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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 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
NASA NTRS1982

A 10-kW series resonant converter design, transistor characterization, and base-drive optimization

The development, components, and performance of a transistor-based 10 kW series resonant converter for use in resonant circuits in space applications is described. The transistors serve to switch on the converter current, which has a half-sinusoid waveform when the transistor is in saturation. The goal of the program was to handle an input-output voltage range of 230-270 Vdc, an output voltage range of 200-500 Vdc, and a current limit range of 0-20 A. Testing procedures for the D60T and D7ST transistors are outlined and base drive waveforms are presented. The total device dissipation was minimized and found to be independent of the regenerative feedback ratio at lower current levels. Dissipation was set at within 10% and rise times were found to be acceptable. The finished unit displayed a 91% efficiency at full power levels of 500 V and 20 A and 93.7% at 500 V and 10 A.

Robson, R. R.↗
NASA NTRS2020

Results of the KRUSTY Warm Critical Experiments

The Kilowatt Reactor Using Stirling TechnologY (KRUSTY) was a prototypic nuclear-powered test of a 5-kW(thermal) Kilopower space reactor. This paper presents results from the KRUSTY warm critical experiments, which were completed prior to the final system test. The first set of criticals comprised cold or zero-power criticals; i.e., the core was not heated by fission power. These were followed by three warm criticals, where fission power heated the core to 200°C, 300°C, and 450°C, respectively. These criticals provided the data, confidence, and regulatory framework that were needed to proceed with the KRUSTY nuclear system test. The criticals also provided valuable data for the benchmarking of codes applicable to all nuclear systems. Finally, a comparison of KRUSTY results to pretest predictions is provided, and overall, the models matched the experimental results very closely.

David I. Poston↗
DOE OSTI2022

OPALCO - Decatur Island Solar and Energy Storage Project: An Assessment of Battery Technical Performance

Orcas Power & Light Cooperative (OPALCO) is a member-owned, nonprofit cooperative utility that provides energy services to approximately 11,200 customers across 20 islands in San Juan County, Washington. OPALCO’s mostly hydroelectric power is generated by Bonneville Power Administration and delivered to the islands by submarine cables. In 2016, as part of the second round of funding from the Washington state Clean Energy Fund, OPALCO received a $1 million matching grant to support a project that deployed a 504-kW LG community photovoltaic (PV) system in combination with a 1 MW/2 MWh lithium-iron-phosphate battery energy storage system (BESS) on Decatur Island, Washington. The Decatur Island Substation is essential to ensuring reliable energy for the residents of the San Juan Islands as it is the point of interconnection with the mainland transmission system. The BESS, in combination with the community solar array, will deliver an innovative method to both defer the costly upgrade of the transmission system and allow for other high-value applications intended to benefit the utility and its customers. In 2018, Pacific Northwest National Laboratory (PNNL) completed a preliminary economic assessment for several identified use cases in collaboration with OPALCO. Between August 2021 and May 2022, extensive testing was conducted, and the results were used to assess the technical performance of the BESS subjected to actual field operations. Both reference performance and use case tests were performed: (a) Reference performance tests assess the general technical capabilities of the BESS, such as energy capacity, round-trip efficiency (RTE), ramp rate, and signal tracking capability. These are the first tests performed (baseline) and are repeated after use case tests (post cycle). A standardized U.S. Department of Energy (DOE) energy storage performance protocol was used to characterize the BESS, including representative duty cycle profiles, test procedure guidance, and calculation guidance for determining key characteristics. (b) Use case tests examine the performance of the BESS for specific use cases using duty cycles developed by PNNL in collaboration with OPALCO. Four use cases were selected for testing: 1) demand charge reduction, 2) load shaping, 3) outage mitigation, and 4) transmission deferral. The use case duty cycles were developed based on utility and site-specific characteristics in addition to the technical characteristics and physical capabilities of the BESS. Use case tests were performed between the baseline and post cycle tests. This report describes the BESS and its components, presents testing and performance analysis results, and shares key insights and lessons learned from this project. Outcomes of the tests and analyses will help OPALCO understand the performance of the Decatur Island BESS in its current state and design appropriate operational strategies for this and other BESSs over the long term.

