tested at a coal-fired power plant. Results from pilot testing were used to develop a preliminary full-scale commercial design. The sorbent selected for pilot-scale evaluation during this project consisted of an ion-exchange resin that incorporated amines covalently bonded to the substrate. A unique temperature-swing-absorption (TSA) process was developed that incorporated a three-stage fluidized-bed adsorber integrated with a single-stage fluidized-bed regenerator. Overall, following start-up and commissioning challenges that are often associated with first-of-a-kind pilots, the pilot plant operated as designed and expected, with a few key exceptions. The two primary exceptions were associated with: (i) handling characteristics of the sorbent, which were sufficiently different at operating temperature than at ambient temperature when design specifications were established with lab-scale testing; and (ii) CO2 adsorption in the transport line between the regenerator and adsorber that preloaded the sorbent with CO2 prior to entering the adsorber. Results from the pilot programme demonstrate that solid-sorbent-based post-combustion capture can be utilized to achieve 90% CO2 capture from coal-fired power plants.

Sjostrom, Sharon↗
DOE OSTI2023

Modular Staged Pressurized Oxy-Combustion (SPOC) Power Plant for Coal and Biomass – Integration of Combustor Boiler and DCC

Critical to the future of power generation is the development of a power plant that will be capable of flexible operation to meet the needs of the modern grid, providing resilient, low-emissions power to a grid that is increasingly seeing a large penetration of intermittent wind and solar. The modular Staged, Pressurized Oxy-Combustion (SPOC) process envisioned by and under development at Washington University in St. Louis (WUSTL) has the potential to achieve these goals. The process offers: 1) a modular plant design for improved operational flexibility; 2) fuel-staging combined with pressurized oxy-combustion, which leads to smaller plant size, higher plant efficiency, and lower cost for pollutant and greenhouse gas removal compared with traditional carbon-capture equipped coal power plants; and 3) small modular boilers and pollutant removal units that can be fabricated in shop and assembled on site, further reducing plant capital costs. Under DOE's support (DE-FE0031925), WUSTL is advancing the development of the critical components for the SPOC power plant, including the integrated combustion system and the direct contact cooler (DCC) from Technology Readiness Level (TRL) 4 to TRL-5, which would allow these technologies to be subsequently incorporated into a pilot plant. This talk will present an overview of the SPOC technology, CFD modeling and validation for burner and boiler development, and recent results to evaluate critical components for system integration needed to advance its TRL.

Magalhaes, Duarte↗
DOE OSTI2023

Development of the Modular Staged Pressurized Oxy-Combustion (SPOC) Power Plant for Coal and Biomass

Critical to the future of power generation is the development of a power plant that will be capable of flexible operation to meet the needs of the modern grid, providing resilient, low-emissions power to a grid that is increasingly seeing a large penetration of intermittent wind and solar. The modular Staged, Pressurized Oxy-Combustion (SPOC) process envisioned by and under development at Washington University in St. Louis (WUSTL) has the potential to achieve these goals. The process offers: 1) a modular plant design for improved operational flexibility; 2) fuel-staging combined with pressurized oxy-combustion, which leads to smaller plant size, higher plant efficiency, and lower cost for pollutant and greenhouse gases removal compared with traditional carbon-capture equipped coal power plants; and 3) small modular boilers and pollutant removal units that can be fabricated in shop and assembled on site, further reducing plant capital costs. Under DOE's support (DE-FE0031925), WUSTL is advancing the development of the critical components for the SPOC power plant, including the integrated combustion system and the direct contact cooler (DCC) from Technology Readiness Level (TRL) 4 to TRL-5, which would allow these technologies to be subsequently incorporated into a pilot plant. This talk will present an overview of the SPOC technology, CFD modeling and validation for burner and boiler development, and recent results to evaluate critical components needed to advance its TRL.

Magalhaes, Duarte↗