14 SOLAR ENERGY↗
DOE OSTI2024

A Tandem Electrolysis Process for Multi-Carbon Chemical Production from Carbon Dioxide (Final Technical Report)

a two-step CO 2 electroreduction process for selective production of acetate and ethylene was successfully developed at the kW-scale. The CO 2 and CO electrolyzers were first investigated individually on the Watt-scale to achieve high current densities and more durable operation by using a reinforced GDL. High CO 2 conversion was obtained in the first CO 2 electrolyzer to produce a CO-dominant gas stream with minimal CO 2 , and highly pure acetate stream was produced in the second CO electrolyzer by using NiFe anode, which promoted alcohol oxidation to carboxylates. The two-step process operated stably for 200 h with acetate and ethylene as the major C 2+ products. Degradation mechanism study revealed that the flooding and the salt formation in the GDL is likely the biggest contributor to the performance degradation for both CO 2 and CO electrolyzers. A 1,000 cm 2 CO electrolyzer stack was then designed, fabricated, and operated up to a total current of 300 A along with a 500 cm 2 CO 2 electrolyzer stack which was operated up to a total current of 100 A. The CO electrolyzer stack demonstrated good stability at 300 A for at least 125 h at a carbon selectivity >96%. The impact of CO 2 , O 2 , N 2 , SO x , and NO x gas impurities on the CO electrolyzer stack was studied and a relatively high resistance to these contaminants was demonstrated. Electroreduction of CO 2 into acetic acid was also demonstrated to be environmentally favorable when compared to the traditional production of acetic acid when powered by renewable electricity. Additionally, electricity cost was identified as the primary source of cost sensitivity indicating substantial economic improvements could be achieved by continuing to drive down the cost of renewable electricity. Overall, the presented approach demonstrates the feasibility of the two-step electrochemical CO 2 reduction process for the effective production of C 2+ products at the kW-scale which should inspire future scaling efforts accelerating commercialization.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1995

A High-Average-Power Free Electron Laser for Microfabrication and Surface Applications

CEBAF has developed a comprehensive conceptual design of an industrial user facility based on a kilowatt ultraviolet (UV) (160-1000 mm) and infrared (IR) (2-25 micron) free electron laser (FEL) driven by a recirculating, energy recovering 200 MeV superconducting radio frequency (SRF) accelerator. FEL users, CEBAF's partners in the Lase Processing Consortium, including AT&T, DuPont, IBM, Northrop Grumman, 3M, and Xerox, are developing applications such as metal, ceramic, and electronic material micro-fabrication and polymer and metal surface processing, with the overall effort leading to later scale-up to industrial systems at 50-100 kW. Representative applications are described. The proposed high-average-power FEL overcomes limitations of conventional laser sources in available power, cost-effectiveness, tunability, and pulse structure.

Dylla, H. F.↗
DOE OSTI2020

Low-cost desalination of seawater and hypersaline brine using nanophotonics enhanced solar energy membrane distillation

A stand-alone small-scale nanophotonics enhanced solar membrane distillation (NESMD) testbed was designed, developed, and tested for desalinating seawater and high salinity feedwaters. This NESMD system can take almost any source water and turn it into clean water with sunlight as the only energy source. The NESMD technology applies nanophotonic coating materials on a commercial hydrophobic polypropylene support of a polytetrafluoroethylene (PTFE) membrane surface. The photothermal coating serves as a solar thermal collector, absorbs solar energy, and generates highly localized heat on the membrane, while the rest of the membrane performs membrane distillation functions. The presented NESMD system is equipped with an internal heat recovery system with no need for external electricity and no additional water for cooling. The NESMD testbed is installed and tested at Rice University campus (29.7174° N, 95.4018° W). In this study, real seawater from Galveston Bay, Texas, U.S. and high salinity simulated feedwaters (total dissolved solids (TDS) of 113 200–200 000 PPM) have been tested for long-term testing under the weather conditions of Houston, Texas. Here, the field testing results showed stable desalination performance in consecutive 5–8 hour operation cycles, with a TDS removal of ≥99.5% in all experiments. An average daily membrane flux of ≥0.75 L m –2 h –1 was achieved at a solar intensity close to 1 kW m –2 without an external heat exchanger. Further investigations and improvements are required to enhance the performance of the reactor since it is still a new promising technology.

14 SOLAR ENERGY↗
DOE OSTI2023

Low Cost Glass-Ceramic Matrix Composite Heat Exchanger

As part of ARPA-E’s High Intensity Thermal Exchange through Materials and Manufacturing Processes (HITEMMP) program, this project sought to develop novel heat exchanger (HX) capabilities to enable efficient and power dense power generation cycles. This class of HX comes under the category of ceramic/composite materials with the higher temperature goal in the program of ≥1100 °C inlet temperature operation. The enabling capability of this effort is the use of glass-ceramic matrix composite (GCMC) material which provides the high temperature durability of a ceramic, the flaw tolerance of a composite, a significantly faster and lower cost manufacturing process than conventional matrix CMCs and very low porosity levels < 0.5%. For thin-walled HX structures and the need to minimize leakage, the low porosity differentiator is particularly important. RTRC has prior experience with this material system and in the current project advanced the component design and manufacturing methods into new territory to produce features required for effective heat exchange under high pressures. In this approach, silicon carbide fiber is fabricated into a fiber preform using various textile processes. Graphite tooling is used both during the build-up of the fiber preform (interior tooling) and after the fiber preform has been completed (exterior tooling). This tooling assembly is heated to high temperature in an environment that has been evacuated and backfilled with inert gas. A reservoir of specialty glass is present and once the desired temperature has been reached to achieve the desired glass viscosity, an actuator distributes the glass throughout the fiber preform using passageways which are part of the tooling design in a process known as glass transfer molding. After the tooling has been removed, the composite is heat treated to convert the amorphous glass to a crystalline ceramic, providing improved properties. The project was divided into three phases focusing on the following: 1) 10 kW HX design and coupon-level tube sheet fabrication, 2) 10 kW HX fabrication, 3) 50 kW HX fabrication. During Budget Period 1 (BP1), additional risks were encountered and the need for additional funds was agreed upon by ARPA-E program leadership. Due to a variety of factors, the contract modification required nominally 18 months to execute at which time the HITEMMP program was effectively concluding. Because of this and the time that would be required to perform BP2 tasks, it was decided to conclude the project at the end of BP1. During the design of the 10 kW HX, manufacturing constraints were learned and incorporated, leading to a revised configuration for the fiber preform and HX. Heat exchange and pressure drop predictions also played a role in modifying the original design concept to be a higher aspect ratio shell-and-tube HX, simplifying the manufacturing process and improving the heat exchanger performance. Good gravimetric and volumetric thermal power densities of 11.2 kW/kg and 10,200 kW/m3 for the entire HX were projected that involved thermo-structural Finite Element Analysis to determine the structural mass needed for the high operation pressures of 250 bar cold inlet and 80 bar hot inlet. Fiber preforms using textile processes were produced for multiple headered tube sheets. Additional challenges were encountered during the glass transfer molding step for which solutions were identified, but programmatics did not allow them to be implemented in BP1. While complete HX test articles were not fabricated, the benefits of this GCMC material for a variety of high temperature applications remain.

30 DIRECT ENERGY CONVERSION↗
NASA NTRS1993

Variable-speed Generators with Flux Weakening

A cost-competitive, permanent-magnet 20 kW generator is designed such that the following criteria are satisfied: an (over) load capability of at least 30 kW over the entire speed range of 60-120 rpm, generator weight of about 550 lbs with a maximum radial stator flux density of 0.82 T at low speed, unity power factor operation, acceptably small synchronous reactances and operation without a gear box. To justify this final design four different generator designs are investigated: the first two designs are studied to obtain a speed range from 20 to 200 rpm employing rotor field weakening, and the latter two are investigated to obtain a maximum speed range of 40 to 160 rpm based on field weakening via the stator excitation. The generator reactances and induced voltages are computed using finite element/difference solutions. Generator losses and efficiencies are presented for all four designs at rated temperature of Tr=120C.

Fardoun, A. A.↗
NASA NTRS1991

Lower hybrid waves excited through linear mode coupling and the heating of ions in the auroral and subauroral magnetosphere

Two related aspects of the linear mode conversion mechanism are considered: (1) the controlled heating of suprathermal ions in the ionosphere and magnetosphere over a powerful VLF/ELF transmitter using lower hybrid (LH) waves excited by the electromagnetic (EM) transmitter signals through linear mode conversion; (2) the excitation of intense LH waves in the auroral regions through the linear conversion of VLF/ELF EM auroral hiss, and the subsequent heating of ions by the excited LH waves. Experimental results are used to demonstrate that strong LH waves can be excited by EM waves down to frequencies as low as 2 kHz in the subauroral low-altitude magnetosphere. It is also shown that an approximately 250 kW VLF/ELF transmitter operating in the subauroral region at 2 kHz could excite sufficiently intense LH waves to heat suprathermal 1 eV H(+) ions and 16 eV O(+) ions to roughly 50 eV in a region extending in altitude from 1000 to 5000 km above the transmitter with a horizontal scale of about 500 km. If coherent wave stochastic heating occurs, the O(+) energy gain could be as large as 200 eV.

Bell, T. F.↗
NASA NTRS2004

Progress on the Plasmoid Thruster Experiment (PTX)

A plasmoid is a compact plasma structure with an integral magnetic field, that may be categorized according to the relative strength of the poloidal and toroidal magnetic field (B(sub p) and B(sub t), respectively). An object with B(sub p)/B(sub t), much much more than 1 is called a Field Reverse Configuration (FRC); if B(sub p) approximately equal to B(sub t), it is called a Spheromak. The thruster operates by repetitively producing plasmoids that are accelerated and ejected at high velocity. As this process is inductive, there are no electrodes. Also, the magnetic structure of the plasmoid should suppress thermal and mass losses to the wall, and improve detachment of the plasma exhaust from the thruster. This concept should be capable of producing an Isp in the range of 5,000 - 10,000 s with thrust densities of order 10(exp 5) N per square meters. The current experiment is designed to produce jet powers in the range of 5-10 kW, although the concept should be scalable into the MW range. In PTX, the plasmoid is formed inside of a single turn conical theta-pinch coil (17.58 cone angle). The coil is driven by a 640 nF, 35 kV capacitor bank, which rings at a frequency of 500 kHz. Previous experiments on PTX were conducted with a static-fill of propellant gas (6% H2 in He), and demonstrated reliable ionization over a pressure range of 40 - 200 mTorr. We are now adding a fast gas-puff valve to load the propellant, and a ringing pre-ionization circuit (f = 5 Mhz) to better control the plasmoid formation. An alternate coil (8.58 cone angle) will also be used, so as to investigate the effect of coil shape on performance. In addition, a variety of propellants will be used, including hydrogen, nitrogen, and argon. The plasmoid mass and velocity will be measured with a variety of diagnostics, including external B-dot probes and flux loops, a high-speed framing camera, and a HeNe laser interferometer. Internal B-dot probes and a quadruple Langmuir probe will provide additional measurements of the plasmoid shape and structure, as well as density, and will be described in a companion paper. The experimental results will be compared to calculations made using a 0-D coil-gun model and also a 2-D time dependent MHD code.

Martin, Adam↗
NASA NTRS1992

Experimental testing of prototype face gears for helicopter transmissions

An experimental program to test the feasibility of using face gears in a high-speed and high-power environment was conducted. Four face gear sets were tested, two sets at a time, in a closed-loop test stand at pinion rotational speeds to 19,100 rpm and to 271 kW. The test gear sets were one-half scale of the helicopter design gear set. Testing the gears at one-eighth power, the test gear set had slightly increased bending and compressive stresses when compared to the full scale design. The tests were performed in the LeRC spiral bevel gear test facility. All four sets of gears successfully ran at 100 percent of design torque and speed for 30 million pinion cycles, and two sets successfully ran at 200 percent of torque for an additional 30 million pinion cycles. The results, although limited, demonstrated the feasibility of using face gears for high-speed, high-load applications.

Handschuh, R.↗
NASA NTRS1961

Experiments with Plasmas Produced by Potassium-Seeded Cyanogen Oxygen Flames for Study of Radio Transmission at Simulated Reentry Vehicle Plasma Conditions

A method for the chemical production of an ionized gas stream for application to radio transmission studies is described. Involved is the combustion of gaseous cyanogen and oxygen with the addition of vaporized potassium in some cases to further increase the ionization. Experiments are described in which a 3-inch-diameter subsonic free jet at atmospheric pressure is used, and the results are presented. The plasma obtained by using this method is sufficient to simulate plasma conditions expected for reentering hypersonic vehicles. The unseeded plasma stream temperature is indicated to be about 4,200 K, with the degree of ionization indicated to be that expected from thermal equilibrium considerations. Measurements of radio-signal loss due to the unseeded flame plasma are presented for microwaves of 8 to 20 kmc transmitted through the stream and for a dipole transmitting model of 219.5 mc immersed in the stream. Favorable comparison of these results with the simple plane-wave signal-attenuation theory was obtained. In the case of a 9.4-kmc microwave signal of 30-kw peak power, the preliminary indication is that the plasma characteristics were not changed due to this strong signal. Comparison of a simplified concept of radio-signal attenuation due to plasmas is made with some hypersonic reentry vehicle signal-loss data. Other areas of plasma research using this method for the transmission problem are indicated.

Huber, Paul W.↗
NASA NTRS1985

Feasibility of steady-state, multi-megawatt MPD thrusters

The feasibility of operating the MPD thruster at sustained, multi-megawatt power levels for application to nuclear powered earth orbital maneuvering and outer planet orbiters is addressed by examining cathode erosion processes. The cathode is studied first since it operates in the most severe environment. Due to current, power, and geometrical constraints imposed by the need for high thruster efficiency the cathode must provide 200-400 A/sq cm at incandescent temperatures. This level must be sustained for hundreds of hours to propel a 13,000 kg payload, 5 MW vehicle from low earth orbit to say geosynchronous orbit in 7 days. The physics of thermionic emission are shown by experiment and theory to dominate the thermal balance and cathode sheath such that electron cooling keeps the cathode cool enough to avoid rapid evaporation. Experiments using a subscale MPD test device operating at continuous power levels of 10-30 kW show that cathode temperature can be kept to 2100-2200 K at the high current densities required for a full-sized, multi-megawatt thruster.

King, D. Q.↗
NASA NTRS1980

Research on design feasibility of high-power light-weight dc-to-dc converters for space power application

The development of 5 kW converters with 100 kHz switching frequencies, consisting of two submodules each capable of 2.5 kW of output power, is discussed. Two semiconductor advances allowed increased power levels. Field effect transistors with ratings of 11 A and 400 V were operated in parallel to provide a converter output power of approximately 2000 W. Secondly, bipolar power switching transistor was operated in conjunction with a turn-off snubber circuit to provide converter output power levels approaching 1000 W. The interrelationships between mass, switching frequency, and efficiency were investigated. Converters were constructed for operation at a maximum output power level of 200 W, and a comparison was made for operation under similar input/output conditions for conversion frequencies of 20 kilohertz and 100 kilohertz. The effects of nondissipative turn-off snubber circuitry were also examined. Finally, a computerized instrumentation system allowing the measurement of pertinent converter operating conditions as well as the recording of converter waveforms is described.

Wilson, T. G.↗
NASA NTRS1975

Advanced propulsion concepts study: Comparative study of solar electric propulsion and laser electric propulsion

Solar electric propulsion (SEP) and laser electric propulsion (LEP) was compared. The LEP system configuration consists of an 80 kW visible laser source on earth, transmitting via an 8 m diameter adaptively controlled phased array through the atmosphere to a 4 m diameter synchronous relay mirror that tracks the LEP spacecraft. The only significant change in the SEP spacecraft for an LEP mission is the replacement of the two 3.7 m by 33.5 m solar cell arrays with a single 8 m diameter laser photovoltaic array. The solar cell array weight is decreased from 320 kg to 120 kg for an increase in payload of 200 kg and a decrease in specific mass of the power system from 20.5 kg/kW to 7.8 kg/kW.

Forward, R. L.↗
NASA NTRS1987

Controller for a High-Power, Brushless dc Motor

Driving and braking torques controllable. Control circuit operates 7-kW, 45-lb-ft (61-N-m), three-phase, brushless dc motor in both motor and generator modes. In motor modes, energy from power source is pulse-width modulated to motor through modified "H-bridge" circuit, in generator mode, energy from motor is pulse-width modulated into bank of load resistors to provide variable braking torques. Circuit provides high-resolution torque control in both directions over wide range of speeds and torques. Tested successfully at bus voltages up to 200 Vdc and currents up to 45 A.

Fleming, David J.↗
DOE OSTI2022

A Simplified Numerical Approach to Characterize the Thermal Response of a Moving Bed Solar Reactor

Abstract Concentrated solar thermochemical storage in the form of a zero-emission fuel is a promising option to produce long-duration energy storage. Solar fuel is produced using a cavity reactor that captures concentrated solar radiation from a solar field of heliostats. In this paper, heat transfer model of a tubular plug-flow reactor designed and manufactured for a solar fuel production is presented. Experimental data collected from a fixed bed tubular reactor testing are used for model comparison. The system consists of an externally heated tube with counter-current flowing gas and moving solid particles as the heated media. The proposed model simulates the dynamic behavior of temperature profiles of the tube wall, gas, and particles under various gas flowrates and residence times. The heat transfer between gas–wall, solid particle–wall, and gas–solid particle is numerically studied. The model results are compared with the results of experiments done using a 4 kW furnace with a 150 mm heating zone surrounding a horizontal alumina tube (reactor) with 50.8 mm outer diameter and thickness of 3.175 mm. Solid fixed particles of magnesium manganese oxide (MgMn2O4) with the size of 1 mm are packed within the length of 250 mm at the center of the tube length. Simulation results are assessed with respect to fixed bed experimental data for four different gas flowrates, namely, 5, 10, 15, and 20 standard liters per minute of air, and furnace temperatures in the range of 200–1200 °C. The simulation results showed good agreement with maximum steady state error that is less than 6% of those obtained from the experiments for all runs. The proposed model can be implemented as a low-order physical model for the control of temperature inside plug-flow reactors for thermochemical energy storage applications.

Engineering↗